PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
Table of Contents
MQ POWER
DCA-220SSK
TM
WHISPERWATT
GENERATOR
(Standard)
Up to S/N3696500
S/N3699150 to S/N3699619
S/N3699637 to S/N3703349
S/N3703364 to S/N3703853
S/N3703869~
(For serial numbers not listed, please refer to Sunbelt or GEER manuals)
Revision #3 (06/05/01)
MULTIQUIP INC.
18910 WILMINGTON AVE.
PARTS DEPARTMENT:
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
SERVICE DEPARTMENT:
800-835-2551
FAX:310-537-3927
FAX:310-638-8046
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310 - 537-3927
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 3
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
Here's How To Get Help ........................................3
Table Of Contents ................................................. 4
Parts Ordering Procedures ................................... 5
Rules for Safe Operation ...................................... 6-9
Towing Safety Precaution ..................................... 10
Trailer Safety Guidelines....................................... 11-17
TrailerWiring Diagram ........................................... 18
Electrical Brake Troubleshooting........................... 19
Hydraulic BrakeTroubleshooting........................... 20
Operation and Safety Decals................................ 21-22
DCA 220 Specifications ....................................... 23
General Information .............................................. 24-26
Major Components ............................................... 27
Dimensions........................................................... 28-29
Control Panel Descriptions ................................... 30-31
Engine Operating Panel Descriptions ................... 32-33
OutputTerminal Overview ..................................... 34-41
Installation ............................................................ 42-43
Pre Setup ............................................................. 44-47
Load Application ................................................... 48
Generator Start-up Procedure (Manual) ................ 49-52
Generator Start-up Procedure (Auto) .................... 53
Generator Shut-Down Procedure .......................... 54
Maintenance ......................................................... 56-59
GeneratorWiring Diagram ..................................... 60
EngineWiring Diagrams ....................................... 62-63
EngineTroubleshooting .........................................64-65
Generator/EngineTroubleshooting ........................ 66
MPECTroubleshooting .........................................67
Explanation of Code in Remarks Column ............. 68
Serial Numbers Pertaining to Unit ........................ 68
Suggested Spare Parts ........................................69
DCA-220SSK GENERATOR
Generator Assembly-Up to S/N1337562...............70-73
Generator Assembly-S/N1337563~ ...................... 74-77
Control Box and Panel Assembly-
Up to S/N1337562 ................................................78-81
Control Box and Panel (Optional)-
Up to S/N1337562 ................................................82-85
Control Panel Assembly-S/N1337563~.................86-87
Control Box Assembly-S/N1337563~ ................... 88-91
Engine & Radiator Assembly-Up to S/N1337562..92-95
Engine & Radiator Assembly-
S/N1337563 to 3690734 ....................................... 96-99
Engine & Radiator Assembly-S/N3690735~ ......... 100-103
Engine Operating and Output Terminal Assembly-
Up to S/N1337562 ................................................104-109
Engine Operating Panel Assembly (Opt. Parts,
with Slow-Down)-Up to S/N1337562 ..................... 110-115
Engine Operating Panel Assembly-S/N1337563~ 116-119
Output Terminal Panel Assembly-
S/N1337563 to 3690734 ....................................... 120-121
OutputTerminal Panel Assembly-S/N3690735~ ...122-123
Actuator-S/N3690735~ .........................................124-125
Battery Assembly .................................................126-127
Muffler Assembly ................................................. 128-129
Fuel Tank Assembly-Up to S/N1337562 ...............130-131
Fuel Tank Assembly-S/N1337563~....................... 132-133
Enclosure Assembly-Up to S/N1337562 ..............134-139
Enclosure Assembly-S/N1337563~ ...................... 140-145
Rubber Seal Assembly-Up to S/N1337562 ........... 146-147
Rubber Seal Assembly-S/N1337563~ .................. 148-149
Automatic Oil Feeder Assembly (Opt. Parts)-
Up to S/N1337562 ................................................150-151
Control Box Assembly Remote (Opt. Parts)-
Up to S/N1337562 ................................................152-153
Name Plate And Decals .......................................154-157
NOTE
Specification
and
part
Terms and Condition of Sale — Parts .................. 158
number are subject to
change without notice.
PAGE 4 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
PARTS ORDERING PROCEDURES
■ Dealer account number
■ Dealer name and address
■ Shipping address (if different than billing address)
■ Return fax number
■ Applicable model number
■ Quantity, part number and description of each part
■ Specify preferred method of shipment:
UPS Ground
•
UPS Second Day or Third Day*
•
UPS Next Day*
•
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
Airborne Express*
•
Truck or parcel post
•
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
Additional Discount
1-9 items
3%
10+ items**
5%
only
s
der
ed or
x
a
f
For
Get special freight allowances
when you order 10 or more
line items via FAX!**
Now! Direct TOLL-FREE access
to our Parts Department!
■
UPS Ground Service at no charge for freight
■
PS Third Day Service at one-half of actual freight cost
Toll-freenationwide:
800-421-1244
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
Toll-free FAX:
*DISCOUNTS ARE SUBJECT TO CHANGE*
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 5
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
RULES FOR SAFE OPERATION
CAUTION:
Failure to follow instructions in this manual
■
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
may lead to serious injury or even death!
This equipment is to be operated by trained
and qualified personnel only!This equipment
is for industrial use only.
The following safety guidelines should always be used when
operating the DCA-220SSK portable generator:
■
High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
GENERAL SAFETY
■
DO NOT operate or service this equipment
before reading this entire manual.
■
The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is restricted it will cause serious
damage to the generator or engine and may cause injury
to people.The generator engine gives off DEADLY carbon
monoxide gas.
■
This equipment should not be operated by
persons under 18 years of age.
■
NEVER operate this equipment without
proper protective clothing, shatterproof
glasses, steel-toed boots and other
protective devices required by the job.
CAUTION
:
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
Always refuel in a well-ventilated area,
away from sparks and open flames.
■
NEVER operate this equipment under the
influence or drugs or alcohol.
■
Always use extreme CAUTION
when working with flammable liquids.
When refueling, stop the engine and
allow it to cool.DO NOT smoke around
or near the machine. Fire or explosion
could result from fuel vapors, or if fuel
is spilled on a hot engine.
■
NEVER use accessories or attachments, which are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
■
Manufacturer does not assume responsibility for any
accident due to equipment modifications.
■
NEVER operate the generator in an
■
Whenever necessary, replace nameplate, operation and
explosive atmosphere or near combustible materials. An
explosion or fire could result causing severe bodily harm
or even death.
safety decals when they become difficult read.
■Always check the machine for loosened threads or bolts
before starting.
■Topping-off to filler port is dangerous, as it tends to spill
fuel.
PAGE 6 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
RULES FOR SAFE OPERATION
CAUTION
:
CAUTION
:
■
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
■
NEVER touch output terminals during operation. This is
Radiator
extremely dangerous. Always stop the machine when
1. Radiator Cap - Removing the radiator cap while the
engine is hot due to high pressure, will result in boiling
water to gush out of the radiator, therefore causing
severe scalding to any persons in the general area of
the generator.
contact with the output terminals.
CAUTION
:
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
■
Backfeed to a utility system can cause electrocution
and.or property damage. Do not connect to any
building's electrical system except through an approved
device or after building main switch is opened.
CAUTION
:
Never use damaged or worn cables when
connecting power tools or equipment to the
generator. Make sure power connecting
cables are securely connected to the
generator’s output terminals, insufficient
tightening of the terminal connections may
cause damage to the generator and electrical
shock.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 7
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
RULES FOR SAFE OPERATION
Battery
!
!
!
!
NEVER Run engine without air filter. Severe engine
damage may occur.
CAUTION
:
Always service air cleaner frequently to prevent carburetor
malfunction.
Never over fill the battery with water above
the upper limit.
Always disconnect the battery before performing service
on the generator.
Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
generator.
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
!
Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.
!
!
!
!
DO NOT leave the generator running in the manual mode
unattended.
DO NOT allow unauthorized people to operate this
equipment.
1. DO NOT drop the battery. There is the possibility of risk
Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
that the battery may explode.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact
with a flame or spark, an explosion could occur.
Refer to the Komatsu Engine Owner's Manual for engine
technical questions or information.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
Loading and Unloading (Crane)
!
Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
!
!
Always drain fuel prior to lifting.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
Always make sure crane or lifting device has been
properly secured to the hook of guard frame on generator.
!
!
NEVER lift the machine while the engine is running.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.
Use adequate lifting cable (wire or rope) of sufficient
strength.
!
!
!
When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.
NEVER allow any person or animal to stand underneath
the machine while lifting.
When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure the
generator during transport.
PAGE 8 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
RULES FOR SAFE OPERATION
Transporting
Maintenance Safety
■
■
■
Always shutdown engine before transporting.
■
NEVER lubricate components or attempt service on a
running machine.
Tighten fuel tank cap securely.
■
Always allow the machine a proper amount of time to
cool before servicing.
Drain fuel when transporting generator over long
distances or bad roads.
■
■
Keep the machinery in proper running condition.
■
■
Always tie-down the generator during transportation by
securing the generator.
Fix damage to the machine immediately and always
replace broken parts.
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
■
Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
Emergencies
Always know the location of the nearest fire
■
■
DO NOT use plastic containers to dispose of hazardous
waste.
■
extinguisher and first aid kit. Know the location of the
nearest telephone. Also know the phone numbers of the
nearest ambulance, doctor and fire department.
DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 9
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TOWING
Towing Safety Precautions
■
■
ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
CAUTION :
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
Check with your county or state safety towing
regulations department before towing your
generator.
■
Remember the maximum speed unless otherwise posted
for highway towing is 45 MPH. Recommended off-road
towing is not to exceed 10 MPH or less depending on
type of terrain.
To reduce the possibility of an accident
while transporting the generator on public roads, always
make sure that the trailer (Figure 1) that supports the
generator and the towing vehicle are in good operating
condition and both units are mechanically sound.
■
■
■
Place chocked blocks underneath wheel to prevent
rolling, while parked.
Place support blocks underneath the trailer's bumper to
prevent tipping, while parked.
The following list of suggestions should be used when towing
your generator:
Use the trailer's hand winch to adjust the height of the
trailer, then insert locking pin to lock wheel stand in place,
while parked.
■
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■
Avoid sudden stops and starts.This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■
ALWAYS inspect the hitch and coupling for wear.NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■
■
■
Avoid sharp turns to prevent rolling.
■
■
Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 1. Generator with Trailer
PAGE 10 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — TRAILER-SAFETY GUIDELINES
CAUTION:
4.
5.
6.
Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
Frame Width - This measurement is from fender to
fender.
Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters (175,185,
205, etc.). The tire diameter must match the diameter
of the tire rim.
Explanation of Chart:
This section is intended to provide the user with trailer ser-
vice and maintenance information. The service and mainte-
nance guidelines referenced in this section apply a wide range
of trailers. Remember periodic inspection of the trailer will
ensure safe towing of the equipment and will prevent dam-
age to the equipment and personal injury.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
11. Tire Rim - Tires are mounted on a tire rim. The tire rim
must match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. SeeTable 4 and Figure 5 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please not that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shock
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
!
!
!
!
!
!
Brakes
Tires
Lug NutTorquing
Suspension
Electrical
BrakeTroubleshootingTables
Use the following definitions reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
16. Application - Indicates which units can be employed
on a particular trailer.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 11
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
FUEL
CELL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10-15
TRLR-10X
TLG-12, DCA15,
TLW-300
NO
NO
1900LBS
1900LBS
1900LBS
2200LBS
2700LBS
2700LBS
2700LBS
2700LBS
2990LBS
7000LBS
7000LBS
7000LBS
7000LBS
10000LBS
11160LBS
14000LBS
18000LBS
18000LBS
30000LBS
30000LBS
96"
96"
96"
85"
50"
50"
50"
42"
800LB.
FULL TILT WHEEL
TLG-12, DCA15,
TLW-300
NO
NO
800LB.
FULL TILT WHEEL
TRLR-10XF
TRLR-225W
BLW-400
TLG-12, DCA15,
TLW-300
51 GAL
NO
NO
800LB.
FULL TILT WHEEL
DCA-10
NO
800LB.
FULL TILT WHEEL
BLW-400
NO
ELECTRIC
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB.
FULL TILT WHEEL
TRLR-15XF
TRLR-50X
DCA-15
41 GAL
NO
NO
NO
124"
124"
124"
120"
186"
138"
138"
190"
186"
204"
222"
238"
238"
384"
384"
55"
55"
55"
66"
77"
66"
66"
76"
77"
84"
83"
83"
83"
96"
96"
800LB.
FULL TILT WHEEL
DCA-25
800LB.
FULL TILT WHEEL
TRLR-50XF
TRLR-25SBT
TRLR-70W
TRLR-70X
DCA-25
41 GAL
NO
NO
800LB.
FULL TILT WHEEL
DCA-25
NO
800LB.
FULL TILT WHEEL
DCA-45, -60, 70
DCA-45, -60, 70
DCA-45, -60, 70
DCA-100, 125
NO
SURGE
2000LB.
FLAT PAD
OPT
SURGE
2000LB.
FLAT PAD
TRLR-70XF
TRLR-100XF
TRLR-85/125
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800SX
53 GAL
150 GAL
145 GAL
200 GAL
250 GAL
250 GAL
350 GAL
550 GAL
550 GAL
SURGE
2000LB.
FLAT PAD
HYDRAULIC SURGE
HYDRAULIC
HYDRAULIC SURGE
HYDRAULIC SURGE
HYDRAULIC SURGE
ELECTRIC
AIR
2000LB.
FLAT PAD
DCA-85, 100,
125
2000LB.
FLAT PAD
DCA-150, 180
5000 LB.
FLAT PAD
DCA-220
5000 LB.
FLAT PAD
DCA-300
5000 LB.
FLAT PAD
DCA-400
5000 LB.
FLAT PAD
DCA-600, 800
DCA-600, 800
5000 LB.
FLAT PAD
AIR
5000 LB.
FLAT PAD
PAGE 12 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10-15W
2" BALL CLASS
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X2
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
6 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
3 LEAF
3 LEAF
3 LEAF
Q FLEX
3 LEAF
4 LEAF
4 LEAF
4 LEAF
5 LEAF
5 LEAF
5 LEAF
5 LEAF
7 LEAF
7 LEAF
Q FLEX
Q FLEX
Q FLEX
7 LEAF
AIR-RIDE
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10X
TRLR-10XF
TRLR-225W
BLW 400
2"BALL CLASS
2 ADJUSTABLE
175-13C
175-13C
13"X4.5"
13"X4.5"
13X4.5"
13 X 4.5"
13"X4.50"
13"X4.50"
13"X4.50"
14"X5"
2200#2X2
2200#2X2
2200#2X2
2200#2X2
3500# 2-1/2"
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
2"BALL CLASS
2 ADJUSTABLE
2"BALL CLASS
2 ADJUSTABLE
175-13B
2"BALL CLASS
2 ADJUSTABLE
175-13C
TRLR-15XF
TRLR-50X
TRLR-50XF
TRLR-70W
TRLR-70X
TRLR-70XF
2" BALL CLASS
2" BALL CLASS
2" BALL CLASS
B78-13LRC
B78-13LRC
B78-13LRC
4 POLE RUBBER
FLAT
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
3500lbs.
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs.
3"
4 POLE RUBBER
FLAT
TRLR-100XF ADJUSTABLE 2-5/6
205-15C
BIAS (4)
14"X5.5"
14"x6"
3500lbs
3"
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
6 WIRE LOOM
6 WIRE LOOM
OPT 3" EYE
TRLR-85/125 ADJUSTABLE 2-5/6
ST225/75R15D
RADIAL (4)
(2)-6000lbs
(2)-6000lbs
(2)-7000lbs
(2)-6000lbs
(3)-7000lbs.
(3)-10000lbs
(3)-10000lbs
OPT 3" EYE
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800AR
3" BALL EYE
750-16 E
BIAS (4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
5TH WHEEL
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
ST215/75R17.5H
RADIAL (8)
16"X7"
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 13
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER SAFETY GUIDELINES
Brakes
Before any brake synchronizations adjustments can be made,
If your trailer has a braking system, the brakes should be the trailer brakes should be burnished-in by applying the
inspected the first 200 miles of operation. This will allow the brakes 20-30 times with approximately a 20 m.p.h. decrease
brake shoes and drums to seat properly. After the first 200 in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for
mile interval, inspect the brakes every 3,000 miles. If driving brakes to cool between application. This allows the brake
over rough terrain, inspect the brakes more frequently.
shoes to slightly be seated into the brake drum surface.
Electric Brakes
Figure 2 displays the major electric brake components that
Electrically actuated brakes (Figure 2) are similar to hydraulic will require inspection and maintenance. Please inspect these
brakes. The basic difference is that hydraulic brakes are components as required.
actuated by an electromagnet.
Listed below are some of the advantages that electric brakes Electric Brake Adjustment
have over hydraulic brakes:
1. Place the trailer on jack stands. Make sure the jack
!
!
!
!
Brake system can be manually adjusted to provide the
corrected braking capability for varying road and load 2. Check the wheel and drum for free rotation.
conditions
Brake system can be modulated to provide more or less
braking force, thus easing the brake load on the towing 4. With a screwdriver or standard adjusting tool, rotate the
vehicle
Brake system has very little lag time between the time
the vehicle’s brakes are actuated and the trailer’s brakes 5. Adjust the brake shoes outward until the pressure of the
are actuated
stands are placed on secure level ground.
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
star wheel of the adjuster assembly to expand the brake
shoes.
lining against the wheel drum makes the wheel difficult
to turn.
Brake system can provide an independent emergency
brake system
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
In order to properly synchronize the towing vehicle’s braking 7. Replace the adjusting hole cover and lower the trailer to
to the trailer’s braking system, can only be accomplished the ground.
by road testing. Brake lockup, grabbiness or harshness is 8. Repeat steps 1 through 6 on the remaining brakes.
due to lack of synchronization between the tow vehicle and
the trailer being towed or under-adjusted brakes.
PAGE 14 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
Hydraulic/Air/Surge Brakes
components that will require inspection and maintenance.
Hydraulic brakes (Figure 3) should not require any special Inspect these components as required using steps 1 through
attention with the exception of routine maintenance such as 6 as referenced in the electric brake adjustments section.
shoe and lining replacement. These brakes can be adjusted
in the same manner as electric brakes. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Figure 3 below displays the major hydraulic/air/surge brake
Figure 3. Hydraulic Brake Components
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 15
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the
air pressure in
the inner tube
may cause pieces of the rim to
explode (break off) with great force
and cause serious eye or bodily
injury.
Suspension
The leaf suspension springs and associated components
(Figure 4) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 3.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.
Figure 4. Major Suspension Components
PAGE 16 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER SAFETY GUIDELINES
Table 3. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
SHACKLE BOLT
SNUG FIT ONLY
LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
RETAIN NUT-BOLT ASSEMBLY
.
PARTS MUST ROTATE FREELY.
SPRING EYE BOLT
.
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
Lug NutTorque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 5. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined byTable 4.
3.
After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 4. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 5. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 17
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER-WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
PAGE 18 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER-BRAKETROUBLESHOOTING
Table 5. Electric Brake Troubleshooting
Symptom
Possible Cause
Any open circuits or broken wires?
Any short circuits?
Solution
No Brakes or Intermittent Brakes
Find and correct.
Find and correct.
Test and correct.
Find and repair.
Find and secure.
Clean or replace.
Faulty controller?
Any loose connections?
Ground wire secure?
Weak Brakes or Brakes Pull to
One Side
Grease or oil on magnets or linings?
Connections corroded?
Clean and correct cause
of corrosion.
Brake drums scored or grooved?
Brakes synchronized?
Machine or replace.
Correct.
Locking Brakes
Noisy Brakes
Brake components loose, bent or broken?
Brake drums out-of-round?
Replace components.
Replace.
Systemlubricated?
Lubricate.
Brake components correct?
Bearings of the wheel adjusted?
Replace and correct.
Adjust.
Dragging Brakes
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 19
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TRAILER-BRAKETROUBLESHOOTING
Table 6. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Brake line broken or kinked?
Brake lining glazed?
Solution
Repair or replace.
Reburnish or replace.
Correct weight.
No Brakes
Weak Brakes or Brakes Pull to
One Side
Trailer overloaded?
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Brake components loose, bent or broken?
Brake drums out-of-round?
Systemlubricated?
Locking Brakes
Noisy Brakes
Replace components.
Replace.
Lubricate.
Brake components correct?
Replace and correct.
Dragging Brakes
Brake lining thickness correct or in right
wrong position?
Install new shoes and
linings.
Enough brake fluid or correct fluid?
Replace rubber parts
fill with dot4 fluid.
PAGE 20 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —OPERATION AND SAFETY DECALS
Machine Safety Decals
The DCA-220SSK generator is equipped with a number of safety decals.These decals are provided for operator safety and
maintenance information. The illustration below and on the preceding pages shows the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 21
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —OPERATION AND SAFETY DECALS
PAGE 22 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK SPECIFICATIONS
Table 7. Specifications
Generator Specifications
Model
Type
DCA-220SSK
Revolving field, self ventilated, open protected type synchronous generator
Armature Connection
Phase
Star with Neutral
3
Standby Output
Prime Output
Voltage
242 KVA (193.6 KW)
220 KVA (176 KW)
240V or 480V
Frequency
Speed
60 Hz
1800 rpm
Power Factor
Aux. AC Power
Voltage
0.8
Single Phase, 60 Hz
120 V
Output
4.8 KW(2.4 KWx 2)
Engine Specifications
KOMATSU SA6D125E-2
4 Cycle, water-cooled, direct injection, turbo-charged
6 cylinders
Model
Type
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
4.9 in. x 5.9 in. (125 mmx 150 mm)
273 HP/1800 rpm
671 cu. in. (11000 cc)
Electric
Coolant Capacity
Lube Oil Capacity
11.1 gal. (42 liters)
10.4 gal. (40 liters)
12.3 gal(46.6L)/hr at full load
9.4 gal(35.6L)/hr at 3/4 load
Fuel Consumption
6.5gal(24.6L)/hr at 1/2 load
4.0gal(15.1L)/hr at 1/4 load
Battery
Fuel
12V- 150 AH x 2
#2 Diesel Fuel
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 23
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERAL INFORMATION
DCA-220SSK FAMILIARIZATION
Generator
Control Box
The “Control Box” is provided with the following:
"
"
"
Main Circuit Breaker 600 amps
Over-Current Relay
High Idle Adjust Trimmer
The MQ Power Model DCA-220SSK is a 176 kW generator
that is designed as a high quality portable (requires a trailer
for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
Open Delta Excitation System
Engine Control Panel
The DCA-220SSK generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
The “Engine Control Panel” is provided with the following:
"
"
"
"
"
"
"
"
"
"
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
EngineWarning Lamp Module
Engine Speed Switch
Pre-Heat Button
Pre-Heat Lamp
Emergency Stop Button
Battery Switch
There are four leads: A, B, C and D. During light loads, the
power to the AutomaticVoltage Regulator (AVR) is supplied
from the leads parallel connections of B&C. When loads
increase, the AVR switches and accepts power from leads
A&D. The output of leads A&D increase proportionally with
load. This of adding the voltages to each phase provides
better voltage response during heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
Generator Control Panel
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a "fixed ceiling" and responds
according the demands of the required load.
The “Generator Control Panel”is provided with the following:
"
"
"
"
"
"
"
"
"
"
Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
Microprocessor Controlled Alarm System
AC Voltmeter (Volts)
The DCA-220SSK generator is equipped with various alarms
and LED status indicators.These alarms and status indicators
are provided to add safety to the generator when operating
under normal conditions. The DCA-220SSK generator is
designed to shutdown in the event of low oil, high coolant
temperature, low battery and other operation conditions that
may cause severe damage to the generator.
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Panel Light
Panel Light Switch
Pilot Lamp
Microprocessor Engine Control Unit
Control Box
The “Control Box” is provided with the following:
"
"
"
Main Circuit Breaker 600 amps
Over-Current Relay
High Idle Adjust Trimmer
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
"
"
"
"
Three 240/139V output receptacles, 50 amp
Two 120V input receptacles, 20 amp
3 Load Circuit Breakers 265V @65 amps
2 Load GFCI Circuit Breakers 265V@ 20amps
PAGE 24 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERAL INFORMATION (OPTIONS)
Engine
CAUTION
:
The DCA-220SSK is powered by a 4 cycle, water cooled,
turbocharged KOMATSU Model SA6D125E-2 diesel engine.
This engine is designed to meet every performance
requirement for the generator. Reference Table 1, page 16
for engine specifications.
ALWAYS unplug the jacket water heater
before servicing.
In keeping with Multiquip's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Battery Charger
The basic controls and indicators for the DCA-220SSK
generator are addressed on the following pages.
The battery charger will operate in a‘BOOST’mode until the
battery’s current acceptance falls to 70% of the charger’s
rating. The charger will then go into a‘FLOAT’mode, where
it discharges a lower voltage until an AC failure, or the battery
is discharged.
Electronic Governor System
The electronic governor system replaces the standard
mechanical governor system. The frequency regulation
improves from ±3.0% regulation with the mechanical governor
to ±0.25% regulation with the electronic governor system.
JacketWater Heater
The jacket water heater is a 1500-watt heater designed to
keep the coolant warm in the engine block for fast starts
and load acceptance. The heater is thermostatically
controlled and once an acceptable engine temperature is
achieved it will cycle on and off, operating only about 1/3 of
the time, which makes it more efficient than the direct block
type heater. It is designed to keep the engine coolant
between 100 and 120 degrees Fahrenheit.
Under normal conditions, 20 to 15 minutes is required to
raise the engine temperature of a cold engine to 100 degrees
Fahrenheit.
NOTE:
The jacket water heater can be
serviced if not functioning
properly.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 25
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —WATER SEPARATOR FILTER (OPTIONAL)
Water Separator Filter
CAUTION
:
The DCA-220SSK generator may be equipped with a“Water
Fuel Separator". This unit is designed to prevent dirt, rust,
algae, varnishes and water from entering the fuel system.
DO NOT turn the control valve while the
generator is in operation.This may stop fuel
flow to the generator if both filters are set to
the OFF position.
This water separator system is designed around two filters
connected in parallel (Figure 6). These two filters can be
configured in a variety of ways to filter water from the fuel
system.
For best results it is best to have both filters active (ON) at
the same time or use only one filter, and use the other filter
as a reserve, that way you can use the filters alternately
every time the filter element is replaced.
Figure 6.Water Separator Filter
Collection BowlWater Drainage
Inspect or drain the water in the collection bowl daily. The
collection bowl must be drained before contaminants reach
the bottom of the turbine.
To drain the collection bowl perform the following:
1. Open the self-venting drain to evacuate contaminants
with a suitable collection container in place.
2. Prime the unit by removing the filter lid and filling with
clean fuel.
3. Replace the filter lid and snugly tighten the T-handle by
hand only.
PAGE 26 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — MAJOR COMPONENTS
Figure 7. Major Components
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 27
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — DIMENSIONS (TOP AND SIDE)
Figure 8a. Dimensions
PAGE 28 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — DIMENSIONS (FRONT AND REAR)
Figure 8b. Dimensions
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 29
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — CONTROL PANEL
Figure 9. Control Panel
PAGE 30 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — CONTROL PANEL
If the engine does not engage (start) by the third attempt,
the engine will be shutdown by the MPEC's " Over Crank
Protection" mode. If the engine engages at a speed (RPM's)
that is not safe, the MPEC will shutdown the engine by
initializing the "Over Speed Protection" mode.
The definitions below describe the controls and functions of
the DCA-220SSK " Control Panel " (Figure 9).
1. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz ±1 Hz .
2. AC Ammeter – Indicates the amount of current the
Also the MPEC will shutdown the generator in the event of
low oil pressure, high coolant temperature, low coolant level,
and loss of magnetic pickup. These conditions can be
observed by monitoring the LED status indicators on the
front of the MPEC module.
load is drawing from the generator.
3. Ammeter Change-Over Switch – This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals, or
to be switched off.
A. Off/Manual/Auto Switch – This switch controls the
running of the generator.If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the manual position, the generator will start
immediately.
4. AC Voltmeter – Indicates the single phase output
voltage present at the UVW terminals.
5. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
If the generator is to be connected to a building's AC
power source via a transfer switch (isolation), place
the switch in the auto position. In this position the
generator will monitor the AC line output from the
building's power source.
6. Pilot Lamp – Indicates that the generator is working
properly.
7. Main Circuit Breaker – This three-pole, 600 amp main
breaker is provided to protect the UVW voltage output
terminals from overload.
B. Low Oil Pressure – Indicates the engine pressure
has fallen below 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
sending unit. This is considered a major fault.
8. Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage.
C. High Coolant Temperature – Indicates the engine
temperature has exceeded 215°F. The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
9. Panel Light – Normally used in dark areas or at night
time.When activated, panel lights will illuminate.When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
10. Panel Light Switch – When activated will turn on control
panel light.
D. Overcrank Shutdown – Indicates the unit has
attempted to start a pre- programmed number of times,
and has failed to start. The number of cycles and
duration are programmable.Typical programmable start
settings is 3 cycles with a 10 second duration .This is
considered a major fault.
11. MPEC – Microprocessor
Engine Control Module –
(MPEC) has a vertical row
of status LED's (Figure 10),
that when lit, indicate that an
engine malfunction (fault),
has been detected. When a
fault has been detected the
MPEC will evaluate the fault
and if the fault is major will
E. Overspeed Shutdown – Indicates the engine is
running at an unsafe speed.This is considered a major
fault.
F. Engine Running – Indicates that engine is running at
a safe operating speed.
Figure 10. MPEC Module
shutdown the generator.
During cranking cycle , The MPEC will attempt to crank the
engine for 10 seconds before disengaging.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 31
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL
Figure 11. Engine Operating Panel
PAGE 32 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of
the DCA-220SSK " Engine Operating Panel "(Figure 11).
E. Clogged Air Filter Lamp – This lamp goes
ON when the air filter is clogged. If this
lamp goes ON during normal operation of
the generator, stop the engine and replace
the air filter.
1. Engine Speed Switch – This switch controls the
constant speed of the engine.
2. Caution Lamp - This light indicates the generator is
running.
3. Throttle Handle - This handle controls the speed of
the engine (low or high).
6. Oil Pressure Gauge – During normal operation this
gauge be should read in the “GREEN” zone. When
starting the generator the oil pressure mar read a little
bit higher, but after the engine warms up the oil pressure
should return to the green zone.
4. Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s
when the rated load is applied. In addition a built in 7. WaterTemperature Gauge – During normal operation
hour meter will record the number of operational hours
that the generator has been in use.
this gauge be should read in the “GREEN” zone.
8. Charging Ammeter Gauge – Indicates the current
being supplied by the engine’s alternator which provides
current for generator’s control circuits and battery
charging system.
5. Engine Warning Display Module – This module
display’s the following engine failures:
A. Overheat Lamp – This lamp goes ON when
the cooling water temperature rises
abnormally. If the lamp goes ON during
normal operation of the generator, the
emergency shutdown device will stop the
engine automatically.
9. Pre-Heat Lamp – Indicates that the glow
plugs of the diesel engine are hot and the
engine is ready to be started.
B. Low Oil Pressure Lamp – During normal
operation of the generator this lamp should
remain OFF. When the Auto-OFF/Reset-
Manual switch is set to the “Manual” position
to start the engine, the lamp will be lit.After
the oil pressure rises after start-up the lamp
will go OFF. If this lamp is ever lit (ON)
during normal operation of the generator,
the emergency shutdown device will stop
the engine automatically.
10. Emergency Stop Button – Push this
button inward to stop the engine in the
event of an emergency.DO NOT use this
button as a means of stopping the
engine.
11. Starter Switch - This turns the generator on or off.
(The generator is not equipped with this feature if has
MPEC (see Control Panel).
12. Battery Switch – This switch should
be set to the ON position during
normal operation. When the engine
has been stop, place this switch in
the OFF position. DO NOT turn this
switch during normal operation, it
could cause damage to the electrical
equipment.
C. Low Fuel Level Lamp – When this lamp
is ON, it is time to stop the engine and add
fuel. Remember to let the engine cool
before adding fuel.
D. Low Battery Fluid Lamp – This lamp goes
ON when the battery fluid is low. If this
lamp goes ON during normal operation of
the generator, stop the engine and fill the
battery with distilled water to the specified
level.
13. Air Cleaner Indicator - Indicates the
air filter needs replacement.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 33
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — OUTPUTTERMINAL PANEL OVERVIEW
OUTPUTTERMINAL FAMILIARIZATION
The “Output Terminal Panel” is provided with the following:
Connecting Load
Loads can be connected to the generator by the UVW Lugs or
the convenience receptacles. (See Figure 14). Make sure to
read the operation manual before attempting to connect a load
to the generator.
"
"
"
"
Three 120/240V output receptacles, 50 amp
Two 120V input receptacles, 20 amp
3 Load Circuit Breakers 250V @50 amps
2 Load GFCI Circuit Breakers 120V@ 20amps
Control Box
The “Control Box” is provided with the following:
"
"
Main Circuit Breaker 600 amps
Over-Current Relay
Output Terminal Panel
The Output Control Panel (See Figure 16) is located on the
right hand side (left from control panel) of the generator.
The UVW lugs are protected by a face plate cover that can
be secured in the close position by a pad lock. (See Figure
12).
FIGURE 14. Connecting Load
Circuit Breakers
To protect the generator from an overload, a 3-pole, 600 amp,
main circuit breaker is provided to protect the UVW output
terminals from overload. In addition two single-pole, 20 amp
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload.Three 50 amp load circuit breakers
have also been provided to protect the load side of the
generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
Maximum Output
FIGURE 12. Output Terminal Cover
The entire load connected to the UVW Lugs, all four slots in the
duplex receptacles, and the must not exceed 88 kW in standby
or 80 kW in prime output.
120Volt Receptacle
Two GFCI Duplex Nema 5-20R (120V, 20 Amp) receptacle
is provided on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle
is controlled by the circuit breaker located on the control
panel.
Twist Lock Dual Voltage Receptacles - To use these
receptacles, place the voltage selector switch in the single
phase 240/120 voltage position and adjust the output
voltage to 240 volts with the voltage regulator on the
Control Panel. Place the voltmeter change-over switch to
the U-W position and the ammeter change-over switch to
the U or W to read the output.
Pressing the reset button resets the receptacle after being
tripped. Pressing the "Test Button" (See Figure 13) in the
center of this receptacle will check the GFCI function. The
receptacle should be tested at least once a month.
FIGURE 13. GFCI Test Button
PAGE 34 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — OUTPUTTERMINAL PANEL OVERVIEW
FIGURE 15. Output Terminal Panel
NOTE
Legs
O
and Ground are
considered Bonded Grounds.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 35
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — OUTPUTTERMINAL PANEL OVERVIEW
Output Terminal Panel Available Voltages
Maximum Amps
A wide range of voltages are available to supply load to
many different applications. Voltages may be selected by
using the voltage selector switch and how you hookup
your hard wire connection to the generator. To obtain some
of the voltages listed, fine adjustment with the Voltage
Regulator on the control panel is necessary. See the table
below (Table 8) for a list of available voltages the generator
is able to supply.
The following table show the maximum amps the entire
generator can provide. Do not exceed the maximum amps
listed (See Table 9 below).
Table 9. Maximum Amps
Rated
Maximum Amps
Voltage
Table 8. Voltages Available
Single Phase
488.9 amps (4 wire)
120 Volt
3 Phase Voltage
208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT
(Reconnectable)
Single Phase
120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT
(Adjustable)
Single Phase
244.4 amps (4 wire)
240 Volt
Three Phase
529.3 amps
240 Volt
Voltage Selector Switch
The voltage selector switch is located above the UVWO
Hard Wire Hookup Panel. It has been provided for ease of
voltage selection.
Three Phase
264.6 amps
480 Volt
CAUTION :
NEVER switch Voltage Selector Switch
position while the engine is engaged.
Voltage Selector Switch Locking Button
The voltage selector switch has a locking button to protect
the generator and generator load from being switched while
the engine is running. To lock the Voltage Selector Switch,
press in the red button located on the Voltage Selector
Switch, and use a pad lock to hold it into this position
(See Figure 17, page 37).
Over Current Relay
An over current relay is connected to the circuit breaker.
In an over current situation, both the circuit breaker and
the over current relay may trip. If the circuit breaker can
not be reset, the reset button on the over current relay
must be pressed. The over current relay is located in the
control box.
PAGE 36 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — OUTPUTTERMINAL PANEL OVERVIEW
How to read the output terminal gauges.
The gauges and knobs on the control panel DO NOT effect
the generator output in any fashion. They are there to
simply help the operator observe how much power is being
supplied produced at the UVWO legs.
When the Voltage selector switch is in the 240/120V
position (see Figure 16), place the AC Voltmeter Change-
over switch to the W-U position and the AC ammeter
Change -over Switch to the U or W position to read the
output on the selected leg.
FIGURE 20. AC Ammeter
(Amp reading on U lug)
FIGURE 19. AC Ammeter
Change-over Switch
(Reading the U leg on the
output terminal panel)
NOTE
When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.
FIGURE 16. Voltage Selector Switch 240/120V Single Phase
Position
FIGURE 17. AC Voltmeter
FIGURE 18. AC Voltmeter
Change-over switch
Gauge
(Reading the W-U leg on
(Volt reading on W-U Lug)
the output terminal panel)
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 37
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — OUTPUTTERMINAL PANEL OVERVIEW
480/240V Hard Wire Hookup
240/120V HardWire Hookup
The output terminal panel, when suppling three phase 240
volts, will provide one circuit available at 241 amps with any
two wires plus the ground.(See Figure 24 below.) The voltage
selector switch must be set at the three phase 480/277V
position.
The output terminal panel, when suppling single phase 120
volts, will provide three legs available with 222.2 amps each
on three different circuits. (See Figure 23 below.) The voltage
selector switch must be set at the single phase 240/120V
position.
The output terminal panel, when suppling 3 phase 480 volts,
will provide one circuit available at 120 amps available with
all three wires plus ground. (See Figure 23 below.) The
voltage selector switch must be set at the three phase 480/
277V position.
The output terminal panel, when suppling single phase 240
volts, will provide one leg only with 111.1 amps available.
(See Figure 22 below.) The voltage selector switch must be
set at the single phase 240/120V position.
FIGURE 21. Voltage Selector Switch 240/120V Single Phase
Position
FIGURE 23. Voltage Selector Switch 480/277V Three Phase
Position
FIGURE 24. Hard Wire Hookup at 480/240V Position
FIGURE 22. Hard Wire Hookup at 240/120V Position
PAGE 38 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — OUTPUTTERMINAL PANEL OVERVIEW
Voltage Selector Switch- 3 Phase 480/277V Position
Single Phase: 480V, 440V, or 416 Volt
The following are additional voltages available when the
voltage selector switch is in the 3 phase 480/277V
position. (See figure 25 below.)
The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 25),
can offer SINGLE PHASE power at 480V, 440V, or 416V.
After hooking up the hard wires to the lugs as shown in
Figure 28 below, 480V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 440 volt will be
reached when the Voltage Regulator Knob is turned down,
and 416 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 26).
FIGURE 26. Voltage
Selector Switch 270/120V
Single Phase
Position
FIGURE 25. Voltage Selector Switch 480/277V Single Phase
Position
FIGURE 28. Hard Wire Hookup for Single Phase 480V, 440V,
or 416V
Single Phase: 277V, 254V, or 240V
3 Phase, 480V, 440V, or 416 Volt
The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 26),
can offer SINGLE PHASE power at 277V, 254V, or 240V.
After hooking up the hard wires to the lugs as shown in
Figure 29 below, 277V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 254 volt will be
reached when the Voltage Regulator Knob is turned down,
and 240 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 26).
The following connection, with the voltage selector switch
locked into the 3 phase 480/277V position (See Figure 26),
can offer THREE PHASE power at 480V, 440V, or 416V.
After hooking up the hard wires to the lugs as shown in
figure 28 below, 480V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 440 volt will be
reached when the Voltage Regulator Knob is turned down,
and 416 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 26).
FIGURE 27. Hard Wire Hookup for Three Phase 480V, 440V,
or 416V
FIGURE 29. Hard Wire Hookup for Single Phase 277V, 254V,
or 240V
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 39
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — OUTPUTTERMINAL PANEL OVERVIEW
Single Phase: 240V, 220V, or 208Volt
Voltage Selector Switch- 3 Phase 240/139V Position
The following are additional voltages available when the
voltage selector switch is in the 3 phase 240/139V
position. (See Figure 30 below.)
The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 30),
can offer SINGLE PHASE power at 240V, 220V, or 208V.
After hooking up the hard wires to the lugs as shown in
Figure 33 below, 240V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 220 volt will be
reached when the Voltage Regulator Knob is turned down,
and 208 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 31).
FIGURE 31. Voltage
Regulator Knob located
on the control panel
FIGURE 33. Hard Wire Hookup for Single Phase 240V, 220V,
or 208V
FIGURE 30. Voltage Selector Switch 240/139V Three Phase
Position
Single Phase: 139V, 127V, or 120V
3 Phase, 240V, 220V, or 208 Volt
The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 30),
can offer SINGLE PHASE power at 139V, 127V, or 120V.
After hooking up the hard wires to the lugs as shown in
Figure 34 below, 139V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 127 volt will be
reached when the Voltage Regulator Knob is turned down,
and 120 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 31).
The following connection, with the voltage selector switch
locked into the 3 phase 240/139V position (See Figure 30),
can offer THREE PHASE power at 270V, 220V, or 208V.
After hooking up the hard wires to the lugs as shown in
Figure 32 below, 240V will be the voltage with the Voltage
Regulator Knob turned toward maximum. 220 volt will be
reached when the Voltage Regulator Knob is turned down,
and 208 volt when the Voltage Regulator Knob is toward
the lowest setting (See Figure 31).
FIGURE 32. Hard Wire Hookup for Three Phase 240V, 220V,
or 208V
FIGURE 34. Hard Wire Hookup for Single Phase 139V, 127V,
or 120V
PAGE 40 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — OUTPUTTERMINAL PANEL OVERVIEW
Single Phase: 120 Volt
Voltage Selector Switch- Single Phase 240/120V
Position
The following are additional voltages available when the
voltage selector switch is in the single phase 240/120V
position. (See Figure 35 below)
The following connection, with the voltage selector switch
locked into the single phase 240/120V position (See
Figure 35), will offer SINGLE PHASE power at 120V. After
hooking up the hard wires to the lugs as shown in Figure
38 below, use the Voltage Regulator Knob to fine tune to
120V. (See Figure 36).
FIGURE 36. Voltage
Regulator Knob
located on the control
panel
FIGURE 35. Voltage Selector Switch 240/120V Single Phase
Position
FIGURE 38. Hard Wire Hookup for Single Phase, 120 volt
Single Phase, 240 Volt
The following connection, with the voltage selector switch
locked into the single phase 240/120V position (See
Figure 35), will offer SINGLE PHASE power at 240V. After
hooking up the hard wires to the lugs as shown in Figure
37 below, use the Voltage Regulator Knob to fine tune to
240V. (See Figure 36)
FIGURE 37. Hard Wire Hookup for Single Phase 240 volt
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 41
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — INSTALLATION
Outdoor Installation
CAUTION
:
Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure the generator is on secure
level ground so it cannot slide or shift around. Also install
the generator so the exhaust will not be discharged in the
direction of nearby homes.
An electric shock may happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from electrical shock.
Generator Grounding
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine parts and alternator.
Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as
practical.
CAUTION :
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside.The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
2. When grounding the generator (Figure 39) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully.Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
NOTE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
PAGE 42 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — INSTALLATION
Figure 39. Typical Generator Grounding Application
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 43
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — PRE-SETUP
General Inspection Prior to Operation
Circuit Breakers
The DCA-220SSK generator has been thoroughly inspected To protect the generator from an overload, a 3-pole, 600 amp,
and accepted prior to shipment from the factory. However, main circuit breaker is provided to protect the UVW output
be sure to check for damaged parts or components, or loose terminals from overload. In addition two single-pole, 20 amp
nuts and bolts, which could have occurred in transit.
GFCI circuit breakers are provided to protect the GFCI
receptacles from overload.Three 50 amp load circuit breakers
have also been provided to protect the load side of the
generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
Extension Cable
When electric power is to be provided to various tools or
loads at some distance from the generator, extension
cords are normally used. Cables should be sized to allow
for distance in length and amperage so that the voltage
drop between the generator and point of use (load) is held
to a minimum. Use Cable Selection Guide (Table 10 ) as
a guide for selecting proper cable size.
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
Table 10. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Maximum Allowable Cable Length
Current in
Amperes
At 120
Volts
At 240
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
5
300
600
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
1200
1800
2400
3600
4800
7.5
10
15
20
900
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage.
PAGE 44 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — PRE-SETUP
Fuel
Lubrication Oil
Fill the fuel tank with clean and fresh diesel fuel. DO NOT
fill the tank beyond capacity.
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, but without being screw
into the filler hole, verify that the oil level is maintained
between the two notches (Figure 39) on the dipstick. See
Table 11 for proper selection of engine oil.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel. Wipe up any spilled fuel immediately.
CAUTION
:
Never fill the fuel tank while the engine is
running or in the dark. Diesel spillage on a
hot engine can cause a fire or explosion.
If diesel spillage occurs, wipe up the
spilled diesel completely to prevent fire
hazards.
Coolant
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.
Figure 39. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean and viscous. If the oil is not clean, drain the oil by
removing the oil drain plug, and refill with the specified amount
of oil as outlined in the Komatsu Engine Owner's Manual.
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
Table 11. Recommended Motor Oil
Temperature Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
SAE 10W or SAE 10W-30
Below 5° C (-15°)
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 45
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — PRE-SETUP
Cleaning the Radiator
CAUTION :
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the radiator
fins with compressed air. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
battery disconnected.
When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.
Day-to-day addition of coolant is done from the reserve tank.
When adding coolant to the radiator, DO NOT remove the
radiator cap until the unit has completely cooled. See Table
12 for engine, radiator, and reserve tank coolant capacities.
Make sure the coolant level in the reserve tank is always
between the "H" and the "L" markings.
Air Cleaner
Periodic cleaning/replacement is necessary. See
maintenance section for instruction to cleaning/replacing air
cleaner.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear. See maintenance section on replacing
belts. To adjust tension:
Table 12. Coolant Capacity
1. Insert a bar between alternator and the cylinder block to
fix alternator in position. When fixing the alternator in
position, insert a wooden block between the bar and
alternator to prevent damage to the alternator.
2. Loosen bolts and nuts located on the alternator.
3. Move alternator with the bar so the deflection of the belt
is approx. 8mm.
Engine and Radiator
Reserve Tank
11.1 Gal. (42.0 Liters)
2 Quarts (1.9 Liters)
Operation in Freezing Weather
4. Tighten the bolt and nuts to fix the alternator back to
position.
When operating in freezing weather, be certain the proper
Day-to-day addition of coolant is done from the
amount of antifreeze (Table 13) has been added.
The fan belt tension is proper if the fan belt bends 7 to 10
mm (Figure 40) when depressed with the thumb as shown
below.
Table 13. Anti-Freeze Operating Temperatures
Freezing Point
Boiling Point
Vol %
Anti-Freeze
°C
-24
-37
°F
°C
°F
40
50
-12
-34
106
108
222
226
Figure 40. Fan Belt Tension
CAUTION
:
NOTE
Never place hands near the belts or fan
while the generator set is running.
When the antifreeze is mixed with
water, the antifreeze mixing ratio must
be less than 50%.
PAGE 46 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — PRE-SETUP
Battery Cable Installation
CAUTION
:
ALWAYS be sure the battery cables (Figure 41) are properly
connected to the battery terminals as shown below. The
RED cable is connected to the positive terminal of the battery,
and the BLACK cable is connected to the negative terminal
of the battery.
Inadequate battery connections may cause
poor starting of the generator, and create
other malfunctions.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness.Tighten all hose clamps and check hoses
for leaks.
If any hose (fuel or oil) lines are defective replace them
immediately.
Figure 41. Battery Connections
Battery
CAUTION
:
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68 F). If the specific gravity
should fall to 1.245 or lower, it indicates the battery is
discharged and needs to be recharged or replaced.
Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions. Always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help inhibit corrosion.
If the battery cable is connected
incorrectly, electrical damage to the
generator will occur. Pay close attention
to the polarity of the battery when
connecting the battery.
When connecting battery do the following:
1. DO NOT connect the battery cables to the battery
terminals when the Off/Manual/Auto switch is in either
the manual or auto position (ON). ALWAYS make sure
that the Off/Manual/Auto switch is in the OFF position
when connecting the battery.
2. Place a small amount of grease around both battery
terminals. This will ensure a good connection and will
help prevent corrosion around the battery terminals.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 47
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — LOAD APPLICATION
Single Phase Load
CAUTION
:
Motors and motor-driven equipment draw
much greater current for starting than
during operation.
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.
An inadequate size connecting cable which
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.
cannot carry the required load can cause a voltage drop
which can burn out the appliance or tool and overheat the
cable.
"
"
"
When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
NOTE
If wattage is not given on the
equipment's name plate, approximate
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
WATTS = VOLTAGE x AMPERAGE
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
The power factor of this generator is 1.0. See Table 14.
below when connecting loads.
CAUTION:
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.
Table 14. Power Factor By Load
Type Of Load
Power Factor
Single-phase induction motors
0.4 - 0.75
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
Fluorescent lamps, mercury lamps
Electronic devices, communication
equipment
NOTE
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
If
output
(kVA)
is
not
given
on the equipment nameplate, approximate
output may be determined by multiplying
voltage by amperage by
.
PAGE 48 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)
Jacket Water Heater and Internal Battery Charger 120
VAC Output Receptacles (OPTIONAL)
WARNING:
This generator is equipped with two 120VAC, 20 amp output
receptacles located on the output terminal panel, page 36,
Figure 12.
"
The engine's exhaust contains harmful
emissions. ALWAYS ventilate the
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
Before Starting
Engine
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 19). To apply
commercial power to these receptacles, a power cord of
adequate size will be required.
1. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.
2. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 9 on page 41).
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times.To
apply power to the jacket water heater simply apply power
to the jacket water heater receptacle via commercial power
using an power cord of adequate size.
3. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary.Always maintain
the coolant level between the FULL and LOW markings
on the coolant container. Be sure the radiator cap is
fastened securely.
If the generator will be used daily, the battery should normally
not require charging. If the generator will be idle (not used)
for long periods of time, apply power to the battery charger
receptacle via commercial power using an power cord of
adequate size.
4. Check the fuel level on the fuel gauge. If fuel is low, fill
the fuel tank with clean fresh unleaded automotive diesel.
If diesel spillage occurs, completely wipe up the spilled
fuel immediately.
When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator's
internal battery charger.This will ensure that the engine will
not fail due to a dead battery.
Before Starting
Generator and Control Panel
CAUTION:
"
NEVER start the engine with the
main, GFCI or load circuit breakers
in the ON position.
CAUTION:
ALWAYS have power applied to the
generator's internal battery charger
when connecting the generator to a
isolation (transfer) switch. Remember
before connecting this generator to
any buildings electrical system, have
a licensed electrician perform the
installation of the transfer switch.
1. Be sure to disconnect the electrical load and switch the
main, load and G.F.C.I. circuit breakers (Figure 42) to
the “OFF” position prior to starting the engine.
Figure 42. Main, GFCI and
Load Circuit Breakers
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 49
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)
2. Connect the load to the UVW terminals as shown in
Figure 43. These terminals can be found on the output
terminal panel, see page 35 Figure 15. To gain access
to the output terminals lift the UVW cover. Make sure to
tighten terminal nuts securely to prevent load wires from
slipping out.
4. Close all engine enclosure doors (Figure 45).
Figure 45. Engine Enclosure Doors
5. Set the battery ON/OFF switch (Figure 46) to the ON
position.
Figure 43. UVW Terminal Lugs (Load)
3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 44).
Figure 46. Battery ON/OFF Switch
6. When starting the generator in COLD weather conditions,
press and hold the engine preheat button (Figure 47)
until the preheat lamp (Figure 48) is lit (ON).
TIVE
NEGA
POSTIVE
Y
TTER
BA
Figure 47. Engine Pre-Heat Button
Figure 48. Engine Pre-Heat Lamp
Figure 44. Battery Connections
PAGE 50 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)
7. Place the Off/Manual/Auto switch (Figure 49) in the
MANUAL position (down).Observe that the engine begins
to crank.
Figure 51. Frequency Meter (Hz)
11. The generator's voltage meter (Figure 52) displays the
Figure 49. Off/Manual/Auto Switch (Manual)
120 VAC in VOLTS. If the voltage is not within the
specified frequency tolerance, use the voltage
adjustment control knob (Figure 53) to increase or
decrease the desired voltage.
8. After engine starts, verify that the "Engine Running"
status LED (Figure 50) on the Microprocessor Engine
Control Module (MPEC) display is "ON" (lit).
Figure 52. Voltage Meter (Volts)
Figure 50. MPEC Engine Running Status LED
9. If the generator is equipped with a ignition switch, turn
the key to “Start” position (Figure 51). Once the engine
starts, release the key to the “on” position.
Figure 53. Voltage Adjust Control
Knob
12. The ammeter (Figure 54) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator’s alternator.
40
20
60
0
75
Figure 51. Engine Ignition Switch
A
10. The generator's frequency meter (Figure 52) displays
the 60 cycle output frequency in HERTZ.
Figure 54. Ammeter (No Load)
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 51
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERATOR START-UP PROCEDURE (MANUAL)
13. The engine oil pressure gauge (Figure 55) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure should be
approximately 25 psi.
16. Turn the MAIN, GFCI and LOAD circuit breakers to their
"ON" position (Figure 58).
Figure 58. Main and GFCI Circuit Breakers
Figure 55. Oil Pressure Gauge
14. The coolant temperature gauge (Figure 56) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (Green Zone).
17. Observe the generator's ammeter (Figure 59) and verify
that it reads the anticipated amount of current with
respect to the load. Remember the ammeter will only
display a current reading if the load is in use.
40
20
60
0
75
WATER TEMP
A
Figure 56. Coolant Temperature Gauge
Figure 59. Ammeter (Load)
15. The tachometer (Figure 57) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed should be approximately
1800 RPM’s.
18. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 57. Engine Tachometer
PAGE 52 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERATOR START-UP PROCEDURE (AUTO)
When starting generator in Auto mode use the "Manual Start-
up" procedure except where noted (see below).
CAUTION:
CAUTION:
Before connecting this generator to any
1. Perform steps 1 through 8 (Before Starting, page 43-
45) as outlined in the manual starting procedure.
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.
2. Apply commercial power to the internal battery charger
receptacle (to ensure good starting) via commercial
power. An external power cord will be required.
3. Apply commercial power to the jacket water heater
receptacle (not necessary for warm climates) via
commercial power. An external power cord will be
required.
When connecting the generator to a
isolation (transfer) switch, ALWAYS have
power applied to the generator's internal
battery charger. This will ensure that the
engine will not fail due to a dead battery.
4. Place the Off/Manual/Auto switch (Figure 60) in the
AUTO position (up).
Starting the generator in the "AUTO" mode is similar to
starting the generator in the "MANUAL" mode, with a few
exceptions.
Figure 60. Off/Manual Auto Switch
(AUTO)
CAUTION:
When running the generator in the AUTO
mode, remember the generator can start
up at any time without warning. NEVER
attempt to perform any maintenance when
the generator is in the auto mode.
5. Continue to follow the steps outline in the manual start-
up procedure (start at step 11, page 46).
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 53
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERATOR SHUTDOWN PROCEDURE
Emergency Stop
Engine Shutdown
To shutdown the generator use the following procedure:
1. To stop the engine in the event of an emergency, PUSH
the emergency stop button ( Figure 63) inward.This button
is located on the generator's engine operating panel,
see page 32, Figure 11.
1. Place both the MAIN, GFCI and LOAD circuit breakers
to the "OFF position".
2. Let the engine cool by running it for 3-5 minutes with no
load applied.
3. Place the Off/Manual/Auto Switch (Figure 61) in the "OFF/
RESET" position.
Figure 63. Emergency Stop Button
CAUTION
:
Figure 61. Off/Manual Auto Switch (OFF)
NEVER stop the engine suddenly except
in an emergency. DO NOT use the
emergency stop switch a as method of
shutting down the engine. This switch is
ONLY to be used in the event of an
emergency.
4. Verify that the "Engine Running" status LED (Figure 62)
on the Microprocessor Engine Control Module (MPEC)
display is "OFF" (not lit).
Figure 62. MPEC Engine Running
Status LED (OFF)
5. Remove the load from the UVW terminal strip (Figure 16).
PAGE 54 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTE PAGE
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 55
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — MAINTENANCE
General Inspection
Fuel Addition
Prior to each use, the generating set should be cleaned and Add diesel fuel (the grade may vary according to season
inspected for deficiencies. Check for loose, missing or and locations). Always pour through the mesh filter.
damaged nuts, bolts or other fasteners. Also check for fuel Removing Water from theTank
or oil leaks.
Air Cleaner
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
Every 50 hours: If dust indicator is red, clean the air cleaner cock and drain the contents. During cold weather, the greater
element.
Outer Element:
the empty volume inside the tank, the easier it is for water to
condense. This can be reduced by always keeping the tank
1. Loosen wing bolt, remove dust cup, then remove wing as full as possible.
nut and take out element. Air Removal
2. Clean the inside of the body and cover using a damp If air enters the fuel injection system of a diesel engine,
cloth.
starting becomes impossible. After running out of fuel, or
3. Blow dry with compressed air (0.69Mpa (7kgf.cm2, after disassembling the fuel system, bleed the system
99.4 PSI ) maximum) against the side of the element according to the following procedure.
along the pleats. Then blow dry against outside along To restart after running out of fuel, turn the key switch to the
the pleats, then against inside again.
“START” position for 15-30 seconds. Try again, if needed.
4. Remove one seal each time the element is cleaned.
This unit is equipped with an automatic air bleeding system.
5. Replace the outer element after cleaning it 6 times or Service Daily
after one year. Replace the outer element if indicator is If engine is operating in very dusty and dry grass conditions,
red even after cleaning it.
a clogged air cleaner will result in high fuel consumption,
6. Check the inner cylinder element clamping nut for loss of power and excessive carbon buildup in the
looseness, and retighten if necessary.
7. If seal washer is damaged or the threads of wing nut are
damaged, replace.
8. Remove evacuator valve and clean it with compressed
air. Reinstall.
Inner element (if equipped)
1. Remove the cover and outer element, then remove the
inner element.
2. Cover the air connector opening (outer side) with clean
cloth or cloth tape.
3. Clean the inside of the body. Remove air connector
opening protection.
4. Install a new inner cylinder element to the cylinder and
tighten the nut.
5. Install element.
combustion chamber.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in diesel. Securely
fasten the fuel strainer cap so that fuel will not leak. Check
the fuel strainer every 200 hours of operation or once a month.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level.The oil level
must be between the two notches on the dipstick as shown
in Figure 14, page 39.
Flushing Out Radiator and Changing Coolant
6. After replacing the element, press the button of the dust
indicator to return the red piston to its original position.
1. Stop the engine and allow to cool. Tighten valve of the
corrosion resistor (if equipped).
2. Turn water filer cap slowly and remove it.
3. Prepare a container to catch the coolant, then open drain
plug of the radiator or heat exchanger and drain plug of
the engine, and drain the coolant.
4. After draining the coolant, close drain plugs and fill with
tap water.
PAGE 56 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — MAINTENANCE
5. When the water level is near the mouth of the water Changing Oil
filler, open drain plugs and start the engine, and run at
low idling. Keep the engine running at low idling and
flush the radiator for about 10 minutes.
1. Make sure the oil is cool before changing.
2. Set a container directly under the drain plug of the oil
pan. Loosen the drain plug slowly.
6. Adjust the flow of the water flowing in and draining out to
ensure that the radiator is always full during the flushing
operation, While flushing water through the system,
watch carefully the water inlet hose does not come out
of the radiator filler port.
3. Check the drained oil for excessive metal particles or
foreign material. Contact the distributor if there is metal
particles or foreign material.
4. Using a filter wrench, turn filter cartridge to the left to
remove it. If the filter cartridge is filled with a large
amount of oil, wait 10 minutes or so before removing.
Make sure there is no old gasket stuck on the filter holder.
7. After flushing, stop the engine, open drain plug and drain
the water, then close drain plugs.
8. After draining the water, flush the system with a flushing
agent. See instructions on flushing agent label.
5. Tighten drain plug. Clean the filter holder, fill the new
filter cartridge with clean engine oil, coat the packing
and thread of the new filter cartridge with engine oil,
then install it to the filter holder. Tighten until the gasket
surface contacts the seal surface of the filter holder,
then tighten it a further 3/4 to 1 turn.
9. After flushing, open drain plugs and drain out all the
water, then close drain plugs and add tap water so the
water level is near the mouth of the water filler.
10. When the water level is near the mouth of the water
filler, open drain plugs and start the engine, run at low
idling and continue to flush the system until clean water
comes out. Adjust the flow of the water flowing in and
draining out to ensure the radiator is always full during
the flushing operation.
6. Add engine oil through oil filler until the oil level is between
the H and L marks on the dipstick.
7. Run the engine at idling for a short time, then stop the
engine. Recheck the oil level and fill as necessary.
Replacing fuel filter
11. When clean water comes out, stop the engine, drain all
the water, then close drain plugs.
1. Set the container under the filter cartridge to catch fuel.
2. Using a filter wrench, turn the filter cartridge to the left
to remove it.
12. Remove the corrosion resistor (if equipped) and open
valve.
3. Clean the filter holder, fill the new filter cartridge with
fuel, coat the packing surface of the filter cartridge with
engine oil, then install the cartridge to the filter holder.
13. Supply water until it flows over the water filler.
14. Drain the water inside reserve tank, clean the inside of
the reserve tank, then fill with coolant/water mixture to
between the full and low lines.
4. When installing, tighten until the packing surface
contacts the seal surface of the filter holder then tighten
a further 2/3 of a turn. If the filter cartridge is tighten too
much, the packing will be damaged and will cause fuel
leakage. Fuel leakage will occur if the filter cartridge is
not tightened enough. Always tighten to the correct
angle.
15. Stop the engine, wait for 3 minutes, add tap water until
the water level reaches near the water filer port, then
tighten the radiator cap.
Check Electric Heater (If equipped)
Before starting in cold weather (once a year), please contact
your Komatsu distributor for inspection. Remove electric
heater from the engine intake manifold and check for
disconnections or dirt. When checking or installing the electric
heater, replace the gasket with a new part.
5. After replacing filter cartridge, loosen air bleed plug.
6. Loosen the knob of feed pump, and pump it up and down
until no bubbles come our with the fuel from air bleed
plug.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 57
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — MAINTENANCE
7. After bleeding the air, tighten air bleed plug, then push in Generator Storage
the knob of feed pump and lock it in position.
8. Replace Corrosion resistor cartridge (if equipped)
9. Screw in valves at the top of the corrosion resistor.
For storage of the generator for over 30 days, the following
is required:
"
"
Fill the fuel tank completely, lubricate and change oil.
10. Using a filter wrench, turn the cartridge to the left to
remove it.
Disconnect the negative terminals of the battery and
cover it, or remove it from the machine and store it
separately.
11. Coat the seal surface of the new cartridge with engine
oil and install it to the filter holder.
"
If the ambient temperature is expected to drop below
0oC, add antifreeze to the radiator.
12. Tighten until he packing surface contacts the seal
surface of the filter holder, then tighten a further 2/3 of a
turn.
Removal from long term storage:
13. Open valves.
"
Apply oil to the engine valve and rocker arms, and
examine the operating condition of the valves.
Cleaning breather element
1. Loosen the clamp, then remove the hose and take out
breather. Wipe off the dirt around the breather. Check
the O-ring, and replace if necessary.
"
Remove the oil filler pipe from the turbocharger oil inlet
port, add 0.5-1L (0.13-0.26gal) of oil to the turbocharger,
reinstall the oil filler pipe.
2. Wash the breather in diesel fuel or flushing oil, blow dry
with compressed air, then reinstall it.
"
"
"
"
Change the oil in engine oil pan.
Replace all the filters.
3. Inspect the hose and if there is any deteriorated oil stuck
inside the hose. Replace hose if necessary.
Flush the inside of the cooling system.
Drain the water from the fuel tank and bleed the air from
the fuel system.
Greasing
Using a grease pump, grease the fan hub (1 place) and
tension pulley (2 places).
"
If the engine has not been started for more than one
year, contact your Komatsu distributor to have engine
overhauled.
PAGE 58 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — MAINTENANCE
10 Hrs
DAILY
250 Hrs
500 Hrs
1000 Hrs
INSPECTION / MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Check Water Separator (if applicable)
Replace Engine Oil and Filter *1
Clean Air Filter
X
X
X
X
ENGINE
Drain Bottom of Fuel Tank
Clean Unit, Inside and Outside
Change Fuel Filter *2
X
X
X
Replace Water Separator Element *3
(X)
Clean Radiator and Check Coolant Protection
Level
Replace Air Filter Element
Change Corrosion Resistor
Check all Hoses and Clamps
Clean Inside of Fuel Tank
X
X
X
X
X
Measure Insulation Resistance Over 3M ohms
GENERATOR
1
*
*
*
Replace engine oil anf filter at 100 hours, first time only.
Replace fuel filter at 250 Hours, first time only.
Refer to the item "Water Separator Filter".
2
3
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 59
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — GENERATORWIRING DIAGRAM
PAGE 60 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTE PAGE
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 61
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — ENGINEWIRING DIAGRAM (WITH MPEC)
PAGE 62 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — ENGINEWIRING DIAGRAM (WITH KEY IGNITION)
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 63
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by diagnosis based on the Engine Troubleshooting
proper handling and maintenance inspections, (Table 15). If the problem cannot be remedied, consult our
but in the event of a breakdown, use the tables shown for
company's business office or service plant.
TABLE 15. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
No fuel?
SOLUTION
Replenish fuel.
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
Bleed system.
Remove water from fuel tank.
Clean fuel pipe.
Fuel filter clogged?
Clean or change fuel filter.
Excessively high viscosity of fuel
or engine oil at low temperature?
Use the specified fuel or engine oil.
Fuel with low cetane number?
Use the specified fuel.
Tighten nut.
Fuel leak due to loose injection
pipe retaining nut?
Engine does not start.
Incorrect injection timing?
Fuel cam shaft worn?
Adjust.
Replace.
Injection nozzle clogged?
Injection pump malfunctioning?
Clean injection nozzle.
Repair or replace.
Seizure of crankshaft, camshaft,
piston, cylinder liner or bearing?
Repair or replace.
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Compression leak from cylinder?
Improper valve timing?
Piston ring and liner worn?
Excessive valve clearance?
Battery discharged?
Correct or replace timing gear.
Replace.
Adjust.
Charge battery.
Repair or replace.
Repair or replace.
Connect wiring.
Starter malfunctioning?
Key switch malfunctioning?
Wiring disconnected?
Starter does not run.
PAGE 64 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TROUBLESHOOTING (ENGINE)
TABLE 15. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
Air cleaner clogged?
SOLUTION
Clean or change.
Clean or change.
Fuel leak due to loose injection
pipe retaining nut?
Tighten nut.
Repair or replace.
Adjust.
Injection pump malfunctioning?
Engine revolution is not smooth.
Incorrect nozzle opening
pressure?
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe clogged?
Governor malfunctioning?
Excessive engine oil?
Clean.
Repair.
Reduce to the specified level.
Piston ring and liner worn or
stuck?
Repair or replace.
Either white or blue exhaust gas
is observed.
Incorrect injection timing?
Deficient compression?
Overload?
Adjust.
Adjust top clearance.
Lessen the load.
Use the specified fuel.
Clean or change.
Clean or change.
Repair or replace the nozzle.
Adjust.
Low grade fuel used?
Fuel filter clogged?
Either black or dark gray exhaust
gas is observed.
Air cleaner clogged?
Deficient nozzle injection?
Incorrect injection timing?
Engine's moving parts seem to
be seizing?
Repair or replace.
Deficient output.
Uneven fuel injection?
Repair or replace the injection pump.
Repair or replace the nozzle.
Deficient nozzle injection?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Compression leak?
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 65
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TROUBLESHOOTING (GENERATOR/ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for diagnosis based on the Engine and Radiator Troubleshooting (Table 16) and the
MPEC Troubleshooting (Table 17). If the problem cannot be remedied, consult our company's business office or service
plant.
TABLE 16. ENGINE & GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
Dead battery?
SOLUTION
Replace battery.
Engine fails to start and starter does not
rotated.
Defective starter switch?
Fuse F5 burned out?
Broken pre-heat circuit?
No fuel?
Replace switch.
Replace fuse.
Check pre-heat circuit.
Add fuel.
Engine fails to start and starter rotates.
Engine starts and remains at low speed.
Defective wiring?
Check wiring.
Clogged fuel strainer?
Clogged air cleaner?
Clean or replace.
Clean or replace.
Check and repair wiring.
Replace rectifier (RE1).
Replace rotor.
Disconnected wiring?
No voltage present in AC power source?
Defective rotor?
Engine speed rises and no voltage is
present in AC power source.
Defective voltmeter?
Replace voltmeter.
Check and repair wiring.
Replace armature.
Replace circuit breaker (protector).
Disconnected wiring?
Layer short-circuit in armature winding?
Defective circuit breaker (protector)?
Engine speed rises and AC power
voltage is too low or cannot be used.
Layer short-circuit, broken wires in armature
winding?
Repair or replace armature.
Defective engine regulator?
Defective wiring?
Replace regulator.
Engine speed rises and battery
discharges too soon.
Repair or replace wiring.
Repair or replace alternator.
Replace alternator bearings.
Defective alternator?
Engine speed rises and engine seems
overloaded.
Damaged alternator bearing?
PAGE 66 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK —TROUBLESHOOTING (MPEC)
TABLE 17. MPEC TROUBLESHOOTING
Sympton
Possible Cause
Solution
Low oil level?
Fill oil level.
Oil pressure sending unit failure?
Time delay malfuntion in MPEC?
Wire shorted?
Replace oil pressure sending unit.
Refer to dealer.
Low oil pressure light is
on.
Inspect/repair wire.
Fill coolant level.
Low coolant level?
Low coolant level light
is on.
Sending unit failure?
Replace sending unit.
Replace/charge battery.
Tighten/replace fan belt.
Clean/repair radiator grill.
Close doors.
Low battery voltage?
Fan belt tension incorrect?
Air flow is not circulation through radiator?
Doors open?
Exhaust leaking?
Replace/repair gaskets or faulty part.
Check/reduce load.
Replace thermostat.
Clear all air intakes.
Replace temperature switch.
Fill fuel level.
High coolant temperture
light is on.
Generator being overloaded?
Thermostat failure?
Air intake blocked?
Temperature switch failure?
No or low Fuel?
Overcrank light is on.
Overspeed light is on.
MPEC needs to be calibrated?
RPM engine speed too high?
Governor actuator needs to be adjusted?
Governor controller needs to be adjusted?
MPEC needs to be calibrated?
Magnetic pick up out of adjustment?
Magnetic pick up dirty?
Refer to dealer.
Adjust RPM.
Adjust governor actuator.
Adjust governor controller.
Refer to dealer.
Adjust magnetic pick up.
Clean magnetic pick up.
Loss of MPU light(s) or
on.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 67
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Serial Numbers Pertaining to Unit
DCA-220SSK Standard:
Up to S/N3696500
Items Found In the “Remarks” Column
S/N3699150 to S/N3699619
S/N3699637 to S/N3703349
S/N3703364 to S/N3703853
S/N3703869~
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the“Items Number”Column
All parts with same symbol in the number column, , #,
, belong to the same assembly or kit.
+, %, or
*
■
Note: If more than one of the same reference number is listed,
the last one listed indicates newest (or latest) part available.
PAGE 68 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — SUGGESTED SPARE PARTS
DCA-220SSKW/KOMATSU S6D125E-2
DIESEL ENGINE
1 to 5 Units
Qty.
P/N
Description
10 .......6125817032 ............. AIR FILTER
10 .......6003118293 ............. FUEL FILTER
10 .......6002111231 ............. OIL FILTER
5 ......... 6004111020 ............. CARTRIDGE, CORROSION RESISTOR
1 ......... 0601805950 ............. MAIN CIRCUIT BREAKER
1 ......... 0602115008 ............. PILOT LAMP, ENGINETROUBLE
2 ......... 0601810204 ............. BULB, ENGINETROUBLE
2 ......... 0412122265 ............. ENGINE FAN BELT
1 ......... 6008155390 ............. SWITCH, STARTER
5 ......... 615 ........................... KEY SET, STARTER SWITCH (2)
2 ......... 6008711170 ............. OIL SWITCH
1 ......... 6151619320 ............. RADIATOR HOSE (UPPER)
1 ......... 6151619330 ............. RADIATOR HOSE (LOWER)
1 ......... 0845500104 ............. FUEL CAP
1 ......... 0601820625 ............. AUTOMATIC VOLTAGE REGULATOR
1 ......... 0601840073 ............. VOLTAGE REGULATOR (RHEOSTAT)
1 ......... 0601840121 ............. KNOB, VOLTAGE REGULATOR
1 ......... 0601810072 ............. PILOT LAMP
2 ......... 0601810261 ............. BULB, PILOT LAMP
1 ......... TR60110235100 ...... CAP, RADIATOR
1 ......... 0602122200 ............. UNIT, OIL PRESSURE
1 ......... 0602123204 ............. UNIT, WATER TEMPERATURE
1 ......... 0602121052 ............. CHARGING AMMETER
NOTE
Part number on this Suggested Spare
Parts list may supercede/replace the
P/N shown in the text pages of this
book.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 69
Download from Www.Somanuals.com. All Manuals Search And Download.
Generator S/N1337562~
Table of Contents
DCA-220SSK — GENERATOR ASSY.
GENERATOR ASSY. UP TO S/N1337562
PAGE 70 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Generator up to S/N1337562
Generator S/N1337562~
Table of Contents
DCA-220SSK — GENERATOR ASSY.
GENERATOR ASSY. UP TO S/N1337562
NO
1
PART NO
8181000002
PART NAME
ROTOR ASSY.
FIELD ASSY.
QTY.
REMARKS
1
1
1
8
8
9
1
8
8
1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
1-18
2
3
4
5
5-1
6
6-1
7
7-1
8
8171070002
0012112040
0042512000
8171611003
8171015003
0012116040
0042616000
8171026003
0601821349
0601822615
8171020004
8171020504
0010110020
0040010000
0601000209
0070806312
0080000060
8171614003
0012112035
0042512000
8181340303
0226100430
8171323004
0223300120
8171323103
0221200300
0010110035
031110160
8171324003
0226000270
0225000480
0010106016
0040006000
031110160
8171315002
8171350003
0012110060
0042610000
031110160
FAN
HEX. HEAD BOLT
LOCKWASHER
COUPLING DISK
BALANCING PLATE
HEX. HEAD BOLT
LOCKWASHER
SET PLATE, RECTIFIER
RECTIFIER ................................................3........ PT 3610
SURGE ABSORBER .................................1........ ERZ-M20JK621B
INSULATORWASHER
INSULATORWASHER
HEX. HEAD BOLT
LOCKWASHER
BALANCING WEIGHT KIT
BEARING...................................................1........ 6312 DU
SNAP RING
COUPLING RING
HEX. HEAD BOLT
LOCKWASHER
STATOR ASSY.
RUBBER SEAL
CLAMPER
1
1
6
6
1
1
1
8
8
1
1
1
1
1
1
2
RUBBER SEAL
CLAMPER
RUBBER SEAL
HEX. HEAD BOLT
9
10
10-1
10-2
11
12
13
14
15
PLAIN WASHER ........................................2........ REPLACES 0041610000
COVER
RUBBER SEAL
RUBBER SEAL
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER ........................................6........ REPLACES 0041606000
END BRACKET
FIELD ASSY., EXCITER
HEX. HEAD BOLT
LOCKWASHER
1
2
1
6
6
1
1
6
6
16
17
18
PLAIN WASHER ........................................6........ REPLACES 0041610000
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 71
Download from Www.Somanuals.com. All Manuals Search And Download.
Generator S/N1337562~
Table of Contents
DCA-220SSK — GENERATOR ASSY.
GENERATOR ASSY. UP TO S/N1337562
PAGE 72 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Generator up to S/N1337562
Generator S/N1337562~
Table of Contents
DCA-220SSK — GENERATOR ASSY.
GENERATOR ASSY. UP TO S/N1337562
NO
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
PART NO
PART NAME
GROMMET
QTY.
1
REMARKS
0845044904
012212045
0040012000
031112230
8171310004
8171312004
8171331003
0010106016
0040006000
952404470
8171333003
0010106030
0040006000
952404470
0012112035
0042512000
8171332003
0605000012
0030020000
030220510
HEX. HEAD BOLT...................... 8 ......... REPLACES 0010112045
LOCKWASHER
PLAIN WASHER ........................ 8 ......... REPLACES 0041612000
COVER, BEARING
GASKET, BEARING
COVER, END BRACKET
HEX. HEAD BOLT
LOCKWASHER
8
1
1
1
12
12
PLAIN WASHER ........................ 12........ REPLACES 0041606000
COVER, END BRACKET
HEX. HEAD BOLT
LOCKWASHER
1
2
2
PLAIN WASHER ........................ 2 ......... REPLACES 0041606000
HEX. HEAD BOLT
LOCKWASHER
COVER, FAN
RUBBER SUSPENSION
HEX. NUT
12
12
1
2
4
LOCKWASHER ......................... 4 ......... REPLACES 0040020000
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 73
Download from Www.Somanuals.com. All Manuals Search And Download.
Generator up to S/N1337562
Table of Contents
DCA-220SSK — GENERATOR ASSY.
GENERATOR ASSY. S/N1337563~
PAGE 74 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Generator up to S/N1337562
Generator S/N1337562~
Table of Contents
DCA-220SSK — GENERATOR ASSY.
GENERATOR ASSY. S/N1337563~
NO
1
1-1
1-2
1-3
1-7
PART NO
C1110100202
PART NAME
ROTOR ASSY.
FIELD ASSY.
QTY.
1
1
REMARKS
0601842334
0601823282
0018205020
0040005000
0041205000
8171070002
8171611003
C1164200004
8171015003
0012116045
0042616000
0601000209
C1112500004
0071906314
8171614003
0012112035
0042512000
0012112040
0042512000
C1130100103
0226100420
8171323004
0223300120
8171323103
0221200300
0010110035
0041210000
C1132200003
0226000510
0225000470
0017106016
0601850144
C1154000002
C1138000003
RESISTOR ............................................ 1 .......... SMRK 80W 100KOHM
RECTIFIER ........................................... 1 .......... RM50TC24
HEX. SOCKET HEAD CAP SCREW
LOCKWASHER
PLAIN WASHER
2
2
2
1
9
1
1
8
8
1
1
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
2
FAN
COUPLING DISK
WASHER, COUPLING HUB
BALANCING PLATE
HEX. HEAD BOLT
LOCKWASHER
BALANCING WEIGHT KIT
BEARING FLANGE
BEARING.............................................. 1 .......... 6314DDUC3
COUPLING RING
HEX. HEAD BOLT
LOCKWASHER
HEX. HEAD BOLT
LOCKWASHER
STATOR ASSY.
RUBBER SEAL
CLAMPER
RUBBER SEAL
CLAMPER
RUBBER SEAL
HEX. HEAD BOLT
PLAIN WASHER
COVER
RUBBER SEAL
RUBBER SEAL
HEX. HEAD BOLT
GROMMET
END BRACKET
FIELD ASSY. EXCITER
1
8
8
8
8
1
1
1
1
1
1
2
2
1
2
1
6
1
1
1
3
4
5
6
7
7-1
7-2
7-3
7-4
7-5
7-9
7-7
7-8
7-9
7-10
7-11
7-12
8
9
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 75
Download from Www.Somanuals.com. All Manuals Search And Download.
Generator up to S/N1337562
Table of Contents
DCA-220SSK — GENERATOR ASSY.
GENERATOR ASSY. S/N1337563~
PAGE 76 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Generator up to S/N1337562
Generator S/N1337562~
Table of Contents
DCA-220SSK — GENERATOR ASSY.
GENERATOR ASSY. S/N1337563~
NO
10
PART NO
0012110065
0042610000
PART NAME
HEX. HEAD BOLT
LOCKWASHER
QTY.
REMARKS
4
4
0041210000
0017112045
C1154400004
C1154300004
0010106065
0040006000
0041206000
C1154400103
0017106016
0012112035
0042512000
C1132300103
C1132300114
0010106030
0041206000
0600815000
0605000012
0030020000
0040020000
PLAIN WASHER
HEX. HEAD BOLT
COVER, BEARING
GASKET, BEARING
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
SUCTION COVER
HEX. HEAD BOLT
HEX. HEAD BOLT
LOCKWASHER
COVER, FAN ........................................ 1 .......... S/N3690735TO 3692206
COVER, FAN ........................................ 1 .......... S/N3692207~
HEX. HEAD BOLT
PLAIN WASHER
NUT ....................................................... 1 .......... S/N3692207~
4
6
1
1
4
4
4
1
8
11
12
13
14
15
16
17
18
19
19
20
12
12
1
1
21
22
RUBBER SUSPENSION
HEX. NUT
LOCKWASHER
2
4
4
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 77
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
Cont. Panel S/N1337563~
Cont. Box S/N1337563~
DCA-220SSK — CONTROL BOX AND PANEL ASSY.
CONTROL PANEL ASSY. UP TO S/N1337562
PAGE 78 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box and Panel up to S/N1337562
Cont. Panel S/N1337563~
Cont. Box S/N1337563~
Table of Contents
DCA-220SSK — CONTROL BOX AND PANEL ASSY.
CONTROL PANEL ASSY. UP TO S/N1337562
NO.
1
2
3
4
5
6
7
8
PART NO.
PART NAME
CONTROL BOX
QTY. REMARKS
1
8181812502
0601801167
0027106010
0601805950
0601820625
0027105012
0601820193
0027103010
0601820851
0027104016
0601823757
0601823143
PYCA1
TRANSFORMER, AMMETER ............................ 2 ...... CT5MR 400/5A
MACHINE SCREW
CIRCUIT BREAKER ........................................... 1 ...... TO-600CA 600A
AUTOMATICVOLTAGE REGULATOR
MACHINE SCREW
CONDESER ........................................................ 1 ...... 40FAL 155U#L2
MACHINE SCREW
OVER CURRENT RELAY.................................... 1 ...... THK20
MACHINE SCREW
RELAY ................................................................ 2 ...... MY2 DC24V
SOCKET, RELAY ................................................ 2 ...... PYF 08A
HOLDER ............................................................. 2 ...... REPLACES 0601824400
4
1
4
2
9
10
11
12
2
13
14
15
16
17
0027104016
0601823240
0027105016
0801850004
0021005020
0040050000
0041205000
0030006000
0601830715
8181861103
8181852104
0017106025
8181853104
8131852504
0801831804
0040010000
0041410000
0017108030
8181822603
8181822503
0225100095
0605011211
MACHINE SCREW
RECTIFIER ......................................................... 1 ...... DE4503
4
MACHINE SCREW
RESISTOR UNIT
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
HEX. NUT
1
1
1
1
1
1
18
19
20
21
22
23
24
25
26
27
28
29
29-1
30
SELECTOR SWITCH, VOLTAGE ........................ 1 ...... S332T
SET BOARD, CHANGE TERMINAL
CHANGETERMINAL
HEX. HEAD BOLT
CHANGE PLATE
HEX. HEAD BOLT
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
CONTROL PANEL
CONTROL PANEL
RUBBER SEAL
1
10
20
6
10
16
26
26
4
1
1
4
4
PIN
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 79
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
Cont. Panel S/N1337563~ Cont. Box S/N1337563~
DCA-220SSK — CONTROL BOX AND PANEL ASSY.
CONTROL PANEL ASSY. UP TO S/N1337562
PAGE 80 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box and Panel up to S/N1337562
Cont. Panel S/N1337563~
Cont. Box S/N1337563~
Table of Contents
DCA-220SSK — CONTROL BOX AND PANEL ASSY.
CONTROL PANEL ASSY. UP TO S/N1337562
NO.
PART NO.
PART NAME
QTY. REMARKS
31
32
33
34
35
36
0601800470
0601805726
0601801040
0601800239
0601801041
0601810072
0601810261
0601840073
0601840121
0601822408
0601802810
0840303303
0021004020
0040004000
0041204000
0027104010
0027104010
0601810072
0601810261
0601830682
0601810161
0601810214
0207004000
0601830710
7431822104
0027103016
0030003000
0805001304
0041608000
0605010710
3871824004
0041606000
0605010502
8181814504
0017106016
8181826504
0017106016
8181827503
0017106016
0010010025
0030010000
0040010000
0041610000
FREQ. METER.................................................... 1 ...... PAK80 220V 45~65Hz
AC AMMETER .................................................... 1 ...... PSK80 0~400A
CHG.-OVR. SW, AMMETER ............................... 1 ...... SL2VS
AC VOLTMETER ................................................. 1 ...... PCK80 0~600V
CHG.-OVR.SW, VOLTMETER ............................. 1 ...... SL2AS
PILOT LAMP ....................................................... 1 ...... LP132DC 220V
BULB
RHEOSTAT (VOLTAGE REGULATOR) ................ 1 ...... RA20A2SE102BJ
KNOB
1
37
38
39
39-1
40
41
1
EARTH LEAKAGE RELAY ................................. 1 ...... TZS15HCD 30mA
0-PHASE SEQ.TRANSFORMER ....................... 1 ...... TZS15
BRACKET, EARTH LEAKAGE RELAY
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
MACHINE SCREW
1
2
2
2
2
4
42
43
44
MACHINE SCREW
SYNCHRONIZING LAMP.................................... 2 ...... LD132DC 220V
BULB
2
45
46
SELECTOR SW. SINGLE/PAR............................ 1 ...... AH30P2B31
PANEL LIGHT ..................................................... 1 ...... V325070
BULB
1
47
48
49
50
HEX. NUT
2
SWITCH, PANEL LIGHT ..................................... 1 ...... S301T
COVER
MACHINE SCREW
1
4
HEX. NUT
4
51
52
53
54
55
56
57
58
59
60
61
62
63
SET SCREW
4
PLAIN WASHER
SNAP RING
4
4
STOPPER, CONTROL PANEL
PLAIN WASHER
SNAP PIN
2
2
2
COVER, CONTROL
HEX. HEAD BOLT
SIDE PANEL, CONTROL BOX
HEX. HEAD BOLT
PANEL, CONTROL BOX
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. NUT
1
13
2
16
1
12
4
4
LOCKWASHER
4
PLAIN WASHER
8
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 81
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — CONTROL BOX ASSY. (OPTIONAL PARTS)
CONTROL BOX ASSY. (OPTIONAL PARTS) UP TO S/N1337562
PAGE 82 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box (Options) up to S/N1337562
Table of Contents
DCA-220SSK — CONTROL BOX ASSY. (OPTIONAL PARTS)
CONTROL BOX ASSY. (OPTIONAL PARTS) UP TO S/N1337562
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
CONTROL BOX
QTY.
1
REMARKS
8181812502
0601801167
0027106010
0601805950
0601820625
0027105012
0601820193
0027103010
0601820851
0027104016
0601823757
0601823143
PYCA1
CURRENTTRANSFORMER, AMMETER ... 2 ........ CT5MR 440/5A
MACHINE SCREW
CIRCUIT BREAKER.................................... 1 ........ TO600CA 600A
AUTOMATICVOLTAGE REGULATOR ......... 1 ........ NTA-5A-27
MACHINE SCREW
CONDENSER .............................................. 1 ........ 40FAL155U #L2
MACHINE SCREW
OVER CURRENT RELAY ............................ 1 ......THK20
MACHINE SCREW
RELAY......................................................... 2 ........ MY2DC24V
SOCKET, RELAY ........................................ 2 ........ PYF08A
HOLDER ...................................................... 2 ........ REPLACES 0601824400
4
4
2
9
10
11
12
2
13
14
15
16
17
0027104016
0601821370
0027105016
0801850004
0021005020
0032005000
0401450050
020106050
0601830715
8181861103
8181852104
011606025
8181853104
8131852504
012210020
0040010000
0041410000
011208030
8181833003
011008020
0601823704
0027104010
8181822603
8181822503
0225100095
0605011211
0601800470
0601800790
MACHINE SCREW
4
RECTIFIER ................................................. 1 ........ DE4503 REPLACES 0601823240
MACHINE SCREW
RESISTOR UNIT
MACHINE SCREW
LOCKWASHER .......................................... 1 ........ REPLACES 0040005000
PLAIN WASHER.......................................... 1 ........ REPLACES 0041205000
HEX. NUT .................................................... 1 ........ REPLACES 0030006000
SELECTOR SWITCH, VOLTAGE................. 1 ........ S332T
SET BOARD, CHANGE TERMINAL
CHANGETERMINAL
HEX. HEAD BOLT ....................................... 20 ...... REPLACES 0017106025
CHANGE PLATE
HEX. HEAD BOLT
1
1
1
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
33-1
34
35
36
1
10
6
10
HEX. HEAD BOLT ....................................... 16 ...... REPLACES 0801831804
LOCKWASHER
PLAIN WASHER
26
26
HEX. HEAD BOLT ....................................... 4 ........ REPLACES 0017108030
SET PANEL, ELECTRIC PARTS
HEX. HEAD BOLT ....................................... 4 ........ REPLACES 0017108020
REVERSE POWER RELAY
MACHINE SCREW
CONTROL PANEL
CONTROL PANEL
RUBBER SEAL
PIN .............................................................. 4 ........ B-99-2
FREQUENCY METER ................................ 1 ........ PAK80 220V 45~65HZ
AC AMMETER ............................................ 1 ........ PSK80 0~400A 0~800A
REPLACES 0601805726
1
1
4
1
1
4
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 83
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — CONTROL BOX ASSY. (OPTIONAL PARTS)
CONTROL BOX ASSY. (OPTIONAL PARTS)UP TO S/N1337562
PAGE 84 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box (Options) up to S/N1337562
Table of Contents
DCA-220SSK — CONTROL BOX ASSY. (OPTIONAL PARTS)
CONTROL BOX ASSY. (OPTIONAL PARTS)UP TO S/N1337562
NO
37
38
39
40
PART NO
PART NAME
QTY.
REMARKS
0601801040
0601800239
0601801041
0601800570
CHANGE-OVER SWITCH, AMMETER ....... 1 ........ SL2AS
AC VOLTMETER ......................................... 1 ........ PCK80 0~600V
CHANGE-OVER SWITCH, AMMETER ....... 1 ........ SL2 VS
AC WATTMETER......................................... 1 ........ PWTK8020~0~200kW
INCLUDE ITEM W/#
40-1# 0601804021
TRANSDUCER, WATTMETER .................... 1 ........ WT64M
41
42
0027104010
0601810072
0601810261
0601840073
0601840121
0601822408
MACHINE SCREW
PILOT LAMP ............................................... 1 ........ LP132DC 220V
BULB, 13W
RHEOSTAT (VOLTAGE REGULATOR)......... 1 ........ RA20A2SE102BJ
KNOB
4
1
43
44
45
1
EARTH LEAKAGE RELAY.......................... 1 ........ TZS15HC-D 30mA
INCLUDE ITEM W/+
45-1+ 0601802810
ZERO-PHASE-SEQUENCE
CURRENTTRANSFORMER ....................... 1 ........ TZS-15
46
47
0840303303
021004020
040004000
031104080
0027104010
0027104010
0601810072
0601810261
0601830682
0601910161
0601810214
0030004000
0601830710
0805001304
031108160
0605010710
3871824004
952404470
505015300
8181814504
0017106016
8181826504
0017106016
8181827503
0017106016
0105091025
020310080
0040010000
031110160
BRACKET, EARTH LEAKAGE RELAY
MACHINE SCREW
LOCKWASHER
PLAIN WASHER.......................................... 2 ........ REPLACES 0041204000
MACHINE SCREW
MACHINE SCREW
SYNCHRONIZING LAMP ............................ 2 ........ LD132DC 220V
BULB, 13W
SELECTOR SWITCH, SINGLE/PAR. .......... 1 ........ AH30P2B31
PANEL LIGHT ............................................. 1 ........ V 325070
1
2
2
48
49
50
2
4
2
51
52
BULB
1
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
HEX. NUT .................................................... 2 ........ REPLACES 0207004000
SWITCH, PANEL LIGHT
SET SCREW
PLAIN WASHER.......................................... 4 ........ REPLACES 0041608000
SNAP RING
STOPPER, CONTROL PANEL
PLAIN WASHER.......................................... 2 ........ REPLACES 0041606000
SNAP RING ................................................ 2 ........ REPLACES 0605010502
COVER, CONTROL BOX
HEX. HEAD BOLT
SIDE PANEL , CONTROL BOX
HEX. HEAD BOLT
1
4
4
2
1
13
2
16
1
PANEL, CONTROL BOX
HEX. HEAD BOLT
HEX. HEAD BOLT ....................................... 4 ........ REPLACES 0010010025
HEX. NUT .................................................... 4 ........ REPLACES 0030010000
12
LOCKWASHER
4
PLAIN WASHER.......................................... 8 ........ REPLACES 0041610000
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 85
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box and Panel up to S/N1337562
Cont. Box S/N1337563~
Table of Contents
DCA-220SSK — CONTROL PANEL ASSY.
CONTROL PANEL ASSY. S/N1337563~
PAGE 86 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box and Panel up to S/N1337562
Cont. Box S/N1337563~
Cont. Panel S/N1337563~
Table of Contents
DCA-220SSK — CONTROL PANEL ASSY.
CONTROL PANEL ASSY. S/N1337563~
NO.
PART NO.
PART NAME
QTY.
REMARKS
1
2
3
4
5
6
7
8
9
C1224000503
C1224000603
0605011211
0601807622
0601806980
0601801040
0601806887
0601801041
0601810072
0601810261
0601840073
060184012
0601810161
0601810214
0207004000
0601830710
C9221100004
0040008000
0041208000
0080200007
0017108040
ECU9988N*
0601831340
0601830765
DYNT11100
CONTROL PANEL
CONTROL PANEL
PIN
1
1
2
FREQ. METER ............................................. 1 ............ RSC80F 45~65Hz 200V
AC AMMETER .............................................. 1 ............ RSS80 0~400A
CHG.OVR. SW.-AMMETER .......................... 1 ............ SL2AS
AC VOLTMETER ........................................... 1 ............ RSR80 0~600V
CHG.OVR.SW-VOLTMETER ......................... 1 ............ SL2VS
PILOT LAMP ................................................. 1 ............ KO132DC 220V
BULB
RHEOSTAT (VOLTAGE REGULATOR) .......... 1 ............ RA20A2SE102BJ
KNOB
PANEL LIGHT
BULB
HEX. NUT
SWITCH, PANEL LIGHT
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
SNAP RING
1
10
11
12
1
1
1
2
1
2
2
2
2
4
13
14
15
16
17
18
18
19
HEX. HEAD BOLT
ENGINE CONTROLLER ............................... 1 ............ REPLACES 0602202545
SWITCH,82608DPDT .................................... 1 ............ S/N3696501TO3698120
SWITCH,S3037;............................................ 1 ............ S/N3698121~
SPEED SENSOR ......................................... 1 ............ S/N3696501~;
REPLACES 0602120497
*NOTE:
WHEN ORDERING PART NUMBER 17,
PLEASE INDICATE SERIAL NUMBER.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 87
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box and Panel up to S/N1337562
Cont. Panel S/N1337563~
Table of Contents
DCA-220SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY. S/N1337563~
PAGE 88 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box and Panel up to S/N1337562
Cont. Panel S/N1337563~ Cont. Box S/N1337563~
Table of Contents
DCA-220SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY. S/N1337563~
NO. PART NO.
PART NAME
QTY.
REMARKS
1
1
2
3
4
C1214000412
C1214000422
0601806133
0027106016
0601807364
CONTROL BOX..................................... 1 ..........S/N 1337563TO3690734
CONTROL BOX..................................... 1 ..........S/N3690735~
TRANSFORMER, AMMETER .............. 3 ..........CT5MRN
MACHINE SCREW
CIRCUIT BREAKER ............................. 1 ..........XE600NS 600A
HANDLE, CIRCUIT BREAKER
AUTOMATICVOLTAGE REGULATOR ... 1 ..........NTA5A2T
MACHINE SCREW
OVER CURRENT RELAY...................... 1 ..........THN20HZKP3.6A
6
4-1 0601802525
1
5
6
7
8
9
0601820625
0027105016
0601820892
0027104016
0601824542
4
MACHINE SCREW
2
RELAY
2
10 0027103010
11 C1274000103
12 8181852104
13 0017106025
14 8181853104
15 8131852504
16 C0277200004
17 0801831804
18 0040010000
19 0041410000
20 0017108030
21 C1261500114
21 C1261501304
22 0017108020
23 6008151252
MACHINE SCREW
SET BOARD CHANGE TERMINAL
CHANGETERMINAL
HEX. HEAD BOLT
CHANGE PLATE
HEX. HEAD BOLT
TERMINAL PLATE
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
SET PANEL, ELECTRIC PARTS .......... 1 ..........S/N1337563TO 3696500
SET PANEL, ELECTRIC PARTS .......... 4 ..........S/N3696501~
HEX. HEAD BOLT
4
1
10
20
6
13
3
13
26
26
4
4
EMERGENCY RELAY .......................... 1 ..........S/N3690735TO 3701661
REPLACES0602200446
24 0017106016
25 0602201911
26 0027106016
27 3871824004
28 0041206000
29 0605010502
30 C1214500004
31 0017108020
32 C1214300004
33 0017108020
34 C1214400004
35 0017108020
36 0017110025
37 0601823861
38 0027104010
HE.X HEAD BOLT ................................ 4 ..........S/N3690735TO 3701661
UNIT, BATTERY SENSOR .................... 1 ..........C7038A0000
MACHINE SCREW
STOPPER, CONTROL PANEL
PLAIN WASHER
SNAP PIN
COVER, CONTROL BOX
HEX. HEAD BOLT
SIDE PANEL, CONTROL BOX
HEX. HEAD BOLT
PANEL, CONTROL BOX
HEX. HEAD BOLT
1
1
1
1
1
8
1
4
1
8
4
HEX. HEAD BOLT
STOP UNITMSA9014............................ 1 ..........S/N3696501TO 3701661
MACHINE SCREW ............................... 2 ..........S/N3696501TO 3701661
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 89
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box and Panel up to S/N1337562 Cont. Panel S/N1337563~
Table of Contents
DCA-220SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY. S/N1337563~
PAGE 90 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box and Panel up to S/N1337562
Table of Contents
Cont. Panel S/N1337563~
Cont. Box S/N1337563~
DCA-220SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY. S/N1337563~
NO. PART NO.
39 0601823240
40 0027104030
41 0601802149
0601806671
PART NAME
QTY.
REMARKS
RECTIFIER;DE4503 ............................. 4 ..........S/N3696501TO 3701661
MACHINE SCREW ............................... 2 ..........S/N3696501TO 3701661
FUSE;10A
1
FUSE;15A ............................................. 1 ..........S/N3701662~
HOLDER, FUSE .................................... 1 ..........S/N3696501~
MACHINE SCREW ............................... 1 ..........
0601802218
42 0027103020
43 0601823732
0601827655
RELAY;LY2DC24V ................................. 1 ..........S/N6396501TO3699126
RELAY;LY2DDC24V .............................. 1 ..........S/N369501~
SOCKET;PTF08A ................................. 1 ..........S/N369501~
HOLDER ............................................... 1 ..........S/N3696501~;REPLACES 0601824400
MACHINE SCREW ............................... 2 ..........S/N3696501~
RELAY;HE1ADC24V ............................. 1 .......... S/N3696501~
MACHINE SCREW ............................... 2 ..........S/N3696501~
TERMINAL BOARD .............................. 1 ..........S/N3696501~
MACHINE SCREW ............................... 2 ..........S/N3696501~
0601823109
PYCA1
44 0027104020
45 0601823706
46 0027104010
47 0601815402
48 0027104020
49 DYN110654000024 CONTROLLER ...................................... 1 ..........S/N3701662~;REPLACES 0602202598
50 DYNT11200
51 0027104020
52 0601840009
53 C3262600004
54 0017106015
SPEED SENSOR.................................. 1 ..........S/N3701662~;REPLACES 0602120498
MACHINE SCREW ............................... 4 ..........S/N3701662~
RHEOSTAT;RA20A2SE502BJ .............. 1 ..........S/N3701662~
BRACKET ............................................. 1 ..........S/N3701662~
HEX. HEAD BOLT ................................. 1 ..........S/N3701662~
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 91
Download from Www.Somanuals.com. All Manuals Search And Download.
S/N1337563 to 3690734
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. UP TO S/N1337562
PAGE 92 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562 S/N1337563 to 3690734
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. UP TO S/N1337562
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
REMARKS
0602000123
615619350
615619340
0010012045
0030012000
0040012000
0041612000
8185123004
0017110025
6151619320
6151619330
0726020980
0728100909
0728100809
0728101029
0728100197
0728001920
6125817032
6001811510
6203306104
0603301000
0603302000
0603303000
6002111231
6003118293
6004111151
ENGINE ................................................... 1 .........S6D125-1
RADIATOR................................................ 1 .........REPLACES 0602011866
RUBBER SHEET...................................... 2 .........REPLACES 0605000073
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
BRACKET, RADIATOR
HEX. HEAD BOLT
RADIATOR HOSE .................................... 1 .........REPLACES 0602013976
RADIATOR HOSE .................................... 1 .........REPLACES 0602014469
RADIATOR HOSE .................................... 1 .........REPLACES 0602013977
HOSE BAND ............................................ 2 .........REPLACES 0602014056
HOSE BAND ............................................ 2 .........REPLACES 0602014067
HOSE BAND ............................................ 1 .........REPLACES 0602014350
HOSE BAND ............................................ 2 .........REPLACES 0602014058
AIR CLEANER ......................................... 1 .........REPLACES 0602040057
ELEMENT, AIR CLEANER ....................... 1 .........REPLACES 0602040156
CAP, AIR CLEANER ................................ 1 .........REPLACES 0602040751
4
4
4
4
2
6
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
SOCKET
ELBOW UNION
SLEEVE
NUT
1
1
1
1
CARTRIDGE, OIL FILTER ....................... 1 .........REPLACES 0602041146
CARTRIDGE, FUEL FILTER .................... 2 .........REPLACES 0602042146
CARTRIDGE, CORROSION RESISTOR 1
REPLACES 0602045147 &
6004111020
26
27
28
29
30
31
32
33
34
35
36
37
38
39
8185112004
0010018060
0030018000
0040018000
0041618000
060500011
0030016000
0040016000
7492025104
0017108025
0131904000
7492026104
0605515091
0802081003
ENGINE FOOT
HE.X HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WSAHER
RUBBER SUSPENSION
HEX. NUT
LOCKWASHER
DRAIN JOINT
HEX. HEAD BOLT
CAP
DRAIN HOSE
HOSE BAND
1
2
2
2
4
2
4
4
1
2
1
1
2
1
RESERVE TANK
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 93
Download from Www.Somanuals.com. All Manuals Search And Download.
S/N1337563 to 3690734
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. UP TO S/N1337562
PAGE 94 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562 S/N1337563 to 3690734
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. UP TO S/N1337562
NO
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
PART NO
PART NAME
QTY.
1
REMARKS
0602010900
8182082103
0225000600
0017106025
0017108020
0199601100
0193601400
0193600500
0605515024
0194800750
0605515000
8185199004
0010016020
0040016000
0041616000
8182256304
0017110020
8182256104
0017108016
CAP, RESERVE TANK
BRACKET, RESERVE TANK
RUBBER CUSHION
HEX. HEAD BOLT
HEX. HEAD BOLT
HOSE
HOSE
HOSE
HOSE BAND
HOSE
1
1
1
2
1
1
1
4
1
1
1
2
2
2
1
2
HOSE BAND
PANEL
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
SUPPORT ROD
HEX. HEAD BOLT
SUPPORT ROD
HEX. HEAD BOLT
1
2
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 95
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. S/N1337563 TO 3690734
PAGE 96 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562
S/N1337563 to 3690734
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. S/N1337563 TO3690734
NO
1
PART NO
PART NAME
QTY.
REMARKS
C1924200024
6125817032
6002111231
6003118293
6004111151
0602040678
8185112004
0010118060
0030018000
0040018000
0041218000
0605000011
0030016000
0040016000
6252619720
6152619170
0010112050
0030012000
0040012000
0041212000
8195123104
0017112025
0017110025
6152621520
6152611531
0726120911
0728100809
0728100909
0728100197
3972054104
3972054304
C9601000104
0017108025
0131508000
0603325017
ENGINE ...................................................... 1............ KOMATSU S6D125E-2
ELEMENT, AIR CLEANER .......................... 1............ REPLACES 0602040156
CARTRIDGE, OIL FILTER .......................... 1............ REPLACES 0602041146
CARTRIDGE, FUEL FILTER ....................... 1............ REPLACES 0602042146
CARTRIDGE, CORROSION RESISTOR..... 1............ REPLACES 0602045143
DUST SENSOR; ......................................... 1............ REX018126
ENGINE FOOT
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
RUBBER SUSPENSION
HEX. NUT
1-1
1-2
1-3
1-4
1-5
2
3
4
5
6
1
2
2
2
4
2
4
4
7
8
9
LOCKWASHER
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
RADIATOR................................................... 1............ REPLACES 0602011946
RUBBER SHEET......................................... 2............ REPLACES 0605000490
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
BRACKET, RADIATOR
HEX. HEAD BOLT
HEX. HEAD BOLT
RADIATOR HOSE ....................................... 1............ REPLACES 0602014513
RADIATOR HOSE ....................................... 1............ REPLACES 0602014641
RADIATOR HOSE ....................................... 1............ REPLACES 0602014541
HOSE BAND ............................................... 6............ REPLACES 0602014067
HOSE BAND ............................................... 2............ REPLACES 0602014056
HOSE BAND ............................................... 2............ REPLACES 0602014058
4
4
4
8
2
2
2
DRAIN JOINT
PACKING
DRAIN JOINT
HEX. HEAD BOLT
NIPPLE
1
1
1
2
1
1
VALVE
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 97
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. S/N1337563 TO 3690734
PAGE 98 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562
S/N1337563 to 3690734
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. S/N1337563 TO 3690734
NO
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
PART NO
PART NAME
HOSE JOINT
DRAIN HOSE
HOSE BAND
PLUG
RESERVE TANK
CAP, RESERVE TANK
BRACKET, RESERVE TANK
HOSE
HOSE
HOSE
HOSE BAND
HOSE
BREATHER PIPE
HEX. HEAD BOLT
U BOLT
HEX. NUT
HOSE
HOSE BAND
CLAMPER ROD
HEX. HEAD BOLT
CLAMPER ROD
HEX. HEAD BOLT
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
QTY.
1
REMARKS
0602022294
0265800260
0605515074
0132008000
0802081003
0602010900
C1317100103
0193601300
0199601300
0193600550
0605515013
0194800750
C1327100103
0017108020
0603320111
0207008000
0268500650
0605515073
C1358300804
0017110020
C1358300104
0017110020
0010016030
0040016000
0041216000
1
2
1
1
1
1
1
1
1
4
1
1
2
1
2
1
2
1
4
1
1
1
1
1
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 99
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562
Table of Contents
S/N1337563 to 3690734
DCA-220SSK — ENGINE & RADIATOR ASSY.
PAGE 100 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562 S/N1337563 to 3690734
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. S/N3690735~
NO
PART NO
PART NAME
QTY.
REMARKS
1
C1924200144
ENGINE ...................................................... 1............ KOMATSU S6D125E-2;
S/N3690735TO 3701661
C1925200064
6125817032
6002111231
6003118293
6004111151
0602040678
0605000011
0030016000
0040016000
6152619720
6152619170
0010112050
0040012000
0041212000
8195123104
0017112025
0017110025
6152621520
6152611531
0726120911
0728100809
0728100909
0728001920
3972054104
3972054304
C9601000104
0017108025
0131508000
0603325017
0602022294
0265800240
0605515074
ENGINE ...................................................... 1............ KOMATSU S6D125E2;S/N3701662~
ELEMENT, AIR CLEANER .......................... 1............ REPLACES 0602040156
CARTRIDGE, OIL FILTER .......................... 1............ REPLACES 0602041146
CARTRIDGE, FUEL FILTER ....................... 1............ REPLACES 0602042146
CARTRIDGE, CORROSION RESISTOR..... 1............ REPLACES 0602045143
DUST SENSOR .......................................... 1............ REX018126
1-1
1-2
1-3
1-4
1-5
2
3
4
5
6
RUBBER SUSPENSION
HEX. NUT
LOCK WASHER
2
4
4
RADIATOR................................................... 1............ REPLACES 0602011946
RUBBER SHEET......................................... 2............ REPLACES 0605000490
7
9
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
BRACKET, RADIATOR
HEX. HEAD BOLT
HEX. HEAD BOLT
4
4
8
2
2
2
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
RADIATOR HOSE ....................................... 1............ REPLACES 0602014549
RADIATOR HOSE ....................................... 1............ REPLACES 0602014641
RADIATOR HOSE ....................................... 1............ REPLACES 0602014541
HOSE BAND ............................................... 6............ REPLACES 0602014067
HOSE BAND ............................................... 2............ REPLACES 0602014056
HOSE BAND ............................................... 2............ REPLACES 0602014058
DRAIN JOINT
PACKING
DRAIN JOINT
HEX. HEAD BOLT
NIPPLE
1
1
1
2
1
1
1
1
2
VALVE
HOSE JOINT
DRAIN HOSE
HOSE BAND
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 101
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562
S/N1337563 to 3690734
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. S/N3690735~
PAGE 102 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine up to S/N1337562
S/N1337563 to 3690734
S/N3690735~
Table of Contents
DCA-220SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY. S/N3690735~
NO
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
44
45
46
47
48
49
PART NO
PART NAME
PLUG
RESERVE TANK
CAP, RESERVE TANK
BRACKET, RESERVE TANK
HOSE
HOSE
HOSE
HOSE BAND
HOSE
BREATHER PIPE
HEX. HEAD BOLT
U BOLT
HEX. NUT
HOSE
QTY.
1
REMARKS
0132008000
0802081003
0602010900
C1317100103
0199601300
0193601300
0193600550
0605515013
0194800750
C1327100103
0017108020
0603320111
0207008000
0268500650
0605515073
C1358300804
C1358300814
C1358300104
0017110020
0010016030
0040016000
0041216000
1
1
1
1
1
1
4
1
1
2
1
2
1
2
HOSE BAND
CLAMPER ROD .......................................... 1............ S/N3690735TO3691726
CLAMPER ROD .......................................... 1............ S/N3691727~
CLAMPER ROD
HEX. HEAD BOLT
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
1
3
1
1
1
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 103
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Output Term.S/N3690735~
Eng. Op S/N1337563~
Table of Contents
DCA-220SSK — ENGINE OPERATING AND OUTPUTTERMINAL ASSY.
ENGINE OPERATING AND OUTPUT TERMINAL ASSY. UP TO S/N1337562
PAGE 104 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Engine Op. up to S/N1337562
Output Term.S/N3690735~
Eng. Op S/N1337563~
Table of Contents
DCA-220SSK — ENGINE OPERATING AND OUTPUTTERMINAL ASSY.
ENGINE OPERATING AND OUTPUT TERMINAL ASSY. UP TO S/N1337562
NO
1
PART NO
PART NAME
QTY.
1
1
12
REMARKS
8182111003
8182111303
0017106016
0602101000
0021008080
020108060
0040008000
031108160
0800250300
6008155390
0806410000
6008153730
0602120054
0602120178
0602122053
0602122200
0602123053
0602123204
0602121052
0602040690
0603300000
0603302000
0603303000
0190001000
0602115008
0601810204
0602103091
0601810244
0601830710
0601830685
8185312002
012010030
020310080
0040010000
031110160
8192183004
0010010055
020310080
031110160
8182152004
8182152104
0602180106
020108060
0207006000
OPERATING PANEL
OPERATING PANEL
HEX. HEAD BOLT
BATTERY SWITCH .................................. 1 .........9827300090
MACHINE SCREW
HEX. NUT ................................................. 2 .........REPLACES 0030008000
LOCKWASHER
PLAIN WASHER....................................... 4 .........REPLACES 0041608000
THROTTLE HANDLE
STARTER SWITCH .................................. 1 .........REPLACES 0602100049
EMERGENCY STOP BUTTON ................ 1 .........REPLACES 0602104045
PREHEAT LAMP ...................................... 1 .........REPLACES 0602102055
TACHOMETER ......................................... 1 .........25000KX3710
CABLE, TACHOMETER ........................... 1 .........62100KX0700
OIL PRESSURE GAUGE ......................... 1 .........42000KV0300
UNIT, OIL PRESSURE ............................. 1 .........53000AC0101
WATER TEMPERATURE GAUGE ............ 1 .........40000KV0700
UNIT, WATERTEMPERATURE ................ 1 .........51400KA1200
CHARGING AMMETER ........................... 1 .........43000KV0300
INDICATOR, AIR CLEANER..................... 1 .........RBX002252
2
3
4
2
2
5
6
7
8
1
9
10
11
12
13
14
15
16
17
18
19
20
21
HALF UNION, PT 1/8 x 4
SLEEVE
NUT
1
1
1
1
NYLON PIPE
ENGINE WARNING DISPLAY LED .......... 1 .........V 336760
BULB
CAUTION LAMP, RUNNING ..................... 1 .........REPLACES 0602103090
BULB
CHANGE-OVER SWITCH, AUTO/LOW .... 1 .........S/N1325370TO 1326266;S301T
SPEED CHANGE-OVER SWITCH ........... 1 .........S/N1326267~;AH30PCB032D
6
22
23
1
24
25
SUPPORT LEG
1
HEX. HEAD BOLT .................................... 5 .........REPLACES 0010010030
HEX. NUT ................................................. 2 .........REPLACES 0030010000
LOCKWASHER
PLAIN WASHER....................................... 7 .........REPLACES 0041610000
LINK, GOVERNOR ROD
HEX. HEAD BOLT
HEX. NUT ................................................. 1 .........REPLACES 0030010000
PLAIN WASHER....................................... 2 .........REPLACES 0041610000
5
26
27
1
1
28
29
30
31
32
GOVERNOR ROD
GOVERNOR ROD
BALL JOINT
1
1
2
HEX. NUT ................................................. 2 .........REPLACES 0030008000
HEX. NUT
2
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 105
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Output Term.S/N3690735~
Eng. Op S/N1337563~
Table of Contents
DCA-220SSK — ENGINE OPERATING AND OUTPUTTERMINAL ASSY.
ENGINE OPERATING AND OUTPUT TERMINAL ASSY. UP TO S/N1337562
PAGE 106 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Engine Op. up to S/N1337562
Output Term.S/N3690735~
Eng. Op S/N1337563~
Table of Contents
DCA-220SSK — ENGINE OPERATING AND OUTPUTTERMINAL ASSY.
ENGINE OPERATING AND OUTPUT TERMINAL ASSY. UP TO S/N1337562
NO
PART NO
PART NAME
QTY.
REMARKS
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
0802100704
0207006000
031108160
952404470
0605010503
1819001931
8182159304
0027106012
011008020
0601802133
0802100204
0802101204
8182159103
011208030
0021005020
0032005000
0041205000
0601823873
011606025
6008151252
0017106016
0602201910
0027106016
8182210113
0017106016
8181860103
0801830304
0801830804
0039316000
0040016000
0041416000
3461860504
0801832304
0039306000
0040006000
0041406000
0010008030
0040008000
031108160
0601812597
PIN BOLT
HEX. NUT
1
1
PLAIN WASHER....................................... 3 .........REPLACES 0041608000
PLAIN WASHER....................................... 1 .........REPLACES 0041606000
SNAP PIN
CONTROLLER ......................................... 1 .........REPLACES 0602210803
BRACKET
MACHINE SCREW
HEX. HEAD BOLT .................................... 4 .........REPLACES 0017108020
FUSE........................................................ 1 .........F-5 5A
JOINT
SPRING
BRACKET
HEX. HEAD BOLT .................................... 2 .........REPLACES 0017108030
MACHINE SCREW
LOCKWASHER ....................................... 1 .........REPLACES 0040005000
PLAIN WASHER
UNIT, AUTO, IDLING ................................ 1 .........REPLACES 0601823872
HEX. HEAD BOLT .................................... 2 .........REPLACES 0017106025
EMERGENCY RELAY.............................. 1 .........REPLACES 0602200446
1
1
3
1
1
1
1
1
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
HEX. HEAD BOLT
UNIT, BATTERY SENSOR ....................... 1 .........C703900000
4
MACHINE SCREW
COVER, ELECTRIC PARTS
HEX. HEAD BOLT
SET BOARD, OUTPUT TERMINAL
OUTPUTTERMINAL
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
TERMINAL PLATE
TERMINAL SCREW
HEX. NUT
1
1
1
1
7
7
14
21
28
3
1
5
2
6
5
5
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER....................................... 5 .........REPLACES 0041608000
RECEPTACLE, AUX. POWER;1136X ...... 1 .........REPLACES 0601811018
68
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 107
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Output Term.S/N3690735~
Table of Contents
Eng. Op S/N1337563~
DCA-220SSK — ENGINE OPERATING AND OUTPUTTERMINAL ASSY.
ENGINE OPERATING AND OUTPUT TERMINAL ASSY. UP TO S/N1337562
PAGE 108 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Engine Op. up to S/N1337562
Output Term.S/N3690735~
Eng. Op S/N1337563~
Table of Contents
DCA-220SSK — ENGINE OPERATING AND OUTPUTTERMINAL ASSY.
ENGINE OPERATING AND OUTPUT TERMINAL ASSY. UP TO S/N1337562
NO
69
PART NO
PART NAME
QTY.
2
2
REMARKS
0025004016
0042304000
0042404000
0601802010
0845032304
0223300060
0019106020
0042306000
0042406000
0601811262
0601811409
0845044604
0027103010
0025013010
0042303000
0042403000
0021003010
0040003000
0021103010
8185182003
0019112045
0042412000
0805009804
0205012000
0845043704
0040506000
011206020
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
2
70
71
71-1
72
CIRCUIT BREAKER................................. 1 .........KM-2 220V 15A
BRACKET, CIRCUIT BREAKER
RUBBER CUSHION
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
RECEPTACLE REMOTE CONTROL ........ 1 .........NWPC-254-RF
CAP, RECEPTACLE ................................. 1 .........NWPC-25-RCa
BRACKET
1
1
4
4
4
73
74
75
76
77
1
MACHINE SCREW................................... 3 .........REPLACES 0021103010
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
COVER, OUTPUT TERMINAL
HEX. HEAD BOLT
PLAIN WASHER
RUBBERWASHER
HEX. NUT
3
3
3
1
1
1
1
2
4
2
2
2
1
78
79
80
81
82
83
84
85
86
LOCK
TOOTHEDWASHER
HEX. HEAD BOLT .................................... 1 .........REPLACES 0017106020
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 109
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS)
ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS WITH SLOW DOWN)-UP TO S/N1337562
PAGE 110 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine Op. (Options)
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS)
ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS WITH SLOW DOWN)- UP TO S/N1337562
NO
1
2
3
4
PART NO
PART NAME
OPERATING PANEL
HEX. HEAD BOLT
QTY. REMARKS
1
12
8182111003
0017106016
0602101000
0021008080
020108060
0040008000
031108160
0800250300
6008155390
0806410000
6008153730
0602120054
0602120178
0602122053
0602122200
0602123053
0602123204
0602121052
0602040690
0603300000
0603302000
0603303000
0190001000
0602115008
0601810204
0601830707
0601830683
0601831200
0602103091
0601810244
8185312002
012010030
020310080
0040010000
031110160
8192183004
0010010055
020310080
031110160
8182152004
8182152104
0602180106
BATTERY SWITCH ...........................................1....... 9827300090
MACHINE SCREW
HEX. NUT ..........................................................2....... REPLACES 0030008000
LOCKWASHER
PLAIN WASHER................................................4....... REPLACES 0041608000
THROTTLE HANDLE
STARTER SWITCH ...........................................1....... REPLACES 0602100049
EMERGENCY STOP BUTTON .........................1....... REPLACES 0602104045
PREHEAT LAMP ...............................................1....... REPLACES 0602102055
TACHOMETER;25000KX3710 ...........................1....... REPLACES 0602120052
CABLE, TACHOMETER ....................................1....... 62100KX0700
OIL PRESSURE GAUGE ..................................1....... 42000KV0300
UNIT, OIL PRESSURE ......................................1....... 53000AC0101
WATER TEMPERATURE GAUGE .....................1....... 40000KV0700
UNIT, WATERTEMPERATURE .........................1....... 51400KA1200
CHARGING AMMETER ....................................1....... 43000KV0300
INDICATOR, AIR CLEANER..............................1....... RBX002252
HALF UNION, PT 1/8 x 4
SLEEVE
NUT
NYLON PIPE
ENGINE WARNING DISPLAY LED ...................1....... V 336760
BULB
SWITCH, SLOW DOWN....................................1....... S-331T
SELECTOR SWITCH, REMOTE CONTROL .....1....... AH30P2B33
REMOVE BUTTON, IDLING..............................1....... MB201110K
PILOT LAMP, IDLING ........................................1....... REPLACES 0602103090
BULB
SUPPORT LEG
HEX. HEAD BOLT .............................................5....... REPLACES 0010010030
HEX. NUT ..........................................................2....... REPLACES 0030010000
LOCKWASHER
PLAIN WASHER................................................7....... REPLACES 0041610000
LINK, GOVERNOR ROD
HEX. HEAD BOLT
HEX. NUT ..........................................................1....... REPLACES 0030010000
PLAIN WASHER................................................2....... REPLACES 0041610000
GOVERNOR ROD
GOVERNOR ROD
BALL JOINT
2
2
5
6
7
8
1
9
10
11
12
13
14
15
16
17
18
19
20
21
1
1
1
1
6
22
23
24
25
1
1
26
27
5
28
29
1
1
30
31
32
1
1
2
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 111
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS)
ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS WITH SLOW DOWN)- UP TO S/N1337562
PAGE 112 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine Op. (Options)
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS)
ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS WITH SLOW DOWN) UP TO S/N1337562
NO
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
PART NO
PART NAME
QTY.
REMARKS
020108060
0207006000
0802100704
0207006000
031108160
952404470
0605010503
1819001931
8182159304
0027106012
011008020
0601802133
0802100204
0802101204
8182159103
011208030
0021005020
0032005000
0041205000
0601820995
0027105010
0601822560
0027105010
0601820067
0021005020
0032005000
58151
HEX. NUT ................................................. 2 .........REPLACES 0030008000
HEX. NUT
PIN BOLT
HEX. NUT
2
1
1
PLAIN WASHER....................................... 3 .........REPLACES 0041608000
PLAIN WASHER....................................... 1 .........REPLACES 0041606000
SNAP PIN
CONTROLLER ......................................... 1 .........REPLACES 0602210803
BRACKET
MACHINE SCREW
HEX. HEAD BOLT .................................... 4 .........REPLACES 0017108020
FUSE........................................................ 1 .........F-5 5A
JOINT
SPRING
BRACKET
HEX. HEAD BOLT .................................... 2 .........REPLACES 0017108030
MACHINE SCREW
LOCKWASHER ....................................... 1 .........REPLACES 0040005000
PLAIN WASHER
RELAY...................................................... 2 .........JA1C-TM DC24
MACHINE SCREW
BUZZER ................................................... 1 .........BA-047
MACHINE SCREW
RECTIFIER .............................................. 1 .........PB2510
MACHINE SCREW
1
1
3
1
1
1
1
1
50
51
52
53
54
55
4
1
1
LOCKWASHER ....................................... 1 .........REPLACES 0040005000
PLAIN WASHER....................................... 1 .........REPLACES 0041205000
56
57
58
59
60
61
62
63
64
65
08002323306
8182630104
0027105010
011206020
6008151252
0017106016
0602201910
0027106016
0601821370
0021005035
0032005000
58151
SLOW DOWN UNIT
BRACKET
MACHINE SCREW
HEX. HEAD BOLT .................................... 4 .........REPLACES 0017106020
EMERGENCY RELAY.............................. 1 .........REPLACES 0602200446
HEX. HEAD BOLT
UNIT, BATTERY SENSOR ....................... 1 .........C703900000
MACHINE SCREW
RECTIFIER;DE4503................................. 2 ......... REPLACES 0601823240
MACHINE SCREW
LOCKWASHER ....................................... 1 .........REPLACES 0040005000
PLAIN WASHER....................................... 1 .........REPLACES 0041205000
1
1
6
4
1
1
66
67
68
69
8182210113
0017106016
8181860103
0801830304
COVER, ELECTRIC PARTS
HEX. HEAD BOLT
SET BOARD, OUTPUT TERMINAL
1
1
1
7
OUTPUTTERMINAL
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 113
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS)
ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS WITH SLOW DOWN) UP TO S/N1337562
PAGE 114 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine Op. (Options)
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS)
ENGINE OPERATING PANEL ASSY. (OPTIONAL PARTS WITH SLOW DOWN) UP TO S/N1337562
NO
70
71
72
73
74
75
76
77
78
79
PART NO
PART NAME
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
TERMINAL PLATE
TERMINAL SCREW
HEX. NUT
QTY.
7
14
21
28
3
1
5
6
REMARKS
0801830804
0039316000
0040016000
0041416000
3461860504
0801832304
0039306000
0040006000
952404470
011208030
0040008000
031108160
0601812597
0025004016
0042304000
0042404000
0601802010
0845032304
0223300060
0019106020
0042306000
0042406000
0601811262
0601811409
0027103010
0025013010
0042303000
0042403000
8185182003
0019112045
0042412000
0805009804
0205012000
0845043704
0040506000
011206020
0840300803
LOCKWASHER
PLAIN WASHER....................................... 6 .........REPLACES 0041606000
HEX. HEAD BOLT .................................... 5 .........REPLACES 0010008030
LOCKWASHER
PLAIN WASHER....................................... 5 .........REPLACES 0041608000
RECEPTACLE, AUX. POWER;1136X ...... 1 .........REPLACES 0601811018
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
5
80
81
2
2
2
82
83
83-1
84
CIRCUIT BREAKER................................. 1 .........KM-2 220V 15A
BRACKET, CIRCUIT BREAKER
RUBBER CUSHION
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
RECEPTACLE REMOTE CONTROL ........ 1 .........NCS-4410-RF
CAP, RECEPTACLE ................................. 1 .........NCS-44-RCa
MACHINE SCREW................................... 3 .........REPLACES 0021103010
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
COVER, OUTPUT TERMINAL
HEX. HEAD BOLT
PLAIN WASHER
RUBBERWASHER
HEX. NUT
SPRING
TOOTHEDWASHER
HEX. HEAD BOLT .................................... 1 .........REPLACES 0017106020
CURRENTTRANSFORMER
1
1
4
4
4
85
86
87
88
3
3
3
1
2
4
2
2
2
1
89
90
91
92
93
94
95
96
97
2
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 115
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine Op. up to S/N1337562
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY. S/N1337563~
PAGE 116 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine Op. up to S/N1337562
Eng. Op S/N1337563~
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY. S/N1337563~
NO
1
1
PART NO
PART NAME
QTY.
REMARKS
C1352101103 OPERATING PANEL ....................... 1 .......... UPTOS/N3696500
C1352101113 OPERATING PANEL ....................... 1 .......... S/N3696501TO3701661
C1352101123 OPERATING PANEL ....................... 1 .......... S/N3701662~
1
2
0019106016
0042306000
0042406000
0602101000
0021008080
0030008000
0040008000
0041608000
0800250300
6008155390
0601830448
0806410000
0602104045
0601831557
6008153730
0602120054
0602120175
0602122060
0602122200
0602123061
0602123206
0602121052
0602125060
0602115014
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
BATTERY SWITCH ......................... 1 .......... 9827300090
MACHINE SCREW
HEX. NUT
LOCKWASHER
PLAIN WASHER
THROTTLE HANDLE ...................... 1 .......... UPTO 3701661
STARTER SWITCH ......................... 1 .......... UPTO S/N3696500;REPLACES 0602100049
PREHEAT BUTTON ........................ 1 .......... S/N3696501~;AH25FB10
STOP BUTTON ............................... 1 .......... UPTO S/N3696500;REPLACES 0602104045
EMERGENCY STOP BUTTON ....... 1 .......... S/N3696501TO3701661
EMERGENCY STOP BUTTON ....... 1 .......... S/N3701662~
PREHEAT LAMP............................. 1 .......... REPLACES 0602102055
TACHOMETER................................ 1 .......... 25000KX4110
CABLE, TACHOMETER .................. 1 .......... 62100KX0700
OIL PRESSURE GAUGE ................ 1 .......... 42000KX1410
UNIT, OIL PRESSURE.................... 1 .......... 53000AC0101
WATER TEMPERATURE GAUGE ... 1 .......... 40000KX0910
UNIT, WATERTEMPERATURE ....... 1 .......... 51400KS0600
CHARGINE AMMETER .................. 1 .......... 43000KV0300
FUEL GAUGE ................................. 1 .......... 41000KW0110
MONITOR ....................................... 1 .......... V337660
12
12
12
3
4
2
2
2
4
5
6
6
7
7
7
8
9
10
11
12
13
14
15
16
17
18
18
19
20
21
C1484000202 SUPPORT LEG .............................. 1 .......... UP TO S/N3701661
C1484000212 SUPPORT LEG .............................. 1 .......... S/N3701662~
0010110030
HEX. HEAD BOLT
5
C1355100104 LINK, GOVERNOR ROD ................. 1 .......... UP TO S/N3701661
0010010035
0030010000
0041210000
HEX. HEAD BOLT........................... 1 .......... UP TO S/N3701661
LOCKWASHER .............................. 1 .......... UP TO S/N3701661
PLAIN WASHER ............................. 1 .......... UP TO S/N3701661
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 117
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine Op. up to S/N1337562
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY. S/N1337563~
PAGE 118 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine Op. up to S/N1337562
Eng. Op S/N1337563~
Table of Contents
DCA-220SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY. S/N1337563~
NO
PART NO
PART NAME
QTY.
REMARKS
22
23
24
25
26
27
28
29
30
31
32
33
C1355300404 GOVERNOR ROD ........................... 1 .......... UP TO S/N3701661
C1355300304 GOVERNOR ROD ........................... 1 .......... UP TO S/N3701661
0602180106
0207008000
0041206000
0207006000
0041206000
0605010502
BALL JOINT.................................... 2 .......... UP TO S/N3701661
HEX. NUT ....................................... 2 .......... UP TO S/N3701661
PLAIN WASHER ............................. 2 .......... UP TO S/N3701661
HEX. NUT ....................................... 2 .......... UP TO S/N3701661
PLAIN WASHER ............................. 2 .......... UP TO S/N3701661
SNAP PIN ....................................... 2 .......... UP TO S/N3701661
C1355200804 BRACKET, THROTTLE WIRE ......... 1 .......... UP TO S/N3701661
0017106025 HEX. HEAD BOLT........................... 2 .......... UP TO S/N3701661
C1355200603 BRACKET, THROTTLE WIRE ......... 1 .......... UP TO S/N3701661
0010310040
0040010000
0041210000
0010310050
0040010000
0041210000
0601830710
HEX. HEAD BOLT........................... 1 .......... UP TO S/N3701661
LOCKWASHER .............................. 1 .......... UP TO S/N3701661
PLAIN WASHER ............................. 1 .......... UP TO S/N3701661
HEX. HEAD BOLT........................... 1 .......... UP TO S/N3701661
LOCKWASHER .............................. 1 .......... UP TO S/N3701661
PLAIN WASHER ............................. 1 .......... UP TO S/N3701661
ENGINE SPEED SWITCH;S301T; . 1 .......... S/N3701662~
34
35
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 119
Download from Www.Somanuals.com. All Manuals Search And Download.
Engine Op. up to S/N1337562
Output Term.S/N3690735~
Table of Contents
DCA-220SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY. S/N1337563 TO3690734
PAGE 120 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Engine Op. up to S/N1337562
Table of Contents
DCA-220SSK — OUTPUTTERMINAL ASSY.
OUTPUTTERMINAL ASSY.S/N1337563TO3690734
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
1
8
REMARKS
C1231700003
0801030304
0801830804
0039316000
0040016000
0041416000
3461860504
0019108040
0205008000
0042308000
0042408000
0601812597
0601811034
0027104016
0030004000
0041204000
0601804887
0601805840
C1261600204
0223300200
0017106020
C1237100103
0019112045
0042412000
0805009804
0205012000
0845043704
C1237100204
0017108020
SET BOARD, OUTPUT TERMINAL
OUTPUTTERMINAL
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
TERMINAL PLATE
HEX. HEAD BOLT
HEX. NUT
8
16
24
32
3
5
5
LOCKWASHER
PLAIN WASHER
10
10
9
10
11
RECEPTACLE, AUX. POWER; 5-20R ............. 2 ........ S/N1337563TO 1338269
RECEPTACLE, AUX. POWER; C6369............. 3 ........ REPLACES 0601812565
MACHINE SCREW
HEX.NUT
10
10
10
PLAIN WASHER
12
13
14
14-1
15
16
17
18
19
20
21
22
23
CIRCUIT BREAKER; KM51 20A ..................... 2 ........ REPLACES 0601805313
CIRCUIT BREAKER; KM52 50A
BRACKET, CIRCUIT BREAKER
RUBBER CUSHION
HEX. HEAD BOLT
COVER, OUTPUT TERMINAL
HEX. HEAD BOLT
PLAIN WASHER
RUBBERWASHER
HEX. NUT
SPRING
3
1
1
2
1
2
2
2
2
2
1
9
COVER, OUTPUT TERMINAL
HEX. HEAD BOLT
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 121
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Engine Op. up to S/N1337562
Table of Contents
DCA-220SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY. S/N3690735~
PAGE 122 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Output Term.S/N1337563 to 3690734
Engine Op. up to S/N1337562
Output Term.S/N3690735~
Table of Contents
DCA-220SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY. S/N3690735~
NO
PART NO
PART NAME
QTY.
REMARKS
1
2
3
4
5
6
7
8
C1231700003
0801030304
0801830804
0039316000
0040016000
0041416000
3461860504
0019108040
0205008000
0042308000
0042408000
0601805313
0601805840
C1261600204
0017106020
0601812598
0601812565
0027104015
0030004000
0041204000
C1237100113
0019112045
0042412000
0805015604
0205012000
0845043704
C1237100214
0017108020
C0237101504
0805015604
0845054204
0017110040
0601815324
0027104020
0601850275
0601851780
SET BOARD, OUTPUT TERMINAL
OUTPUTTERMINAL
HEX. HEAD BOLT
HEX. NUT
1
8
8
16
24
32
3
5
5
10
10
LOCKWASHER
PLAIN WASHER
TERMINAL PLATE
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
CIRCUIT BREAKER ........................................ 2 ........ KM51B 265V 20
CIRCUIT BREAKER ........................................ 3 ........ KM52 265V 50A
BRACKET, CIRCUIT BREAKER
HEX. HEAD BOLT
RECEPTACLE ................................................. 2 ........ GF530EM
RECEPTACLE ................................................. 3 ........ CS6369
MACHINE SCREW
HEX. NUT
PLAIN WASHER
COVER, OUTPUT TERMINAL
HEX. HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX. NUT
SPRING
COVER
HEX. HEAD BOLT
COVER, OUTPUT TERMINAL
STAY RUBBER
COLLAR
9
10
11
12
13
14
15
1
2
10
10
10
1
2
2
2
2
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
7
1
1
2
HEX. HEAD BOLT
2
TERMINAL BOARD;TS22P............................. 1 ........ S/N3696501~
MACHINE SCREW .......................................... 2 ........ S/N3696501~
GROMMET ...................................................... 1 ........ S/N3696501~
GROMMET ...................................................... 2 ........ S/N3700671~
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 123
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — ACTUATOR ASSY.
ACTUATOR ASSY. S/N3690735~
PAGE 124 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Actuator
Table of Contents
DCA-220SSK — ACTUATOR ASSY.
ACTUATOR ASSY. S/N3690735~
NO
PART NO
PART NAME
QTY.
REMARKS
1
2
3
4
5
DYNC11024000024 ACTUATOR ...................................................... 1 ........ REPLACES 0602150091
DYNC182
LEVER............................................................. 1 ........ REPLACES 0602211090
C1356200004
0012310030
0010306035
0207006000
0040006000
0041206000
0602211091
0602180190
0602211092
0010106025
0207006000
0041206000
0010106025
0207006000
0041206000
BRACKET, ACTUATOR
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
ROD
BALL JOINT
HEX. NUT
HEX. HEAD BOLT
HEX. NUT
1
4
4
4
4
4
1
2
2
1
1
4
1
1
1
6
7
8
9
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
10
PLAIN WASHER
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 125
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — BATTERY ASSY.
BATTERY ASSY.
PAGE 126 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Battery
Table of Contents
DCA-220SSK — BATTERY ASSY.
BATTERY ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
REMARKS
0165614551
0805000804
0805000904
0805002904
0037808000
0040008000
031108160
8182280304
C1347600004
8182280104
C1347600104
8182280504
C1347600504
8182280704
C1347600304
8182280904
C1347200104
012010030
BATTERY ................................... 2 ......... 145G51 12V-150 Ah
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
WING NUT
2
2
4
4
4
LOCKWASHER
PLAIN WASHER ........................ 4 ......... REPLACES 0041608000
BATTERY CABLE ...................... 1 ......... UPTO S/N1337562
BATTERY CABLE ...................... 1 ......... S/N1337563~
BATTERY CABLE ...................... 1 ......... UPTO S/N1337562
BATTERY CABLE ...................... 1 ......... S/N1337563~
BATTERY CABLE ...................... 1 ......... UPTO S/N1337562
BATTERY CABLE ...................... 1 ......... S/N1337563~
BATTERY CABLE ...................... 1 ......... UPTO S/N1337562
BATTERY CABLE ...................... 1 ......... S/N1337563~
EARTH CABLE .......................... 1 ......... UPTO S/N1337562
EARTH CABLE .......................... 1 ......... S/N1337563~
HEX. HEAD BOLT...................... 4 ......... REPLACES 0010010030
HEX. NUT .................................. 4 ......... REPLACES 0030010000
HEX. HEAD BOLT...................... 1 ......... UPTO S/N1337562
HEX. HEAD BOLT...................... 1 ......... S/N1337563~
LOCKWASHER ......................... 1 ......... S/N1337563~
PLAIN WASHER ........................ 1 ......... S/N1337563~
9
10
11
12
13
14
15
020310080
0017110025
0010110020
0040010000
004161000
16
17
18
19
0040510000
0845040414
0845041304
0602220203
TOOTHEDWASHER
TERMINAL CAP (+)
TERMINAL CAP (-)
1
2
2
BATTERY SENSOR ................... 1 ......... REPLACES 0602220204;
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 127
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — MUFFLER ASSY.
MUFFLER ASSY. UP TO S/N1337562
MUFFLER ASSY. S/N1337563~
PAGE 128 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Muffler
Table of Contents
DCA-220SSK — MUFFLER ASSY.
MUFFLER ASSY. UP TO S/N1337562
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
MUFFLER
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
EXHAUST PIPE
GASKET .................................. 1 ........... REPLACES 0602320059
GASKET
HEX. HEAD BOLT
HEX. NUT
QTY.
REMARKS
8182311002
0019110030
0042310000
0042410000
8182350003
6150115750
7502356004
0010312060
0030312000
0040012000
031112230
1
4
4
4
1
2
8
8
8
9
10
11
LOCKWASHER
PLAIN WASHER ...................... 16 ......... REPLACES 0041612000
MUFFLER ASSY. S/N1337563~
NO
1
2
3
4
PART NO
PART NAME
MUFFLER
QTY.
REMARKS
C1331100702
0019210025
C1334000403
6150115751
7502356004
0010312050
0030312000
0040012000
0041212000
0010312055
0030312000
0040012000
0041212000
C1331300104
C1334200104
0017108020
C1334300104
0017108020
0603320129
0207010000
1
4
1
HEX. HEAD BOLT
EXHAUST PIPE
GASKET .................................. 1 ........... REPLACES 0602320142
GASKET
HEX. HEAD BOLT
5
6
1
4
4
4
8
4
4
4
8
2
2
4
1
4
2
HEX. NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
COVER
SHEET
HEX. HEAD BOLT
BRACKET
HEX. HEAD BOLT
U BOLT
7
8
9
10
11
12
13
14
HEX. NUT
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 129
Download from Www.Somanuals.com. All Manuals Search And Download.
Fuel Tank S/N1337563~
Table of Contents
DCA-220SSK — FUELTANK ASSY.
FUEL TANK ASSY. UP TO S/N1337562
PAGE 130 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Fuel Tank up to S/N1337562
Fuel Tank S/N1337563~
Table of Contents
DCA-220SSK — FUELTANK ASSY.
FUEL TANK ASSY. UP TO S/N1337562
NO
PART NO
PART NAME
QTY.
REMARKS
1
8185510103
8185510703
0845500104
0810105400
8185523104
0805003404
011008020
020108060
0041608000
0805013804
0845032204
0802011104
0150000018
0191302250
0191301850
0605515014
0605503009
0802120604
0845039604
FUEL TANK .............................. 1 ........... S/N 1325370TO 1326838
FUEL TANK .............................. 1 ........... S/N1326839 TO1337562
CAP, FUEL TANK
FUEL FILTER
TANK BAND
1
1
2
4
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PAD, TANK BAND
HEX. HEAD BOLT.................... 2 ........... REPLACES 0017108020
HEX. NUT ................................ 2 ........... REPLACES 0030008000
PLAIN WASHER
TANK SHEET
DRAIN JOINT
PLUG
2
3
1
1
1
1
1
4
1
1
1
O RING
SUCTION HOSE
RETURN HOSE
HOSE BAND
FUEL SENSOR
PACKING
RUBBER SEAL
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 131
Download from Www.Somanuals.com. All Manuals Search And Download.
Fuel Tank up to S/N1337562
Table of Contents
DCA-220SSK — FUELTANK ASSY.
FUEL TANK ASSY. S/N1337563~
PAGE 132 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Fuel Tank up to S/N1337562
Fuel Tank S/N1337563~
Table of Contents
DCA-220SSK — FUELTANK ASSY.
FUEL TANK ASSY. S/N1337563~
NO
1
1-1
PART NO
PART NAME
FUEL TANK
CAP, FUEL TANK
KEY
QTY.
1
1
1
1
1
2
2
4
2
2
6
1
1
1
1
1
REMARKS
C1364000403
0605505005
0605550505
0810105400
0264100385
0605515079
8175523104
0805003414
0017108020
0037908000
0222100200
0130206000
8085512104
0603325011
0132006000
0191302300
0191302800
0605515019
0605503020
0802120604
0605501050
0602021155
0027104010
0845039604
1-2
1-3
1-4
2
3
4
5
6
7
8
FUEL FILTER
HOSE, FUEL GAUGE
HOSE BAND
TANK BAND
PAD, TANK BAND
HEX. HEAD BOLT
HEX. HEAD BOLT
TANK SHEET
STREET ELBOW
DRAIN PIPE
VALVE
9
10
11
12
13
14
15
16
17
18
19
PLUG
SUCTION HOSE
RETURN HOSE
HOSE BAND
FUEL SENSOR
PACKING
UNIT, FUEL .............................. 1 ........... 52000KA9810
PACKING ................................. 1 ........... 52391KW3700
MACHINE SCREW
RUBBER SEAL
1
4
1
1
1
1
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 133
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
S/N1337563~
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. UP TO S/N1337562
PAGE 134 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
Table of Contents
S/N1337563~
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. UP TO S/N1337562
NO
1
PART NO
PART NAME
BASE
BASE
QTY.
REMARKS
8185111002
8185111012
8185116004
011008020
8185121002
8185121012
8185102003
0019110025
0042310000
0042410000
8185125104
8185102604
011008020
0845042703
011008020
8185125003
8185125013
011008020
8185131002
8185131012
0019114050
0205014000
0042314000
0042414000
0019114040
0205014000
0042314000
0042414000
8185141002
8185141012
8185102704
0019110025
0042310000
0042410000
8185155003
8185102804
01108020
1
1
1
2
3
4
FLOOR PANEL
HEX. HEAD BOLT.............................. 12......... REPLACES 0019208020
FRONT FRAME
FRONT FRAME
LINING
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
COVER, FRONT FRAME
LINING
HEX. HEAD BOLT.............................. 19 ......... REPLACES 0019208020
FILLER BRACKET
HEX. HEAD BOLT.............................. 4........... REPLACES 0019208020
COVER, FRONT FRAME
COVER, FRONT FRAME
1
1
1
8
8
8
1
1
5
6
7
8
9
10
1
1
1
11
12
HEX. HEAD BOLT.............................. 12 ......... REPLACES 0019208020
CENTER FRAME
CENTER FRAME
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
REAR FRAME
REAR FRAME
LINING
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
COVER, REAR FRAME
LINING
HEX. HEAD BOLT.............................. 17 ......... REPLACES 0019208020
GUIDE PANEL, AIR
LINING
HEX. HEAD BOLT.............................. 12 ......... REPLACES 0017108020
GUIDE PANEL, AIR
LINING
HEX. HEAD BOLT.............................. 4........... REPLACES 0017108020
DOOR, REAR FRAME
1
1
4
4
4
8
8
8
8
16
1
1
1
4
4
4
1
1
13
14
15
16
17
18
19
8185155104
8185102904
01108020
8185118504
8185103004
01108020
1
1
20
21
1
1
22
23
8185143103
1
8185143113
DOOR, REAR FRAME
1
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 135
Download from Www.Somanuals.com. All Manuals Search And Download.
S/N1337563~
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. UP TO S/N1337562
THE PART NUMBER INDICATED IS ORANGE.
PLEASE ADDTHE FOLLOWING LETTERS
WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 136 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
Table of Contents
S/N1337563~
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. UP TO S/N1337562
NO
PART NO
PART NAME
QTY.
REMARKS
24
8185143003
8185143013
3515147104
0025006016
0205006000
0042306000
0042406000
0805037204
0845033904
01108020
DOOR, REAR FRAME
DOOR, REAR FRAME
WINDOW PLATE
MACHINE SCREW
HEX. NUT
LOCKWASHER
PLAIN WASHER
DOOR HANDLE
LINK, DOOR ROD
1
1
2
12
12
12
24
1
25
26
27
28
29
30
31
32
33
34
35
36
37
38
1
HEX. HEAD BOLT...................... 1 ........REPLACES 0019208020
8185146104
8185146004
0805011404
0027104010
031110160
0605010504
0805011304
0805011204
0025006020
0205006000
0042306000
0042406000
0845028203
M9110100204
0845045004
0845028303
M9110100304
0845045004
011008020
8185161002
8185102103
0800251701
0025006016
0042306000
0042406000
8185161102
8185103104
011008020
8185181002
8185103704
0019108065
030208200
031108160
8185172103
DOOR ROD
DOOR ROD
LOCK
1
1
1
MACHINE SCREW .................... 2 ........REPLACES 0041610000
PLAIN WASHER
SNAP RING
4
2
1
1
4
4
4
8
2
STOPPER, DOOR
STOPPER, DOOR
MACHINE SCREW
HEX. NUT
LOCKWASHER
PLAIN WASHER
HINGE
HINGE........................................ 2 ........REPLACES 0845047104
WASHER
HINGE
HINGE........................................ 2 ........REPLACES 0845047204
WASHER
HEX. HEAD BOLT...................... 8 ........REPLACES 0019208020
ROOF PANEL
LINING
FILLER COVER
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
ROOF PANEL
LINING
HEX. HEAD BOLT...................... 40.......REPLACES 0019208020
SPLASHER PANEL
LINING
HEX. HEAD BOLT
LOCKWASHER ......................... 6 ........REPLACES 0042308000
PLAIN WASHER ........................ 6 ........REPLACES 0042408000
SIDE PANEL
39
39-1
40
2
2
40-1
41
42
2
1
1
1
2
2
2
1
1
43
44
45
46
47
1
1
6
48
49
1
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 137
Download from Www.Somanuals.com. All Manuals Search And Download.
S/N1337563~
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. UP TO S/N1337562
THE PART NUMBER INDICATED IS ORANGE.
PLEASE ADDTHE FOLLOWING LETTERS
WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 138 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
S/N1337563~
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. UP TO S/N1337562
NO
PART NO
PART NAME
QTY.
REMARKS
8185172103
8185102403
8185172003
8185172013
8185102303
0019108065
030208200
031108160
8185176204
8185103504
8185176104
8185103404
011008020
8185171103
8185171113
8185103803
8185171003
8185171013
8185102203
8185171303
8185171313
8185103204
8185171203
8185171213
8185102503
0845033304
0845034204
0845034104
011008020
0810009103
0845046904
0845045004
0810009203
0845047004
0845045004
011008020
8185176004
8185103304
8185176304
8185103604
011008020
0845031504
0194500700
0605515003
0800517103
0021106020
SIDE PANEL
LINING
SIDE PANEL
SIDE PANEL
LINING
1
1
1
1
1
4
50
51
HEX. HEAD BOLT
LOCKWASHER ......................... 4 ................... REPLACES 0042308000
PLAIN WASHER ........................ 4 ................... REPLACES 0042408000
GUIDE PANEL, AIR
LINING
GUIDE PANEL, AIR
LINING
HEX. HEAD BOLT...................... 16.................. REPLACES 0017108020
SIDE DOOR
SIDE DOOR
LINING
SIDE DOOR
SIDE DOOR
LINING
SIDE DOOR
SIDE DOOR
LINING
SIDE DOOR
SIDE DOOR
LINING
52
53
2
2
1
1
54
55
1
1
1
1
1
1
1
1
1
1
1
1
7
4
3
56
57
58
59
60
61
62
63
DOOR HANDLE
DOOR LATCH
DOOR LATCH
HEX. HEAD BOLT...................... 7 ................... REPLACES 0019208020
HINGE
HINGE
WASHER
HINGE
8
8
8
8
8
8
63-1
64
HINGE
WASHER
64-1
65
66
HEX. HEAD BOLT...................... 48.................. REPLACES 0019208020
GUIDE PANEL, AIR
LINING
GUIDE PANEL, AIR
LINING
HEX. HEAD BOLT...................... 22.................. REPLACES 0017108020
CAP
HOSE
HOSE BAND
EMBLEM
2
2
1
1
67
68
69
70
71
72
73
20
1
2
2
4
MACHINE SCREW
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 139
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. S/N1337563~
PAGE 140 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
S/N1337563~
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. S/N1337563~
NO
PART NO
PART NAME
QTY.
REMARKS
1
1
1
C1414000412
C1414001202
C1414001502
C1494000104
C3414100104
C3414100004
0019208020
C1424000602
C1424001102
C1494100403
0019110020
0019210025
004231000
BASE ......................................... 1 .................. S/N1337563TO 3690734
BASE ......................................... 1 .................. S/N3690735TO 3701661
BASE ......................................... 1 .................. S/N3701662~
LINING
1
2
3
4
5
5
FLOOR PANEL
FLOOR PANEL
HEX.HEAD BOLT
1
1
16
FRONT FRAME ......................... 1 .................. S/N1337563TO 3701661
FRONT FRAME ......................... 1 .................. S/N3701662~
LINING
1
6
6
HEX. HEAD BOLT...................... 8 .................. S/N1337563TO 3690734
HEX. HEAD BOLT...................... 8 .................. S/N3690735~
LOCKWASHER
PLAIN WASHER
COVER, FRONT FRAME
LINING
HEX. HEAD BOLT
FILLER BRACKET
HEX. HEAD BOLT
COVER, FRONT FRAME
HEX. HEAD BOLT
CENTER FRAME
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
REAR FRAME
8
8
1
1
21
1
4
1
14
1
4
4
4
4
4
4
4
4
1
1
004241000
7
C1424200204
8175924104
0019208020
0845042703
0019208020
C1424200503
0019208020
C1434000202
0010114050
0030014000
0040014000
0041214000
0010120050
0030020000
0040020000
0041220000
C1444000412
C1494300504
0019110020
0019210025
0042310000
0042410000
8
9
10
11
12
13
14
15
16
LINING
17
17
HEX. HEAD BOLT...................... 4 .................. S/N1337563TO 3690734
HEX. HEAD BOLT...................... 4 .................. S/N3690735~
LOCKWASHER
PLAIN WASHER
4
4
THE PART NUMBER INDICATED IS ORANGE.
PLEASE ADDTHE FOLLOWING LETTERS
WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 141
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY.S/N1337563~
PAGE 142 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
S/N1337563~
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. S/N1337563~
NO
18
PART NO
PART NAME
COVER, REAR FRAME
LINING
DUCT
LINING
QTY.
1
1
1
1
12
17
1
1
2
12
1
4
1
4
REMARKS
C1444300403
C1494300304
C1444300303
C1494300404
0038408000
0019208020
C1444200103
8175143303
8225147004
0037906000
B9114500104
0207006000
B9114000102
0021806016
0030006000
8175146204
8175146304
0845050704
0205006000
0042306000
0042406000
0805011304
0805011204
0207006000
0845047104
0845045004
0845047204
0845045004
0019208020
C1464100102
C1494500204
0800251701
0025006020
0042306000
0042406000
C146420002
C1494500004
19
20
21
22
23
24
25
26
27
28
29
HEX. NUT
HEX. HEAD BOLT
DOOR, REAR FRAME
DOOR, REAR FRAME
WINDOW PLATE
HEX. NUT
DOOR POCKET
HEX. NUT
DOOR HANDLE
MACHINE SCREW
HEX. NUT .................................. 4 .................. S/N3690735~
DOOR ROD
DOOR ROD
STAY
30
31
32
33
1
1
4
8
8
8
HEX. NUT
LOCKWASHER
PLAIN WASHER
STOPPER, DOOR
STOPPER, DOOR
HEX. NUT
HINGE
WASHER
HINGE
WASHER
HEX. HEAD BOLT
ROOF PANEL
LINING
FILLER COVER
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
ROOF PANEL
LINING
34
35
36
37
1
4
2
2
2
2
4
1
1
1
2
2
2
1
1
38
39
40
41
42
43
THE PART NUMBER INDICATED IS ORANGE.
PLEASE ADDTHE FOLLOWING LETTERS
WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 143
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY.S/N1337563~
PAGE 144 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Enclosure up to S/N1337562
S/N1337563~
Table of Contents
DCA-220SSK — ENCLOSURE ASSY.
ENCLOSURE ASSY. S/N1337563~
NO
44
45
45
45
45
46
PART NO
PART NAME
HEX. HEAD BOLT
QTY.
40
REMARKS
0019208020
C1454201212
C1454201222
C1454201232
C1455200002
0019108065
0042308000
0042408000
C1454000903
C1494401604
C1454300604
C1494402904
0038408000
B9114000002
0825007362
0021806016
0030006000
0845046904
0845045004
0845047004
0845045004
0019208020
0601850097
0021008025
C1454001003
C1494401704
C1454300604
C1494402104
0038408000
C1454001103
C1494401904
C1454300704
C1494402004
0038408000
C1454001203
C1494401804
0845031504
0600500090
0021106020
SPLASHER PANEL ................... 1 .................. S/N1337563TO3690734
SPLASHER PANEL ................... 1 .................. S/N3690735TO 3696500
SPLASHER PANEL ................... 1 .................. S/N3696501TO 3700670
SPLASHER PANEL ................... 1 .................. S/N 3700671~
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
SIDE DOOR
LINING
DUCT
LINING
HEX. NUT
DOOR HANDLE
DOOR HANDLE
MACHINE SCREW
HEX. NUT
HINGE
WASHER
6
6
6
1
1
1
1
7
4
3
28
28
6
5
5
5
47
48
49
50
51
52
53
54
HINGE
WASHER
HEX. HEAD BOLT
STOPPER
MACHINE SCREW
SIDE DOOR
LINING
55
56
57
58
25
10
10
1
1
1
59
DUCT
LINING
1
60
61
HEX. NUT .................................. 7 .................. S/N1337563TO 3690734
SIDE DOOR
LINING
DUCT
LINING
HEX. NUT .................................. 5 .................. S/N1337563TO 3690734
SIDE DOR
LINING
CAP
1
1
1
1
62
63
64
1
1
15
2
65
66
67
EMBLEM
MACHINE SCREW
4
THE PART NUMBER INDICATED IS ORANGE.
PLEASE ADDTHE FOLLOWING LETTERS
WHEN ORDERING COLOR OF UNIT:
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 145
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
S/N1337563~
DCA-220SSK —RUBBER SEAL ASSY.
PAGE 146 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Seals up to S/N1337562
S/N1337563~
Table of Contents
DCA-220SSK —RUBBER SEAL ASSY.
RUBBER SEAL ASSY. UP TO S/N1337562
NO
74
75
76
77
78
79
80
81
82
83
84
PART NO
PART NAME
QTY.
REMARKS
0223301230
0223300965
0223300710
0223300630
0223300640
0223301310
0225101400
0221200695
0221201120
0221201180
0225101200
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
5
4
1
1
4
1
4
2
1
1
1
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 147
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
Seals up to S/N1337562
DCA-220SSK —RUBBER SEAL ASSY.
PAGE 148 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Seals up to S/N1337562
Table of Contents
S/N1337563~
DCA-220SSK —RUBBER SEAL ASSY.
RUBBER SEAL ASSY. S/N1337563~
NO
1
2
3
4
5
6
8
8
PART NO
PART NAME
QTY.
REMARKS
0228901250
0228901010
0228900650
0228901050
0229201300
0228901280
0228800760
0221200760
0228801100
0229201200
0228100120
0228100510
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
4
4
2
3
4
2
RUBBER SEAL ........................ 2 ........... S/N1337563TO 3701661
RUBBER SEAL ........................ 2 ........... S/N3701662~
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
9
2
1
4
4
10
11
12
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 149
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — AUTOMATIC OIL FEEDER ASSY.
AUTOMATIC OIL FEEDER ASSY. UP TO S/N1337562
PAGE 150 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
Oil Feeder
DCA-220SSK — AUTOMATIC OIL FEEDER ASSY.
AUTOMATIC OIL FEEDER ASSY. UP TO S/N1337562
NO
1
PART NO
PART NAME
OIL TANK
CAP, OIL TANK
QTY.
REMARKS
8195591103
0810105104
0132000000
01120825
1
1
1
2
3
PLUG
HEX. HEAD BOLT...................... 4 ......... REPLACES 0017108025
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
0130200000
0602211212
8185524504
0011305100
011606025
0605511090
012210035
0805531204
0805531304
4542025004
3475512004
3475006304
0193101600
0193101600
0191600270
0605515000
0605515098
7432051504
0197301200
0605515014
STREET ELBOW
SOLENOID VALVE
BRACKET, SOLENOID VALVE
HEX. HEAD BOLT...................... 2 ......... REPLACES 0017105012
HEX. HEAD BOLT...................... 2 ......... REPLACES 0017106025
OIL LEVEL REGULATOR
HEX. HEAD BOLT...................... 2 ......... REPLACES 0010010035
BUSHING
HOSE JOINT
HOSE JOINT
HOSE JOINT
PACKING
HOSE
HOSE
HOSE
HOSE BAND
HOSE BAND
HOSE JOINT
HOSE
1
1
1
1
1
4
1
1
1
1
1
1
4
2
1
1
1
HOSE BAND
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 151
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK — CONTROL BOX ASSY. REMOTE (OPTIONAL PARTS)
CONTROL BOX ASSY. REMOTE (OPTIONAL PARTS) UP TO S/N1337562
PAGE 152 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Control Box Remote (Options)
Table of Contents
DCA-220SSK — CONTROL BOX ASSY. REMOTE (OPTIONAL PARTS)
CONTROL BOX ASSY. REMOTE (OPTIONAL PARTS) UP TO S/N1337562
NO
1
2
3
4
PART NO
PART NAME
CONTROL BOX, REMOTE
U BOLT
QTY.
REMARKS
0841000604
0802710204
0802710304
020106050
0040006000
952404470
0601810475
0601810256
0601830613
0601851503
0840306704
0601811367
0840306904
0601811515
0606302020
0601810461
0601810254
0601810460
0601810254
0601830607
0601830608
0601830417
0601851501
0840301104
0601811332
0840200800
0601811516
1
1
2
WASHER
HEX. NUT ................................................ 2 .......... REPLACES 0030006000
LOCKWASHER
PLAIN WASHER ...................................... 2 .......... REPLACES 0041606000
PILOT LAMP, SLOW SPEED .................. 1 .......... APNE133-R
2
5
BULB
1
6
7
8
9
10
11
12
13
SELECTOR SWITCH, ENGINE SPEED . 1 .......... ASN30L10
CABLE FITTING ...................................... 1 .......... HNG21R12
CABLE
PLUG ....................................................... 2 .......... NWPC254PM11
EXTENSION CABLE
RECEPTACLE ......................................... 1 .......... NWPC254AdF11
CONTROL BOX, REMOTE ...................... 1 .......... AGF511
CAUTION LAMP, PREHEAT & IDLING.... 1 .......... APNE188R
BULB
PILOT LAMP, ENGINE SPEED ............... 1 .......... APNE188G
BULB
STARTER SWITCH ................................. 1 .......... ASN20L5S
SWITCH, SLOW DOWN .......................... 1 .......... ASN310
EMERGENCY STOP BUTTON................ 1 .......... ABN110
CABLE FITTING ...................................... 1 .......... HNG33
CABLE
PLUG ....................................................... 2 .......... NCS4410PM
EXTENSION CABLE
RECEPTACLE ......................................... 1 .......... NCS4410AdF
1
1
1
14
1
15
16
17
18
19
20
21
22
1
1
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 153
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK-DECALS ASSY.
DECALS ASSY.
PAGE 154 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Decals
Table of Contents
DCA-220SSK-DECALS ASSY.
DECALS ASSY.
NO. PART NO.
PART NAME
QTY. REMARKS
1-1 0840626802 DECAL; HANDLING PROCEDURES;S3181A ...................... 1 ........ S/N1325370TO 1326266
1-1 0840632002 DECAL; HANDLING PROCEDURES;S3387......................... 1 ........ S/N1326267TO 1337562
1-1 0800655603 DECAL; HANDLING PROCEDURES;S2763A ...................... 1 ........ S/N1337563TO 3696500
1-1 C1551000503 DECAL; HANDLING PROCEDURES;C1510050 ................... 1 ........ S/N3696501TO 3701661
1-1 C1552000403 DECAL; HANDLING PROCEDURES;B15200010 ................. 1 ........ S/N3701662~
1-1 0840614303 DECAL; HANDLING PROCEDURES;S2633......................... 1 ........ WITH SLOW DOWN
1-2 0840601604 DECAL;CAUTION;S1679 ..................................................... 1 ........ WITH SLOW DOWN
1-2 B1552000103 DECAL;CAUTION;B15200010 ............................................. 2 ........ S/N3696501TO 3701661
1-2 C9522100003 DECAL;CAUTION;C92210000 ............................................. 2 ........ S/N3701662~
1-2 0840621803 DECAL; PROC. FOR PARALLEL OPER;S2753 ................... 1 ........ S/N1325370TO 1326266
1-2 0840632203 DECAL; PROC. FOR PARALLEL OPER;S3391 ................... 1 ........ S/N136267TO 1337562
1-2 0840621902 DECAL; PROC. FOR PARALLEL OPER-;S2754 .................. 1 ........ S/N1325370TO 1326266
1-2 0840632302 DECAL; PROC. FOR PARALLEL OPER-;S3392 .................. 1 ........ S/N136267TO 1337562
CONTROL BOX GROUP
2-1 0800520100 PLATE;ON/OFF;AT202
2-2 0800520904 PLATE; AMMETER CHG.OVR.SWITCH;N2438
2-3 0800520814 PLATE;VOLTMETER CHG.OVR.SWITCH;N2439
1
1
1
2-4 0800664504 DECAL;CIRCUIT BREAKER;S1307 ..................................... 1 ........ UPTO S/N1337562
2-4 0840624504 DECAL;CIRCUIT BREAKER;S3031 ..................................... 1 ........ S/N1337563~
2-5 0800667204 DECAL;PANEL LIGHT SWITCH;S809.................................. 1 ........ UPTO S/N1337562
2-5 0840624604 DECAL;PANEL LIGHT SWITCH;S3032 ................................ 1 ........ S/N1337563~
2-6 0800662004 DECAL;PILOT LAMP;S848 .................................................. 1 ........ UPTO S/N1337562
2-6 0840624704 DECAL;PILOT LAMP;S3033 ................................................ 1 ........ S/N1337563~
2-7 0800623504 DECAL;VOLTAGE REGULATOR;S708A ............................... 1 ........ UPTO S/N1337562
2-7 0840624804 DECAL;VOLTAGE REGULATOR;S3034 ............................... 1 ........ S/N1337563~
2-8 B9531100604 DECAL;WARNING ELECTRICAL SHOCK;B93110060......... 1 ........ S/N1337563~
2-9 0800640703 DECAL;SETTING FOR OUTPUT VOLTAGE;S1322 ............. 1 ........ UPTO S/N1337562
2-9 C0551000903 DECAL;SETTING FOR OUTPUTVOLTAGE;C05100090...... 1 ........ S/N1337563~
2-10 C2551000004 DECAL; SAFETY INSTRUCTIONS ...................................... 1 ........ S/N1337563~
2-11 C1561101603 DECAL;WHISPERWATT220 ................................................. 1 ........ S/N1337563~
2-12 C9502400004 DECAL; HIGH IDLE SPEED;C90240000 .............................. 1 ........ S/N3701662~
2-13 0600500091 DECAL; ENGINE CONTROLLER ......................................... 1 ........ S/N3696501~
ENGINE AND RADIATOR GROUP
3-1 6360610304 DECAL;WATER;S1880
1
1
2
1
3-2 6360620204 DECAL;OIL DRAIN PLUG;S1885
3-3 B9504000404 DECAL;WARNING-MOVING PARTS;B9040040
3-4 B9504100104 DECAL;WARNING-HOT COOLANT;B90410010
FUELTANK GROUP
8-1 1320620904 DECAL; DIESEL FUEL;S1756
8-2 6360620004 DECAL;FUEL DRAIN PLUG;S1883
8-3 B9504500004 DECAL;WARNING-FLAMMABLE;B90450000
1
1
1
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 155
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
DCA-220SSK-DECALS ASSY.
DECALS ASSY.
PAGE 156 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
Decals
Table of Contents
DCA-220SSK-DECALS ASSY.
DECALS ASSY.
NO. PART NO.
PART NAME
ENGINE OPERATING GROUP
QTY.
REMARKS
4-1 0840625004 DECAL;PREHEAT LAMP;S3036 .......................................... 1 ........ UPTO S/N3701661
4-1 C15520000103OPERATING PANEL;C15200001 .......................................... 1 ........ S/N3701662~
4-2 0840625104 DECAL;STARTER SWITCH;S3037 ...................................... 1 ........ UPTO S/N3696500
4-2 C9501400304 DECAL;PREHEAT BUTTON;C90140030 ............................. 1 ........ S/N3696501TO 3701661
4-3 C0551000504 DECAL;BATTERY SWITCH;C05100050
1
4-4 C0551000704 DECAL;THROTTLE HANDLE;C05100070 ............................ 1 ........ UP TOS/N3701661
4-5 C0551000804 DECAL;EMERGENCY STOP;C05100080 ............................ 1 ........ UP TO S/N3696500
4-5 0840647804 DECAL; EMERGENCY STOP;S4100 ................................... 1 ........ S/N3696501TO 3701661
OUTPUTTERMINAL GROUP
5-1 0840614104 DECAL;GROUND;S2635
5-2 0840619904 DECAL;DANGER;S2731
1
1
5-3 B4551000103 DECAL;RECEPTACLE AND CIR. BREAKER;B45100010 .... 1 ........ UPTO S/N3690734
5-3 C0551001503 DECAL;RECPTACLE AND CIR.BREAKER;C05100150 ....... 1 ........ S/N3690735~
5-4 B9511100304 DECAL;WARNING-ELECTRICAL SHOCK;B91110030
5-5 B9511100404 DECAL;WARNING-ELEC.SHOCK;B91110040
5-6 B95531100504DECAL;WARNING-ELEC.SHOCK;B91110050
5-7 C0551000404 DECAL;3-PHASE OUTPUTTERMINAL;C05100040
1
1
1
1
5-8 C1551000404 DECAL;240/139V;C15100040 ............................................... 2 ........ UPTO S/N3696500
5-8 9039209064 DECAL;START CONTACT;S4468 ......................................... 1 ........ S/N3696501~
BATTERY GROUP
6-1 0800689404 DECAL;+;S2090
6-2 0800689504 DECAL;-;S2091
2
2
6-3 C9505300004 DECAL;CAUTION;C90530000 .............................................. 1 ........ S/N3696501~
MUFFLER GROUP
7-1 B9504200004 DECAL;WARNING-EXHAUST;B90420000
1
BONNET GROUP
9-1 1320610603 DECAL;WATER-OIL;S1760
9-2 1320621504 DECAL;SUPPORT HOOK;S2257
9-3 0840625902 DECAL;MQ;S3057
9-4 B9504000304 DECAL;CAUTION-HOT PARTS;B90400030
9-5 B9531100604 DECAL;WARNING-ELEC.SHOCK;B93110060
9-6 C1561100503 DECAL;STRIPE
9-7 C1561100603 DECAL;STRIPE
9-8 C1561100304 DECAL;STRIPE
9-9 C1561100703 DECAL;STRIPE
9-10 C1561100104 DECAL;STRIPE
1
2
1
1
1
1
1
2
1
2
1
1
9-11 C1561100403 DECAL;STRIPE
9-12 C1561100203 DECAL;STRIPE
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 157
Download from Www.Somanuals.com. All Manuals Search And Download.
Table of Contents
TERMS AND CONDITIONS OF SALE — PARTS
Effective: July 1, 2000
PAYMENT TERMS
4. Freight is at the sender’s expense. All
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
PRICINGANDREBATES
Terms of payment for parts are net 10 days.
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspecific
dateandallordersreceivedonorafterthatdate
willbebilledattherevisedprice.Rebatesfor
price declines and added charges for price
increaseswillnotbemadeforstockonhand
atthetimeofanypricechange.
5. Parts must be in new and resalable
condition,intheoriginalMultiquippackage
(ifany),andwithMuiltiquippartnumbers
clearlymarked.
FREIGHTPOLICY
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signedmanifesthasbeenobtainedfromthe
carrier,andanyclaimforshortageordamage
mustbesettledbetweentheconsigneeandthe
carrier.
6. Thefollowingitemsarenotreturnable:
Multiquipreservestherighttoquoteandsell
directtoGovernmentagencies,andtoOriginal
EquipmentManufactureraccountswhouse
our products as integral parts of their own
products.
a. Obsolete parts. (If an item is listed
inthepartspricebookasbeing
replaced by another item, it is
obsolete.)
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
andotherrubberparts)thatwere
purchasedmorethansixmonths
priortothereturndate.
MINIMUMORDER
SPECIALEXPEDITINGSERVICE
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
A$20.00to$50.00surchargewillbeaddedto
theinvoiceforspecialhandlingincludingbus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
partstothecarrier.
c. Anylineitemwithanextendeddealer
netpriceoflessthan$5.00.
d. Special order items.
RETURNEDGOODSPOLICY
e. Electricalcomponents.
LIMITATIONSOFSELLER’SLIABILITY
Returnshipmentswillbeacceptedandcredit
will be allowed, subject to the following
provisions:
f.
Paint,chemicals,andlubricants.
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
beapprovedbyMultiquippriortoshipment.
7. Thesenderwillbenotifiedofanymaterial
receivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Sales that defines item numbers,
quantities,anddescriptionsoftheitems
tobereturned.
8. Such material will be held for 5 working
days from notification, pending
instructions. If a reply is not received
within5days,thematerialwillbereturned
tothesenderathisexpense.
LIMITATIONOFWARRANTIES
a. Thepartsnumbersanddescriptions
mustmatchthecurrentpartsprice
list.
Nowarranties,expressorimplied,aremade
in connection with the sale of parts or trade
accessories nor as to any engine not
manufacturedbyMultiquip.Suchwarranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes not
authorizes any person to assume for it any
other obligation or liability whatever in
connectionwiththesaleofitsproducts.Apart
fromsuchwrittenstatementofwarranty,there
arenowarranties,express,impliedorstatutory,
which extend beyond the description of the
productsonthefacehereof.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. Thelistmustbetypedorcomputer
generated.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. Thelistmuststatethereason(s)for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhich
theitemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. Thelistmustincludethenameand
phonenumberoftheperson
requestingtheRMA.
3. A copy of the Return Material
Authorizationmustaccompanythereturn
shipment.
PAGE 158 — DCA-220SSK — PARTS AND OPERATION MANUAL (STD) — REV. #3 (06/05/01)
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTE PAGE
DCA-220SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (06/05/01) — PAGE 159
Download from Www.Somanuals.com. All Manuals Search And Download.
PARTS AND OPERATION MANUAL
Table of Contents
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SERVICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
Manufactured for Multiquip Inc.
by
DENYO MANUFACTURING, CO., USA
MULTIQUIP INC.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-537-3927
WWW:multiquip.com
Atlanta • Boise • Dallas • Houston • Newark
Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX
Download from Www.Somanuals.com. All Manuals Search And Download.
|
