PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA-600SSK
60 Hz GENERATOR
(KOMATSU SA6D170AE-1 DIESEL ENGINE)
PARTS LIST NO. C4875300104C
SERIAL NO. 3692434~
Revision #7 (04/30/10)
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.
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PROPOSITION 65WARNING
Diesel engine exhaust and some of
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TABLE OF CONTENTS
MQ Power DCA-600SSK COMPONENT DRAWINGS
Generator Assembly ......................................... 72-75
Control Box Assembly ....................................... 76-83
Engine Radiator Assembly................................ 84-87
Engine Operating Panel Assembly ................... 88-89
AC Generator
Proposition 65Warning .....................................................2
Parts Ordering Procedures ...............................................5
Specifications Generator/Engine ......................................6
Dimensions (Top and Side) ...............................................8 Output Terminal Assembly ................................ 90-93
Dimensions (Front and Rear) ............................................ 9
Safety Alert Messages Symbols............................... 10-11
Rules for Safe Operation ........................................... 12-15
Installation ................................................................. 16-17
Towing Rules for Safe Operation .................................... 18
Trailer Safety Guidelines................................................. 19
Trailer Specifications ................................................. 20-21
Operation and Safety Decals..................................... 22-25
General Information ........................................................ 26
Major Components ......................................................... 27
Generator Control Panel (Up to S/N 3698616) ................ 28
Generator Control Panel (S/N 3698617~)........................ 28
Generator Control Panel Description............................... 29
Engine Operating Panel (Up to S/N 3698616) ................. 30
Engine Operating Panel (S/N 3698617~) ........................ 30
Engine Operating Panel Description ............................... 31
OutputTerminal Panel Overview ................................ 32-34
Load Application ............................................................. 35
Generator Outputs .......................................................... 36
Generator Outputs/Gauge Reading................................. 37
OutputTerminal Panel Connections ........................... 38-39
Pre Setup .................................................................. 40-44
Generator Start-up Procedure (Key Switch) .............. 45-47
Generator Start-up Procedure ( Manual MPEC) ............. 48
Generator Start-up Procedure (Auto MPEC) .................. 49
Generator Shutdown Procedure ...................................... 50
Maintenance .............................................................. 51-55
Trailer Brakes Maintenance ............................................ 56
Trailer Maintenance.................................................... 57-58
TrailerWiring Diagrams .............................................. 59-60
Generator Wiring Diagram ............................................... 61
Generator Main Breaker Wiring Diagram......................... 62
EngineWiring Diagrams ............................................ 63-64
Electronic Governor ControllerWiring Diagram ............... 65
EngineTroubleshooting .............................................. 66-67
GeneratorTroubleshooting .............................................. 68
Engine ContollerTroubleshooting (MPEC) ...................... 69
Explanation of Codes in Remarks Column ..................... 70
Battery Assembly .............................................. 94-95
Muffler Assembly .............................................. 96-97
Fuel Tank Assembly .......................................... 98-99
Enclosure #1 Assembly................................. 100-101
Enclosure #2 Assembly................................. 102-105
Enclosure #3 Assembly................................. 106-107
Enclosure (Rubber Seals)............................. 108-109
Name Plate and Decals ................................ 110-113
Terms and Conditions Of Sale — Parts ............... 114
Specification and part
number are subject to
change without notice.
PAGE 4 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
January 1st, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
N View Parts Diagrams
N Order Parts
N Print Specification Information
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Goto www.multiquip.com and click on
to log in and save!
Order Parts
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
Order via Phone:
1-800-427-1244
Non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
R
Dealer Account Number
R
Specify Preferred Method of Shipment:
R
R
R
R
R
Dealer Name and Address
ꢀ UPS/Fed Ex
ꢀ DHL
ꢀ Truck
N
N
Priority One
Ground
Shipping Address (if different than billing address)
Return Fax Number
N Next Day
Second/Third Day
Applicable Model Number
N
Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 5
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DCA-600SSK — SPECIFICATIONS
Table 1. Generator Specifications
Model
Type
DCA-600SSK
Revolving field, self ventilated, drip proof, single bearing
Armature Connection
Phase
Star with Neutral
3
528 KW (660KVA)
Standby Output
Prime Output
Voltages — 1Ø
Voltages — 3Ø
Power Factor
Frequency
480 KW (600 KVA)
120,127,139,240,254,277 (Adjustable)
208,220,240,416,440,480 (Reconnectable)
0.8
60 Hz
Frequency Regulation:
No load to full load
Isochronous under varying loads from no load to 100% rated load
Frequency Regulation:
Steady State
0.25 of mean value for constant loads from no load to full load
Insulation
Class F
75
Sound Level dB(A)
(full load at 23 feet)
Dimensions Approx.
(L x W x H)
204.72 x 64.96 x 98.49 in. (5200 x 1650 x 2,500 mm.)
Dry Net Weight
19,553 lbs. (8,869 kg.)
Table 2. Engine Specifications
KOMATSU SA6D170AE-1
direct injection, turbo-charged with after-cooler
6 cylinders
Type
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
6.8 in. x 6.8 in. (170 mm x 170 mm)
688 HP/1800 rpm
1411.5 cu. in. (23150 cc)
Electric
Coolant Capacity
Lube Oil Capacity
29.6 gal. (112 liters)
16.1 gal. (60.9 liters)
33.9 gal. (128.3L)/hr at full load
3/4 load
1/4 load
Fuel Consumption
1/2 load
12V- 200 Ah x 2 (24V System)
#2 Diesel Fuel
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DCA-600SSK — DIMENSIONS (TOP AND SIDE)
Figure 1. Dimensions
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DCA-600SSK — DIMENSIONS (FRONT , REAR AND DOORS)
Figure 2. Dimensions
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 9
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DCA-600SSK — SAFETY MESSAGE ALERT SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with "Hazard Symbols" which
appear throughout this manual, and will be referenced in
conjunction with Safety "Message Alert Symbols".
Safety precautions should be followed at all times when
operating this equipment.Failure to read and understand the
Safety Messages and Operating Instructions could result in
injury to yourself and others.
This Owner's Manual has been
developed to provide complete
WARNING - LETHAL EXHAUST GASES
NOTE
instructions for the safe and
efficient operation of the
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
MQPower Model DCA-600SSK
WHISPERWATT™ GENERATOR.
DEATH if inhaled. NEVER operate this
Before using this generator, ensure that the operating
individual has read and understands all instructions in
this manual.
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
SAFETY MESSAGE ALERT SYMBOLS
Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fill the fuel tank while the engine
is running or hot.
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING, or CAUTION.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
DANGER
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
WARNING
WARNING - BURN HAZARDS
Engine components can generate extreme
heat.To prevent burns, DO NOT touch these
areas while the engine is running or
immediately after operations. NEVER
operate the engine with heat shields or heat
guards removed.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
DANGER - ELECTROCUTION HAZARDS
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
PAGE 10 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
CAUTION - RESPIRATORY HAZARDS
NEVER operate equipment with covers,
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
ALWAYS wear approved respiratory
protection.
CAUTION - ACCIDENTAL STARTING
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
ALWAYS wear approved eye and
hearing protection.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - EQUIPMENT DAMAGE MESSAGES
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury and damage to the engine
or equipment can result if operating in
speed ranges above maximum allowable.
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
This generator, other property,
or the surrounding environment
could be damaged if you do not
follow instructions.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 11
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DCA-600SSK — RULES FOR SAFE OPERATION
■
ALWAYS check the machine for loosened threads or bolts
before starting.
DANGER - READTHIS MANUAL!
Failure to follow instructions in this manual 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.
■
NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe bodily harm or even death.
■
■
NEVER touch the hot exhaust manifold, muffler
or cylinder. Allow these parts to cool before
servicing engine or generator.
The following safety guidelines should always be used when
operating the DCA-600SSK Whisperwatt™ Generator.
General Safety:
HighTemperatures – Allow the engine
to cool before performing service and
maintenance functions. Contact with
hot! components can cause serious
burns.
■
DO NOT operate or service this
equipment before reading this entire
manual.
The operator MUST BE familiar with proper safety
precautions and operations techniques before using
generator.
■
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
■
■
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.
engine and may cause injury
to people. The generator
engine gives off DEADLY
carbon monoxide gas.
■
■
■
■
■
DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■
■
NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
NEVER run engine without air filter.Severe engine damage
may occur.
DO NOT leave the generator running in the manual mode
unattended.
NEVER operate this equipment under the influence or
drugs or alcohol.
Refer to the KOMATSU Engine Owner's Manual for
engine technical questions or information.
ALWAYS store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children.
■
■
■
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. Unauthorized
equipment modification will void all warranties.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
PAGE 12 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — RULES FOR SAFE OPERATION
Generator Grounding
DANGER - ELECTROCUTION HAZARDS
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
During operation of this generator, there
exists the possibility of electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
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.
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator. Make sure power connecting
cables are securely connected to the generator’s output
The following safety recommendations should also be
followed:
terminals, insufficient tightening of the terminal connections
WET
HANDS
may cause damage to the generator
■
■
■
ALWAYS make sure generator is properly grounded.
NEVER use gas piping as an electrical ground.
and electrical shock.
NEVER grab or touch a live power
ALWAYS make sure that electrical circuits are properly
grounded per the National Electrical Code (NEC) and
local codes before operating generator. Severe injury or
DEATH! by electrocution can result from operating an
ungrounded generator.
cord with wet hands.
POWER
CORD
(POWER ON)
NEVER touch output terminals
during operation. This is extremely
dangerous. ALWAYS stop the
machine and place the circuit
breaker in the OFF position when
contact with the output terminals is
required.
■
ALWAYS be sure to use the ground terminal (green wire)
when connecting a load to the U,V, and W output
terminal lugs.
Electrical Safety
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.
ALWAYS have a licensed electrician
perform the installation
■
ALWAYS have a qualified electrician perform the
generator wiring installation.
■
ALWAYS make sure generator installation is accordance
with the National Electrical Code (NEC) and local codes
before operating generator.
■
■
■
NEVER use a defective or frayed power cable. Check
the cable for cuts in the insulation.
NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
ALWAYS make certain that proper extension cord has
been selected for the job. See Table 5.
■
■
NEVER power cables or cords lay in water.
NEVER stand in water while AC power from the generator
is being transfer to a load.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 13
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DCA-600SSK— RULES FOR SAFE OPERATION
Maintenance Safety
Battery Safety
■
The electrical voltage required to operate the generator Use the following guidelines when handling the battery:
can cause severe injury or even death through physical
contact with live circuits. Turn all circuit breakers OFF
■
The battery contains acids that can
cause injury to the eyes and skin. To
avoid eye irritation, always wear safety
glasses.
before performing maintenance on the generator.
■
■
■
■
NEVER lubricate components or attempt service on a
running machine.
■
Use well insulated gloves when picking up the battery.
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
DANGER - EXPLOSION HAZARDS
Follow all Battery Safety Guidelines listed in this manual
when handleing or servicing the generator.
The risk of an explosion exists when performing service
on the battery. To avoid severe injury or DEATH:
ALWAYS allow the machine a proper amount of time to
cool before servicing.
DO NOT drop the battery.There
is the possibility of risk that the
battery may explode.
■
■
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always
replace broken parts.
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.
■
ALWAYS service air cleaner frequently to prevent engine
malfunction.
WARNING - BURN HAZARDS
■
ALWAYS keep the battery charged. If the battery is not
To prevent burns, DO NOT touch or open any of the below
mentioned components while the engine is
running or immediately after operations.
Always allow sufficient time for the engine
and generator to cool before performing
maintenance.
charged a buildup of combustible gas will occur.
ALWAYS keep battery charging and cables in good
working condition. Repair or replace all worn cables.
ALWAYS recharge the battery in an vented air
environment, to avoid risk of a dangerous concentration
of combustible gases.
■
Radiator Cap - Removing the radiator cap while the
engine is hot will result in high pressurized, boiling water
to gush out of the radiator, causing severe scalding to
any persons in the general area of the generator.
In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
In case the battery liquid (dilute sulfuric acid) comes in
contact with your EYES, rinse eyes immediately with
plenty of water and contact the nearest doctor or hospital
to seek medical attention.
■
Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant gushing
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
■
Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil gushing
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
PAGE 14 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — RULES FOR SAFE OPERATION
Towing &Transporting Safety
■
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 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 the trailer
that supports the generator and the towing vehicle are in
good operating condition and both units are mechanically
sound.
■
■
■
Place chock blocks underneath wheel to prevent rolling,
while parked.
The following list of safety precautions should be followed
when towing your generator:
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
Avoid sudden stops and starts.This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
CAUTION - FOLLOWTOWING REGULATIONS
Check with your local county or state safety towing
regulations, in addition to meeting Department of
Transportation (DOT) SafetyTowing Regulations, before
towing your generator.
■
■
Avoid sharp turns.
Trailer should be adjusted to a level position at all times
when towing.
■
■
Raise and lock trailer wheel stand in up position when
transporting.
■
■
■
ALWAYS shutdown engine before transporting.
Tighten both fuel tank caps securely.
The maximum speed for highway towing is 55 MPH
unless posted otherwise. Recommended off-road towing
is not to exceed 15 MPH or less depending on type of
terrain.
If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. Follow the listed Towing & Transporting Safety
guidelines for basic towing techniques.
■
Place support blocks underneath the trailer’s bumper to
prevent tipping, 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.”
■
■
Avoid sharp turns to prevent rolling.
DO NOT transport generator with fuel in tank.
■
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
Emergencies
■
■
■
ALWAYS know the location of the
nearest fire extinguisher.
Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS know the location of the
nearest and first aid kit.
■
■
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
ALWAYS know the location of the
nearest phone or keep a phone on
the job site, in case of emergencies.
ALWAYS attach trailer’s safety chains to towing vehicle
properly.
■
ALWAYS have easy access to the phone
numbers of the nearest Ambulance, Doctor
and Fire Department. This information will
be invaluable in the case of an emergency.
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■
DOT Requirements include the following:
Connect and test electric brake operation.
Secure portable power cables in cable tray with tie
wraps.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 15
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DCA-600SSK — INSTALLATION
DCA-600SSK — INSTALLATION
Figure 3. Typical Generator Grounding Application
PAGE 16 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — INSTALLATION
Generator Grounding
Outdoor Installation
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide or
shift around. Also install the generator in a manner so that
the exhaust will not be discharged in the direction of nearby
homes.
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.
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.
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.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to engine
and alternator parts.
2. When grounding the generator (Figure 3) 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.
CAUTION - EXHAUST HAZARD
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.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried aminimum of 8 ft. into the ground.
Indoor Installation
When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
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.
NOTE
electrician.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are to
resist damage to the bottom of the generator and to maintain
alignment.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 17
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DCA-600SSK —TOWING RULES FOR SAFE OPERATION
■
ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
Towing Safety Precautions
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and working
properly.
CAUTION -TOWING REGULATIONS
Check with your county or state safety towing regulations
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 the trailer
(Figure 4) 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 the towing vehicle and
the 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 4. Generator and Trailer
PAGE 18 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — TRAILER-SAFETY GUIDELINES
5. Frame Width - Measurement is from fender to fender
6. Jack Stand - Trailer support device with maximum pound
requirement from the tongue of the trailer.
7. Coupler - Type of hitch used on the trailer for towing.
CAUTION - TRAILER INSPECTION
ALWAYS make sure the trailer is in good operating con-
dition. Check the tires for proper inflation and wear. Also
check the wheel lug nuts for proper tightness.
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:
9. Tire Ply - The tire ply (layers) number is rated in letters;
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
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
ensure safe towing of the equipment and will prevent dam- 11. Tire Rim - Tires mounted on a tire rim. The tire rim must
age to the equipment and personal injury.
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. See Table 17 and Figure 67 for lug nut tightening
and sequence.
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:
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches. Please note 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.
Brakes
Tires
Lug NutTorquing
Suspension
Electrical
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
BrakeTroubleshootingTables
Use the following definitions when reading Table 3.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting equipment.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy-
draulic, hydraulic-surge and air.
16. Application - Indicates which units can be employed
on a particular trailer.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
4. Frame Length - Measurement is from the ball hitch to
the rear bumper (reflector).
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 19
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DCA-600SSK —TRAILER-SPECIFICATIONS
Table 3. Trailer Specifications
MODEL
APPLICATION
FUEL CELL
BRAKE SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
SDW225,
SGW250,TLW300
NO
NO
NO
NO
NO
NO
1,900 LBS.
862 Kg.
96 inches
2.43 meters
50 inches
1.27 meters
800 LBS. (363 Kg.)
FULL TILT WHEEL
TRLR-10W
TRLR-10
DCA10, TLG12, DCA-
15
1,900 LBS.
862 Kg.
96 inches
2.43 meters
50 inches
1.27 meters
800 LBS. (363 Kg.)
FULL TILT WHEEL
DCA10, TLG-12,
DCA15, TLW-300
52 Gallons
197 Liters
1,900 LBS.
862 Kg.
96 inches
2.43 meters
50 inches
1.27 meters
800 LBS. (363 Kg.)
FULL TILT WHEEL
TRLR-10XF
TRLR-225W
WELDERS,
DA7000SS
NO
2,200 LBS.
998 Kg.
85 inches
2.43 meters
42 inches
1.06 meters
800 LBS. (363 Kg.)
FULL TILT WHEEL
W/MAST 154 in.
3.19 meters
55 inches
1.40 meters
2,700 LBS.
1,224 Kg.
800 LBS. (363 Kg.)
FULL TILT WHEEL
TRLR-BLW400
BLW-400
NO
NO
ELECTRIC
W/O 124 in.
3.14 meters
(78 inches TALL)
1.98 meters
DCA-25
DCA-25
NO
NO
2,700 LBS.
1,224 Kg.
124 inches
3.14 meters
55 inches
1.40 meters
800 LBS. (363 Kg.)
FULL TILT WHEEL
TRLR-50X
TRLR-50XF
TRLR-70W
41 Gallons
155 Liters
2,700 LBS.
1,224 Kg.
124 inches
3.14 meters
55 inches
1.40 meters
800 LBS. (363 Kg.)
FULL TILT WHEEL
DCA-45, -60, 70
DCA-45, -60, 70
DCA-45, -60, 70
DCA-100, 125
DCA-85, 100, 125
DCA-150, 180
DCA-220
NO
SURGE
7,000 LBS.
3,175 Kg.
186 inches
4.72 meters
77 inches
1.95 meters
2,000 LBS. (907 Kg.)
FLAT PAD
OPT
SURGE
7,000 LBS.
3,175 Kg.
138 inches
3.50 meters
66 inches
1.67 meters
2,000 LBS. (907 Kg.)
FLAT PAD
TRLR-70X
53 Gallons
201 Liters
SURGE
7,000 LBS
3,175 Kg.
138 inches
3.50 meters
66 inches
1.67 meters
2,000 LBS. (907 Kg.)
FLAT PAD
TRLR-70XF
TRLR-100XF
TRLR-85/125
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800SX
150 Gallons
568 Liters
HYDRAULIC SURGE
HYDRAULIC
HYDRAULIC SURGE
HYDRAULIC SURGE
HYDRAULIC SURGE
ELECTRIC
AIR
7,000 LBS.
3,175 Kg.
190 inches
4.82 meters
76 inches
1.93 meters
2,000 LBS. (907 Kg.)
FLAT PAD
145 Gallons
549 Liters
10,000 LBS.
4,536 Kg.
186 inches
4.72 meters
77 inches
1.95 meters
2,000 LBS. (907 Kg.)
FLAT PAD
200 Gallons
757 Liters
11,160 LBS.
5,062 Kg.
204 inches
5.18 meters
84 inches
2.13 meters
5,000 LBS. (2,268 Kg.)
FLAT PAD
250 Gallons
946 Liters
14,000 LBS.
3,175 Kg.
222 inches
3.63 meters
83 inches
2.10 meters
5,000 LBS. (2,268 Kg.)
FLAT PAD
DCA-300
250 Gallons
946 Liters
18,000 LBS.
8,165 Kg.
238 inches
6.04 meters
83 inches
2.10 meters
5,000 LBS. (2,268 Kg.)
FLAT PAD
DCA-400
350 Gallons
1, 324 Liters
18,000 LBS.
8,165 Kg.
238 inches
6.04 meters
83 inches
2.10 meters
5,000 LBS. (2,268 Kg.)
FLAT PAD
DCA-600, 800
DCA-600, 800
550 Gallons
2,082 Liters
30,000 LBS.
13,607 Kg.
384 inches
9.75 meters
96 inches
2.43 meters
5,000 LBS. (2,268 Kg.)
FLAT PAD
550 Gallons
2,082 Liters
AIR
30,000 LBS.
13,607 Kg.
384 inches
9.75 meters
96 inches
2.43 meters
5,000 LBS. (2,268 Kg.)
FLAT PAD
PAGE 20 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK —TRAILER-SPECIFICATIONS
Table 3. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS
SUSPENSION
ELECTRICAL
2" BALL CLASS
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X2
5 LUG
3 LEAF
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10W
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"
14"X5"
2200#2X2
2200#2X2
2200#2X2
2200#2X2
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
Q FLEX
3 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 POLE FLAT
TRLR-10
TRLR-10XF
TRLR-225W
TRLR-BLW 400
TRLR-50X
2"BALL CLASS
2 ADJUSTABLE
4 POLE FLAT
2"BALL CLASS
2 ADJUSTABLE
175-13B
4 POLE FLAT
2"BALL CLASS
2 ADJUSTABLE
175-13C
4 POLE FLAT
2" BALL CLASS
B78-13LRC
B78-13LRC
3,500 lbs.
2-3/8"
4 POLE RUBBER FLAT
4 POLE RUBBER FLAT
4 POLE RUBBER FLAT
4 POLE RUBBER FLAT
4 POLE RUBBER FLAT
4 WIRE LOOM
2" BALL CLASS
3,500 lbs.
2-3/8"
TRLR-50XF
TRLR-70W
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
3,500 lbs.
3"
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3,500 lbs.
3"
TRLR-70X
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3,500 lbs.
3"
TRLR-70XF
TRLR-100XF
TRLR-85/125
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800AR
ADJUSTABLE 2-5/6 OPT
3" EYE
205-15C
BIAS (4)
14"X5.5"
14"x6"
3,500 lbs.
3"
ADJUSTABLE 2-5/6 OPT
3" EYE
ST225/75R15D
RADIAL (4)
(2)-6,000 lbs.
(2)-6,000 lbs.
(2)-7,000 lbs.
(2)-6,000 lbs.
(3)-7,000 lbs.
(3)-10,000 lbs.
(3)-10,000 lbs.
4 WIRE LOOM
3" BALL EYE
3" EYE ADJUSTABLE
3" EYE ADJUSTABLE
3" EYE ADJUSTABLE
5TH WHEEL
750-16 E
BIAS (4)
16"X7"
4 WIRE LOOM
ST235/85R16E
RADIAL(4)
16"X7"
4 WIRE LOOM
ST235/85R16E
RADIAL(6)
16"X7"
4 WIRE LOOM
ST235/85R16E
RADIAL(6)
16"X7"
4 WIRE LOOM
ST215/75R17.5H
RADIAL (8)
16"X7"
6 WIRE LOOM
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
6 WIRE LOOM
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 21
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DCA-600SSK — OPERATION AND SAFETY DECALS
Machine Safety Decals
The DCA-600SSK generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information.The illustrations 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.
PAGE 22 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — OPERATION AND SAFETY DECALS
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 23
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DCA-600SSK — OPERATION AND SAFETY DECALS
PAGE 24 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — OPERATION AND SAFETY DECALS
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 25
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DCA-600SSK — GENERAL INFORMATION
DCA-600SSK FAMILIARIZATION
Generator
Open Delta Excitation System
The DCA-600SSK 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 MQ Power Model DCA-600SSK is a 528 kW generator
that has been 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.
There are four connections of the open delta A, B, C, and D.
During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to B,
A to D, and C to D. These three phases of the voltage input
to the voltage regulator are then rectified and are the
excitation current for the exciter section.
Engine Control Panel
The “Engine Control Panel” is provided with the following:
Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Engine Warning Lamp Module
Throttle Lever (Up to S/N 3698616)
Ignition Switch (Up to S/N 3698616)
Engine Speed Switch (S/N 3698617~)
Pre-Heat Button (S/N 3698617~)
Pre-Heat Lamp
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
Emergency Stop Button
Battery Switch
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 up to the
horsepower of the engine.
Generator Control Panel
The “Generator Control Panel”is provided with the following:
Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Panel Light
Panel Light Switch
MPEC Module (S/N 3698617~)
Pilot Lamp
Engine
The DCA-600SSK is powered by a 4 cycle, water cooled,
turbocharged KOMATSU Model SA6D170AE-1 diesel engine.
This engine is designed to meet every performance
requirement for the generator. Reference Table 2 for engine
specifications.
In keeping with Multiquip's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Microprocessor Controlled Alarm System
The basic controls and indicators for the DCA-600SSK
generator are addressed on the following pages.
The DCA-600SSK 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-600SSK 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.
Electronic Governor System
The electronic governor system is made up of two parts, an
electronic controller that monitors frequency variation as the
load increases and decreases, and an electronic actuator
that controls the engine throttle. The frequency is regulated
at 0.25 to help protect sensitive equipment.
PAGE 26 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — MAJOR COMPONENTS
ONENTS
Table 4. Generator Major Components
ITEM NO.
DESCRIPTION
Generator Assembly
1
2
3
4
5
6
7
8
9
Generator Control Panel Assembly
Engine and Radiator Assembly
Engine Operating Panel Assembly
Battery Assembly
Enclosure Assembly
Fuel Tank Assembly
Muffler Assembly
Output Terminal Assembly
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 27
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DCA-600SSK — GENERATOR CONTROL PANEL
Up to S/N 3698616
S/N 3698617~
Figure 6. Generator Control Panel
PAGE 28 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — GENERATOR CONTROL PANEL
The definitions below describe the controls and functions of During cranking cycle , The MPEC will attempt to crank
the DCA-600SSK " Control Panel " (Figure 6).
the engine for 10 seconds before disengaging. If the engine
does not engage (start) by the third attempt, the engine will
be shutdown by the engine controller’s " Over Crank
Protection" mode. If the engine engages at a speed (RPM's)
that is not safe, the controller will shutdown the engine by
initializing the "Over Speed Protection" mode.
1. Pilot Lamp – Indicates that the generator is working
properly.
2. Panel Light – Normally used in dark areas or at night
time.When activated, panel lights will illuminate.When
lit this light will make it easier to read the meters and
gauges. When the generator is not in use be sure to
turn the panel light switch to the OFF position.
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.
3. Frequency Meter – Indicates the output frequency in
hertz (Hz). Normally 60 Hz 1 Hz .
4. AC Ammeter – Indicates the amount of current the
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.
load is drawing from the generator.
5. AC Voltmeter – Indicates the single phase output
voltage present at the UVWO terminals. .
6. 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.
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. The generator will engage when
commercial power falls below a preset level.
7. 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
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 and will
shut down the generator.
8. Panel Light Switch – When activated, this switch will
turn on the luminate the control panel.
9. 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 and will shut down the generator.
10. Main Circuit Breaker – This three-pole, 1600 amp main
breaker is provided to protect the UVWO voltage output
terminals from overload.
11. MPEC – Microprocessor
Engine Control Module –
(MPEC) has a vertical row
of status LED's (inset), 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
shutdown the generator.
D. Overcrank Shutdown – Indicates the unit has
attempted to be started 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 and will shut down
the generator.
E. Overspeed Shutdown – Indicates that 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.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 29
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DCA-600SSK — ENGINE OPERATING PANEL
Up to S/N 3698616
S/N 3698617~
Figure 7. Engine Operating Panels
PAGE 30 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENGINE OPERATING PANEL
3.
Pre-Heat Lamp – Indicates that the glow plugs of the
diesel engine are hot and the engine is ready to be started.
The definitions below describe the controls and functions of the
DCA-600SSK " Engine Operating Panels " (Figure 7).
4.
Emergency Stop Button – Push this button inward to
stop the engine in the event of an emergency. DO NOT
use this button as a normal means of stopping the engine.
1.
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 hour meter
will record the number of operational hours that the
generator has been in use.
5.
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.
2.
Engine Warning Display (LED) 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.
6.
7.
Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.
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.
8.
9.
Fuel Level Gauge – Indicates amount of diesel fuel
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 illuminate.
After the oil pressure rises after start-up the
lamp will go OFF. If this lamp is ever illuminated (ON)
during normal operation of the generator, the emergency
shutdown device will stop the engine automatically.
remaining.
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.
10. Preheat Switch (S/N 3698617~) – Press on to heat glow
plugs in cold weather conditions.
11. Engine Speed Switch (S/N 3698617~) – This switch
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.
changes the engine speed from idle to normal.
12. Ignition Switch (Up to S/N 3698616) – Four position
switch, pre-heat, stop, run and start. Insert ignition
key to start and stop engine.
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. Throttle Lever (Up to S/N 3698616) - This lever controls
the speed of the engine (low or high).
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.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 31
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DCA-600SSK — OUTPUTTERMINAL OVERVIEW
Output Terminal Familiarization
Output Terminal Panel
Shown below (Figure 8) is the OutputTerminal Panel , lift
up on the cover to gain access to receptacles and terminal
lugs.
The “Output Terminal Panel ” (Figure 8) is provided with
the following:
Three 240/139V output receptacles, 50 amp
Three AUX. circuit breakers 240V @50 amps
Two 120V GFCI receptacles, 20 amp
Two (2) GFCI circuit breakers 120V@ 20 amps
Eight (16) output terminal lugs
Terminal legs "O" and "Ground"
are considered bonded grounds.
Figure 8. Output Terminal Panel
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DCA-600SSK — OUTPUT TERMINAL PANEL OVERVIEW
Each auxiliary receptacle is protected by a 50 amp circuit
120VAC GFCI Receptacles
breaker.These breakers are located directly above the GFCI
receptacles. Remember the load output (current) on all three
receptacles is dependent on the load requirements of the
UVWO terminals.
There are two 120VAC, 20 amp GFCI (Duplex Nema 5-20R)
recepacles provided on the output terminal panel. These
receptacles can be accessed in any voltage change-over
board position. Each receptacle is protected by a 20 amp
circuit breaker. These breakers are located directly above
the GFCI receptacles. Remember the load output (current)
of both GFCI receptacles is dependent on the load
requirements of the UVWO terminals.
Turn the voltage regulator control knob (Figure 11) on the
control panel to obtain the desired voltage.Turning the knob
clockwise will increase the voltage, turning the knob counter-
clockwise will decrease the voltage.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the "Test Button" (See Figure 9) in
the center of the receptacle will check the GFCI function.
Both receptacles should be tested at least once a month.
Figure 11. Voltage Regulator Control Knob
Access to UVWOTerminals
The UVWO terminal lugs are protected by a terminal cover
(Figure 12). Un-lock the locking latch, and lift the terminal
cover to gain access to the UVWO terminals.
After the load wires have been securely attached to the
UVWO terminals, place the terminal cover in the down
position and secure the locking latch.
Figure 9. G.F.C.I. Receptacle
Twist Lock DualVoltage 240/139VAC Receptacles
There are three 240/139 VAC, 50 amp auxiliary twist-lock
(CS-6369) receptacles (Figure 10) provided on the output
terminal panel. These receptacles can be accessed in any
voltage change-over board position.
Figure 12. Terminal Cover (UVWO Terminals)
Figure 10. 240/139 VAC Twist-Lock
Auxiliary Receptacles
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 33
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DCA-600SSK — OUTPUT TERMINAL PANEL OVERVIEW
Over Current Relay
Connecting Loads
An over current relay (Figure 14) is connected to the main
circuit breaker. In the event of an overload, both the circuit
Loads can be connected to the generator by the UVWO terminal
lugs or the convenience receptacles. (See Figure 13). Make
sure to read the operation manual before attempting to connect breaker and the over current relay may trip. If the circuit
a load to the generator.
breaker can not be reset, the reset button on the over cur-
rent relay must be pressed. The over current relay is lo-
cated in the control box.
To protect the UVWO output terminals from overload, a 3-
pole, 1,600 amp, main circuit breaker is provided. Make
sure to switch ALL circuit breakers to the "OFF" position
prior to starting the engine.
Figure 14. Over Current Relay
Maximum Power Output (KW)
The entire load connected to the UVWO output terminal lugs,
duplex and auxiliary receptacles must not exceed 528 kW in
standby or 480 kW in prime output.
Figure 13. Connecting Loads
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DCA-600SSK— LOAD APPLICATION
Single Phase Load
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
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.
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.
tors and motor-driven equipment
w much greater current for
rting than during operation.
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.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 5.
WATTS = VOLTAGE x AMPERAGE
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.
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
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.
Table 5. Power Factor By Load
Type Of Load
Power Factor
Single-phase induction motors
0.4 - 0.75
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
Electric heaters, incandescent
lamps
1.0
0.4 - 0.9
1.0
Fluorescent lamps, mercury lamps
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
Electronic devices, communication
equipment
Common power tools
0.8
DANGER - ELECTRICAL SYSTEM HAZARDS
Table 6. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts Maximum Allowable Cable Length
Before connecting this generator to any building’s electrical
system, a licensed electrician must install an isolation
(transfer) switch. Serious damage to the building’s
electrical system may occur without this transfer switch.
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
If 3Ø load (kVA) is not given on
the equipment nameplate,
approximate 3Ø load output
1200
1800
2400
NOTE
maybedeterminedby multiplying
voltage by amperage by 1.732.
50 ft.
CAUTION: Equipment damage can result from low voltage.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 35
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DCA-600SSK — GENERATOR OUTPUTS
Generator OutputVoltages
Generator Amperage
Tables 8 and 9 describe the generator’s current output capa-
bility for both 1Ø-phase and 3Ø phase applications.
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by apply-
ing jumpers (6) to the voltage change-over board (Figure 15).
To obtain some of the voltages as listed in Table 7 (see
below) will require a fine adjustment using the voltage regu-
lator (VR) control knob located on the control panel.
Table 8. Generator Ampere
Ratings — 1Ø
kW
40
139V
240V
277V
480V
83
Voltage Change-Over Board
288
167
144
The voltage change-over board (Figure 15) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
80
576
333
289
167
250
333
417
500
583
667
750
833
917
1,000
120
863
500
433
160
1,151
1,439
1,727
2,014
2,302
2,590
2,878
3,165
3,453
667
578
200
833
722
240
1,000
1,167
1,333
1,500
1,667
1,833
2,000
866
280
1,011
1,155
1,300
1,444
1,588
1,733
320
360
400
440
480 (max)
Table 9. Generator Ampere
Ratings — 3Ø
Figure 15. Voltage Change-Over Board
240V Configuration
kW
240V
480V
40
120
60
DANGER - CHANGING JUMPER PLATES
80
241
120
180
241
301
361
421
481
541
601
662
722
NEVER attempt to place jumper plates on the voltage
change-over board while the generator is in operation.There
exists the possibility of electrocution, electrical shock or
burn, which can cause severe bodily harm or even death!
120
361
160
481
200
601
240
722
280
842
Table 7. Generator Available Voltages
320
962
Three-Phase
208V
220V
240V
416V
440V
480V
277V
360
1,083
1,203
1,323
1,443
Single-Phase 120V
127V
139V
240V
254V
400
440
480(max)
PAGE 36 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — GENERATOR OUTPUTS/GAUGE READING
Maximum Amps
Table 10 shows the maximum amps the generator can pro-
vide. DO NOT exceed the maximum amps as listed.
Table 10. Generator Maximum Amps
Model
DCA600SSK
Maximum Amps
Rated Voltage
Single Phase
120 Volt
1,333.3 amps (4 wire)
Single Phase
240 Volt
666.7 amps (4 wire)
1.443 amps
Figure 18 AC Voltmeter
Gauge
(Volt reading on W-U Lug)
Figure 17. AC Voltmeter
Change-Over Switch
Three Phase
240 Volt
Three Phase
480 Volt
721.7 amps
40
20
60
How to Read the OutputTerminal Gauge.
0
75
The AC ammeter and AC voltmeter change-over switches
on the control panel DO NOT effect the generator output.
They are provided to help observe how much power is being
supplied, produced at the UVWO terminals lugs.
A
When the voltage change-over board is jumpered for 3Ø,
240V operation (See Figure 16), place the AC Voltmeter
Change-Over Switch (Figure 17) to the W-U position and
the AC Ammeter Change-Over Switch (Figure 19) to the U
or W position to read the output on the selected leg.
Figure 19. AC Ammeter
Change-Over Switch
Figure 20. AC Ammeter
(Amp reading on U lug)
The ammeter and voltmeter
gauges are only active when the
UVWO terminals are in use.
NOTE
Figure 16. Voltage Change-Over Board
240V Configuration
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 37
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DCA-600SSK — OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are de-
pendent on the placement of the jumpers plates (6) on the
Voltage Change-Over Board and the adjustment of the
Voltage Regulator Control Knob.
Figure 23. Voltage Regulator Knob
1Ø-240V UVWOTerminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 21 .
Remember the voltage change-over board determines the
range of the output voltage and can be configured in two
different positions that provide 6 different output voltages at
the UVWO output terminals. The generator is shipped from
the factory in the 240V configuration. The voltage regulator
(VR) allows the user to increase or decrease the selected
voltage.
2. Connect the load wires to the UVWO terminals as shown
in Figure 24.
3Ø-240V UVWOTerminal Output Voltages
1. Jumper the voltage change-over board for 240V operation
as shown in Figure 21.
Figure 24. UVWO Terminal Lugs
1Ø-240V Connections
Figure 21. Voltage Change-Over Board
240V Configuration
1Ø-139V UVWOTerminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 240V operation as shown in Figure 21.
2. Connect the load wires to the UVWO terminals as shown
in Figure 22.
2. Connect the load wires to the UVWO terminals as shown
in Figure 25.
Figure 22. UVWO Terminal Lugs
3Ø-240V Connections
3. Turn the voltage regulator knob (Figure 23) clockwise to
increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required
Figure 25. UVWO Terminal Lugs
1Ø-139V Connections
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DCA-600SSK — OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWOTerminal Output Voltages
1Ø-480V UVWOTerminal Output Voltages
1. Jumper the voltage change-over board for 480V operation 1. Make sure the voltage change-over board is jumpered
as shown in Figure 26.This configuration uses 6 jumper
plates in 3 different positions. Remember there are 2
jumper plates at every position. Every jumper plate must
be used.
for 480V operation as shown in Figure 26.
2. Connect the load wires to the UVWO terminals as shown
in Figure 28.
Figure 26. Voltage Change-Over Board
480V Configuration
Figure 28. UVWO Terminal Lugs
1Ø-480V Connections
2. Connect the load wires to the UVWO terminals as shown
in
1Ø-277V UVWOTerminal Output Voltages
1. Make sure the voltage change-over board is jumpered
for 480V operation as shown in Figure 26.
2. Connect the load wires to the UVWO terminals as shown
in Figure 29.
Figure 27. UVWO Terminal Lugs
3Ø-480V Connections
ALWAYS make sure that the
connections to the UVWO
NOTE
terminals are secure and tight.
The possibility of arcing exists,
that could cause a fire.
Figure 29. UVWO Terminal Lugs
1Ø-277V Connections
DANGER - UVWO OUTPUTTERMINALS
NEVER attempt to connect a load to the UVWO output
terminals while the generato is operating.The possibility
r
exists of serious injury, electrical shock, electrocution even
death.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 39
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DCA-600SSK — PRE-SETUP
Fuel Check
Circuit Breakers
To protect the generator from an overload, a 3-pole, 800 amp,
main circuit breaker is provided to protect the UVWO 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 auxiliary receptacles
from overload. Make sure to switch ALL circuit breakers to
the "OFF" position prior to starting the engine.
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a hot engine can cause a fire or explosion.
If fuel spillage occurs, wipe up the spilled fuel completely
to prevent fire hazards. NEVER smoke around or near the
generator.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but DO NOT overfill. Make sure the generator is level.
Also verify that the oil level is maintained between the two
notches (Figure 30) on the dipstick. See Table 11 for proper
selection of engine oil.
REFILLING THE FUEL SYSTEM
CAUTION - REFUELINGTHE GENERATOR
ONLY properly trained personel who have read and
understand this section should refill the fuel tank system.
The DCA600SSK series generators may (if equipped with a
trailer or skid) have a double fuel tank system (Figure 31),
which consists of an internal generator fuel tank, and a
trailer mounted fuel tank. It is also possible the generator
can be equipped with a skid mounted fuel tank (Figure 32).
The skid type fuel system does not use the internal generator
fuel tank.
Figure 30. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. 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. Oil should be
warm before draining.
Use the instructions in this section that applies to your type
of fuel tank system.
Other types of motor oils may be substituted if they meet
the following requirements:
ALWAYS fill the fuel tank with clean and fresh #2 diesel
fuel. DO NOT fill the fuel tanks beyond their capacities.
API Service Classification CH-4
API Service Classification CG-4
API Service Classification CF-4
ACEA Specification E3
Pay attention to the fuel tank capacity when replenishing
fuel. 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.
ACEA Specification E2
Table 11. Recommended Motor Oil
Temperature
Type Oil
Range
14oF ~ 50oF
SAE 10W
(-10oC ~ 10oC)
32oF and above
SAE30 or SAE 10W-30
(0oC and above
Figure 31 Double Fuel Tank System
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DCA-600SSK — PRE-SETUP
CAUTION -TRAILER FUELTANK
ALWAYS! fill trailer tank first with #2 diesel fuel, before
filling secondary internal tank.
Figure 32. Skid Type Fuel Tank System
Refueling Procedure:
WARNING - RESPIRATORY HAZARDS
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. Level Tanks – make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity. See Figure 33.
Figure 34. Fuel Tank Filling Order
CAUTION - REFUELINGTHE GENERATOR
ALWAYS place trailer on firm level ground before refueling
to prevent spilling and maximize the amount of fuel that
can be pumped into the tank.
ONLY! use #2 diesel fuel when
refueling.
NOTE
Fuel from the secondary inner
tank will eventually drain into the
primary trailer tank.
NOTE
Figure 33. Only Fill on Level Ground
2. Trailer Fuel Tank First – The trailer fuel tank is the
primary fuel tank and holds a larger capacity of fuel.
The fuel in the trailer will be filtered and sent to the
engine. ALWAYS fill trailer fuel tank (Figure 34) first.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 41
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DCA-600SSK — PRE-SETUP
3. NEVER overfill trailer fuel tank – It is important to
read the trailer fuel gauge when filling trailer fuel tank.
DO NOT wait for fuel to rise in filler neck. See Figure 35.
5. Figure 37 below reflects a full fuel system.
Figure 35. Full Trailer Tank
Figure 37. Full Fuel System
6. Fuel from the engine return line will drain into the secondary
internal fuel tank. This fuel will eventually drain into the
primary trailer tank in order to return to the engine.
CAUTION - REFUELINGTHE GENERATOR
DO NOT OVER-FILL fuel system. Leave room for fuel
expansion . Fuel expands when heated (Figure 36).
CAUTION - REFUELING SECONDARY FUELTANK
It is recommended to only fill the internal secondary take to 3/
4 full in order to allow for fuel return, fuel expansion, and to
avoid spillage. See Figure 38 for fuel expansion.
4. Once the trailer tank is full, the secondary inner tank
can be filled (See Figure 36). Notice how the trailer
filler tube level rises when the internal tank is filled.
Figure 38. Fuel Expansion
Figure 36. Filling Secondary Internal Fuel Tank
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DCA-600SSK— PRE-SETUP
Coolant (Ethylane Glycol [Green] /Water — 50/50 mix)
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.
When the antifreeze is mixed with
water, the antifreeze mixing ratio
must be less than 50%.
NOTE
Cleaning the Radiator
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
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
negative battery terminal disconnected.
WARNING - BURN HAZARDS
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled.The
possibility of hot! coolant exists which
can cause severe burns.
Air Cleaner
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Komatsu Engine Owner's Manual.
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 and adjust it in accordance with the
Komatsu Engine Owner's Manual.
Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 12 for engine and radiator, coolant capacities. Make
sure the coolant level in the recovery tank is always between
the "H" and the "L" markings.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 39) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
Reserve Tank
16.9 Gal. (64.0 Liters)
2 Quarts (1.9 Liters)
Figure 39. Fan Belt Tension
CAUTION - ROTATING PARTS
Operation FreezingWeather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
NEVER place hands near
the belts or fan while the
generator set is running.
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
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 43
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DCA-600SSK— PRE-SETUP
Battery
When connecting battery do the following:
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 are
not properly maintained. Add only distilled water when
replenishment is necessary.
1. NEVER connect the battery cables to the battery
terminals when the ignition switch is in either the Pre-
Heat, RUN, or START position. ALWAYS make sure
that the ignition switch is in the STOP position when
connecting the battery.
DO NOT over fill. 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 an approved battery terminal
treatment compound. Replace battery with only
recommended type battery.
2. Place a small amount of battery terminal treatment
compound around both battery terminals.This will ensure
a good connection and will help prevent corrosion around
the battery terminals.
If the battery cable is connected
incorrectly, electrical damage to the
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 that the battery is
dead and needs to be recharged or replaced.
generator will occur. Pay close
attention to the polarity of the
battery when connecting the
battery.
NOTE
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 40) 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.
CAUTION - BATTERY SERVICING SAFETY
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
Alternator
CAUTION - BATTERY SERVICING SAFETY
The polarity of the alternator is negative grounding type.
When an inverted circuit connection takes place, the circuit
will be in short circuit instantaneously resulting the alternator
failure.
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
DO NOT put water directly on the alternator. Entry of water
into the alternator leads an electrolyte corrosion causing an
alternator failure.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
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.
Figure 40. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
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DCA-600SSK — GEN. START-UP PROCEDURE (MANUAL)
1. Place the main, G.F.C.I. and aux. circuit breakers (Figure 42)
in the “OFF” position prior to starting the engine.
BEFORE STARTING
CAUTION - LETHAL EXHAUST HAZARD
The engine's exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
If applicable perform the following:
Apply commercial power to the internal battery charger
receptacle (to ensure good starting) via commercial power.
An external power cord will be required.This capability is an
option.
Figure 42. Main, Aux. and GFCI
Circuit Breakers (OFF)
Apply commercial power to the jacket water heater
receptacle (not necessary for warm climates) via commercial
power.An external power cord will be required.This capability
is an option.
2. Connect the load to the UVWO terminals or auxiliary
receptacles as shown in Figure 43. These load
connection points can be found on the output terminal
panel. To gain access to the UVWO terminals or other
power receptacles, unlock the access cover and lift the
door.
Generator and Control Panel
WARNING - STARTINGTHE GENERATOR
3. Tighten the UVWO terminal nuts securely to prevent
load wires from slipping out.
NEVER! manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.
Steps 1 thru 19 are referenced
for Engine Operating Panel up
to S/N 3698616. See Figure 41
NOTE
below.This unit has an ignition
switch and a throttle handle.
Figure 43. Load Connections
4. Close all engine enclosure doors (Figure 44).
Figure 41. Engine Operating Panel
Up To S/N 3698616
Figure 44. Engine Enclosure Doors
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 45
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DCA-600SSK— GENERATOR START-UP PROCEDURE (MANUAL)
5. Set the battery ON/OFF switch (Figure 45) to the “ON”
11. The generator's frequency meter (Figure 50) should be
position.
displaying the 60 cycle output frequency in HERTZ.
Figure 45. Battery ON/OFF Switch
Figure 50. Frequency Meter (Hz)
6. When starting the generator in COLD weather conditions,
turn the ignition key to the “PREHEAT ” position (Figure 46),
12. The generator's AC-voltmeter (Figure 51) will display the
generator’s output in VOLTS. If the voltage is not within
the specified tolerance, use the voltage adjustment
control knob (Figure 52) to increase or decrease the
desired voltage.
Figure 46. Ignition Switch (Pre-Heat)
7. Verify that the pre-heat lamp(Figure 47) is lit (ON) before
starting engine.
Pre-Heat
Lamp
Figure 51. AC Voltmeter
Figure 47. Pre-Heat Lamp
8. Place the engine throttle lever in the “LOW” position
(Figure 48).
Figure 52. Voltage Adjust Control Knob
13. The ammeter (Figure 53) will indicate zero amps with no
load applied. When a load is applied, the ammeter will
indicate the amount of current that the load is drawing
from the generator.
Figure 48. Engine Throttle Control
9. Turn the ignition key to the “START” position (Figure 49)
and listen for the engine to begin cranking. After the
engine starts release the ignition key.
Figure 53. Ammeter (No Load)
Figure 49. Engine Ignition Switch
10. Once the engine has started, let it run for 3-5 minutes,
then turn the throttle handle control (Figure 48) to the
“HIGH” position.
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DCA-600SSK— GENERATOR START-UP PROCEDURE (MANUAL)
14. The engine oil pressure gauge (Figure 54) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure is approximately
17. Place the main, GFCI, and aux. circuit breakers in the
“ON” position (Figure 57).
4
8
ENGINE OIL PRESSURE
kg/cm2
0
Figure 54. Oil Pressure Gauge
15. The coolant temperature gauge (Figure 55) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (Green Zone).
Figure 57. Main, Aux. and GFCI
Circuit Breakers (ON)
18. Observe the generator's ammeter (Figure 58) and verify
it reads the anticipated amount of current with respect
to the load. The ammeter will only display a current
reading if a load is in use.
WATER TEMP
Figure 55. Coolant Temperature Gauge
16. The tachometer gauge (Figure 56) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Figure 58. Ammeter (Load)
19. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 56. Engine Tachometer Gauge
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 47
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DCA-600SSK — GENERATOR START-UP PROCEDURE (MANUAL)
22. Place the engine speed switch in the “LOW ” position
BEFORE STARTING
(Figure 62).
Generator and Control Panel
CAUTION:
NEVER! manually start the engine with the
main, GFCI or auxiliary circuit breakers in
the ON (closed) position.
Figure 62. Engine Speed Switch (Low)
23. Place the Auto-Off/Reset-Manual switch in the “Manual”
position to start the engine (Figure 63). Once the engine
starts, let the engine run for 1-2 minutes. Listen for any
abnormal noises.
Steps 20 thru 26 are referenced
for Engine Operating Panel
S/N 3698617~. See Figure 59
below.This unit does not have
an ignition switch or a throttle
handle. It does have an “engine
speed switch” that is used in
conjunction with the MPEC
unit.
NOTE
Figure 63. Auto-Off/Reset-Manual Switch
24. Once the engine is warm and the engine is running
properly, place the engine speed switch in the “HIGH ”
position (Figure 64).
Figure 59. Engine Operating Panel
S/N 3698617~
Figure 64. Engine Speed Switch (High)
25. Verify that the "Engine Running" status LED on the MPEC
unit (Figure 65) is "ON" (lit) after the engine has been started.
20. Set the battery ON/OFF switch (Figure 60) to the “ON”
position.
Figure 60. Battery ON/OFF Switch
21. Press and hold the engine preheat button (Figure 59)
Figure 65. Engine Running LED (ON)
until the preheat lamp is lit (ON).
26. Continue operating the generator as outlined in steps
11 thru 19 (pages 46-47).
Pre-Heat
Lamp
Pre-Heat
Button
Figure 60. Pre-Heat Button/ Lamp
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DCA-600SSK — GENERATOR START-UP PROCEDURE (AUTO MODE)
DANGER - ELECTRICAL SYSTEM HAZARDS
CAUTION - ENGINE SPEED SWITCH
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious damage to the
building’s electrical system may occur
without this transfer switch.
The Engine Speed Switch must be set to the "High"
position when running in the Auto-Start mode. Failing to
set the switch in the proper position can result in damage
to your generator when it turns on.
When the generator is set in the “
AUTO ” mode, the generator will
automatically start in the event of
CAUTION - BACKUP GENERATOR USE
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.
NOTE
commercial power falling below a
prescribed level by means of a
contact closure that is generated
automatically by a transfer switch.
3. Set the engine speed switch (Figure 67) to the “High”
WARNING - AUTO MODE MAINTENANCE
position.
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.
Figure 67. Engine Speed Switch (High)
When starting generator in AUTO mode use the "Manual
Start-up" procedure except where noted (see below).
4. Place the Off/Manual/Auto switch (Figure 68) on the
MPEC unit to the AUTO position.
1. Perform steps 1 through 4 in the Before Starting section
(page 45) as outlined in the Manual Starting Procedure.
2. Set the battery ON/OFF switch (Figure 66) to the “ON”
position.
Figure 68. Off/Manual Auto Switch (AUTO)
5. Continue operating the generator as outlined in steps
11 thru 19 (pages 46-47).
Figure 66. Battery ON/OFF Switch
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 49
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DCA-600SSK — GENERATOR SHUT-DOWN PROCEDURE
Engine Shutdown Ignition Key (Up to S/N 3698616)
To shutdown the generator use the following procedure:
Engine Shutdown Controller (S/N 3698617~)
To shutdown the generator use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers 1. Place both the MAIN, GFCI and LOAD circuit breakers
(Figure 69) to the "OFF position".
as shown in Figure 67 to the "OFF position".
2. Place the engine speed switch in the “LOW ” position
(Figure 73).
Figure 73. Engine Speed Switch (High)
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
4. Place the Auto-Off/Reset-Manual switch (Figure 74) to
Figure 69. Main, Aux. and GFCI
Circuit Breakers (OFF)
the OFF/Reset position.
2. Place the throttle control (Figure 70) in the “LOW”position.
Figure 74. Off/Manual Auto Switch (AUTO)
Figure 70. Engine Throttle Control
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
4. Place the ignition key (Figure 71) in the “STOP” position.
5. Verify that the all status LED's on the MPEC display
are "OFF" (not lit).
6. Remove all loads from the generator.
CAUTION - EMERGENCY STOP SWITCH
NEVER stop the engine suddenly except in an emergency.
DO NOT use the emergency stop switch a as method of
shutting down the generator. This switch is ONLY to be
used in the event of an emergency.
Figure 71. Ignition Key Switch (STOP position)
5. Remove all loads from the generator.
Emergency Shutdown Procedure
1. PUSH inward the emergency stop button located on the
engine operating panel (Figure 72) to turn off the
generator in the event of an emergency. This button is
located on either Engine Operating Panel.
To disengage the emergency
stop function, pull the emergency
stop button outward to its
original position.This will allow
the generator to operate normally.
Rememberthe generator will not
start if the emergency stop
button is engaged.
NOTE
Figure 72. Emergency Stop Button
PAGE 50 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — MAINTENANCE
Use Table 14 shown below as a general checklist to be
performed on a daily basis.
TABLE 14.
10 Hrs
DAILY
250 Hrs
500 Hrs 1000 Hrs
INSPECTION / MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
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
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
Measure Insulation Resistance Over 3M
ohms
X
GENERATOR
1
*
*
Replace engine oil anf filter at 100 hours, first time only.
Replace fuel filter at 250 Hours, first time only.
2
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 51
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DCA-600SSK — 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
or oil leaks.
Air Cleaner
Every 50 hours:If dust indicator is RED, clean the air cleaner
element.
Removing Water from the Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the greater
the empty volume inside the tank, the easier it is for water to
Outer Element:
condense. This can be reduced by always keeping the tank
as full as possible.
1. Loosen wing bolt, remove dust cup, then remove wing
nut and take out element.
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or
after disassembling the fuel system, bleed the system
according to the following procedure.
To restart after running out of fuel, turn the key switch to the
“START” position for 15-30 seconds. Try again, if needed.
This unit is equipped with an automatic air bleeding system.
2. Clean the inside of the body and cover using a damp
cloth.
3. Blow dry with compressed air (0.69Mpa {7kgf.cm2,
99.4 PSI} maximum) against the side of the element
along the pleats. Then blow dry against outside along
the pleats, then against inside again.
4. Remove one seal each time the element is cleaned.
Service Daily
5. Replace the outer element after cleaning it 6 times or
after one year. Replace the outer element if indicator is
red even after cleaning it.
If engine is operating in very dusty and dry grass conditions,
a clogged air cleaner will result in high fuel consumption,
loss of power and excessive carbon buildup in the
combustion chamber.
6. Check the inner cylinder element clamping nut for
looseness, and retighten if necessary.
Cleaning the Fuel Strainer
7. If seal washer is damaged or the threads of wing nut are
damaged, replace.
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.
8. Remove evacuator valve and clean it with compressed
air. Reinstall.
Check Oil Level
Inner element (if equipped)
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 30.
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.
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.
4. Install a new inner cylinder element to the cylinder and
tighten the nut.
5. Install element.
6. After replacing the element, press the button of the dust
indicator to return the red piston to its original position.
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DCA-600SSK — MAINTENANCE
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.
WARNING - BURN HAZARDS
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
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.
Changing Oil
Flushing Out Radiator and Changing Coolant
1. Make sure the oil is cool before changing.
1. Stop the engine and allow to cool. Tighten valve of the
corrosion resistor (if equipped).
2. Set a container directly under the drain plug of the oil
pan. Loosen the drain plug slowly.
2. Turn water filer cap slowly and remove it.
3. Check the drained oil for excessive metal particles or
foreign material. Contact the distributor if there is metal
particles or foreign material.
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. 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.
4. After draining the coolant, close drain plugs and fill with
tap water.
5. When the water level is near the mouth of the water
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.
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.
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.
6. Add engine oil through oil filler until the oil level is between
the H and L marks on the dipstick.
7. After flushing, stop the engine, open drain plug and drain
the water, then close drain plugs.
7. Run the engine at idling for a short time, then stop the
engine. Recheck the oil level and fill as necessary.
8. After draining the water, flush the system with a flushing
agent. See instructions on flushing agent label.
Replacing Fuel Filter
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.
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.
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.
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.
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.
11. When clean water comes out, stop the engine, drain all
the water, then close drain plugs.
12. Remove the corrosion resistor (if equipped) and open
valve.
13. Supply water until it flows over the water filler.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 53
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DCA-600SSK — MAINTENANCE
5. After replacing filter cartridge, loosen air bleed plug.
Generator Storage:
6. Loosen the knob of feed pump, and pump it up and down
until no bubbles come out with the fuel from air bleed
plug.
For storage of the generator for over 30 days, the following
is required:
Fill the fuel tank completely. Treat with fuel stabilizer if
necessary.
7. After bleeding the air, tighten air bleed plug, then push in
the knob of feed pump and lock it in position.
Completely drain oil from the crankcase and refill if
necessary with fresh oil.
8. Replace Corrosion resistor cartridge (if equipped)
9. Screw in valves at the top of the corrosion resistor.
Clean the entire generator, internal and external.
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 generator 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.
Cover the generator set and store in a clean, dry place
13. Open valves.
Removal From Long Term Storage:
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 (0.13-0.26 gal) 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
1. 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.
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DCA-600SSK — MAINTENANCE
Jacket Water Heater and Internal Battery Charger 120
VAC Input Receptacles (OPTIONAL)
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.
This generator is equipped with two 120VAC, 20 amp input
receptacles located on the output terminal panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
To ensure adequate starting
capability, always have power
applied to the generator's
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 75). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
NOTE
internal battery charger.
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.
ery Charger/Jacket Water
ater Power Connections
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 55
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DCA-600SSK —TRAILER BRAKES MAINTENANCE
Brakes
Trailer brakes should be inspected the first 200 miles of
operation. This will allow the brake shoes and drums to seat
properly. After the first 200 mile interval, inspect the brakes
every 3,000 miles. If driving over rough terrain, inspect the
brakes more frequently.
Air Brake System
Air brakes use compressed air to make the brakes function.
Air brakes are a good and safe way of stopping large and
heavy vehicles. There are many components that make up
an air-brake system, such as the air compressor, air
compressor governor, air storage tanks and air tank drains.
These components need to be maintained by qualified and
trained technicians.
S-Cam Brakes
Figure 76. Hydraulic Brake Components
Brake Drums (or discs), Linings, and Hoses
When the brake pedal is pushed, air is let into each brake
chamber (Figure 76). Air Pressure pushes the rod out, moving
the slack adjuster, thus twisting the brake cam shaft. This
turns the s-cam (so called because it is shaped like the
letter "S").
Brake drums or discs must not have cracks longer than one
half the width of the friction area. Linings must not be loose,
soaked with oil or grease or be dangerously thin. Mechanical
parts must be in place, not broken or missing. Check that
all air hoses connected to the brake chambers are not worn
or cut due to rubbing.
The s-cam forces the brake shoes away from one another
and presses them against the inside of the brake drum.When
the brake pedal has been released, the s-cam rotates back
and a spring pulls the brake shoes away from the drum,
letting the wheels roll freely.
Air Leaks
AirTank Drains
Always check for brake air leaks before towing the trailer.
NEVER tow the trailer with an brake air leak problem. The
possibility exists of brake failure.
Compressed air usually has some water in it which is bad
for the air brake system. Water can freeze in cold weather
and thus cause brake failure. The water tends to collect in
the bottom of the air tank. Daily air tank drainage is required
to remove water from the air tank.
Table 15. Air Brake Troubleshooting
Symptom
Possible Cause
Air Brake line broken or kinked?
Worn lining?
Solution
Repair or replace.
Replace lining.
No Brakes
Slack adjustment incorrect?
Brake lining glazed?
Adjust correctly.
Reburnish or replace.
Correct weight.
Trailer overloaded?
Use Table 15 as a basic
troubleshooting guide when
brake problems occur.
Weak Brakes or Brakes Pull to
One Side
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
NOTE
Tires unmatched on the same axle?
Brake components loose, bent or broken?
Brake drums out-of-round?
Brake lining glazed?
Locking Brakes
Replace components.
Replace.
Replace brake lining.
Noisy Brakes
Drums and lining glazed?
Replace brake lining and
drum.
Brake lining thickness incorrect or not
adjusted correctly?
Install new shoes and linings.
Dragging Brakes
Zerk fittings lubricated?
Lubricate zerk fittings.
PAGE 56 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK —TRAILER MAINTENANCE
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 - EYESIGHT HAZARD
ALWAYS wear safety glasses when
removing or installing force fitted parts.
Failure to comply may result in serious
injury.
CAUTION - REPAIRINGTRAILERWHEELS
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
Suspension
The leaf suspension springs and associated components
(Figure 77) 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 17.
cause serious eye or bodily injury.
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 16 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
ALWAYS wear safety glasses
when removing or installing force
fitted parts. Failure to comply
NOTE
may result in serious injury.
Figure 77. Major Suspension Components
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 57
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DCA-600SSK —TRAILER MAINTENANCE
Table 17. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
SHACKLE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
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 78. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 18.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 18. 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 78. Wheel Lug Nuts Tightening Sequence
NEVER use an pneumatic air
gun to tighten wheel lug nuts.
Use a torque wrench to tighten
lug nuts.
NOTE
PAGE 58 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK —TRAILER-WIRING DIAGRAM
Figure 79. Trailer Wiring Diagram (5-Pin)
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 59
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DCA-600SSK —TRAILER-WIRING DIAGRAM
Figure 80. Trailer Wiring Diagram (7-Pin)
PAGE 60 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK —GENERATORWIRING DIAGRAM
ING DIA
m
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 61
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DCA-600SSK — GENERATOR WIRING DIAGRAM (MAIN BREAKER)
Figure 82. Main Circuit Breaker Wiring Diagram
PAGE 62 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENGINEWIRING DIAGRAM
Continued on
next page
Figure 83. Engine Wiring Diagram
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 63
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DCA-600SSK — ENGINEWIRING DIAGRAM
Continued from
pre
Figure 84. Engine Wiring Diagram(Continued)
PAGE 64 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ELECTRONIC GOV. CONTROLLER WIRING DIAGRAM
Figure 85. Electronic Governor Controller
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 65
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DCA-600SSK —TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 20 (Engine Troubleshooting) as a basic guideline for troubleshooting the engine. If the problem
cannot be remedied, consult our company's business office or service plant.
TABLE 20. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
No fuel?
SOLUTION
Replenish fuel.
Bleed system.
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
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.
Compression leak from
cylinder?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
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 66 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK —TROUBLESHOOTING (ENGINE)
TABLE 20. 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.
Repair or replace.
Piston ring and liner worn or
stuck?
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.
Uneven fuel injection?
Repair or replace the injection pump.
Repair or replace the nozzle.
Deficient output.
Deficient nozzle injection?
Replace head gasket, tighten cylinder head bolt, glow plug and
nozzle holder.
Compression leak?
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 67
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DCA-600SSK —TROUBLESHOOTING (GENERATOR/ENGINE)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 21 (Generator Troubleshooting) as a basic guideline for troubleshooting the generator. If the problem
cannot be remedied, consult our company's business office or service plant.
TABLE 21. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
AC Voltmeter defective?
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
Is wiring connection loose?
Is AVR defective?
No Voltage Output
Replace if necessary.
Defective Rotating Rectifier?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Turn engine throttle lever to "High".
Check wiring and repair.
Low Voltage Output
High Voltage Output
Replace if necessary.
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Short Circuit in load?
Over current?
Check load and repair.
Confirm load requirements and reduce.
Check and replace.
Circuit Breaker Tripped
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
PAGE 68 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK —TROUBLESHOOTING (MPEC)
Use Table 22 (Engine ControllerTroubleshooting) as a basic guideline for troubleshooting the MPEC. If the problem cannot
be remedied, consult our company's business office or service plant.
TABLE 22. ENGINE CONTROLLER TROUBLESHOOTING (MPEC)
Sympton
Possible Cause
Solution
Low oil level?
Fill oil level.
Oil pressure sending unit failure?
Time delay malfuntion in Controller?
Wire shorted?
Replace oil pressure sending unit.
Refer to dealer.
Low oil pressure light
is on.
Inspect/repair wire.
Low coolant level?
Fill 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.
High coolant
temperture light is on.
Generator being overloaded?
Thermostat failure?
Replace thermostat.
Clear all air intakes.
Replace temperature switch.
Fill fuel level.
Air intake blocked?
Temperature switch failure?
No or low Fuel?
Overcrank light is on.
Overspeed light is on.
Controller needs to be calibrated?
RPM engine speed too high?
Governor actuator needs to be adjusted?
Governor controller needs to be adjusted?
Engine Controller 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-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 69
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EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
QTY. Column
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice.Multiquip
does not guarantee the availability of the parts listed.
A blank entry generally indicates that the item is not sold
separately.Other entries will be clarified in the“Remarks”
Column.
SAMPLE PARTS LIST
REMARKS Column
NO. PART NO. PART NAME
QTY. REMARKS
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
1
2%
12345
BOLT......................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN............NOT SOLD SEPARATELY
WASHER, 3/8 IN....1 .....MQ-45T ONLY
2% 12347
3
4
12348
12349
HOSE ..................A/R ...MAKE LOCALLY
BEARING ..............1 .....S/N 2345B AND ABOVE
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
NO. Column
Indicated by:
Unique Symbols — All items with same unique
symbol
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items.Examples include battery cables, shims,
and certain washers and nuts.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
“Not Sold Separately”— Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
PAGE 70 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — SUGGESTED SPARE PARTS
DCA-600SSK w/SA6D170AE-1 KOMATSU ENGINE
1 to 3 Units
Qty.
P/N
Description
20 ............ 6125817032 ..................... AIR FILTER, INNER & OUTER
30 ............ 6003117111 ..................... FUEL FILTER
30 ............ 6002111231 ..................... OIL FILTER
2 .............. 6004111030 ..................... CARTRIDGE, CORROSION RESISTOR
1 .............. 0601810575 ..................... PILOT LAMP, ENGINE TROUBLE
1 .............. 0601810576 ..................... PILOT LAMP, ENGINE TROUBLE
1 .............. 0412222568 ..................... ENGINE FAN BELT
1 .............. 6008155390 ..................... SWITCH STARTER UP TO S/N 3698616
3 .............. 615 .................................. KEY SET, STARTER SWITCH (2) UP TO S/N 3698616
2 .............. 0602122281 ..................... OIL SWITCH
1 .............. 6995621691 ..................... RADIATOR HOSE (UPPER)
1 .............. 6162639650 ..................... RADIATOR HOSE (LOWER)
1 .............. 0605505030 ..................... FUEL CAP
1 .............. 0601820625 ..................... AUTOMATICVOLTAGE REGULATOR
1 .............. 0601805313 ..................... CIRCUIT BREAKER, 265V, 20A
1 .............. 0601805840 ..................... CIRCUIT BREAKER, 265V, 50A
1 .............. 0601802525 ..................... HANDLE, MAIN CURRENT BREAKER
1 .............. 0601840073 ..................... VOLTAGE REGULATOR (RHEOSTAT)
2 .............. 0601840121 ..................... KNOB, VOLTAGE REGULATOR
1 .............. 0601810072 ..................... PILOT LAMP
2 .............. 0601810261 ..................... BULB PILOT LAMP
1 .............. 23S0311150M ................. CAP, RADIATOR
1 .............. 0602122203 ..................... UNIT OIL PRESSURE
1 .............. 0602123206 ..................... UNIT, WATERTEMPERATURE
1 .............. 0602121052 ..................... CHARGING AMMETER
1 .............. ECU9988N600/800 .......... ECU ENGINE CONTROLLER S/N 3698617~
Part number on this Suggested Spare
Parts List may super cede/replace the
P/N shown in the text pages of this
NOTE
book.
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 71
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DCA-600SSK — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 72 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — GENERATOR ASSY.
GENERATOR ASSY.
NO
1
2
PART NO
PART NAME
QTY.
REMARKS
8181000002
ROTOR ASSY................................... 1 ........ INCLUDE ITEMS W/
*
FIELD ASSY.
1
3
0601842366
8171020004
8171020504
8461070002
8461614003
012212025
RESISTOR ....................................... 4 ........ SMRK 80W 50 KOHMS
*
4
INSULATORWASHER
INSULATORWASHER
FAN
COUPLING RING
HEX. HEAD BOLT ............................ 6 ........ REPLACES 0010312025
1
1
1
1
*
5
*
6
*
7
*
8
*
8
0042512000
C4163100004
8461612004
8461015003
0012120055
0042620000
8461026023
0601823282
0018205020
0032005000
0401450050
0010112020
0040012000
0601000209
7431014003
0070106321
0080000105
0012116060
0042516000
C4130100203
7431323003
7431323123
7431323204
0016310080
020310080
LOCKWASHER
6
1
1
*
9
COUPLING DISK ASSY.
WASHER, COUPLING HUB
BALANCING PLATE
HEX. HEAD BOLT
LOCKWASHER
SET PLATE, RECTIFIER
RECTIFIER ...................................... 2 ........ RM50TC-24
HEX. SOCKET HEAD CAP SCREW 4
LOCKWASHER ............................... 4 ........ REPLACES 0040005000
PLAIN WASHER............................... 4 ........ REPLACES 0041205000
HEX. HEAD BOLT
LOCKWASHER
BALANCING WEIGHT KIT
BEARING FLANGE
BEARING
*
10
*
11
12
13
14
15
16
16
16
17
17
18
19
20
21
22
22
23
24
25
26
27
27
27
27
28
29
30
31
31
31
1
*
*
*
*
*
*
*
*
*
*
*
*
*
*
12
12
1
6
6
1
1
1
1
6
6
1
4
4
2
4
SNAP RING
HEX. HEAD BOLT
LOCKWASHER
STATOR ASSY.
CLAMPER
CLAMPER
CLAMPER
HEX. HEAD BOLT
HEX. NUT......................................... 4 ........ REPLACES 0030010000
LOCKWASHER
PLAIN WASHER............................... 4 ........ REPLACES 0041210000
HEX. HEAD BOLT ............................ 8 ........ REPLACES 0017110020
END BRACKET
0040010000
031110160
012210020
8461315002
C4137000003
0012110075
0042610000
031110160
8
1
1
6
6
FIELD ASSY. EXCITER
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER............................... 6 ........ REPLACES 0041210000
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 73
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DCA-600SSK — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 74 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — GENERATOR ASSY.
GENERATOR ASSY.
NO
32
33
33
33
34
35
36
36
36
37
38
39
40
41
42
43
44
45
45
46
47
48
49
49
PART NO
PART NAME
QTY.
REMARKS
0845044904
0016316045
0040016000
0041216000
7431310003
8461312004
0016308095
0040008000
0311108160
0010110016
0803000104
8461335004
8461334003
0105050616
0017106050
8461333003
0105050616
0012112040
0042512000
8461332003
0017106050
0605000012
0030020000
030220510
GROMMET
1
8
8
8
1
2
3
3
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
COVER, BEARING
GASKET, BEARING
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER............................... 3 ........ REPLACES 0041208000
HEX. HEAD BOLT
PACKING
BRACKET, COVER
COVER, STATOR
HEX. HEAD BOLT ............................ 4 ........ REPLACES 0017106012
HEX. HEAD BOLT
LOCKWASHER
HEX. HEAD BOLT ............................ 2 ........ REPLACES 0017106012
1
1
1
1
2
1
HEX. HEAD BOLT
LOCKWASHER
COVER, FAN
HEX. HEAD BOLT
RUBBER SUSPENSION
HEX. NUT
16
16
1
1
4
8
LOCKWASHER ............................... 8 ........ REPLACES 0040020000
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 75
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DCA-600SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 76 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO
1
1
2
3
4
4
4
5
6
7
8
9
10
10
11
11
12
13
14
14
14
14
15
15
15
16
16
16
16
16
17
17
17
18
18
19
20
21
22
23
24
25
PART NO
PART NAME
QTY.
REMARKS
8481812502
4215000012
0601806153
0017108020
C4261501503
C4262500003
C4262500213
011208030
0601820625
0027105015
0601820892
0027104015
0601823706
0601823706
0027104014
0027104014
C5352800003
0017106016
0601802133
0601802164
0601802149
0601802218
0021004020
0040004000
0041204000
0601823757
0601827655
0601823153
0601823143
PYCA1
CONTROL BOX ........................................ 1 .........S/N 3744467 AND BELOW
CONTROL BOX ........................................ 1 .........S/N 3744468 AND ABOVE
CURRENTTRANSFORMER, AMMETER 3 .........CW-40LM 1200/5A
HEX. HEAD BOLT
6
SET PANEL, ELECTRIC PARTS.............. 1 .........S/N 3692434~3698616
SET PANEL, ELECTRIC PARTS.............. 1 .........S/N 3698617~3744467
SET PANEL, ELECTRIC PARTS.............. 1 .........3744468 AND ABOVE
HEX. HEAD BOLT .................................... 8 .........REPLACES P/N 0017108030
AUTOMATICVOLTAGE REGULATOR
MACHINE SCREW................................... 4 .........REPLACES P/N 0027105016
OVER CURRENT RELAY
MACHINE SCREW................................... 2 .........REPLACES P/N 0027105016
RELAY...................................................... 1 .........S/N 3692434~S/N 3698616
RELAY...................................................... 2 .........S/N 3698617 AND ABOVE
MACHINE SCREW................................... 2 .........S/N 3692434~S/N 3698616
MACHINE SCREW................................... 4 .........S/N 3698617~ABOVE
1
1
BRACKET
1
6
1
1
1
1
3
3
3
HEX. HEAD BOLT
FUSE (LEFT SIDE) 5A
FUSE 30A
FUSE (RIGHT SIDE) 10A
HOLDER, FUSE
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
RELAY, MY2 DC24V ................................ 1 .........S/N 3692434~S/N 3698616
RELAY, LY2 DC24V .................................. 1 .........S/N 3698617~S/N 3699208
RELAY, LY2-D DC24V .............................. 1 .........S/N 3699209 AND ABOVE
SOCKET, PYF14A ................................... 1 .........S/N 3698617 AND ABOVE
HOLDER,.................................................. 1 .........REPLACES P/N 0601824400
RELAY, MY4 DC24V
SOCKET, PYF14A
HOLDER ................................................... 2 .........REPLACES 0601824400
MACHINE SCREW
MACHINE SCREW
RELAY...................................................... 1 .........REPLACES P/N 0602201246
HEX. HEAD BOLT REPLACES P/N 0017105016
UNIT, BATTERY SENSOR ....................... 1 .........C7038A0000
HEX. HEAD BOLT
CONTROLLER ......................................... 1 .........REPLACES P/N 0602202536
HEX. NUT
0601823759
0601823146
PYCA1
2
2
0027104015
0027104015
1750733520
0017105015
0602201911
0017106020
6162839180
0207006000
0601807030
6
8
S/N 3744467 AND BELOW
S/N 3744468 AND ABOVE
2
1
4
CIRCUIT BREAKER, XS1600NE 1600A .. 1 .........S/N 3744467 AND BELOW
..............................................................................INCLUDES ITEM W/
CIRCUIT BREAKER, SV8 1600A ............ 1 .........S/N 3744468 AND ABOVE
HANDLE, CIRCUIT BREAKER ................ 1 .........S/N 3744467 AND BELOW
*
25
25-1
0601807516
0601802525
*
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 77
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DCA-600SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 78 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO
26
27
28
29
29
29
29
29
29
29
30
31
32
33
34
35
36
37
38
38
38
38
39
40
40
40
41
42
42
42-1
42-2
43
44
45
46
47
48
49
49
50
51
52
PART NO
PART NAME
QTY.
REMARKS
7971816104
7971816304
0017108020
0021008045
0030008000
0040008000
0041208000
0015308045
0042508000
0041208000
7431861113
7431852104
0017108035
7971852504
7431853104
0801832504
0040020000
0041420000
0010110040
0030010000
0040010000
0041210000
6008153600
0010010040
0040010000
0041210000
C4224001403
7971822603
C4225000213
0228800124
0228800100
0605011211
0601800480
0601800736
0601801040
0601800252
0601801041
0601810072
0601810261
0601840073
0601840121
BRACKET, CIRCUIT BREAKER .............. 1 .........S/N3744467 AND BELOW
BRACKET, CIRCUIT BREAKER .............. 1 .........S/N3744467 AND BELOW
HEX. HEAD BOLT .................................... 4 .........S/N3744467 AND BELOW
MACHINE SCREW................................... 4 .........S/N3744467 AND BELOW
HEX. NUT ................................................. 4 .........S/N3744467 AND BELOW
WASHER, LOCK ...................................... 4 .........S/N3744467 AND BELOW
WASHER, FLAT ....................................... 4 .........S/N3744467 AND BELOW
HEX. SOCKET HEAD CAP SCREW........ 8 .........S/N3744468 AND ABOVE
WASHER, LOCK ...................................... 8 .........S/N3744468 AND ABOVE
WASHER, FLAT ....................................... 8 .........S/N3744468 AND ABOVE
CHANGE-OVER BOARD, VOLTAGE
CHANGETERMINAL
HEX. HEAD BOLT
TERMINAL PLATE
CHANGE PLATE
HEX. HEAD BOLT
WASHER, LOCK
WASHER, FLAT
HEX. HEAD BOLT
HEX. NUT
1
10
20
7
6
17
20
20
4
4
4
WASHER, LOCK
WASHER, FLAT
4
APS UNIT ................................................ 1 .........REPLACES P/N 0602201245
HEX. HEAD BOLT
WASHER, LOCK
WASHER, FLAT
4
4
4
1
CONTROL PANEL (GEN-SIDE)
CONTROL PANEL (CB-SIDE) .................. 1 .........S/N3744467 AND BELOW
CONTROL PANEL (CB-SIDE) .................. 1 .........S/N3744468 AND ABOVE
RUBBER SEAL ........................................ 2 .........S/N3744467 AND BELOW
RUBBER SEAL ........................................ 2 .........S/N3744467 AND BELOW
PIN
4
1
1
1
1
FREQUENCY METER, 45~65 Hz
AC AMMETER, 0~1200A, 0~2400A
CHANGE-OVER SWITCH, AMMETER
AC VOLTMETER,0~600V
CHANGE-OVER SWITCH, VOLTMETER 1
PILOT LAMP
BULB
1
1
1
1
RHEOSTAT (VR), 2W 1K
KNOB
Ω
ECU9988N600/800 ENGINE CONTROLLER ........................... 1 .........REPLACES P/N's 0601827396
..............................................................................AND P/N 0602202545
52
0602120495
SEALED CABLE
1
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 79
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DCA-600SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 80 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — CONTROL BOX ASSY. (S/N 3692433 AND BELOW)
CONTROL BOX ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
53
82608
SWITCH ................................................... 1 .........S/N 3692434~3698616
..............................................................................REPLACES P/N 0601831340
SWITCH ................................................... 1 .........S/N 3698617 AND ABOVE
53
54
54
55
56
57
57
57
57
58
58
0601830765
0601810161
0601810214
0207004000
0601830710
C9221100004
0040008000
031108160
PANEL LIGHT
BULB
HEX. NUT
SWITCH, PANEL LIGHT
HEX. HEAD BOLT
WASHER, LOCK
WASHER, FLAT ....................................... 2 .........REPLACES P/N 0041208000
SNAP RING
HEX. HEAD BOLT
WASHER, LOCK
1
1
2
1
2
2
0080200007
C9221100004
0040008000
2
2
2
58
58
59
60
61
62
63
64
65
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
031108160
0080200007
3871824004
952404470
505015300
8481814503
011008020
8481812104
7971812104
C4215300004
0017108020
8481825104
8481825304
0017108020
012010030
0017108020
Z0110000904
020106050
0027105020
C5352800104
0017105015
0601810575
0601810576
0601831205
0601840009
WASHER, FLAT ....................................... 2 .........REPLACES P/N 0041208000
SNAP RING
STOPPER, CONTROL PANEL
2
2
WASHER, FLAT ....................................... 2 .........REPLACES P/N 0041206000
SNAP PIN ................................................ 2 .........REPLACES P/N 0605010502
COVER, CONTROL BOX
HEX. HEAD BOLT
SIDE PANEL, CONTROL BOX
1
10
1
REPLACES P/N 0017108020
SIDE PANEL, CONTROL BOX ................. 1 .........S/N 3744467 AND BELOW
SIDE PANEL, CONTROL BOX ................. 1 .........S/N 3744468 AND ABOVE
HEX. HEAD BOLT
12
1
1
PANEL, CONTROL BOX
PANEL, CONTROL BOX
HEX. HEAD BOLT
15
HEX. HEAD BOLT .................................... 5 .........REPLACES P/N 0017110030
HEX. HEAD BOLT
RESISTOR UNIT, 1/4W 560
HEX. NUT ................................................. 2 .........REPLACES P/N 0030006000
3
2
Ω
x 4
MACHINE SCREW
BRACKET
2
1
HEX. HEAD BOLT .................................... 4 .........REPLACES P/N 0017105016
PILOT LAMP, ENG. TROUBLE, DC24V
PILOT LAMP, ENG. TROUBLE, DC24V
RESET SWITCH
1
1
1
2
RHEOSTAT (DROOP & IDLE SPEED
CONTROLLER), 2W 5k
TERMINAL BOARD
MACHINE SCREW
HEX. HEAD BOLT
Ω
81
82
83
0601815802
0027104020
0801830904
1
2
3
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 81
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DCA-600SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 82 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO
84
85
86
87
87
87
88
88
89
89
90
91
PART NO
PART NAME
QTY.
REMARKS
0602120498
0601815402
0027104020
0601823732
0601823109
PYCA1
SPEED SENSOR
1
TERMINAL BOARD ................................. 1 .........S/N 3698617 AND ABOVE
MACHINE SCREW................................... 2 .........S/N 3698617 AND ABOVE
RELAY, LY2 DC24V .................................. 1 .........S/N 3744468 AND ABOVE
SOCKET, PTF08A.................................... 1 .........S/N 3744468 AND ABOVE
HOLDER ................................................... 1 .........REPLACES P/N 0601824400
ON LAMP (CIRCUIT BREAKER) ............. 1 .........S/N 3744468 AND ABOVE
BULB ........................................................ 1 .........S/N 3744468 AND ABOVE
OFF LAMP (CIRCUIT BREAKER) ........... 1 .........S/N 3744468 AND ABOVE
BULB ........................................................ 1 .........S/N 3744468 AND ABOVE
ON SWITCH (CIRCUIT BREAKER) ......... 1 .........S/N 3744468 AND ABOVE
OFF SWITCH (CIRCUIT BREAKER) ....... 1 .........S/N 3744468 AND ABOVE
0601810467
0601810235
0601810476
0601810235
0601831224
0601830498
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 83
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DCA-600SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 84 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO
1
2
PART NO
C4924200114
6162639171
PART NAME
QTY. REMARKS
ENGINE ..................................................... 1 .......SA6D170AE1
RADIATOR .................................................. 1 .......REPLACES 0602011986
INCLUDE ITEM W/
*
3
4
23S0311150M
CAP, RADIATOR......................................... 1 .......REPLACES 0602011058
RUBBER SHEET........................................ 2 .......REPLACES 0605000098
*
6995621350
0010118100
0030018000
0040018000
0041218000
8495123004
0010112025
0040012000
0041212000
0017110025
6995621690
6162639650
6162639640
0773050004
6128619530
6128619650
0728101029
0728100167
0728100489
6125817032
6008157190
6002111231
0727061510
6003117111
6004111030
7435112004
8485112004
0010118060
0030018000
0040018000
0041218000
0605000012
0030020000
030220510
5
6
7
8
HEX. HEAD BOLT
HEX. NUT
8
16
8
16
2
4
4
LOCKWASHER
PLAIN WASHER
BRACKET, RADIATOR
HEX. HEAD BOLT
PLAIN WASHER
PLAIN WASHER
HEX. HEAD BOLT
RADIATOR HOSE, UPPER ........................ 1........REPLACES 0602013953
RADIATOR HOSE, LOWER ....................... 1........REPLACES 0602014649
RADIATOR PIPE ........................................ 1........REPLACES 0602013305
DRAIN VALVE ............................................ 1........REPLACES 0602012054
RADIATOR HOSE ...................................... 1........REPLACES 0602013079
RADIATOR HOSE ...................................... 1........REPLACES 0602013954
HOSE BAND .............................................. 8........REPLACES 0602014350
HOSE BAND .............................................. 2........REPLACES 0602014059
HOSE BAND .............................................. 2........REPLACES 0602014351
ELEMENT, AIR CLEANER ......................... 2........REPLACES 0602040156
DUST SENSOR ......................................... 1........REPLACES 0602040647
CARTRIDGE, OIL FILTER ......................... 2........REPLACES 0602041146
HOSE ......................................................... 1........REPLACES 0602014648
CARTRIDGE, FUEL FILTER ...................... 2........REPLACES 0602042155
CARTRIDGE, CORROSION RESISTOR.... 1........REPLACES 0602045149
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
4
4
ENGINE FOOT
ENGINE FOOT
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
RUBBER SUSPENSION
HEX. NUT
1
2
6
6
6
6
4
8
LOCKWASHER ......................................... 8 .......REPLACES 0040020000
PUMP ......................................................... 1 .......GM-2524H
0602023161
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 85
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DCA-600SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 86 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
PART NO
PART NAME
QTY. REMARKS
0010108025
031108160
020108060
0131710060
0131708060
0130206000
0602022202
3502054124
0802024004
0191601350
0605515134
0602010230
8492082103
0229200700
0017106030
0021108020
020108060
0199601200
0194001600
0605515013
0728002023
0194201000
0605515014
8482256304
8482256104
0010118040
0040018000
0041218000
0017110025
0017112025
0412222568
6125817032
6162134911
6127814823
0728101589
6162837530
HEX. HEAD BOLT
4
PLAIN WASHER......................................... 4 .......REPLACES 0041208000
HEX. NUT ................................................... 4 .......REPLACES 0207008000
BUSHING
BUSHING
STREET ELBOW
HOSE JOINT
DRAIN JOINT
PACKING
HOSE
1
1
3
3
1
1
1
2
1
1
1
1
2
HOSE BAND
RESERVE TANK
BRACKET, RESERVE TANK
RUBBER CUSHON
HEX. HEAD BOLT
MACHINE SCREW
HEX. NUT ................................................... 1 .......REPLACES 0207008000
HOSE
1
1
3
HOSE
HOSE BAND
HOSE BAND .............................................. 1 .......REPLACES 0602014055
HOSE BAND
HOSE BAND
CLAMPER ROD
CLAMPER ROD
HEX. HEAD BOLT
LOCKWASHER
1
1
1
1
2
2
2
1
1
1
2
1
1
2
1
PLAIN WASHER
HEX. HEAD BOLT
HEX. HEAD BOLT
V-BELT SET
AIR CLEANER ASSY.
AIR CLEANER CONNECTOR
GASKET, AC CONNECTOR
CLAMP, HOSE A/C TO TURBO
HOSE, A/C TO TURBO
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 87
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DCA-600SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 88 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO
1
2
2
2
2
3
4
4
5
6
7
8
PART NO
PART NAME
QTY.
REMARKS
C4484000602
012212035
0030012000
0040012000
031112230
0017110025
C4352100503
C4352100513
011008020
011008020
8085182004
8085183004
011206020
0315262002
0805008804
0805008704
0021008070
0040008000
031108160
0601830780
0601850267
6008155390
SUPPORT LEG
1
HEX. HEAD BOLT .................................... 4 .........REPLACES 0010012035
HEX. NUT
LOCKWASHER
PLAIN WASHER....................................... 4 .........REPLACES 0041212000
HEX. HEAD BOLT
OPERATING PANEL ................................ 1 .........S/N 3692434 - 3698616
OPERATING PANEL ................................ 1 .........S/N 3698617 AND ABOVE
HEX. HEAD BOLT .................................... 4 .........REPLACES 0017108020
HEX. HEAD BOLT .................................... 6 .........REPLACES 0017108020
RUBBER COVER
SET FRAME, RUBBER COVER
HEX. HEAD BOLT .................................. 12 .........REPLACES 0017106020
BATTERY SWITCH .................................. 1 .........REPLACES 0602101012
SET PLATE, BATTERY SWITCH
STAY, BATTERY SWITCH
MACHINE SCREW
4
4
2
2
2
9
10
11
12
13
13
13
14
14
15
1
2
2
2
LOCKWASHER
PLAIN WASHER....................................... 2 .........REPLACES 0041208000
THROTTLE LEVER, ARNS1-2020 ........... 1 .........S/N 3692434 - 3693908
GROMMET............................................... 1 .........S/N 3693909 - 3698616
STARTER SWITCH .................................. 1 .........REPL. 0602100049
..............................................................................S/N 3692434 - 3698616
KEY, STARTER SWITCH ......................... 1 .........UP TO S/N 3698616
EMERGENCY STOP BUTTON ................ 1 .........REPLACES 0602104045
PREHEAT LAMP ...................................... 1 .........REPLACES 0602103043
TACHOMETER ......................................... 1 .........25000-KX4110
CABLE, TACHOMETER ........................... 1 .........62500-KA8610 L=3500
OIL PRESSURE GAUGE ......................... 1 .........42000KX1410
UNIT, OIL PRESSURE ............................. 1 .........53600KX0501
WATERTEMPERATURE GAUGE ............ 1 .........40000KX0910
UNIT, WATERTEMPERATURE ................ 1 .........51400KS0600
CHARGING AMMETER ........................... 1 .........43000KV0300
FUEL GAUGE .......................................... 1 .........41000KW0110
ENGINE WARNING DISPLAY .................. 1 .........V3376600000
ENGINE SPEED SWITCH, S-301T ......... 1 .........S/N 3698617~
PREHEATING SWITCH ........................... 1 .........0806130070 S/N 3698617~
GROMMET............................................... 1 .........UP TO S/N 3693908
GROMMET............................................... 2 .........S/N 3693908~
15A
16
17
18
19
20
21
22
23
24
25
26
27
28
29
29
615
0806410000
0814721200
0602120054
0602120165
0602122060
0602122203
0602123061
0602123206
0602121052
0602125060
0602115014
0601830710
0602210649
0601850267
0601850267
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 89
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DCA-600SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
PAGE 90 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO
1
2
3
4
4
4
4
5
5
5
5
6
6
6
6
7
PART NO
PART NAME
QTY. REMARKS
C4231700603
7521860504
7521850504
0010112040
0030012000
0040012000
031112230
012212045
0030012000
0040012000
0041212000
0010112040
0030012000
0040012000
031112230
0801830404
0801830904
0039320000
030220510
0041420000
0010112050
0030012000
0040012000
031112230
0601850275
0601815324
0027104020
C4237101304
7971867114
7521865804
0019106020
0042306000
0042406000
0605010660
0207006000
012212045
031112230
0805009804
SET BOARD, OUTPUT TERMINAL
OUTPUTTERMINAL
BRACKET, OUTPUT TERMINAL
HEX. HEAD BOLT
1
4
4
8
8
8
HEX. NUT
LOCKWASHER
PLAIN WASHER....................................... 16 .......REPLACES 0041212000
HEX. HEAD BOLT ...................................... 8 .......REPLACES 0010112045
HEX. NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
8
8
16
24
24
24
LOCKWASHER
PLAIN WASHER....................................... 48 .......REPLACES 0041212000
TERMINAL
HEX. HEAD BOLT
HEX. NUT
1
1
2
8
9
10
11
12
12
12
12
13
14
15
16
17
18
19
19
19
20
21
22
23
24
LOCKWASHER ......................................... 3 .......REPLACES 0040020000
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
4
6
6
6
LOCKWASHER
PLAIN WASHER....................................... 12 .......REPLACES 0041212000
GROMMET
1
1
2
1
1
1
5
5
5
2
2
TERMINAL BOARD
MACHINE SCREW
COVER, OUTPUT TERMINAL
RUBBER SHEET
SET PLATE, RUBBER SHEET
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
KNOB
HEX. NUT
HEX. HEAD BOLT ...................................... 4 .......REPLACES 0010112045
PLAIN WASHER......................................... 4 .......REPLACES 0041212000
STAY RUBBER
4
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 91
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DCA-600SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
PAGE 92 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO
25
26
27
27
27
28
29
30
30
31
31
32
32
32-1
32-1
33
34
35
36
36
36
37
38
PART NO
PART NAME
HEX. NUT
STOPPER
QTY. REMARKS
0030012000
7521865603
0010108030
020108060
4
1
1
HEX. HEAD BOLT
HEX. NUT ................................................... 1 .......REPLACES 0030008000
PLAIN WASHER......................................... 2 .......REPLACES 0041208000
COVER
0041208000
C4237100504
011008020
1
HEX. HEAD BOLT ...................................... 5 .......REPLACES 0017108020
CIRCUIT BREAKER 265V, 20A ................. 2 .......S/N 3744467 AND BELOW
CIRCUIT BREAKER 1P, 20A ..................... 2 .......S/N 3744468 AND ABOVE
CIRCUIT BREAKER 265V, 50A ................. 3 .......S/N 3744467 AND BELOW
CIRCUIT BREAKER 2P, 50A ..................... 3 .......S/N 3744468 AND ABOVE
BRACKET, CIRCUIT BREAKER ................ 1 .......S/N 3744467 AND BELOW
BRACKET, CIRCUIT BREAKER ................ 1 .......S/N 3744468 AND ABOVE
RUBBER CUSHION ................................... 1 .......S/N 3744467 AND BELOW
RUBBER CUSHION ................................... 1 .......S/N 3744468 AND ABOVE
0601805313
0601808803
0601805840
0601808804
C4261601203
C4261601403
0223300200
0221200150
0017106030
0601812597
0601811034
0021304015
0030004000
031104080
HEX. HEAD BOLT
2
RECEPTACLE, GF-530EM......................... 2 .......REPLACES 0601812598
RECEPTACLE, CS6369 ............................. 3 .......REPLACES 0601812565
MACHINE SCREW................................... 10 .......REPLACES 0027104015
HEX. NUT
PLAIN WASHER....................................... 10 .......REPLACES 0041204000
COVER
GROMMET................................................. 2 .......S/N 3700697 AND BELOW
10
C423711203
0601851780
1
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 93
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DCA-600SSK — BATTERY ASSY.
BATTERY ASSY.
PAGE 94 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — BATTERY ASSY.
BATTERY ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
REMARKS
0168719052
0805018904
0805007804
0805006504
0037808000
0040008000
031108160
8482280104
8482280304
7432280504
7432280904
7432281104
0347010030
0208110000
0845040114
0845041004
0602220205
BATTERY
2
2
2
4
4
4
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
WING NUT
LOCKWASHER
PLAIN WASHER....................................... 4 .........REPLACES 0041208000
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
EARTH CABLE
HEX. HEAD BOLT
HEX. NUT
TERMINAL CAP (+)
TERMINAL CAP (-)
BATTERY SENSOR
1
1
1
1
1
4
4
2
2
1
9
10
11
12
13
14
15
16
17
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 95
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DCA-600SSK — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 96 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — MUFFLER ASSY.
MUFFLER ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
MUFFLER
HEX. HEAD BOLT
PACKING
PACKING
PACKING
HEX. HEAD BOLT
LOCKWASHER
HEX. HEAD BOLT
HEX. HEAD BOLT
QTY.
1
REMARKS
8482311002
0019210020
7432356504
7432356604
7432356704
0019110030
0042310000
0042410000
0019108030
030208200
031108160
C4334000513
0010116060
0010116050
0030016000
0040016000
0041216000
7472355003
C3334200704
0010112050
0030012000
0040012000
031112230
8225125604
011008020
020108060
C4334200504
4
2
1
1
14
14
14
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
LOCKWASHER ....................................... 8 .........REPLACES 0042308000
PLAIN WASHER....................................... 8 .........REPLACES 0042308000
EXHAUST PIPE
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
OUTLET PIPE
GASKET
HEX. HEAD BOLT
HEX. NUT
1
8
8
8
16
24
1
1
4
4
4
LOCKWASHER
PLAIN WASHER....................................... 8 .........REPLACES 0041212000
COVER
HEX. HEAD BOLT .................................... 4 .........REPLACES 0017108020
HEX. NUT ................................................. 4 .........REPLACES 0207008000
2
GASKET
2
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 97
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DCA-600SSK — FUELTANK ASSY.
FUEL TANK ASSY
PAGE 98 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — FUELTANK ASSY.
FUEL TANK ASSY.
NO
1
1
2
2A
3
4
5
6
7
PART NO
PART NAME
QTY.
REMARKS
C4364000703
C4364000713
0605505030
0601850590
0810105400
0264100385
0605515079
7435523104
0805003414
011008020
FUELTANK .............................................. 1 .........S/N UP TO 3692433
FUELTANK .............................................. 1 .........S/N 3692434~
CAP, FUEL TANK ..................................... 1 .........REPLACES 0605505005
KEY .......................................................... 1 .........REPLACES 0601850505
FUEL FILTER
HOSE, FUEL GAUGE
HOSE BAND
TANK BAND
1
1
2
2
4
PAD, TANK BAND
8
9
HEX. HEAD BOLT .................................... 2 .........REPLACES 0017108020
HEX. NUT ................................................. 2 .........REPLACES 0037908000
020108060
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
0222100600
0130206000
7435517114
7525516504
0019108030
0205008000
030208200
TANK SHEET
STREET ELBOW, 1/2
DRAIN PIPE
BRACKET
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER ....................................... 2 .........REPLACES 0042308000
PLAIN WASHER....................................... 4 .........REPLACES 0042408000
VALVE
6
1
1
1
2
2
031108160
0603325011
0132006000
7435512104
0605511033
0602022209
0602022203
7435514304
0191403850
0191301100
0191104000
0191001800
0605515073
0605515000
0605503009
0802120604
0605501050
0602021155
0027104010
0845039604
1
3
2
2
1
1
2
1
1
1
1
6
2
1
1
PLUG, 1/2
LONG NIPPLE
THREE WAY VALVE
HOSE JOINT
HOSE JOINT
HOSE JOINT
SUCTION HOSE
SUCTION HOSE
RETURN HOSE
RETURN HOSE
HOSE BAND
HOSE BAND
FUEL SENSOR
PACKING
UNIT, FUEL .............................................. 1 .........52000KA9810
PACKING.................................................. 1 .........52391KW3700
MACHINE SCREW
RUBBER SEAL
5
1
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 99
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DCA-600SSK — ENCLOSURE #1 ASSY.
ENC
INDICATES DEFAULT COLOR
ITH DIFFERENT COLOR,
NG LETTERS WITH THE PART
R-GRAY
MQGRN-GREEN
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 100 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
NO
1
1
2
3
4
5
6
PART NO
PART NAME
QTY.
REMARKS
C4414000102
C4414000112
3875116304
7435116104
011008020
8495118003
011008020
BASE ....................................................................... 1 ......... S/N 3744467 AND BELOW
BASE ....................................................................... 1 ......... S/N 3744468 AND ABOVE
FLOOR PANEL
FLOOR PANEL
HEX. HEAD BOLT .................................................. 18 ......... REPLACES 0017108020
GUIDE PANEL, AIR
HEX. HEAD BOLT .................................................... 4 ......... REPLACES 0017108020
1
1
1
7
7
8
8
9
9
C4424002303
C4494100203
C4424000403
C4494100203
C4424000302
C4494100203
C4424000202
C4494100203
011008020
C4424700004
C4494100203
C4424300203
C4494100203
C4424300003
C4494100203
011008020
0019210025
8485125203
8485125104
8465924104
011008020
0845042703
0019208020
7525125304
0019206016
8475125003
011008020
0600500090
0021106020
C4434000112
C4434000122
0010120075
0030020000
0030020000
0041220000
0010120065
0030020000
030220510
FRONT FRAME
LINING
FRONT FRAME
LINING
FRONT FRAME
LINING
FRONT FRAME
LINING
1
1
1
1
1
1
1
1
10
10
11
12
12
13
13
14
14
15
16
17
18
18
19
20
21
22
23
24
25
26
27
28
28
29
29
29
29
30
30
30
30
31
32
32
33
34
35
36
37
38
39
HEX. HEAD BOLT .................................................. 26 ......... REPLACES 0017108020
GUIDE PANEL, AIR
LINING
GUIDE PANEL, AIR
LINING
GUIDE PANEL, AIR
LINING
1
1
1
1
1
1
HEX. HEAD BOLT .................................................. 30 ......... REPLACES 0017108020
HEX. HEAD BOLT
COVER, FRONT FRAME
COVER, FRONT FRAME
LINING
HEX. HEAD BOLT .................................................. 32 ......... REPLACES 0019208020
FILLER BRACKET
HEX. HEAD BOLT .................................................... 4 ......... REPLACES 0019208020
COVER
HEX. HEAD BOLT
COVER FRONT FRAME
8
1
1
1
1
1
6
1
HEX. HEAD BOLT .................................................. 12 ......... REPLACES 0019208020
EMBLEM
MACHINE SCREW
1
2
CENTER FRAME .................................................... 1 ......... S/N 3744467 AND BELOW
CENTER FRAME .................................................... 1 ......... S/N 3744468 AND ABOVE
HEX. HEAD BOLT
HEX. NUT
LOCK WASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCK WASHER ....................................................... 8 ......... REPLACES 0040020000
PLAIN WASHER
COVER
HEX. HEAD BOLT .................................................. 12 ......... REPLACES 0017108020
HEX. NUT .............................................................. 12 ......... REPLACES 0207008000
ROOF PANEL
ROOF PANEL
ROOF PANEL
HEX. NUT .............................................................. 14 ......... REPLACES 0207008000
FILLER COVER
6
6
6
12
8
8
0041220000
C4434200013
011008020
16
2
020108060
8495161103
C4464100003
C4464100103
020108060
0800251701
0019206016
011008020
1
1
1
1
2
HEX. HEAD BOLT
HEX. HEAD BOLT .................................................. 30 ......... REPLACES 0019208020
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 101
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DCA-600SSK — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
COLOR
OR,
HE PART
NUMBER:
MQGR-GRAY
MQGRN-GREEN
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 102 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
NO
1
2
3
3
3
4
5
6
PART NO
PART NAME
QTY. REMARKS
1
1
21
21
21
1
1
1
18
C4444000003
3875151004
0205006000
0042306000
0042406000
C4444000103
C4444000203
C4444000303
0017110025
011008020
REAR FRAME
LOUVER PANEL
HEX. NUT
LOCKWASHER
PLAIN WASHER
REAR FRAME
REAR FRAME
REAR FRAME
HEX. HEAD BOLT
7
8
HEX. HEAD BOLT ...................................... 5 .......REPLACES 0017108020
9
0019210025
7975155003
3875944104
3875151104
0205006000
0042306000
0042406000
7975156004
8495946104
011008020
HEX. HEAD BOLT
COVER, REAR FRAME
LINING
LOUVER PANEL
HEX. NUT
LOCKWASHER
PLAIN WASHER
DUCT COVER
LINING
HEX. HEAD BOLT .................................... 17 .......REPLACES 0017108020
HEX. HEAD BOLT .................................... 23 .......REPLACES 0019208020
VISOR
VISOR
4
1
1
10
10
11
12
12
12
13
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
21
32
33
33
1
16
16
16
1
1
011008020
C4444300703
3875165803
011008020
7975143003
7975143113
3875147204
3875147304
020106050
B9114000102
0021806016
7975146004
7975146104
0845050704
0207006000
0805011304
0805011204
0207006000
M9110100204
0845045004
1
1
HEX. HEAD BOLT .................................... 12 .......REPLACES 0019208020
DOOR, REAR FRAME
DOOR, REAR FRAME
WINDOW PLATE
1
1
1
1
WINDOW PLATE
HEX. NUT ................................................. 12 .......REPLACES 0207306000
DOOR HANDLE
MACHINE SCREW
DOOR ROD
DOOR ROD
STAY
1
4
1
1
4
8
1
1
4
HEX. NUT
STOPPER, DOOR
STOPPER, DOOR
HEX. NUT
HINGE ........................................................ 2 .......REPLACES 0845047104
WASHER
2
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 103
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DCA-600SSK — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR,
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART
NUMBER:
MQGR-GRAY
MQGRN-GREEN
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 104 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
NO
34
34
35
36
37
38
39
40
41
41
42
42
43
43
44
45
45
46
47
48
49
49
50
51
52
53
54
PART NO
PART NAME
HINGE ....................................................... 2.........REPLACES 0845047204
WASHER
HEX. HEAD BOLT ..................................... 6.........REPLACES 0019208020
QTY.
REMARKS
M9110100340
0845045004
011008020
2
0845031504
0601850097
011208025
CAP
STOPPER
4
2
MACHINE SCREW.................................... 2.........REPLACES 0021008025
0600500090
0021106020
C4464200303
8485960104
C4464200403
8485960104
C4464200503
8485960104
C4464500304
C4464500204
8485960104
020108060
C4464500404
011008020
8485166004
8485968104
011008020
EMBLEM
MACHINE SCREW
ROOF PANEL
LINING
ROOF PANEL
LINING
ROOF PANEL
LINING
GUIDE
1
2
1
1
1
1
1
1
1
1
1
PANEL
LINING
HEX. NUT ................................................ 27.........REPLACES 0207008000
PANEL
HEX. HEAD BOLT ................................... 11.........REPLACES 0017108020
1
COVER, ROOF PANEL
LINING
1
1
HEX. HEAD BOLT ..................................... 9.........REPLACES 0017108020
HEX. HEAD BOLT ................................... 30.........REPLACES 0019208020
011008020
0019210025
B9114500104
0207006000
HEX. HEAD BOLT
DOOR POCKET
HEX. NUT
4
1
4
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 105
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DCA-600SSK — ENCLOSURE #3 ASSY.
ENCLOSURE #3 ASSY.
THE PART NUMBER ABOVE INDICATES DEFAULT COLOR
OF ORANGE. TO ORDER WITH DIFFERENT COLOR,
PLEASE ADD THE FOLLOWING LETTERS WITH THE PART
NUMBER:
MQGR-GRAY
MQGRN-GREEN
MQW-WHITE
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 106 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — ENCLOSURE #3 ASSY.
ENCLOSURE #3 ASSY.
NO
1
PART NO
PART NAME
QTY. REMARKS
C4454201603
C4454201613
C4454201623
0019110070
0042310000
0042410000
8495172003
8495972104
8495172103
8495972304
8495172203
8495972504
8495172303
8495972704
0019108070
030208200
SPLASHER PANEL ..................... 1 ....... S/N 3692434 - 3700696
SPLASHER PANEL ..................... 1 ....... S/N 3700696 - 3744467
SPLASHER PANEL ..................... 1 ....... S/N 3744468 AND ABOVE
1
1
2
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
SIDE PANEL
LINING
6
6
2
2
6
3
1
3
1
4
SIDE PANEL
LINING
1
4
1
5
SIDE PANEL
LINING
1
5
1
6
SIDE PANEL
LINING
1
6
1
7
HEX. HEAD BOLT
16
7
LOCKWASHER ..........................16 ....... REPLACES 0042308000
PLAIN WASHER .........................16 ....... REPLACES 0042408000
7
031108160
8
8485171003
8485970103
8485171103
8485970303
7975171403
7975171413
8485970503
7975171203
7975970704
7525151504
7525151404
7975151004
0205006000
0042306000
0042406000
8485176004
8485976104
7865176004
7865976104
8465176004
8465176014
8465976104
011008020
SIDE DOOR
LINING
SIDE DOOR
LINING
1
1
1
1
8
9
9
10
10
10
11
11
12
13
14
15
15
15
16
16
17
17
18
18
18
19
20
21
22
23
23
24
24
25
26
27
28
29
SIDE DOOR ................................. 1 ....... S/N 3692434 - 3696513
SIDE DOOR ................................. 1 ....... S/N 3696514 AND ABOVE
LINING
SIDE DOOR
LINING
LOUVER PANEL
LOUVER PANEL
LOUVER PANEL
HEX. NUT
1
1
1
1
1
1
28
28
28
1
LOCKWASHER
PLAIN WASHER
DUCT
LINING
1
DUCT
1
LINING
1
DUCT ........................................... 1 ....... S/N 3692434 - 3696513
DUCT ........................................... 1 ....... S/N 3696514 AND ABOVE
LINING
1
HEX. HEAD BOLT.......................22 ....... REPLACES 0017108020
0825007362
B9114000002
0021806016
0845046904
0845045004
0845047004
0845045004
011008020
DOOR HANDLE
DOOR HANDLE
MACHINE SCREW
HINGE
3
4
28
8
WASHER
8
HINGE
8
WASHER
8
HEX. HEAD BOLT.......................39 ....... REPLACES 0019208020
0845031504
0601850097
011208025
CAP
STOPPER
16
10
MACHINE SCREW ...................... 9 ....... REPLACES 0021008025
0021008020
MACHINE SCREW
1
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 107
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DCA-600SSK — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
PAGE 108 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
6
REMARKS
0228901640
0228900970
0228901100
0228900990
0229201650
0228800860
0228801380
0229200780
0229201490
0229200595
0229201490
0228100280
0228100520
0228100150
0228100580
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
4
4
2
2
2
2
2
1
2
1
2
2
2
2
9
10
11
12
13
14
15
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 109
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DCA-600SSK — NAMEPLATE AND DECALS
NAME PLATE AND DECALS
PAGE 110 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — NAMEPLATE AND DECALS
NAME PLATE AND DECALS
NO
PART NO
PART NAME
QTY.
REMARKS
CONTROL BOX GROUP
1
Z0110001204 DECAL:DROOP, Z011000120
1
UP TO S/N 3693908
2
3
Z0110001304 DECAL: IDLE SPEED ................................................ 1 ........ Z011000130
Z0110001504 DECAL: RESET ......................................................... 1 ........ Z011000150
4
5
6
7
8
9
10
11
12
13
0800520100
0800520904
0800520814
0840624504
0840624604
0840624704
0840624804
PLATE; ON-OFF........................................................ 1 ........ AT-202
PLATE; AMMETER CHANGE-OVER SWITCH .......... 1 ........ N-2438
PLATE;VOLTMETER CHANGE-OVER SWITCH ....... 1 ........ N-2439
DECAL; CIRCUIT BREAKER ..................................... 1 ........ S-3031
DECAL; PANEL LIGHT............................................... 1 ........ S-3032
DECAL; PILOT LAMP ................................................ 1 ........ S-3033
DECAL;VOLTAGE REGULATOR................................ 1 ........ S-3034
B9531100604 DECAL;WARNING ELECTRIC SHOCK HAZARD ..... 1 ........ B93110060
C9521203003 DECAL; SETTING FOR OUTPUT VOLTAGE ............. 1 ........ C92120300
C4561101803 DECAL;WHISPERWATT 600 ..................................... 1 ........ C46110180
ENGINE OPERATING PANEL GROUP
14
15
16
17
18
19
20
21
22
0800588004
0800682004
0840655804
0840625004
0800686004
9039208704
0840655004
0840631204
9039208694
DECAL: THROTTLE LEVER ..................................... 1 ........ N-3808
DECAL: BATTERY SWITCH ..................................... 1 ........ S-874
DECAL: STARTER SWITCH ..................................... 1 ........ S-4515
DECAL: PREHEAT LAMP ......................................... 1 ........ S-3036
DECAL: STOP BUTTON ........................................... 1 ........ S-878
DECAL: ENGINE SPEED ......................................... 1 ........ S-4452
DECAL: HEATER SWITCH ....................................... 1 ........ S-4506
DECAL: RED CIRCLE ............................................... 1 ........ S-3346
DECAL: HIGH-LOW .................................................. 1 ........ S-4451
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 111
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DCA-600SSK — NAMEPLATE AND DECALS
NAME PLATE AND DECALS
PAGE 112 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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DCA-600SSK — NAMEPLATE AND DECALS
NAME PLATE AND DECALS
NO
PART NO
PART NAME
QTY.
REMARKS
PROCEDURE GROUP
23
24
C4551001002 DECAL: HANDLING PROCEDURES ........................ 1 ........ C45100100
8490611303
DECAL: PROCEDURES FOR START UP................. 1 ........ S-4519
ENGINE & RADIATOR GROUP
25
26
27
28
29
30
31
32
0800616204
0800689204
6360610304
0840611903
DECAL: WATER DRAIN COCK ................................. 1 ........ S-705
DECAL: COOLINGWATER ....................................... 1 ........ S-961
DECAL: WATER ........................................................ 1 ........ S-1880
DECAL: PRECAUTIONS ON HANDLING ................. 1 ........ S-2570
B9504000404 DECAL: WARNING MOVING PARTS ........................ 2 ........ B90400040
B9504100104 DECAL: WARNING HOT COOLANT.......................... 1 ........ B90410010
0966810000
6162937111
DECAL: WARNING .................................................... 1 ........ REPLACES 0600501100
DECAL: FUEL PRIMING ........................................... 1 ........ REPLACES 0600500011
OUTPUTTERMINAL GROUP
33
34
35
36
37
38
39
40
41
C0551000404 DECAL; 3-PHASE OUTPUT TERMINAL.................... 1 ........ C05100040
0840614104
9039202064
0840655704
DECAL; GROUND ...................................................... 1 ........ S-2635
DECAL; START CONTACT......................................... 1 ........ S-4468
DECAL; TERMINAL COVER STOPPER .................... 1 ........ S-4516
B4551000103 DECAL; RECEPTACLE & CIRCUIT BREAKER ......... 1 ........ B45100010
B9511100304 DECAL;WARNING ..................................................... 1 ........ B91110030
B9511100404 DECAL;WARNING ELECTRIC SHOCK HAZARD ..... 1 ........ B91110040
B9531100504 DECAL;WARNING ELECTRIC SHOCK HAZARD ..... 1 ........ B93110050
C1551000404 DECAL; 240/139VOLT ............................................... 2 ........ C15100040
BATTERY GROUP
42
43
0800689404
0800689504
DECAL: + .................................................................. 2 ........ S-2090
DECAL: - ................................................................... 1 ........ S-2091
MUFFLER ASSY.
44
45
B9504200004 DECAL;WARNING ENGINE EXHAUST .................... 1 ........ B90420000
B9511100204 DECAL: CAUTION HOT SURFACES ........................ 1 ........ B91110020
FUELTANK GROUP
46
47
48
49
50
51
0800688404
0800688504
1320620904
6360620004
0840607104
DECAL; FUEL INLET ................................................. 1 ........ S-1344
DECAL; FUEL OUTLET ............................................. 1 ........ S-1345
DECAL; DIESEL FUEL .............................................. 1 ........ S-1756
DECAL; FUEL DRAIN PLUG...................................... 1 ........ S-1883
DECAL; FUEL GAUGE............................................... 1 ........ S-2365
B9504500004 DECAL;WARNING DIESEL FUEL ............................. 1 ........ B90450000
ENCLOSURE GROUP
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
0800615102
1320610603
1320621504
0840625902
DECAL; CAUTION AGAINST OIL AND ..................... 1 ........ S-544A
DECAL;WATER-OIL................................................... 1 ........ S-1760
DECAL; SUPPORT HOOK......................................... 2 ........ S-2257
DECAL; MQ ............................................................... 1 ........ S-3057
B9504000304 DECAL; CAUTION HOT PARTS ................................. 1 ........ B90400030
B9521100404 DECAL; SAFETY INSTRUCTIONS ............................ 1 ........ B92110040
B9531100604 DECAL;WARNING ELECTRIC SHOCK HAZARD ..... 1 ........ B93110060
C4561101603 STRIPE
C4561101503 STRIPE
C4561101303 STRIPE
C4561101204 STRIPE
C4561101704 STRIPE
C4561101104 STRIPE
C4561101403 STRIPE
C4561101003 STRIPE
C4561100904 STRIPE
1
1
1
2
2
2
1
1
2
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 113
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TERMS AND CONDITIONS OF SALE — PARTS
Effective: October 1, 2002
PAYMENT TERMS
5. Parts must be in new and resalable
condition,intheoriginalMultiquippack-
age (if any), and with Multiquip part
numbersclearlymarked.
Multiquip reserves the right to quote and sell
directtoGovernmentagencies,andtoOriginal
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
Terms of payment for parts are net 10 days.
FREIGHTPOLICY
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifesthasbeenobtainedfromthecarrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
6. Thefollowingitemsarenotreturnable:
SPECIALEXPEDITINGSERVICE
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
A$35.00surchargewillbeaddedtotheinvoice
forspecialhandlingincludingbusshipments,
insuredparcelpostorincaseswhereMultiquip
mustpersonallydeliverthepartstothecarrier.
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
priortothereturndate.
LIMITATIONSOFSELLER’SLIABILITY
MINIMUMORDER
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
itemwithrespecttowhichdamagesareclaimed,
andinnoeventshallMultiquipbeliableforloss
of profit or good will or for any other special,
consequentialorincidentaldamages.
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
c. Anylineitemwithanextendeddealer
netpriceoflessthan$5.00.
RETURNEDGOODSPOLICY
d. Special order items.
Returnshipmentswillbeacceptedandcredit
willbeallowed,subjecttothefollowingprovi-
sions:
LIMITATIONOFWARRANTIES
e. Electricalcomponents.
f. Paint,chemicals,andlubricants.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
Nowarranties,expressorimplied,aremadein
connectionwiththesaleofpartsortradeacces-
soriesnorastoanyenginenotmanufactured
byMultiquip.Suchwarrantiesmadeinconnec-
tion with the sale of new, complete units are
madeexclusivelybyastatementofwarranty
packagedwithsuchunits,andMultiquipnei-
ther assumes not authorizes any person to
assume for it any other obligation or liability
whatever in connection with the sale of its
products.Apartfromsuchwrittenstatementof
warranty, there are no warranties, express,
impliedorstatutory,whichextendbeyondthe
descriptionoftheproductsonthefacehereof.
1. AReturnedMaterialAuthorizationmust
be approved by Multiquip prior to ship-
ment.
7. The sender will be notified of any
materialreceivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Salesthatdefinesitemnumbers,quanti-
ties, and descriptions of the items to be
returned.
8. Such material will be held for five
workingdaysfromnotification,pending
instructions. If a reply is not received
within five days, the material will be
returnedtothesenderathisexpense.
a. Thepartsnumbersanddescriptions
must match the current parts price
list.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. Incaseswhereanitemisaccepted,for
which the original purchase document
cannotbedetermined,thepricewillbe
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. The list must state the reason(s) for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhichthe
itemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. The list must include the name and
phonenumberofthepersonrequest-
ingtheRMA.
PRICINGANDREBATES
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspe-
cific date and all orders received on or after
that date will be billed at the revised price.
Rebatesforpricedeclinesandaddedcharges
forpriceincreaseswillnotbemadeforstock
onhandatthetimeofanypricechange.
3. AcopyoftheReturnMaterialAuthoriza-
tionmustaccompanythereturnshipment.
4. Freight is at the sender’s expense. All
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
PAGE 114 — DCA-600SSK — OPERATION AND PARTS MANUAL (STD) — REV. #7 (04/30/10)
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NOTE PAGE
DCA-600SSK — OPERATION AND PARTS MANUAL (STD)— REV. #7 (04/30/10) — PAGE 115
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OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
MULTIQUIP CORPORATE OFFICE
18910 Wilmington Ave
Carson, CA 90746
Tel. (800) 421-1244
Fax (800) 537- 3927
Contact: [email protected]
Web: www.multiquip.com
MQ Power
1800 Water Ridge Rd.
Suite 500/600
Lewisville, TX 75057
Tel. (800) 883-2551
Fax (972) 315-1847
Contact: [email protected]
Web: www.mqpower.com
MQ Parts Department
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service/Tech Support/Warranty
800-835-2551 Fax: 310-638-8046
© COPYRIGHT 2010, MULTIQUIP INC.
MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the
property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times.This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
Further, MQ Power disclaims any warranties or guaranties, expressed or implied, with regards to the information contained in this manual.
Manufactured for
Multiquip Inc.
by
DENYO CO., LTD, JAPAN
Your Local Dealer is:
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