MQ Power DCA-300SSK III Series, Parts And Operation Manual

Page 1: ...A FEMA FEMA PARTS AND OPERATION MANUAL Revision 1 06 02 03 MULTIQUIPINC PARTS DEPARTMENT 18910 WILMINGTON AVE 800 427 1244 CARSON CALIFORNIA 90746 FAX 800 672 7877 310 537 3700 SERVICE DEPARTMENT 800 421 1244 800 835 2551 FAX 310 537 3927 FAX 310 638 8046 E mail mq multiquip com www multiquip com COPYRIGHT 2003 MULTIQUIP INC PARTS LIST NO C2871300704 SERIAL NO 3708297 ...

Page 2: ...PAGE 2 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 ...

Page 3: ...E HAVE THE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SERVICE DEPARTMENT 800 421 1244 FAX 310 537 4259 TECHNICAL ASSISTANCE 800 478 1244 FAX 310 631 5032 WARRANTY DEPARTMENT 888 661 4279 or 310 661 4279 FAX 310 537 1173 ...

Page 4: ...onnections 30 31 Pre Setup 32 35 Generator Start up Procedure Manual 36 38 Generator Start up Procedure MPEC Auto 39 Generator Shutdown Procedure 40 Maintenance 42 46 GeneratorWiring Diagram 47 EngineWiring Diagram 48 EngineTroubleshooting 49 50 GeneratorTroubleshooting 51 Engine ControllerTroubleshooting MPEC 52 Explanation of Codes in Remarks Column 54 Suggested Spare Parts 55 COMPONENT DRA COMP...

Page 5: ...Ext 279 Multiquip s Main Phone Numbers 800 421 1244 Fax 310 537 3927 310 537 3700 Note Unlessotherwiseindicatedbycustomer all orders are treated as Standard Orders and will ship within 24 hours We will make every effort to ship AirShipments thesamedaythattheorderis received ifpriorto2PMwestcoasttime Stock Orders must be so noted on fax or web forms Extra Discounts All parts orders which include co...

Page 6: ...d n u s u o n o r h c o s I n o i t a l u g e R y c n e u q e r F e t a t S y d a e t S d a o l l l u f o t d a o l o n m o r f s d a o l t n a t s n o c r o f e u l a v n a e m f o 5 2 0 n o i t a l u s n I F s s a l C A B d l e v e L d n u o S t e e f 3 2 t a d a o l l l u F 1 7 x o r p p A s n o i s n e m i D H x W x L m m 0 8 1 x 2 4 1 x 9 8 3 n i 1 7 x 6 5 x 3 5 1 t h g i e W t e N y r D g k ...

Page 7: ...DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 PAGE 7 NOTE PAGE ...

Page 8: ...PAGE 8 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 Figure 1 Dimensions Side and Top Views DCA 300SSK III DIMENSIONS TOP AND SIDE ...

Page 9: ...DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 PAGE 9 Figure 2 Dimensions Rear and Front Views DCA 300SSK III DIMENSIONS FRONT AND REAR ...

Page 10: ...CAUTION CAUTION You CAN be injured if you DO NOT follow directions HAZARD SYMBOLS Potential hazards associated with the DCA 300SSK III generators operation will be referenced with Hazard Symbols which appear throughout this manual and will be referenced in conjunction with Safety Message Alert Symbols Rotating Parts NEVER operate equipment with covers or guards removed Keep fingers hands hair and ...

Page 11: ...plosion or fire could result causing severe bodily harm or even death High Temperatures Allow the engine to cool before performing service and maintenance functions Contact with hot components can cause serious burns 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 a...

Page 12: ...generator and place the main circuit breaker in the OFF position when contact with the output terminals is required There exists the possibility of electrocution electrical shock or burn which can cause severe bodily harm or even death 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 termi...

Page 13: ...bustible gas will occur 4 ALWAYS keep battery charging and cables in good working condition Repair or replace all worn cables 5 ALWAYS recharge the battery in an vented air environment to avoid risk of a dangerous concentration of combustible gases 6 In case the battery liquid dilute sulfuric acid comes in contact with clothing or skin rinse skin or clothing immediately with plenty of water 7 In c...

Page 14: ...PAGE 14 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 Figure 3 Typical Generator Grounding Application DCA 300SSK III INSTALLATION ...

Page 15: ...etheenginetoheatexcessively and possibly burn the valves 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 Th...

Page 16: ...00SSK III generator is equipped with a number of safety decals These decals are provided for operator safety and maintenance information The illustration below and on the preceding pages show the decals as they appear on the machine Should any of these decals become unreadable replacements can be obtained from your dealer ...

Page 17: ...DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 PAGE 17 DCA 300SSK III OPERATION AND SAFETY DECALS ...

Page 18: ...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 There are four connections of the open delta A B C and D Duringsteadystateloads thepowerfromthevoltageregulator is supplied from the parallel connections of A to B A to D and C to D These three...

Page 19: ... a r e n e G O N M E T I N O I T P I R C S E D 1 y l b m e s s A r e l f f u M 2 y l b m e s s A e n i g n E 3 y l b m e s s A e r u s o l c n E 4 y l b m e s s A r o t a r e n e G 5 y l b m e s s A l a n i m r e T t u p t u O 6 y l b m e s s A y r e t t a B 7 y l b m e s s A l e n a P l o r t n o C r o t a r e n e G 8 y l b m e s s A l e n a P g n i t a r e p O e n i g n E ...

Page 20: ...PAGE 20 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III GENERATOR CONTROL PANEL Figure 6 Generator Control Panel ...

Page 21: ... 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 Also the engine controller 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...

Page 22: ...PAGE 22 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III ENGINE OPERATING PANEL Figure 7 Engine Operating Panels ...

Page 23: ...eat lamp is lit ON 10 Emergency Stop Button Push this button inward to stop the engine in the event of an emergency DO NOT use this button as a means of stopping the engine 11 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...

Page 24: ...rovided with the following z Three 240 139V output receptacles 50 amp z Three circuit breakers 240V 50 amps z Two 120V GFCI receptacles 20 amp z Two 2 GFCI circuit breakers 120V 20 amps z Eight 8 output terminal lugs Output Terminal Panel Shown below Figure 8 is the OutputTerminal Panel lift up on the cover to gain access to receptacles and terminal lugs NOTE Terminal legs O and Ground are conside...

Page 25: ...uirements 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 increasethe voltage turning the knob counter clockwise will decrease the voltage Figure 10 240 139 VAC Twist Lock Auxiliary Receptacles DCA 300SSK III OUTPUT TERMINAL PANEL OVERVIEW Twist Lock DualVoltage 240 139VAC Receptacles There a...

Page 26: ...uit breakers to the OFF position prior to starting the engine Over Current Relay An over current relay Figure 14 is connected to the main circuit breaker In the event of an overload both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over cur rent relay must be pressed The over current relay is lo cated in the control box Fig...

Page 27: ...y lamp a capacity of up to the generating set s rated output kW multiplied by 0 6 can be used z When connecting an electric drill or other power tools pay close attention to the required starting current capacity NOTE WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 4 below when connecting loads Three Phase Load When calculating the power requirements for 3 phase power ...

Page 28: ...severe bodily harm or even death Generator Amperage Tables 7 and 8 describe the generator s current output capa bility for both 1Ø phase and 3Ø phase applications s e g a t l o V e l b a l i a v A r o t a r e n e G 6 e l b a T e s a h P e e r h T V 8 0 2 V 0 2 2 V 0 4 2 V 6 1 4 V 0 4 4 V 0 8 4 e s a h P e l g n i S V 0 2 1 V 7 2 1 V 9 3 1 V 0 4 2 V 4 5 2 V 7 7 2 s g n i t a R e r e p m A r o t a r...

Page 29: ... the selected leg The ammeter and voltmeter gauges areonlyactivewhenthe UVWO terminals are in use NOTE Figure 16 Voltage Change Over Board 240V Configuration Maximum Amps Table 9 shows the maximum amps the generator can pro vide DO NOT exceed the maximum amps as listed Figure 18 AC Voltmeter Gauge Volt reading on W U Lug Figure 17 AC Voltmeter Change Over Switch A 0 40 60 75 20 Figure 20 AC Ammete...

Page 30: ...elected voltage 3Ø 240V UVWOTerminal OutputVoltages 1 Jumperthevoltagechange overboardfor240Voperation as shown in Figure 21 Figure 22 UVWO Terminal Lugs 3Ø 240V Connections 2 Connect the load wires to the UVWO terminals as shown in Figure 22 3 Turn the voltage regulator knob Figure 23 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjus...

Page 31: ...e 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 28 1Ø 277V UVWOTerminal OutputVoltages 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 29 UVWO Terminal Lugs 1Ø 277V Connections A...

Page 32: ...cation E3 z ACEA Specification E2 Other types of motor oils may be substituted if they meet the following requirements WARNING WARNING WARNING WARNING WARNING ONLY properly trained personnel who have read and understand this section should refill the fuel tank system Use 2 diesel fuel Fuel spillage on a hot engine can cause a fire or explosion If fuel spillage occurs wipe up the spilled fuel compl...

Page 33: ...ill from the tank before reaching full capacity DANGER DANGER DANGER DANGER DANGER Diesel fuel and its vapors are dangerous to your health and the surrounding environment Avoid skin contact and or inhaling fumes Figure 31 Skid Type Fuel Tank System ONLY use 2 diesel fuel when refueling NOTE WARNING WARNING WARNING WARNING WARNING DO NOT OVER FILL fuel system Leave room for fuel expansion Fuel expa...

Page 34: ...Cleaning the Radiator 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 Air Cleaner Periodic cleaning replacement is necessary Inspect it in accordance with the Komatsu Engine Owner...

Page 35: ...onnections If any wiring or connections are exposed insulation missing replace wiring immediately Piping and Hose Connection Inspect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately If the battery cable is connected incorrectly electricaldamagetothe generator w...

Page 36: ... ALWAYS have adequate ventilation when operating Direct exhaust away from nearby personnel DCA 300SSK III GEN START UP PROCEDURE MANUAL Figure 35 Load Connections NEVER manually start the engine with the main GFCI or auxiliary circuit breakers in the ON closed position CAUTION BEFORE STARTING Generator and Control Panel 4 Close all engine enclosure doors Figure 36 Figure 36 Engine Enclosure Doors ...

Page 37: ...43 Frequency Meter Hz 11 The generator s frequency meter Figure 43 should be displaying the 60 cycle output frequency in HERTZ DCA 300SSK III GENERATOR START UP PROCEDURE MANUAL 7 Place the engine speed switch in the LOW position Figure 39 Figure 40 Auto Off Reset Manual Switch 8 Place the Auto Off Reset Manual switch in the Manual position to start the engine Figure 40 Once the engine starts let ...

Page 38: ...ely 1800 RPM s 15 The coolanttemperaturegauge Figure48 willindicate the coolant temperature Under normal operating conditions the coolant temperature should be between 165 and 215 degrees Fahrenheit Green Zone Figure 48 Coolant Temperature Gauge WATER TEMP 0 4 8 kg cm2 ENGINE OIL PRESSURE Figure 50 Main Aux and GFCI Circuit Breakers ON 17 Place the main GFCI and aux circuit breakers in the ON posi...

Page 39: ...Start up procedure except where noted see below 1 Performsteps1through5 intheBeforeStarting section page 36 as outlined in theManualStarting Procedure Figure 52 Engine Speed Switch High Figure 53 Off Manual Auto Switch AUTO 4 Place the Off Manual Auto switch Figure 53 on the MPEC unit to the AUTO position The Engine Speed Switch must be set to the High position when running in the Auto Start mode ...

Page 40: ...PEC display are OFF not lit 3 Remove all loads from the generator Emergency Shutdown Procedure 1 PUSH inward the RED emergency stop button located on the engine operating panel Figure 57 to turn off the generator in the event of an emergency Figure 57 Emergency Stop Button NEVER stop the engine suddenly except in an emergency DO NOT use the emergency stop switch a as method of shutting down the ge...

Page 41: ...DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 PAGE 41 NOTE PAGE ...

Page 42: ... c e h C X r e t l i F d n a l i O e n i g n E e c a l p e R 1 X y r e t t a B e c i v r e S X e d i s t u O d n a e d i s n I t i n U n a e l C X r e t l i F l e u F e g n a h C 2 X t n a l o o C k c e h C d n a r o t a i d a R n a e l C l e v e L n o i t c e t o r P X t n e m e l E r e t l i F r i A e c a l p e R X s t a t s o m r e h T t s e T X r o t a i d a R h s u l F s p m a l C d n a s e s...

Page 43: ...y vary according to season and locations Always pour through the mesh filter RemovingWater from theTank 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 condense This can be reduced by always keeping the tank as ...

Page 44: ...drain plugs 12 Remove the corrosion resistor if equipped and open valve 13 Supply water until it flows over the water filler 14 Drain the water inside reserve tank clean the inside of the reserve tank then fill with coolant water mixture to between the full and low lines 15 Stop the engine wait for 3 minutes add tap water until the water level reaches near the water filer port then tighten the rad...

Page 45: ...z If the engine has not been started for more than one year contact your Komatsu distributor to have engine overhauled 5 After replacing filter cartridge loosen air bleed plug 6 Loosen the knob of feed pump and pump it up and down until no bubbles come out with the fuel from air bleed plug 7 After bleeding the air tighten air bleed plug then push in the knob of feed pump and lock it in position 8 ...

Page 46: ...n 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 thejacketwaterheaterreceptacleviacommercialpowerusing an power cord of adequate size DCA 300SSK III MAINTENANCE If the generator ...

Page 47: ...DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 PAGE 47 DCA 300SSK III GENERATORWIRING DIAGRAM ...

Page 48: ...PAGE 48 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III ENGINEWIRING DIAGRAM ...

Page 49: ...e c w o l h t i w l e u F l e u f d e i f i c e p s e h t e s U n o i t c e j n i e s o o l o t e u d k a e l l e u F t u n g n i n i a t e r e p i p t u n n e t h g i T g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n r o w t f a h s m a c l e u F e c a l p e R d e g g o l c e l z z o n n o i t c e j n I e l z z o n n o i t c e j n i n a e l C g n i n o i t c n u f l a m p m u p n o ...

Page 50: ... d e i f i c e p s e h t o t e c u d e R r o n r o w r e n i l d n a g n i r n o t s i P k c u t s e c a l p e r r o r i a p e R g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n o i s s e r p m o c t n e i c i f e D e c n a r a e l c p o t t s u j d A t s u a h x e y a r g k r a d r o k c a l b r e h t i E d e v r e s b o s i s a g d a o l r e v O d a o l e h t n e s s e L d e s u l e...

Page 51: ...d R V A s I y r a s s e c e n f i e c a l p e R r e i f i t c e R g n i t a t o R e v i t c e f e D e c a l p e r d n a k c e h C t u p t u O e g a t l o V w o L t c e r r o c d e e p s e n i g n e s I h g i H o t r e v e l e l t t o r h t e n i g n e n r u T e s o o l s n o i t c e n n o c g n i r i w s I r i a p e r d n a g n i r i w k c e h C R V A e v i t c e f e D y r a s s e c e n f i e c a ...

Page 52: ... t r e p m e t t c e r r o c n i n o i s n e t t l e b n a F t l e b n a f e c a l p e r n e t h g i T r o t a i d a r h g u o r h t n o i t a l u c r i c t o n s i w o l f r i A l l i r g r o t a i d a r r i a p e r n a e l C n e p o s r o o D s r o o d e s o l C g n i k a e l t s u a h x E t r a p y t l u a f r o s t e k s a g r i a p e r e c a l p e R d e d a o l r e v o g n i e b r o t a r e n...

Page 53: ...DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 PAGE 53 NOTE PAGE ...

Page 54: ...icular part is used Model Number Where indicated this shows that the corresponding part is utilized only with this specific model number or model number variant Items Found In the Items Number Column Allpartswithsamesymbolinthenumbercolumn or belong to the same assembly or kit Note If more than one of the same reference number is listed the last one listed indicates newest or latest part available...

Page 55: ...51 CARTRIDGE CORROSION RESISTOR 3 0810105400 FUEL FILTER FUEL TANK 2 0412122263 ENGINE FAN BELT SET 1 6152611530 RADIATOR HOSE UPPER 1 6152621540 RADIATOR HOSE LOWER 1 0605505030 FUEL CAP 1 0601850590 KEY FUEL CAP 1 0601820625 AUTOMATICVOLTAGE REGULATOR 1 0601810072 PILOT LAMP 2 0601810261 BULB PILOT LAMP 1 0602122200 UNIT OIL PRESSURE 1 0602123206 UNIT WATERTEMPERATURE 1 0602121052 CHARGING AMMET...

Page 56: ...PAGE 56 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 GENERATOR ASSY DCA 300SSK III GENERATOR ASSY ...

Page 57: ...201614003 COUPLING RING 1 16 0012116040 HEX HEAD BOLT 6 17 0042516000 LOCKWASHER 6 18 0012112040 HEX HEAD BOLT 12 18 0042512000 LOCKWASHER 12 19 C2130100103 STATOR ASSY 1 20 0226200430 RUBBER SEAL 1 21 8201323004 CLAMPER 1 22 0223300140 RUBBER SEAL 1 23 8201323103 CLAMPER 1 24 0221200350 RUBBER SEAL 1 25 0010110035 HEX HEAD BOX 2 25 0041210000 PLAINWASHER 2 26 C2132200003 COVER 1 27 0226000275 RUB...

Page 58: ...PAGE 58 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III GENERATOR ASSY GENERATOR ASSY ...

Page 59: ...16 HEX HEAD BOLT 8 40 0012112035 HEX HEAD BOLT 16 40 0042512000 LOCKWASHER 16 41 C3132300003 COVER FAN 1 S N3691259TO 3692208 41 C3132300014 COVER FAN 1 S N3692209 42 0010106030 HEX HEAD BOLT 1 42 0041206000 PLAINWASHER 1 42 0600815000 NUT 1 S N3692209 43 0605000012 RUBBER SUSPENSION 2 44 0030020000 HEX NUT 4 44 0040020000 LOCKWASHER 4 DCA 300SSK III GENERATOR ASSY ...

Page 60: ...PAGE 60 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III CONTROL BOX ASSY CONTROL BOX ASSY ...

Page 61: ...ASHER 4 S N3691259TO 3706720 9 0601820625 AUTOMATICVOLTAGE REGULATOR 1 NTA 5A 2T 10 0027105016 MACHINE SCREW 4 11 0601820892 OVER CURRENT RELAY 1 TH N20HZKP 12 0027104016 MACHINE SCREW 2 13 C2274000103 CHANGE OVER BOARDVOLTAGE 1 14 8201852104 CHANGETERMINAL 10 15 0017108030 HEX HEAD BOLT 20 16 C2277200004 TERMINAL PLATE 3 17 8201853104 CHANGE PLATE 6 18 8201852504 HEX HEAD BOLT 13 19 0801830704 HE...

Page 62: ...PAGE 62 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III CONTROL BOX ASSY CONTROL BOX ASSY CONT ...

Page 63: ...E REGULATOR 1 RA20A2SE102BJ 2W 1K OHM 41 0601840121 KNOB 1 42 0601810161 PANEL LIGHT 1 V325070 42 0601810214 BULB 1 43 0207004000 HEX NUT 2 44 0601830710 SWITCH PANEL LIGHT 1 45 C2214600104 COVER 1 S N3691259TO 3706720 46 0027105016 MACHINE SCREW 4 S N3691259TO 3706720 47 C9221100004 HEX HEAD BOLT 2 47 0040008000 LOCKWASHER 2 47 0041208000 PLAINWASHER 2 47 505015300 SNAP RING 2 REPLACES 0080200007...

Page 64: ...PAGE 64 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III CONTROL BOX ASSY CONTROL BOX ASSY CONT ...

Page 65: ...LAY 1 S N3699682 65 0601823109 SOCKET 1 S N3696507 65 0601824400 HOLDER 1 S N3696507 66 0027104020 MACHINE SCREW 2 S N3696507 67 0601823706 RELAY HE1ADC24V 1 S N3696507 68 0027104015 MACHINE SCREW 2 S N3696507 69 0601815402 TERMINAL BOARD TS144P 1 S N3696507 70 0027104020 MACHINE SCREW 2 S N3696507 71 ECU9988N300 400 CONTROLLER 1 REPLACES 0601827396 0602202545 72 0601831340 SWITCH 82608DPDT 1 S N3...

Page 66: ...PAGE 66 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III ENGINE RADIATOR ASSY ENGINE RADIATOR ASSY ...

Page 67: ...8 0030020000 NUT HEX 8 9 004002000 WASHER SPRING 4 10 0041220000 WASHER PLAIN 8 11 C2311100504 BRACKET RADIATOR 2 12 0010112025 BOLT HEX HEAD 2 13 0040012000 WASHER SPRING 2 14 0041212000 WASHER PLAIN 2 15 0017110025 BOLT HEX HEAD 2 16 6152611530 HOSE RADIATOR 1 REPLACES 06020 14539 17 6125621540 HOSE RADIATOR 1 REPLACES 06020 14653 18 0726120911 HOSE RADIATOR 1 REPLACES 06020 14541 19 0728100809 ...

Page 68: ...PAGE 68 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 ENGINE RADIATOR ASSY DCA 300SSK III ENGINE RADIATOR ASSY ...

Page 69: ...55 15170 HOSE BAND 1 37 02691 00650 HOSE 1 38 C23271 00103 PIPE BREATHER 1 39 00171 08020 BOLT HEX HEAD 2 40 06033 20112 U BOLT 1 41 02070 08000 NUT HEX HEAD 2 42 02682 00700 HOSE 1 43 06055 15132 HOSE BAND 2 44 C23583 01003 ROD CLAMPER 1 45 00171 10020 BOLT HEX HEAD 2 46 C23583 00003 ROD CLAMPER 1 47 00171 08020 BOLT HEX HEAD 1 48 00100 16030 BOLT HEX HEAD 1 49 00400 16000 WASHER SPRING 1 50 0041...

Page 70: ...PAGE 70 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY ...

Page 71: ...507 22 0601831557 EMERGENCY STOP BUTTON 1 S N3701674 AR22V2R01R 23 6008153730 PREHEAT LAMP 1 REPLACES 0602102055 24 0602120054 TACHOMETER 1 25000 KX4110 25 0602120156 CABLE TACHOMETER 1 62500 KA4210L 3000 26 0602122060 OIL PRESSURE GAUGE 1 42000 KX1410 27 0602122200 UNIT OIL PRESSURE 1 53000 AC0101 28 0602123061 WATERTEMPERATURE GAUGE 1 40000 KX0910 29 0602123206 UNIT WATERTEMPERATURE 1 51400 KS06...

Page 72: ...PAGE 72 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY S N3691259 UP TO S N3691258 ...

Page 73: ...0601808803 CIRCUIT BREAKER QOU120B 20A 2 S N3706721 REPL 0601805313 10 0601805840 CIRCUIT BREAKER KM 52 265V 50A 3 S N3691259TO 3706720 10 0601808804 CIRCUIT BREAKER QOU250B 50A 3 S N3706721 11 C1261600204 BRACKET CIRCUIT BREAKER 1 S N3691259TO 3706720 11 C3261600704 BRACKET CIRCUIT BREAKER 1 S N3706721 12 0223300200 RUBBER CUSHION 1 S N3691259TO 3706720 12 0221200150 RUBBER CUSHION 1 S N3706721 1...

Page 74: ...PAGE 74 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY S N3691259 UP TO S N3691258 ...

Page 75: ...7 24 0017108020 HEX HEAD BOLT 9 25 C0237101504 COVER OUTPUTTERMINAL 1 S N 3691259 26 0805015604 RUBBERWASHER 1 S N 3691259 27 0845054204 COLLER 2 S N 3691259 28 0017110040 HEX HEAD BOLT 2 S N 3691259 29 0601815324 TERMINAL BOARD TS22P 1 S N3696507 30 0027104020 MACHINE SCREW 2 S N3696507 31 0601850275 GROMMET 1 S N3696507 32 0601851780 GROMMET 2 S N3700674 34 C2237101504 COVER 1 S N 3708297 35 C22...

Page 76: ...PAGE 76 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III ACTUATOR ASSY ACTUATOR ASSY S N3701674 ...

Page 77: ...VER 1 REPLACES 0602211090 3 C1356200004 BRACKET ACTUATOR 1 4 0012310030 HEX HEAD BOLT 4 5 0010306035 HEX HEAD BOLT 4 5 0207006000 HEX NUT 4 5 0040006000 LOCKWASHER 4 5 0041206000 PLAINWASHER 4 6 0602211091 ROD 1 7 0602180190 BALL JOINT 2 8 0602211092 HEX NUT 2 9 0010106025 HEX HEAD BOLT 1 9 0207006000 HEX NUT 1 9 0041206000 PLAINWASHER 1 10 0010106025 HEX HEAD BOLT 1 10 0207006000 HEX NUT 1 10 004...

Page 78: ...PAGE 78 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III BATTERY ASSY BATTERY ASSY ...

Page 79: ...TERY BAND 1 4 0805002904 BATTERY BOLT 2 5 0037808000 WING NUT 2 6 0040008000 LOCKWASHER 2 7 0041208000 PLAINWASHER 2 8 C2347600404 BATTERY CABLE 1 9 C2347600104 BATTERY CABLE 1 10 C2347600204 BATTERY CABLE 1 11 C2347600304 BATTERY CABLE 1 12 C2347200004 EARTH CABLE 1 13 0010010030 HEX HEAD BOLT 4 14 0030010000 HEX NUT 4 15 0845040414 TERMINAL CAP 2 16 0845041304 TERMINAL CAP 2 17 0602220204 BATTER...

Page 80: ...PAGE 80 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III MUFFLER ASSY MUFFLER ASSY ...

Page 81: ...503 EXHAUST PIPE 1 S N 3708297 4 6150115751 GASKET 1 REPLACES 0602320142 5 7502356004 GASKET 1 S N 1337508TO 3691258 5 C1334200304 GASKET 1 S N 3691259TO 3708296 5 6150115751 GASKET 1 S N 3708297 6 0010312050 HEX HEAD BOLT 4 6 0030312000 HEX NUT 4 6 0040012000 LOCKWASHER 4 6 0041212000 PLAINWASHER 8 7 0010112055 HEX HEAD BOLT 4 7 0030012000 HEX NUT 4 7 0040012000 LOCKWASHER 4 7 0041212000 PLAINWAS...

Page 82: ...1 05 07 03 DCA 300SSK III ENCLOSURE ASSY ENCLOSURE ASSY THE SERIAL NUMBER MAY BE REQUIRED 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 ...

Page 83: ...E 1 15 00192 08020 BOLT HEX HEAD 14 16 C24340 01002 FRAME CENTER 1 17 00101 14050 BOLT HEX HEAD 4 17 00300 14000 NUT HEX 4 17 00400 14000 WASHER SPRING 4 17 00412 14000 WASHER PLAIN 8 18 00101 14040 BOLT HEX HEAD 8 18 00300 14000 NUT HEX 8 18 00400 14000 WASHER SPRING 8 18 00412 14000 WASHER PLAIN 16 19 C24440 00302 FRAME REAR 1 19 C24943 00204 LINING 1 20 00192 10025 BOLT HEX HEAD 4 21 00171 1002...

Page 84: ...1 05 07 03 ENCLOSURE ASSY DCA 300SSK III ENCLOSURE ASSY THE SERIAL NUMBER MAY BE REQUIRED 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 ...

Page 85: ...INE 2 48 C24641 00402 PANEL ROOF 1 48 C24945 00804 LINING 1 49 08002 51701 COVER FILLER 1 50 00250 06015 SCREW MACHINE 2 50 00423 06000 WASHER SPRING 2 50 00424 06000 WASHER PLAIN 2 51 C24642 00502 PANEL ROOF 1 51 C24945 00904 LINING 1 52 00192 08020 BOLT HEX HEAD 32 53 C24542 01402 PANEL SPLASHER 1 54 00191 08065 BOLT HEX HEAD 6 54 00423 08000 WASHER SPRING 6 54 00424 08000 WASHER PLAIN 6 55 C245...

Page 86: ...1 05 07 03 DCA 300SSK III ENCLOSURE ASSY THE SERIAL NUMBER MAY BE REQUIRED 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 ENCLOSURE ASSY ...

Page 87: ...28 66 00300 06000 NUT HEX 16 67 08450 46904 HINGE 6 67 08450 45004 WASHER 6 68 08450 47004 HINGE 5 68 08450 45004 WASHER 5 69 00192 08020 BOLT HEX HEAD 25 70 06018 50097 STOPPER 8 71 00254 08025 SCREW MACHINE 8 72 08450 31504 CAP 15 73 06005 00090 EMBLEM 2 74 00211 06016 SCREW MACHINE 4 75 C24645 00204 GUTTER 2 77 0019208020 HEX HEAD BOLT 4 78 C1425700004 RADIATOR PANEL 1 79 0019206015 HEX HEAD BO...

Page 88: ...PAGE 88 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III RUBBER SEAL ASSY RUBBER SEAL ASSY ...

Page 89: ...SEAL 6 2 0228901090 RUBBER SEAL 4 3 0228900650 RUBBER SEAL 2 4 0228901030 RUBBER SEAL 4 5 0229201400 RUBBER SEAL 4 6 0229201300 RUBBER SEAL 1 7 0228800705 RUBBER SEAL 2 S N3691259TO 3701673 7 0221200705 RUBBER SEAL 2 S N3701674 8 0228801200 RUBBER SEAL 2 9 0228100120 RUBBER SEAL 4 10 0228100510 RUBBER SEAL 4 DCA 300SSK III RUBBER SEAL ASSY ...

Page 90: ...PAGE 90 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 OIL PIPING ASSY DCA 300SSK III OIL PIPING ASSY ...

Page 91: ... 0602023040 PUMP 1 2 C2324400004 BRACKET PUMP 1 3 0017110025 HEX HEAD BOLT 2 4 0017106025 HEX HEAD BOLT 5 5 7522054204 BUSHING 1 6 0131506000 NIPPLE 1 7 0120006005 VALVE 1 8 3972027104 HOSE JOINT 2 9 0191600900 HOSE 1 10 0605515074 HOSE BAND 2 11 0193301200 HOSE 1 12 0605515004 HOSE BAND 1 DCA 300SSK III OIL PIPING ASSY ...

Page 92: ...PAGE 92 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III FUELTANK ASSY ...

Page 93: ...O PART NAME QTY REMARKS 1 3000 CAP FUEL 1 2 2140 VENT EMERGENCY 1 3 REDUCER 1 2 to 3 8 1 OBTAIN LOCALLY 4 REDUCER 1 2 to 3 8 1 OBTAIN LOCALLY 5 9070 GAUGE FUEL LEVEL 1 6 SBT300 12H TANK FUEL LESS FORK POCKETS 1 SEE NOTE BELOW NOTE FORK Fork pockets must be added to the above part number when ordering a replacement fuel tank ...

Page 94: ...PAGE 94 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III BATTERY CHARGER ASSY BATTERY CHARGER ASSY ...

Page 95: ... 95 DCA 300SSK III BATTERY CHARGER ASSY BATTERY CHARGER ASSY NO PART NO PART NAME QTY REMARKS 1 FC2462011U CHARGER BATTERY 24V 6A 1 2 CABLE 14 3 x 9 1 MAKE LOCALLY 3 HBL5278C RECEPTACLE 15A 1 4 M1940011014Q DECAL BATTERY CHARGER 1 CHAN CHANGE xsdsdssFDADF ADSFAFDSAFAF ...

Page 96: ...PAGE 96 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III NAME PLATE AND DECALS NAME PLATE AND DECALS ...

Page 97: ...12 C2551000004 DECAL SAFETY INSTRUCTIONS 1 C25100000 13 C2561101903 DECAL WHISPERWATT 300 1 C26110190 14 C9502400004 DECAL HIGH IDLE SPEED C90240000 1 S N3701674 15 0600500091 DECAL ENGINE CONTROLLER 1 S N3696507 ENGINE OPERATING PANEL GROUP 19 0840625004 DECAL PREHEAT LAMP S 3036 1 S N3691259TO 3701673 19 C155200013 DECAL OPERATING PANEL C15200001 1 S N3701674 20 0840625104 DECAL STARTER SWITCH S...

Page 98: ...PAGE 98 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III NAME PLATE AND DECALS NAME PLATE AND DECALS ...

Page 99: ...51000803 DECAL RECEPT CIRCT BREAKER C15100080 1 S N3706721 27 B9511100304 DECAL WARNING 1 B91110030 28 B9511100404 DECAL WARNING 1 B91110040 29 B9531100504 DECAL WARNING 1 B93110050 30 C0551000404 DECAL 3 PHASE OUTPUT TERMINAL 1 C05100040 31 9039209064 DECAL START CONTACT S4468 1 S N3696507 BATTERY GROUP 32 0800689404 DECAL 1 S 2090 33 0800689504 DECAL 1 S 2091 34 C9505300004 DECAL CAUTION 1 C9053...

Page 100: ...PAGE 100 DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 DCA 300SSK III NAME PLATE AND DECALS NAME PLATE AND DECALS ...

Page 101: ...0625902 DECAL MQ 1 S 3057 42 B9504000304 DECAL CAUTION 1 B90400030 43 B9531100604 DECAL WARNING 1 B93110060 44 C2561101003 STRIPE 1 45 C2561101603 STRIPE 1 46 C2561101303 STRIPE 1 TO S N 3708296 46 C2561102003 STRIPE 1 S N 3708297 47 C2561101404 STRIPE 1 TO S N 3708296 47 C2561102103 STRIPE 2 S N 3708297 48 C2561101204 STRIPE 2 49 C2561101803 STRIPE 1 50 C2561101503 STRIPE 1 TO S N 3708296 50 C256...

Page 102: ...components f Paint chemicals andlubricants g Decalsandpaperproducts h Itemspurchasedinkits 7 The sender will be notified of any materialreceivedthatisnotacceptable 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 9 Creditonreturnedpartswillbeissuedat dealer net pri...

Page 103: ...DCA 300SSK III PARTS AND OPERATION MANUAL FEMA REV 1 05 07 03 PAGE 103 NOTE PAGE ...

Page 104: ...lanta Boise Dallas Houston Newark Quebec Canada Manchester UK RioDeJaniero BR Guadalajara MX HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HANDWHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SERVICE DEPARTMENT 800 421 1244 FAX 310 537 4259 TECHNICAL ASSISTANCE 800 478 1244 FAX 310 631 5032 WARRANTY DEPARTMENT 888 661 4279 or 310 661 4...