MULTIQUIP DCA-400SPK Specifications

MULTIQUIP DCA-400SPK Specifications
PARTS AND OPERATION MANUAL
© COPYRIGHT 2001, MULTIQUIP INC.
MQ POWER
DCA-400SPK
TM
WHISPERWATT
GENERATOR
PARTS LIST NO. C3873300104
Revision #0 (06/19/01)
MULTIQUIP INC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
SERVICE DEPARTMENT:
310-537-3700
800-421-1244
800-835-2551
FAX: 310-537-3927
FAX: 310-638-8046
E-mail:[email protected] • www:multiquip.com
PAGE 2 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PAR
TS DEP
AR
TMENT
ARTS
DEPAR
ARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
VICE DEP
AR
TMENT
SER
DEPAR
ARTMENT
SERVICE
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEP
AR
TMENT
DEPAR
ARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 3
TABLE OF CONTENTS
Here's How To Get Help .............................................3
Table Of Contents ......................................................4
Rules For Safe Operation ...................................... 6-9
Towing ......................................................................10
Trailer Safety Guidelines .................................... 11-17
Trailer Wiring Diagram..............................................18
Electric Brake Troubleshooting .................................19
Hydraulic Brake Troubleshooting .............................20
Operation And Safety Decals ............................. 21-22
Specifications ...........................................................23
General Information ........................................... 24-25
Major Components ..................................................26
Dimensions (Top, Side And Rear)...................... 28-29
Control Panel...................................................... 30-31
Engine Operating Panel ..................................... 32-33
Output Terminal Panel ........................................ 34-39
Installation .......................................................... 40-41
Pre-Setup ........................................................... 42-45
Load Application ......................................................46
Generator Start-Up Procedure .......................... 47-50
Generator Shut-Down Procedure ............................52
Maintenance ...................................................... 54-57
Generator Wiring Diagram .......................................58
Engine Wiring Diagram ............................................60
Troubleshooting (Engine) ................................... 62-63
Troubleshooting (Engine/Generator) .......................64
Explanation Of Codes In Remarks Column .............66
Suggested Spare Parts ............................................67
MQ Power DCA-400SPK
AC Generator
Generator Assembly .......................................... 68-71
Control Box Assembly ........................................ 72-75
Engine Radiator Assembly ................................. 76-79
Engine Operating Panel Assembly .................... 80-81
Output Terminal Assembly ................................. 82-83
Battery Assembly ............................................... 84-85
Muffler Assembly ............................................... 86-87
Fuel Tank Assembly ........................................... 88-89
Enclosure Assembly ........................................... 90-97
Enclosure (Rubber Seals) .................................. 98-99
Oil Piping Assembly ....................................... 100-101
Name Plate and Decals ................................. 101-105
Terms and Conditions Of Sale — Parts ................ 106
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
PARTS ORDERING PROCEDURES
■
■
■
■
■
■
■
Dealer account number
Dealer name and address
Shipping address (if different than billing address)
Return fax number
Applicable model number
Quantity, part number and description of each part
Specify preferred method of shipment:
•
•
•
•
UPS Ground
UPS Second Day or Third Day*
UPS Next Day*
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
•
Airborne Express*
Truck or parcel post
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
1-9 items
Additional Discount
3%
10+ items**
5%
Get special freight allowances
when you order 10 or more
line items via FAX!**
■ UPS Ground Service at no charge for freight
■ PS Third Day Service at one-half of actual freight cost
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
*DISCOUNTS ARE SUBJECT TO CHANGE*
ount
c
s
i
D
Fax
Extra
c USA
i
t
s
e
m
for Do
Only
s
r
e
l
a
De
UPS l
Specia
only
orders
d
e
x
a
f
For
Now! Direct TOLL-FREE access
to our Parts Department!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
800/6-PARTS-7 • 800-672-7877
Fax order discount and UPS special programs revised June 1, 1995
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 5
RULES FOR SAFE OPERATION
CAUTION:
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.
The following safety guidelines should always be used when
operating the DCA-400SPK portable generator:
GENERAL SAFETY
■ DO NOT operate or service this equipment before
reading this entire manual.
■ 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.
■ NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
■ NEVER operate this equipment under the
influence or drugs or alcohol.
■ 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.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Always check the machine for loosened threads or bolts
before starting.
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■ High Temperatures – Allow the
engine to cool before adding fuel or performing service
and maintenance functions. Contact with hot components
can cause serious burns.
■ The engine of this generator requires an adequate free
flow of cooling air. Never operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is restricted it will cause serious
damage to the generator or engine and may cause injury
to people. The generator engine gives off DEADLY carbon
monoxide gas.
CAUTION:
Always refuel in a well-ventilated area,
away from sparks and open flames.
■ Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool. DO NOT smoke around or near
the machine. Fire or explosion could
result from fuel vapors, or if fuel is
spilled on a hot engine.
■ NEVER operate the generator in an
explosive atmosphere or near combustible materials. An
explosion or fire could result causing severe bodily harm
or even death.
■ Topping-off to filler port is dangerous, as it tends to spill
fuel.
PAGE 6 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
RULES FOR SAFE OPERATION
CAUTION:
CAUTION:
DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
■ NEVER touch output terminals during operation. This is
extremely dangerous. Always stop the machine when
contact with the output terminals.
CAUTION:
Radiator
1. Radiator Cap - Removing the radiator cap while the
engine is hot due to high pressure, will result in boiling
water to gush out of the radiator, therefore causing
severe scalding to any persons in the general area
of the generator.
2. Coolant Drain Plug - Removing the coolant drain
plug while the engine is hot will result in hot coolant
to gush out of the coolant drain plug, therefore
causing severe scalding to any persons in the
general area of the generator.
■ 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.
3. Engine Oil Drain Plug - Removing the engine oil
drain plug while the engine is hot will result in hot oil
to gush out of the oil drain plug, therefore causing
severe scalding to any persons in the general area
of the generator.
CAUTION:
Never use damaged or worn cables when
connecting power tools or equipment to the
generator. Make sure power connecting
cables are securely connected to the
generator’s output terminals, insufficient
tightening of the terminal connections may
cause damage to the generator and
electrical shock.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 7
RULES FOR SAFE OPERATION
Battery
CAUTION:
Never over fill the battery with water above
the upper limit.
The battery contains acids that can cause injury to the
eyes and skin. To avoid eye irritation, always wear safety
glasses. Use well insulated gloves when picking up the
battery. Use the following guidelines when handling the
battery:
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
■ NEVER Run engine without air filter. Severe engine
damage may occur.
■ Always service air cleaner frequently to prevent
carburetor malfunction.
■ Always disconnect the battery before performing service
on the generator.
■ Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
generator.
■ Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out
of the reach of children.
■ DO NOT leave the generator running in the manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
■ Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate
equipment.
ual for
Manual
■ Refer to the K omatsu Engine Owner's Man
engine technical questions or information.
2. DO NOT expose the battery to open flames, sparks,
cigarettes etc. The battery contains combustible gases
and liquids. If these gases and liquids come in contact Loading and Unloading (Crane)
with a flame or spark, an explosion could occur.
■ Before lifting, make sure the generator's lifting hook is
3. Always keep the battery charged. If the battery is not
secure and that there is no apparent damage to the
charged a buildup of combustible gas will occur.
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
4. Always keep battery charging and booster cables in good
before lifting.
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment, ■ Always drain fuel prior to lifting.
to avoid risk of a dangerous concentration of combustible ■ Always make sure crane or lifting device has been
gases.
properly secured to the hook of guard frame on generator.
6. In case the battery liquid (dilute sulfuric acid) comes in ■ NEVER lift the machine while the engine is running.
contact with clothing or skin, rinse skin or clothing ■ Use adequate lifting cable (wire or rope) of sufficient
immediately with plenty of water.
strength.
7. In case the battery liquid (dilute sulfuric acid) comes in ■ When lifting the generator, always use the balanced
contact with your eyes, rinse eyes immediately with
center-point suspension hook and lift straight upwards.
plenty of water, then contact the nearest doctor or hospital,
■ NEVER allow any person or animal to stand underneath
and seek medical attention.
the machine while lifting.
■ When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure
the generator during transport.
PAGE 8 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
RULES FOR SAFE OPERATION
Transporting
■ Always shutdown engine before transporting.
■ Tighten fuel tank cap securely.
■ Drain fuel when transporting generator over long distances
or bad roads.
■ Always tie-down the generator during transportation by
securing the generator.
■ If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
Emergencies
■ Always know the location of the nearest fire extinguisher
and first aid kit. Know the location of the nearest telephone.
Also know the phone numbers of the nearest ambulance,
doctor and fire department.
Maintenance Safety
■ NEVER lubricate components or attempt service on a
running machine.
■ Always allow the machine a proper amount of time to
cool before servicing.
■ Keep the machinery in proper running condition.
■ Fix damage to the machine immediately and always
replace broken parts.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 9
DCA-400SPK — TOWING
Towing Safety Precautions
CAUTION :
Check with your county or state safety
towing regulations department before
towing your generator. Vehicle towing
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 1) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.
The following list of suggestions should be used when towing
your generator:
■ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■ ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains
etc.
■ Check the tire air pressure on both towing vehicle and
trailer. Also check the tire tread wear on both vehicles.
■ ALWAYS make sure the trailer is equipped with a "Safety
Chain".
■ ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and
working properly.
■ 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.
■ Place chocked blocks underneath wheel to prevent
rolling
rolling, while parked.
■ Place support blocks underneath the trailer's bumper to
prevent tipping, while parked.
■ 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.
■ Avoid sudden stops and starts. This can cause skidding,
or jackknifing. Smooth, gradual starts and stops will
improve gas milage.
■ Avoid sharp turns to prevent rolling.
■ Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
Figure 1. Generator with Trailer
PAGE 10 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — TRAILER-SAFETY GUIDELINES
CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
Explanation of Chart:
This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range
of trailers. Remember periodic inspection of the trailer will
ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:
„
„
„
„
„
„
Brakes
Tires
Lug Nut Torquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions with reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when transporting equipment.
2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This 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.
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.
9. Tire Ply - The tire ply (layers) number is rated in
letters; 2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the
trailer’s axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 4 and Figure 5 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please not that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 11
DCA-400SPK — TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
FU E L
C E LL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10W
SDW225,
SGW250,TLW300
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-10
DCA10, TLG12,
DCA-15
NO
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-10XF
DCA10, TLG-12,
DCA15, TLW-300
52 GAL
NO
1900LB S
96"
50"
800LB .
FULL TILT WHEEL
TRLR-225W
WELDERS,
D A 7000S S
NO
NO
2200LB S
85"
42"
800LB .
FULL TILT WHEEL
TRLR-BLW400
BLW-400
NO
ELECTRIC
2700LB S
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB .
FULL TILT WHEEL
TRLR-50X
DCA-25
NO
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TRLR-50XF
DCA-25
41 GAL
NO
2700LB S
124"
55"
800LB .
FULL TILT WHEEL
TRLR-70W
DCA-45, -60, 70
NO
SURGE
7000LB S
186"
77"
2000LB .
FLAT PAD
TRLR-70X
DCA-45, -60, 70
OPT
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TRLR-70XF
DCA-45, -60, 70
53 GAL
SURGE
7000LB S
138"
66"
2000LB .
FLAT PAD
TRLR-100XF
DCA-100, 125
150 GAL
HYDRAULIC SURGE
7000LB S
190"
76"
2000LB .
FLAT PAD
TRLR-85/125
DCA-85, 100,
125
145 GAL
HYDRAULIC
10000LB S
186"
77"
2000LB .
FLAT PAD
TRLR-150XF
DCA-150, 180
200 GAL
HYDRAULIC SURGE
11160LBS
204"
84"
5000 LB .
FLAT PAD
TRLR-220XF
DCA-220
250 GAL
HYDRAULIC SURGE
14000LB S
222"
83"
5000 LB .
FLAT PAD
TRLR-300XF
DCA-300
250 GAL
HYDRAULIC SURGE
18000LB S
238"
83"
5000 LB .
FLAT PAD
TRLR-400XF
DCA-400
350 GAL
ELECTRIC
18000LB S
238"
83"
5000 LB .
FLAT PAD
TRLR-600XF
DCA-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
TRLR-800SX
DCA-600, 800
550 GAL
AIR
30000LB S
384"
96"
5000 LB .
FLAT PAD
PAGE 12 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10W
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X 2
5 LUG
3 LE A F
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-10XF
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13"X4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-225W
2" B A LL C LA S S
2 ADJUSTABLE
175-13B
13X4.5"
2200#2X 2
5 LUG
Q F LE X
4 POLE FLAT
TRLR-BLW
400
2" B A LL C LA S S
2 ADJUSTABLE
175-13C
13 X 4.5"
2200#2X 2
5 LUG
3 LE A F
4 POLE FLAT
TRLR-50X
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-50XF
2" B A LL C LA S S
B78-13LRC
13"X4.50"
3500lbs.
2-3/8"
5 LUG
4 LE A F
4 POLE RUBBER
FLAT
TRLR-70W
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-70X
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-70XF
2" B A LL C LA S S
3" ADJUSTABLE
205-14C
BIAS (4)
14" X 5"
3500lbs.
3"
5 LUG
5 LE A F
4 POLE RUBBER
FLAT
TRLR-100XF
ADJUSTABLE 2-5/6
OPT 3" EYE
205-15C
BIAS (4)
14"X5.5"
3500lbs
3"
5 LUG
5 LE A F
4 WIRE LOOM
TRLR-85/125
ADJUSTABLE 2-5/6
OPT 3" EYE
ST225/75R15D
RADIAL (4)
14"x6"
(2)-6000lbs
6 LUG
7 LE A F
4 WIRE LOOM
TRLR-150XF
3" BALL EYE
750-16 E
BIAS (4)
16" X 7"
(2)-6000lbs
8 LUG
7 LE A F
4 WIRE LOOM
TRLR-220XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16" X 7"
(2)-7000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-300XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(2)-6000lbs
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-400XF
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16" X 7"
(3)-7000lbs.
8 LUG
Q F LE X
4 WIRE LOOM
TRLR-600XF
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
7 LE A F
6 WIRE LOOM
TRLR-800AR
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16" X 7"
(3)-10000lbs
8 LUG
AIR-RIDE
6 WIRE LOOM
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 13
DCA-400SPK — TRAILER SAFETY GUIDELINES
Brakes
If your trailer has a braking system, the 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.
trailer being towed or under-adjusted brakes.
Before any brake synchronizations adjustments can be made,
the trailer brakes should be burnished-in by applying the
brakes 20-30 times with approximately a 20 m.p.h. decrease
in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for
brakes to cool between application. This allows the brake
shoes to slightly be seated into the brake drum surface.
Electric Brakes
Electrically actuated brakes (Figure 2) are similar to hydraulic
brakes. The basic difference is that hydraulic brakes are Figure 2 displays the major electric brake components that
actuated by an electromagnet.
will require inspection and maintenance. Please inspect these
components as required.
Listed below are some of the advantages that electric brakes
have over hydraulic brakes:
Electric Brake Adjustment
„ Brake system can be manually adjusted to provide the 1. Place the trailer on jack stands. Make sure the jack
corrected braking capability for varying road and load
stands are placed on secure level ground.
conditions
2. Check the wheel and drum for free rotation.
„ Brake system can be modulated to provide more or less 3. Remove the adjusting hole cover from the adjusting slot
braking force, thus easing the brake load on the towing
at the bottom brake backing plate.
vehicle
4. With a screwdriver or standard adjusting tool, rotate the
„ Brake system has very little lag time between the time
star wheel of the adjuster assembly to expand the brake
the vehicle’s brakes are actuated and the trailer’s brakes
shoes.
are actuated
5. Adjust the brake shoes outward until the pressure of the
„ Brake system can provide an independent emergency
lining against the wheel drum makes the wheel difficult
brake system
to turn.
6. Rotate the star wheel in the opposite direction until the
Remember in order to properly synchronize the tow vehicle’s
wheel rotates freely with slight lining drag.
braking to the trailer’s braking, can only be accomplished by
road testing. Brake lockup, grabbiness or harshness is due 7. Replace the adjusting hole cover and lower the trailer to
the ground.
to lack of synchronization between the tow vehicle and the
8. Repeat steps 1 through 6 on the remaining brakes.
PAGE 14 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
Hydraulic/Air/Surge Brakes
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such as
shoe and lining replacement. These brakes can be adjusted
in the same manner as electric brakes. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Figure 3 below displays the major hydraulic/air/surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 6 as referenced in the electric brake adjustments
section.
Figure 3. Hydraulic Brake Components
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 15
DCA-400SPK — TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very impor tant and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked, the air pressure in the inner
tube may cause pieces of the rim to
explode (break off) with great force and
cause serious eye or bodily injury.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold before operation DO NOT
bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Suspension
The leaf suspension springs and associated components
(Figure 4) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately. Torqued suspension components
as detailed in Table 3.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.
Figure 4. Major Suspension Components
PAGE 16 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — TRAILER SAFETY GUIDELINES
Table 3. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
3/8" U-BOLT
MIN-30 MAX-35
7/16" U-BOLT
MIN-45 MAX-60
1/2" U-BOLT
MIN-45 MAX-60
SHACKLE BOLT
SPRING EYE BOLT
SNUG FIT ONLY. PARTS MUST ROTATE FREELY.
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY.
SHOULDER TYPE
MIN-30 MAX-50
SHACKLE BOLT
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 5. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 4. Tire Torque R equirements
Wheel Si ze
Fi rst Pass
FT-LBS
Second
P a ss
FT-LBS
Thi rd Pass
FT-LBS
12"
20-25
35-40
50-65
13"
20-25
35-40
50-65
14"
20-25
50-60
90-120
15"
20-25
50-60
90-120
16"
20-25
50-60
90-120
Figure 5. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 17
DCA-400SPK — TRAILER-WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
PAGE 18 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — TRAILER-BRAKE TROUBLESHOOTING
Table 5. Electric B rake Troubleshooting
Symptom
Possible C ause
Solution
No Brakes or Intermi ttent
Brakes
Any open ci rcui ts or broken wi res?
Fi nd and correct.
Any short ci rcui ts?
Fi nd and correct.
Faulty controller?
Test and correct.
Any loose connecti ons?
Fi nd and repai r.
Ground wi re secure?
Fi nd and secure.
Grease or oi l on magnets or li ni ngs?
C lean or replace.
C onnecti ons corroded?
C lean and correct
cause of corrosi on.
Brake drums scored or grooved?
Machi ne or replace.
Brakes synchroni zed?
C orrect.
Brake components loose, bent or
broken?
Replace components.
Brake drums out-of-round?
Replace.
System lubri cated?
Lubri cate.
Brake components correct?
Replace and correct.
Beari ngs of the wheel adjusted?
Adjust.
Weak Brakes or Brakes
Pull to One Si de
Locki ng Brakes
Noi sy Brakes
D raggi ng Brakes
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 19
DCA-400SPK — TRAILER-BRAKE TROUBLESHOOTING
Table 6. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Repair or replace.
Weak Brakes or Brakes Pull to
One Side
Brake lining glazed?
Reburnish or replace.
Trailer overloaded?
Correct weight.
Brake drums scored or grooved?
Machine or replace.
Tire pressure correct?
Inflate all tires equally.
Tires unmatched on the same axle?
Match tires.
Brake components loose, bent or broken?
Replace components.
Brake drums out-of-round?
Replace.
System lubricated?
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness correct or in right
wrong position?
Install new shoes and
linings.
Enough brake fluid or correct fluid?
Replace rubber par ts
fill with dot4 fluid.
Locking Brakes
Noisy Brakes
Dragging Brakes
PAGE 20 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — OPERATION AND SAFETY DECALS
Machine Safety Decals
The DCA-400SPK generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information. The illustration below and on the preceding pages shows the decals as they appear on the
machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 21
DCA-400SPK — OPERATION AND SAFETY DECALS
PAGE 22 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — SPECIFICATIONS
Table 7. Specifications
Generator Specifications
Model
DCA-400SPK
Type
Revolving field, self ventilated, open protected type synchronous generator
Armature Connection
Star with Neutral
Phase
3
Standby Output
440 KVA (352.0 KW)
Prime Output
400 KVA (320.0 KW)
Voltage
240V or 480V
Frequency
60 Hz
Speed
1800 rpm
Power Factor
0.8
Aux. AC Power
Single Phase, 60 Hz
Voltage
120 V
Output
4.8 KW (2.4 KW x 2)
Engine Specifications
Model
KOMATSU SA6D140-A
Type
4 Cycle, water-cooled, direct injection, turbo-charged with after-cooler
No. of Cylinders
6 cylinders
Bore x Stroke
5.5 in. x 6.5 in. (140 mm x 165mm)
Rated Output
478 HP/1800 rpm
Displacement
930 cu. in. (15240 cc)
Starting
Electric
Coolant Capacity
16.4 gal. (62 liters)
Lube Oil Capacity
19.5 gal. (74 liters)
20.4gal. (77.5L)/hr at full load
15.8gal.(59.8L)/hr at 3/4 load
11.0gal.(41.6L)/hr at 1/2 load
6.6gal.(25.0L)/hr at 1/4 load
Fuel Consumption
Battery
12V- 200 AH x 2
Fuel
#2 Diesel Fuel
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 23
DCA-400SPK — GENERAL INFORMATION
DCA-400SPK FAMILIARIZATION
Control Box
Generator
The “Control Box” is provided with the following:
ator z Main Circuit Breaker 1060 amps
The MQ Power Model DCA-400SPK is a 320 kW gener
generator
that is designed as a high quality portable (requires a trailer z Over-Current Relay
for transport) power source for telecom sites, lighting z High Idle Adjust Trimmer
facilities, power tools, submersible pumps and other
industrial and construction machinery.
Open Delta Excitation System
Engine Control Panel
The DCA-400SPK generator is equipped with the state of
the art "Open-Delta" excitation system. The open delta
The “Engine Control Panel” is provided with the following:
system consist of an electrically independent winding wound
z Tachometer
among stationary windings of the AC output section.
z Water Temperature Gauge
z Oil Pressure Gauge
There are four leads: A, B, C and D. During light loads, the
z Charging Ammeter Gauge
power to the Automatic Voltage Regulator (AVR) is supplied
z Engine Warning Lamp Module
from the leads parallel connections of B&C. When loads
z Engine Speed Switch
increase, the AVR switches and accepts power from leads
z Pre-Heat Button
A&D. The output of leads A&D increase proportionally with
z Pre-Heat Lamp
load. This of adding the voltages to each phase provides
z Emergency Stop Button
better voltage response during heavy loads.
z Battery Switch
The connections of the AVR to the AC output windings are
Generator Control Panel
The “Generator Control Panel” is provided with the following:
z Output Voltage Adjustment Knob
z Frequency Meter (Hz)
z AC Ammeter (Amps)
z AC Voltmeter (Volts)
z Ammeter Change-Over Switch
z Voltmeter Change-Over Switch
z Panel Light
z Panel Light Switch
z Pilot Lamp
Output Terminal Panel
for sensing only. No power is required from these windings.
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.
Microprocessor Controlled Alarm System
The DCA-400SPK 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-400SPK 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.
The “Output Terminal Panel” is provided with the following:
z
z
z
z
Three 240/139V output receptacles, 50 amp
Two 120V input receptacles, 20 amp
3 Load Circuit Breakers 265V @65 amps
2 Load GFCI Circuit Breakers [email protected] 20amps
PAGE 24 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — GENERAL INFORMATION
Engine
The DCA-400SPK is powered by a 4 cycle, water cooled,
turbocharged KOMATSU Model SA6D140-Adiesel engine.
This engine is designed to meet every performance
requirement for the generator. Reference Table 1, page 16
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.
The basic controls and indicators for the DCA-400SPK
generator are addressed on the following pages.
Mechanical Governor System
The mechanical governor system control the RPM of the
engine. When the engine demands increase or decrease,
the mechanical governor system regulates the frequency
variation to ±1.5%. The electronic governor option increases frequency variation to ±0.25%.
Jacket Water Heater (OPTIONAL)
The jacket water heater is a 1500-watt heater designed to
keep the coolant warm in the engine block for fast starts
and load acceptance. The heater is thermostatically
controlled and once an acceptable engine temperature is
achieved it will cycle on and off, operating only about 1/3 of
the time, which makes it more efficient than the direct block
type heater. It is designed to keep the engine coolant
between 100 and 120 degrees Fahrenheit.
Under normal conditions, 20 to 15 minutes is required to
raise the engine temperature of a cold engine to 100 degrees
Fahrenheit.
Battery Charger
The battery charger will operate in a ‘BOOST’ mode until the
battery’s current acceptance falls to 70% of the charger’s
rating. The charger will then go into a ‘FLOAT’ mode, where
it discharges a lower voltage until an AC failure, or the battery
is discharged.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 25
DCA-400SPK — MAJOR COMPONENTS
Figure 6. Major Components
PAGE 26 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
NOTE PAGE
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 27
DCA-400SPK — DIMENSIONS (TOP AND SIDE)
Figure 7a. Dimensions
PAGE 28 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — DIMENSIONS (FRONT AND REAR)
Figure 7b. Dimensions
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 29
DCA-400SPK — CONTROL PANEL
Figure 8. Control Panel
PAGE 30 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — CONTROL PANEL
The definitions below describe the controls and functions of
the DCA-400SPK " Control Panel " (Figure 8).
1. Pilot Lamp – Indicates that the generator is working
properly.
If the engine does not engage (start) by the third attempt,
the engine will be shutdown by the MPEC's " Over Crank
Protection" mode. If the engine engages at a speed (RPM's)
that is not safe, the MPEC will shutdown the engine by
initializing the "Over Speed Protection" mode.
2. Panel Light – Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When Also the MPEC will shutdown the generator in the event of
the generator is not in use be sure to turn the panel low oil pressure, high coolant temperature, low coolant level,
and loss of magnetic pickup. These conditions can be
light switch to the OFF position.
observed by monitoring the LED status indicators on the
3. Frequency Meter – Indicates the output frequency in front of the MPEC module.
hertz (Hz). Normally 60 Hz ±1 Hz .
A. Off/Manual/Auto Switch – This switch controls the
4. AC Ammeter – Indicates the amount of current the
running of the generator. If this switch is left in the "OFF"
load is drawing from the generator.
position, the generator will not run. When this switch is
set to the manual position, the generator will start
5. AC Voltmeter – Indicates the single phase output
immediately.
voltage present at the UVW terminals.
If the generator is to be connected to a building's AC
6. Ammeter Change-Over Switch – This switch allows
power source via a transfer switch (isolation), place
the AC ammeter to indicate the current flowing to the
the switch in the auto position. In this position the
load connected to any phase of the output terminals, or
generator will monitor the AC line output from the
to be switched off.
building's power source.
7. Voltmeter Change-Over Switch – This switch allows
the AC voltmeter to indicate phase to phase voltage B. Low Oil Pressure – Indicates the engine pressure
has fallen below 15 psi. The oil pressure is detected
between any two phases of the output terminals or to
using variable resistive values from the oil pressure
be switched off.
sending unit. This is considered a major fault.
8. Panel Light Switch – When activated will turn on control
C. High Coolant Temperature – Indicates the engine
panel light.
temperature has exceeded 215°F. The engine
9. Voltage Regulator Control – Allows manual
temperature is detected using variable resistive values
adjustment of the generator’s output voltage.
from the temperature sending unit. This is considered
a major fault.
10. MPEC – Microprocessor
Engine Control Module –
D. Overcrank Shutdown – Indicates the unit has
(MPEC) has a vertical row
attempted to start a pre- programmed number of times,
of status LED's (Figure 9),
and has failed to start. The number of cycles and
that when lit, indicate that an
duration are programmable. Typical programmable start
engine malfunction (fault),
settings is 3 cycles with a 10 second duration .This is
has been detected. When a
considered a major fault.
fault has been detected the
E. Overspeed Shutdown – Indicates the engine is
MPEC will evaluate the fault
running at an unsafe speed. This is considered a major
and if the fault is major will
fault.
shutdown the generator.
Figure 9. MPEC Module F. Engine Running – Indicates that engine is running at
a safe operating speed.
During cranking cycle , The MPEC will attempt to crank the
engine for 10 seconds before disengaging.
11. Main Circuit Breaker – This three-pole, 800 amp main
breaker is provided to protect the UVW voltage output
terminals from overload.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 31
DCA-400SPK — ENGINE OPERATING PANEL
Figure 10. Engine Operating Panel
PAGE 32 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of 4.
the DCA-400SPK " Engine Operating Panel "(Figure 10).
1.
Throttle Handle - This handle controls the speed of
the engine (low or high).
2.
Tachometer – Indicates engine speed in RPM’s for 60
Hz operation. This meter should indicate 1800 RPM’s 5.
when the rated load is applied. In addition a built in hour
meter will record the number of operational hours that 6.
the generator has been in use.
3.
Engine Warning Display Module – This module
display’s the following engine failures:
A. Overheat Lamp – This lamp goes ON when
the cooling water temperature rises
abnormally. If the lamp goes ON during normal
operation of the generator, the emergency
shutdown device will stop the engine
automatically.
B. Low Oil Pressure Lamp – During normal
operation of the generator this lamp should
remain OFF. When the Auto-OFF/ResetManual switch is set to the “Manual” position
to start the engine, the lamp will be lit. After
the oil pressure rises after start-up the lamp will go
OFF. If this lamp is ever lit (ON) during normal operation
of the generator, the emergency shutdown device will
stop the engine automatically.
C. Low Fuel Level Lamp – When this lamp is
ON, it is time to stop the engine and add
fuel. Remember to let the engine cool before
adding fuel.
D. Low Battery Fluid Lamp – This lamp goes
ON when the battery fluid is low. If this lamp
goes ON during normal operation of the
generator, stop the engine and fill the
battery with distilled water to the specified
level.
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.
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.
7.
Fuel Gauge - Indicates amount of diesel fuel available.
8.
Pre-Heat Lamp – Indicates that the glow
plugs of the diesel engine are hot and the
engine is ready to be started.
9.
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.
10. Starter Switch – Use this switch to
preheat the engine and turn on the
generator (This feature will not be on
the unit if it is equipped with a MPECsee Control Panel).
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 the electrical
equipment
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-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 33
DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel” is provided with the following:
z Two 120V GFCI receptacles, 20 amp
z Three 240/139V output receptacles, 50 amp
z Two 120V input receptacles, 20 amp (optional)
z 3 Load Circuit Breakers 265V @65 amps
z 2 Load GFCI Circuit Breakers [email protected] 20amps
Connecting Load
Loads can be connected to the generator by the UVWO Lugs or
the convenience receptacles. (See figure 13). Make sure to
read the operation manual before attempting to connect a load
to the generator.
Control Box
The “Control Box” is provided with the following:
z Main Circuit Breaker 1000 amps
z Over-Current Relay
Output Terminal Panel
The Output Control Panel (See Figure 14) is located on the
right hand side (left from control panel) of the generator.
The UVWO lugs are protected by a face plate cover that
can be secured in the close position by a pad lock. (See
Figure 11).
FIGURE 11. Output Terminal Cover
FIGURE 13. Connecting Load
Circuit Breakers
To protect the generator from an overload, a 3-pole, 1000
amp, main circuit breaker is provided to protect the UVW
output terminals from overload. In addition two single-pole,
20 amp GFCI circuit breakers are provided to protect the
GFCI receptacles from overload. Three 50 amp load circuit
breakers have also been provided to protect the load side of
the generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
Maximum Output
The entire load connected to the UVWO Lugs, all four slots in
the duplex receptacles, and the must not exceed 352 kW in
standby or 320 in prime output.
120 Volt Recetacle
Two GFCI Duplex Nema 5-20R (120V, 20 Amp) recepacle is
provided on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle Twist Lock Dual Voltage Receptacles
is controlled by the circuit breaker located on the control Three CS-6369 auxiliary power receptacles have been
panel.
provided to supply 208/120V. The voltage regulator knob
on the control panel may need to be used to adjust the
voltage to 208 or 416V.
Pressing the reset button resets the receptacle after being
tripped. Pressing the "Test Button" (See Figure 12) in the
center of this receptacle will check the GFCI function. The
receptacle should be tested at least once a month.
Input Receptacles
Two 120 volt, 20 amp input receptacles are provided to supply
power to accessories, such as the battery charger (optional) or
FIGURE 12. GFCI Test Button
jacket water heater (optional).
PAGE 34 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW
NOTE
FIGURE 14. Output Terminal Panel
Legs O and Ground are
considered Bonded Grounds.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 35
DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW
Output Terminal Panel Available Voltages
A wide range of voltages are available to supply load to
many different applications. Voltages may be selected by
using the voltage change-over board and how you hookup
your hard wire connection to the generator. To obtain some
of the voltages listed, fine adjustment with the Voltage
Regulator on the control panel is necessary. See the table
below (Table 8) for a list of available voltages the generator
is able to supply.
Maximum Amps
The following table show the maximum amps the entire
generator can provide. Do not exceed the maximum amps
listed. (See Table 9)
Table 9. Maximum Amps
Model:
DCA400SPK
Rated
Voltage
Maximum Amps
Single Phase
120 Volt
888.9 amps (4 wire)
Single Phase
240 Volt
444.4 amps (4 wire)
Three Phase
240 Volt
962.3 amps
Three Phase
480 Volt
481.1 amps
TABLE 8. VOLTAGES AVAILABLE
MODEL
D C A 400S S K
3 PHASE VOLTAGE
(RECONNECTABLE)
208 VOLT
220 VOLT
240 VOLT
416 VOLT
440 VOLT
480 VOLT
SINGLE PHASE
(ADJUSTABLE)
120 VOLT
127 VOLT
139 VOLT
240 VOLT
254 VOLT
277 VOLT
CAUTION :
NEVER attempt to change the Voltage
Change-over board while the engine is
engaged.
Over Current Relay
An over current relay is connected to the circuit breaker.
In an over current situation, both the circuit breaker and
the over current relay may trip. If the circuit breaker can
not be reset, the reset button on the over current relay
must be pressed. The over current relay is located in the
control box.
PAGE 36 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW
How to read the output terminal gauges.
The gauges and knobs on the control panel DO NOT effect
the generator output in any fashion. They are there to
simply help the operator observe how much power is being
supplied produced at the UVWO legs.
To read the output of the W-U legs, for example, place the
AC Voltmeter Change-over switch to the W-U position and
the AC ammeter Change -over Switch to the U or W
position to read the output on the selected leg.
FIGURE 15. AC Voltmeter
Change-over switch
(Reading the W-U leg on
the output terminal panel)
FIGURE 17. AC Ammeter
Change-over Switch
(Reading the U leg on the
output terminal panel)
FIGURE 16. AC Voltmeter
Gauge
(Volt reading on W-U Lug)
FIGURE 18. AC Ammeter
(Amp reading on U lug)
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 37
DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW
Voltage Change-over Board
The voltage change-over board changes the available
voltages of the output terminal panel UVWO lugs. The
voltage change-over board is located on the control box
behind the control panel. There are six (6) plates that can
be set into two set positions to get six different voltages.
Unless specified differently, the generator comes from the
factory in the 240V position.
Single Phase, 240 Volt
The following connection, with the voltage change-over
board set into the 240V set position (See Figure 19), can
offer SINGLE PHASE power at 240V. After hooking up
the hard wires to the lugs as shown in figure 21 below,
240V will be the voltage output.
240 Volt Set position
The voltage change-over board 240V set position uses all
6 plates in 6 different connection places. See figure 19
below.
FIGURE 21. Hard Wire Hookup for Single Phase 240V
FIGURE 19. Voltage Change-over Board 240V set position.
3 Phase, 240 Volt
The following connection, with the voltage change-over
board set into the 240V set position (See Figure 19), can
offer THREE PHASE power at 240V. After hooking up the
hard wires to the lugs as shown in figure 20 below, 240V
will be the voltage output.
FIGURE 20. Hard Wire Hookup for Three Phase 240V
Single Phase, 139 Volt
The following connection, with the voltage change-over
board set into the 240V set position (See Figure 19), can
offer SINGLE PHASE power at 139V. After hooking up
the hard wires to the lugs as shown in figure 22 below,
139V will be the voltage output.
FIGURE 22. Hard Wire Hookup for Single Phase 139V
PAGE 38 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW
480 Volt Set position
The voltage change-over board 480V set position uses all
6 plates in 3 different connection places. There are 2
plates at every position (Every plate is used). See figure
23 below.
Single Phase, 480 Volt
The following connection, with the voltage change-over
board set into the 480V set position (See Figure 23), can
offer SINGLE PHASE power at 480V. After hooking up
the hard wires to the lugs as shown in figure 25 below,
480V will be the voltage output.
FIGURE 23. Voltage Change-over Board 480V set position.
3 Phase, 480 Volt
The following connection, with the voltage change-over
board set into the 480V set position (See Figure 23), can
offer THREE PHASE power at 480V. After hooking up the
hard wires to the lugs as shown in figure 24 below, 480V
will be the voltage output.
FIGURE 24. Hard Wire Hookup for Three Phase 480V
FIGURE 25. Hard Wire Hookup for Single Phase 480V
Single Phase, 277 Volt
The following connection, with the voltage change-over
board set into the 480V set position (See Figure 23), can
offer SINGLE PHASE power at 277V. After hooking up
the hard wires to the lugs as shown in figure 26 below,
277V will be the voltage output.
FIGURE 26. Hard Wire Hookup for Single Phase 277V
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 39
DCA-400SPK — INSTALLATION
Outdoor Installation
Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure the generator is on secure
level ground so 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.
CAUTION :
An electric shock may happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from electrical shock.
Generator Grounding
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION :
Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
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.
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.
2. When grounding the generator (Figure 27) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
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.
NOTE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
PAGE 40 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — INSTALLATION
Figure 27.
Typical Generator Grounding Application
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 41
DCA-400SPK — PRE-SETUP
General Inspection Prior to Operation
Circuit Breakers
The DCA-400SPK generator has been thoroughly inspected
and accepted prior to shipment from the factory. However,
be sure to check for damaged parts or components, or loose
nuts and bolts, which could have occurred in transit.
To protect the generator from an overload, a 3-pole,1060
amp, main circuit breaker is provided to protect the UVW
output terminals from overload. In addition two single-pole,
20 amp GFCI circuit breakers are provided to protect the
GFCI receptacles from overload. Three 50 amp load circuit
breakers have also been provided to protect the load side of
the generator from overload. Make sure to switch ALL circuit
breakers to the "OFF" position prior to starting the engine.
Extension Cable
When electric power is to be provided to various tools or
loads at some distance from the generator, extension
cords are normally used. Cables should be sized to allow
for distance in length and amperage so that the voltage
drop between the generator and point of use (load) is held
to a minimum. Use the Cable Selection Guide (Table 10)
as a guide for selecting proper cable size.
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
Table 10. C able Selection (60 H z , Single Phase Operation)
Load In Watts
C urrent
At
in
At 120
240
Amperes Volts
Volts
Maximum Allow able C able Length
#10 Wire
#12 Wire
#14 Wire
#16 Wire
2.5
300
600
1000 ft.
600 ft.
375 ft.
250 ft.
5
600
1200
500 ft.
300 ft.
200 ft.
125 ft.
7.5
900
1800
350 ft.
200 ft.
125 ft.
100 ft.
10
1200
2400
250 ft.
150 ft.
100 ft.
15
1800
3600
150 ft.
100 ft.
65 ft.
20
2400
4800
125 ft.
75 ft.
50 ft.
C AUTION: Equi pment damage can result from low voltage.
PAGE 42 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — PRE-SETUP
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, but without being screw
into the filler hole, verify that the oil level is maintained
between the two notches (Figure 28) on the dipstick. See
Table 9 for proper selection of engine oil.
Fuel
Fill the fuel tank with clean and fresh diesel fuel. DO NOT
fill the tank beyond capacity.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 23,
Specification Table 7.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel. Wipe up any spilled fuel immediately.
CAUTION:
Never fill the fuel tank while the engine is
running or in the dark. Diesel spillage on a
hot engine can cause a fire or explosion.
If diesel spillage occurs, wipe up the
spilled diesel completely to prevent fire
hazards.
Coolant
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.
Figure 28. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean and viscous. If the oil is not clean, drain the oil by
removing the oil drain plug, and refill with the specified amount
of oil as outlined in the Komatsu Engine Owner's Manual.
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the engine
manual for further details.
Table 11. Recommended Motor Oil
Temperature
R an g e
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
S A E 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
Below 5° C (-15°)
SAE 10W or SAE 10W-30
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 43
DCA-400SPK — PRE-SETUP
CAUTION :
When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.
Day-to-day addition of coolant is done from the reserve tank.
When adding coolant to the radiator, DO NOT remove the
radiator cap until the unit has completely cooled. See Table
12 for engine, radiator, and reserve tank coolant capacities.
Make sure the coolant level in the reserve tank is always
between the "H" and the "L" markings.
Table 12. C oolant C apaci ty
Engi ne and Radi ator
16.9 Gal. (64.0
Li ters)
Reserve Tank
2 Quarts (1.9 Li ters)
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Table 11. Anti-Freeze Operating Temperatures
Freezing Point
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
battery disconnected.
Air Cleaner
Periodic cleaning/replacement is necessary. See
maintenance section for instruction to cleaning/replacing air
cleaner.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear. See maintenance section on replacing
belts. To adjust tension:
1. Insert a bar between alternator and the cylinder block to
fix alternator in position. When fixing the alternator in
position, insert a wooden block between the bar and
alternator to prevent damage to the alternator.
2. Loosen bolts and nuts located on the alternator.
3. Move alternator with the bar so the deflection of the belt
is approx. 8mm.
4. Tighten the bolt and nuts to fix the alternator back to
position.
The fan belt tension is proper if the fan belt bends 7 to 10
mm (Figure 29) when depressed with the thumb as shown
below.
Boiling Point
Vol %
Anti-Freeze
°C
°F
°C
°F
40
-24
-12
106
222
50
-37
-34
108
226
Figure 29. Fan Belt Tension
CAUTION :
NOTE
When the antifreeze is mixed with
w ater
atio m
ust
ater,, the antifreez
antifreezee mixing rratio
must
be less than 50%.
Never place hands near the belts or fan
while the generator set is running.
PAGE 44 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — PRE-SETUP
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 30) 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 :
Inadequate battery connections may cause
poor starting of the generator, and create
other malfunctions.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check hoses
for leaks.
Figure 30. Battery Connections
CAUTION :
If the battery cable is connected
incorrectly, electrical damage to the
generator will occur. Pay close attention
to the polarity of the battery when
connecting the battery.
When connecting battery do the following:
1. DO NOT connect the battery cables to the battery
terminals when the Off/Manual/Auto switch is in either
the manual or auto position (ON). ALWAYS make sure
that the Off/Manual/Auto switch is in the OFF position
when connecting the battery.
If any hose (fuel or oil) lines are defective replace them
immediately.
Battery
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68°F). If the specific gravity
should fall to 1.245 or lower, it indicates the battery is
discharged and needs to be recharged or replaced.
Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions. Always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help inhibit corrosion.
2. Place a small amount of grease around both battery
terminals. This will ensure a good connection and will
help prevent corrosion around the battery terminals.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 45
DCA-400SPK — LOAD APPLICATION
Single Phase Load
CAUTION:
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.
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.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 14.
below when connecting loads.
Motors and motor-driven equipment draw
much greater current for starting than
during operation.
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.
z 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.
z 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.
z When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
CAUTION:
Table 14. Pow er Factor B y Load
Type Of Load
Si ngle-phase i nducti on
motors
Electri c heaters,
i ncandescent lamps
Fluorescent lamps, mercury
lamps
Electroni c devi ces,
communi cati on equi pment
Pow er Factor
0.4 - 0.75
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.
1.0
0.4 - 0.9
1.0
Three Phase Load
When calculating the power requirements for 3-phase power
use the following equation:
NOTE
If output (kVA) is not given
on the equipment nameplate, approximate
output may be determined by multiplying
voltage by amperage by
.
PAGE 46 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — GENERATOR START-UP PROCEDURE (MANUAL)
WARNING:
Before Starting
zThe engine's exhaust contains harmful
W AY S ventilate the
emissions. A LLW
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.
Engine
1. Check the lubricating oil level prior to starting the engine.
Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.
2. When there is not enough lubricating oil, fill the crankcase
with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 11 on page 43).
3. Check the coolant level in the radiator and subtank.
Replenish with antifreeze as necessary. Always maintain
the coolant level between the FULL and LOW markings
on the coolant container. Be sure the radiator cap is
fastened securely.
4. Check the fuel level on the fuel gauge. If fuel is low, fill
the fuel tank with clean fresh unleaded automotive diesel.
If diesel spillage occurs, completely wipe up the spilled
fuel immediately.
Before Starting
Generator and Control Panel
CAUTION:
z NEVER start the engine with the
main, GFCI or load circuit breakers
in the ON position.
1. Be sure to disconnect the electrical load and switch the
main, load and G.F
.C
.I. circuit breakers (Figure 31) to
G.F.C
.C.I.
the “OFF” position prior to starting the engine.
Jacket Water Heater and Internal Battery Charger 120
VAC Output Receptacles (OPTIONAL)
This generator is equipped with two 120 VAC, 20 amp output
receptacles located on the output terminal panel, page 43,
Figure 14.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 31). To apply
commercial power to these receptacles, a power cord of
adequate size will be required.
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.
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.
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.
CAUTION:
ALWAYS have power applied to the
generator's internal battery charger
when connecting the generator to a
isolation (transfer) switch. Remember
before connecting this generator to
any buildings electrical system, have
a licensed electrician perform the
installation of the transfer switch.
Figure 31. Main, GFCI and
Load Circuit Breakers
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 47
DCA-400SPK — GENERATOR START-UP PROCEDURE (MANUAL)
2. Connect the load to the UVW terminals as shown in
Figure 32. These terminals can be found on the output
terminal panel, see page 35 Figure 14. To gain access
to the output terminals lift the UVW cover. Make sure to
tighten terminal nuts securely to prevent load wires from
slipping out.
4. Close all engine enclosure doors (Figure 34).
Figure 34. Engine Enclosure Doors
5. Set the battery ON/OFF switch (Figure 35) to the ON
position.
Figure 32. UVW Terminal Lugs (Load)
3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 33).
Figure 35. Battery ON/OFF Switch
IVE
ST
PO
E
TIV
GA
NE
6. When starting the generator in COLD weather conditions,
press and hold the engine preheat button (Figure 36)
until the preheat lamp (Figure 37) is lit (ON).
RY
E
TT
A
B
Figure 36. Engine Pre-Heat Button
Figure 33. Battery Connections
Figure 37. Engine Pre-Heat Lamp
PAGE 48 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — GENERATOR START-UP PROCEDURE (MANUAL)
7. Place the Off/Manual/Auto switch (Figure 38) in the
MANUAL position (down). Observe that the engine begins
to crank.
Figure 41. Frequency Meter (Hz)
Figure 38. Off/Manual/Auto Switch (Manual)
8. After engine starts, verify that the "Engine Running"
status LED (Figure 39) on the Microprocessor Engine
Control Module (MPEC) display is "ON" (lit).
11. The generator's voltage meter (Figure 42) displays the
120 VAC in VOLTS. If the voltage is not within the
specified frequency tolerance, use the voltage
adjustment control knob (Figure 43) to increase or
decrease the desired voltage.
Figure 42. Voltage Meter (Volts)
Figure 39. MPEC Engine Running Status LED
9. If the generator is equipped with a ignition switch, turn
the key to “Start” position (Figure 40). Once the engine
starts, release the key to the “on” position.
Figure 43. Voltage Adjust Control
Knob
12. The ammeter (Figure 44) will indicate zero amps with no
load applied. When a load is applied, this meter will
indicate the amount of current that the load is drawing
from the generator’s alternator.
20
Figure 40. Engine Ignition Switch
40
0
60
75
A
10. The generator's frequency meter (Figure 41) displays
the 60 cycle output frequency in HERTZ.
Figure 44. Ammeter (No Load)
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 49
DCA-400SPK — GENERATOR START-UP PROCEDURE (MANUAL)
13. The engine oil pressure gauge (Figure 45) will indicate
the oil pressure (kg/ cm2) of the engine. Under normal
operating conditions the oil pressure should be
approximately 25 psi.
16. Turn the MAIN, GFCI and LOAD circuit breakers to their
"ON" position (Figure 48).
Figure 48. Main and GFCI Circuit Breakers
Figure 45. Oil Pressure Gauge
14. The coolant temperature gauge (Figure 46) will indicate
the coolant temperature. Under normal operating
conditions the coolant temperature should be between
165 and 215 degrees Fahrenheit (Green Zone).
17. Observe the generator's ammeter (Figure 49) and verify
that it reads the anticipated amount of current with
respect to the load. Remember the ammeter will only
display a current reading if the load is in use.
20
40
0
WATER
60
75
TEMP
A
Figure 46. Coolant Temperature Gauge
Figure 49. Ammeter (Load)
15. The tachometer (Figure 47) will indicate the speed of
the engine when the generator is operating. Under normal
operating conditions this speed should be approximately
1800 RPM’s.
18. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 47. Engine Tachometer
PAGE 50 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — GENERATOR START-UP PROCEDURE (AUTO)
CAUTION:
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.
CAUTION:
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.
When starting generator in Auto mode use the "Manual Startup" procedure except where noted (see below).
1. Perform steps 1 through 6 (Before Starting, page 4748) as outlined in the manual starting procedure.
2. Apply commercial power to the internal battery charger
receptacle (to ensure good starting) via commercial
power. An external power cord will be required.
3. Apply commercial power to the jacket water heater
receptacle (not necessary for warm climates) via
commercial power. An external power cord will be
required.
4. Place the Off/Manual/Auto switch (Figure 50) in the
AUTO position (up).
Starting the generator in the "AUTO" mode is similar to
starting the generator in the "MANUAL" mode, with a few
exceptions.
CAUTION:
When running the generator in the AUTO
mode, remember the generator can start
up at any time without warning. NEVER
attempt to perform any maintenance when
the generator is in the auto mode.
Figure 50. Off/Manual Auto Switch
(AUTO)
5. Continue to follow the steps outline in the manual startup procedure (start at step 11, page 49).
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 51
DCA-400SPK — GENERATOR SHUTDOWN PROCEDURE
Engine Shutdown
To shutdown the generator use the following procedure:
1. Place both the MAIN, GFCI and LOAD circuit breakers
to the "OFF position".
2. Let the engine cool by running it for 3-5 minutes with no
load applied.
Emergency Stop
1. To stop the engine in the event of an emergency, PUSH
the emergency stop button ( Figure 53) inward.This button
is located on the generator's engine operating panel,
see page 30, Figure 11.
3. Place the Off/Manual/Auto Switch (Figure 51) in the "OFF/
RESET" position
Figure 53. Emergency Stop Button
Figure 51. Off/Manual Auto Switch (OFF)
4. Verify that the "Engine Running" status LED (Figure 52)
on the Microprocessor Engine Control Module (MPEC)
display is "OFF" (not lit).
CAUTION:
NEVER stop the engine suddenly except
in an emergency. DO NOT use the
emergency stop switch a as method of
shutting down the engine. This switch is
ONLY to be used in the event of an
emergency.
Figure 52. MPEC Engine Running
Status LED (OFF)
5. Remove the load from the UVWO terminal strip (Figure 18
on page 48).
PAGE 52 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
NOTE PAGE
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 53
DCA-400SPK — MAINTENANCE
General Inspection
Prior to each use, the generating set should be cleaned and
inspected for deficiencies. Check for loose, missing or
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.
Outer Element:
1. Loosen wing bolt, remove dust cup, then remove wing
nut and take out element.
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.
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.
6. Check the inner cylinder element clamping nut for
looseness, and retighten if necessary.
7. If seal washer is damaged or the threads of wing nut are
damaged, replace.
8. Remove evacuator valve and clean it with compressed
air. Reinstall.
Inner element (if equipped)
1. Remove the cover and outer element, then remove the
inner element.
2. Cover the air connector opening (outer side) with clean
cloth or cloth tape.
3. Clean the inside of the body. Remove air connector
opening protection.
4. Install a new inner cylinder element to the cylinder and
tighten the nut.
5. Install element.
6. After replacing the element, press the button of the dust
indicator to return the red piston to its original position.
Fuel Addition
Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.
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
condense. This can be reduced by always keeping the tank
as full as possible.
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.
Service Daily
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.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in diesel. Securely
fasten the fuel strainer cap so that fuel will not leak. Check
the fuel strainer every 200 hours of operation or once a month.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil level
must be between the two notches on the dipstick as shown
in Figure 28, page 43.
Flushing Out Radiator and Changing Coolant
1. Stop the engine and allow to cool. Tighten valve of the
corrosion resistor (if equipped).
2. Turn water filer cap slowly and remove it.
3. Prepare a container to catch the coolant, then open drain
plug of the radiator or heat exchanger and drain plug of
the engine, and drain the coolant.
4. After draining the coolant, close drain plugs and fill with
tap water.
PAGE 54 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — MAINTENANCE
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.
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.
7. After flushing, stop the engine, open drain plug and drain
the water, then close drain plugs.
8. After draining the water, flush the system with a flushing
agent. See instructions on flushing agent label.
9. After flushing, open drain plugs and drain out all the
water, then close drain plugs and add tap water so the
water level is near the mouth of the water filler.
10. When the water level is near the mouth of the water
filler, open drain plugs and start the engine, run at low
idling and continue to flush the system until clean water
comes out. Adjust the flow of the water flowing in and
draining out to ensure the radiator is always full during
the flushing operation.
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.
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 radiator cap.
Check Electric Heater (If equipped)
Before starting in cold weather (once a year), please contact
your Komatsu distributor for inspection. Remove electric
heater from the engine intake manifold and check for
disconnections or dirt. When checking or installing the electric
heater, replace the gasket with a new part.
Changing Oil
1. Make sure the oil is cool before changing.
2. Set a container directly under the drain plug of the oil
pan. Loosen the drain plug slowly.
3. Check the drained oil for excessive metal particles or
foreign material. Contact the distributor if there is metal
particles or foreign material.
4. Using a filter wrench, turn filter cartridge to the left to
remove it. If the filter cartridge is filled with a large
amount of oil, wait 10 minutes or so before removing.
Make sure there is no old gasket stuck on the filter holder.
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. Add engine oil through oil filler until the oil level is between
the H and L marks on the dipstick.
7. Run the engine at idling for a short time, then stop the
engine. Recheck the oil level and fill as necessary.
Replacing fuel filter
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.
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.
5. After replacing filter cartridge, loosen air bleed plug.
6. Loosen the knob of feed pump, and pump it up and down
until no bubbles come our with the fuel from air bleed
plug.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 55
DCA-400SPK — MAINTENANCE
7. After bleeding the air, tighten air bleed plug, then push in
the knob of feed pump and lock it in position.
8. Replace Corrosion resistor cartridge (if equipped)
9. Screw in valves at the top of the corrosion resistor.
10. Using a filter wrench, turn the cartridge to the left to
remove it.
11. Coat the seal surface of the new cartridge with engine
oil and install it to the filter holder.
12. Tighten until he packing surface contacts the seal
surface of the filter holder, then tighten a further 2/3 of a
turn.
13. Open 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.
2. Wash the breather in diesel fuel or flushing oil, blow dry
with compressed air, then reinstall it.
3. Inspect the hose and if there is any deteriorated oil stuck
inside the hose. Replace hose if necessary.
Greasing
Using a grease pump, grease the fan hub (1 place) and
tension pulley (2 places).
Generator Storage
For storage of the generator for over 30 days, the following
is required:
z Fill the fuel tank completely, lubricate and change oil.
z Disconnect the negative terminals of the battery and
cover it, or remove it from the machine and store it
separately.
z If the ambient temperature is expected to drop below
0oC, add antifreeze to the radiator.
Removal from long term storage:
z Apply oil to the engine valve and rocker arms, and
examine the operating condition of the valves.
z Remove the oil filler pipe from the turbocharger oil inlet
port, add 0.5-1L (0.13-0.26gal) of oil to the turbocharger,
reinstall the oil filler pipe.
z Change the oil in engine oil pan.
z Replace all the filters.
z Flush the inside of the cooling system.
z Drain the water from the fuel tank and bleed the air from
the fuel system.
z If the engine has not been started for more than one
year, contact your Komatsu distributor to have engine
overhauled.
PAGE 56 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — MAINTENANCE
TABLE 15.
INSPECTION / MAINTENANCE
ENGINE
10 Hrs
DAILY
Check Engine Fluid Levels
X
Check Air Cleaner
X
Check Battery Acid Level
X
Check Fan Belt Condition
X
Check for Leaks
X
Check for Loosening of Parts
X
250 Hrs
Replace Engine Oil and Filter *1
X
Clean Air Filter
X
Drain Bottom of Fuel Tank
X
Clean Unit, Inside and Outside
X
2
GENERATOR
500 Hrs
Change Fuel Filter *
X
Clean Radiator and Check Coolant
Protection Level
X
1000 Hrs
Replace Air Filter Element
X
Change Corrosion Resistor
X
Check all Hoses and Clamps
X
Clean Inside of Fuel Tank
X
Measure Insulation Resistance Over
3M ohms
X
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Replace fuel filter at 250 Hours, first time only.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 57
DCA-400SPK — GENERATOR WIRING DIAGRAM
PAGE 58 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
NOTE PAGE
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 59
DCA-400SPK — ENGINE WIRING DIAGRAM
PAGE 60 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — ENGINE WIRING DIAGRAM (MPEC)
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 61
DCA-400SPK — TROUBLESHOOTING (ENGINE)
Practically all breakdowns can be prevented by proper
handling and maintenance inspections, but in the event of a
breakdown, use the tables shown for
diagnosis based on the Engine Troubleshooting (Table 16). If
the problem cannot be remedied, consult our company's
business office or service plant.
TAB LE 16. EN GIN E TR OU B LESH OOTIN G
SYMPTOM
Engi ne does not start.
POSSIB LE PR OB LEM
SOLU TION
No fuel?
Repleni sh fuel.
Ai r i n the fuel system?
Bleed system.
Water i n the fuel system?
Remove water from fuel tank.
Fuel pi pe clogged?
C lean fuel pi pe.
Fuel fi lter clogged?
C lean or change fuel fi lter.
Excessi vely hi gh vi scosi ty
of fuel or engi ne oi l at low
temperature?
Use the speci fi ed fuel or engi ne oi l.
Fuel wi th low cetane
number?
Use the speci fi ed fuel.
Fuel leak due to loose
i njecti on pi pe retai ni ng nut?
Ti ghten nut.
Incorrect i njecti on ti mi ng?
Adjust.
Fuel cam shaft worn?
Replace.
Injecti on nozzle clogged?
C lean i njecti on nozzle.
Injecti on pump
malfuncti oni ng?
Repai r or replace.
Sei zure of crankshaft,
camshaft, pi ston, cyli nder
li ner or beari ng?
Repai r or replace.
C ompressi on leak from
cyli nder?
Replace head gasket, ti ghten cyli nder head bolt, glow
plug and nozzle holder.
Improper valve ti mi ng?
C orrect or replace ti mi ng gear.
Pi ston ri ng and li ner worn?
Replace.
Excessi ve valve clearance?
Adjust.
Battery di scharged?
C harge battery.
Starter malfuncti oni ng?
Repai r or replace.
Key swi tch malfuncti oni ng?
Repai r or replace.
Wi ri ng di sconnected?
C onnect wi ri ng.
Starter does not run.
PAGE 62 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — TROUBLESHOOTING (ENGINE)
TABLE 16. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
Engine revolution is not
smooth.
Either white or blue exhaust
gas is observed.
Either black or dark gray
exhaust gas is observed.
Deficient output.
POSSIBLE PROBLEM
SOLUTION
Fuel filter clogged or dirty?
Clean or change.
Air cleaner clogged?
Clean or change.
Fuel leak due to loose
injection pipe retaining nut?
Tighten nut.
Injection pump
malfunctioning?
Repair or replace.
Incorrect nozzle opening
pressure?
Adjust.
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe
clogged?
Clean.
Governor malfunctioning?
Repair.
Excessive engine oil?
Reduce to the specified level.
Piston ring and liner worn
or stuck?
Repair or replace.
Incorrect injection timing?
Adjust.
Deficient compression?
Adjust top clearance.
Overload?
Lessen the load.
Low grade fuel used?
Use the specified fuel.
Fuel filter clogged?
Clean or change.
Air cleaner clogged?
Clean or change.
Deficient nozzle injection?
Repair or replace the nozzle.
Incorrect injection timing?
Adjust.
Engine's moving parts
seem to be seizing?
Repair or replace.
Uneven fuel injection?
Repair or replace the injection pump.
Deficient nozzle injection?
Repair or replace the nozzle.
Compression leak?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 63
DCA-400SPK — TROUBLESHOOTING (GENERATOR/ENGINE)
Practically all breakdowns can be prevented by proper diagnosis based on the Engine and Radiator Troubleshooting
handling and maintenance inspections, but in the event of a (Table 17). If the problem cannot be remedied, consult our
breakdown, use the tables shown for
company's business office or service plant.
TABLE 17. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
SOLUTION
AC Voltmeter defective?
Check output voltage using a voltmeter.
Is wiring connection loose?
Check wiring and repair.
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier?
Check and replace.
Is engine speed correct?
Turn engine throttle lever to "High".
Is wiring connections loose?
Check wiring and repair.
Defective AVR?
Replace if necessary.
Is wiring connections loose?
Check wiring and repair.
Defective AVR?
Replace if necessary.
Short Circuit in load?
Check load and repair.
Over current?
Confirm load requirements and reduce.
Defective circuit breaker?
Check and replace.
Over current Relay actuated?
Confirm load requirement and replace.
No Voltage Output
Low Voltage Output
High Voltage Output
Circuit Breaker Tripped
PAGE 64 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — TROUBLESHOOTING (MPEC)
TAB LE 18. MPEC TR OU B LESH OOTIN G
Sympton
Low oi l pressure
li ght i s on.
Low coolant level
li ght i s on.
Hi gh coolant
temperture li ght i s
on.
Overcrank li ght i s
on.
Overspeed li ght i s
on.
Loss of MPU
li ght(s) or on.
Possible C ause
Solution
Low oi l level?
Fi ll oi l level.
Oi l pressure sendi ng uni t fai lure?
Replace oi l pressure sendi ng uni t.
Ti me delay malfunti on i n MPEC ?
Refer to dealer.
Wi re shorted?
Inspect/repai r wi re.
Low coolant level?
Fi ll coolant level.
Sendi ng uni t fai lure?
Replace sendi ng uni t.
Low battery voltage?
Replace/charge battery.
Fan belt tensi on i ncorrect?
Ti ghten/replace fan belt.
Ai r flow i s not ci rculati on through
radi ator?
C lean/repai r radi ator gri ll.
D oors open?
C lose doors.
Exhaust leaki ng?
Replace/repai r gaskets or faulty part.
Generator bei ng overloaded?
C heck/reduce load.
Thermostat fai lure?
Replace thermostat.
Ai r i ntake blocked?
C lear all ai r i ntakes.
Temperature swi tch fai lure?
Replace temperature swi tch.
No or low Fuel?
Fi ll fuel level.
MPEC needs to be cali brated?
Refer to dealer.
RPM engi ne speed too hi gh?
Adjust RPM.
Governor actuator needs to be adjusted?
Adjust governor actuator.
Governor controller needs to be
adjusted?
Adjust governor controller.
MPEC needs to be cali brated?
Refer to dealer.
Magneti c pi ck up out of adjustment?
Adjust magneti c pi ck up.
Magneti c pi ck up di rty?
C lean magneti c pi ck up.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 65
EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the “Items Number” Column
All parts with same symbol in the number column, , #, +,
*
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 66 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — SUGGESTED SPARE PARTS
DCA-400SPK W/K
OMA
TSU SA6D140E-2
W/KOMA
OMATSU
DIESEL ENGINE
1 to 5 Units
Qty.
P/N
Description
10 .....6125817051 ... AIR FILTER
10 .....6003117111 ... FUEL FILTER
10 .....6002111231 ... OIL FILTER
5 ....... 6004111171 ... CARTRIDGE, CORROSION RESISTOR
1 ....... 0601804887 ... CIRCUIT BREAKER
1 ....... 0601810575 ... PILOT LAMP, ENGINE TROUBLE
1 ....... 0601810576 ... PILOT LAMP, ENGINE TROUBLE
1 ....... 0412122258 ... ENGINE FAN BELT
1 ....... 6008155390 ... SWITCH, STARTER
5 ....... 615 ................ KEY SET, STARTER SWITCH (2)
2 ....... 0602122281 ... OIL SWITCH
1 ....... 6212619610 ... RADIATOR HOSE (UPPER)
1 ....... 6212616930 ... RADIATOR HOSE (LOWER)
1 ....... 0605505030 ... FUEL CAP
1 ....... 061820625 .... AUTOMATIC VOLTAGE REGULATOR
1 ....... 0601807307 ... MAIN CIRCUIT BREAKER
1 ....... 0601805840 ... CIRCUIT BREAKER
1 ....... 0601802525 ... HANDLE, MAIN CIRCUIT BREAKER
1 ....... 0601840073 ... VOLTAGE REGULATOR (RHEOSTAT)
2 ....... 0601840121 ... KNOB, VOLTAGE REGULATOR
1 ....... 0601810072 ... PILOT LAMP
2 ....... 0601810261 ... BULB, PILOT LAMP
1 ....... 2016012191 ... CAP, RADIATOR
1 ....... 0602122200 ... UNIT, OIL PRESSURE
1 ....... 0602123206 ... UNIT, WATER TEMPERATURE
1 ....... 0602121052 ... CHARGING AMMETER
NOTE
Part number on this Suggested Spare
Parts list may supercede/replace the
P/N shown in the text pages of this
book.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 67
DCA-400SPK GENERATOR ASSY.
GENERATOR ASSY.
PAGE 68 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
1-18
1-19
2
3
4
5
5-1
6
6-1
7
7-1
8
9
10
10-1
10-2
11
12
13
14
15
16
17
18
19
PART NO.
8211000012
8201070002
0012112040
0042512000
8201611004
8201015003
0012116040
0042616000
8171026013
0601821349
0601822615
8171020004
8171020504
0010110020
0040010000
0601000209
8201014004
0071906315
0080000075
8201614003
0012116040
0042516000
8211340303
0226200495
8211323004
0223300172
8211323103
0221200440
0010110035
0041210000
8211324003
0226000303
0225000590
0017106016
8201315102
8201350003
0012110075
0042610000
0041210000
0845044904
0010112045
0040012000
PART NAME
QTY.
REMARKS
ROTOR ASSY.
1
FIELD ASSY.
1
FAN
HEX. HEAD BOLT
12
LOCK WASHER
12
COUPLING DISK
12
BALANCING PLATE
1
HEX. HEAD BOLT
10
LOCK WASHER
10
SET PLATE RECTIFIER
1
RECTIFIER ..................................................... 3 ......... PT3610
SURGE ABSORBER ...................................... 1 ......... ERZM20JK621B
INSULATOR WASHER
1
INSULATOR WASHER
1
HEX. HEAD BOLT
6
LOCK WASHER
6
BALANCING WEIGHT KIT
1
BEARING FLANGE
1
BEARING ........................................................ 1 ......... 76315DDUC3
SNAP RING
1
COUPLING RING
1
HEX. HEAD BOLT
6
LOCK WASHER
6
STATOR ASSY.
1
RUBBER SEAL
1
CLAMPER
1
RUBBER SEAL
1
CLAMPER
1
RUBBER SEAL
1
HEX. HEAD BOLT
2
PLAIN WASHER
2
COVER
1
RUBBER SEAL
2
RUBBER SEAL
1
HEX. HEAD BOLT
6
END BRACKET
1
FIELD ASSY. EXCITER
1
HEX. HEAD BOLT
6
LOCK WASHER
6
PLAIN WASHER
6
GROMMET
1
HEX. HEAD BOLT
8
LOCK WASHER
8
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 69
DCA-400SPK GENERATOR ASSY.
GENERATOR ASSY.
PAGE 70 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK GENERATOR ASSY.
GENERATOR ASSY.
NO.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
PART NO.
0041212000
8201310014
8201312014
0010106065
0040006000
0041206000
8171331013
0017106012
8171333003
0010106030
0040006000
0041206000
0012112035
0042512000
8201332003
0605000012
0030020000
0040020000
PART NAME
PLAIN WASHER
COVER, BEARING
GASKET, BEARING
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
COVER, END BRACKET
HEX. HEAD BOLT
COVER, END BRACKET
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
HEX. HEAD BOLT
LOCK WASHER
COVER, FAN
RUBBER SUSPENSION
HEX. NUT
LOCK WASHER
QTY.
8
1
1
6
6
6
1
6
1
2
2
2
16
16
1
4
8
8
REMARKS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 71
DCA-400SPK CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 72 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO
1
2
3
4
4-1
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
PART NO
PART NAME
QTY.
REMARKS
8221812812
0601801170
0027106016
0601805771
0601802522
0601820625
0027105012
0601820853
0027104016
0601823757
0601823143
PYCA1
0027104016
8221861103
8221852104
0017108030
8221853104
0801830804
0040016000
0041416000
0801830704
0040012000
0041412000
0010010035
0040010000
0041210000
8221833403
0017108020
0602201911
0027106016
0602200446
0017106016
9039211273
8221822503
C ONTROL BOX
1
CURRENT TRANSFORMER, AMMETER . 3 ........ CW5L 750/5A
MACHINE SCREW
6
CIRCUIT BREAKER .................................. 1 ........ TO1000B 1000A
HANDLE, CIRCUIT BREAKER
1
AUTOMATIC VOLTAGE REGULATOR ........ 1 ........ NTA5A2T
MACHINE SCREW
4
OVERCURRENT RELAY ........................... 1 ........ THK20KP
MACHINE SCREW
2
RELAY ....................................................... 2 ........ MY2DC24V
SOCKET .................................................... 2 ........ PYF08A
HOLDER .................................................... 2 ........ REPLACES0601824400
MACHINE SCREW
4
SET BOARD, CHANGE TERMINAL
1
CHANGE TERMINAL
10
HEX.HEAD BOLT
20
CHANGE PLATE
6
HEX. HEAD BOLT
10
LOCK WASHER
10
PLAIN WASHER
10
HEX. HEAD BOLT
16
LOCK WASHER
16
PLAIN WASHER
16
HEX. HEAD BOLT
4
LOCK WASHER
4
PLAIN WASHER
4
SET PANEL, ELECTRIC PARTS
1
HEX HEAD BOLT
4
UNIT, BATTERY SENSOR ......................... 1 ........ C7038A0000
MACHINE SCREW
1
EMERGENCY RELAY ............................... 1 ........ 6008151252
HEX. HEAD BOLT
4
CONTROL PANEL
1
CONTROL PANEL
1
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 73
DCA-400SPK CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 74 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
PART NO
PART NAME
QTY.
REMARKS
0605011211
0601800470
0601805750
0601801040
0601800233
0601801041
0601810072
0601810261
060184073
0601840121
0601810161
0601810214
0207004000
0601830710
0805001304
0041208000
0605010710
3871824004
0041206000
0605010502
8221814704
0017108020
8221826904
0017108020
8221827704
0017108020
0010010035
0030010000
0040010000
0041210000
PIN
4
FREQUENCY METER ............................ 1............ PAK80 220V 45~65Hz
AC AMMETER ........................................ 1............ PSK60 0~750A 0~1500A
CHG.OVER SWITCH,AMMETER ........... 1............ SL2AS
AC VOLTMETER ..................................... 1............ PCK80 0~600V
CHG.OVER SWITCH, VOLTMETER ....... 1............ SL2VS
PILOT LAMP
1
BULB
1
RHEOSTAT ............................................. 1............ RA20A2SE102BJ
KNOB
1
PANEL LIGHT
1
BULB
1
HEX. NUT
2
SWITCH, PANEL LIGHT ......................... 1............ S301T
SET PANEL
4
PLAIN WASHER
4
SNAP RING
4
STOPPER, CONTROL PANEL
2
PLAIN WASHER
2
SNAP PIN
2
COVER, CONTROL BOX
1
HEX.HEAD BOLT
8
SIDE PANEL, CONTROL BOX
1
HEX. HEAD BOLT
4
PANEL, CONTROL BOX
1
HEX.HEAD BOLT
8
HEX. HEAD BOLT
4
HEX. NUT
4
LOCK WASHER
4
PLAIN WASHER
8
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 75
DCA-400SPK ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 76 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
PART NO.
8210150104
6212619900
8215103504
6995619230
0010120055
0040020000
0041220000
8215123004
0010112025
0040012000
0041212000
6212619610
6212619630
0726102612
6212619650
0728100909
0728101029
0728100489
0728100167
6128817051
6002111230
6003117130
6004111170
8215112203
0010118060
0030018000
0040018000
0041218000
0605000012
0030020000
0040020000
0802081003
PART NAME
QTY.
REMARKS
ENGINE .......................................................... 1 ......... SA6D140A
RADIATOR ...................................................... 1 ......... REPLACES 0602011885
RUBBER SEAL
1
RUBBER SHEET ............................................ 2 ......... REPLACES 0605000085
HEX. HEAD BOLT
4
LOCK WASHER
4
PLAIN WASHER
4
BRACKET, RADIATOR
2
HEX. HEAD BOLT
4
LOCK WASHER
4
PLAIN WASHER
4
RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013962
RADIATOR HOSE ........................................... 1 ......... REPLACES 0602014467
RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013963
RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013964
HOSE BAND ................................................... 3 ......... REPLACES 0602014056
HOSE BAND ................................................... 1 ......... REPLACES 0602014350
HOSE BAND ................................................... 2 ......... REPLACES 0602014351
HOSE BAND ................................................... 2 ......... REPLACES 0602014059
ELEMENT, AIR CLEANER .............................. 1 ......... REPLACES 0602040157
CARTRIDGE, OIL FILTER .............................. 1 ......... REPLACES 0602041146
CARTRIDGE, FUEL FILTER ........................... 1 ......... REPLACES 0602042157
CARTRIDGE, CORROSION RESISTOR ........ 1 ......... REPLACES 0602045144
ENGINE FOOT
1
HEX. HEAD BOLT
2
HEX. NUT
2
LOCK WASHER
2
PLAIN WASHER
4
RUBBER SUSPENSION
4
HEX. NUT
8
LOCK WASHER
8
RESERVE TANK
1
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 77
DCA-400SPK ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 78 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO.
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
PART NO.
0602010900
8212082103
0229200600
0017106025
0017108020
0199601150
0193601300
0605515024
0194700400
0194700450
0198501050
3972220103
0017110025
8212256104
0019208020
8212044103
0017110025
PART NAME
CAP, RESERVE TANK
BRACKET, RESERVE TANK
RUBBER CUSHION
HEX. HEAD BOLT
HEX. HEAD BOLT
HOSE
HOSE
HOSE BAND
HOSE
HOSE
HOSE
SUPPORT ROD
HEX. HEAD BOLT
SUPPORT ROD
HEX. HEAD BOLT
OIL PANEL
HEX. HEAD BOLT
QTY.
1
1
1
1
2
1
1
2
1
1
1
1
2
1
2
1
2
REMARKS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 79
DCA-400SSKENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 80 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO
1
2
3
4
5
6
7
8
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
39
PART NO
9039211283
0017106016
0602101000
0021008080
0030008000
0040008000
00412080000
0840201200
08212183004
0845045604
0042412000
0205008000
0042308000
0042408000
8212152004
8212152104
0602180106
0030008000
0207006000
0602100049
0601804045
0602102055
0602120054
0602120156
0602122053
0602122200
0602123053
0602123206
0602121052
0602124053
0602123206
0602040690
6203306104
0603300000
0603301000
0603302000
0603303000
0190001600
0602115008
0601810204
8221860203
0801830404
0801830904
0039320000
0040020000
PART NAME
OPERATING PANEL
HEX. HEAD BOLT
BATTERY SWITCH
MACHINE SCREW
HEX. NUT
LOCK WASHER
PLAIN WASHER
THROTTLE HANDLE`
LINK, GOVERNOR ROD
PIN BOLT
PLAIN WASHER
HEX. NUT
LOCK WASHER
PLAIN WASHER
GOVERNOR ROD
GOVERNOR ROD
BALL JOINT
HEX. NUT
HEX. NUT
STARTER SWITCH
STOP BUTTON
PREHEAT INDICATOR
TACHOMETER
CABLE, TACHOMETER
OIL PRESSURE GAUGE
UNIT, OIL PRESSURE
WATER TEMPERATURE GAUGE
UNIT, WATER TEMPERATURE
CHARGING AMMETER
OIL TEMPERATURE GAUGE
UNIT, OIL TEMPERATURE
INDICATOR, AIR CLEANER
SOCKET
HALF UNION
ELBOW UNION
SLEEVE
NUT
NYLON PIPE
OK MONITOR
BULB
SET BOARD, OUTPUT TERMINAL
OUTPUT TERMINAL
HEX. HEAD BOLT
HEX. NUT
LOCK WASHER
QTY.
1
12
1
2
2
2
2
1
1
1
20
1
1
2
1
1
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
6
1
8
8
16
24
REMARKS
9827300090
6008155390
0806410000
6008153730
25000KX4110
62500KA4210 L=3000
42000KV0300
53000AC0101
4000KV0700
51000KS0600
43000KV0300
40000KV0800
51400KS0600
RBX002252
V33676A
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 81
DCA-400SSKENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 82 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO
40
41
42
43
44
45
46
47
47-1
48
49
50
51
52
53
54
55
PART NO
0041420000
3501860604
0019110040
0042310000
0042410000
0601812597
0601811034
0601805313
0601805840
8211834203
0223300200
0019106035
0042306000
0042406000
8215082003
0019112045
0042412000
0805009804
0205012000
0845043704
0019208020
PART NAME
PLAIN WASHER
TERMINAL PLATE
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
RECEPTACLE, AUX. POWER
RECEPTACLE, AUX. POWER
CIRCUIT BREAKER
CIRCUIT BREAKER
BRACKET, CIRCUIT BREAKER
RUBBER CUSHION
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
COVER, OUTPUT TERMINAL
HEX. HEAD BOLT
PLAIN WASHER
RUBBER WASHER
HEX. NUT
SPRING
HEX. HEAD BOLT
QTY.
32
3
5
5
5
2
3
2
3
1
1
2
2
2
1
2
4
2
2
2
2
REMARKS
5-20R GF5352
CS6369
KM51 20A
KM52 50A
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 83
DCA-400SPK — BATTERY ASSY.
BATTERY ASSY.
PAGE 84 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — BATTERY ASSY.
BATTERY ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
PART NO.
0168719052
0805018904
0805006404
0805006504
0037808000
0040008000
0041208000
8212265304
8212265104
6212265504
8212265704
8212265904
0010010030
0030010000
0845040114
0845041004
0845040214
0845041104
0602220205
PART NAME
BATTERY
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
WING NUT
LOCK WASHER
PLAIN WASHER
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
EARTH CABLE
HEX. HEAD BOLT
HEX. NUT
TERMINAL CAP
TERMINAL CAP
TERMINAL CAP
TERMINAL CAP
BATTERY SENSOR
QTY.
2
2
1
2
2
2
2
1
1
1
1
1
4
4
1
1
1
1
1
REMARKS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 85
DCA-400SPK — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 86 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — MUFFLER ASSY.
MUFFLER ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
11-1
12
13
14
15
16
17
18
19
20
21
22
PART NO.
8212311002
0019112025
0042312000
0042412000
8212356004
8222356104
8222356204
0019110030
0042310000
0042410000
8212350003
0602320095
0010312060
0010312030
0030312000
0040012000
0041212000
8212355003
7432356104
0019112050
0030012000
0042312000
0042412000
PART NAME
MUFFLER
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
PACKING
PACKING
PACKING
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
EXHAUST PIPE
GASKET
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. NUT
LOCK WASHER
PLAIN WASHER
OUTLET PIPE
GASKET
HEX. HEAD BOLT
HEX. NUT
LOCK WASHER
PLAIN WASHER
QTY.
1
4
4
4
2
1
1
10
10
10
1
2
4
4
8
4
12
1
1
4
4
4
8
REMARKS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 87
DCA-400SPK — FUEL TANK ASSY.
FUEL TANK ASSY.
PAGE 88 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — FUEL TANK ASSY.
FUEL TANK ASSY.
NO.
1
1-1
1-2
1-3
1-4
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
PART NO.
8215510503
0845500104
0810105400
0264100390
0605515079
8225523104
0805003414
0017108020
0037908000
0222100300
0130206000
3515512014
0603325011
0132006000
0191302290
0191302390
0191003750
0605515014
0605515024
0605503020
0802120604
0845039604
PART NAME
FUEL TANK
CAP, FUEL TANK
FUEL FILTER
HOSE, FUEL GAUGE
HOSE BAND
TANK BAND
PAD, TANK BAND
HEX. HEAD BOLT
HEX. NUT
TANK SHEET
STREET ELBOW
DRAIN JOINT
VALVE
PLUG
SUCTION HOSE
RETURN HOSE
RETURN HOSE
HOSE BAND
HOSE BAND
FUEL SENSOR
PACKING
RUBBER SEAL
QTY.
1
1
1
1
2
2
4
2
2
6
1
1
1
1
1
1
1
4
2
1
1
1
REMARKS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 89
DCA-400SPK — ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 90 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
PART NO.
8215111022
3515116114
8215116004
0019208020
8215020204
8215102003
0019110025
0042310000
0042410000
8225125104
8225125204
8225102104
0019208020
0845042703
0019208020
8215125003
0019208020
8215131202
0010120070
0030020000
0040020000
0041220000
0010120060
0030020000
0040020000
0041220000
8215041414
8215940304
8225151004
0207006000
PART NAME
BASE
FLOOR PANEL
FLOOR PANEL
HEX. HEAD BOLT
FRONT FRAME
LINING
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
COVER, FRONT FRAME
COVER, FRONT FRAME
LINING
HEX. HEAD BOLT
FILLER BRACKET
HEX. HEAD BOLT
COVER, FRONT FRAME
CENTER FRAME
HEX. HEAD BOLT
HEX. NUT
LOCK WASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCK WASHER
PLAIN WASHER
REAR FRAME
LINING
LOUVER PANEL
HEX. NUT
QTY.
1
1
1
14
1
1
8
8
8
1
1
1
28
1
4
1
REMARKS
1
6
6
6
12
8
8
8
16
1
1
1
18
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 91
DCA-400SPK — ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 92 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
PART NO.
0019110025
0042310000
0042410000
8215155203
8215946304
8195151204
0207006000
0019208020
8215155104
8215102804
0017108020
8215143503
8225143403
8225147004
0037906000
0845050804
0845052404
0021806016
8225146204
8225146304
0845050704
0207006000
0805011304
0805011204
0207006000
0845047104
0845045004
0845047204
0845045004
0019208020
8215161002
PART NAME
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
COVER, REAR FRAME
LINING
LOUVER PANEL
HEX. NUT
HEX. HEAD BOLT
DUCT COVER
LINING
HEX. HEAD BOLT
DOOR, REAR FRAME
DOOR, REAR FRAME
WINDOW PLATE
HEX. NUT
DOOR HANDLE
KEY, DOOR HANDLE
MACHINE SCREW
DOOR ROD
DOOR ROD
STAY
HEX. NUT
STOPPER, DOOR
STOPPER, DOOR
HEX. NUT
HINGE
WASHER
HINGE
WASHER
HEX. HEAD BOLT
ROOF PANEL
QTY.
4
4
4
1
1
3
18
15
1
1
12
1
1
2
12
1
1
4
1
1
4
8
1
1
4
2
2
2
2
6
1
REMARKS
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 93
DCA-400SPK — ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 94 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
PART NO.
0800251701
0025006016
0042306000
0042406000
8215161102
8215102103
0019208020
0019110025
0042310000
0042410000
9039211263
8215103204
0019108065
0042308000
0042408000
8215172113
8215972904
8215172013
8215972904
8215172803
8215102404
8215172903
8215102303
0019110070
0042310000
0042410000
8215171803
8215970903
8215171903
8215970903
8215172603
8215971104
8215172703
8215971304
PART NAME
FILLER COVER
MACHINE SCREW
LOCK WASHER
PLAIN WASHER
ROOF PANEL
LINING
HEX. HEAD BOLT
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
SPLASHER PANEL
LINING
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
SIDE PANEL
LINING
SIDE PANEL
LINING
SIDE PANEL
LINING
SIDE PANEL
LINING
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
SIDE DOOR
LINING
SIDE DOOR
LINING
SIDE DOOR
LINING
SIDE DOOR
LINING
QTY.
1
2
2
2
1
1
10
42
42
42
1
1
6
6
6
1
1
1
1
1
1
1
1
16
16
16
1
1
1
1
1
1
1
1
REMARKS
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 95
DCA-400SPK — ENCLOSURE ASSY.
ENCLOSURE ASSY.
PAGE 96 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — ENCLOSURE ASSY.
ENCLOSURE ASSY.
NO.
PART NO.
PART NAME
60
61
62
63
8195151004
8215151004
0207006000
8215176004
8215974504
8215176204
8215103404
0017108020
0825007362
0605010225
0021806016
0845046904
0845045004
0845047004
0845045004
0019208020
0601850097
0021008025
0845031504
8215312002
0017110030
0010110030
0030010000
0040010000
0041210000
6360510003
0021106020
LOUVER PANEL
LOUVER PANEL
HEX. NUT
DUCT
LINING
DUCT
LINING
HEX. HEAD BOLT
DOOR HANDLE
KEY
MACHINE SCREW
HINGE
WASHER
HINGE
WASHER
HEX. HEAD BOLT
STOPPER
MACHINE SCREW
CAP
SUPPORT LEG
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. NUT
LOCK WASHER
PLAIN WASHER
EMBLEM
MACHINE SCREW
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
QTY.
REMARKS
2
1
18
2
1
1
1
18
7
1
28
8
8
8
8
40
10 .......... 30029
10
20
1
3
2
2
2
2
2
4
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
1-ORANGE
6 -CATERPILLAR YELLOW
2-WHITE
3 -SPECTRUM GRAY 7 -CATO GOLD
4 -SUNBELT GREEN 8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 97
DCA-400SPK — RUBBER SEAL ASSY.
PAGE 98 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
NO.
79
80
81
82
83
84
85
86
87
88
89
PART NO.
0228901450
0228901390
0228900795
0228900850
0229201440
0229201440
0228800795
0228801240
0229201340
0228100120
0228100510
PART NAME
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
QTY.
3
3
8
1
1
2
2
2
1
4
4
REMARKS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 99
DCA-400SPK — OIL PIPING ASSY.
OIL PIPING ASSY.
PAGE 100 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — OIL PIPING ASSY.
OIL PIPING ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NO.
0602023040
8215191013
0017106025
0017110030
7522054204
0131506000
0120006005
3972027104
3972054104
3972054304
0265801650
0605515003
0193301200
0605515004
PART NAME
PUMP
BRACKET, PUMP
HEX. HEAD BOLT
HEX. HEAD BOLT
BUSHING
NIPPLE
VALVE
HOSE JOINT
HOSE JOINT
PACKING
HOSE
HOSE BAND
HOSE
HOSE BAND
QTY.
1
1
5
4
1
1
1
1
1
1
1
2
1
1
REMARKS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 101
DCA-400SPK — NAME PLATE AND DECALS
NAME PLATE AND DECALS
CONTROL BOX GROUP
ENGINE OPERATING PANEL GROUP
PAGE 102 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — NAME PLATE AND DECALS
NAME PLATE ASSY.
NO.
PART NO.
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
0800520100
0800520904
0800520814
0840624504
0840624604
0840624704
0840624804
B9531100604
C0551000903
C2551000004
C3561101103
PART NAME
QTY.
REMARKS
CONTROL BOX GROUP
PLATE: ON-OFF .............................................. 1 ......... AT-202
PLATE: AMMETER CHNG.-OVER SWTH. ..... 1 ......... N-2438
PLATE: VOLTMETER CHNG.-OVER SWTH. .. 1 ......... N-2439
DECAL: CIRCUIT BREAKER .......................... 1 ......... S-3031
DECAL: PANEL LIGHT SWITCH ..................... 1 ......... S-3032
DECAL: PILOT LAMP ..................................... 1 ......... S-3033
DECAL: VOLTAGE REGULATOR ..................... 1 ......... S-3034
DECAL: WARNING .......................................... 1 ......... B93110060
DECAL: OUTPUT VOLTAGE SETTING ........... 1 ......... C05100090
DECAL: SAFTETY INSTRUCTIONS ............... 1 ......... C25100000
DECAL: WHISPERWATT 400 .......................... 1 ......... C36110110
4-1
4-2
4-3
4-4
4-5
0840625004
0840625104
C0551000504
C0551000704
C0551000804
ENGINE OPERATING PANEL GROUP
DECAL: PREHEAT LAMP ............................... 1 ......... S-3036
DECAL: STARTER SWITCH ........................... 1 ......... S-3037
DECAL: BATTERY SWITCH ........................... 1 ......... C05100050
DECAL: LOW - HIGH ...................................... 1 ......... C05100070
DECAL: STOP BUTTON ................................. 1 ......... C05100080
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 103
DCA-400SPK — NAME PLATE AND DECALS
NAME PLATE AND DECALS
BONNET GROUP
BATTERY GROUP
ENGINE AND RADIATOR GROUP
PAGE 104 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
DCA-400SPK — NAME PLATE AND DECALS
NAME PLATE ASSY.
NO.
PART NO.
PART NAME
3-1
3-2
3-3
6360610304
B9504000404
B9504100104
ENGINE & RADIATOR GROUP
DECAL: WATER ............................................... 1 ......... S-1880
DECAL: WARNING .......................................... 2 ......... B90400040
DECAL: WARNING .......................................... 1 ......... B90410010
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
0840614104
0840619904
B4551000103
B9511100304
B9511100404
B9531100504
C0551000404
C1551000404
OUTPUT TERMINAL GROUP
DECAL: GROUND ........................................... 1 ......... S-2635
DECAL: DANGER ............................................ 1 ......... S2731
DECAL: RECEPTACLE & CIRCUIT BREAK ... 1 ......... B45100010
DECAL: WARNING .......................................... 1 ......... B91110030
DECAL: WARNING .......................................... 1 ......... B91110040
DECAL: WARNING .......................................... 1 ......... B93110050
DECAL: 3-PHASE OUTPUT TERMINAL ......... 1 ......... C05100040
DECAL: 240/139 VOLT .................................... 2 ......... C15100040
6-1
6-2
0800689404
0800689504
BATTERY GROUP
DECAL: + ........................................................ 1 ......... S-2090
DECAL: - ......................................................... 1 ......... S-2091
7-1
7-2
B9504200004
B9511100204
MUFFLER GROUP
DECAL: WARNING ........................................... 1 ......... B90420000
DECAL : CAUTION ........................................... 1 ......... B91110020
1320620904
6360620004
B9504500004
FUEL TANK GROUP
DECAL: DIESEL FUEL .................................... 1 ......... S-1756
DECAL: FUEL DRAIN PLUG ............................ 1 ......... S-1883
DECAL: WARNING ........................................... 1 ......... B90450000
9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8
9-9
9-10
9-11
1320610603
1320621504
0840625902
B9504000304
C3561101003
C3561100903
C3561100604
C3561100803
C3561100104
C3561100703
C3561100203
BONNET GROUP
DECAL: WATER - OIL ....................................... 1 ......... S-1760
DECAL: SUPPORT HOOK ............................... 2 ......... S-2257
DECAL: MQ ...................................................... 1 ......... S-3057
DECAL: CAUTION ............................................ 1 ......... B90400030
STRIPE
1
STRIPE
1
STRIPE
2
STRIPE
1
STRIPE
2
STRIPE
1
STRIPE
1
1-1
0800655603
DECAL: HANDLING PROCEDURES .............. 1 ......... S-2763A
8-1
8-2
8-3
QTY.
REMARKS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 105
TERMS AND CONDITIONS OF SALE — PARTS
Effective: July 1, 2000
PAYMENT TERMS
4.
Terms of payment for parts are net 10 days.
FREIGHT POLICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a signed
manifest has been obtained from the carrier,
and any claim for shortage or damage must be
settled between the consignee and the carrier.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
5.
Parts must be in new and resalable
condition, in the original Multiquip package
(if any), and with Muiltiquip part numbers
clearly marked.
6.
The following items are not returnable:
MINIMUM ORDER
a.
Obsolete parts. (If an item is listed
in the parts price book as being
replaced by another item, it is
obsolete.)
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
prior to the return date.
PRICING AND REBATES
Prices are subject to change without prior
notice. Price changes are effective on a specific
date and all orders received on or after that date
will be billed at the revised price. Rebates for
price declines and added charges for price
increases will not be made for stock on hand at
the time of any price change.
Multiquip reserves the right to quote and sell
direct to Government agencies, and to Original
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
SPECIAL EXPEDITING SERVICE
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
c.
Any line item with an extended dealer
net price of less than $5.00.
RETURNED GOODS POLICY
d.
Special order items.
Return shipments will be accepted and credit
will be allowed, subject to the following
provisions:
e.
Electrical components.
f.
Paint, chemicals, and lubricants.
LIMITATIONS OF SELLER’S LIABILITY
g.
Decals and paper products.
h.
Items purchased in kits.
Multiquip shall not be liable here under for
damages in excess of the purchase price of the
item with respect to which damages are claimed,
and in no event shall Multiquip be liable for loss
of profit or good will or for any other special,
consequential or incidental damages.
1.
A Returned Material Authorization must
be approved by Multiquip prior to shipment.
2.
To obtain a Return Material Authorization,
a list must be provided to Multiquip Parts
Sales that defines item numbers,
quantities, and descriptions of the items to
be returned.
a.
3.
The parts numbers and descriptions
must match the current parts price
list.
b.
The list must be typed or computer
generated.
c.
The list must state the reason(s) for
the return.
d.
The list must reference the sales
order(s) or invoice(s) under which
the items were originally purchased.
e.
The list must include the name and
phone number of the person
requesting the RMA.
A copy of the Return Material
Authorization must accompany the return
shipment.
7.
The sender will be notified of any material
received that is not acceptable.
8.
Such material will be held for 5 working
days from notification, pending
instructions. If a reply is not received
within 5 days, the material will be returned
to the sender at his expense.
9.
Credit on returned parts will be issued at
dealer net price at time of the original
purchase, less a 15% restocking charge.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
11. Credit issued will be applied to future
purchases only.
A $20.00 to $50.00 surcharge will be added to
the invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
LIMITATION OF WARRANTIES
No warranties, express or implied, are made in
connection with the sale of parts or trade
accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes not
authorizes any person to assume for it any
other obligation or liability whatever in
connection with the sale of its products. A part
from such written statement of warranty, there
are no warranties, express, implied or statutory,
which extend beyond the description of the
products on the face hereof.
PAGE 106 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)
NOTE PAGE
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 107
PARTS AND OPERATION MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PAR
TS DEP
AR
TMENT
ARTS
DEPAR
ARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
VICE DEP
AR
TMENT
SER
ARTMENT
SERVICE
DEPAR
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEP
AR
TMENT
DEPAR
ARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
Manufactured for Multiquip Inc.
by
DENYO MANUFACTURING, CO., USA
MULTIQUIP INC.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX: 310-537-3927
E-MAIL: [email protected]
WWW: multiquip.com
Atlanta • Boise • Dallas • Houston • Newark
Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX
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