Multiquip DCA-15SPX3 User Manual

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PARTS AND OPERATION MANUAL

MQ POWER

Model DCA-15SPX3

WHISPERWATT

GENERATOR

Revision #2 (09/03/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-835-2551 FAX: 310-537-3927 FAX: 310-638-8046

E-mail:mq@multiquip.com • www:multiquip.com

SERVICE DEPARTMENT:

PAGE 2 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

ARAR

TS DEPTS DEP

TS DEP

ARAR

TS DEPTS DEP 800/427-1244 or 310/537-3700 FAX: 800/672-7877 or 310/637-3284

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

SERSER

SER

SERSER 800/835-2551 or 310/537-3700 FAX: 310/638-8046

WW 800/835-2551, or 310/537-3700 FAX: 310/698-8046

MAINMAIN

MAIN

MAINMAIN 800/421-1244 or 310/537-3700 FAX: 310/537-3927

VICE DEPVICE DEP

VICE DEP

VICE DEPVICE DEP

ARRANTY DEPARRANTY DEP

ARRANTY DEP

ARRANTY DEPARRANTY DEP

ARAR

TMENTTMENT

TMENT

ARAR

TMENTTMENT

ARAR

TMENTTMENT

TMENT

TMENTTMENT

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help ............................................ 3

Table Of Contents ..................................................... 4

Parts Ordering Procedures ....................................... 5

Rules For Safe Operation ...................................... 6-9

Towing ..................................................................... 10

Trailer Safety Guidelines .................................... 11-16

Operation and Safety Decals ............................. 17-18

Specifications .......................................................... 19

General Information ................................................ 20

Major Components ................................................. 21

Dimensions ............................................................. 22

Control Panel Description .................................. 24-25

Output Terminal Information .............................. 26-28

Installation .......................................................... 30-31

Pre-Setup ........................................................... 32-35

Load Application ..................................................... 36

Generator Start-up Procedure ........................... 37-38

Generator Shutdown Procedure ............................. 39

Maintenance ...................................................... 40-41

Generator Wiring Diagram ...................................... 42

Engine Wiring Diagram ........................................... 43

Troubleshooting (Engine) ................................... 44-44

Troubleshooting (Generator/Engine) ...................... 46

Explanation of Codes in Remarks Section.............. 48

Suggested Spare Parts ........................................... 49

MQ Power DCA-15SPX3 Portable Generator

Generator Assembly .......................................... 50-51

Control Box Assembly ........................................ 52-53

Output Terminal Assembly ................................. 54-55

Engine and Radiator Assembly .......................... 56-57

Battery Assembly ............................................... 58-59

Muffler Assembly ............................................... 60-61

Fuel Tank Assembly ........................................... 62-63

Enclosure Assembly ........................................... 64-67

Rubber Seals Assembly ..................................... 68-69

Operation and Safety Decal Locations .............. 70-71

Kubota V2203-D1-B Engine

Crankcase Assembly ......................................... 72-73

Oil Pan Assembly ............................................... 74-75

Cylinder Head Assembly .................................... 76-77

Gearcase Assembly ...........................................78-79

Main Bearing Case Assembly ............................ 80-81

Head Cover Assembly ....................................... 82-83

Inlet Manifold Assembly .....................................84-85

Exhaust Manifold Assembly ............................... 86-87

Valve & Rocker Assembly .................................. 88-89

Camshaft Assembly ...........................................90-91

Piston and Crankshaft Assembly .......................92-93

Flywheel Assembly ............................................94-95

Starter Assembly & Mounting ............................96-97

Starter (Components) Assembly ......................98-99

Nozzle Holder Assembly ............................... 100-101

Injection Pump 1 Assembly ........................... 102-103

Injection Pump 2 Assembly ........................... 104-105

Fuel Camshaft Assembly .............................. 106-107

Governor Assembly ...................................... 108-109

Speed Control Plate Assembly ..................... 110-111

Engine Stop Lever Assembly ........................ 112-113

Stop Solenoid Assembly ............................... 114-115

Alternator Assembly ...................................... 116-117

Alternator (Components) Assembly .............. 118-119

Fan Assembly................................................ 120-121

Water Flange & Thermostat Assembly ........ 122-123

Water Pump Assembly .................................. 124-125

Radiator Assembly ........................................ 126-127

Fuel Filter Assembly ..................................... 128-129

Terms and Conditions Of Sale — Parts ................ 130

PAGE 4 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

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 Additional Discount

1-9 items 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.

Extra Fax Discount

for Domestic USA

Dealers Only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

CAUTION:

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool

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.

before servicing engine or generator.

RULES FOR SAFE OPERATION

The following safety guidelines should always be used when operating the DCA-15SPX3 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, steeltoed boots and other protective devices required by the job.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with

■

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

CAUTION:

■

NEVER operate this equipment under the influence or drugs or alcohol.

hot

components can cause serious burns.

flow is restricted it will cause serious damage to the generator or engine and may

cause injury to people. Remember the generator engine gives off DEADLY carbon monoxide gas.

Always refuel in a well-ventilated area, away from sparks and open flames.

■

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.

■

Manufacture 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.

PAGE 6 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

■

Always use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO

smoke around or near the machine.

NOT

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

Topping-off to filler port is dangerous, as it tends to spill fuel.

bodily harm or even death.

RULES FOR SAFE OPERATION

CAUTION:

■

NEVER touch output terminals during operation. This is

Always stop the machine when contact

extremely dangerous. with the output terminals is required.

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.

Radiator

1. Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, 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.

2. Coolant Drain Plug - Removing the coolant drain plug

CAUTION:

3. Engine Oil Drain Plug - Removing the engine oil drain

■

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.

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.

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.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 7

■

CAUTION:

NEVER Run engine without air filter. Severe engine damage

may occur.

Battery

■

Always service air cleaner frequently to prevent carburetor

■

Never over fill the battery with water above the upper limit.

The battery has 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:

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 it is not being used. 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.

RULES FOR SAFE OPERATION

■

Always be sure the operator is familiar with proper safety precautions and operations techniques before using generator.

■

Refer to the technical questions or information.

1. DO NOT drop the battery. There is the possibility of risk the battery may explode.

2. DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact

Loading and Unloading (Crane)

■

Before lifting, make sure the generator's lifting hook is secure and that there is no apparent damage to the generator itself (loose screws, nuts and bolts). If any part is loose or damaged, please take corrective action before lifting.

with a flame or spark, an explosion could occur.

■

Always drain fuel prior to lifting.

3. Always keep the battery charged. If the battery is not

■

charged, a buildup of combustible gas will occur.

4. Always keep battery charging and booster cables in good working condition. Repair or replace all worn cables.

5. Always recharge the battery in an open air environment, to avoid risk of a dangerous concentration of combustible gases.

6. In case the battery liquid (dilute sulfuric acid) comes in contact with

clothing or skinclothing or skin

clothing or skin

clothing or skinclothing or skin

, rinse skin or clothing

immediately with plenty of water.

7. In case the battery liquid (dilute sulfuric acid) comes in

Always make sure crane or lifting device has been properly secured to the hook of guard frame on generator.

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or rope) of sufficient strength.

■

When lifting the generator, always use the balanced centerpoint suspension hook and lift straight upwards.

■

NEVER allow any person or animal to stand underneath the machine while lifting.

■

When loading the generator on a truck, be sure to use the front and back frame bars as a means to secure the generator during transport.

contact with your eyes, rinse eyes immediately with plenty of water, then contact the nearest doctor or hospital, and seek medical attention.

Kubota Engine Owner's ManualKubota Engine Owner's Manual

Kubota Engine Owner's Manual

Kubota Engine Owner's ManualKubota Engine Owner's Manual

for engine

PAGE 8 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

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

first aid kitfirst aid kit

and

first aid kit

first aid kitfirst aid kit

Also know the phone numbers of the nearest

doctordoctor

doctor

and

doctordoctor

. Know the location of the nearest telephone.

fire departmentfire department

fire department

fire departmentfire department

fire extinguisherfire extinguisher

fire extinguisher

fire extinguisherfire extinguisher

ambulanceambulance

ambulance

ambulanceambulance

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, fuel, and fuel filters. DO NOT use plastic containers to dispose of hazardous

waste. DO NOT pour waste, oil or fuel directly onto the ground,

down a drain or into any water source.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 9

■

Towing Safety Precautions

ALWAYS attach trailer's safety chain to bumper of towing

vehicle.

CAUTION :

■

ALWAYS make sure that the vehicle and trailer directional,

■

Check with your county or state safety towing regulations department before towing your generator.

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

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 the towing vehicle and the trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

backup, brake, and trailer lights are connected and working properly.

■

The maximum speed (unless otherwise posted) for highway towing is 45 M.P.H.. Recommended off-road towing is not to exceed 10 M.P.H. or less depending on type of terrain.

■

Place while parked.

■

Place prevent

■

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.

DCA-15SPX3 — TOWING

chocked blocks

support blocks

tippingtipping

tipping

tippingtipping

underneath wheel to prevent

underneath the trailer's bumper to

, while parked.

rolling rolling

rolling,

rolling rolling

Figure 1. DCA-15SPX3 and Towing Trailer

PAGE 10 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — 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 3 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-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 11

DCA-15SPX3 —TRAILER-SPECIFICATIONS

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FX05-RLRT 52-ACDLAG14ONSBL0072"421"55.BL008

W07-RLRT 07,06-,54-ACDONEGRUSSBL0007"681"77.BL0002

X07-RLRT 07,06-,54-ACDTPOEGRUSSBL0007"831"66.BL0002

FX07-RLRT 07,06-,54-ACDLAG35EGRUSSBL0007"831"66.BL0002

FX001-RLRT 521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002

521/58-RLRT ,001,58-ACD

521

FX051-RLRT 081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005

FX022-RLRT 022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005

FX003-RLRT 003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005

FX004-RLRT 004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

FX006-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

XS008-RLRT 008,006-ACDLAG055RIASBL00003"483"69.BL0005

ONONSBL0091"69"05.BL008

LAG25ONSBL0091"69"05.BL008

ONONSBL0022"58"24.BL008

LAG541CILUARDYHSBL00001"681"77.BL0002

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PAGE 12 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 —TRAILER-SPECIFICATIONS

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X05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

FX05-RLRT SSALCLLAB"2CRL31-87B"05.4X"31.sbl0053

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DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 13

DCA-15SPX3 —TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

CAUTION:

DO NOT attempt to repair or modify a wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim is

cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

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 2) 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.

PAGE 14 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

Figure 2. Major Suspension Components

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TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

DCA-15SPX3 — TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

RETAIN NUT

BOLT ASSEMBLY

05-XAM03-NIM

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 3. 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.

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Figure 3. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 15

DCA-15SPX3 —TRAILER WIRING DIAGRAM

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 16 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — OPERATION AND SAFETY DECALS

Machine Safety Decals

The DCA-15SPX3 generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages show these decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 17

Machine Safety Decals

DCA-15SPX3 — OPERATION AND SAFETY DECALS

PAGE 18 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — SPECIFICATIONS

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DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 19

DCA-15SPX3 — GENERAL INFORMATION

DCA-15SPX3 3 FAMILIARIZATION Generator

genergener

The MQ Power Model DCA-15SPX3 is a 15 kW that has been designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Control Panel

The control panel is provided with the following:

One GFCI 120 volt receptacle, 20 amp (single-phase)

15 kW Output Terminal (UNV)

Main Circuit Breaker 65 amps

GFCI Circuit Breaker 20 amps

AC Ammeter Indicator

AC Voltmeter Indicator

Output Voltage Adjustment Knob

Engine Warning Indicator

Engine Speed Control Lever

Hour Meter

Ground Ter minal

gener

genergener

atorator

ator

atorator

Open Delta Excitation System

The DCA-15SPX3 generator is equipped with the state of the art " system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four Leads: A, B, C and D. During light loads, the power to the from the leads of B & C, when loads increase, the AVR switches and accepts power from leads A & D. The output of leads A & D increase proportionally with load. This has the effect of adding the voltages of each phase to provide better voltage response during heavy loads.

The connections of the AVR to the AC output windings are for the sole purpose of sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current due to its independent power supply offering maximum motor starting capabilities. The excitation does not have a " demands of the required load.

Engine

Open-DeltaOpen-Delta

Open-Delta

Open-DeltaOpen-Delta

utomatic utomatic

utomatic

utomatic utomatic

fixed ceilingfixed ceiling

fixed ceiling

fixed ceilingfixed ceiling

" excitation system. The open delta

oltage Regulator oltage Regulator

oltage Regulator

oltage Regulator oltage Regulator

" and responds according the

(AVR) is supplied

The DCA-15SPX3 is powered by a 4-cylinder KUBOTA Model V2203 performance requirement for the generator. Reference Table 5, page 19 for engine specifications.

In keeping with MQ Power'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-15SPX3 generator are addressed on the following pages.

diesel diesel

diesel

diesel diesel

engine. This engine is designed to meet every

PAGE 20 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — MAJOR COMPONENTS

Figure 4. DCA-15SPX3 Generator Major Components

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 21

DCA-15SPX3 — DIMENSIONS

Figure 5. Dimensions

PAGE 22 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

NOTE PAGE

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 23

DCA-15SPX3 — CONTROL PANEL

Figure 6. Control Panel

PAGE 24 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — CONTROL PANEL

The definitions below describe the controls and functions of the DCA-15SPX3 "

1. Frequency Meter – Indicates the output frequency in hertz (Hz). Normally 60 Hz ±1 Hz.

2. AC Ammeter – Indicates the amount of current the load is drawing from the generator.

3. AC Voltmeter – Indicates the single phase output voltage present at the U & V terminals.

4. Engine Warning Indicator- This engine warning indicator will notify possible damage before it occurs:

A. Oil Pressure - the light will go on during initial

start, but will go out once the engine is warm. If the oil pressure light comes on during operation, this may indicate critical low oil level.

B. Charge Light - This light indicates the battery is

not charging.

C. Water Temperature Light - This light indicates the

coolant temperature is abnormally high.

D. Engine Protection - This will shut down the engine

if there is an abnormal event that may have occurred. This prevents damage to the engine.

Control Panel Control Panel

Control Panel

Control Panel Control Panel

"(Figure 6).

12. Engine Speed Control Lever - This lever controls the speed of the engine speed from idle to high for maximum rpm.

13. Ground Terminal – If required this ground terminal is to be used in conjunction with the GFCI receptacle only.

14. AC Output Terminals – These three output terminals (UNV), provide the single phase output voltage to the load source. NEVER connect a load to these output terminals when the main circuit breaker is "ON" and the engine is running.

15. Voltage Adjust Control Knob – Used to adjust the generator's single phase output voltage at the UNV output terminals. This control knob is to be used in conjunction with the AC voltmeter.

16. Main Circuit Breaker – This three-pole, 65 amp main breaker is provided to protect the single phase UNV voltage output from overload.

5. Hour Meter – Indicates the amount of hours the generator has been in operational use.

6. GFCI Circuit Breaker – This single-pole, 20 amp breaker is provided to protect the 120 VAC GFCI receptacle from overload.

7. Starter Switch - This is to turn on and off the engine with a key.

8. CS6369 Receptacle - This locking type receptacle provides 240/120VAC single output voltage, for equipment not exceeding 50 amps.

9. 240 VAC Receptacle – Provides 240 VAC single phase output voltage, normally used for small power tools that do not exceed 20 amps.

10. 120 VAC Receptacle – Provides 120 VAC single phase output voltage, normally used for small power tools that do not exceed 20 amps.

11. 120VAC Receptacle (GFCI)- Provides 120 VAC single phase output voltage, normally used for small power tools that do not exceed 20 amps.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 25

DCA-15SPX3 — OUTPUT TERMINAL INFORMATION

DCA-15SPX3 FAMILIARIZATION

The Output Terminal panel is provided with the following:

One GFCI 120 Volt Receptacle, 20 Amp (single-phase)

15 kW Output Terminal (UNV)

Ground Ter minal

Main Circuit Breaker 65 amps

GFCI Circuit Breaker 20 amps

120 Volt Receptacle

One GFCI Duplex Nema 5-20R (120V, 20 Amp) receptacle is provided on the output terminal. This receptacle can be used anytime the generator is in operation. The receptacle is controlled by the circuit breaker located on the control panel.

Pressing the reset button resets the receptacle after being tripped. Pressing the "Test Button" (See Figure 7) in the center of this receptacle will check the GFCI function. The receptacle should be tested at least once a month.

NEMA L5-30R Output Receptacle

The L5-30R receptacle supplies 30 amps at 120 volts. A 30 amp circuit breaker helps protect any load that it is feeding.

NEMA L6-30R Output Receptacle

The L6-30R supplies 30 amps at 240 volts. A 30 amp circuit breaker helps protect any load that it is feeding.

NEMA CS-6369 Output Receptacle

The CS-6369 supplies 50 amps at 120/240 volts. A 50 amp circuit breaker helps protect any load that it is feeding.

Connecting Load

Loads can be connected to the generator by the UNV Lugs or the duplex receptacle (See figure 3). Make sure to read the operation manual before attempting to connect a load to the generator.

Circuit Breakers

The DCA-15SPX3 has a main 65 amp circuit breaker and receptacle circuit breakers that are listed above. The main purpose of the circuit breakers is to protect the load the generator is powering.

Figure 7. GFCI Test Button

Maximum Output

The entire load connected to the UNV Lugs and both slots in the duplex receptacle must not exceed 16.5 kW in standby or 15 kW in prime output.

Maximum Amps

The generator will provide a maximum total amps of 62.5.

Do not exceed the maximum allowed amperage!

PAGE 26 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — OUTPUT TERMINAL INFORMATION

Figure 8. Receptacle Location on

Generator

Figure 9. Receptacle Details

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 27

DCA-15SPX3 — OUTPUT TERMINAL INFORMATION

120V Hard Wire Hookup

The output terminal panel, when suppling single phase 120 volts, will provide two circuits available at 62.5 amps with any two wires plus the ground. (See Figure 10 below.)

240V Hard Wire Hookup

The output terminal panel, when suppling single phase 240 volts, will provide one circuit available at 62.5 amps with two wires plus the ground. (See Figure 11 below.)

Figure 10. Hard Wire Hookup

for 120 Volt

Figure 11. Hard Wire Hookup

for 240 Volt

NOTE

When using plural single phase voltages, make sure to balance the load on each of the single phase legs.

PAGE 28 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

NOTE PAGE

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 29

DCA-15SPX3 — 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.

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 the 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 overheat.

Eliminate the danger of deadly carbon monoxide gas. Remember that exhaust fumes from any diesel engine are very poisonous if discharged in a closed room, but harmless if allowed to mix with the outside air. If the generator is installed indoors, you must make provisions from venting the engine exhaust to the outside of the building.

CAUTION :

Generator Grounding

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 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 12) 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.

An electric shock is apt to 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.

NOTE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DO NOT cover ventilation areas on the enclosure. Covering the ventilation grids will cause the engine to overheat.

PAGE 30 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — INSTALLATION

CAUTION :

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 31

Figure 12. Typical Generator Grounding Application

Always check local codes for proper grounding codes and laws.

DCA-15SPX3 — PRE-SETUP

General Inspection Prior to Operation

The DCA-15SPX3 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.

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 Table 6 (cable selection guide) as a guide for selecting proper cable size.

Circuit Breaker

To protect the generator from an overload,

main main

main

circuit breaker is provided to protect the UNV output

main main

from overload. In addition a 2-pole, 20 amp breaker is provided to protect the GFCI receptacle from overload. Make sure to switch both circuit breakers to the "OFF" position prior to starting the engine.

a 3-pole, 65 amp,

GFCIGFCI

GFCI

circuit

GFCIGFCI

NOTE

ALWAYS consult with a licensed

electrician for correct extension cord wire size.

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PAGE 32 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — 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 13) on the dipstick. See Table 7 for proper selection of engine oil.

Fuel

Fill the fuel tank with clean and fresh fill the tank beyond capacity.

Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed on page 19 Specification Table 5.

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 :

Coolant

diesel fueldiesel fuel

diesel fuel

diesel fueldiesel fuel

Never fill the fuel tank while the engine is running or in the dark. Gasoline spillage on a hot engine can cause a fire or explosion. If gasoline spillage occurs, wipe up the spilled gasoline completely to prevent fire hazards.

. DO NOT

Use only drinkable tap water. If hard water or water with

Figure 13. 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 Kubota Engine Owner's Manual.

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An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system.

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DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 33

DCA-15SPX3 — 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

8. 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.

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Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 9) has been added.

Day-to-day addition of coolant is done from the

Cleaning the Outer 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 radiator is dangerous, so clean only with the engine turned off and the battery disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the Kubota Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the Kubota Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 14) when depressed with the thumb as shown below. Never place hands near the belts or fan while the generator is running.

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When the antifreeze is mixed withWhen the antifreeze is mixed with

When the antifreeze is mixed with

When the antifreeze is mixed withWhen the antifreeze is mixed with ww

aterater

, the antifreez, the antifreez

ater

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aterater

, the antifreez, the antifreez

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be less than 50%.

be less than 50%.be less than 50%.

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atio matio m

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ust

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Figure 14. Fan Belt Tension

CAUTION :

Never place hands near the belts or fan while the generator set is running.

Adjusting Fan Belt

If the fan belt does not have the 10 to 15mm defection follow the procedure below to adjust: Loosen the alternator adjusting plate and alternator mounding bolt. Pivot the alternator at the mounting bolt toward the engine left or right until the belt reflects the proper tension. Tighten the mounting bolt and the adjusting bolt.

PAGE 34 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — PRE-SETUP

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. DO NOT over fill.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

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 to inhibit corrosion.

Battery Cable Installation ALWAYS be sure the battery cables (Figure 15) are properly

connected to the battery terminals as shown below. The cable is connected to the positive terminal of the battery, and the BLACK cable is connected to the negative terminal of the battery.

REDRED

RED

REDRED

CAUTION :

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery

terminals when the key is in the ignition and is set in 'START' mode. ALWAYS remove the key from the ignition and the ignition switch is in the OFF position when connecting the battery.

2. Place a small amount of grease around both battery

terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

CAUTION :

If the battery cable is connected incorrectly, damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

Figure 15. Battery Connections

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose (fuel or oil) lines are defective replace them immediately.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 35

DCA-15SPX3 — LOAD APPLICATION

Single Phase, Load

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 1.0. See Table 10. below when connecting loads.

CAUTION:

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.

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.

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.

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:

Motors and motor-driven equipment draw much greater current for starting than during operation.

Before connecting this generator to any building’s electrical system, a licensed

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PAGE 36 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

0.1

electrician must install an isolation (transfer) switch. Serious injury or death may result without this transfer switch.

DCA-15SPX3 — GENERATOR START-UP PROCEDURE

WARNING:

The engine's exhaust contains harmful

ALAL

emissions.

ALAL

YS YS

ventilate the

YS YS

exhaust when operating inside tunnels, excavations or buildings. Direct exhaust away from nearby personnel.

Before Starting

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 7 on page 29).

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 that 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 fuel. If fuel spillage occurs, clean immediately.

2. Connect the load to the UNV terminals as shown in Figure 17. These terminals can be found on the front of the generator by lifting the UNV lug cover. It may be necessary to remove the retaining lug that secures the cover. Make sure to tighten terminal nuts securely to prevent load wires from slipping out.

3. After attaching the load wires to the AC output terminals, secure the UNV cover by inserting the retaining screw (Figure 18) back into the cover.

Figure 17. UNV Terminal Lugs (Load)

Before Starting

Generator and Control Panel

CAUTION:

NEVER start the engine with the

GFCIGFCI

GFCI

circuit breakers in the ON

GFCIGFCI

position.

1. Be sure to disconnect the electrical load and switch the

main main

main

main main

and

G.FG.F

G.F

G.FG.F

.C.C

.I..I.

.I.

circuit breakers (Figure 16) to the

.C.C

.I..I.

“OFF” position prior to starting the engine.

CIRCUIT BREAKER

MAIN

OFF

Figure 16. Main and GFCI Circuit Breakers

CIRCUIT BREAKER

GFCI RECEPTACLE

OFF

mainmain

main

mainmain

Figure 18. UNV Lug Cover

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 37

DCA-15SPX3 — GENERATOR START-UP PROCEDURE

4. Connect the negative battery cable (BLACK) to the negative post on the battery (Figure 19).

8. Pull the lever and turn to the right to increase the engine speed. (Figure 23).

e X. Not In Auto

NEGATIVE

POSTIVE

Figure 23. Engine Throttle Lever (HIGH)

BATTERY

9. The generator's voltage meter (Figure 24) displays the

Figure 19. Battery Connections

120 VAC in VOLTS . If the voltage is not within the specified frequency tolerance, use the voltage

5. Close all engine enclosure doors (Figure 20).

adjustment control knob to the right of voltage meter to bring the voltage within range.

Figure 20. Engine Enclosure Doors

6. Check the engine speed throttle lever is pushed in (low speed) (Figure 21).

300

150

VAC ADJUST

100

200

100

VOLTAGE ADJUSTMENT CONTROL KNOB

Figure 24. Voltage Meter/

Adjustment Control Knob

Figure 21. Engine Throttle Lever (LOW)

7. Turn the key to preheat until the engine warms up (for 35 minutes). Then turn the key to the right until the engine starts. Release the key to the 'run' mode (Figure 22).

Figure 22. Ignition Switch (START)

PAGE 38 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

10. The ammeter (Figure 25) 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.

Figure 25. Ammeter (No Load)

DCA-15SPX3 — GENERATOR START-UP PROCEDURE

11. If there are no abnormal problems shown on the engine indicator, turn both the MAIN and GFCI circuit breakers to their ON position (Figure 26).

Engine Shutdown

To shutdown the generator use the following procedure:

1. Place both the MAIN and GFCI circuit breakers to the "OFF position"

CIRCUIT BREAKER

MAIN

CIRCUIT BREAKER GFI RECEPTACLE

2. Turn the engine throttle lever to the left and push in to decrease the engine speed.

3. Let the engine run 3-5 minutes with no load applied.

Figure 26. Main and GFCI Circuit Breakers

4. Turn the key to the left to stop the engine (Figure 28).

12. Observe the generator's ammeter (Figure 27) 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.

5. Remove the load from the UNV terminal strip (Figure 14).

Figure 28. Ignition Switch (STOP)

Figure 27. Ammeter (Load)

13. The generator will run until manually stopped or an abnormal condition occurs.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 39

DCA-15SPX3 — MAINTENANCE

General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks.

Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 50 hours: Remove air cleaner element and clean heavy duty paper element with kerosene, or foam element with liquid detergent and hot water. Wrap foam element in a cloth and squeeze dry. For heavy duty paper element, wipe excess kerosene with towel.

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations). Always pour through the mesh filter.

Removing Water from the Fuel 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 more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full as much 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 switch to the “ON” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Service Daily

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber in high fuel consumption.

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 8, page 29.

Replacing Oil Filter

Detach the oil filter cartridge with a filter wrench. Apply a film of oil to the gasket for the cartridge. Screw in the cartridge by hand. When the gasket is in

contact with the seal surface, tighten the cartridge one or two more times by hand.

After the oil cartridge has been replaced, the engine oil will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 400 hours or so.

Apply fuel oil thinly over the gasket and hand-tighten the cartridge into position.

Vent any air.

Flushing Out Radiator and Replacing Coolant

Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.

Check hoses for softening and kinks. Check clamps for signs of leakage.

Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

Tighten both cocks and replace the overflow tank. Replace with coolant (see page 30, Table 5 for mixture). Close radiator cap tightly.

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 gasoline. 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.

PAGE 40 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

CAUTION :

Allow engine to cool when flushing out radiator. Flushing the radiator while hot will damage radiator.

DCA-15SPX3 — MAINTENANCE

Generator Storage

For storage of the generator for over 30 days, the following is required:

Fill the fuel tank completely.

Completely drain the oil from the crankcase and refill with fresh oil.

Clean all external parts of the generator with a cloth.

Cover the generating set and store in a clean, dry place.

ECNANETNIAM/NOITCEPSNI

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

ENIGNE

leveL

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

noitcetorPtnalooCkcehCdnarotaidaRnaelC

tnemelEretliFriAecalpeR X

srH01

YLIAD

srH052 srH005 srH0001

rotsiseRnoisorroCegnahC X

spmalCdnasesoHllakcehC X

knaTleuFfoedisnInaelC X

ROTARENEG

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 41

smhoM3revOecnatsiseRnoitalusnIerusaeM

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

.ylnoemittsrif,sruoH052taretlifleufecalpeR

DCA-15SPX3 —GENERATOR WIRING DIAGRAM

PAGE 42 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 —ENGINE WIRING DIAGRAM

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 43

DCA-15SPX3 — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the

diagnosis based on the Engine Troubleshooting (Table 11) information shown below and on the proceeding page. If the problem cannot be remedied, please consult our company's business office or service plant.

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .sepipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

leuffoytisocsivhgihylevissecxE

?erutarepmetwoltalioenignero

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

GNITOOHSELBUORTENIGNE.11ELBAT

.lioenigneroleufdeificepsehtesU

noitcejniesooloteudkaelleuF

?tungniniaterepip

.tratstonseodenignE

.knarctonlliwenignE

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

?rednilycmorfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

.tunnethgiT

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

?detcennocsidgniriW .gniriwtcennoC

PAGE 44 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.11ELBAT

?tungniniaterepip

.htoomstonsinoituloverenignE

?erusserp

?deggolc

?lioenigneevissecxE .leveldeificepsehtotecudeR

.devresbosi

sagtsuahxeeulbroetihwrehtiE

?kcuts

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.tsujdA

.ecalperroriapeR

.devresbosisag

tsuahxeyargkradrokcalbrehtiE

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?gnizieseb

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?kaelnoisserpmoC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

otmeesstrapgnivoms'enignE

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

.redlohelzzon

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 45

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

DCA-15SPX3 — TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the

diagnosis based on the Generator Troubleshooting (Table 12) information shown below and on the proceeding page. If the problem cannot be remedied, please consult our company's business office or service plant.

MOTPMYS MELBORPELBISSOP NOITULOS

?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

tuptuOegatloVoN

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

tuptuOegatloVwoL

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH

?RVAevitcefeD .yrassecenfiecalpeR

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

GNITOOHSELBUORTROTARENEG.71ELBAT

?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

deppirTrekaerBtiucriC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 46 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

NOTE PAGE

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 47

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,

■

, 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.

NOTE

The contents of this parts catalog areThe contents of this parts catalog are

The contents of this parts catalog are

The contents of this parts catalog areThe contents of this parts catalog are subject to change without notice.subject to change without notice.

subject to change without notice.

subject to change without notice.subject to change without notice.

, #, +, %, or

PAGE 48 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — SUGGESTED SPARE PARTS

DCA-15SPX3 DCA-15SPX3

DCA-15SPX3

DCA-15SPX3 DCA-15SPX3

Qty. P/N Description

1 ......... 0601820626 ......................... AUTOMATIC VOLTAGE REGULATOR

1 ......... 0601806592 ......................... MAIN CIRCUIT BREAKER

1 ......... 0601802609 ......................... RECEPTACLE CIRCUIT BREAKER

1 ......... 0601840073 ......................... VOLTAGE REGULATOR (RHEOSTAT)

3 ......... 700003209 ........................... OIL FILTER

1 ......... 1584139010 ......................... OIL SWITCH

1 ......... 1726697011 ......................... FAN BELT

3 ......... 113043002 ........................... AIR FILTER

3 ......... 7000043081 ......................... FUEL FILTER

1 ......... 1706372940 ......................... RADIATOR HOSE, UPPER

1 ......... 1546172851 ......................... RADIATOR HOSE, LOWER

1 ......... 1949883040 ......................... WATER TEMPERATURE SENDING UNIT

W/KUBOW/KUBO

W/KUBO

W/KUBOW/KUBO

A A

V2203 DIESEL ENGINE 1 V2203 DIESEL ENGINE 1

V2203 DIESEL ENGINE 1

A A

V2203 DIESEL ENGINE 1 V2203 DIESEL ENGINE 1

O 3 UNITSO 3 UNITS

O 3 UNITS

O 3 UNITSO 3 UNITS

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 49

GENERATOR ASSY.

DCA-15SPX3 — GENERATOR ASSY.

PAGE 50 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 7671000102 ROTOR ASSY. 1 2 FIELD ASSY. 1 3 7961025004 RECTIFIER 1

4 0601822643 SURGE ABSORBER ................................... 1 .............TNR23G561K

5 8001070003 FAN 1 6 8351611004 COUPLING DISK 2 7 8351612004 WASHER, COUPLING HUB 1 8 8351615003 BALANCING PLATE 1 9 0010310025 HEX. HEAD BOLT 4 10 0042610000 LOCK WASHER 4 11 0601000209 BALANCING WEIGHT KIT 1

12 0071906308 BEARING .................................................... 1 ............. 6308DDUC3

13 0070506903 BEARING .................................................... 1 ............. 6903ZZ

14 0012108035 HEX. HEAD BOLT 6 15 0042508000 LOCK WASHER 6 16 7671345203 STRATOR ASSY. 1 17 0845041904 GROMMET 1 18 8431350003 FIELD ASSY. EXCITER 1 19 0016008045 HEX. SOCKET HEAD CAP SCREW 3 20 0042508000 LOCK WASHER 3 21 8351315003 END BRACKET 1

22 011208035 HEX.HEAD BOLT ........................................ 6 ............. REPLACES 0017108035

23 8351312004 PACKING 1 24 8351331004 COVER, SUCTION 1 25 0017106016 HEX. HEAD BOLT 3

26 012010030 HEX. HEAD BOLT ....................................... 6 ............. REPLACES 0012110030

27 030210250 LOCK WASHER ........................................... 6 ............. REPLACES 0042510000

28 8401332004 COVER, FAN 1 29 0010106030 HEX. HEAD BOLT 1

30 952404470 PLAIN WASHER .......................................... 1 ............. REPLACES 0041206000

31 0605000006 RUBBER SUSPENSION 2 32 0207010000 HEX. NUT 2

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 51

CONTROL BOX ASSY.

DCA-15SPX3 — CONTROL BOX ASSY.

PAGE 52 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 7671821603 CONTROL PANEL 1

2 0605010060 HINGE...................................................... 2 ........ B1075L

3 0021103010 MACHINE SCREW 8

4 0601800455 FREQUENCY METER ............................. 1 ........ FCF5 240V 45Hz~65Hz

5 0601805746 AC AMMETER ......................................... 1 ........ ACF5 0~100A

6 0601800281 AC VOLTMETER ...................................... 1 ........ SCF5 0~150V 0~300V

7 0601840073 RHEOSTAT (VOLTAGE REGULATOR) ..... 1 ........ RA20A2SE102BJ 2W 1kOHM

8 0601840121 KNOB 1

9 0601802609 CIRCUIT BREAKER ................................ 1 ........ KM2 50A

10 4341817004 BRACKET, CIRCUIT BREAKER 1 11 0027104020 MACHINE SCREW 2

0207004000 HEX. NUT 2

12 0602100059 STARTER SWITCH .................................. 1 ........ 3741059113

13 0601810523 INDICATOR ASSY. ................................... 1 ........ PLB128Q

0601810830 BULB 4

14 0601800682 HOUR METER ......................................... 1 ........ 82014

15 0021806030 MACHINE SCREW 2

16 0601806592 CIRCUIT BREAKER ................................ 1 ........ SC100CS 65A

17 0021004060 MACHINE SCREW 2

0040004000 LOCK WASHER 2

0041204000 PLAIN WASHER 2

18 0601801122 CURRENT TRANSFORMER, AMMETER 1 ........ COC3 100A/5A

19 0027106016 MACHINE SCREW 2

20 0601842304 RESISTOR ............................................... 1 ........ GG20W50OHM

21 0027104012 MACHINE SCREW 2

22 0601820038 RECTIFIER .............................................. 1 ........ S15VB60

23 0027104020 MACHINE SCREW 1

24 0601820626 AUTOMATIC VOLTAGE REGULATOR ...... 1 ........ NTA4A25

25 0017105016 HEX. HEAD BOLT 4

26 0601815759 TERMINAL BOARD ................................. 1 ........ KT206P

27 0027104020 MACHINE SCREW 2

28 0602200474 EMERGENCY UNIT................................. 1 ........ 1714760602

29 0021005045 MACHINE SCREW 2

0040005000 LOCK WASHER 2

0041205000 PLAIN WASHER 2

30 8701899004 FUSE BOX ............................................... 1 ........ FB6PS

0601806642 FUSE ....................................................... 4 ........ 5A

0601806643 FUSE ....................................................... 2 ........ 15A

0601806644 FUSE ....................................................... 2 ........ 30A

31 0027105016 MACHINE SCREW 2

32 0602201273 TIMER...................................................... 1 ........ 1569465992

33 0602202566 RELAY ..................................................... 1 ........ 6888153542

34 0017105016 HEX. HEAD BOLT 2

35 0601806640 FUSE ....................................................... 1 ........ 65A

36 0601842389 RESISTOR ............................................... 1 ........ 8.2OHM 1/2W

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 53

OUTPUT TERMINAL ASSY.

DCA-15SPX3 — OUTPUT TERMINAL ASSY.

PAGE 54 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 7561860104 SET BOARD, OUTPUT TERMINAL 1 2 1621849004 OUTPUT TERMINAL 3 3 0019008020 HEX. HEAD BOLT 3 4 0040008000 LOCK WASHER 9 5 0041408000 PLAIN WASHER 9 6 0039508000 HEX. NUT 3 7 0030008000 HEX. NUT 3 8 7831860104 RUBBER SEAL 1 9 0017106025 HEX. HEAD BOLT 4

10 0601815109 GROUND TERMINAL .......................... 1 ............T381

11 7671865403 COVER, GROUND TERMINAL 1 11-1 7671865804 RUBBER SHEET 1 12 0017106020 HEX. HEAD BOLT 2 13 0821800014 COLLAR 2 14 0805088004 STAY RUBBER 1 15 0207006000 HEX. NUT 1 16 0017106016 HEX. HEAD BOLT 1

17 0601812597 RECEPTACLE ...................................... 1 ............ 520R 125V 20A

18 0601811031 RECEPTACLE ...................................... 1 ............L530R 125V 30A

19 0601811033 RECEPTACLE ...................................... 1 ............L630R 250V 30A

20 0601812565 RECEPTACLE ...................................... 1 ............CS6369 125/250V 50A

21 0027104016 MACHINE SCREW 8

0207004000 HEX. NUT 8 22 7672142003 SLIDE LEVER 1 23 0805012904 KNOB 1 24 7672144103 THROTTLE CABLE 1 25 3032143004 SPRING 1 26 8322145004 BRACKET 1 27 0017110015 HEX. HEAD BOLT 2

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 55

ENGINE & RADIATOR ASSY.

DCA-15SPX3 — ENGINE & RADIATOR ASSY.

PAGE 56 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 7670150204 ENGINE .......................................... 1 .......... KUBOTA V2203

1-1 1732132432 CARTRIDGE, OIL FILTER .............. 1 .......... REPLACES 0602041173

2 1707972063 RADIATOR ...................................... 1 .......... REPLACES 0602011877

3 8345112004 BRACKET, RADIATOR 1 4 8345112204 BRACKET, RADIATOR 1

5 011006010 HEX. HEAD BOLT ........................... 6 .......... REPLACES 0017106010

6 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

7 8345127103 FAN GUARD 1 8 8345127504 BRACKET, FAN GUARD 1 9 8345127604 BRACKET, FAN GUARD 1

10 011006010 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017106010

11 0017106016 HEX. HEAD BOLT 4

12 1542872941 RADIATOR HOSE ........................... 1 .......... REPLACES 0602014560

13 1542872852 RADIATOR HOSE ........................... 1 .......... REPLACES 0602014477

14 1510872873 HOSE BAND ................................... 4 .......... REPLACES 0602014372

15 113R60000B AIR CLEANER ................................ 1 .......... REPLACES 0602046268

113043002 ELEMENT, AIR CLEANER .............. 1 .......... REPLACES 0602046335

16 8722031503 BAND, AIR CLEANER 1

17 011208030 HEX. HEAD BOLT ........................... 1 .......... REPLACES 0017108030

18 8432031104 BRACKET, AIR CLEANER 1

19 011008020 HEX. HEAD BOLT ........................... 4 .......... REPLACES 0017108020

20 8322036103 HOSE, AIR CLEANER 1 21 8432036103 HOSE, AIR CLEANER 1 22 0605515001 HOSE BAND 3 23 8325112114 ENGINE FOOT 1 24 8325112014 ENGINE FOOT 1 25 0012410025 HEX. HEAD BOLT 1 26 0012412025 HEX. HEAD BOLT 7 27 7605419004 RUBBER SUSPENSION 2 28 0207010000 HEX. NUT 2 29 1502025004 DRAIN JOINT 1

30 0602021193 PACKING ........................................ 1 .......... SW16

31 1502025103 DRAIN JOINT 2 32 0802011104 PLUG 2

33 0150000018 O RING ........................................... 2 .......... AP18

34 0017106016 HEX. HEAD BOLT 4 35 0192200430 DRAIN HOSE 1 36 0605515003 HOSE BAND 2

37 1546173341 HOSE .............................................. 1 .......... REPLACES 0602014476

38 1718273341 DRAIN HOSE .................................. 1 .......... REPLACES 0602014661

39 0605515014 HOSE BAND 4 40 0802081403 RESERVE TANK 1 41 0802081104 CAP, RESERVE TANK 1 43 0017106035 HEX. HEAD BOLT 1

44 1559672711 HOSE .............................................. 1 .......... REPLACES 0602014173

45 7222016304 HOSE 1 46 0605515094 HOSE BAND 3

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 57

BATTERY ASSY.

DCA-15SPX3 — BATTERY ASSY.

PAGE 58 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — BATTERY ASSY.

BATTERY ASSY.

NO.PART NO. PART NAME QTY. REMARKS

1 0167306531 BATTERY 1 65D31R 2 8452250003 BATTERY FRAME 1

8345967004 LINING 1 3 0017106016 HEX HEAD BOLT 5 4 7612251004 BATTERY SHEET 1 5 8432255024 BATTERY BAND 1 6 8432256024 BATTERY BOLT 1 7 0017106016 HEX HEAD BOLT 2 8 8432256104 BATTERY BOLT 1 9 0037806000 WING NUT 2 10 0040006000 SPRING WASHER 2

11 952404470 PLAIN WASHER............ 2 ............... REPLACES 0041206000

12 N012CABLE10SPX3 BATTERY CABLE 1 13 N013CABLE10SPX3 BATTERY CABLE 1 14 EARTH10SPX3 EARTH CABLE 1

15 0602220310 TERMINAL ASS’Y. ........ 1 ............... NO.9P

16 0602220311 TERMINAL ASS’Y. ........ 1 ............... NO.9N

17 0602220600 TERMINAL CAP ............ 1 ............... 7C7R

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 59

MUFFLER ASSY.

DCA-15SPX3 — MUFFLER ASSY.

PAGE 60 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8342311003 MUFFLER 1

2 011008020 HEX HEAD BOLT ........................... 6 .......... REPLACES 0017108020

3 8342350103 EXHAUST PIPE 1

4 T007016420 GASKET ......................................... 1 .......... REPLACES 0602320150

5 1502336004 GASKET 1

6 020108060 HEX NUT ........................................ 4 .......... REPLACES 0207008000

7 011208035 HEX HEAD BOLT ........................... 2 .......... REPLACES 0017108035

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 61

FUEL TANK ASSEMBLY

DCA-15SPX3 — FUEL TANK ASSY.

PAGE 62 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — FUEL TANK ASSY.

FUEL TANK ASSEMBLY

NO. PART NO. PART NAME QTY. REMARKS

1 7675510703 FUEL TANK 1 1-1 0810105800 CAP, FUEL TANK 1 1-2 0810105900 FUEL FILTER 1 1-3 0267700245 HOSE, FUEL GAUGE 1 1-4 0605515191 HOSE BAND 2 2 8435525003 BRACKET. FUEL TANK 1

3 011008020 HEX. HEAD BOLT ....................................... 4 ...... REPLACES 0017108020

4 1555527004 TANK SHEET 2 5 8435523014 TANK BAND 2 6 0805003404 PAD, TANK BAND 4

7 011008020 HEX. HEAD BOLT ....................................... 2 ...... REPLACES 0017108020

8 0207308000 HEX. NUT 2 9 7812014003 DRAIN JOINT 1 10 0802011104 PLUG 1

11 0150000018 O RING ....................................................... 1...... AP18

12 0017106016 HEX. HEAD BOLT 2 13 019900640 DRAIN HOSE 1 14 0605515094 HOSE BAND 2

15 1522143016 FUEL FILTER .............................................. 1 ...... REPLACES 0602042462

1522143172 ELEMENT, FUEL FILTER ........................... 1...... REPLACES 0602042551

16 7675528004 BRACKET, FUEL FILTER 1 17 0017108035 HEX. HEAD BOLT 2 18 0017108025 HEX. HEAD BOLT 2

0207008000 HEX. NUT 2 19 0603325013 FUEL COCK, 3/8 1

20 0602022708 HOSE, JOINT ............................................. 1 ...... WHN8

21 0966180180 SUCTION HOSE ......................................... 1...... REPLACES 0605513116

22 0966180340 SUCTION HOSE ......................................... 1...... REPLACES 0605513117

23 0966140180 RETURN HOSE .......................................... 1...... REPLACES 0605514026

24 1491142751 HOSE BAND ............................................... 4...... REPLACES 0605515070

25 1497142751 HOSE BAND ............................................... 1...... REPLACES 0605515072

26 1615511204 RUBBER SEAL 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 63

ENCLOSURE ASSEMBLY

DCA-15SPX3 — ENCLOSURE ASSY.

PAGE 64 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — ENCLOSURE ASSY.

ENCLOSURE ASSEMBLY

NO. PART NO. PART NAME QTY. REMARKS

1 7675111602 BASE 1 2 8445116114 FLOOR PANEL 1 3 0017106016 HEX. HEAD BOLT 8 4 7675121202 FRONT FRAME 1

8345921204 ACOUSTIC SHEET 1

8345924004 ACOUSTIC SHEET 1

5 011008020 HEX. HEAD BOLT ................................ 7 ............. REPLACES 0017108020

6 1625165103 FILLER COVER 1 7 1625165204 CHAIN 1

8 011008020 HEX. HEAD BOLT ................................ 1 ............. REPLACES 0017108020

9 8342313003 COVER, MUFFLER 1

8345925004 ACOUSTIC SHEET 1

10 011008020 HEX. HEAD BOLT ................................ 4 ............. REPLACES 0017108020

11 8435125004 COVER, FRONT FRAME 1

8345923004 ACOUSTIC SHEET 1

12 011008020 HEX. HEAD BOLT ................................ 6 ............. REPLACES 0017108020

13 8345130203 HANGER 1 14 8435132113 HANGER 1

15 012212030 HEX. HEAD BOLT ................................ 6 ............. REPLACES 0017112030

16 7675141802 REAR FRAME 1

17 011008020 HEX. HEAD BOLT ................................ 7 ............. REPLACES 0017108020

18 8345144604 COVER, REAR FRAME 1 19 8345143203 DUCT 1

8345943004 ACOUSTIC SHEET 1 20 0207006000 HEX. NUT 4

21 011008020 HEX. HEAD BOLT ................................ 6 ............. REPLACES 0017108020

22 7675146103 DOOR, REAR FRAME 1 23 8435149004 WINDOW PLATE 1 24 0207006000 HEX. NUT 8 25 0605010230 DOOR HANDLE 1 26 0021805012 MACHINE SCREW 4

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1- ORANGE 2- WHITE 3 -SPECTRUM GRAY 4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 65

5 -BLACK 6 -CATERPILLAR YELLOW 7 -CATO GOLD 8 -RED

ENCLOSURE ASSEMBLY

DCA-15SPX3 — ENCLOSURE ASSY.

PAGE 66 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — ENCLOSURE ASSY.

ENCLOSURE ASSEMBLY

NO. PART NO. PART NAME QTY. REMARKS

27 0810015204 HINGE 2

0810015504 WASHER 2 28 0017106016 HEX. HEAD BOLT 4 29 8345161302 ROOF PANEL 1

8345961304 ACOUSTIC SHEET 1

30 011008020 HEX. HEAD BOLT .............................. 16 ............. REPLACES 0017108020

31 8345172103 SIDE PANEL 1

8345972204 ACOUSTIC SHEET 1 32 8345173104 DUCT 1 33 0207006000 HEX. NUT 5

34 011208035 HEX. HEAD BOLT ................................ 6 ............. REPLACES 0017108035

35 8345170203 SIDE DOOR 1

8345970504 ACOUSTIC SHEET 1 36 8435170203 SIDE DOOR 1

8345970404 ACOUSTIC SHEET 1 37 8345171114 DUCT 1 38 0207006000 HEX. NUT 7 39 B9114000002 DOOR HANDLE 1 40 0021806016 MACHINE SCREW 4 41 8435149104 WINDOW PLATE 1 42 0027103010 MACHINE SCREW 4

0207003000 HEX. NUT 4

43 M9110100304 HINGE .................................................. 2............. REPLACES 0845047204

0845045004 WASHER 2

44 M911B110204 HINGE .................................................. 2............. REPLACES 0845047104

0845045004 WASHER 2

45 011008020 HEX. HEAD BOLT ................................ 8 ............. REPLACES 0017108020

46 0845031504 CAP 4

47 0601851613 STOPPER ............................................2 ............. CP30FF15A

48 0600500090 EMBLEM 1 49 0021106016 MACHINE SCREW 2

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 2-WHITE 3 -SPECTRUM GRAY 4 -SUNBELT GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 67

5 -BLACK 6 -CATERPILLAR YELLOW 7 -CATO GOLD 8 -RED

ENCLOSURE (SEALS )ASSY.

DCA-15SPX3 — ENCLOSURE (RUBBER SEALS) ASSY.

PAGE 68 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — ENCLOSURE (RUBBER SEALS) ASSY.

ENCLOSURE (RUBBER SEALS )ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0229400650 RUBBER SEAL 3 2 0229400895 RUBBER SEAL 2 3 0229200650 RUBBER SEAL 1 4 0220400650 RUBBER SEAL 2 5 0227600895 RUBBER SEAL 2 6 0229400265 RUBBER SEAL 2 7 0229400550 RUBBER SEAL 1 8 0229200580 RUBBER SEAL 2 9 0229200245 RUBBER SEAL 2

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 69

NAME PLATE AND DECALS

DCA-15SPX3 — NAME PLATE AND DECALS

PAGE 70 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

DCA-15SPX3 — NAME PLATE AND DECALS

NAME PLATE AND DECALS

NO. PART NO. PART NAME QTY. REMARKS

1 0800628504 DECAL; GROUND ................................... 1 ............ S1123

2 1630610304 DECAL; DANGER ................................... 1 ............ S1405

3 1630610504 DECAL; CAUTION................................... 1 ............ S1409

4 1320620904 DECAL; DIESEL FUEL ........................... 1 ............ S1756

5 0800650804 DECAL; FUEL GAUGE ............................ 1 ............ S1765

6 6360610304 DECAL; WATER ...................................... 1 ............ S1880

7 6360620004 DECAL; FUEL DRAIN PLUG................... 1 ............ S1883

8 6360620104 DECAL; WATER DRAIN PLUG ................ 1 ............ S1884

9 6360620204 DECAL; OIL DRAIN PLUG ...................... 1 ............ S1884

9 6360620204 DECAL; OIL DRAIN PLUG ...................... 1 ............ S1885

10 0800689404 DECAL; + ................................................ 1 ............ S2090

11 0800689504 DECAL; - ................................................ 1 ............ S2091

12 1320621504 DECAL; SUPPORT HOOK...................... 2 ............S2257

13 6390671104 DECAL; IMPORTANT "CHECK DAILY" ... 1 ............ S2377

14 0840624504 DECAL; CIRCUIT BREAKER .................. 2 ............S3031

15 0840625902 DECAL; MQ ............................................ 1 ............ S3057

16 1980680004 DECAL; FUEL COCK .............................. 1 ............S3704

17 7670623004 DECAL; VOLTAGE REGULATOR............. 1 ............ S3737

18 7670624004 DECAL; GROUND FOR GFCI ................. 1 ............ S3821

19 7670622004 DECAL; SPEED CONTROL HANDLE..... 1 ............ S3822

20 7670654004 DECAL; AC OUTPUT TERMINAL ........... 1 ............ S3823A

21 7670650004 DECAL; DANGER HIGH VOLTAGE ......... 1 ............ S3956

22 7560615004 DECAL; STARTER SWITCH ................... 1 ............ S4547

23 8700611804 DECAL; WARNING .................................. 1 ............ S4984

24 8700611904 DECAL; DANGER ................................... 1 ............ S4985

25 7670630103 DECAL; AC POWER OUTPUT ............... 1 ............ S5272

27 0820610404 DECAL; WARNING 1 28 0820650604 DECAL; DANGER 1 29 8700625504 DECAL; FUSE BOX 1 30 7670633003 STRIPE 1 31 7670633104 STRIPE 1 32 7670633604 STRIPE 1 33 7670633704 STRIPE 1 34 7670633204 STRIPE 1 35 7670633504 STRIPE 1 36 7670633404 STRIPE 1 37 7670633304 STRIPE 1 38 7670633804 STRIPE 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 71

CRANKCASE ASSY.

KUBOTA V2203 - ENGINE — CRANKCASE ASSY.

PAGE 72 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — CRANKCASE ASSY.

CRANKCASE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1649401010 COMP. CRANKCASE ..................... 1 ....... INCL. ITEMS W/#

015# 3415027580 PLUG 1 020# 3221027580 PLUG 2 030# 1552196020 PLUG 6 040# 1552196030 PLUG 2 050# 1739196160 EXPANSION PLUG 3 060# 0631175045 EXPANSION PLUG 1 070# 1522103380 SEALING CAP 6 080# 1522103390 SEALING CAP 2 090# 0501200408 STRAIGHT PIN 2 100# 0501200609 STRAIGHT PIN 2 110# 0501200512 STRAIGHT PIN 2 120# 0501201018 STRAIGHT PIN 1 130# 1522133650 PIPE PIN 1 150 1522133610 PLUG 1 160 1502133660 GASKET 1 170 1522133700 O RING 1 180 1532173340 WATER RETURN PIPE 1 190 1547135010 OIL PUMP ASSY. 1 200 1520635150 OIL PUMP GASKET 1 210 0105350650 BOLT 4 220 0451260060 SPRING WASHER 4 230 1920235660 OIL PUMP DRIVE GEAR 1 240 0571200410 FEATHER KEY 1 250 1522135682 FLANGE NUT 1 260 1584139010 OIL SWITCH 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 73

OIL PAN ASSY.

KUBOTA V2203 - ENGINE — OIL PAN ASSY.

PAGE 74 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — OIL PAN ASSY.

OIL PAN ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1543401613 OIL PAN 1 020 1922801620 OIL PAN GASKET 1 030 1733391010 FLANGE BOLT 24 040 1522133750 PLUG 1 050 1510933660 GASKET 1 060 1595133750 DRAIN PLUG 1 070 0472400160 GASKET 1 080 1562832110 OIL FILTER 1 090 0112360816 BOLT 1 100 0481100160 O RING 1 110 1711136410 OIL GAUGE 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 75

CYLINDER HEAD ASSY.

KUBOTA V2203 - ENGINE — CYLINDER HEAD ASSY.

PAGE 76 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — CYLINDER HEAD ASSY.

CYLINDER HEAD ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1641501752 ENGINE HOOK 1 020 1522101750 ENGINE HOOK 1 030 0112360816 BOLT 1 040 1522191530 STUD 1 050 0215650080 NUT 1 060 0451260080 SPRING WASHER 1 070 0401250080 PLAIN WASHER 1

080 1907703045 COMP. CYLINDER HEAD .............. 1 ..... INCL. ITEMS W/#

090# 1522103370 SEALING CAP 12 100# 1522103490 SEALING CAP 1 110# 1526196010 PLUG 2 120# 1732113580 INLET VALVE GUIDE 4 130# 1732113560 EXHAUST VALVE GUIDE 4 150 1901303450 CYLINDER HEAD BOLT 18 160 1907703310 CYLINDER HEAD GASKET 1 170 1949883040 THERMOSWITCH, ASSY. 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 77

GEAR CASE ASSY.

KUBOTA V2203 - ENGINE — GEAR CASE ASSY.

PAGE 78 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — GEAR CASE ASSY.

GEAR CASE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1718204010 GEAR CASE ASSY ....................... 1 ....... INCL. ITEMS W/#

020# 1685196010 PLUG 2 030# 0481100150 O RING 3 040# 0481100360 O RING 1 050# 1981856280 START SPRING PIN 1 060# 0501200612 STRAIGHT PIN 2 070 1708904130 GEAR CASE GASKET 1 080 0112350860 BOLT 2 090 0115350870 BOLT 5 100 1736791030 BOLT 1 110 0115350880 BOLT 2 120 1736791020 BOLT 3 130 0115350895 BOLT 2 140 0451260080 SPRING WASHER 10 150 0401250080 PLAIN WASHER 1 160 1552132290 PIPE JOINT 1 170 0401150180 PLAIN WASHER 1 180 1524136950 SPRING 1 190 1552136930 VALVE SEAT 1 200 0771503213 BALL 1 210 1552173320 WATER RETURN FLANGE 1 220 1576673330 GASKET 1 230 0102350620 BOLT 3 240 1732132430 OIL FILTER CARTRIDGE 1 250 1585233140 OIL FILTER PLUG 1 260 0481150300 O RING 1 270 1718233110 OIL FILTER FLANGE 1 280 1547154550 BOOST BASE C. GASKET 1 290 1718291510 STUD 4 300 0451260060 SPRING WASHER 4 310 0205650060 NUT 4

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 79

KUBOTA V2203 - ENGINE — MAIN BEARING CASE ASSY.

MAIN BEARING CASE ASSY.

PAGE 80 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — MAIN BEARING CASE ASSY.

MAIN BEARING CASE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1901304090 MAIN BEARING CASE ASSY. 1 020 1901304540 BEARING CASE BOLT 8 030 1907704360 BEARING CASE GASKET 1 040 1901304813 BEARING CASE COVER 1 050 1711804830 CASE COVER GASKET 1 060 0112350825 BOLT 8 070 0112350828 BOLT 8 080 1920204460 OIL SEAL 1 090 1901304040 MAIN BEARING CASE ASSY. 1 100 1901304050 MAIN BEARING CASE ASSY. 1 110 1901304060 MAIN BEARING CASE ASSY. 1 120 1560104560 BEARING CASE BOLT 3

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 81

HEAD COVER ASSY.

KUBOTA V2203 - ENGINE — HEAD COVER ASSY.

PAGE 82 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — HEAD COVER ASSY.

HEAD COVER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1711414510 HEAD COVER 1 020 1547114520 HEAD COVER GASKET 1 030 1718205020 COMP BREATHER 1 040 1711405130 GASKET 2 050 0112350840 BOLT 2 060 1624105670 BREATHER ELEMENT 1 070 1718214490 PLATE 1 080 1718205510 BREATHER TUBE 1 090 0931888200 HOSE CLAMP 2 100 1545192330 CAP NUT 4 110 1502133660 GASKET 4

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 83

INLET MANIFOLD ASSY.

KUBOTA V2203 -ENGINE — INLET MANIFOLD ASSY.

PAGE 84 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 -ENGINE — INLET MANIFOLD ASSY.

INLET MANIFOLD ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1711411760 INLET MANIFOLD 1 020 1718205550 BREATHER JOINT 1 030 1642311820 IN - MANIFOLD GASKET 1 040 0112350822 BOLT 7

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 85

EXHAUST MANIFOLD ASSY.

KUBOTA V2203 - ENGINE — EXHAUST MANIFOLD ASSY.

PAGE 86 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — EXHAUST MANIFOLD ASSY.

EXHAUST MANIFOLD ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1737712312 EXHAUST MANIFOLD 1 020 1552212350 EX-MANIFOLD GASKET 4 030 1522191530 STUD 8 040 1642992010 NUT 8 050 0151350822 STUD 4 060 T007016420 MUFFLER GASKET 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 87

KUBOTA V2203 -EB ENGINE — VALVE AND ROCKER ASSY.

VALVE AND ROCKER ASSY.

PAGE 88 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 -EB ENGINE — VALVE AND ROCKER ASSY.

VALVE AND ROCKER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1648413110 INLET VALVE 4 020 1648413120 EXHAUST VALVE 4 030 1522113240 VALVE SPRING 8 040 1522113330 VALVE SPRING RETAINER 8

050 1522113360 VALVE SPRING COLLAR .............. 8 ....... SET

060 1522113150 VALVE STEM SEAL 8 070 1522113280 VALVE CAP 8 080 1540114052 ROCKER ARM SHAFT ASSY. 1

090# 0341000808 SET SCREW .................................. 2 ....... INCLUDES ITEM W/#

100 1522114350 ROCKER ARM BRACKET 4 110 1552191500 STUD 4 120 0215650080 NUT 4 130 0451260080 SPRING WASHER 4 140 0401250080 PLAIN WASHER 4 150 0541100528 SPRING PIN 1 160 1522114430 ROCKER ARM SHAFT WASHER 2 170 1522114310 ROCKER ARM SPRING 3 180 0461200140 EXTERNAL CIR CLIP 2

190 1562114030 ROCKER ARM ASSY. .................... 8 ....... INCLUDES ITEM W/*

200* 1552114230 ADJUSTING SCREW 8 210* 1502114240 NUT 8

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 89

CAMSHAFT ASSY.

KUBOTA V2203 - ENGINE — CAMSHAFT ASSY.

PAGE 90 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — CAMSHAFT ASSY.

CAMSHAFT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1560115550 TAPPET 8 020 1901315110 PUSH ROD 8

030 1734316010 CAMSHAFT ASSY. ........................ 1 ....... INCLUDES ITEMS W/#

040# 1734316150 CAMSHAFT 1 050# 1552193610 SET SCREW 1 060# 1552116510 CAM GEAR 1 070# 0571200720 FEATHER KEY 1 080# 1522116270 CAMSHAFT STOPPER 1 090 0112350818 BOLT 2

100 1522124010 IDLE GEAR COMP. ........................ 1 ....... INCLUDES ITEMS W/*

110* 1733124980 IDLE GEAR BUSH 1 120 1552124360 COLLAR 1 130 1552124370 COLLAR 1 140 1522124320 IDLE GEAR CIR CLIP 1 150 1981824250 IDLE GEAR SHAFT 1 160 0112350818 BOLT 3

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 91

KUBOTA V2203 - ENGINE — PISTON AND CRANKSHAFT ASSY.

PISTON AND CRANKSHAFT ASSY.

PAGE 92 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — PISTON AND CRANKSHAFT ASSY.

PISTON AND CRANKSHAFT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1907721110 PISTON .......................................... 4 ....... S T D

010 1907721910 PISTON .......................................... 4 ....... + 0.5 M M

020 1733121050 PISTON RING ASSY. 4 030 1490121310 PISTON PIN 4 040 1410921330 PISTON PIN CLIP 8

050 1731122010 CONNECTING ROD ASSY. ............ 4 ....... INCLUDES ITEMS W/*

060* 1733121980 PISTON PIN BUSH 4 070* 1552122142 CONNECTING ROD BOLT 8

080* 1731122310 CRANKPIN METAL ........................ 4 ....... STD SET

080 1733122970 CRANKPIN METAL ........................ 4 ....... - 0.20 M M SET

080 1733122980 CRANKPIN METAL ........................ 4 ....... - 0.40 M M SET

090 1664123010 COMP. CRANKSHAFT ................... 1 ....... INCLUDES ITEMS W/#

100# 0771500401 BALL 4 110# 1920223280 CRANKSHAFT BUSHING 1 120 1547124110 CRANK GEAR 1 130 0571200720 FEATHER KEY 1 140 1547123312 OIL SLINGER 1 150 1920223250 CRANKSHAFT COLLAR 1 160 0481110300 O RING 1 170 1522123360 CRANKSHAFT NUT 1

180 1731123470 CRANKSHAFT METAL ................... 1 ....... STD

180 1731123910 CRANKSHAFT METAL ................... 1 ....... - 0.20 M M

180 1731123920 CRANKSHAFT METAL ................... 1 ....... - 0.40 M M

190 1731123480 CRANKSHAFT METAL ................... 4 ....... STD SET

190 1731123930 CRANKSHAFT METAL ................... 4 ....... - 0.20 M M SET

190 1731123940 CRANKSHAFT METAL ................... 4 ....... - 0.40 M M SET

200 1552123530 SIDE METAL .................................. 2 ....... STD

200 1522123950 SIDE METAL .................................. 2 ....... + 0.20 M M

200 1522123960 SIDE METAL .................................. 2 ....... + 0.40 M M

210 1920223540 SIDE METAL .................................. 2 ....... STD

210 1920223970 SIDE METAL .................................. 2 ....... + 0.20 M M

210 1920223980 SIDE METAL .................................. 2 ....... + 0.40 M M

220 1920204140 OIL SEAL 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 93

FLYWHEEL ASSY.

KUBOTA V2203 -ENGINE — FLYWHEEL ASSY.

PAGE 94 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — FLYWHEEL ASSY.

FLYWHEEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1747525010 COMP. FLYWHEEL 1 INCLUDES ITEMS W/* 020* 1560263820 RING GEAR 1 030 1532125163 FLYWHEEL BOLT 6 040 1747504610 FLYWHEEL HOUSING 1 050 1552104680 COVER 1 060 1552104790 COVER PACKING 1 070 0112360816 BOLT 2 080 0107351032 BOLT 11 090 0107351042 BOLT 3 100 0451260100 SPRING WASHER 11 110 0107351250 BOLT 2 120 0451260120 SPRING WASHER 2

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 95

STARTER ASSY.

KUBOTA V2203 - ENGINE — STARTER ASSY. AND MOUNTING

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KUBOTA V2203 - ENGINE — STARTER ASSY. AND MOUNTING

STARTER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1738163012 STARTER ASSY. 1 020 0151751028 STUD 1 030 0113351030 BOLT 1 040 0217650100 NUT 1 050 0451260100 SPRING WASHER 1 060 0211450080 NUT 1 070 0451260080 SPRING WASHER 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 97

KUBOTA V2203 - ENGINE — STARTER (COMPONENTS) ASSY.

STARTER (COMPONENTS) ASSY.

PAGE 98 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

KUBOTA V2203 - ENGINE — STARTER (COMPONENTS) ASSY.

STARTER (COMPONENTS) ASSY.

NO. PART NO. PART NAME QTY. REMARKS

010 1738163012 STARTER ASSY. .......................... 1 ......... INCLUDES ITEMS W/*

020* 1119763080 YOKE ASSY. 1

030* 1119763070 ARMATURE ASSY. ...................... 1 ......... INCLUDES ITEMS W/#

040*# 1146063500 BEARING 1 050*# 1146063530 BEARING 1 060* 1562163040 OVER RUNNING CLUTCH 1 070* 1648463030 DRIVE END FRAME 1 080* 1648463020 MAGNETIC SWITCH 1 090* 1648463200 END FRAME 1

100* 1738163380 BRUSH HOLDER ASSY. .............. 1 ......... INCLUDES ITEMS W/$

110*$ 1540163390 BRUSH SPRING 4 120* 1146063270 GEAR 1 130* 1146063110 RETAINER 1 140* 1921263100 ROLLER 5 150* 1146063120 SPRING 1 160* 1921297130 BALL 1 170* 1146093310 BOLT 2 180* 1551196660 O RING 2 190* 1119763320 BOLT 2 200* 1551163760 BOLT ASSY. 2 210* 1628563570 DRAIN PIPE 1 220* 1396392010 HEXAGON NUT 1

DCA-15SPX3 GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (09/03/01) — PAGE 99

NOZZLE HOLDER ASSY.

KUBOTA V2203 - ENGINE — NOZZLE HOLDER ASSY.

PAGE 100 — DCA-15SPX3 GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (09/03/01)

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