Multiquip DCA-400SPK User Manual

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PARTS AND OPERATION MANUAL

MQ POWER

DCA-400SPK

WHISPERWATT

GENERATOR

PARTS LIST NO. C3873300104

Revision #0 (06/19/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 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-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

HERE'S HOW TO GET HELP

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

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: 310/638-8046

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-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 3

TABLE OF CONTENTS

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

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

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

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

Trailer Safety Guidelines .................................... 11-17

Trailer Wiring Diagram.............................................. 18

Electric Brake Troubleshooting................................. 19

Hydraulic Brake Troubleshooting ............................. 20

Operation And Safety Decals ............................. 21-22

Specifications ...........................................................23

General Information ........................................... 24-25

Major Components ..................................................26

Dimensions (Top, Side And Rear)...................... 28-29

Control Panel...................................................... 30-31

Engine Operating Panel ..................................... 32-33

Output Terminal Panel ........................................ 34-39

Installation .......................................................... 40-41

Pre-Setup ........................................................... 42-45

Load Application ...................................................... 46

Generator Start-Up Procedure .......................... 47-50

Generator Shut-Down Procedure ............................52

Maintenance ...................................................... 54-57

Generator Wiring Diagram .......................................58

Engine Wiring Diagram ............................................ 60

Troubleshooting (Engine) ................................... 62-63

Troubleshooting (Engine/Generator) .......................64

Explanation Of Codes In Remarks Column .............66

Suggested Spare Parts ............................................67

MQ Power DCA-400SPK AC Generator

Generator Assembly .......................................... 68-71

Control Box Assembly ........................................ 72-75

Engine Radiator Assembly ................................. 76-79

Engine Operating Panel Assembly .................... 80-81

Output Terminal Assembly ................................. 82-83

Battery Assembly ............................................... 84-85

Muffler Assembly ............................................... 86-87

Fuel Tank Assembly ........................................... 88-89

Enclosure Assembly ........................................... 90-97

Enclosure (Rubber Seals) .................................. 98-99

Oil Piping Assembly ....................................... 100-101

Name Plate and Decals ................................. 101-105

Terms and Conditions Of Sale — Parts ................ 106

NOTE

Specification and part numberSpecification and part number

Specification and part number

Specification and part numberSpecification and part number are subject to change withoutare subject to change without

are subject to change without

are subject to change withoutare subject to change without noticenotice

notice

noticenotice

PAGE 4 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

PARTS ORDERING PROCEDURES

■ Dealer account number

■ Dealer name and address

■ Shipping address (if different than billing address)

■ Return fax number

■ Applicable model number

■ Quantity, part number and description of each part

■ Specify preferred method of shipment:

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)*

Airborne Express*

•

Truck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts:

Number of line items ordered 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

UPS

Special

For faxed orders 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-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

RULES FOR SAFE OPERATION

■

CAUTION:

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained

and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the DCA-400SPK portable generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading this entire manual.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

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

■

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

■

The engine of this generator requires an adequate free flow of cooling air. Never operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

CAUTION

hot

components

■

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

■

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

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts before starting.

■

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

■

Always use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT smoke around or near the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

■

NEVER operate the generator in an

explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

or even death.

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

bodily harm

PAGE 6 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

RULES FOR SAFE OPERATION

CAUTION

■

NEVER touch output terminals during operation. This is extremely dangerous. contact with the output terminals.

CAUTION

■

Backfeed to a utility system can cause electrocution and.or property damage. Do not connect to any building's electrical system except through an approved device or after building main switch is opened.

Always stop the machine when

CAUTION

Radiator

1. Radiator Cap - Removing the radiator cap while the

2. Coolant Drain Plug - Removing the coolant drain

3. Engine Oil Drain Plug - Removing the engine oil

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.

engine is hot due to high pressure, will result in boiling water to gush out of the radiator, therefore causing severe scalding to any persons in the general area of the generator.

plug while the engine is hot will result in hot coolant to gush out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

drain plug while the engine is hot will result in hot oil to gush out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

CAUTION

Never use damaged or worn cables when

connecting power tools or equipment to the generator. Make sure power connecting cables are securely connected to the

generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator and electrical shock.

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 7

RULES FOR SAFE OPERATION

Battery

CAUTION

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, always wear safety glasses. Use well insulated gloves when picking up the battery. Use the following guidelines when handling the battery:

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

2. DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

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.

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

■

NEVER Run engine without air filter. Severe engine damage may occur.

■

Always service air cleaner frequently to prevent carburetor malfunction.

■

Always disconnect the battery before performing service on the generator.

■

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

■

Always store equipment properly when not in use. Equipment should be stored in a clean, dry location out of the reach of children.

■

DO NOT leave the generator running in the manual mode unattended.

■

DO NOT allow unauthorized people to operate this equipment.

■

Always read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.

■

Refer to the engine technical questions or information.

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.

■

Always drain fuel prior to lifting.

■

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

omatsu Engine Owner's Manomatsu Engine Owner's Man

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omatsu Engine Owner's Manomatsu Engine Owner's Man

ualual

ual

ualual

for

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

7. In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes, rinse eyes immediately with plenty of water, then contact the nearest doctor or hospital, and seek medical attention.

clothing or skinclothing or skin

clothing or skin

clothing or skinclothing or skin

PAGE 8 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

, rinse skin or clothing

■

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 center-point suspension hook and lift straight upwards.

■

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

■

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

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

RULES FOR SAFE OPERATION

■

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

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

■

Always allow the machine a proper amount of time to cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace broken parts.

■

Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, coolant, fuel, and fuel filters.

■

DO NOT use plastic containers to dispose of hazardous waste.

■

DO NOT pour waste, oil, coolant or fuel directly onto the ground, down a drain or into any water source

. 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

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 9

DCA-400SPK — TOWING

Towing Safety Precautions

CAUTION :

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

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer (Figure 1) that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of suggestions should be used when towing your generator:

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■

ALWAYS attach trailer's safety chain to bumper of towing vehicle.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

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

■

Place

rollingrolling

rolling,

rollingrolling

■

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.

chocked blocks

while parked.

support blocks

tippingtipping

tipping

tippingtipping

, while parked.

underneath wheel to prevent

underneath the trailer's bumper to

■

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

■

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

■

DO NOT transport generator with fuel in tank.

Figure 1. Generator with Trailer

PAGE 10 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — TRAILER-SAFETY GUIDELINES

CAUTION:

ALWAYS make sure the trailer is in good operating condition. Check the tires for proper inflation and wear. Also check the wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide range of trailers. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.

It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions with reading Table 1.

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - This measurement is from the ball hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to fender.

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 4 and Figure 5 or lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed in inches (see Table 3). Please not that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed on a particular trailer.

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 11

DCA-400SPK — TRAILER-SPECIFICATIONS

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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

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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

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PAGE 12 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — TRAILER-SPECIFICATIONS

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DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 13

DCA-400SPK — TRAILER SAFETY GUIDELINES

Brakes

If your trailer has a braking system, the brakes should be inspected the first 200 miles of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes every 3,000 miles. If driving over rough terrain, inspect the brakes more frequently.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to hydraulic brakes. The basic difference is that hydraulic brakes are actuated by an electromagnet.

Listed below are some of the advantages that electric brakes have over hydraulic brakes:



Brake system can be manually adjusted to provide the

corrected braking capability for varying road and load conditions



Brake system can be modulated to provide more or less

braking force, thus easing the brake load on the towing vehicle



Brake system has very little lag time between the time

the vehicle’s brakes are actuated and the trailer’s brakes are actuated



Brake system can provide an independent emergency

brake system

trailer being towed or under-adjusted brakes.

Before any brake synchronizations adjustments can be made, the trailer brakes should be burnished-in by applying the brakes 20-30 times with approximately a 20 m.p.h. decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for brakes to cool between application. This allows the brake shoes to slightly be seated into the brake drum surface.

Figure 2 displays the major electric brake components that will require inspection and maintenance. Please inspect these components as required.

Electric Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes.

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

Remember in order to properly synchronize the tow vehicle’s braking to the trailer’s braking, can only be accomplished by road testing. Brake lockup, grabbiness or harshness is due to lack of synchronization between the tow vehicle and the

6. Rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

7. Replace the adjusting hole cover and lower the trailer to the ground.

8. Repeat steps 1 through 6 on the remaining brakes.

PAGE 14 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — TRAILER SAFETY GUIDELINES

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. These brakes can be adjusted in the same manner as electric brakes. Brake lines should be periodically checked for cracks, kinks, or blockage. Figure 3 below displays the major hydraulic/air/surge brake

components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section.

Figure 3. Hydraulic Brake Components

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 15

DCA-400SPK — TRAILER SAFETY GUIDELINES

Tires/Wheels/Lug Nuts

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

CAUTION:

DO NOT attempt to repair or modify a wheel. DO NOT install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and

cause serious eye or bodily injury.

Suspension

The leaf suspension springs and associated components (Figure 4) should be visually inspected every 6,000 miles for

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.

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 16 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

Figure 4. Major Suspension Components

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DCA-400SPK — TRAILER SAFETY GUIDELINES

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SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY

LOC K ING NUTS OR C OT TER P INS A RE P RO VID ED

. PARTS MUST ROTATE FREELY.

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 5. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 4.

3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

eziSleehW

"2152-0204-5356-05

"3152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

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DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 17

stnemeriuqeReuqroTeriT.4elbaT

ssaPdrihT

SBL-TF

Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-400SPK — TRAILER-WIRING DIAGRAM

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — TRAILER-BRAKE TROUBLESHOOTING

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DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 19

DCA-400SPK — TRAILER-BRAKE TROUBLESHOOTING

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PAGE 20 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — OPERATION AND SAFETY DECALS

Machine Safety Decals

The DCA-400SPK generator is equipped with a number of safety decals. These decals are provided for operator safety and maintenance information. The illustration below and on the preceding pages shows the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 21

DCA-400SPK — OPERATION AND SAFETY DECALS

PAGE 22 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — SPECIFICATIONS

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DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 23

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DCA-400SPK — GENERAL INFORMATION

DCA-400SPK FAMILIARIZATION

Generator

genergener

The MQ Power Model DCA-400SPK is a 320 kW that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

Engine Control Panel

The “Engine Control Panel” is provided with the following:

Tachometer

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Engine Warning Lamp Module

Engine Speed Switch

Pre-Heat Button

Pre-Heat Lamp

Emergency Stop Button

Battery Switch

Generator Control Panel

The “Generator Control Panel” is provided with the following:

Output Voltage Adjustment Knob

Frequency Meter (Hz)

AC Ammeter (Amps)

AC Voltmeter (Volts)

Ammeter Change-Over Switch

Voltmeter Change-Over Switch

Panel Light

Panel Light Switch

Pilot Lamp

Output Terminal Panel

gener

genergener

atorator

ator

atorator

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 1060 amps

Over-Current Relay

High Idle Adjust Trimmer

Open Delta Excitation System

The DCA-400SPK 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 parallel connections of B&C. When loads increase, the AVR switches and accepts power from leads A&D. The output of leads A&D increase proportionally with load. This of adding the voltages to each phase provides better voltage response during heavy loads.

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

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a " according the demands of the required load.

Microprocessor Controlled Alarm System

The DCA-400SPK generator is equipped with various alarms and LED status indicators. These alarms and status indicators are provided to add safety to the generator when operating under normal conditions. The DCA-400SPK generator is designed to shutdown in the event of low oil, high coolant temperature, low battery and other operation conditions that may cause severe damage to the generator.

Open-DeltaOpen-Delta

Open-Delta

Open-DeltaOpen-Delta

utomatic utomatic

utomatic

utomatic utomatic

" excitation system. The open delta

oltage Regulator oltage Regulator

oltage Regulator

oltage Regulator oltage Regulator

fixed ceilingfixed ceiling

fixed ceiling

fixed ceilingfixed ceiling

(AVR) is supplied

" and responds

The “Output Terminal Panel” is provided with the following:

Three 240/139V output receptacles, 50 amp

Two 120V input receptacles, 20 amp

3 Load Circuit Breakers 265V @65 amps

2 Load GFCI Circuit Breakers 265V@ 20amps

PAGE 24 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — GENERAL INFORMATION

Engine

The DCA-400SPK is powered by a 4 cycle, water cooled, turbocharged KOMATSU Model SA6D140-A This engine is designed to meet every performance requirement for the generator. Reference Table 1, page 16 for engine specifications.

In keeping with Multiquip's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

The basic controls and indicators for the DCA-400SPK generator are addressed on the following pages.

Mechanical Governor System

The mechanical governor system control the RPM of the engine. When the engine demands increase or decrease, the mechanical governor system regulates the frequency variation to ±1.5%. The electronic governor option increases frequency variation to ±0.25%.

diesel diesel

diesel

diesel diesel

engine.

Jacket Water Heater (OPTIONAL)

The jacket water heater is a 1500-watt heater designed to keep the coolant warm in the engine block for fast starts and load acceptance. The heater is thermostatically controlled and once an acceptable engine temperature is achieved it will cycle on and off, operating only about 1/3 of the time, which makes it more efficient than the direct block type heater. It is designed to keep the engine coolant between 100 and 120 degrees Fahrenheit.

Under normal conditions, 20 to 15 minutes is required to raise the engine temperature of a cold engine to 100 degrees Fahrenheit.

Battery Charger

The battery charger will operate in a ‘BOOST’ mode until the battery’s current acceptance falls to 70% of the charger’s rating. The charger will then go into a ‘FLOAT’ mode, where it discharges a lower voltage until an AC failure, or the battery is discharged.

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 25

DCA-400SPK — MAJOR COMPONENTS

Figure 6. Major Components

PAGE 26 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

NOTE PAGE

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 27

DCA-400SPK — DIMENSIONS (TOP AND SIDE)

Figure 7a. Dimensions

PAGE 28 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — DIMENSIONS (FRONT AND REAR)

Figure 7b. Dimensions

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 29

DCA-400SPK — CONTROL PANEL

Figure 8. Control Panel

PAGE 30 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — CONTROL PANEL

The definitions below describe the controls and functions of the DCA-400SPK "

1. Pilot Lamp – Indicates that the generator is working properly.

2. Panel Light – Normally used in dark areas or at night time. When activated, panel lights will illuminate. When the generator is not in use be sure to turn the panel light switch to the OFF position.

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

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

5. AC Voltmeter – Indicates the single phase output voltage present at the UVW terminals.

6. Ammeter Change-Over Switch – This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off.

7. Voltmeter Change-Over Switch – This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

8. Panel Light Switch – When activated will turn on control panel light.

9. Voltage Regulator Control – Allows manual adjustment of the generator’s output voltage.

10. MPEC – Microprocessor

Engine Control Module – (MPEC) has a vertical row

of status LED's (Figure 9), that when lit, indicate that an engine malfunction (fault), has been detected. When a fault has been detected the MPEC will evaluate the fault and if the fault is major will shutdown the generator.

During engine for 10 seconds before disengaging.

cranking cycle

Control Panel Control Panel

Control Panel

Control Panel Control Panel

, The MPEC will attempt to crank the

" (Figure 8).

Figure 9. MPEC Module

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the MPEC's " Over Crank Protection" mode. If the engine engages at a speed (RPM's) that is not safe, the MPEC will shutdown the engine by initializing the "Over Speed Protection" mode.

Also the MPEC will shutdown the generator in the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the MPEC module.

A. Off/Manual/Auto Switch – This switch controls the

running of the generator. If this switch is left in the "OFF" position, the generator will not run. When this switch is set to the immediately.

If the generator is to be connected to a building's AC power source via a transfer switch (isolation), place the switch in the generator will monitor the AC line output from the building's power source.

B. Low Oil Pressure – Indicates the engine pressure

has fallen below 15 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 215°F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

D. Overcrank Shutdown – Indicates the unit has

attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. Typical programmable start settings is 3 cycles with a 10 second duration .This is considered a

E. Overspeed Shutdown – Indicates the engine is

running at an unsafe speed. This is considered a fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

11. Main Circuit Breaker – This three-pole, 800 amp main breaker is provided to protect the UVW voltage output terminals from overload.

manual

fault.

position, the generator will start

auto

position. In this position the

major

fault.

major

fault.

major

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 31

DCA-400SPK — ENGINE OPERATING PANEL

Figure 10. Engine Operating Panel

PAGE 32 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-400SPK "

1. Throttle Handle - This handle controls the speed of the engine (low or high).

2. Tachometer – Indicates engine speed in RPM’s for 60 Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

3. Engine Warning Display Module – This module display’s the following engine failures:

A. Overheat Lamp – This lamp goes ON when

the cooling water temperature rises abnormally. If the lamp goes ON during normal operation of the generator, the emergency shutdown device will stop the engine automatically.

B. Low Oil Pressure Lamp – During normal

operation of the generator this lamp should remain OFF. When the Auto-OFF/ResetManual switch is set to the “Manual” position to start the engine, the lamp will be lit. After the oil pressure rises after start-up the lamp will go OFF. If this lamp is ever lit (ON) during normal operation of the generator, the emergency shutdown device will stop the engine automatically.

C. Low Fuel Level Lamp – When this lamp is

ON, it is time to stop the engine and add fuel. Remember to let the engine cool before adding fuel.

D. Low Battery Fluid Lamp – This lamp goes

ON when the battery fluid is low. If this lamp goes ON during normal operation of the generator, stop the engine and fill the battery with distilled water to the specified level.

Engine Operating Panel Engine Operating Panel

Engine Operating Panel

Engine Operating Panel Engine Operating Panel

"(Figure 10).

4. Oil Pressure Gauge – During normal operation this gauge be should read in the “GREEN” zone. When starting the generator the oil pressure mar read a little bit higher, but after the engine warms up the oil pressure should return to the green zone.

5. Water Temperature Gaug e – During normal operation this gauge be should read in the “GREEN” zone.

6. Charging Ammeter Gauge – Indicates the current being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

7. Fuel Gauge - Indicates amount of diesel fuel available.

8. Pre-Heat Lamp – Indicates that the glow plugs of the diesel engine are hot and the engine is ready to be started.

9. Emergency Stop Button – Push this button inward to stop the engine in the event of an emergency. DO NOT use this button as a means of stopping the engine.

10. Starter Switch – Use this switch to preheat the engine and turn on the generator (This feature will not be on the unit if it is equipped with a MPECsee Control Panel).

11. Battery Switch – This switch should be set to the ON position during normal operation. When the engine has been stop, place this switch in the OFF position. DO NOT turn this switch during normal operation, it could cause damage to the electrical equipment

E. Clogged Air Filter Lamp – This lamp goes

ON when the air filter is clogged. If this lamp goes ON during normal operation of the generator, stop the engine and replace the air filter.

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 33

DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel” is provided with the following:

Two 120V GFCI receptacles, 20 amp

Three 240/139V output receptacles, 50 amp

Two 120V input receptacles, 20 amp (optional)

3 Load Circuit Breakers 265V @65 amps

2 Load GFCI Circuit Breakers 265V@ 20amps

Control Box

The “Control Box” is provided with the following:

Main Circuit Breaker 1000 amps

Over-Current Relay

Output Terminal Panel

The Output Control Panel (See Figure 14) is located on the right hand side (left from control panel) of the generator. The UVWO lugs are protected by a face plate cover that can be secured in the close position by a pad lock. (See Figure 11).

Connecting Load

Loads can be connected to the generator by the UVWO Lugs or the convenience receptacles. (See figure 13). Make sure to read the operation manual before attempting to connect a load to the generator.

Circuit Breakers

To protect the generator from an overload, a 3-pole, 1000

main main

amp,

main

main main

output terminals from overload. In addition two single-pole, 20 amp GFCI receptacles from overload. Three 50 amp breakers have also been provided to protect the load side of the generator from overload. Make sure to switch breakers to the "OFF" position prior to starting the engine.

FIGURE 13. Connecting Load

circuit breaker is provided to protect the UVW

GFCIGFCI

GFCI

circuit breakers are provided to protect the

GFCIGFCI

loadload

load

circuit

loadload

ALLALL

ALL

circuit

ALLALL

Maximum Output

FIGURE 11. Output Terminal Cover

120 Volt Recetacle

Two GFCI Duplex Nema 5-20R (120V, 20 Amp) recepacle is provided on the output terminal. This receptacle can be used anytime the generator is in operation. The receptacle 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 12) in the center of this receptacle will check the GFCI function. The receptacle should be tested at least once a month.

FIGURE 12. GFCI Test Button

PAGE 34 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

The entire load connected to the UVWO Lugs, all four slots in the duplex receptacles, and the must not exceed 352 kW in standby or 320 in prime output.

Twist Lock Dual Voltage Receptacles

Three CS-6369 auxiliary power receptacles have been provided to supply 208/120V. The voltage regulator knob on the control panel may need to be used to adjust the voltage to 208 or 416V.

Input Receptacles

Two 120 volt, 20 amp input receptacles are provided to supply power to accessories, such as the battery charger (optional) or jacket water heater (optional).

DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW

NOTE

FIGURE 14. Output Terminal Panel

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 35

Legs O and Ground are considered Bonded Grounds.

DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW

Output Terminal Panel Available Voltages

A wide range of voltages are available to supply load to many different applications. Voltages may be selected by using the voltage change-over board and how you hookup

Maximum Amps

The following table show the maximum amps the entire generator can provide. Do not exceed the maximum amps

listed. (See Table 9) your hard wire connection to the generator. To obtain some of the voltages listed, fine adjustment with the Voltage Regulator on the control panel is necessary. See the table below (Table 8) for a list of available voltages the generator is able to supply.

ELBALIAVASEGATLOV.8ELBAT

LEDOMKSS004ACD

EGATLOVESAHP3

ESAHPELGNIS

)ELBATSUJDA(

TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

)ELBATCENNOCER(

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

CAUTION :

NEVER attempt to change the Voltage

Change-over board while the engine is engaged.

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detaR

egatloV

esahPelgniS

tloV021

esahPelgniS

tloV042

esahPeerhT

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tloV084

spmAmumixaM.9elbaT

spmAmumixaM

)eriw4(spma9.888

)eriw4(spma4.444

spma3.269

spma1.184

Over Current Relay

An over current relay is connected to the circuit breaker. In an over current situation, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

PAGE 36 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW

How to read the output terminal gauges.

The gauges and knobs on the control panel DO NOT effect the generator output in any fashion. They are there to simply help the operator observe how much power is being supplied produced at the UVWO legs.

To read the output of the W-U legs, for example, place the AC Voltmeter Change-over switch to the W-U position and the AC ammeter Change -over Switch to the U or W position to read the output on the selected leg.

FIGURE 15. AC Voltmeter

Change-over switch

(Reading the W-U leg on

the output terminal panel)

FIGURE 17. AC Ammeter

Change-over Switch

(Reading the U leg on the

output terminal panel)

FIGURE 16. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

FIGURE 18. AC Ammeter

(Amp reading on U lug)

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 37

DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW

Voltage Change-over Board

The voltage change-over board changes the available voltages of the output terminal panel UVWO lugs. The voltage change-over board is located on the control box behind the control panel. There are six (6) plates that can be set into two set positions to get six different voltages. Unless specified differently, the generator comes from the factory in the 240V position.

240 Volt Set position

The voltage change-over board 240V set position uses all 6 plates in 6 different connection places. See figure 19 below.

Single Phase, 240 Volt

The following connection, with the voltage change-over board set into the 240V set position (See Figure 19), can offer SINGLE PHASE power at 240V. After hooking up the hard wires to the lugs as shown in figure 21 below, 240V will be the voltage output.

FIGURE 21. Hard Wire Hookup for Single Phase 240V

FIGURE 19. Voltage Change-over Board 240V set position.

3 Phase, 240 Volt

The following connection, with the voltage change-over board set into the 240V set position (See Figure 19), can offer THREE PHASE power at 240V. After hooking up the hard wires to the lugs as shown in figure 20 below, 240V will be the voltage output.

Single Phase, 139 Volt

The following connection, with the voltage change-over board set into the 240V set position (See Figure 19), can offer SINGLE PHASE power at 139V. After hooking up the hard wires to the lugs as shown in figure 22 below, 139V will be the voltage output.

FIGURE 20. Hard Wire Hookup for Three Phase 240V

PAGE 38 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

FIGURE 22. Hard Wire Hookup for Single Phase 139V

DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW

480 Volt Set position

The voltage change-over board 480V set position uses all 6 plates in 3 different connection places. There are 2 plates at every position (Every plate is used). See figure 23 below.

Single Phase, 480 Volt

The following connection, with the voltage change-over board set into the 480V set position (See Figure 23), can offer SINGLE PHASE power at 480V. After hooking up the hard wires to the lugs as shown in figure 25 below, 480V will be the voltage output.

FIGURE 23. Voltage Change-over Board 480V set position.

3 Phase, 480 Volt

The following connection, with the voltage change-over board set into the 480V set position (See Figure 23), can offer THREE PHASE power at 480V. After hooking up the hard wires to the lugs as shown in figure 24 below, 480V will be the voltage output.

FIGURE 25. Hard Wire Hookup for Single Phase 480V

Single Phase, 277 Volt

The following connection, with the voltage change-over board set into the 480V set position (See Figure 23), can offer SINGLE PHASE power at 277V. After hooking up the hard wires to the lugs as shown in figure 26 below, 277V will be the voltage output.

FIGURE 24. Hard Wire Hookup for Three Phase 480V

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 39

FIGURE 26. Hard Wire Hookup for Single Phase 277V

DCA-400SPK — INSTALLATION

Outdoor Installation

CAUTION

Install the generator in a location where it will not be exposed to rain or sunshine. Make sure the generator is on secure level ground so 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.

Generator Grounding

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION :

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must

be routed to a ventilated area.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger. b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 27) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground rod should be buried a minimum of 8 ft. into the ground.

An electric shock may happen when vibrators are used. Pay close attention to handling when operating vibrators and always use rubber boots and gloves to insulate the body from electrical shock.

Mounting

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

PAGE 40 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

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

NOTE

DCA-400SPK — INSTALLATION

Figure 27. Typical Generator Grounding Application

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 41

DCA-400SPK — PRE-SETUP

General Inspection Prior to Operation

The DCA-400SPK generator has been thoroughly inspected and accepted prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts, which could have occurred in transit.

Extension Cable

Circuit Breakers

To protect the generator from an overload, a 3-pole,1060

main main

amp,

main

main main

output terminals from overload. In addition two single-pole, 20 amp GFCI receptacles from overload. Three 50 amp breakers have also been provided to protect the load side of

When electric power is to be provided to various tools or loads at some distance from the generator, extension

the generator from overload. Make sure to switch breakers to the "OFF" position prior to starting the engine.

cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the Cable Selection Guide (Table 10) as a guide for selecting proper cable size.

circuit breaker is provided to protect the UVW

GFCIGFCI

GFCI

circuit breakers are provided to protect the

GFCIGFCI

loadload

circuit

load

loadload

ALLALL

ALL

circuit

ALLALL

NOTE

ALWAYS consult with a licensed

electrician for correct extension cord wire size.

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PAGE 42 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — PRE-SETUP

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but do not overfill. Make sure the generator is level. With the dipstick inserted all the way, but without being screw into the filler hole, verify that the oil level is maintained between the two notches (Figure 28) on the dipstick. See Table 9 for proper selection of engine oil.

Fuel

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

Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed on page 23, Specification Table 7.

The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

CAUTION

diesel fuel.diesel fuel.

diesel fuel.

diesel fuel.diesel fuel.

DO NOT

Never fill the fuel tank while the engine is running or in the dark. Diesel spillage on a hot engine can cause a fire or explosion. If diesel spillage occurs, wipe up the

spilled diesel completely to prevent fire hazards.

Coolant

Use only drinkable tap water. If hard water or water with many impurities is used, the inside of the engine and radiator

Figure 28. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean and viscous. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Komatsu Engine Owner's Manual.

erutarepmeT

egnaR

F°32~F°401

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F°5~F°32

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may become coated with deposits and cooling efficiency will be reduced.

An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system. See the engine manual for further details.

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DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 43

DCA-400SPK — PRE-SETUP

CAUTION :

When adding coolant or antifreeze to the radiator, do not remove the radiator cap until the unit has completely cooled.

Day-to-day addition of coolant is done from the reserve tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 12 for engine, radiator, and reserve tank coolant capacities. Make sure the coolant level in the reserve tank is always between the "H" and the "L" markings.

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Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

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Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the battery disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. See maintenance section for instruction to cleaning/replacing air cleaner.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear. See maintenance section on replacing belts. To adjust tension:

1. Insert a bar between alternator and the cylinder block to fix alternator in position. When fixing the alternator in position, insert a wooden block between the bar and alternator to prevent damage to the alternator.

2. Loosen bolts and nuts located on the alternator.

3. Move alternator with the bar so the deflection of the belt is approx. 8mm.

4. Tighten the bolt and nuts to fix the alternator back to position.

The fan belt tension is proper if the fan belt bends 7 to 10 mm (Figure 29) when depressed with the thumb as shown below.

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NOTE

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

, the antifreez

aterater

, the antifreez, the antifreez

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

be less than 50%.

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

PAGE 44 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

e mixing re mixing r

e mixing r

e mixing re mixing r

atio matio m

atio m

atio matio m

ustust

ust

ustust

Figure 29. Fan Belt Tension

CAUTION

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

DCA-400SPK — PRE-SETUP

Battery Cable Installation ALWAYS be sure the battery cables (Figure 30) are properly

connected to the battery terminals as shown below. The

RED RED

RED

cable is connected to the positive terminal of the battery,

RED RED

and the BLACK cable is connected to the negative terminal of the battery.

Figure 30. Battery Connections

CAUTION

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery terminals when the the manual or auto position (ON). ALWAYS make sure that the Off/Manual/Auto switch is in the OFF position when connecting the battery.

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

Off/Manual/Auto Off/Manual/Auto

Off/Manual/Auto

Off/Manual/Auto Off/Manual/Auto

switch is in either

CAUTION

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.

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level is not properly maintained. Add only distilled water when replenishment is necessary. The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68°F). If the specific gravity should fall to 1.245 or lower, it indicates the battery is discharged and needs to be recharged or replaced. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the terminals firmly tightened. Coating the terminals with a thin film of grease will help inhibit corrosion.

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

2. Place a small amount of grease around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 45

DCA-400SPK — LOAD APPLICATION

Single Phase Load

CAUTION

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and frequency requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130— 150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and

cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable.

starting system of the equipment.

When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up

NOTE

to the generating set’s rated output (kW) can be used.

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

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.

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

An inadequate size connecting cable which

When connecting ordinary power tools, a capacity of up to

The power factor of this generator is 0.8. See Table 14. below when connecting loads.

the generating set’s rated output (kW) multiplied by 0.8 can be used.

CAUTION:

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Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

57.0-4.0

0.1

9.0-4.0

If output (kVA) is not given

0.1

on the equipment nameplate, approximate output may be determined by multiplying voltage by amperage by .

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious injury or death may result without this transfer switch.

NOTE

PAGE 46 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — GENERATOR START-UP PROCEDURE (MANUAL)

WARNING:

The engine's exhaust contains harmful

ALAL

emissions. 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 11 on page 43).

3. Check the coolant level in the radiator and subtank.

Replenish with antifreeze as necessary. Always maintain the coolant level between the FULL and LOW markings on the coolant container. Be sure the radiator cap is fastened securely.

4. Check the fuel level on the fuel gauge. If fuel is low, fill

the fuel tank with clean fresh unleaded automotive diesel. If diesel spillage occurs, completely wipe up the spilled fuel immediately.

Before Starting

Generator and Control Panel

ALAL

YS YS

ventilate the

YS YS

CAUTION:

Jacket Water Heater and Internal Battery Charger 120 VAC Output Receptacles (OPTIONAL)

This generator is equipped with two 120 VAC, 20 amp output receptacles located on the output terminal panel, page 43, Figure 14.

The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal battery charger.

These receptacles will ONLY function when commercial power has been supplied to them (Figure 31). To apply commercial power to these receptacles, a power cord of adequate size will be required.

When using the generator in to apply power to jacket water heater. However, if the generator will be used in idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using an power cord of adequate size.

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator's internal battery charger. This will ensure that the engine will not fail due to a dead battery.

hothot

hot

climates there is no reason

hothot

coldcold

cold

climates it is always a good

coldcold

NEVER start the engine with the

main,main,

GFCI GFCI

main,

GFCI

main,main,

GFCI GFCI

in the ON position.

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

main, load main, load

main, load

main, load main, load

the “OFF” position prior to starting the engine.

G.FG.F

.C.C

and

Figure 31. Main, GFCI and

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 47

.I..I.

G.F

.I.

G.FG.F

circuit breakers (Figure 31) to

.C.C

.I..I.

Load Circuit Breakers

loadload

load

circuit breakers

loadload

CAUTION:

ALWAYS have power applied to the generator's internal battery charger when connecting the generator to a isolation (transfer) switch. Remember before connecting this generator to any buildings electrical system, have

licensed licensed

licensed

licensed licensed

installation of the transfer switch.

electrician perform the

DCA-400SPK — GENERATOR START-UP PROCEDURE (MANUAL)

2. Connect the load to the UVW terminals as shown in

4. Close all engine enclosure doors (Figure 34). Figure 32. These terminals can be found on the output terminal panel, see page 35 Figure 14. To gain access to the output terminals lift the UVW cover. Make sure to tighten terminal nuts securely to prevent load wires from slipping out.

5. Set the battery ON/OFF switch (Figure 35) to the ON position.

Figure 32. UVW Terminal Lugs (Load)

3. Connect the negative battery cable (BLACK) to the negative post on the battery (Figure 33).

Figure 34. Engine Enclosure Doors

NEGATIVE

POSTIVE

BATTERY

Figure 33. Battery Connections

Figure 35. Battery ON/OFF Switch

6. When starting the generator in COLD weather conditions, press and hold the engine preheat button (Figure 36) until the preheat lamp (Figure 37) is lit (ON).

Figure 36. Engine Pre-Heat Button

Figure 37. Engine Pre-Heat Lamp

PAGE 48 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — GENERATOR START-UP PROCEDURE (MANUAL)

7. Place the Off/Manual/Auto switch (Figure 38) in the MANUAL position (down). Observe that the engine begins to crank.

11. The generator's voltage meter (Figure 42) displays the

Figure 38. Off/Manual/Auto Switch (Manual)

8. After engine starts, verify that the "Engine Running" status LED (Figure 39) on the Microprocessor Engine Control Module (MPEC) display is "ON" (lit).

120 VAC in VOLTS. If the voltage is not within the specified frequency tolerance, use the voltage adjustment control knob (Figure 43) to increase or decrease the desired voltage.

Figure 41. Frequency Meter (Hz)

Figure 39. MPEC Engine Running Status LED

9. If the generator is equipped with a ignition switch, turn the key to “Start” position (Figure 40). Once the engine starts, release the key to the “on” position.

12. The ammeter (Figure 44) will indicate zero amps with no load applied. When a load is applied, this meter will indicate the amount of current that the load is drawing from the generator’s alternator.

Figure 40. Engine Ignition Switch

10. The generator's frequency meter (Figure 41) displays the 60 cycle output frequency in HERTZ.

Figure 42. Voltage Meter (Volts)

Figure 43. Voltage Adjust Control

Knob

Figure 44. Ammeter (No Load)

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 49

DCA-400SPK — GENERATOR START-UP PROCEDURE (MANUAL)

13. The engine oil pressure gauge (Figure 45) will indicate the oil pressure (kg/ cm

of the engine. Under normal

16. Turn the MAIN, GFCI and LOAD circuit breakers to their "ON" position (Figure 48).

operating conditions the oil pressure should be approximately 25 psi.

Figure 48. Main and GFCI Circuit Breakers

Figure 45. Oil Pressure Gauge

14. The coolant temperature gauge (Figure 46) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 165 and 215 degrees Fahrenheit (Green Zone).

17. Observe the generator's ammeter (Figure 49) and verify that it reads the anticipated amount of current with respect to the load. Remember the ammeter will only display a current reading if the load is in use.

WATER

TEMP

Figure 46. Coolant Temperature Gauge

15. The tachometer (Figure 47) will indicate the speed of the engine when the generator is operating. Under normal

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

operating conditions this speed should be approximately 1800 RPM’s.

Figure 47. Engine Tachometer

Figure 49. Ammeter (Load)

PAGE 50 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — GENERATOR START-UP PROCEDURE (AUTO)

CAUTION:

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious may result without this transfer switch.

injuryinjury

injury

injuryinjury

deathdeath

death

deathdeath

CAUTION:

Starting the generator in the "AUTO" mode is similar to starting the generator in the "MANUAL" mode, with a few exceptions.

When starting generator in Auto mode use the "Manual Startup" procedure except where noted (see below).

1. Perform steps 1 through 6 (Before Starting, page 47-

48) as outlined in the manual starting procedure.

2. Apply commercial power to the internal battery charger receptacle (to ensure good starting) via commercial power. An external power cord will be required.

3. Apply commercial power to the jacket water heater receptacle (not necessary for warm climates) via commercial power. An external power cord will be required.

4. Place the Off/Manual/Auto switch (Figure 50) in the AUTO position (up).

CAUTION:

When running the generator in the AUTO mode, remember the generator can start

up at any time without warning. NEVER attempt to perform any maintenance when the generator is in the auto mode.

5. Continue to follow the steps outline in the manual start-

Figure 50. Off/Manual Auto Switch

(AUTO)

up procedure (start at step 11, page 49).

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 51

DCA-400SPK — GENERATOR SHUTDOWN PROCEDURE

Engine Shutdown

To shutdown the generator use the following procedure:

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

2. Let the engine cool by running it for 3-5 minutes with no load applied.

3. Place the Off/Manual/Auto Switch (Figure 51) in the "OFF/ RESET" position

Figure 51. Off/Manual Auto Switch (OFF)

4. Verify that the "Engine Running" status LED (Figure 52) on the Microprocessor Engine Control Module (MPEC) display is "OFF" (not lit).

Emergency Stop

1. To stop the engine in the event of an emergency, PUSH the emergency stop button ( Figure 53) inward. This button is located on the generator's engine operating panel, see page 30, Figure 11.

CAUTION

Figure 53. Emergency Stop Button

NEVER stop the engine suddenly except

in an emergency. DO NOT use the emergency stop switch a as method of shutting down the engine. This switch is ONLY to be used in the event of an emergency.

Figure 52. MPEC Engine Running

Status LED (OFF)

5. Remove the load from the UVWO terminal strip (Figure 18 on page 48).

PAGE 52 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

NOTE PAGE

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 53

DCA-400SPK — MAINTENANCE

General Inspection

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

Air Cleaner

Every 50 hours: If dust indicator is red, clean the air cleaner element.

Outer Element:

1. Loosen wing bolt, remove dust cup, then remove wing nut and take out element.

2. Clean the inside of the body and cover using a damp cloth.

3. Blow dry with compressed air (0.69Mpa [7kgf.cm

99.4 PSI] maximum) against the side of the element along the pleats. Then blow dry against outside along the pleats, then against inside again.

4. Remove one seal each time the element is cleaned.

5. Replace the outer element after cleaning it 6 times or after one year. Replace the outer element if indicator is red even after cleaning it.

6. Check the inner cylinder element clamping nut for looseness, and retighten if necessary.

7. If seal washer is damaged or the threads of wing nut are damaged, replace.

8. Remove evacuator valve and clean it with compressed air. Reinstall.

Inner element (if equipped)

1. Remove the cover and outer element, then remove the inner element.

2. Cover the air connector opening (outer side) with clean cloth or cloth tape.

3. Clean the inside of the body. Remove air connector opening protection.

4. Install a new inner cylinder element to the cylinder and tighten the nut.

5. Install element.

6. After replacing the element, press the button of the dust indicator to return the red piston to its original position.

Fuel Addition

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

Removing Water from the Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally remove the drain cock and drain the contents. During cold weather, the greater the empty volume inside the tank, the easier it is for water to condense. This can be reduced by always keeping the tank as full as possible.

Air Removal

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or

after disassembling the fuel system, bleed the system according to the following procedure. To restart after running out of fuel, turn the key switch to the “START” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.

Service Daily

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

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in diesel. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 28, page 43.

Flushing Out Radiator and Changing Coolant

1. Stop the engine and allow to cool. Tighten valve of the corrosion resistor (if equipped).

2. Turn water filer cap slowly and remove it.

3. Prepare a container to catch the coolant, then open drain plug of the radiator or heat exchanger and drain plug of the engine, and drain the coolant.

4. After draining the coolant, close drain plugs and fill with tap water.

PAGE 54 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — MAINTENANCE

5. When the water level is near the mouth of the water filler, open drain plugs and start the engine, and run at low idling. Keep the engine running at low idling and flush the radiator for about 10 minutes.

6. Adjust the flow of the water flowing in and draining out to ensure that the radiator is always full during the flushing operation, While flushing water through the system, watch carefully the water inlet hose does not come out of the radiator filler port.

7. After flushing, stop the engine, open drain plug and drain the water, then close drain plugs.

8. After draining the water, flush the system with a flushing agent. See instructions on flushing agent label.

9. After flushing, open drain plugs and drain out all the water, then close drain plugs and add tap water so the water level is near the mouth of the water filler.

10. When the water level is near the mouth of the water filler, open drain plugs and start the engine, run at low idling and continue to flush the system until clean water comes out. Adjust the flow of the water flowing in and draining out to ensure the radiator is always full during the flushing operation.

11. When clean water comes out, stop the engine, drain all the water, then close drain plugs.

Changing Oil

1. Make sure the oil is cool before changing.

2. Set a container directly under the drain plug of the oil pan. Loosen the drain plug slowly.

3. Check the drained oil for excessive metal particles or foreign material. Contact the distributor if there is metal particles or foreign material.

4. Using a filter wrench, turn filter cartridge to the left to remove it. If the filter cartridge is filled with a large amount of oil, wait 10 minutes or so before removing. Make sure there is no old gasket stuck on the filter holder.

5. Tighten drain plug. Clean the filter holder, fill the new filter cartridge with clean engine oil, coat the packing and thread of the new filter cartridge with engine oil, then install it to the filter holder. Tighten until the gasket surface contacts the seal surface of the filter holder, then tighten it a further 3/4 to 1 turn.

6. Add engine oil through oil filler until the oil level is between the H and L marks on the dipstick.

7. Run the engine at idling for a short time, then stop the engine. Recheck the oil level and fill as necessary.

Replacing fuel filter

1. Set the container under the filter cartridge to catch fuel.

12. Remove the corrosion resistor (if equipped) and open valve.

13. Supply water until it flows over the water filler.

14. Drain the water inside reserve tank, clean the inside of the reserve tank, then fill with coolant/water mixture to between the full and low lines.

15. Stop the engine, wait for 3 minutes, add tap water until the water level reaches near the water filer port, then tighten the radiator cap.

Check Electric Heater (If equipped)

Before starting in cold weather (once a year), please contact your Komatsu distributor for inspection. Remove electric heater from the engine intake manifold and check for disconnections or dirt. When checking or installing the electric heater, replace the gasket with a new part.

2. Using a filter wrench, turn the filter cartridge to the left to remove it.

3. Clean the filter holder, fill the new filter cartridge with fuel, coat the packing surface of the filter cartridge with engine oil, then install the cartridge to the filter holder.

4. When installing, tighten until the packing surface contacts the seal surface of the filter holder then tighten a further 2/3 of a turn. If the filter cartridge is tighten too much, the packing will be damaged and will cause fuel leakage. Fuel leakage will occur if the filter cartridge is not tightened enough. Always tighten to the correct angle.

5. After replacing filter cartridge, loosen air bleed plug.

6. Loosen the knob of feed pump, and pump it up and down until no bubbles come our with the fuel from air bleed plug.

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 55

DCA-400SPK — MAINTENANCE

7. After bleeding the air, tighten air bleed plug, then push in the knob of feed pump and lock it in position.

8. Replace Corrosion resistor cartridge (if equipped)

9. Screw in valves at the top of the corrosion resistor.

10. Using a filter wrench, turn the cartridge to the left to remove it.

11. Coat the seal surface of the new cartridge with engine oil and install it to the filter holder.

12. Tighten until he packing surface contacts the seal surface of the filter holder, then tighten a further 2/3 of a turn.

13. Open valves.

Cleaning breather element

1. Loosen the clamp, then remove the hose and take out breather. Wipe off the dirt around the breather. Check the O-ring, and replace if necessary.

2. Wash the breather in diesel fuel or flushing oil, blow dry with compressed air, then reinstall it.

3. Inspect the hose and if there is any deteriorated oil stuck inside the hose. Replace hose if necessary.

Greasing

Using a grease pump, grease the fan hub (1 place) and tension pulley (2 places).

Generator Storage

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

Fill the fuel tank completely, lubricate and change oil.

Disconnect the negative terminals of the battery and cover it, or remove it from the machine and store it separately.

If the ambient temperature is expected to drop below

C, add antifreeze to the radiator.

Removal from long term storage:

Apply oil to the engine valve and rocker arms, and examine the operating condition of the valves.

Remove the oil filler pipe from the turbocharger oil inlet port, add 0.5-1L (0.13-0.26gal) of oil to the turbocharger, reinstall the oil filler pipe.

Change the oil in engine oil pan.

Replace all the filters.

Flush the inside of the cooling system.

Drain the water from the fuel tank and bleed the air from the fuel system.

If the engine has not been started for more than one year, contact your Komatsu distributor to have engine overhauled.

PAGE 56 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — MAINTENANCE

.51ELBAT

ECNANETNIAM/NOITCEPSNI

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

retliFriAnaelC X

ENIGNE

leveLnoitcetorP

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

*retliFleuFegnahC

tnalooCkcehCdnarotaidaRnaelC

tnemelEretliFriAecalpeR X

rotsiseRnoisorroCegnahC X

srH01

YLIAD

srH052 srH005 srH0001

spmalCdnasesoHllakcehC X

knaTleuFfoedisnInaelC X

ROTARENEG

smhoM3

revOecnatsiseRnoitalusnIerusaeM

.ylnoemittsrif,sruoH052taretlifleufecalpeR

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 57

DCA-400SPK — GENERATOR WIRING DIAGRAM

PAGE 58 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

NOTE PAGE

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 59

DCA-400SPK — ENGINE WIRING DIAGRAM

PAGE 60 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — ENGINE WIRING DIAGRAM (MPEC)

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 61

DCA-400SPK — TROUBLESHOOTING (ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use the tables shown for

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

?erutarepmet

enatecwolhtiwleuF

?rebmun

diagnosis based on the Engine Troubleshooting (Table 16). If the problem cannot be remedied, consult our company's business office or service plant.

?metsysleufehtniretaW .knatleufmorfretawevomeR

ytisocsivhgihylevissecxE

woltalioenigneroleuffo

GNITOOHSELBUORTENIGNE.61ELBAT

.lioenigneroleufdeificepsehtesU

.leufdeificepsehtesU

esooloteudkaelleuF

?tungniniaterepipnoitcejni

.tratstonseodenignE

pmupnoitcejnI

?gninoitcnuflam

?gniraebrorenil

?rednilyc

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

,tfahsknarcfoeruzieS

rednilyc,notsip,tfahsmac

morfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

.tunnethgiT

.ecalperroriapeR

wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzondnagulp

.nurtonseodretratS

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

PAGE 62 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.61ELBAT

esooloteudkaelleuF

?tungniniaterepipnoitcejni

pmupnoitcejnI

?gninoitcnuflam

.htooms

tonsinoituloverenignE

?erusserp

?deggolc

.devresbosisag

tsuahxeeulbroetihwrehtiE

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

?kcutsro

?daolrevO .daolehtnesseL

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

epipwolfrevoleuF

?gninoitcnuflamronrevoG .riapeR

?lioenigneevissecxE .leveldeificepsehtotecudeR

nrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

.tunnethgiT

.ecalperroriapeR

.tsujdA

.ecalperroriapeR

.naelC

.ecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

strapgnivoms'enignE

?gniziesebotmees

.tuptuotneicifeD

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC

.ecalperroriapeR

.redlohelzzondnagulp

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 63

wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

DCA-400SPK — TROUBLESHOOTING (GENERATOR/ENGINE)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use the tables shown for

MOTPMYS MELBORPELBISSOP NOITULOS

?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

tuptuOegatloVoN

?evitcefedRVAsI .yrassecenfiecalpeR

?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

tuptuOegatloVwoL

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH

?RVAevitcefeD .yrassecenfiecalpeR

?daolnitiucriCtrohS .riaperdnadaolkcehC

diagnosis based on the Engine and Radiator Troubleshooting (Table 17). If the problem cannot be remedied, consult our company's business office or service plant.

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

GNITOOHSELBUORTROTARENEG.71ELBAT

deppirTrekaerBtiucriC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 64 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — TROUBLESHOOTING (MPEC)

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

GNITOOHSELBUORTCEPM.81ELBAT

erusserpliowoL

.nosithgil

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

leveltnaloocwoL

.nosithgil

?rotaidar

?neposrooD.sroodesolC

tnaloochgiH

sithgilerutrepmet

.no

?eruliaftinugnidneS.tinugnidnesecalpeR

?egatlovyrettabwoL.yrettabegrahc/ecalpeR

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneserusserplioecalpeR

?CEPMninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF.tlebnafecalper/nethgiT

hguorhtnoitalucrictonsiwolfriA

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT.hctiwserutarepmetecalpeR

.llirgrotaidarriaper/naelC

sithgilknarcrevO

.no

sithgildeepsrevO

.no

UPMfossoL

.noro)s(thgil

?leuFwolrooN.levelleuflliF

?detarbilacebotsdeenCEPM.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

ebotsdeenrellortnocronrevoG

?detsujda

?detarbilacebotsdeenCEPM.relaedotrefeR

?ytridpukcipcitengaM.pukcipcitengamnaelC

?detsujdaebotsdeenrotautcaronrevoG.rotautcaronrevogtsujdA

.rellortnocronrevogtsujdA

?tnemtsujdafotuopukcipcitengaM.pukcipcitengamtsujdA

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 65

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column Serial Numbers-Where indicated, this indicates a serial

number range (inclusive) where a particular part is used. Model Number-Where indicated, this shows that the

corresponding part is utilized only with this specific model number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column, *, #, +, or %, belong to the same assembly or kit.

Note: If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available.

PAGE 66 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — SUGGESTED SPARE PARTS

DCA-400SPK DCA-400SPK

DCA-400SPK

DCA-400SPK DCA-400SPK DIESEL ENGINEDIESEL ENGINE

DIESEL ENGINE

DIESEL ENGINEDIESEL ENGINE

Qty. P/N Description

10 .....6125817051... AIR FILTER

10 .....6003117111... FUEL FILTER

10 .....6002111231... OIL FILTER

5 ....... 6004111171... CARTRIDGE, CORROSION RESISTOR

1 ....... 0601804887... CIRCUIT BREAKER

1 ....... 0601810575... PILOT LAMP, ENGINE TROUBLE

1 ....... 0601810576... PILOT LAMP, ENGINE TROUBLE

1 ....... 0412122258... ENGINE FAN BELT

1 ....... 6008155390... SWITCH, STARTER

5 .......615 ................ KEY SET, STARTER SWITCH (2)

2 ....... 0602122281... OIL SWITCH

1 ....... 6212619610... RADIATOR HOSE (UPPER)

1 ....... 6212616930... RADIATOR HOSE (LOWER)

1 ....... 0605505030... FUEL CAP

1 ....... 061820625 .... AUTOMATIC VOLTAGE REGULATOR

1 ....... 0601807307... MAIN CIRCUIT BREAKER

1 ....... 0601805840... CIRCUIT BREAKER

1 ....... 0601802525... HANDLE, MAIN CIRCUIT BREAKER

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

2 ....... 0601840121... KNOB, VOLTAGE REGULATOR

1 ....... 0601810072... PILOT LAMP

2 ....... 0601810261... BULB, PILOT LAMP

1 ....... 2016012191... CAP, RADIATOR

1 ....... 0602122200... UNIT, OIL PRESSURE

1 ....... 0602123206... UNIT, WATER TEMPERATURE

1 ....... 0602121052... CHARGING AMMETER

W/KW/K

OMAOMA

W/K

W/KW/K

1 to 5 Units1 to 5 Units

1 to 5 Units

1 to 5 Units1 to 5 Units

TSU SA6D140E-2TSU SA6D140E-2

OMA

TSU SA6D140E-2

OMAOMA

TSU SA6D140E-2TSU SA6D140E-2

NOTE

Part number on this Suggested Spare

Parts list may supercede/replace the

P/N shown in the text pages of this

book.

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 67

GENERATOR ASSY.

DCA-400SPK GENERATOR ASSY.

PAGE 68 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8211000012 ROTOR ASSY. 1 1-1 FIELD ASSY. 1 1-2 8201070002 FAN 1-3 0012112040 HEX. HEAD BOLT 12 1-4 0042512000 LOCK WASHER 12 1-5 8201611004 COUPLING DISK 12 1-6 8201015003 BALANCING PLATE 1 1-7 0012116040 HEX. HEAD BOLT 10 1-8 0042616000 LOCK WASHER 10 1-9 8171026013 SET PLATE RECTIFIER 1

1-10 0601821349 RECTIFIER ..................................................... 3 ......... PT3610

1-11 0601822615 SURGE ABSORBER ...................................... 1 ......... ERZM20JK621B

1-12 8171020004 INSULATOR WASHER 1 1-13 8171020504 INSULATOR WASHER 1 1-14 0010110020 HEX. HEAD BOLT 6 1-15 0040010000 LOCK WASHER 6 1-16 0601000209 BALANCING WEIGHT KIT 1 1-17 8201014004 BEARING FLANGE 1

1-18 0071906315 BEARING ........................................................ 1 ......... 76315DDUC3

1-19 0080000075 SNAP RING 1 2 8201614003 COUPLING RING 1 3 0012116040 HEX. HEAD BOLT 6 4 0042516000 LOCK WASHER 6 5 8211340303 STATOR ASSY. 1 5-1 0226200495 RUBBER SEAL 1 6 8211323004 CLAMPER 1 6-1 0223300172 RUBBER SEAL 1 7 8211323103 CLAMPER 1 7-1 0221200440 RUBBER SEAL 1 8 0010110035 HEX. HEAD BOLT 2 9 0041210000 PLAIN WASHER 2 10 8211324003 COVER 1 10-1 0226000303 RUBBER SEAL 2 10-2 0225000590 RUBBER SEAL 1 11 0017106016 HEX. HEAD BOLT 6 12 8201315102 END BRACKET 1 13 8201350003 FIELD ASSY. EXCITER 1 14 0012110075 HEX. HEAD BOLT 6 15 0042610000 LOCK WASHER 6 16 0041210000 PLAIN WASHER 6 17 0845044904 GROMMET 1 18 0010112045 HEX. HEAD BOLT 8 19 0040012000 LOCK WASHER 8

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 69

GENERATOR ASSY.

DCA-400SPK GENERATOR ASSY.

PAGE 70 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

20 0041212000 PLAIN WASHER 8 21 8201310014 COVER, BEARING 1 22 8201312014 GASKET, BEARING 1 23 0010106065 HEX. HEAD BOLT 6 24 0040006000 LOCK WASHER 6 25 0041206000 PLAIN WASHER 6 26 8171331013 COVER, END BRACKET 1 27 0017106012 HEX. HEAD BOLT 6 28 8171333003 COVER, END BRACKET 1 29 0010106030 HEX. HEAD BOLT 2 30 0040006000 LOCK WASHER 2 31 0041206000 PLAIN WASHER 2 32 0012112035 HEX. HEAD BOLT 16 33 0042512000 LOCK WASHER 16 34 8201332003 COVER, FAN 1 35 0605000012 RUBBER SUSPENSION 4 36 0030020000 HEX. NUT 8

0040020000 LOCK WASHER 8

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 71

CONTROL BOX ASSY.

DCA-400SPK CONTROL BOX ASSY.

PAGE 72 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

1 8221812812 C ONTROL BOX 1

2 0601801170 CURRENT TRANSFORMER, AMMETER . 3 ........ CW5L 750/5A

3 0027106016 MACHINE SCREW 6

4 0601805771 CIRCUIT BREAKER .................................. 1 ........ TO1000B 1000A

4-1 0601802522 HANDLE, CIRCUIT BREAKER 1

5 0601820625 AUTOMATIC VOLTAGE REGULATOR ........ 1 ........ NTA5A2T

6 0027105012 MACHINE SCREW 4

7 0601820853 OVERCURRENT RELAY ........................... 1 ........ THK20KP

8 0027104016 MACHINE SCREW 2

9 0601823757 RELAY ....................................................... 2 ........ MY2DC24V

0601823143 SOCKET .................................................... 2 ........ PYF08A

PYCA1 HOLDER .................................................... 2 ........ REPLACES0601824400

10 0027104016 MACHINE SCREW 4 11 8221861103 SET BOARD, CHANGE TERMINAL 1 12 8221852104 CHANGE TERMINAL 10 13 0017108030 HEX.HEAD BOLT 20 14 8221853104 CHANGE PLATE 6 15 0801830804 HEX. HEAD BOLT 10 16 0040016000 LOCK WASHER 10 17 0041416000 PLAIN WASHER 10 18 0801830704 HEX. HEAD BOLT 16 19 0040012000 LOCK WASHER 16 20 0041412000 PLAIN WASHER 16 21 0010010035 HEX. HEAD BOLT 4

0040010000 LOCK WASHER 4

0041210000 PLAIN WASHER 4 22 8221833403 SET PANEL, ELECTRIC PARTS 1 23 0017108020 HEX HEAD BOLT 4

24 0602201911 UNIT, BATTERY SENSOR ......................... 1 ........ C7038A0000

25 0027106016 MACHINE SCREW 1

26 0602200446 EMERGENCY RELAY ............................... 1 ........ 6008151252

27 0017106016 HEX. HEAD BOLT 4 28 9039211273 CONTROL PANEL 1 29 8221822503 CONTROL PANEL 1

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 73

CONTROL BOX ASSY.

DCA-400SPK CONTROL BOX ASSY.

PAGE 74 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

30 0605011211 PIN 4

31 0601800470 FREQUENCY METER ............................ 1............ PAK80 220V 45~65Hz

32 0601805750 AC AMMETER........................................ 1............ PSK60 0~750A 0~1500A

33 0601801040 CHG.OVER SWITCH,AMMETER ........... 1............ SL2AS

34 0601800233 AC VOLTMETER ..................................... 1............ PCK80 0~600V

35 0601801041 CHG.OVER SWITCH, VOLTMETER ....... 1............ SL2VS

36 0601810072 PILOT LAMP 1

0601810261 BULB 1

37 060184073 RHEOSTAT ............................................. 1 ............ RA20A2SE102BJ

38 0601840121 KNOB 1 39 0601810161 PANEL LIGHT 1

0601810214 BULB 1 40 0207004000 HEX. NUT 2

41 0601830710 SWITCH, PANEL LIGHT ......................... 1............ S301T

42 0805001304 SET PANEL 4 43 0041208000 PLAIN WASHER 4 44 0605010710 SNAP RING 4 45 3871824004 STOPPER, CONTROL PANEL 2 46 0041206000 PLAIN WASHER 2 47 0605010502 SNAP PIN 2 48 8221814704 COVER, CONTROL BOX 1 49 0017108020 HEX.HEAD BOLT 8 50 8221826904 SIDE PANEL, CONTROL BOX 1 51 0017108020 HEX. HEAD BOLT 4 52 8221827704 PANEL, CONTROL BOX 1 53 0017108020 HEX.HEAD BOLT 8 54 0010010035 HEX. HEAD BOLT 4

0030010000 HEX. NUT 4

0040010000 LOCK WASHER 4

0041210000 PLAIN WASHER 8

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 75

ENGINE & RADIATOR ASSY.

DCA-400SPK ENGINE & RADIATOR ASSY.

PAGE 76 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8210150104 ENGINE .......................................................... 1 ......... SA6D140A

2 6212619900 RADIATOR ...................................................... 1 ......... REPLACES 0602011885

3 8215103504 RUBBER SEAL 1

4 6995619230 RUBBER SHEET ............................................ 2 ......... REPLACES 0605000085

5 0010120055 HEX. HEAD BOLT 4 6 0040020000 LOCK WASHER 4 7 0041220000 PLAIN WASHER 4 8 8215123004 BRACKET, RADIATOR 2 9 0010112025 HEX. HEAD BOLT 4 10 0040012000 LOCK WASHER 4 11 0041212000 PLAIN WASHER 4

12 6212619610 RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013962

13 6212619630 RADIATOR HOSE ........................................... 1 ......... REPLACES 0602014467

14 0726102612 RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013963

15 6212619650 RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013964

16 0728100909 HOSE BAND ................................................... 3 ......... REPLACES 0602014056

17 0728101029 HOSE BAND ................................................... 1 ......... REPLACES 0602014350

18 0728100489 HOSE BAND ................................................... 2 ......... REPLACES 0602014351

19 0728100167 HOSE BAND ................................................... 2 ......... REPLACES 0602014059

20 6128817051 ELEMENT, AIR CLEANER .............................. 1 ......... REPLACES 0602040157

21 6002111230 CARTRIDGE, OIL FILTER .............................. 1 ......... REPLACES 0602041146

22 6003117130 CARTRIDGE, FUEL FILTER ........................... 1 ......... REPLACES 0602042157

23 6004111170 CARTRIDGE, CORROSION RESISTOR ........ 1 ......... REPLACES 0602045144

24 8215112203 ENGINE FOOT 1 25 0010118060 HEX. HEAD BOLT 2 26 0030018000 HEX. NUT 2 27 0040018000 LOCK WASHER 2 28 0041218000 PLAIN WASHER 4 29 0605000012 RUBBER SUSPENSION 4 30 0030020000 HEX. NUT 8 31 0040020000 LOCK WASHER 8 32 0802081003 RESERVE TANK 1

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 77

ENGINE & RADIATOR ASSY.

DCA-400SPK ENGINE & RADIATOR ASSY.

PAGE 78 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

33 0602010900 CAP, RESERVE TANK 1 34 8212082103 BRACKET, RESERVE TANK 1 35 0229200600 RUBBER CUSHION 1 36 0017106025 HEX. HEAD BOLT 1 37 0017108020 HEX. HEAD BOLT 2 38 0199601150 HOSE 1 39 0193601300 HOSE 1 40 0605515024 HOSE BAND 2 41 0194700400 HOSE 1 42 0194700450 HOSE 1 43 0198501050 HOSE 1 44 3972220103 SUPPORT ROD 1 45 0017110025 HEX. HEAD BOLT 2 46 8212256104 SUPPORT ROD 1 47 0019208020 HEX. HEAD BOLT 2 48 8212044103 OIL PANEL 1 49 0017110025 HEX. HEAD BOLT 2

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 79

ENGINE OPERATING PANEL ASSY.

DCA-400SSKENGINE OPERATING PANEL ASSY.

PAGE 80 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 9039211283 OPERATING PANEL 1 2 0017106016 HEX. HEAD BOLT 12 3 0602101000 BATTERY SWITCH 1 9827300090 4 0021008080 MACHINE SCREW 2

0030008000 HEX. NUT 2 0040008000 LOCK WASHER 2

00412080000 PLAIN WASHER 2 5 0840201200 THROTTLE HANDLE` 1 6 08212183004 LINK, GOVERNOR ROD 1 7 0845045604 PIN BOLT 1 8 0042412000 PLAIN WASHER 20 9 0205008000 HEX. NUT 1

0042308000 LOCK WASHER 1

0042408000 PLAIN WASHER 2 10 8212152004 GOVERNOR ROD 1 11 8212152104 GOVERNOR ROD 1 12 0602180106 BALL JOINT 4 13 0030008000 HEX. NUT 4 14 0207006000 HEX. NUT 4 15 0602100049 STARTER SWITCH 1 6008155390 16 0601804045 STOP BUTTON 1 0806410000 17 0602102055 PREHEAT INDICATOR 1 6008153730 18 0602120054 TACHOMETER 1 25000KX4110 19 0602120156 CABLE, TACHOMETER 1 62500KA4210 L=3000 20 0602122053 OIL PRESSURE GAUGE 1 42000KV0300 21 0602122200 UNIT, OIL PRESSURE 1 53000AC0101 22 0602123053 WATER TEMPERATURE GAUGE 1 4000KV0700 23 0602123206 UNIT, WATER TEMPERATURE 1 51000KS0600 24 0602121052 CHARGING AMMETER 1 43000KV0300 25 0602124053 OIL TEMPERATURE GAUGE 1 40000KV0800 26 0602123206 UNIT, OIL TEMPERATURE 1 51400KS0600 27 0602040690 INDICATOR, AIR CLEANER 1 RBX002252 28 6203306104 SOCKET 1 29 0603300000 HALF UNION 1 30 0603301000 ELBOW UNION 1 31 0603302000 SLEEVE 2 32 0603303000 NUT 2 33 0190001600 NYLON PIPE 1 34 0602115008 OK MONITOR 1 V33676A

0601810204 BULB 6 35 8221860203 SET BOARD, OUTPUT TERMINAL 1 36 0801830404 OUTPUT TERMINAL 8 37 0801830904 HEX. HEAD BOLT 8 38 0039320000 HEX. NUT 16 39 0040020000 LOCK WASHER 24

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 81

ENGINE OPERATING PANEL ASSY.

DCA-400SSKENGINE OPERATING PANEL ASSY.

PAGE 82 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

40 0041420000 PLAIN WASHER 32 41 3501860604 TERMINAL PLATE 3 42 0019110040 HEX. HEAD BOLT 5

0042310000 LOCK WASHER 5

0042410000 PLAIN WASHER 5 43 0601812597 RECEPTACLE, AUX. POWER 2 5-20R GF5352 44 0601811034 RECEPTACLE, AUX. POWER 3 CS6369 45 0601805313 CIRCUIT BREAKER 2 KM51 20A 46 0601805840 CIRCUIT BREAKER 3 KM52 50A 47 8211834203 BRACKET, CIRCUIT BREAKER 1 47-1 0223300200 RUBBER CUSHION 1 48 0019106035 HEX. HEAD BOLT 2

0042306000 LOCK WASHER 2

0042406000 PLAIN WASHER 2 49 8215082003 COVER, OUTPUT TERMINAL 1 50 0019112045 HEX. HEAD BOLT 2 51 0042412000 PLAIN WASHER 4 52 0805009804 RUBBER WASHER 2 53 0205012000 HEX. NUT 2 54 0845043704 SPRING 2 55 0019208020 HEX. HEAD BOLT 2

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 83

BATTERY ASSY.

DCA-400SPK — BATTERY ASSY.

PAGE 84 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0168719052 BATTERY 2 2 0805018904 BATTERY SHEET 2 3 0805006404 BATTERY BAND 1 4 0805006504 BATTERY BOLT 2 5 0037808000 WING NUT 2 6 0040008000 LOCK WASHER 2 7 0041208000 PLAIN WASHER 2 8 8212265304 BATTERY CABLE 1 9 8212265104 BATTERY CABLE 1 10 6212265504 BATTERY CABLE 1 11 8212265704 BATTERY CABLE 1 12 8212265904 EARTH CABLE 1 13 0010010030 HEX. HEAD BOLT 4 14 0030010000 HEX. NUT 4 15 0845040114 TERMINAL CAP 1 16 0845041004 TERMINAL CAP 1 17 0845040214 TERMINAL CAP 1 18 0845041104 TERMINAL CAP 1 19 0602220205 BATTERY SENSOR 1

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 85

MUFFLER ASSY.

DCA-400SPK — MUFFLER ASSY.

PAGE 86 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8212311002 MUFFLER 1 2 0019112025 HEX. HEAD BOLT 4 3 0042312000 LOCK WASHER 4 4 0042412000 PLAIN WASHER 4 5 8212356004 PACKING 2 6 8222356104 PACKING 1 7 8222356204 PACKING 1 8 0019110030 HEX. HEAD BOLT 10 9 0042310000 LOCK WASHER 10 10 0042410000 PLAIN WASHER 10 11 8212350003 EXHAUST PIPE 1 11-1 0602320095 GASKET 2 12 0010312060 HEX. HEAD BOLT 4 13 0010312030 HEX. HEAD BOLT 4 14 0030312000 HEX. NUT 8 15 0040012000 LOCK WASHER 4 16 0041212000 PLAIN WASHER 12 17 8212355003 OUTLET PIPE 1 18 7432356104 GASKET 1 19 0019112050 HEX. HEAD BOLT 4 20 0030012000 HEX. NUT 4 21 0042312000 LOCK WASHER 4 22 0042412000 PLAIN WASHER 8

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 87

FUEL TANK ASSY.

DCA-400SPK — FUEL TANK ASSY.

PAGE 88 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8215510503 FUEL TANK 1 1-1 0845500104 CAP, FUEL TANK 1 1-2 0810105400 FUEL FILTER 1 1-3 0264100390 HOSE, FUEL GAUGE 1 1-4 0605515079 HOSE BAND 2 2 8225523104 TANK BAND 2 3 0805003414 PAD, TANK BAND 4 4 0017108020 HEX. HEAD BOLT 2 5 0037908000 HEX. NUT 2 6 0222100300 TANK SHEET 6 7 0130206000 STREET ELBOW 1 8 3515512014 DRAIN JOINT 1 9 0603325011 VALVE 1 10 0132006000 PLUG 1 11 0191302290 SUCTION HOSE 1 12 0191302390 RETURN HOSE 1 13 0191003750 RETURN HOSE 1 14 0605515014 HOSE BAND 4 15 0605515024 HOSE BAND 2 16 0605503020 FUEL SENSOR 1 17 0802120604 PACKING 1 18 0845039604 RUBBER SEAL 1

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 89

ENCLOSURE ASSY.

DCA-400SPK — ENCLOSURE ASSY.

PAGE 90 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8215111022 BASE 1 2 3515116114 FLOOR PANEL 1 3 8215116004 FLOOR PANEL 1 4 0019208020 HEX. HEAD BOLT 14 5 8215020204 FRONT FRAME 1

8215102003 LINING 1 6 0019110025 HEX. HEAD BOLT 8

0042310000 LOCK WASHER 8

0042410000 PLAIN WASHER 8 7 8225125104 COVER, FRONT FRAME 1 8 8225125204 COVER, FRONT FRAME 1

8225102104 LINING 1 9 0019208020 HEX. HEAD BOLT 28 10 0845042703 FILLER BRACKET 1 11 0019208020 HEX. HEAD BOLT 4 12 8215125003 COVER, FRONT FRAME 1 13 0019208020 14 8215131202 CENTER FRAME 1 15 0010120070 HEX. HEAD BOLT 6

0030020000 HEX. NUT 6

0040020000 LOCK WASHER 6

0041220000 PLAIN WASHER 12 16 0010120060 HEX. HEAD BOLT 8

0030020000 HEX. NUT 8

0040020000 LOCK WASHER 8

0041220000 PLAIN WASHER 16 17 8215041414 REAR FRAME 1

8215940304 LINING 1 18 8225151004 LOUVER PANEL 1 19 0207006000 HEX. NUT 18

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-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 91

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

ENCLOSURE ASSY.

DCA-400SPK — ENCLOSURE ASSY.

PAGE 92 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

20 0019110025 HEX. HEAD BOLT 4

0042310000 LOCK WASHER 4

0042410000 PLAIN WASHER 4 21 8215155203 COVER, REAR FRAME 1

8215946304 LINING 1 22 8195151204 LOUVER PANEL 3 23 0207006000 HEX. NUT 18 24 0019208020 HEX. HEAD BOLT 15 25 8215155104 DUCT COVER 1

8215102804 LINING 1 26 0017108020 HEX. HEAD BOLT 12 27 8215143503 DOOR, REAR FRAME 1 28 8225143403 DOOR, REAR FRAME 1 29 8225147004 WINDOW PLATE 2 30 0037906000 HEX. NUT 12 31 0845050804 DOOR HANDLE 1

0845052404 KEY, DOOR HANDLE 1 32 0021806016 MACHINE SCREW 4 33 8225146204 DOOR ROD 1 34 8225146304 DOOR ROD 1 35 0845050704 STAY 4 36 0207006000 HEX. NUT 8 37 0805011304 STOPPER, DOOR 1 38 0805011204 STOPPER, DOOR 1 39 0207006000 HEX. NUT 4 40 0845047104 HINGE 2

0845045004 WASHER 2 41 0845047204 HINGE 2

0845045004 WASHER 2 42 0019208020 HEX. HEAD BOLT 6 43 8215161002 ROOF PANEL 1

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-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 93

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

ENCLOSURE ASSY.

DCA-400SPK — ENCLOSURE ASSY.

PAGE 94 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

44 0800251701 FILLER COVER 1 45 0025006016 MACHINE SCREW 2

0042306000 LOCK WASHER 2

0042406000 PLAIN WASHER 2 46 8215161102 ROOF PANEL 1

8215102103 LINING 1 47 0019208020 HEX. HEAD BOLT 10 48 0019110025 HEX. HEAD BOLT 42

0042310000 LOCK WASHER 42

0042410000 PLAIN WASHER 42 49 9039211263 SPLASHER PANEL 1

8215103204 LINING 1 50 0019108065 HEX. HEAD BOLT 6

0042308000 LOCK WASHER 6

0042408000 PLAIN WASHER 6 51 8215172113 SIDE PANEL 1

8215972904 LINING 1 52 8215172013 SIDE PANEL 1

8215972904 LINING 1 53 8215172803 SIDE PANEL 1

8215102404 LINING 1 54 8215172903 SIDE PANEL 1

8215102303 LINING 1 55 0019110070 HEX. HEAD BOLT 16

0042310000 LOCK WASHER 16

0042410000 PLAIN WASHER 16 56 8215171803 SIDE DOOR 1

8215970903 LINING 1 57 8215171903 SIDE DOOR 1

8215970903 LINING 1 58 8215172603 SIDE DOOR 1

8215971104 LINING 1 59 8215172703 SIDE DOOR 1

8215971304 LINING 1

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-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 95

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

ENCLOSURE ASSY.

DCA-400SPK — ENCLOSURE ASSY.

PAGE 96 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

60 8195151004 LOUVER PANEL 2 61 8215151004 LOUVER PANEL 1 62 0207006000 HEX. NUT 18 63 8215176004 DUCT 2

8215974504 LINING 1 64 8215176204 DUCT 1

8215103404 LINING 1 65 0017108020 HEX. HEAD BOLT 18 66 0825007362 DOOR HANDLE 7

0605010225 KEY 1 67 0021806016 MACHINE SCREW 28 68 0845046904 HINGE 8

0845045004 WASHER 8 69 0845047004 HINGE 8

0845045004 WASHER 8 70 0019208020 HEX. HEAD BOLT 40

71 0601850097 STOPPER 10 .......... 30029

72 0021008025 MACHINE SCREW 10 73 0845031504 CAP 20 74 8215312002 SUPPORT LEG 1 75 0017110030 HEX. HEAD BOLT 3 76 0010110030 HEX. HEAD BOLT 2

0030010000 HEX. NUT 2

0040010000 LOCK WASHER 2

0041210000 PLAIN WASHER 2 77 6360510003 EMBLEM 2 78 0021106020 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-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 97

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

DCA-400SPK — RUBBER SEAL ASSY.

PAGE 98 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

DCA-400SPK — RUBBER SEAL ASSY.

RUBBER SEAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

79 0228901450 RUBBER SEAL 3 80 0228901390 RUBBER SEAL 3 81 0228900795 RUBBER SEAL 8 82 0228900850 RUBBER SEAL 1 83 0229201440 RUBBER SEAL 1 84 0229201440 RUBBER SEAL 2 85 0228800795 RUBBER SEAL 2 86 0228801240 RUBBER SEAL 2 87 0229201340 RUBBER SEAL 1 88 0228100120 RUBBER SEAL 4 89 0228100510 RUBBER SEAL 4

DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 99

OIL PIPING ASSY.

DCA-400SPK — OIL PIPING ASSY.

PAGE 100 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01)

Multiquip DCA-400SPK User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual