Multiquip DCA400SSK2 User Manual

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PARTS AND OPERATION MANUAL

MQ POWER

DCA-400SSK

DCA-400SSK2

WHISPERWATT

GENERATOR

(STANDARD)

PARTS LIST NO. C3875300104B

S/N UP TO 3701676-400SSK

S/N3101677~ 400SSK2

Revision #3 (09/17/01)

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — 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 Overview ........................ 34-39

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

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

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

Generator Start-Up Procedure (Key Switch) ..... 47-50

Generator Start-Up Procedure (Controller) ............. 51

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

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

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

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

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

Troubleshooting (Generator) ...................................64

Troubleshooting (Engine Controller) ........................65

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

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

MQ Power DCA-400SSK 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

Actuator Assembly ............................................. 86-87

Muffler Assembly ............................................... 88-89

Fuel Tank Assembly ........................................... 90-91

Enclosure #1 Assembly...................................... 92-95

Enclosure #2 Assembly...................................... 96-99

Enclosure #3 Assembly........................................ 100-

103

Enclosure (Rubber Seals) .............................. 104-105

Oil Piping Assembly ....................................... 106-107

Name Plate and Decals ................................. 108-111

Terms and Conditions Of Sale — Parts ................ 112

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — 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-400SSK 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

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, will result in high pressurized, boiling water to spew out of the radiator, 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 flow 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 flow out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

CAUTION

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 7

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.

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.

■

Make sure the 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

omatsu Engine Owner's Man

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

, rinse skin or clothing

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or straps) 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 deteriorated 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 0in 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 9

DCA-400SSK — TOWING

Towing Safety Precautions

CAUTION :

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

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

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

■

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

■

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

■

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

■

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

■

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

■

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

■

The maximum speed unless otherwise posted for highway towing is 55 MPH. It is not recommended for off-road towing. However, if necessary, do not exceed 15 MPH or less depending on type of terrain to prevent damage to the axles.

■

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.

■

DO NOT transport generator with fuel in tank.

chocked blocks

while parked.

support blocks

tippingtipping

tipping

tippingtipping

, while parked.

underneath wheel to prevent

underneath the trailer's bumper to

Figure 1. Generator with Trailer

PAGE 10 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — 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. Usually consists of chains and ‘ball’ or ‘eye’.

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 11

DCA-400SSK — TRAILER-SPECIFICATIONS

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W01-RLRT

01-RLRT

FX01-RLRT

W522-RLRT

004WLB-RLRT

X05-RLRT

FX05-RLRT

W07-RLRT

X07-RLRT

FX07-RLRT

FX001-RLRT

521/58-RLRT

FX051-RLRT

FX022-RLRT

FX003-RLRT

FX004-RLRT

FX006-RLRT

XS008-RLRT

,522WDS

003WLT,052WGS

-ACD,21GLT,01ACD

,21-GLT,01ACD 003-WLT,51ACD

,SREDLEW

SS0007AD

004-WLBONCIRTCELESBL0072"451TSAM/W

52-ACDONONSBL0072"421"55.BL008

52-ACDLAG14ONSBL0072"421"55.BL008

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

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

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

521,001-ACDLAG051EGRUSCILUARDYHSBL0007"091"67.BL0002

521,001,58-ACDLAG541CILUARDYHSBL00001"681"77.BL0002

081,051-ACDLAG002EGRUSCILUARDYHSBL06111"402"48.BL0005

022-ACDLAG052EGRUSCILUARDYHSBL00041"222"38.BL0005

003-ACDLAG052EGRUSCILUARDYHSBL00081"832"38.BL0005

004-ACDLAG053CIRTCELESBL00081"832"38.BL0005

008,006-ACDLAG055RIASBL00003"483"69.BL0005

ONONSBL0091"69"05.BL008

LAG25ONSBL0091"69"05.BL008

ONONSBL0022"58"24.BL008

EMARF

HTGNEL

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HTDIW

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DNATS

LEEHWTLITLLUF

.BL008

LEEHWTLITLLUF

DAPTALF

PAGE 12 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — TRAILER-SPECIFICATIONS

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LEDOM RELPUOC SERIT SLEEHW ELXA SBUH NOISNEPSUS LACIRTCELE

W01-RLRT

01-RLRT

FX01-RLRT

W522-RLRT

004WLB-RLRT

X05-RLRT

FX05-RLRT

W07-RLRT

X07-RLRT

FX07-RLRT

FX001-RLRT

521/58-RLRT

FX051-RLRT

FX022-RLRT

FX003-RLRT

FX004-RLRT

FX006-RLRT

RA008-RLRT

SSALCLLAB"2

ELBATSUJDA2

SSALCLLAB"2 ELBATSUJDA2

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

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C31-571"05.4X"312X2#0022GUL5FAEL3/WMOOLERIW4

C31-571"5.4X"312X2#0022GUL5FAEL3TALFELOP4

B31-571"5.4X312X2#0022GUL5XELFQTALFELOP4

C31-571"5.4X312X2#0022GUL5FAEL3TALFELOP4

"8/3-2

C41-502

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C41-502

)4(SAIB

C41-502

)4(SAIB

C51-502

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"7X"61sbl0006-)2(GUL8FAEL7MOOLERIW4

"7X"61sbl0007-)2(GUL8XELFQMOOLERIW4

"7X"61sbl0006-)2(GUL8XELFQMOOLERIW4

"7X"61.sbl0007-)3(GUL8XELFQMOOLERIW4

"7X"61sbl00001-)3(GUL8FAEL7MOOLERIW6

"7X"61sbl00001-)3(GUL8EDIR-RIAMOOLERIW6

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TALFELOP4

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 13

DCA-400SSK — 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

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.

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

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 trailer being towed or under-adjusted brakes.

PAGE 14 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

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

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

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 15

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

Figure 4. Major Suspension Components

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TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SHACKLE BOLT

SPRING EYE BOLT

DCA-400SSK — TRAILER SAFETY GUIDELINES

stnemeriuqeReuqroTnoisnepsuS.3elbaT

SNUG FIT ONLY

NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT

PARTS MUST ROTATE FREELY.LOCKING

ASSEMBLY

BOLT

SHOULDER TYPE

SHACKLE BOLT

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.

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"2152-0204-5356-05

"3152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 17

DCA-400SSK — TRAILER-WIRING DIAGRAM

NOTE: LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT

PAGE 18 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — TRAILER-BRAKE TROUBLESHOOTING

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DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 19

DCA-400SSK — TRAILER-BRAKE TROUBLESHOOTING

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dnaseohswenllatsnI

.sgninil

.diulf4todhtiwllif

PAGE 20 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — OPERATION AND SAFETY DECALS

Machine Safety Decals

The DCA-400SSK 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 21

DCA-400SSK — OPERATION AND SAFETY DECALS

PAGE 22 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — SPECIFICATIONS

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leuFleuFleseiD2#

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 23

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daol2/1

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daol4/3

daol4/1

DCA-400SSK — GENERAL INFORMATION

DCA-400SSK FAMILIARIZATION

Generator

genergener

The MQ Power Model DCA-400SSK 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:

Auto/Start/Stop Controller (S/N 3696510~)

Tachometer

Water Temperature Gauge

Oil Pressure Gauge

Charging Ammeter Gauge

Engine Warning Lamp Module

Engine Speed Switch (S/N3701667~)

Pre-Heat Button

Pre-Heat Lamp

Emergency Stop Button

Battery Switch

Starter Switch (Up to S/N3696509)

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

Auto On/Off Engine Controller

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

Current Transformer

Automatic Voltage Regulator

Open Delta Excitation System

The DCA-400SSK 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.

Engine Controller Alarm System

The DCA-400SSK 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-400SSK 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:

Three120/240V output receptacles, 50 amp

Two 120V receptacles, 20 amp

3 Circuit Breakers 240V @50 amps

2 GFCI Circuit Breakers 125V@ 20amps

PAGE 24 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — GENERAL INFORMATION

Engine

The DCA-400SSK is powered by a 4 cycle, water cooled, turbocharged KOMATSU Model SA6D140E-2 diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 1, page 16 for engine specifications.

Electronic Governor System

The electronic governor system replaces the standard mechanical governor system. The frequency regulation improves from ±3.0% regulation with the mechanical governor to ±0.25% regulation with the electronic governor system.

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 25

DCA-400SSK — MAJOR COMPONENTS

Figure 6. Major Components

PAGE 26 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

NOTE PAGE

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 27

DCA-400SSK — DIMENSIONS (TOP AND SIDE)

Dry weight: 4270kg (9413.64lb)

Wet weight: 4800kg (10582.08 lb)

Figure 7a. Dimensions

PAGE 28 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — DIMENSIONS (FRONT AND REAR)

Figure 7b. Dimensions

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 29

DCA-400SSK — CONTROL PANEL

Figure 8. Control Panel

PAGE 30 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — CONTROL PANEL

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

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. Engine Controller (for S/N 3696510~) – The engine controller as 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 engine controller will evaluate the fault and if the fault is major will shutdown the generator.

Control Panel Control Panel

Control Panel

Control Panel Control Panel

" (Figure 8).

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

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

manual

fault.

position, the generator will start

auto

position. In this position the

major

fault.

major

fault.

During engine controller will attempt to crank the engine for 10 seconds before disengaging.

cranking cycle

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 31

, The

Figure 9. Engine

Controller Module

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, 1000 amp main breaker is provided to protect the UVW voltage output terminals from overload.

major

DCA-400SSK — ENGINE OPERATING PANEL

Figure 10. Engine Operating Panel

PAGE 32 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — ENGINE OPERATING PANEL

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

1. Throttle Handle ( up to S/N 3701676) - 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.

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.

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 between 42-71 psi. 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 normal.

5. Water Temperature Gaug e – During normal operation this gauge be should read between 165-203

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. Pre-Heat Lamp –Press and hold this button until the preheat lamp is lit (ON).

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

11. Ignition Switch (up to S/N3696509)

– 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 engine controllersee Control Panel).

12. 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

13. Engine Speed Switch (S/N 3701677~) – This switch controls the speed of the engine (high/low).

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 33

DCA-400SSK — OUTPUT TERMINAL PANEL OVERVIEW

OUTPUT TERMINAL FAMILIARIZATION

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

Two 120V GFCI receptacles, 20 amp

Three 120/240V output receptacles, 50 amp

Two 120V output receptacles, 20 amp (optional)

3 Circuit Breakers 240V @50 amps

2 GFCI Circuit Breakers 125V@ 20 amps

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

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-400SSK — OUTPUT TERMINAL PANEL OVERVIEW

NOTE

FIGURE 14. Output Terminal Panel

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 35

Legs O and Ground are considered Bonded Grounds.

DCA-400SSK — 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

)ELBATCENNOCER(

ESAHPELGNIS )ELBATSUJDA(

TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

CAUTION :

NEVER attempt to change the Voltage

Change-over board while the engine is engaged.

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021esahPelgniS

tloV

042esahPelgniS

tloV

esahPeerhT

tloV042

esahPeerhT

tloV084

spmAmumixaM.9elbaT

)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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 37

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

FIGURE 22. Hard Wire Hookup for Single Phase 139V

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 39

FIGURE 26. Hard Wire Hookup for Single Phase 277V

DCA-400SSK — 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

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.

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.

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

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

NOTE

DCA-400SSK — INSTALLATION

Figure 27. Typical Generator Grounding Application

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 41

DCA-400SSK — PRE-SETUP

General Inspection Prior to Operation

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

Extension Cable

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the Cable Selection Guide (Table 10) as a guide for selecting proper cable size.

Circuit Breakers

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

main main

amp,

main

main main

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.

PAGE 42 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — 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 11 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.

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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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03EAS

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DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 43

DCA-400SSK — 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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%loV

ezeerF-itnA

C° F° C° F°

0442-21-601222

0573-43-801622

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

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-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 45

DCA-400SSK — LOAD APPLICATION

Single Phase Load

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

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

NOTE

If wattage is not given on the equipment's name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

CAUTION

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

When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

When connecting a fluorescent or mercury lamp, a capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

When connecting an electric drill or other power tools, pay close attention to the required starting current capacity.

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:

0.1

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

If output (kVA) is not given on the equipment nameplate, approximate output may be determined by multiplying voltage by amperage by and 1.732.

PAGE 46 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — 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

GFCI GFCI

GFCI

GFCI GFCI

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.

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 47

G.FG.F

and

G.F

G.FG.F

Figure 31. Main, GFCI and

loadload

load

circuit breakers in the ON

loadload

.C.C

.I..I.

.I.

circuit breakers (Figure 31) to

.C.C

.I..I.

Load Circuit Breakers

main,main,

main,

main,main,

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-400SSK — GENERATOR START-UP PROCEDURE (KEY SWITCH)

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — GENERATOR START-UP PROCEDURE (KEY SWITCH)

7. If the generator is equipped with a ignition switch, turn the key to “Start” position (Figure 38). Once the engine starts, release the key to the “on” position.

10. The ammeter (Figure 42) 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 38. Engine Ignition Switch

8. The generator's frequency meter (Figure 39) displays the 60 cycle output frequency in HERTZ.

11. The engine oil pressure gauge (Figure 43) will indicate the oil pressure (kg/ cm2) of the engine. Under normal operating conditions the oil pressure should be approximately 25 psi.

Figure 42. Ammeter (No Load)

Figure 39. Frequency Meter (Hz)

9. The generator's voltage meter (Figure 40) displays the 120 VAC in VOLTS. If the voltage is not within the specified frequency tolerance, use the voltage adjustment control knob (Figure 41) to increase or decrease the desired voltage.

12. The coolant temperature gauge (Figure 44) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 165 and 215 degrees Fahrenheit .

Figure 40. Voltage Meter (Volts)

Figure 41. Voltage Adjust Control

Knob

Figure 44. Coolant Temperature Gauge

Figure 43. Oil Pressure Gauge

WATER

TEMP

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 49

DCA-400SSK — GENERATOR START-UP PROCEDURE (KEY SWITCH)

13. The tachometer (Figure 45) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed should be approximately 1800 RPM’s.

16. Observe the generator's ammeter (Figure 48) 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.

Figure 45. Engine Tachometer

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

14. Pull the throttle handle to increase the speed of the engine (Figure 46).

Figure 48. Ammeter (Load)

Figure 46. Engine Throttle

15. Turn the MAIN, GFCI and LOAD circuit breakers to their "ON" position (Figure 47).

Figure 47. Main and GFCI Circuit Breakers

PAGE 50 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — GENERATOR START-UP PROCEDURE (CONTROLLER)

Manual Start-up

1. Follow instructions as with key switch numbers 1-6.

2. Place the Off/Manual/Auto switch (Figure 49) in the MANUAL position. Observe that the engine begins to crank.

Figure 49. Off/Manual/Auto Switch (Manual)

3. After engine starts, verify that the "Engine Running" status LED (Figure 50) on the Microprocessor Engine Control Module (Engine Controller) display is "ON" (lit).

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

CAUTION:

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.

When running the generator in the AUTO

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

Figure 50. Engine Controller Status LED

4. Continue instructions with key switch 8-17.

Auto Start-up

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:

4. Place the Off/Manual/Auto switch (Figure 51) in the AUTO position.

Figure 51. Off/Manual Auto Switch

(AUTO)

5. Continue to follow the steps outline in the manual startup procedure (start at step 11, page 49).

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 51

DCA-400SSK — 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 52) in the "OFF/ RESET" position

Figure 52. Off/Manual Auto Switch (OFF)

4. Verify that the "Engine Running" status LED (Figure 53) on the microprocessor (Engine Controller) display is "OFF" (not lit).

Emergency Stop

1. To stop the engine in the event of an emergency, PUSH the emergency stop button ( Figure 54) inward. This button is located on the generator's engine operating panel, see page 30, Figure 11.

CAUTION

Figure 54. 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 53. Engine Controller Running

Status LED (OFF)

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

PAGE 52 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

NOTE PAGE

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 53

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 55

DCA-400SSK — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — MAINTENANCE

.51ELBAT

ECNANETNIAM/NOITCEPSNI

ENIGNE

renaelCriAkcehC X

skaeLrofkcehC X

retliFriAnaelC X

leveLnoitcetorP

sleveLdiulFenignEkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 57

DCA-400SSK — GENERATOR WIRING DIAGRAM

PAGE 58 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

NOTE PAGE

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 59

DCA-400SSK — ENGINE WIRING DIAGRAM (KEY SWITCH)

PAGE 60 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — ENGINE WIRING DIAGRAM (CONTROLLER)

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 61

DCA-400SSK — 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

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

?tungniniaterepip

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

leuffoytisocsivhgihylevissecxE

?erutarepmetwoltalioenignero

?rebmunenatecwolhtiwleuF .leufdeificepsehtesU

noitcejniesooloteudkaelleuF

GNITOOHSELBUORTENIGNE.61ELBAT

.lioenigneroleufdeificepsehtesU

.tunnethgiT

.tratstonseodenignE

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

,tfahsmac,tfahsknarcfoeruzieS

?gniraebrorenilrednilyc,notsip

?rednilycmorfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

.ecalperroriapeR

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzon

.nurtonseodretratS

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

?detcennocsidgniriW .gniriwtcennoC

PAGE 62 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.61ELBAT

?tungniniaterepip

.htoomstonsinoituloverenignE

?erusserp

?deggolc

?lioenigneevissecxE .leveldeificepsehtotecudeR

.devresbosi

sagtsuahxeeulbroetihwrehtiE

tsuahxeyargkradrokcalbrehtiE

.devresbosisag

?kcuts

?daolrevO .daolehtnesseL

?desuleufedargwoL .leufdeificepsehtesU

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

noitcejniesooloteudkaelleuF

?gninoitcnuflampmupnoitcejnI .ecalperroriapeR

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

?deggolcepipwolfrevoleuF .naelC

?gninoitcnuflamronrevoG .riapeR

ronrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.tsujdA

.ecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

?gnizieseb

.tuptuotneicifeD

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?kaelnoisserpmoC

otmeesstrapgnivoms'enignE

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

.ecalperroriapeR

.redlohelzzon

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 63

dnagulpwolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

DCA-400SSK — 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

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

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.

GNITOOHSELBUORTROTARENEG.71ELBAT

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 64 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — TROUBLESHOOTING (Engine Controller)

notpmySesuaCelbissoPnoituloS

GNITOOHSELBUORTRELLORTNOCENIGNE.81ELBAT

sithgilerusserpliowoL

.no

thgilleveltnaloocwoL

.nosi

tnaloochgiH

.nosithgilerutrepmet

?levelliowoL.levelliolliF

?eruliaftinugnidneserusserpliO .tinugnidneserusserplioecalpeR

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

?eruliaftinugnidneS.tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?tcerrocninoisnettlebnaF .tlebnafecalper/nethgiT

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

?neposrooD.sroodesolC

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliafhctiwserutarepmeT .hctiwserutarepmetecalpeR

.nosithgilknarcrevO?leuFwolrooN.levelleuflliF

?detarbilacebotsdeenrellortnoC.relaedotrefeR

.nosithgildeepsrevO?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogtsujdA

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoC.relaedotrefeR

ro)s(thgilUPMfossoL

.no

?ytridpukcipcitengaM .pukcipcitengamnaelC

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — SUGGESTED SPARE PARTS

DCA-400SSK DCA-400SSK

DCA-400SSK

DCA-400SSK DCA-400SSK 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 ............................... UP TO S/N3706720

1 .............0601807514 ......... CIRCUIT BREAKER ............................... S/N3706721~

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

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

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

1 .............6008155390 ......... SWITCH, STARTER ............................... UP TO S/N3696509

5 .............615 ...................... KEY SET, STARTER SWITCH (2) .......... UP TO S/N3696509

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 .... UP TO S/N3706720

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

1 .............0601840009 ......... RHEOSTAT ............................................. S/N3701677~

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

OMA

W/KW/K

1 to 5 Units1 to 5 Units

1 to 5 Units

1 to 5 Units1 to 5 Units

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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 67

GENERATOR ASSY.

DCA-400SSK GENERATOR ASSY.

PAGE 68 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3110100202 ROTOR ASSY. 1 2 FIELD ASSY. 1 3 0601842401 RESISTOR 80W 2

4 0601823282 RECTIFIER ..................................................... 1 ......... RM50TC-24

5 0018205020 HEX. SOCKET HEAD CAP SCREW 2

0040005000 LOCK WASHER 2

0041205000 PLAIN WASHER 2 6 8201070002 FAN 1 7 8201611004 COUPLING DISK 12 8 C3164200004 WASHER, COUPLING HUB 1 9 8201015003 BALANCING PLATE 1 10 0012116045 HEX. HEAD BOLT 10 11 0042616000 LOCK WASHER 10 12 0601000209 BALANCING WEIGHT KIT 1 13 C3112500004 BEARING FLANGE 1 14 0071906315 BEARING 1 15 8201614003 COUPLING RING 1 16 0012116040 HEX. HEAD BOLT 6 17 0042516000 LOCK WASHER 6 18 0012112040 HEX. HEAD BOLT 12

0042512000 LOCK WASHER 12 19 C3130100003 STATOR ASSY. 1 20 0226200495 RUBBER SEAL 1 21 8211323004 CLAMPER 1 22 0223300172 RUBBER SEAL 1 23 8211323103 CLAMPER 1 24 0221200440 RUBBER SEAL 1 25 0010110035 HEX. HEAD BOLT 2

0041210000 PLAIN WASHER 2 26 C3132200003 COVER 1 27 0226000290 RUBBER SEAL 2 28 0225000590 RUBBER SEAL 1 29 0017106020 HEX. HEAD BOLT 6 30 0601850144 GROMMET 1 31 C3154000002 END BRACKET 1 32 C3138000003 FIELD ASSY. EXCITER 1 33 0012110080 HEX. HEAD BOLT 4

0042610000 LOCK WASHER 4

0041210000 PLAIN WASHER 4

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 69

GENERATOR ASSY.

DCA-400SSK GENERATOR ASSY.

PAGE 70 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

34 0017112045 HEX. HEAD BOLT 8 35 C3154300104 COVER, BEARING 1 35 C3154300004 GASKET, BEARING 1 37 0010106060 HEX. HEAD BOLT 4

0040006000 LOCK WASHER 4

0041206000 PLAIN WASHER 4 38 C3154400003 SUCTION COVER 1 39 0017106016 HEX. HEAD BOLT 8 40 0012112035 HEX. HEAD BOLT 16

0042512000 LOCK WASHER 16 41 C3132300003 COVER, FAN 1 42 0010106030 HEX. HEAD BOLT 1

0041206000 PLAIN WASHER 1 43 0605000061 RUBBER SUSPENSION 4 44 0030016000 HEX. NUT 8

0040016000 LOCK WASHER 8

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 71

CONTROL BOX ASSY.

DCA-400SSK CONTROL BOX ASSY.

PAGE 72 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C3214000912 CONTROL BOX............................................. 1 .......... S/N3692434 TO 3706720

C3214001502 CONTROL BOX............................................. 1 .......... S/N3706721~

2 0601801170 CURRENT TRANSFORMER ........................ 3 .......... CW-5L 750/5A

3 0027106016 MACHINE SCREW 6

4 0601807307 CIRCUIT BREAKER, XS1200NE 1060A ...... 1 .......... S/N3692434 TO 3706720

0601807514 CIRCUIT BREAKER, S7H 1000A .................. 1 .......... S/N3706721~; C0244300003

5 0601802525 HANDLE, CIRCUIT BREAKER ..................... 1 .......... S/N3692434 TO 3706720

6 C3214600004 BRACKET, CIRCUIT BREAKER ................... 2 .......... S/N3692434 TO 3706720

7 0017108020 HEX. HEAD BOLT .......................................... 4 .......... S/N3692434 TO 3706720

8 0021008045 MACHINE SCREW ........................................ 4 .......... S/N3692434 TO 3706720

0040008000 LOCK WASHER............................................. 4 .......... S/N3692434 TO 3706720

0041208000 PLAIN WASHER ............................................ 4 .......... S/N3692434 TO 3706720

9 0601820625 AUTOMATIC VOLTAGE REGULATOR......... 1 .......... NTA5A2T

10 0027105016 MACHINE SCREW 4

11 0601820892 OVER CURRENT RELAY .............................. 1 .......... THN20HZ

12 0027104016 MACHINE SCREW 2 13 C3274000003 CHANGE-OVER BOARD, VOLTAGE 1 14 8221852104 CHANGE TERMINAL 10 15 0017108030 HEX. HEAD BOLT 20 16 C2277200004 TERMINAL PLATE 3 17 8221853104 CHANGE PLATE 6 18 0801830804 HEX. HEAD BOLT 10 19 0040016000 LOCK WASHER 10 20 0041416000 PLAIN WASHER 10 21 0801830704 HEX. HEAD BOLT 13 22 8201852504 HEX. HEAD BOLT 3 23 0040012000 LOCK WASHER 16 24 0041412000 PLAIN WASHER 16 25 0017110030 HEX. HEAD BOLT 4

26 C3261500023 SET PANEL, ELECTRIC PARTS ................... 1 .......... S/N3692434 TO 3696509

C3621501103 SET PANEL, ELECTRIC PARTS ................... 1 .......... S/N3696510~

27 0017108020 HEX. HEAD BOLT 4

28 0602201911 UNIT, BATTERY SENSOR ............................ 1 .......... C7038A0000

29 0027106015 MACHINE SCREW 1

30 0602200446 EMERGENCY RELAY ................................... 1 .......... S/N3692434 TO 3701676; 6008151252

31 0017106015 HEX. HAD BOLT ............................................ 4 .......... S/N3692434 TO 3701676

32 0601824542 RELAY ............................................................ 2 .......... HH62S DC24V

33 0027103010 MACHINE SCREW 4 34 C3224001303 CONTROL PANEL 1

35 C3224001203 CONTROL PANEL ........................................ 1 .......... S/N3692434 TO 3706720

C3224002403 CONTROL PANEL ........................................ 1 .......... S/N3706721~

36 0228800100 RUBBER SEAL .............................................. 2 .......... S/N3692434 TO 3706720

0228800110 RUBBER SEAL .............................................. 2 .......... S/N3706721~

37 0228800124 RUBBER SEAL .............................................. 2 .......... S/N3692434 TO 3706720

0228800165 RUBBER SEAL .............................................. 2 .......... S/N3706721~

38 0605011211 PIN 2

39 0601807622 FREQUENCY METER .................................. 1 .......... RSC-80F 45~65Hz 220V

40 0601806987 AC AMMETER ............................................... 1 .......... RSS80 0~750A 0~1500A

41 0601801040 CHANGE-OVER SW., AMMETER ................. 1 .......... SL2AS

42 0601806887 AC VOLTMETER ........................................... 1 .......... RSR80 0~600V

43 0601801041 CHANGE-OVER SW., VOLTMETER ............. 1 .......... SL2VS

44 0601810072 PILOT LAMP .................................................. 1 .......... LP132DC 220V

0601810261 BULB 1

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 73

CONTROL BOX ASSY.

DCA-400SSK CONTROL BOX ASSY.

PAGE 74 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

45 0601840073 RHEOSTAT (VOLT. REGULATOR)............... 1 .......... RA20A2SE102BJ 2W 1K OHM

46 0601840121 KNOB 1

47 0601810161 PANEL LIGHT ................................................ 1 .......... V325070

48 0207004000 HEX. NUT 2 49 0601830710 PANEL LIGHT SWITCH 1 50 C9221100004 HEX. HEAD BOLT 2

0040008000 LOCK WASHER 2 0041208000 PLAIN WASHER 2

0080200007 SNAP RING 2 51 0017108040 HEX. HEAD BOLT 4 52 3871824004 STOPPER, CONTROL PANEL 1 53 0041206000 PLAIN WASHER 1 54 0605110502 SNAP PIN 1 55 8221814804 COVER, CONTROL BOX 1 56 0017108020 HEX. HEAD BOLT 8 57 8224117004 SIDE PANEL, CONTROL BOX 1 58 0017108020 HEX. HEAD BOLT 4 59 8221827704 PANEL, CONTROL BOX 1 60 0017108020 HEX. HEAD BOLT 8 61 0017110035 HEX. HEAD BOLT 4

0207010000 HEX. NUT 4

62 0601823861 ENGINE STOP UNIT ..................................... 1 .......... S/N3696510 TO 3701676

63 0027104015 MACHINE SCREW ........................................ 2 .......... S/N3696510 TO 3701676

64 0601823240 RECTIFIER .................................................... 4 .......... S/N3696510 TO 3701676; DE4503

65 0021004030 MACHINE SCREW ........................................ 2 .......... S/N3696510 TO 3701676

0040004000 LOCK WASHER............................................. 2 .......... S/N3696510 TO 3701676

0041204000 PLAIN WASHER ............................................ 2 .......... S/N3696510 TO 3701676

66 0601802149 FUSE, 10A ..................................................... 1 .......... S/N3696510 TO 3701676

0601802149 FUSE, RIGHT (10A) ...................................... 1 .......... S/N3701677~

0601806671 FUSE, LEFT (15A) ......................................... 1 .......... S/N3701677~

0601802218 HOLDER, FUSE ............................................ 1 .......... S/N3696510~

67 0027103020 MACHINE SCREW ........................................ 2 .......... S/N3696510~

68 LY2DC24V RELAY ............................................................ 1 .......... S/N3696510 TO 3701676;

REPLACES 0601823732

LY2DDC24V RELAY ............................................................ 1 .......... S/N3699150~; REPLACES 0601827655

PTF08A SOCKET ........................................................ 1 .......... S/N3696510~; REPLACES 0601823109

0601824400 HOLDER ........................................................ 1 .......... S/N3696510~; PYCA1

39 0027104020 MACHINE SCREW ........................................ 2 .......... DS/N3696510~

70 0601823706 RELAY ............................................................ 1 .......... S/N3696510~

71 0027104015 MACHINE SCREW ........................................ 2 .......... S/N3696510~

72 0601815402 TERMINAL BOARD ....................................... 1 .......... S/N3696510~; TS144P

73 0027104020 MACHINE SCREW ........................................ 2 .......... S/N3696510~

74 0601827396 ENGINE CONTROLLER ............................... 1 .......... S/N3696510 TO 3699149

ECU9988N ENGINE CONTROLLER ............................... 1 .......... S/N3699150~; REPLACES 0602202545

75 0601831340 SWITCH ......................................................... 1 .......... S/N3696510 TO 3698125; 82608DPDT

0601830765 SWITCH ......................................................... 1 .......... S/N3698126~;S303T

76 0602120498 SPEED SENSOR ........................................... 1 .......... S/N3696510~;DYNT11200

0602202470 SEALED CABLE ............................................ 1 .......... S/N3696510~;TEHN23670201

77 DYN110654000024 CONTROLLER .............................................. 1 .......... S/N3701677~

78 0027104020 MACHINE SCREW ........................................ 4 .......... S/N3701677~

79 0601840009 RHEOSTAT.................................................... 1 .......... S/N3701677~; RA20ASE502BJ

80 C3262600004 BRACKET ...................................................... 1 .......... S/N3701677~

81 0017106015 HEX. HEAD BOLT .......................................... 2 .......... S/N3701677~

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 75

ENGINE & RADIATOR ASSY.

DCA-400SSK ENGINE & RADIATOR ASSY.

PAGE 76 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3924200054 ENGINE .......................................................... 1 ......... S/N3692434 TO 3701676;

KOMATSU SA6D 140E-2

C3925200004 ENGINE .......................................................... 1 ......... S/N3701677~; SA6D140E-2

2 6125817051 ELEMENT, AIR CLEANER ............................... 1 ......... REPLACES 0602040157

3 6002111231 CARTRIDGE, OIL FILTER .............................. 1 ......... REPLACES 0602041146

4 6003117111 CARTRIDGE, FUEL FILTER ........................... 1 ......... REPLACES 0602042157

5 6004111171 CARTRIDGE, CORROSION RESISTOR ........ 1 ......... REPLACES 0602045144

6 0602040678 DUST SENSOR 1 7 C3304200104 ENGINE FOOT 1 8 0010118060 HEX. HEAD BOLT 2 9 0030018000 HEX. NUT 2 10 0040018000 LOCK WASHER 2 11 0041218000 PLAIN WASHER 4 12 0605000061 RUBBER SUSPENSION 4 13 0030016000 HEX. NUT 8 14 0040016000 LOCK WASHER 8

15 6212619902 RADIATOR ...................................................... 1 ......... REPLACES 0602011943

2016012191 RADIATOR CAP 1

16 6995619230 RUBBER SHEET ............................................ 2 ......... REPLACES 0605000085

17 0010120055 HEX. HEAD BOLT 4 18 0040020000 LOCK WASHER 4 19 0041220000 PLAIN WASHER 4 20 C3311100204 BRACKET, RADIATOR 2 21 0010112025 HEX. HEAD BOLT 4 22 0040012000 LOCK WASHER 4 23 0041212000 PLAIN WASHER 4

24 6212619610 RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013962

25 6212616930 RADIATOR HOSE ........................................... 1 ......... REPLACES 0602014467

26 0726102612 RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013963

27 6138619260 RADIATOR HOSE ........................................... 1 ......... REPLACES 0602013062

28 0728100909 HOSE BAND ................................................... 6 ......... REPLACES 0602014056

29 0728101029 HOSE BAND ................................................... 2 ......... REPLACES 0602014350

30 0728100489 HOSE BAND ................................................... 2 ......... REPLACES 0602014351

31 0728100167 HOSE BAND ................................................... 2 ......... REPLACES 0602014059

32 0802081003 RESERVE TANK 1

33 0802010900 CAP, RESERVE TANK .................................... 1 ......... REPLACES 0602010900

34 C3317100103 BRACKET, RESERVE TANK 1 35 0199101150 HOSE 1 36 0193601500 HOSE 1 37 0605515013 HOSE BAND 2 38 0194700400 HOSE 1 39 0194700450 HOSE 1 40 0268500950 HOSE 1 41 0605515074 HOSE BAND 2 42 C3327200004 HOSE CLAMPER 1

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 77

ENGINE & RADIATOR ASSY.

DCA-400SSK ENGINE & RADIATOR ASSY.

PAGE 78 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

43 8212044103 OIL PANEL 1 44 0017110025 HEX. HEAD BOLT 2 45 C3358300204 CLAMPER ROD 1 46 0017110025 HEX. HEAD BOLT 2 47 8212256104 CLAMPER ROD 1 48 0019208020 HEX. HEAD BOLT 2 49 8215103504 RUBBER SEAL 1

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 79

ENGINE OPERATING PANEL ASSY.

DCA-400SSKENGINE OPERATING PANEL ASSY.

UP TO S/N 3701676

PAGE 80 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

S/N 3701677~

DCA-400SSK ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C3353100003 OPERATING PANEL ................................ 1 ......... S/N3692434 TO 3696509

C2352100213 OPERATING PANEL ................................ 1 ......... S/N3696510 TO 3701676

C2352100223 OPERATING PANEL ................................ 1 ......... S/N3701677

2 0017106015 HEX. HEAD BOLT 8 3 0207006000 HEX. NUT 4

4 0602101000 BATTERY SWITCH .................................. 1 ......... 9827300090

5 0021008080 MACHINE SCREW 2

0030008000 HEX. NUT 2 0040008000 LOCK WASHER 2 0041208000 PLAIN WASHER 2

6 0800250300 THROTTLE HANDLE................................ 1 ......... S/N3692434 TO 3701676

7 C3355100304 LINK, GOVERNOR ROD .......................... 1 ......... S/N3692434 TO 3701676

8 C3355200004 BRACKET ................................................ 1 ......... S/N3692434 TO 3701676

9 0017110025 HEX. HEAD BOLT .................................... 2 ......... S/N3692434 TO 3701676

10 0010010035 HEX. HEAD BOLT .................................... 1 ......... S/N3692434 TO 3701676

11 0030010000 HEX. NUT ................................................. 1 ......... S/N3692434 TO 3701676

12 0041210000 PLAIN WASHER ....................................... 2 ......... S/N3692434 TO 3701676

13 C3355300204 GOVERNOR ROD .................................... 1 ......... S/N3692434 TO 3701676

14 C3355300304 GOVERNOR ROD .................................... 1 ......... S/N3692434 TO 3701676

15 0602180106 BALL JOINT ............................................. 2 .........S/N3692434 TO 3701676

16 0030008000 HEX. NUT ................................................. 2 ......... S/N3692434 TO 3701676

17 0207006000 HEX. NUT ................................................. 2 ......... S/N3692434 TO 3701676

18 0041206000 PLAIN WASHER ....................................... 2 ......... S/N3692434 TO 3701676

19 0041206000 PLAIN WASHER ....................................... 2 ......... S/N3692434 TO 3701676

20 0605010502 SNAP PIN ................................................ 2 .........S/N3692434 TO 3701676

21 0602100049 STARTER SWITCH .................................. 1 ......... S/N3692434 TO 3696509; 6008155390

0601830448 PREHEAT BUTTON ................................. 1 ......... S/N3696510~; AH25FB10

22 0602104045 STOP BUTTON ........................................ 1 ......... S/N3692434 TO 3701676; 0806410000

0601831557 EMERGENCY STOP BUTTON ................ 1 ......... S/N3701677~; AR22V2R01R

23 0602102055 PRHEAT LAMP ........................................ 1 ......... 6008153730

24 0602120054 TACHOMETER ......................................... 1 ......... 25000KX4110

25 0602120156 CABLE, TACHOMETER ........................... 1 ......... 62500KA4210 L=3000

26 0602122060 OIL PRESSURE GAUGE ......................... 1 .........42000KX1410

27 0602122200 UNIT, OIL PRESSURE ............................. 1 ......... 53000AC0101

28 0602123061 WATER TEMPERATURE GAUGE ............ 1 .........40000KX0910

29 0602123206 UNIT, WATER TEMPERATURE ................ 1 .........41400KS0600

30 0602121052 CHARGING AMMETER ........................... 1 ......... 43000KV0300

31 0602125060 FUEL GAUGE .......................................... 1 .........41000KW0110

32 0602115014 MONITOR ................................................. 1 ......... V3376600000

33 C3484000103 SET FRAME 1 34 0010110030 HEX. HEAD BOLT 2

0030010000 HEX. NUT 2 0040010000 LOCK WASHER 2 0041210000 PLAIN WASHER 4

35 0601830710 ENGINE SPEED SWITCH ....................... 1 ......... S/N3701677~; S301T

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 81

OUTPUT TERMINAL ASSY.

DCA-400SSK — OUTPUT TERMINAL ASSY.

PAGE 82 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8221860203 SET BOARD, OUTPUT TERMINAL 1 2 0801030404 OUTPUT TERMINAL 8 3 0801830904 HEX. HEAD BOLT 8 4 0039320000 HEX. NUT 16 5 0040020000 LOCK WASHER 24 6 0041420000 PLAIN WASHER 32 7 3501860604 TERMINAL PLATE 3 8 0019110050 HEX. HEAD BOLT 5

0042310000 LOCK WASHER 5 0042410000 PLAIN WASHER 5

9 0601804887 CIRCUIT BREAKER ..................................... 2 ........... S/N 3692434 TO 3606720;

KM-51 265V 20A REPLACES 0601805313

0601808803 CIRCUIT BREAKER ...................................... 2 .......... S/N3606721~; QOU120B 20A

10 0601805840 CIRCUIT BREAKER ..................................... 3 ........... S/N 3692434 TO 3606720;

KM-52 265V 50A

0601808804 CIRCUIT BREAKER ..................................... 3 ........... S/N3606721~; QOU250B 50A

11 C1261600204 BRACKET, CIRCUIT BREAKER ................... 1 ........... S/N 3692434 TO 3606720

C3261600704 BRACKET, CIRCUIT BREAKER ................... 1 ........... S/N3606721~

12 0223300200 RUBBER CUSHION ...................................... 1 ........... S/N 3692434 TO 3606720

0221200150 RUBBER CUSHION ...................................... 1 ........... S/N3606721~

13 0017106020 HEX. HEAD BOLT 2 14 0601812598 RECEPTACLE 2

15 0601811034 RECEPTACLE ............................................... 3 ........... REPLACES 0601812565

16 0027104016 MACHINE SCREW 10

0030004000 HEX. NUT 10 0041204000 PLAIN WASHER 10

17 C3237100113 COVER, OUTPUT TERMINAL 1 18 0019112045 HEX. HEAD BOLT 2 19 0042412000 PLAIN WASHER 2 20 0805015604 STAY RUBBER 2 21 0205012000 HEX. NUT 2 22 0845043704 SPRING 2 23 C3237100214 COVER 1 24 0017108020 HEX. HEAD BOLT 7 25 C0237101504 COVER, OUTPUT TERMINAL 1 26 0805015604 STAY RUBBER 1 27 0845054204 COLLAR 2 28 0017110040 HEX. HEAD BOLT 2

29 0601815324 TERMINAL BOARD ....................................... 1 .......... S/N3696510~

30 0027104020 MACHINE SCREW ........................................ 2 .......... S/N3696510~

31 0601850275 GROMMET .................................................... 1 .......... S/N3696510~

32 0601851780 GROMMET .................................................... 2 .......... S/N3700680~

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 83

BATTERY ASSY.

DCA-400SSK — BATTERY ASSY.

PAGE 84 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — 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 C3347600004 BATTERY CABLE 1 9 C3347600104 BATTERY CABLE 1 10 C3347600304 BATTERY CABLE 1 11 C3347600204 BATTERY CABLE 1 12 C3347200004 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-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 85

ACTUATOR ASSY.

DCA-400SSK — ACTUATOR ASSY.

PAGE 86 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — ACTUATOR ASSY.

ACTUATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 DYNC11020300024 ACTUATOR ........................................... 1 ......S/N3701677~;REPLACES 0602150092

2 0602211090 LEVER .................................................. 1 ......S/N3701677~; DYNC182

3 C3356200004 BRACKET, ACTUATOR .........................1 ......S/N3701677~

4 0012310060 HEX. HEAD BOLT .................................2 ...... S/N3701677~

5 0016006070 HEX. SOCKET HEAD CAP SCREW .... 4 ......S/N3701677~

0207006000 HEX. NUT .............................................4 ...... S/N3701677~

0040006000 LOCK WASHER .................................... 4 ...... S/N3701677~

0041206000 PLAIN WASHER ................................... 4 ......S/N3701677~

6 0602211091 ROD ...................................................... 1 ......S/N3701677~

7 0602180190 BALL JOINT ..........................................2 ...... S/N3701677~

8 0602210092 HEX. NUT .............................................2 ...... S/N3701677~

9 0010106025 HEX. HEAD BOLT .................................1 ...... S/N3701677~

0207006000 HEX. NUT .............................................1 ...... S/N3701677~

10 0010106025 HEX. HEAD BOLT .................................1 ...... S/N3701677~

0207006000 HEX. NUT .............................................1 ...... S/N3701677~

0041206000 PLAIN WASHER ................................... 1 ......S/N3701677~

11 012310040 HEX. HEAD BOLT .................................1 ...... S/N3701677~

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 87

MUFFLER ASSY.

DCA-400SSK — MUFFLER ASSY.

PAGE 88 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3331100102 MUFFLER 1 2 0019210020 HEX. HEAD BOLT 4 3 C3334200204 PACKING 2 4 C3334200504 PACKING 1 5 C3334200604 PACKING 1 6 0019210025 HEX. HEAD BOLT 8 7 C3334000103 EXHAUST PIPE 1 8 0602320195 GASKET 2 9 0010316080 HEX. HEAD BOLT 4

0030316000 HEX. NUT 8 0042516000 LOCK WASHER 4 0041616000 PLAIN WASHER 8

10 0010316050 HEX. HEAD BOLT 4

0042516000 LOCK WASHER 4

0041616000 PLAIN WASHER 4 11 8212355003 OUTLET PIPE 1 12 7432356104 GASKET 1 13 0019112045 HEX. HEAD BOLT 4

0030012000 HEX. NUT 4

0042312000 LOCK WASHER 4

0042412000 PLAIN WASHER 8 14 8225125604 COVER 2 15 0019108020 HEX. HEAD BOLT 4

0207008000 HEX. NUT 4

0042308000 LOCK WASHER 4

0042408000 PLAIN WASHER 4 16 0019110030 HEX. HEAD BOLT 7

0042310000 LOCK WASHER 7

0042410000 PLAIN WASHER 7

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 89

FUEL TANK ASSY.

DCA-400SSK — FUEL TANK ASSY.

PAGE 90 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3364000603 FUEL TANK 1

2 0605505030 CAP, FUEL TANK ............................................ 1 ......... REPLACES 0605505005

0601850590 KEY ................................................................. 1 ......... REPLACES 0601850505

3 0810105400 FUEL FILTER 1 4 0264100385 HOSE, FUEL GAUGE 1 5 0605515079 HOSE BAND 2 6 0605503020 FUEL SENSOR 1 7 0802120604 PACKING 1

8 0605501050 UNIT, FUEL ..................................................... 1 ......... 52000-KA9810

9 0602021155 PACKING ........................................................ 1 ......... 52391-KW3700

10 0027104010 MACHINE SCREW 5 11 8225523104 TANK BAND 2 12 0805003414 PAD, TANK BAND 4 13 0017108020 HEX. HEAD BOLT 2 14 0037908000 HEX. NUT 2 15 0222100300 TANK SHEET 6 16 0130206000 STREET ELBOW 1 17 3515512014 DRAIN PIPE 1 18 0603325011 VALVE 1 19 0132006000 PLUG 1 20 0845039604 RUBBER SEAL 1 21 0191303000 SUCTION HOSE 1 22 0191303000 RETURN HOSE 1 23 0191004200 RETURN HOSE 1 24 0605515019 HOSE BAND 4 25 0605515013 HOSE BAND 2

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 91

ENCLOSURE #1 ASSY.

DCA-400SSK — ENCLOSURE #1 ASSY.

PAGE 92 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3414000202 BASE ............................................................. 1 .......... S/N3692434 TO 3701676

C3414001902 BASE ............................................................. 1 .......... S/N3701677~

2 C3414100104 FLOOR PANEL 1 3 C3414100004 FLOOR PANEL 1 4 0019208020 HEX. HEAD BOLT 14 5 C3424001204 FRONT FRAME 1

C3494100903 LINING ........................................................... 1 .......... S/N3692434 TO 3701676

C3494101703 LINING ........................................................... 1 .......... S/N3701677~

6 C342400103 FRONT FRAME 1

C3494100903 LINING ........................................................... 1 .......... S/N3692434 TO 3701676

C3494101703 LINING ........................................................... 1 .......... S/N3701677~

7 C3424000202 FRONT FRAME 1

C3494100903 LINING ........................................................... 1 .......... S/N3692434 TO 3701676

C3494101703 LINING ........................................................... 1 .......... S/N3701677~

8 C3424000302 FRONT FRAME 1

C3494100903 LINING ........................................................... 1 .......... S/N3692434 TO 3701676

C3494101703 LINING ........................................................... 1 .......... S/N3701677~

9 0017108020 HEX. HEAD BOLT 20

10 C3424300403 GUIDE PANEL, AIR ....................................... 1 .......... S/N3692434 TO 3701676

C3424300603 GUIDE PANEL, AIR ....................................... 1 .......... S/N3701677~

C3494100903 LINING ........................................................... 1 .......... S/N3692434 TO 3701676

C3494101703 LINING ........................................................... 1 .......... /N3701677

11 C3424300303 GUIDE PANEL, AIR 1

C3494100903 LINING ........................................................... 1 .......... S/N3692434 TO 3701676

C3494101703 LINING ........................................................... 1 .......... S/N3701677~

12 0019208020 HEX. HEAD BOLT 24 13 0019210025 HEX. HEAD BOLT 8 14 C3424201403 COVER, FRONT FRAME 1 15 C3424201304 COVER, FRONT FRAME 1

C3494101004 LINING 1 16 0019208020 HEX. HEAD BOLT 28

THE DEFAULT PART NUMBER FOR THE COLOR ORANGE. PLEASE INDICATE COLOR WHEN ORDERING:

MQW-WHITE

MQGRN-GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 93

ENCLOSURE #1 ASSY.

DCA-400SSK — ENCLOSURE #1 ASSY.

PAGE 94 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

17 0845042703 FILLER BRACKET 1 18 0019208020 HEX. HEAD BOLT 4 19 C3424201503 COVER, FRONT FRAME 1 20 0019208020 HEX. HEAD BOLT 14 21 0600500090 EMBLEM 1 22 0021106020 MACHINE SCREW 2 23 C3434000202 CENER FRAME 1 24 0010120070 HEX. HEAD BOLT 6

0030020000 HEX. NUT 6

0040020000 LOCK WASHER 6

0041220000 PLAIN WASHER 12 25 0010120060 HEX. HEAD BOLT 8

0030020000 HEX. NUT 8

0040020000 LOCK WASHER 8

0041220000 PLAIN WASHER 16 26 C3464100102 ROOF PANEL 1 27 0800251701 FILLER COVER 1 28 0025006015 MACHINE SCREW 2

0042306000 LOCK WASHER 2

0042406000 PLAIN WASHER 2 29 0019208020 HEX. HEAD BOLT 28

30 C3464501004 BRACKET ...................................................... 2 .......... S/N3707481~

THE DEFAULT PART NUMBER FOR THE COLOR ORANGE. PLEASE INDICATE COLOR WHEN ORDERING:

MQW-WHITE

MQGRN-GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 95

ENCLOSURE #2 ASSY.

DCA-400SSK — ENCLOSURE #2 ASSY.

THE DEFAULT PART NUMBER FOR THE COLOR ORANGE. PLEASE INDICATE COLOR WHEN ORDERING:

MQW-WHITE

MQGRN-GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 96 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3444000903 REAR FRAME 1 2 8195151204 LOUVER PANEL 1 3 C3454700104 LOUVER PANEL 2 4 8175151204 LOUVER PANEL 1 5 0207006000 HEX. NUT 22 6 C3444000402 REAR FRAME 1

8225940104 LINING 1 7 0017108020 HEX. HEAD BOLT 11 8 0019210025 HEX. HEAD BOLT 4 9 0017110025 HEX. HEAD BOLT 3 10 C3444300703 COVER, REAR FRAME 1

C3494300604 LINING 1 11 8195151004 LOUVER PANEL 3 12 0207006000 HEX. NUT 18 13 C3444300804 DUCT COVER 1

C3494300704 LINING 1 14 0017108020 HEX. HEAD BOLT 12 15 0019208020 HEX. HEAD BOLT 15 16 C3444200503 DOOR, REAR FRAME 1 17 C3444200903 DOOR, REAR FRAME 1 18 8225147004 WINDOW PLATE 2 19 0037906000 HEX. NUT 12 20 B9114500104 DOOR POCKET 1 21 0207006000 HEX. NUT 4 22 B9114000102 DOOR HANDLE 1 23 0021806016 MACHINE SCREW 4

0030006000 HEX. NUT 4 24 8225146204 DOOR ROD 1 25 8225146304 DOOR ROD 1 26 0845050704 STAY 4 27 0207006000 HEX. NUT 8 28 0805011304 STOPPER, DOOR 1 29 0805011204 STOPPER, DOOR 1 30 0207006000 HEX. NUT 4

31 M9110100204 HINGE ........................................................... 2 ........... REPLACES 0601850505

0845045004 WASHER 2 32 0845047204 HINGE 2

0845045004 WASHER 2 33 0019208020 HEX. HEAD BOLT 6 34 0601850097 STOPPER 2 35 0021008025 MACHINE SCREW 2 36 0845031504 CAP 4

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 97

ENCLOSURE #2 ASSY.

DCA-400SSK — ENCLOSURE #2 ASSY.

PAGE 98 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

DCA-400SSK — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

37 0600500090 EMBLEM 1 38 0021106020 MACHINE SCREW 2 39 C3464200102 ROOF PANEL 1

C3494500204 LINING 1 40 C3464500304 COVER, ROOF PANEL 1

C3494500304 LINING 1 41 0017108020 HEX. HEAD BOLT 9 42 0019208020 HEX. HEAD BOLT 24 43 0019210025 HEX. HEAD BOLT 4

44 C3464501104 BRACKET ..................................................... 2 ........... S/N3707481~

THE DEFAULT PART NUMBER FOR THE COLOR ORANGE. PLEASE INDICATE COLOR WHEN ORDERING:

MQW-WHITE

MQGRN-GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01) — PAGE 99

ENCLOSURE #3 ASSY.

DCA-400SSK — ENCLOSURE #3 ASSY.

THE DEFAULT PART NUMBER FOR THE COLOR ORANGE. PLEASE INDICATE COLOR WHEN ORDERING:

MQW-WHITE

MQGRN-GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 100 — DCA-400SSK — PARTS AND OPERATION MANUAL (STD)— REV. #3 (09/17/01)

Multiquip DCA400SSK2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual