Multiquip DCA-400SSV User Manual

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PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-400SSV

60 Hz GENERATOR

PARTS LIST NO. C3871301004

Revision #0 (04/19/06)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

reproduced, or altered without written permission. All other trademarks are the property of thier respective owners and used with permission.

This manual should remain with the unit if resold.

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are based on the design or the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and

DCA-400SSV WHISPERWATT AC Generator

. Multiquip Inc. reserves the right to discontinue or change specifications,

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 3

MQ POWER DCA-400SSVMQ POWER DCA-400SSV

MQ POWER DCA-400SSV

MQ POWER DCA-400SSVMQ POWER DCA-400SSV

TMTM

WHISPERWHISPER

WHISPER

WHISPERWHISPER

California Proposition 65 Warning ..................................... 2

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

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

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

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ........................................... 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals....................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Generator Control Panel ............................................ 20-21

Engine Operating Panel .................................................. 22

Output Terminal Panel Familiarization ........................ 24-26

Load Application ............................................................. 27

Generator Outputs .......................................................... 28

Gauge Reading ............................................................... 29

Output Terminal Panel Connections ........................... 30-31

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

Generator Start-up Procedure (Manual) ..................... 36-37

Generator Start-up Procedure (Auto Mode) .................... 38

Generator Shut-Down Procedure .................................... 39

Maintenance (Engine) ................................................ 40-42

Jacket Water Heater/battery Charger (Option) ................ 43

Maintenance (Trailer) ................................................. 44-47

Trailer Wiring Diagram .....................................................48

Generator Wiring Diagram ............................................... 49

Engine Wiring Diagram S/N 3722759 & Below ................ 50

Engine Wiring Diagram S/N 3722760 & Above ............... 51

Generator Troubleshooting .............................................. 52

Engine Controller Troubleshooting ................................... 53

Troubleshooting Diagnostic Lamp ................................... 54

Explanation of Code in Remarks Column ....................... 56

Suggested Spare Parts .................................................. 57

TTTT

TMTM

GENERATORGENERATOR

GENERATOR

GENERATORGENERATOR

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .................................................. 58-61

Engine Operating Panel Assembly ............................ 62-63

Control Box Assembly ............................................... 64-67

Engine and Radiator Assembly ................................. 68-71

Output Terminal Assembly .........................................

Battery Assembly ...................................................... 74-75

Muffler Assembly ...................................................... 76-77

Fuel Tank Assembly .................................................. 78-79

Enclosure #1 Assembly ............................................ 76-79

Enclosure #2 Assembly ............................................ 76-79

Enclosure #3 Assembly ............................................ 76-79

Rubber Seals Assembly ............................................ 80-81

Nameplate and Decals .............................................. 82-83

Terms and Condition of Sale — Parts ............................ 84

NOTE

Specification and part number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

72-73

PAGE 4 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ 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:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u c k

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

EXT. EXT.

279 279

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

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.

at no charge for freight

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

MQPOWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-MAIL: mqpower@multiquip.com INTERNET: www.mqpower.com

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

DCA-400SSV— SPECIFICATIONS

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PAGE 6 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm060,1(.ni37.14G).mm094(.ni03.91

B).mm09

C).mm018(.ni88.13I ).mm002,4(.ni3.561

D).mm508(.ni96.13J ).mm001,2(.ni76.28

E).mm064(

F).mm018(.ni88.13

4(.ni03.91H ).mm060,1(.ni37.14

.ni11.81K ).mm004,1(.ni11.55

).mm(.ninoisnemiDretteLecnerefeR).mm(.ninoisnemiD

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 7

DCA-400SSV— SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others.

This Owner's Manual has been

NOTE

developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-400SSV

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

Whisperwatt™ Generator.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

equipment in a confined area or enclosed structure that does not provide ample free flow air.

WARNING - EXPLOSIVE FUEL

DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

Hazard Symbols

Message Alert Symbols

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

Gasoline

its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

is extremely flammable, and

" which

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

DCA-400SSV— SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF

switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings

of the engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 9

DCA-400SSV— RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

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

General Safety:

■

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

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

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.

or even

DEATH

! This equipment is to be

DCA-400SSVWhisperwatt™ AC Generator.

ALWAYS check the machine for loosened threads or bolts

before starting.

■

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

■

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 performing service and maintenance functions. Contact with

hot!

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. 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.

bodily harm or even death.

NEVER

operate the generator in any

■

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. Unauthorized equipment modification will void all warranties.

■

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

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

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

DO NOT leave the generator running in the unattended.

Refer to the technical questions or information.

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

VOLVO Engine Owner's Manual

manual mode

for engine

PAGE 10 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— RULES FOR SAFE OPERATION

Generator Grounding

DANGER - ELECTROCUTION HAZARDS

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

During operation of this generator, there exists the possibility of

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

(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.

The following safety recommendations should also be followed:

To avoid these hazards: NEVER use damaged or worn cables when connecting

equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

ungrounded generator.

■

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

and electrical shock. NEVER grab or touch a live power

cord with wet hands. NEVER touch output terminals

during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

Electrical Safety

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

ALWAYS make sure generator installation is accordance with the

National Electrical Code

(NEC) and local codes

before operating generator.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.

■

NEVER power cables or cords

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

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 have a licensed electrician perform the installation

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 11

DCA-400SSV— RULES FOR SAFE OPERATION

Maintenance Safety

■

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. before performing maintenance on the generator.

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator.

■

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

■

Keep the machinery in proper running condition.

■

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

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

Radiator Cap - Removing the radiator cap while the engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■

Coolant Drain Plug - Removing the coolant drain plug while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

Turn all circuit breakers OFF

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, glasses.

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

■■

■

DO NOT drop the battery. There

■■

is the possibility of risk that the battery may explode.

■■

■

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.

ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

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

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

always

clothing or skin

EYES

wear safety

severe injury

, rinse eyes immediately with

DEATH:

, rinse skin or clothing

■

Engine Oil Drain Plug - Removing the engine oil drain plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

PAGE 12 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— RULES FOR SAFE OPERATION

■

Towing & Transporting Safety

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

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

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

■

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

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Emergencies

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

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

■

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

■

ALWAYS attach trailer’s safety chains to towing vehicle properly.

■

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

■

DOT Requirements include the following:

z z

Trailer tires should be inflated to 50 psi cold.

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 13

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

ALWAYS know the location of the nearest phone or

the job site,

ALWAYS have easy access to the phone

numbers of the nearest and be invaluable in the case of an emergency.

fire extinguisher

first aid kit

keep a phone on

in case of emergencies.

Fire Department

Ambulance, Doctor

. This information will

DCA-400SSV— GENERATOR DECALS

The DCA-400SSVgenerator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

Figure 2. Generator Decals

PAGE 14 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 15

DCA-400SSV— INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— INSTALLATION

Outdoor Installation

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

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

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

CAUTION - EXHAUST HAZARD

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

Indoor Installation

Generator Grounding

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

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies 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 4) 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 aminimum of 8 ft. into the ground.

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.

Mounting

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

NOTE

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

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 17

DCA-400SSV— GENERAL INFORMATION

DCA-400SSVWhisperwatt™ Series Familiarization Generator

The MQ Power Model DCA-400SSVis a 320 kW

generator

(Figure 5) 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.

Open Delta Excitation System

The DCA-400SSVgenerator is equipped with the state of the

Open-Delta

art " consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D,

Engine Operating Panel

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

■■

■

Tachometer

■■

■

Emergency Stop Switch

■■

■

Water Temperature Gauge

■■

■

Oil Pressure Gauge

■■

■

Charging Ammeter Gauge

■■

■

Fuel Level Gauge

■■

■

Pre-Heat Button

■■

■

Engine Speed Switch

■■

■

Battery Switch

■■

■

Alarm (Water Temp., Oil Pressure, Fuel)

■■

Generator Control Panel

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

■■

■

Frequency Meter (Hz)

■■

■

AC Ammeter (Amps)

■■

■

AC Voltmeter (Volts)

■■

■

Ammeter Change-Over Switch

■■

■

Voltmeter Change-Over Switch

■■

■

Voltage Regulator

■■

■

Panel Light/Panel Light Switch

■■

■

3-Pole, 1,000 amp Main Circuit Breaker

■■

■

“Control Box” (located behind the Gen. Control Panel)

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifer

■■

■

Starter Relay

■■

■

Engine Controller (Computer Controlled)

■■

■

Voltage Selector Switch

■■

Output Terminal Panel

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

■■

■

Three 120/240V output receptacles (CS-6369), 50A

■■

■

Three auxilliary circuit breakers, 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Five output terminal lugs (3Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

PAGE 18 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

and C to D. These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of 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

The DCA-400SSVis powered by a 6 cylinder, water cooled, direct injection, turbocharged

TAD1241GE Diesel Engine

every performance requirement for the generator. Reference Table 1 for engine specifications.

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

Electric Governor System

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

Extension Cables

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

" excitation system. The open delta system

fixed ceiling

" and responds

VOLVO Model PENTA

. This engine is designed to meet

DCA-400SSV— MAJOR COMPONENTS

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Figure 5. Major Components

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 19

DCA-400SSV— GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

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

1. Pilot Lamp – Indicates the

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. AC Voltmeter – Indicates the output voltage present at the

U,V, and W Output Terminal Lugs

4. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz.

5. AC Ammeter – Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

6. 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.

7. 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. This switch does not effect the generator output in any fashion, it is for current reading only.

Generator Control Panel

(Figure 6).

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

9. Voltage Regulator Control – Allows ±15% manual adjustment of the generator’s output voltage.

10. Main Circuit Breaker – This three-pole, 1,000 amp main breaker is provided to protect the the

Output Terminal Lugs

11. Auto On/Off Engine Controller (MPEC) –

This controller has a vertical row of status LED's (inset), 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 all major faults will shutdown the generator. During

cycle

crank the engine for 10 seconds before disengaging.

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the

Over Speed Protection

from overload.

cranking

, The MPEC will attempt to

Over Crank Protection

mode.

mode. If the engine

U,V, and W

PAGE 20 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— GENERATOR CONTROL PANEL

Also the engine controller will shut down the engine 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 controller module.

A. MPEC Control Switch – This switch controls the

running of the unit. If this switch is set to the OFF/RESET position, the unit will not run. When this switch is set to the MANUAL position, the generator will start immediately.

If the generator is to be connected to a building's AC

Located behind the generator control panel is the

Control Box

electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■■

■

Over-Current Relay

■■

■

Voltage Rectifer (AVR)

■■

■

Starter Relay

■■

Current Transformer

■

■■

■

Voltage Selector Switch

■■

■

Three Phase Circuit Breaker

■■

power source via a transfer switch (isolation), place the switch in the AUTO position. In this position the generator will monitor the AC line output from the

NOTE

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

major

fault.

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 239°F. The engine temperature is detected using variable resistive values

In the event of a short circuit or over current condition, it will automatically trip the 600 amp main breaker.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

from the temperature sending unit. This is considered a

major

fault.

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,V, and W

to the

load.

Output Terminal Panel

, press the

main

closed

position (ON).

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. It is pre-set at 3 cycles with a 10 second duration. This is considered a

major

fault.

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

major

fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 21

DCA-400SSV— ENGINE OPERATING PANEL

Figure 7. Engine Operating Panel

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

1. 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.

2. Oil Pressure Gauge – During normal operation this gauge be should read between 44 to 73 psi. (303~503 kPa). When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

3. Water Temperature Gauge – During normal operation this gauge be should read between 167° and 203°F.

4. 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.

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

6. Engine Warning Lamps – There are three engine warning lamps, they are defined as follows:

A. Overheat Lamp – This lamp goes ON

Engine Operating Panel

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.

(Figure 7).

B. Low Oil Pressure Lamp – During normal

operation of the generator this lamp should remain OFF. When the Manual switch is set to the “Manual” position to start the engine, the lamp will be lit. After the oil pressure rises after startup 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.

7. Engine Speed Switch – This switch controls the speed of the engine (low/high).

8. 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.

9. 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.

Auto-OFF/Reset

PAGE 22 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

NOTE PAGE

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 23

DCA-400SSV— OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal

Output Terminal Familiarization

The “

Output Terminal Panel

following:

■■

■

Three (3) 120/240V output receptacles @ 50 amp

■■

lugs.

■■

■

Three (3) Circuit Breakers @ 50 amps

■■

Two (2) 100V GFCI receptacles @ 20 amp

■

■■

Two (2) GFCI Circuit Breakers @ 20 amps

■

■■

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

■

■■

NOTE

Terminal legs “O” and “Ground”

are considered

bonded grounds

” (Figure 8) is provided with the

Figure 8. Output Terminal Panel

PAGE 24 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the being tripped. Pressing the the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

(See Figure 9) in

Each auxilliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the

Output Terminal Lugs

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

voltage regulator control knob

increase

decrease

Figure 11. Voltage Regulator Control Knob

the voltage, turning the knob counter-

the voltage.

(Figure 11) on the

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxilliary twist-lock (CS-6369) recepacles (Figure 10) provided on the output terminal panel.These receptacles can when the voltage selector switch is placed in the

phase 240/120 position.

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

only

be accessed

single-

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 25

DCA-400SSV— OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Terminal Lugs

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 1000A to switch ALL circuit breakers to the OFF position prior to starting the engine.

or the convienience receptacles (Figure 12).

main

circuit breaker is provided. Make sure

Ouput

Over Current Relay

over current relay

An circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the rent relay must be pressed. The over current relay is located in the control box.

(Figure 13) is connected to the main

reset button

Figure 13. Over Current Relay

on the over cur-

Figure 12. Connecting Loads

PAGE 26 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage,

frequency

Three Phase Load

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

, and voltage 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

NOTE

starting system of the equipment.

If wattage is not given on the equipment's name plate,

NOTE

approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

NOTE

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out

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the appliance or tool and overheat the cable. See Table 6.

■■

■

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.

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

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

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DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 27

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER - ELECTRICAL SYSTEM HAZARDS

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

(transfer) switch

licensed electrician

must install an

. Serious damage to the building’s

isolation

electrical system may occur without this transfer switch.

DCA-400SSV — GENERATOR OUTPUTS

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Generator Output Voltages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by applying jumpers (6) to the

voltage change-over board

(Figure 14).

Generator Amperage

Tables 8 and 9 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

To obtain some of the voltages as listed in Table 6 (see below) will require a fine adjustment using the

lator

(VR)

control knob

located on the control panel.

Voltage Change-Over Board

The

voltage change-over board

(Figure 14) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection.

voltage regu-

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Figure 14. Voltage Change-Over Board

CAUTION - CHANGING VOLTAGES

NEVER attempt to place jumper plates on the

change-over board

There exist the possibility of

while the generator is in operation.

electrocution, electrical

voltage

shock or burn, which can cause severe bodily harm or even death

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PAGE 28 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— GENERATOR OUTPUTS/ GAUGE READING

Maximum Amps

Table 10 shows the vide. DO NOT exceed the maximum amps as listed.

maximum

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amps the generator can pro-

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Change-Over Switch

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How to Read the Output Terminal Gauge.

The AC ammeter and AC voltmeter change-over switches on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

When the voltage change-over board is jumpered for 3Ø, 240V operation (See Figures 16 and17), place the

meter Change-Over Switch

W-U position and the

(See Figures 18 and 19) to the

AC Ammeter Change-Over Switch

AC Volt-

Figure 18. AC Ammeter

Change-Over Switch

(Figure 18) to the U or W position to read the output on the selected leg.

Figure 17. AC Voltmeter Gauge

(Volt reading on W-U Lug)

Figure 19. AC Ammeter (Amp reading on U lug)

Figure 15. Voltage Change-Over Board

240V Configuration

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 29

NOTE

The

ammeter

gauge will only

show a reading when the

Output Terminal Lugs

are

connected to a load and in use.

DCA-400SSV— OUTPUT TERMINAL PANEL CONNECTIONS

UVWO Terminal Output Voltages

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the

Voltage Change-Over Board Voltage Regulator Control Knob

and the adjustment of the

Figure 22. Voltage Regulator Knob

Remember the voltage change-over board determines the

range

of the output voltage and can be configured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V configuration. The voltage regulator (VR) allows the user to increase or decrease the selected

1Ø-240V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 20 .

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 20.

Figure 20. Voltage Change-Over Board

240V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 21.

1Ø-139V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 20.

2. Connect the load wires to the UVWO terminals as shown in Figure 24.

Figure 23. UVWO Terminal Lugs

1Ø-240V Connections

Figure 21. UVWO Terminal Lugs

3Ø-240V Connections

3. Turn the voltage regulator knob (Figure 22) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required

PAGE 30 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

Figure 24. UVWO Terminal Lugs

1Ø-139V Connections

DCA-400SSV— OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation

as shown in Figure 25. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate

must

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 25.

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

be used.

Figure 25. Voltage Change-Over Board

480V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 26.

1Ø-277V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 25.

Figure 27. UVWO Terminal Lugs

1Ø-480V Connections

NOTE

Figure 26. UVWO Terminal Lugs

3Ø-480V Connections

ALWAYS make sure that the

connections to the UVWO terminals are The possibility of arcing exists, that could cause a fire.

secure

2. Connect the load wires to the UVWO terminals as shown in Figure 28.

Figure 28. UVWO Terminal Lugs

1Ø-277V Connections

and tight.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 31

DCA-400SSV— PRE-SETUP

Circuit Breakers

Fuel Check

To protect the generator from an overload, a 3-pole, 600 amp,

main

circuit breaker is provided to protect the

Output Terminals

20 amp

GFCI

from overload. In addition two single-pole,

circuit breakers are provided to protect the

GFCI receptacles from overload. Three 50 amp

U,V, and W

load

circuit

breakers have also been provided to protect the auxiliary

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level. and verify that the oil level is maintained between the two notches (Figure 29) on the dipstick. See Table 11 for proper selection of engine oil.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

Figure 29. Engine Oil Dipstick

This generator has an internal fuel tank located inside the

When checking the engine oil, be sure to check if the oil is clean. 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 Volvo Engine Owner's Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:

■■

■

API Service Classification CC/SC

■■

■

API Service Classification CC/SD

■■

■

API Service Classification CC/SE

■■

■

API Service Classification CC/SF

■■

trailer frame and may also be equipped with an environmental fuel tank (Figure 30). fresh

#2 diesel fuel.

capacities. Pay attention to the fuel tank capacity when replenishing

fuel.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.

hot

engine can cause a

ALWAYS

fill the fuel tanks with clean

fire

explosion

DO NOT fill the fuel tanks beyond their

Figure 30. Internal Fuel Tank System

PAGE 32 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— PRE-SETUP

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 31).

CAUTION - REFUELING THE GENERATOR

ALWAYS

to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

place trailer on firm level ground before refueling

3. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and fill tank (Figure 32).

Figure 32. Fueling the Generator

Figure 31. Only Fill on Level Ground

NOTE

ONLY! use

refueling.

#2 diesel fuel

3. NEVER overfill fuel tank – It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 33).

when

Figure 33. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 34).

Figure 34. Fuel Expansion

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 33

DCA-400SSV— PRE-SETUP

Coolant (Antifreeze/Summer Coolant/Water)

VOLVO recommends VOLVO antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the VOLVO Engine Owner's Manual for further details.

Cleaning the Radiator

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

negative

WARNING - BURN HAZARDS

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

If adding coolant/antifreeze mix to the

accordance with the VOLVO Engine Owner's Manual.

radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

hot!

coolant exists which

can cause severe burns.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the VOLVO

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

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 35) when depressed with the thumb as shown below.

capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

battery terminal disconnected.

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

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Figure 35. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

PAGE 34 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— PRE-SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

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

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation ALWAYS be sure the battery cables (Figure 36) are properly

connected to the battery terminals as shown below. The Red Cable is connected to the positive terminal of the battery,

and the Black Cable is connected to the negative terminal of the battery.

CAUTION - BATTERY SERVICING SAFETY

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the the MANUAL position. ALWAYS make sure that the

Control Switch

connecting the battery.

2. Place a small amount of battery terminal treatment

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

NOTE

CAUTION - BATTERY SERVICING SAFETY

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

Alternator

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

MPEC Control Switch

is in either

MPEC

is in the OFF/RESET position when

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.

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Figure 36. Battery Connections

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 35

DO NOT put water directly on the alternator. Entry of water

into the alternator can cause corrision and damage the alternator.

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 ( immediately.

fuel

oil

) lines are defective replace them

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

Before Starting

CAUTION - LETHAL EXHAUST HAZARD

Starting (Manual)

1. In cold weather conditions, press and hold the

button

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER!

1. Place the

manually start the engine with the

auxiliary

(Figure 37) in the OFF position prior to starting the engine.

circuit breakers in the ON (closed) position.

main, G.F.C.I.,

and

aux.

main, GFCI

circuit breakers

engine glow plugs.

2. Place the engine speed switch (Figure 40) in the “ (down) position.

3. Once the engine glow plugs have been warmed, place

the start the engine (Figure 41).

pre-heat

(Figure 39) for at least 50 seconds to warm the

Figure 39. Pre-Heat Button

LOW

”

Figure 40. Engine Speed Switch (Low)

MPEC Control Switch

in the MANUAL position to

Figure 37. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the the been configured for the desired output voltage.

3. Connect the load to the

terminal lugs

connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

4. Tighten terminal nuts securely to prevent load wires from slipping out.

5. Close all engine enclosure doors (Figure 38).

voltage change-over board

receptacles or

as shown in Figure 12. These load

the

has

output

4. Once the engine starts, let it engine run for 1-2 minutes. Listen for any abnormal noises. If any abnormalities exists shutdown the engine and correct the problem. If the engine is running smoothly, place the engine speed switch (Figure 42) in the “

5. Verify that the Engine Running status LED on the MPEC unit (Figure 43) is ON (lit) after the engine has been started.

Figure 41. MPEC Control Switch

(Manual Position)

HIGH

” (up) position.

Figure 42. Engine Speed Switch (High)

Figure 38. Engine Enclosure Doors

PAGE 36 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

Figure 43. Engine Running LED (ON)

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

6. The generator's frequency meter (Figure 44) should be displaying the 60 cycle output frequency in HERTZ.

Figure 44. Frequency Meter (Hz)

7. The generator's AC-voltmeter (Figure 45) will display the generator’s output in VOLTS. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 46) to increase or decrease the desired voltage.

10. The (Figure 49) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 165 and 203 degrees Fahrenheit (

11. The will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1600 RPM’s.

12. Place the

ON position (Figure 51).

coolant temperature gauge

Green Zone

tachometer gauge

main, GFCI

(Figure 50)

, and

aux

. circuit breakers in the

Figure 49. Coolant

Temperature Gauge

Figure 50. Engine

Tachometer Gauge

Figure 46. Voltmeter

Figure 46. Voltage Adjust Control Knob

8. The ammeter (Figure 47) will indicate applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

9. The engine oil pressure gauge (Figure 48) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 44 to 73 psi. (303~503 kPa). When starting the genera

zero amps

with no load

Figure 47. Ammeter

(No Load)

Figure 48. Oil

Pressure Gauge

Figure 51. Main, Aux. and GFCI

Circuit Breakers (ON)

13. Observe the generator's ammeter (Figure 52) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 52. Ammeter

(Load)

14. The generator will run until manually stopped or an

abnormal condition occurs.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 37

DCA-400SSV— GENERATOR START-UP PROCEDURE (AUTO MODE)

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

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

electrician (transfer)

building’s electrical system may occur without this transfer switch.

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.

NOTE

must install an

switch

CAUTION - BACKUP GENERATOR USE

. Serious damage to the

When the generator is set in the

AUTO mode, the generator will

automically start

comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

licensed

isolation

in the event of

When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below).

1. Perform steps 1 through 5 in the as outlined in the

2. Place the position

3. Place the position

4. Continue operating the generator as outlined in the

Manual Start-up

Manual

Before Starting

Manual Starting Procedure

engine speed switch

Figure 53. Engine Speed Switch (High)

MPEC Control Switch

Figure 54. MPEC Control Switch (AUTO)

procedure (start at step 5).

(Figure 53) in the HIGH

(Figure 54) in the AUTO

section .

WARNING - AUTO MODE MAINTENANCE

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.

CAUTION - ENGINE SPEED SWITCH

The

Engine Speed Switch

position when running in the set the switch in the proper position can result in damage to your generator when it turns on.

NOTE

must be set to the “High”

Auto-Start

When the MPEC is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically.

mode. Failing to

Control Switch

PAGE 38 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— GENERATOR SHUT-DOWN PROCEDURES

WARNING -

NEVER stop the engine suddenly except in an emergency.

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 38 to the OFF position.

2. Place the engine speed switch (Figure 55) in the “

(down) position.

Figure 55. Engine Speed Switch (Low)

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

4. Place the

OFF/RESET position.

SHUTTING DOWN THE GENERATOR

MPEC Control Switch

(Figure 56) to the

LOW

Emergency Shutdown Procedure

1. To stop the engine in the event of an emergency, PUSH the emergency stop button ( Figure 57) inward. This button is located on the engine operating panel, see Figure 7.

”

Figure 57. Emergency Stop Button

Figure 56. MPEC Control Switch (Off/Reset)

5. Verify that the are OFF (not lit).

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening of components that may have occured during operation.

all

status LED on the MPEC display

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 39

DCA-400SSV— MAINTENANCE

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General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element (Figure 59) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator (Figure 58) is attached to the air cleaner. When

NOTE

the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

PAGE 40 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

Figure 58. Air Cleaner/Indicator

The air filter should not be changed until the indicator reads “RED”. Dispose of old air filter it may not be cleaned or reused.

DCA-400SSV— MAINTENANCE

Service Daily

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

frequently

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

Cleaning Inside the Fuel Tank

Drain the fuel inside the fuel tank completely. Using a spray washer (Figure 59) wash out any deposits or debris that have accumulated inside the fuel tank.

if these conditions exists.

dusty

dry grass

Fuel Tank Inspection

In addition to cleaning the fuel tank, the following components should be inspected for wear:

■■

■

Rubber Suspension – look for signs of wear or

■■

deformity due to contact with oil. Replace the rubber suspension if necessary.

■■

■

Fuel Hoses – inspect nylon and rubber hoses for signs

■■

of wear, deteration and hardning.

■■

■

Fuel Tank Lining – inspect the fuel tank lining for signs

■■

of excessive amounts of oil or other foreign matter.

Cleaning the Fuel Strainer

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

Replacing Fuel Filter

Replace the fuel filter cartridge with new one every 500 hours or so.

Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

Figure 59. Fuel Tank Cleaning

Vent any air

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 41

DCA-400SSV— MAINTENANCE

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. See the

Manual

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

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 30.

Replacing Oil Filter

for details.

Remove the old oil filter. Apply a film of oil to the gasket on the new oil filter. Install the new oil filter.

VOLVO Engine

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Radiator Cleaning

The radiator (Figure 60) should be sprayed (cleaned) with a high pressure washer when excessive amouts of dirt and debris have accumulated on the cooling fins or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the fins and tube.

cool

when flushing out

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

Flushing Out Radiator and Replacing Coolant

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

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

Tighten both cocks and replace the overflow tank. Replace with coolant as recommended by the engine

manufaturer. Close radiator cap tightly. Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

Figure 60. Air Cleaner/Indicator

Generator Storage

For longe term storage of the generator the following is recommended:

Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.

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

Clean the entire generator, internal and external. Cover the generating set and store in a clean, dry place. Disconnect the battery. Make sure engine coolant is at proper level. If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block and completely remove the tires.

PAGE 42 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— MAINTENANCE

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

This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the

battery charger

These receptacles will ONLY function when commercial power has been supplied to them (Figure 61). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

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.

jacket water heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

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.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

Figure 61. Battery Charger &

Jacket Water Heater Power Connections

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 43

DCA-400SSV— TRAILER MAINTENANCE

Trailer Maintenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the DCA400SSV

1. Fuel Cell - Provides an adequate amount of fuel for the

2. Braking System - System employed in stopping the

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the

4. Frame Length - Measurement is from the ball hitch to

5. Frame Width - Measurement is from fender to fender

Whisperwatt

equipment in use. Fuel cells must be empty when transporting equipment.

trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

maximum number of pounds the trailer can carry, including the fuel cell (empty).

the rear bumper (reflector).

™

Generator.

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

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

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

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

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

12. Lug Nuts - Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 18 and Figure 64 for lug nut tightening and sequence.

13. Axle - Indicates the maximum weight the axle can sup- port in pounds, and the diameter of the axle expressed in inches. Please note 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.

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.

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.

PAGE 44 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— TRAILER MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

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

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 62) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

brakes more frequently. Figure 62 displays the major hydraulic surge brake

components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 15 as listed below:

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

Figure 62. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

Actuator

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

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying

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

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

8. Repeat steps 1 through 7 on the remaining brakes.

sure that it is functioning correctly. Never use an undersize actuator.

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DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 45

DCA-400SSV— TRAILER MAINTENANCE

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.

Suspension

leaf suspension

The (Figure 63) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 17.

removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

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.

springs and associated components

Figure 63. Major Suspension Components

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 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SNUG FIT ONLY

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

stnemeriuqeReuqroTnoisnepsuS.71elbaT

PARTS MUST ROTATE FREELY

BOLT ASSEMBLY

05-XAM03-NIM

PAGE 46 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— TRAILER MAINTENANCE

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 64). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 18.

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

stnemeriuqeReuqroTeriT.81elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

Figure 64. Wheel Lug Nuts

Tightening Sequence

NOTE

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 47

DCA-400SSV— TRAILER WIRING DIAGRAM

Figure 65. Trailer/Towing Vehicle Wiring Diagram

PAGE 48 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— GENERATOR WIRING DIAGRAM

Figure 66. Generator Wiring Diagram

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 49

DCA-400SSV — ENGINE WIRING DIAGRAM (S/N 3722759 AND BELOW)

Figure 67. Engine Wiring Diagram 9S/N 3722759 AND BELOW

PAGE 50 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV — ENGINE WIRING DIAGRAM (S/N 3722760 AND ABOVE)

Figure 68. Engine Wiring Diagram (S/N 3722760 AND ABOVE)

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 51

DCA-400SSV— TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 52 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 20 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?levelliowoL.levelliolliF

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

ltnaloocwoL

.nosithgil

sithgilleve

)dellatsnIyllanoitpO(.no

erutrepmettnaloochgiH

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.srood

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruli

aftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneseru

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .t

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

esolC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwseruta

sserplioecalpeR

lebnafecalper/nethgiT

repmetecalpeR

?leuFwolrooN.levelleuflliF

.nosithgilknarcrevO

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogt

nosithgildeepsrevO

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

E.relaedotrefeR

ro)s(thgilUPMfossoL

.no

tengaM .pukcipcitengamnaelC

?ytridpukcipci

?detarbilacebotsdeenrellortnoCenign

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

sujdA

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 53

DCA-400SSV— TROUBLESHOOTING (DIAGNOSTIC LAMP)

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself. The malfunction can be determined by examining the flashing pattern of the diagnostic lamp (Figure 69) located in the control box.

Figure 69. Diagnostic Panel

Method of Operation

1. Normally, the diagnostic lamp will be

MPEC Control Switch

position.

2. If engine trouble occurs, the diagnostic lamp will be

brightly

manual position.

3. The diagnostic lamp will indicate an error code via a flashing pattern on the lamp. This pattern will become visible once the the reset button on the control box has been pushed and released. The error code consists of a series of flashes by the lamp. The error codes are defined as follows:

lit as long as the control switch is left in the

is placed in the MANUAL

dimly

lit when the

Example Error Code 2.

Figure 71 displays the error code for

Figure 71. Error Code High Temperature Intake

NOTE

4. In a situation where several engine malfunctions occur simultaneously, the code for each malfunction will flash one after another in sucession.

5. After all engine related malfunctions have been diagnosed and corrected, and the generator is operating in a normal maner the following code (Figure 72) should be displayed once the reset button is pressed and released

high temp intake

The error code will flash each time the reset button is pressed and released until the problems have been corrected.

Figure 72. Normal Operating Code

Example Error Code 1.

Figure 70 displays the error code for

Figure 70. Error Code Low Radiator Coolant

PAGE 54 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

low radiator coolant

NOTE

For a complete understanding of error codes and troubleshooting procedures, refer to the enclosed engine instruction manual.

When the

Switch

position, the same error codes will apply. Codes will not be active until the unit is activated.

MPEC Control

is placed in the AUTO

NOTE PAGE

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 55

DCA-400SSV— EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ....................... 1 .... INCLUDES ITEMS W/

2*12347 WASHER, 3/8 IN. ....1 ....

3 12348 HOSE .................... A/R .. MAKE LOCALLY

4 12349 BEARING ................ 1 .... S/N 2345B AND ABOVE

NO. Column

Unique Symbols - All items with same unique symbol

, #, +, %, or >) in the number column belong to the same

(

assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers - Duplicate numbers indicate multiple part numbers are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTE

without notice

WASHER, 1/4 IN. ...........

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

. Multiquip does not

NOT SOLD SEPARATELY MQ-45T ONLY

QTY. Column

Numbers Used - Item quantity can be indicated by a number,

a blank entry, or A/R. A/R (As Required) is generally used for hoses or other parts

that are sold in bulk and cut to length. A blank entry generally indicates that the item is not sold

separately. Other entries will be clarified in the “Remarks” Column.

REMARKS Column

Some of the most common notes found in the “Remarks”

Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit

symbol will be included when this item is purchased. Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

range where a particular part is used. Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Specific Model Number Use

only with the specific model number or model number variant listed. It can also be used to show a part is NOT used on a specific model or model number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

- All items on the parts list with the same unique

- Used to list an effective serial number

- Indicates that the part is used

PART NO. Column

Numbers Used - Part numbers can be indicated by a number,

a blank entry, or TBD. TBD (To Be Determined) is generally used to show a part

that has not been assigned a formal part number at time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clarified in the “Remarks” Column.

PAGE 56 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

“Make/Obtain Locally”

purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately”

purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.

- Indicates that the part can be

- Indicates that an item cannot be

DCA-400SSV— SUGGESTED SPARE PARTS

DCA-400SSVWHISPER WATTGENRATOR

W/VOLVO PENTA TAD1241GE DIESEL ENGINE

1 TO 3 UNITS

Qty. P/N Description

1 .........

1 ......... 0605505005 ........ CAP, FUEL TANK

1 .........

1 ......... V8170312 ............ WATER PUMP

1 .........

1 ......... V1077574 ........... SENSOR OIL, PRESSURE & TEMP.

1 ......... V968559 ............ O-RING, SENSOR OIL, PRESSURE & TEMP.

1 ......... V20424056 ........ FUEL PRESSURE MONITOR

1 ......... V947622 ............ GASKET, FUEL PRESSURE MONITOR

1 ......... V862154 ............ SENSOR,TEMP., COOLANT-WATER

1 ......... V11998 ..............GASKET, TEMP., COOLANT-WATER

1 ......... V862627 ............ SENSOR, OIL TEMPERATURE

1 ......... V11998 ..............GASKET, OIL TEMPERATURE

1 ......... V866835 ............ SENSOR, PRESSURE

6 ......... V8193841 .......... CARTRIDGE, FUEL FILTER

6 ......... V8159975 .......... CARTRIDGE, FUEL PRE-FILLER

6 ......... V466634 ............ CARTRIDGE, OIL FILTER, FULL-FLOW

6 ......... V477556 ............ CARTRIDGE, OIL FILTER, BY-PASS

6 ......... V1699830 .......... CARTRIDGE, FILTER COOLANT

3 ......... V3827643 .......... ELEMENT, AIR CLEANER

1 ......... 0601807514 ....... CIRCUIT BREAKER

1 ......... LY2DUS24VDC .. RELAY

V3827266 ........... HOSE, RADIATOR UPPER

V3827265 ........... HOSE, RADIATOR LOWER

V1674922 ........... CAP, FILLER, EXPANSION TANK

V1674083 ........... CAP, PRESSURE EXPANSION TANK

V3828041 ........... V-BELT, MAIN

V3173821 ........... ALTERNATOR 12 VDC

V978207 ............ V-BELT, ALTERNATOR

V20374281 ......... SENSOR, COOLANT TEMP

V949656 .............. O-RING, SENSOR, COOLANT TEMP.

NOTE

Part number on this Suggested Spare Parts list may supercede/replace the P/N shown in the text pages of this book.

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 57

GENERATOR ASSY.

DCA-400SSV— GENERATOR ASSY.

PAGE 58 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3110100902 ROTOR ASSY. 1 1-1 FIELD ASSY. 1 1-2 0601842401 RESISTOR 80W 300K 2 1-3 0601823282 RECTIFIER, RM50TC-24 1 1-4 0018205020 HEX SOCKET HEAD CAP SCREW 2 1-4A 0040005000 SPRING WASHER 2 1-4B 0041205000 PLAIN WASHER 2 1-5 8201070002 FAN 1 1-6 8201611004 COUPLING DISK 12 1-7 C3164200004 WASHER, COUPLING HUB 1

1-8 8201015003 BALANCING PLATE ............................. 1 ........... PURCHASE ITEM 1-11 AS A SET

1-9 0012116045 HEX HEAD BOLT 10 1-10 0042616000 SPRING WASHER 10 1-11 0601000209 BALANCING WEIGHT KIT 1 1-12 C3112500004 BEARING FLANGE 1 1-13 0071906315 BEARING, 6315DDU C3 1 2 C3164400103 COUPLING RING 1 3 0010312050 HEX HEAD BOLT 8 4 0042512000 SPRING WASHER 8 5 0010312040 HEX HEAD BOLT 12 5A 0042512000 SPRING WASHER 12 6 C3130100003 STATOR ASSY. 1 6-1 0226200495 RUBBER SEAL 1 6-2 8211323004 CLAMPER 1 6-3 0223300172 RUBBER SEAL 1 6-4 8211323103 CLAMPER 1 6-5 0221200440 RUBBER SEAL 1 6-6 0010110035 HEX HEAD BOLT 2 6-6A 0041210000 PLAIN WASHER 2 6-7 C3132200003 COVER 1 6-8 0226000290 RUBBER SEAL 2 6-9 0225000590 RUBBER SEAL 1 6-10 0017106020 HEX HEAD BOLT 6 6-11 0601850144 GROMMET 1 7 C3154000002 END BRACKET 1 8 C3138000003 FIELD ASSY. EXCITER 1 9 0012110080 HEX HEAD BOLT 4 9A 0042610000 SPRING WASHER 4 9B 0041210000 PLAIN WASHER 4 10 0017112045 HEX HEAD BOLT 8 11 C3154300104 COVER, BEARING 1 12 C3154300004 GASKET, BEARING 1

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 59

GENERATOR ASSY. (CONT.)

DCA-400SSV— GENERATOR ASSY. (CONT.)

PAGE 60 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— GENERATOR ASSY. (CONT.)

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

13 0010106060 HEX HEAD BOLT 4 13A 0040006000 SPRING WASHER 4 13B 0041206000 PLAIN WASHER 4 14 C3154400003 SUCTION COVER 1 15 0017106016 HEX HEAD BOLT 8 16 C3164600103 COUPLING ADAPTER 1 17 0010310030 HEX HEAD BOLT 12 17 0042510000 SPRING WASHER 12 18 C3164701404 SPACER, BEARING 1 19 0070506208 BEARING, 6208ZZ 1 20 0010312040 HEX HEAD BOLT 16 20 0042512000 SPRING WASHER 16 21 C3132300014 COVER, FAN 1 22 0010106030 HEX HEAD BOLT 1 22A 0041206000 PLAIN WASHER 1 22B 0600815000 NUT 1 23 0605000061 RUBBER SUSPENSION 4 24 0030016000 HEX NUT 8 24A 0040016000 SPRING WASHER 8

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 61

ENGINE OPERATING PANEL ASSY.

DCA-400SSV— ENGINE OPERATING PANEL ASSY.

PAGE 62 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3352101303 OPERATING PANEL 1 2 0017106016 HEX, HEAD BOLT 8 3 0207006000 HEX, NUT 4

4 0602101000 BATTERY SWITCH ................................... 1 ............... REPLACES P/N 9827300090

5 0021008080 MACHINE SCREW 2 5A 0030008000 HEX, NUT 2 5B 0040008000 SPRING WASHER 2 5C 0041208000 PLAIN WASHER 2 6 0601830710 ENGINE SPEED SWITCH 1 7 0601830449 EMERGENCY STOP BUTTON 1

8 V877179 TACHOMETER .......................................... 1 ............... REPLACES P/N 0602120024

9 V873198 OIL PRESSURE GAUGE .......................... 1 ............... REPLACES P/N 0602122024

10 V873196 WATER TEMPERATURE GAUGE ............. 1 ............... REPLACES P/N 0602123024

11 0602121052 CHARGING AMMETER 1 12 0602125060 FUEL GAUGE 1 13 0602103090 ALARM LAMP 3 13A 0601810244 BULB 3 14 C3484000903 SET FRAME 1 15 0010110030 HEX, HEAD BOLT 2 15A 0030010000 HEX, NUT 2 15B 0040010000 SPRING WASHER 2 15C 0041210000 PLAIN WASHER 4 16 C3374200104 COVER, AIR CLEANER 1 17 0017108020 HEX, HEAD BOLT 2

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 63

CONTROL BOX ASSY.

DCA-400SSV— CONTROL BOX ASSY.

PAGE 64 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3214001502 CONTROL BOX 1 2 0601801170 CURRENT TRANSFORMER, CW-5L 750/5A 3 3 0027106016 MACHINE SCREW 6 4 0601807514 CIRCUIT BREAKER, 1000A 1 5 0601820625 AUTOMATIC VOLTAGE REGULATOR 1 6 0027105016 MACHINE SCREW 4 7 0601820892 OVER CURRENT RELAY 1 8 0027104016 MACHINE SCREW 2 9 C3274000003 CHANGE-OVER BOARD, VOLTAGE 1 10 8221852104 CHANGE TERMINAL 10 11 0017108030 HEX HEAD BOLT 20 12 C2277200004 TERMINAL PLATE 3 13 8221853104 CHANGE PLATE 6 14 0801830804 HEX HEAD BOLT 10 15 0040016000 SPRING WASHER 10 16 0041416000 PLAIN WASHER 10 17 0801830704 HEX HEAD BOLT 13 18 8201852504 HEX HEAD BOLT 3 19 0040012000 SPRING WASHER 16 20 0041412000 PLAIN WASHER 16 21 0017110030 HEX HEAD BOLT 4 22 C3261502303 SET PANEL, ELECTRIC PARTS 1 23 0017108020 HEX HEAD BOLT 4 24 0601802149 FUSE, 10A 1 24A 0601802211 HOLDER, FUSE 1 25 0027103020 MACHINE SCREW 2 26 0601824961 TIMER, DC/AC24V 1 26A 0601823151 SOCKET 1 27 0027104025 MACHINE SCREW 2

28 LY2DUS24VDC RELAY, 24VDC ................................................. 5 ............. REPLACES P/N 0601827655

28A 0601823109 SOCKET, PTF08A 5 28B 0601824400 HOLDER, PYC-A1 5 29 0027104020 MACHINE SCREW 10 30 0601840227 RHEOSTAT(HIGH IDLE SPEED REG.) 1

2W 500 OHM 31 C3262600004 BRACKET 1 32 0017106016 HEX HEAD BOLT 2 33 0601820995 RELAY, JA1C-TMDC24V 1 34 0027104016 MACHINE SCREW 2 35 0601823240 RECTIFIER, DE4503 1 36 0027105020 MACHINE SCREW 1 37 C3261601004 SWITCH BRACKET 1

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 65

CONTROL BOX ASSY. (CONT.)

DCA-400SSV— CONTROL BOX ASSY. (CONT)

PAGE 66 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— CONTROL BOX ASSY. (CONT)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

38 0601810575 DIAGNOSTIC LAMP, DC24V 1 39 0601831205 RESET SWITCH 1 40 C3267600004 RESISTOR UNIT, 1/4W 39/120 OHM 1 41 0027105020 MACHINE SCREW 1 42 0030006000 HEX NUT 1 43 0017106016 HEX HEAD BOLT 4 44 0601815402 TERMINAL BOARD 1 45 0601815464 TERMINAL BOARD 1 46 0027104020 MACHINE SCREW 4 47 C3224001303 CONTROL PANEL 1 48 C3224002403 CONTROL PANEL 1 48-1 0228800110 RUBBER SEAL 2 48-2 0228800165 RUBBER SEAL 2 49 0605011211 PIN 2 50 0601807622 FREQUENCY METER, 45~65Hz 220V 1 51 0601806987 AC AMMETER, 0~750A, 0~1500A 1 52 0601801040 CHANGE-OVER SWITCH, AMMETER 1 53 0601806887 AC VOLTMETER, 0~600V 1 54 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1 55 0601810072 PILOT LAMP, LP-132DC 220V 1 55A 0601810261 BULB, CT-13W 1 56 0601840073 RHEOSTAT (VOLTAGE REG.), 2W 1K OHM 1 57 0601840121 KNOB 1

58 ECU9988N400V ENGINE CONTROLLER ......................................1 ............. REPLACES P/N 0602202640

59 0601830765 SWITCH 1 60 0601810161 PANEL LIGHT 1 60A 0601810214 BULB 1 61 0207004000 HEX NUT 2 62 0601830710 SWITCH, PANEL LIGHT 1 63 C9221100004 HEX, HEAD BOLT 2 63A 0040008000 SPRING WASHER 2 63B 0041208000 PLAIN WASHER 2 63C 0080200007 SNAP RING 2 64 0017108040 HEX HEAD BOLT 4 65 3871824004 STOPPER, CONTROL PANEL 1 66 0041206000 PLAIN WASHER 1 67 0605010502 SNAP PIN 1 68 8221814804 COVER, CONTROL BOX 1 69 0017108020 HEX, HEAD BOLT 8 70 8224117004 SIDE PANEL, CONTROL BOX 1 71 0017108020 HEX, HEAD BOLT 4 72 8221827704 PANEL, CONTROL BOX 1 73 0017108020 HEX, HEAD BOLT 8 74 0017110035 HEX, HEAD BOLT 4 74A 0207010000 HEX, NUT 4

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 67

ENGINE AND RADIATOR ASSY.

DCA-400SSV— ENGINE AND RADIATOR ASSY.

PAGE 68 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3924200154 ENGINE AND RADIATOR SET .......................1 ................ INCLUDES ITEMS W/

1-1*V3827643 ELEMENT, AIR CLEANER ..............................1 ................ REPLACES P/N 0602046623

1-2 1-3 1-4 1-5 1-6 1-7 1-8 2 C3304200304 ENGINE FOOT 1 3 C3304200204 ENGINE FOOT 1 4 C3304200504 ENGINE FOOT 1 5 C3304200404 ENGINE FOOT 1 6 0010316045 HEX, HEAD BOLT 16 7 0040016000 SPRING WASHER 16 8 0041216000 PLAIN WASHER 16 9 0605000061 RUBBER SUSPENSION 4 10 0030016000 HEX, NUT 8 11 0040016000 SPRING WASHER 8 12 C3311100403 FAN SHROUD 1 13 C3311600004 RUBBER SHEET 2 14 0010112050 HEX, HEAD BOLT 8 15 0040012000 SPRING WASHER 8 16 0041212000 PLAIN WASHER 8 17 6452025504 DRAIN JOINT 1 18 0802024004 PACKING 1 19 0130008000 ELBOW JOINT, 3/4” 1 20 0602022294 HOSE JOINT 2 21 C0321200004 DRAIN JOINT 1 22 C0321300004 CAP 1 23 0017108025 HEX HEAD BOLT 2 24 0603325017 VALVE 1 25 0265800460 DRAIN HOSE 1 26 0605515074 HOSE BAND 2

27 V948867 ADAPTER ........................................................1 ................ REPLACES P/N 0603306591

28 V977409 ELBOW JOINT ................................................ 1 ................ REPLACES P/N 0603306296

29 V974320 VALVE ............................................................. 1 ................ REPLACES P/N 0602012070

30 E2924100124 CONNECTOR 1 31 0131608040 REDUCING NIPPLE, 3/4X3/8” 1 32 0131104000 SOCKET 3/8” 1 33 0130204000 STREET ELBOW 3/8” 1 34 0602022219 HOSE JOINT 1 35 7812014003 DRAIN JOINT 1

V466634 CARTRIDGE, OIL FILTER, FULL-FLOW .........2 ................ REPLACES P/N 0602041275

V477556 CARTRIDGE, OIL FILTER, BY-PASS .............. 1 ................ REPLACES P/N 0602041276

V8193841 CARTRIDGE, FUEL FILTER ........................... 1 ................ REPLACES P/N 0602042561

V8159975 CARTRIDGE, FUEL PRE-FILLER ...................1 ................ REPLACES P/N 0602042765

V1699830 CARTRIDGE, FILTER COOLANT ................... 1 ................ REPLACES P/N 0602045160

V3828765 INDICATOR, AIR CLEANER ............................1 ................ REPLACES P/N 0602040605

V3828448 AIR CLEANER, COMPLETE 1

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 69

ENGINE AND RADIATOR ASSY.

DCA-400SSV— ENGINE AND RADIATOR ASSY.

PAGE 70 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

36 0802011104 PLUG 1 37 0150000018 O-RING 1 38 0017106025 HEX, HEAD BOLT 2 39 0199900900 DRAIN HOSE 1 40 0605515094 HOSE BAND 2 41 0191302200 OVERFLOW HOSE 1 42 0605515094 HOSE BAND 1 43 0269600780 BREATHER HOSE 1 44 0605515067 HOSE BAND 2 45 V3827266 HOSE, RADIATOR UPPER 1 46 V3827265 HOSE, RADIATOR LOWER 1 47 V1674922 CAP, FILLER, EXPANSION TANK 1 48 V1674083 CAP, PRESSURE, EXPANSION TANK 1 49 TBD TANK, EXPANSION 1 50 V3173821 ALTERNATOR 12 VDC 1 51 V978207 V-BELT, ALTERNATOR 1 52 V3832674 STARTER MOTOR 1 53 V3828964 FAN 1 54 V3828041 V-BELT, MAIN 1 56 V8149186 THERMOSTAT 1 57 V1544710 SEALING RING 1 58 V8170514 GASKET 2 59 V8170312 WATER PUMP COMPLETE 1 60 V925255 O-RING 1 61 V20374281 SENSOR, COOLANT TEMP. 1 62 V949656 O-RING, SENSOR, COOLANT TEMP. 1 63 V1077574 SENSOR OIL, PRESSURE & TEMP. 1 64 V968559 O-RING, SENSOR OIL, PRESSURE & TEMP. 1 65 V20424056 FUEL PRESSURE MONITOR 1 66 V947622 GASKET, FUEL PRESSURE MONITOR 1 67 V862154 SENSOR,TEMPERATURE COOLANT-WATER 1 68 V11998 GASKET, TEMP, COOLANT-WATER 1 69 V862627 SENSOR, OIL TEMPERATURE 1 70 V11998 GASKET, OIL TEMPERATURE 1 71 V866835 SENSOR, PRESSURE 1 72 V862251 SENSOR, TACHOMETER 1 73 V948884 WASHER 1 74 V8140024 SENSOR, LEVEL 1 75 V888301 RADIATOR 1

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 71

OUTPUT TERMINAL ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-400SSV— OUTPUT TERMINAL ASSY.

PAGE 72 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8221860203 SET BOARD, OUTPUT TERMINAL 1 2 0801830404 OUTPUT TERMINAL 8 3 0801830904 HEX, HEAD BOLT 8 4 0039320000 HEX, NUT 16 5 0040020000 SPRING WASHER 24 6 0041420000 PLAIN WASHER 32 7 3501860604 TERMINAL PLATE 3 8 0019110050 HEX, HEAD BOLT 5 8A 0042310000 SPRING WASHER 5 8B 0042410000 PLAIN WASHER 5 9 0601808803 CIRCUIT BREAKER, 20A 2 10 0601808804 CIRCUIT BREAKER, 50A 3 11 C3261600704 BRACKET, CIRCUIT BREAKER 1 11-1 0221200150 RUBBER CUSHION 1 12 0017106020 HEX, HEAD BOLT 2 13 0601812598 RECEPTACLE, GF-530EM 2 14 0601812565 RECEPTACLE, CS-6369 3 15 0027104016 MACHINE SCREW 10 15A 0030004000 HEX, NUT 10 15B 0041204000 PLAIN WASHER 10 16 C3238100003 COVER, OUTPUT TERMINAL 1 17 0019112045 HEX, HEAD BOLT 2 18 0042412000 PLAIN WASHER 2 19 0805015604 STAY RUBBER 2 20 0205012000 HEX, NUT 2 21 0845043704 SPRING 2 22 C3237100404 COVER 1 23 0017108020 HEX, HEAD BOLT 7 24 C0237101504 COVER, OUTPUT TERMINAL 1 25 0017110040 HEX, HEAD BOLT 2 26 0845054204 COLLAR 2 27 0805015604 STAY RUBBER 1 28 0601815324 TERMINAL BOARD 1 29 0027104020 MACHINE SCREW 2 30 0601850275 GROMMET 1 31 0601851780 GROMMET 2 32 C2237101504 COVER 1 33 C2237400104 BRACKET 1 34 0017106020 HEX, HEAD BOLT 2

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 73

BATTERY ASSY.

DCA-400SSV— BATTERY ASSY.

PAGE 74 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0168614551 BATTERY 2 2 0805000804 BATTERY SHEET 2 3 3972250004 BATTERY BAND 1 4 0805002904 BATTERY BOLT 2 5 0037808000 WING NUT 2 6 0040008000 SPRING WASHER 2 7 0041208000 PLAIN WASHER 2 8 E6348600304 BATTERY CABLE 1 9 C3347601704 BATTERY CABLE 1 10 C3347601504 BATTERY CABLE 1 11 C3347200304 BATTERY CABLE 1 12 C3347200204 EARTH CABLE 1 13 0347010030 HEX, HEAD BOLT 4 14 0208110000 HEX, NUT 4 15 0845040414 TERMINAL CAP(+) 2 16 0845041304 TERMINAL CAP(-)

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 75

MUFFLER ASSY.

DCA-400SSV— MUFFLER ASSY.

PAGE 76 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3331100502 MUFFLER 1 2 0019210025 HEX, HEAD BOLT 4 3 C3334000703 EXHAUST PIPE 1 4 C3334000803 EXHAUST PIPE 1 5 0602325085 SEAL CLAMP 1 6 C3334200804 GASKET 1 7 0010316070 HEX, HEAD BOLT 4 7A 0030316000 HEX, NUT 4 7B 0042516000 SPRING WASHER 4 7C 0041216000 PLAIN WASHER 8 8 C3331300404 COVER 1 9 C3331300504 COVER 1 10 0019208020 HEX, HEAD BOLT 4 11 C3484100014 COVER 1 12 0010310025 HEX, HEAD BOLT 4 12A 0042510000 SPRING WASHER 4 12B 0041210000 PLAIN WASHER 4 13 0010310030 HEX, HEAD BOLT 3 13A 0042510000 SPRING WASHER 3 13B 0041210000 PLAIN WASHER 3

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 77

FUEL TANK ASSY.

DCA-400SSV— FUEL TANK ASSY.

PAGE 78 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3364001703 FUEL TANK 1 1-1 0605505005 CAP, FUEL TANK 1 1-1A 0601850505 KEY 1 1-2 0810105400 FUEL FILTER 1 1-3 0264100425 HOSE, FUEL GAUGE 1 1-4 0605515079 HOSE BAND 2 2 0605503020 FUEL SENSOR 1 3 0802120604 PACKING 1 4 0605501050 UNIT, FUEL 1 5 0602021155 PACKING 1 6 0022905015 MACHINE SCREW 5 7 8225523104 TANK BAND 2 8 0805003414 PAD, TANK BAND 4 9 0017108020 HEX, HEAD BOLT 2 10 0207308000 HEX, NUT 2 11 0222100300 TANK SHEET 6 12 0130206000 STREET ELBOW, 1/2” 1 13 3515512014 DRAIN PIPE 1 14 0603325011 VALVE, 1/2” 1 15 0132006000 PLUG, 1/2” 1 16 0845039604 RUBBER SEAL 1 17 C3367200204 JOINT PIPE 1

18 V956984 NUT ........................................................... 1 ................REPLACES P/N 0603303070

19 V980782 SLEEVE 1 REPLACES P/N 0603302070 20 C3367300104 JOINT PIPE 1

21 V956983 NUT ........................................................... 1 ................REPLACES P/N 0603303071

22 V956969 SLEEVE .................................................... 1 ................REPLACES P/N 0603302071

23 0191403650 SUCTION HOSE 1 24 0191303950 RETURN HOSE 1 25 0605515132 HOSE BAND 2 26 0605515121 HOSE BAND 2

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 79

ENCLOSURE #1 ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

DCA-400SSV— ENCLOSURE #1 ASSY.

PAGE 80 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3414002802 BASE 1 2 C3414100104 CAP, FUEL TANK 1 3 C3414100704 FLOOR PANEL 1 4 C3414100604 FLOOR PANEL 1 5 0019208020 HEX, HEAD BOLT 26 6 C3424001204 FRONT FRAME 1 6A C3494102103 LINING 1 7 C3424002713 FRONT FRAME 1 7A C3494102103 LINING 1 8 C3424002802 FRONT FRAME 1 8A C3494102103 LINING 1 9 C3424002902 FRONT FRAME 1 9A C3494102103 LINING 1 10 0019208020 HEX, HEAD BOLT 20 11 C3424300803 GUIDE PANEL, AIR 1 11A C3494102103 LINING 1 12 C3424300303 GUIDE PANEL, AIR 1 12A C3494102103 LINING 1 13 0019208020 HEX, HEAD BOLT 24 14 0019210025 HEX, HEAD BOLT 8 15 C3424201403 COVER, FRONT FRAME 1 16 C3424202504 COVER, FRONT FRAME 1 16A C3494102404 LINING 1 17 0845042703 FILLER BRACKET 1 18 0019208020 HEX, HEAD BOLT 4 19 0019208020 HEX, HEAD BOLT 28 20 C3424202603 COVER, FROM FRAME 1 21 0019208020 HEX, HEAD BOLT 14 22 C3434001002 CENTER FRAME 1 23 0010120070 HEX, HEAD BOLT 4 23A 0030020000 HEX, NUT 4 23B 0040020000 SPRING WASHER 4 23C 0041220000 PLAIN WASHER 8 24 0010120060 HEX, HEAD BOLT 8 24A 0030020000 HEX, NUT 8 24B 0040020000 SPRING WASHER 8 24C 0041220000 PLAIN WASHER 16 25 C3464100802 ROOF PANEL 1 25A C3494501604 LINING 1 26 0800251701 FILLER COVER 1 27 0025006016 MACHINE SCREW 2 27A 0042306000 SPRING WASHER 2 27B 0042406000 PLAIN WASHER 2 28 0019208020 HEX, HEAD BOLT 20 29 C3464501504 GUTTER 2 30 0019208020 HEX, HEAD BOLT 2 31 0600500090 EMBLEM 1 32 0021106016 MACHINE SCREW 2

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 81

ENCLOSURE #1 ASSY.

DCA-400SSV— ENCLOSURE #2 ASSY.

ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT:

1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 82 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— ENCLOSURE #2 ASSY.

ENCLOSURE #1 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3444002203 REAR FRAME 1 2 8195151204 LOUVER PANEL 1 3 C3454700104 LOUVER PANEL 2 4 8175151204 LOUVER PANEL 1 5 0207006000 HEX, NUT 22 6 C3444001702 REAR FRAME 1 6A 8225940104 LINING 1 7 0017108020 HEX, HEAD BOLT 11 8 0019210025 HEX, HEAD BOLT 4 9 0017110025 HEX, HEAD BOLT 3 10 C3444302203 COVER, REAR FRAME 1 10A C3494302004 LINING 1 11 8195151004 LOUVER PANEL 3 12 0207006000 HEX, NUT 18 13 C3444302104 DUCT COVER 1 13A C3491400004 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 0021806015 MACHINE SCREW 4 23A 0030006000 HEX, NUT 4 24 8225146204 DOOR ROD 1 25 8225146304 DOOR ROD 1

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 83

ENCLOSURE #2 ASSY. (CONT.)

DCA-400SSV— ENCLOSURE #2 ASSY. (CONT.)

PAGE 84 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— ENCLOSURE #2 ASSY. (CONT.)

ENCLOSURE #2 ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

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 0845047104 HINGE 2 31A 0845045004 WASHER 2 32 0845047204 HINGE 2 32A 0845045004 WASHER 2 33 0019208020 HEX, HEAD BOLT 6 34 0601850097 STOPPER 2 35 0025408025 MACHINE SCREW 2 36 0845031504 CAP 4 37 C3464200702 ROOF PANEL 1 37A C3494501304 LINING 1 38 C3464501204 COVER, ROOF PANEL 1 38A C3494501404 LINING 1 39 0017108020 HEX, HEAD BOLT 15 40 C3374200003 COVER, AIR CLEANER 1 41 0017108020 HEX, HEAD BOLT 6 42 0019208020 HEX, HEAD BOLT 20 43 0019210025 HEX, HEAD BOLT 4 44 C3464501604 GUTTER 2 45 0019208020 HEX, HEAD BOLT 2 46 0600500090 EMBLEM 1 47 0021106016 MACHINE SCREW 2

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 85

ENCLOSURE #3 ASSY.

DCA-400SSV— ENCLOSURE #3 ASSY.

PAGE 86 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— ENCLOSURE #3 ASSY.

ENCLOSURE #3 ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C3454202902 SPLASHER PANEL 4 2 0019108065 HEX, HEAD BOLT 6 2A 0042308000 SPRING WASHER 6 2B 0042408000 PLAIN WASHER 6 3 C3454102603 SIDE PANEL 1 3A C3494409304 LINING 1 4 C3454102703 SIDE PANEL 1 4A C3494409404 LINING 1 5 C3454700604 LOUVER PANEL 2 6 C3454303604 DUCT 2 6A C3494410504 LINING 2 7 C3454700504 LOUVER PANEL 1 8 C3454303704 DUCT 1 8A C3494410604 LINING 1 9 0207006000 HEX, NUT 23 10 0019108065 HEX, HEAD BOLT 3 10A 0042308000 SPRING WASHER 3 10B 0042408000 PLAIN WASHER 3 11 0019108055 HEX, HEAD BOLT 1 11A 0042308000 SPRING WASHER 1 11B 0042408000 PLAIN WASHER 1 12 C3454004903 SIDE DOOR 1 12A C3494409604 LINING 1 13 C3454005003 SIDE DOOR 1 13A C3494409704 LINING 1 14 C3454005103 SIDE DOOR 1 14A C3494410004 LINING 1 15 C3454005203 SIDE DOOR 1 15A C3494402704 LINING 1

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 87

ENCLOSURE #2 ASSY. (CONT.)

DCA-400SSV— ENCLOSURE #3 ASSY. (CONT)

PAGE 88 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— ENCLOSURE #3 ASSY. (CONT)

ENCLOSURE #2 ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

16 8195151004 LOUVER PANEL 4 17 3875151304 LOUVER PANEL 1 18 0207006000 HEX, NUT 30 19 C3454303104 DUCT 1 19A C3494409804 LINING 1 20 C3454303204 DUCT 1 20A C3494409904 LINING 1 21 C3454303304 DUCT 1 21A C3494410304 LINING 1 22 C3454303404 DUCT 1 22A C3494410404 LINING 1 23 C3454303504 DUCT 1 23A C3494410104 LINING 1 24 0207006000 HEX, NUT 36 25 B9114000002 DOOR HANDLE 4 26 0825007362 DOOR HANDLE 3 27 0021806015 MACHINE SCREW 16 27A 0030006000 HEX, NUT 16 28 0845046904 HINGE 8 28A 0845045004 WASHER 8 29 0845047004 HINGE 8 29A 0845045004 WASHER 8 30 0019208020 HEX, HEAD BOLT 38 31 0601850097 STOPPER 10 32 0025408025 MACHINE SCREW 10 33 0845031504 CAP 16 34 0021806015 MACHINE SCREW 12

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 89

RUBBER SEALS ASSY.

DCA-400SSV— RUBBER SEALS ASSY.

PAGE 90 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0228901390 RUBBER SEAL 6 2 0228901075 RUBBER SEAL 4 3 0228900825 RUBBER SEAL 4 4 0228901410 RUBBER SEAL 1 5 0228800445 RUBBER SEAL 4 6 0228900790 RUBBER SEAL 2 7 0228900810 RUBBER SEAL 1 8 0229201400 RUBBER SEAL 4 9 0229201340 RUBBER SEAL 1 10 0221200795 RUBBER SEAL 2 11 0228801240 RUBBER SEAL 2 12 0228100120 RUBBER SEAL 4 13 0228100510 RUBBER SEAL 4

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 91

NAMEPLATE AND DECALS ASSY.

DCA-400SSV— NAMEPLATE AND DECALS ASSY.

PAGE 92 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— NAMEPLATE AND DECALS ASSY.

NAME PLATE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1-1 C3551002303 DECAL; HANDLING PROCEDURES....................................... 1 ..... C35100230

1-2 C9522100003 DECAL; CAUTION ................................................................... 2 ..... C92210000

CONTROL BOX GROUP

2-1 0800520100 PLATE: ON-OFF ...................................................................... 1 ..... AT-202

2-2 0800520904 PLATE; AMMETER CHANGE-OVER SWITCH ....................... 1 ..... N-2438

2-3 0800520814 PLATE; VOLTMETER CHANGE-OVER SWITCH .................... 1 ..... N-2439

2-4 0840624504 DECAL; CIRCUIT BREAKER .................................................. 1 ..... S-3031

2-5 0840624604 DECAL; PANEL LIGHT SWITCH ............................................. 1 ..... S-3032

2-6 0840624704 DECAL; PILOT LAMP.............................................................. 1 ..... S-3033

2-7 0840624804 DECAL; VOLTAGE REGULATOR ............................................. 1 ..... S-3034

2-8 B9531100604 DECAL; WARNING ELECTRIC SHOCK HAZARD .................. 1 ..... B93110060

2-9 C0551000903 DECAL; SETTING FOR OUTPUT VOLTAGE .......................... 1 ..... C05100090

2-10 C2551000004 DECAL; SAFETY INSTRUCTION ............................................ 1 ..... C25100000

2-11 C3551001004 DECAL; DIAGNOSTIC LAMP.................................................. 1 ..... C35100100

2-12 C3561101803 DECAL; WHISPERWATT 400 .................................................. 1 ..... C36110180

2-13 C9502400004 DECAL; HIGH IDLE SPEED ................................................... 1 ..... C90240000

2-14 Z0110001504 DECAL; RESET ....................................................................... 1 ..... Z01000150

ENGINE & RADIATOR GROUP

3-1 1320610603 DECAL; WATER - OIL .............................................................. 1 ..... S-1760

3-2 6360610304 DECAL; WATER ....................................................................... 1 ..... S-1880

3-3 6360620204 DECAL; OIL DRAIN PLUG ...................................................... 1 ..... S-1885

3-4 B9504000304 DECAL; CAUTION HOT PARTS .............................................. 1 ..... B90400030

3-5 B9504000404 DECAL; WARNING MOVING PARTS ...................................... 2 ..... B90400040

3-6 B9504100104 DECAL; WARNING HOT COOLANT ........................................ 1 ..... B90410010

3-7 C3551001303 DECAL; AIR BLEEDING PROCEDURE .................................. 1 ..... C35100130

3-8 C3551002704 DECAL; COOLING WATER DRAIN PLUG ............................... 1 ..... C35100270

ENGINE OPERATING PANEL GROUP

4-1 C0551000504 DECAL; BATTERY SWITCH.................................................... 1 ..... C05100050

4-2 C3551002504 DECAL; ALARM LAMP ........................................................... 1 ..... C35100250

4-3 C3551002604 DECAL; OPERATING PANEL .................................................. 1 ..... C35100260

OUTPUT TERMINAL GROUP

5-1 0840614104 DECAL; GROUND ................................................................... 1 ..... S-2635

5-2 0840619904 DECAL; DANGER HIGH VOLTAGE ......................................... 1 ..... S-2731

5-3 9039209064 DECAL; START CONTACT ...................................................... 1 ..... S-4468

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 93

PAGE 94 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

DCA-400SSV— NAMEPLATE AND DECALS ASSY.

NAME PLATE AND DECALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

5-4 B9511100304 DECAL; WARNING .............................................................. 1 ......... B91110030

5-5 B9511100404 DECAL; WARNING ELECTRIC SHOCK HAZARD .............. 1 ......... B91110040

5-6 B9531100504 DECAL; WARNING ELECTRIC SHOCK HAZARD .............. 1 ......... B93110050

5-7 C0551000404 DECAL; 3-PHASE OUTPUT TERMINAL ............................. 1 ......... C05100040

5-8 C1551000803 DECAL; RECEPTACLE & CIRCUIT BREAKER .................. 1 ......... C15100080

BATTERY GROUP

6-1 0800689404 DECAL; + ............................................................................ 1 ......... S-2090

6-2 0800689504 DECAL; - ............................................................................. 1 ......... S-2091

6-3 C9505300004 DECAL; CAUTION ............................................................... 1 ......... C90530000

MUFFLER GROUP

7-1 B9504200004 DECAL; WARNING ENGINE EXHAUST .............................. 1 ......... B90420000

FUEL TANK GROUP

8-1 1320620904 DECAL; DIESEL FUEL ........................................................ 1 ......... S-1756

8-2 6360620004 DECAL; FUEL DRAIN PLUG ............................................... 1 ......... S-1883

8-3 B9504500004 DECAL; WARNING DIESEL FUEL ...................................... 1 ......... B90450000

BONNET GROUP

9-1 1320621504 DECAL; SUPPORT HOOK .................................................. 2 ......... S-2257

9-2 0840625902 DECAL; MQ ......................................................................... 1 ......... S-3057

9-3 C3561101003 STRIPE 1 9-4 C3561101703 STRIPE 1 9-5 C3561101503 STRIPE 2 9-6 C3561100803 STRIPE 1 9-7 C3561100104 STRIPE 2 9-8 C3561101603 STRIPE 1 9-9 C3561100203 STRIPE 1

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 95

Effective: October 1, 2002

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1. A Returned Material Authorization must be approved by Multiquip prior to shipment.

2. To obtain a Return Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The par ts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and

phone number of the person requesting the RMA.

3. A copy of the Return Material Authorization must accompany the return shipment.

4. Freight is at the sender’s expense. All parts must be returned freight prepaid to Multiquip’s designated receiving point.

5. Parts must be in new and resalable con-

6. The following items are not returnable:

7. The sender will be notified of any

8. Such material will be held for five

9. Credit on returned parts will be issued at

10. In cases where an item is accepted, for

11. Credit issued will be applied to future

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates

for price declines and added charges for price dition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

a. Obsolete parts. (If an item is in the

price book and shows as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber par ts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00.

d. Special order items.

e. Electrical components.

f. Paint, chemicals, and lubricants. g. Decals and paper products.

h. Items purchased in kits.

material received that is not acceptable.

working days from notification, pending instructions. If a reply is not received within five days, the material will be returned to the sender at his expense.

dealer net price at time of the original purchase, less a 15% restocking charge.

which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

purchases only.

increases will not be made for stock on hand at

the time of any price change.

Multiquip reserves the right to quote and sell

direct to Government agencies, and to Original

Equipment Manufacturer accounts who use

our products as integral parts of their own

products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice

for special handling including bus shipments,

insured parcel post or in cases where Multiquip

must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for

damages in excess of the purchase price of the

item with respect to which damages are claimed,

and in no event shall Multiquip be liable for loss

of profit or good will or for any other special,

consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in

connection with the sale of parts or trade

accessories nor as to any engine not manufac-

tured by Multiquip. Such warranties made in

connection with the sale of new, complete units

are made exclusively by a statement of war-

ranty packaged with such units, and Multiquip

neither assumes not authorizes any person to

assume for it any other obligation or liability

whatever in connection with the sale of its

products. Apart from such written statement of

warranty, there are no warranties, express,

implied or statutory, which extend beyond the

description of the products on the face hereof.

PAGE 96 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)

NOTE PAGE

DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06) — PAGE 97

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MQ POWER CORPORATE OFFICE

18910 Wilmington Ave. 800-421-1244 Carson, CA 90746 Email: mqpower@multiquip.com Internet: www.mqpower.com

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-835-2551 310-537-3700

TECHNICAL ASSISTANCE

800-835-2551

WARRANTY DEPARTMENT

800-835-2551, 310-537-3700,

ON-HAND

EXT.

279

EXT.

279

WHEN CALLING

FAX:

310-632-2656

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-638-8046

FAX:

310-638-8046

FAX:

310-638-8046

Your Local Dealer is:

Manufactured for Multiquip Inc.

DENYO CO., LTD, JAPAN

MQ POWER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-632-2656 E-mail: mqpower@multiquip.com Internet: www.mqpower.com

Multiquip DCA-400SSV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual