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MULTIQUIP DCA-400SSV Specifications

1. HH 20 wo PHA a REPLACES 0601850505 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 97 DCA 400SSK ENCLOSURE 2 ASSY ENCLOSURE 2 ASSY PAGE 98 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK ENCLOSURE 2 ASSY ENCLOSURE 2 ASSY NO PART NO PART NAME QTY REMARKS 37 0600500090 EMBLEM 1 38 0021106020 MACHINE SCREW 2 39 C3464200102 ROOF PANEL 1 C3494500204 LINING 1 40 C3464500304 COVER ROOF PANEL 1 C3494500304 LINING 1 41 0017108020 HEX HEAD BOLT 9 42 0019208020 HEX HEAD BOLT 24 43 0019210025 HEX HEAD BOLT 4 44 C3464501104 BRACKET ET 5 3707481 THE DEFAULT PART NUMBER FOR THE COLOR ORANGE PLEASE INDICATE COLOR WHEN ORDERING MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 99 DCA 400SSK ENCLOSURE 3 ASSY ENCLOSURE 3 ASSY THE DEFAULT PART NUMBER FOR THE COLOR ORANGE PLEASE INDICATE COLOR WHEN ORDERING MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED PAGE 100 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK ENCLOSURE 3 ASSY ENCLOSURE 3 ASSY NO PART NO PART NAME QTY REMARKS 1 C3454201022 SPLASHER PANEL ee 5
2. Last REPLACES 0602010900 34 C3317100103 BRACKET RESERVE TANK 1 35 0199101150 HOSE 1 36 0193601500 HOSE 1 37 0605515013 HOSE BAND 2 38 0194700400 HOSE 1 39 0194700450 HOSE 1 40 0268500950 HOSE 1 41 0605515074 HOSE BAND 2 42 C3327200004 HOSE CLAMPER 1 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 77 DCA 400SSK ENGINE amp RADIATOR ASSY ENGINE amp RADIATOR ASS 07 49 RI 20 M acl qi filer 1 aM d m My ee PAGE 78 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK ENGINE amp RADIATOR ASSY ENGINE amp RADIATOR ASSY NO PART PART NAME QTY REMARKS 43 8212044103 OIL PANEL 1 44 0017110025 HEX HEAD BOLT 2 45 C3358300204 CLAMPER ROD 1 46 0017110025 HEX HEAD BOLT 2 47 8212256104 CLAMPER ROD 1 48 0019208020 HEX HEAD BOLT 2 49 8215103504 RUBBER SEAL 1 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 79 DCA 400SSKENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY PAGE 80 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY NO PARTNO PART NAME QTY REMARKS 1 C3353100003 OPERATING PANEL Toss S N3692434 TO 3696509 C2352100213
3. v fol OIL PRESS Low Battery Fluid Lamp This lamp goes ON when the battery fluid is low Ifthis lamp goes ON during normal operation of the generator stop the engine and fill the battery with distilled water to the specified level 1 m lt m LOW LEVEL Clogged Air Filter Lamp This lamp goes ON when the air filter is clogged If this lamp goes ON during normal operation of the generator stop the engine and replace the air filter e AIR FILTER 4 Emergency Stop Button Push this Ignition Switch up to S N3696509 Oil Pressure Gauge During normal operation this gauge be should read between 42 71 psi When starting the generator the oil pressure mar read a little bit higher but after the engine warms up the oil pressure should return to normal Water Temperature Gauge During normal operation this gauge be should read between 165 203 F 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 Fuel Gauge Indicates amount of diesel fuel available Pre Heat Lamp Indicates that the glow plugs of the diesel engine are hot and the engine is ready to be started PRE HEAT LAMP Pre Heat Lamp Press and hold this button until the preheat lamp is lit ON button inward to stop the engine in the event of an emergen
4. 0601810261 BULB PILOT LAMP EE 2016012191 RADIATOR NE 0602122200 UNIT OIL PRESSURE Vu 0602123206 UNIT WATER TEMPERATURE 0602121052 CHARGING AMMETER NOTE Part number on this Suggested Spare Parts list may supercede replace the P N shown in the text pages of this book DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 67 40055 GENERATOR ASSY DCA GENERATOR ASSY 5 cp gt oc 1 am HL lt 5 z lt z lt CC TT an N lt a x 77 N T lt a amp DCA 400SSK GENERATOR ASSY GENERATOR ASSY NO PART NO C3110100202 0601842401 0601823282 0018205020 0040005000 0041205000 8201070002 8201611004 C3164200004 8201015003 0012116045 0042616000 0601000209 C3112500004 0071906315 8201614003 0012116040 0042516000 0012112040 0042512000 C3130100003 0226200495 8211323004 0223300172 8211323103 0221200440 0010110035 0041210000 C3132200003 0226000290 0225000590 0017106020 0601850144 C3154000002 C3138000003 0012110080 0042610000 0041210000 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 69 PART NAME ROTOR ASSY FIELD ASSY RESISTOR 80W RECTIFIER HEX SOCKET HEAD CAP SCREW LOCK WASHER PLAIN WASHER FAN COUPLING DISK WASHER COUPLIN
5. When connecting a fluorescent or mercury lamp a capacity of up to the generating set s rated output KW multiplied by 0 6 can be used When connecting an electric drill or other power tools pay close attention to the required starting current capacity When connecting ordinary power tools a capacity of up to the generating set s rated output KW multiplied by 0 8 can be used CAUTION Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch Serious injury or death may result without this transfer switch NOTE If output KVA is not given on the equipment nameplate approximate output may be determined by multiplying voltage by amperage by and 1 732 PAGE 46 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK GENERATOR START UP PROCEDURE MANUAL WARNING The engine s exhaust contains harmful emissions ALWAYS ventilate the exhaust when operating inside tunnels excavations or buildings Direct exhaust away from nearby personnel Before Starting Engine 1 Check the lubricating oil level prior to starting the engine Make sure the generator is level The oil level must be maintained between two notches on the dipstick 2 When there is not enough lubricating oil fill the crankcase with high grade motor oil Use a high quality detergent oil classified CC or higher See Tab
6. High Voltage Output Is wiring connections 100567 Check wiring and repair Defective AVR Replace if necessary Circuit Breaker Tripped Short Circuit in load Check load and repair Over current Confirm load requirements and reduce Defective circuit breaker Check and replace Over current Relay actuated Confirm load requirement and replace PAGE 64 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK TROUBLESHOOTING Engine Controller TABLE 18 ENGINE CONTROLLER TROUBLESHOOTING Posete Cause Low oil pressure light is Low oil Low olee Fill level temperture light is on DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 65 EXPLANATION OF CODE IN REMARKS COLUMN How to read the marks and remarks used in this parts book Items Found In the Remarks Column Serial Numbers Where indicated this indicates a serial number range inclusive where a particular part is used Model Number Where indicated this shows that the corresponding part is utilized only with this specific model number or model number variant Items Found In the Items Number Column All parts with same symbol the number column or belong to the same assembly or kit Note If more than one of the same reference number is listed the last one listed indicates newest or latest part
7. 00 100 mm CODE WIRE COLOR 2 Qo 38 38mm B BLACK RED 410 6 WHITE 14 14mm BR BROWN Y YELLOW LIGHT BLUE LIGHT GREEN MARK v VIOLET o 1 25 mm ORANGE PAGE 60 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK ENGINE WIRING DIAGRAM CONTROLLER B AUTO MANUAL ee CHANGE OVER SW R 4 2114 5 ap TERMINAL DEA 02 BLOCK2 AE HEATER RELAY sys CONNECTOR EMERGENCY 5 5 Y View from inserting wire side d STOP BUTTON eus BUTTON d AIR HEATER p Te R STOP SOLENOID gt ENGINE STOP UNIT SENSOR MI H p LJ 5 gt G 2 1 STARTER R B 3 314 ALTERNATOR 5 5151 ao 2 gt 49 e 100 100 100 EEE ua 718 718 3 BATTERY T BATTERY SENSOR O UNIT BATTERY 1 WIRE SIZE HE J R B TO EVE oL TB 2 ACC DCA 220 300SSK 14 G A A OIL FILTER DCA 400SSK 22 BATTERY SW WATER OIL SENSOR TEMP PRESS sw SW BRIW BR W TOTB2 ACC FUEL SENSOR COLOR CODE TABLE RELAY INSIDE CONNECTION WIRE SIZE TABLE RED _______ 5 BRI BROWN YELLOW 4 7 v VIOLET O ORANGE I 49 Wx _______ DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 1
8. 1 S N3701677 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 87 DCA 400SSK MUFFLER ASSY MUFFLER ASSY PAGE 88 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK MUFFLER ASSY MUFFLER ASSY NO PART NO CO 11 13 14 15 C3331100102 0019210020 C3334200204 C3334200504 C3334200604 0019210025 C3334000103 0602320195 0010316080 0030316000 0042516000 0041616000 0010316050 0042516000 0041616000 8212355003 7432356104 0019112045 0030012000 0042312000 0042412000 8225125604 0019108020 0207008000 0042308000 0042408000 0019110030 0042310000 0042410000 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 89 PART NAME MUFFLER HEX HEAD BOLT PACKING PACKING PACKING HEX HEAD BOLT EXHAUST PIPE GASKET HEX HEAD BOLT HEX NUT LOCK WASHER PLAIN WASHER HEX HEAD BOLT LOCK WASHER PLAIN WASHER OUTLET PIPE GASKET HEX HEAD BOLT HEX NUT LOCK WASHER PLAIN WASHER COVER HEX HEAD BOLT HEX NUT LOCK WASHER PLAIN WASHER HEX HEAD BOLT LOCK WASHER PLAIN WASHER REMARKS DCA 400SSK FUEL TANK ASSY FUEL TANK ASSY PAGE 90 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK FUELTANK ASSY FUEL TANK ASSY NO PART NO PART NAME QTY REMARKS 1 C336400
9. oc 1 am HL lt 5 z lt z lt CC TT an N lt a x 77 N T lt a amp DCA 400SSK OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY NO PART QTY REMARKS 1 8221860203 SET BOARD OUTPUT TERMINAL 1 2 0801030404 OUTPUT TERMINAL 8 3 0801830904 HEX HEAD BOLT 8 4 0039320000 HEX NUT 16 5 0040020000 LOCK WASHER 24 6 0041420000 PLAIN WASHER 32 7 3501860604 TERMINAL PLATE 3 8 0019110050 HEX HEAD BOLT 5 0042310000 LOCK WASHER 5 0042410000 PLAIN WASHER 5 9 0601804887 CIRCUIT BREAKER ee 5 3692434 3606720 KM 51 265V 20 REPLACES 0601805313 0601808803 CIRCUIT BREAKER ee 5 3606721 QOU120B 20A 10 0601805840 CIRCUIT BREAKER SIN 3692434 TO 3606720 52 265V 50 0601808804 CIRCUIT BREAKER Mint S N3606721 QOU250B 50A 11 C1261600204 BRACKET CIRCUIT BREAKER RENEE SIN 3692434 TO 3606720 C3261600704 BRACKET CIRCUIT BREAKER Pinters S N3606721 12 0223300200 RUBBER CUSHION 5 3692434 3606720 0221200150 RUBBER CUSHION Vitner S N3606721 13 0017106020 HEX HEAD BOLT 2 14 0601812598 RECEPTACLE 2 15 0601811034 HEGER TAG LE ae Sin REPLACES 0601812565 16 0027104016 MACHINE SCREW 10 0030004000 HEX NUT 10 0041204000 PLAIN WASHER 10 17 C3237100113 COVER OUTPUT TERMINAL 1
10. 91110030 DECAL WARNING ee Pa B91110040 DECAL WARNING ER B93110050 DECAL 3 PHASE OUTPUT TERMINAL Tuis C05100040 DECAL START CONTACT pe LEE S N3696510 54468 BATTERY GROUP DEGAS 5 2090 DECAL vadet Tamni S 2091 DECAL CAUTION ua sanden T esae C90530000 MUFFLER GROUP DECAL WARNING EE B90420000 DECAL CAUTION 891110020 FUEL TANK GROUP DECAL DIESEL FUEL Pans 5 1756 DECAL FUEL DRAIN PLUG 5 1883 DEGAE WARNING B90450000 BONNET GROUP DECAL WATER 5 1760 DECAL SUPPORT 5 2257 pistor d S 3057 DECAL CAUTION pp 890400030 STRIPE 1 STRIPE 1 STRIPE 2 STRIPE 1 STRIPE 2 STRIPE 1 STRIPE 1 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 111 Effective July 1 2000 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 addedto the invoice All shipments are F O B point of origin Multiquip s responsibility ceases whena signed manifest has been obtained from the carrier and any claim for shortage or damage mustbe settled betweenthe consignee and the carrier MINIMUM ORDER The minimum charge
11. NOTE PAGE DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 53 DCA 400SSK MAINTENANCE General Inspection Prior to each use the generating set should be cleaned and inspected for deficiencies Check for loose missing or damaged nuts bolts or other fasteners Also check for fuel or oil leaks Air Cleaner Every 50 hours If dust indicator is red clean the air cleaner element Outer Element 1 Loosen wing bolt remove dust cup then remove wing nut and take out element 2 Clean the inside of the body and cover using a damp cloth 3 Blow dry with compressed air 0 69Mpa 7kgf cm 99 4 PSI maximum against the side of the element along the pleats Then blow dry against outside along the pleats then against inside again 4 Remove one seal each time the element is cleaned 5 Replace the outer element after cleaning it 6 times or after one year Replace the outer element if indicator is red even after cleaning it 6 Check the inner cylinder element clamping nut for looseness and retighten if necessary 7 fseal washer is damaged or the threads of wing nut are damaged replace 8 Remove evacuator valve and clean it with compressed air Reinstall Inner element if equipped 1 Remove the cover and outer element then remove the inner element 2 Cover the air connector opening outer side
12. COPYRIGHT 2001 MULTIQUIP ING PARTS AND OPERATION MANUAL MQ POWER DCA 400SSK DCA 400SSK2 WHISPERWATT GENERATOR STANDARD PARTS LIST NO C3875300104B S N UP TO 3701676 400SSK S N3101677 400SSK2 Revision 3 09 17 01 MULTIQUIP INC PARTS DEPARTMENT 18910 WILMINGTON AVE 800 427 1244 CARSON CALIFORNIA 90746 FAX 800 672 7877 4 310 537 3700 SERVIGE DEPARTMENT 800 421 1244 800 835 2551 FAX 310 537 3927 FAX 310 638 8046 POWER E mail mq multiquip com www multiquip com CALIFORNIA Proposition 65 Warnin Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 HERE S HOW GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SERVICE DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 WARRANTY DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 MAIN 800 421 1244 or 310 537 3700 FAX 310 537 3927 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 3 TABLE OF CONTENTS Here s How To Get Help es 3 Table Of Contents 4 Rules For Safe Operation 6 9 TOWING 10 Trailer Safety
13. VOLTMETER oe RSR80 0 600V 43 0601801041 CHANGE OVER SW VOLTMETER ire SL2VS 44 0601810072 PILOT LAMP LP132DC 220V 0601810261 BULB 1 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 73 7202 M 2 DCA 400SSK CONTROL BOX ASSY CONTROL BOX ASSY E 87 rr gt LU 1 ES lt D lt lt LU a CD lt x CD 72 T lt a lt LU DCA 400SSK CONTROL BOX ASSY CONTROL BOX ASSY NO PARTNO 45 0601840073 46 0601840121 47 0601810161 48 0207004000 49 0601830710 50 C9221100004 0040008000 0041208000 0080200007 51 0017108040 52 3871824004 53 0041206000 54 0605110502 55 8221814804 56 0017108020 57 8224117004 58 0017108020 59 8221827704 60 0017108020 61 0017110035 0207010000 62 0601823861 63 0027104015 64 0601823240 65 0021004030 0040004000 0041204000 66 0601802149 0601802149 0601806671 0601802218 67 0027103020 68 LY2DC24V LY2DDC24V 0601824400 39 0027104020 70 0601823706 71 0027104015 72 0601815402 73 0027104020 74 0601827396 ECU9988N 75 0601831340 0601830765 76 0602120498 0602202470 77 DYN110654000024 78 0027104020 79 0601840009 80 C3262600004 81 0017106015 PART NAME QTY REMARKS R
14. BATTERY CABLE EARTH CABLE HEX HEAD BOLT HEX NUT TERMINAL CAP TERMINAL CAP TERMINAL CAP TERMINAL CAP BATTERY SENSOR QTY 2 2 1 2 2 2 2 1 1 1 1 1 4 4 1 1 1 1 1 REMARKS DCA 400SSK ACTUATOR ASSY ACTUATOR ASSY PAGE 86 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK ACTUATOR ASSY ACTUATOR ASSY NO PART NO PART NAME QTY REMARKS 1 DYNC1 1020300024 ACTUATOR oinnia na 1 SIN3701677 REPLACES 0602150092 2 0602211090 LEVER 1 S N3701677 DYNC182 3 C3356200004 BRACKET ACTUATOR 1 8 3701677 4 0012310060 HEX HEAD BOLT 2 9 N3701677 5 0016006070 HEX SOCKET HEAD CAP SCREW 4 S N3701677 0207006000 HEX NUT n do 4 5 N3701677 0040006000 LOCK WASHER es 4 5 N3701677 0041206000 PLAIN WASHER 4 S IN3701677 6 0602211091 RODi einu 1 S N3701677 7 0602180190 BALL JOINT uidi cat ipod 2 9 N3701677 8 0602210092 HEX NU efl pce perdis 2 S N3701677 9 0010106025 HEX HEAD BOLT 1 S N3701677 0207006000 HEX 1 S N3701677 10 0010106025 HEX HEAD BOLT ir tib oi b 1 8 3701677 0207006000 HEX NUT 1 S N3701677 0041206000 PLAIN WASHER 1 S N3701677 11 012310040 HEX HEAD
15. Excessive valve clearance Adjust Starter does not run Battery discharged Charge battery Starter malfunctioning Repair or replace Key switch malfunctioning Repair or replace Wiring disconnected Connect wiring PAGE 62 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK TROUBLESHOOTING ENGINE TE 16 ENGINE TROUBLESHOOTING CONTINUED TABLE 16 ENGINE TROUBLESHOOTING CONTINUED SYMPTOM POSSIBLE PROBLEM SOLUTION Engine revolution is not smooth Fuel filter clogged or dirty Clean or change Air cleaner clogged Clean or change Fuel leak due to loose injection pipe retaining nut Tighten nut Injection pump malfunctioning Repair or replace Incorrect nozzle opening pressure Adjust Injection nozzle stuck or clogged Repair or replace Fuel over flow pipe clogged Clean Governor malfunctioning Repair Either white or blue exhaust gas is observed Excessive engine oil Reduce to the specified level Piston ring and liner worn or stuck Repair or replace Incorrect injection timing Adjust Deficient compression Adjust top clearance Either black or dark gray exhaust gas is observed Overload Lessen the load Low grade fuel used Use the specified fuel Fuel filter clogged Clean or change
16. STD REV 3 09 17 01 PAGE 15 DCA 400SSK TRAILER SAFETY GUIDELINES Tires Wheels Lug Nuts Tires and wheels are a very important and critical components of the trailer When specifying or replacing the trailer wheels it is important the wheels tires and axle are properly matched GAUTION DO NOT attempt to repair or modify wheel DO NOT install in inner tube to correct leak through the rim If the rim is cracked the air pressure in the inner tube may cause pieces of the rim to explode break off with great force and cause serious eye or bodily injury Tire Wear Inflation Tire inflation pressure is the most important factor in tire life Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot Check inflation pressure weekly during use to insure the maximum tire life and tread wear Table 2 Tire Wear Troubleshooting will help pinpoint the causes and solutions of tire wear problems CAUTION PA 2 ALWAYS wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury TABLE 2 TIRE WEAR TROUBLESHOOTING erten CAUSE sonon Adjust pressure to Center Wear Over Inflation particular load per tire Edge Wear Under Inflation manufacturer Adjust pressure to particular load per tire manufacturer Make sure load does not exceed axle rating Align wheels Side Wear L
17. TACH HOURS Figure 48 Ammeter Load Figure 45 Engine Tachometer 17 The generator will run until manually stopped or an abnormal condition occurs 14 Pull the throttle handle to increase the speed of the engine Figure 46 AN HIGH Figure 46 Engine Throttle 15 Turn the MAIN GFCI and LOAD circuit breakers to their position Figure 47 CIRCUIT BREAKER CIRCUT BREAKER CIRCUIT BREAKER GFCI RECEPTACLE OUTPUT RECEPTACLES AE X Figure 47 Main and GFCI Circuit Breakers PAGE 50 40055 PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK GENERATOR START UP PROCEDURE CONTROLLER Manual Start up 1 Follow instructions as with key switch numbers 1 6 2 Place the Off Manual Auto switch Figure 49 in the MANUAL position Observe that the engine begins to crank AUTO MANUAL OFF RESET Figure 49 Off Manual Auto Switch Manual 3 After engine starts verify that the Engine Running status LED Figure 50 on the Microprocessor Engine Control Module Engine Controller display is ON lit AUTO MANUAL OFF RESET 2 LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING a va POWER Figure 50 Engine Controller Status LED 4 Continue instructions with key switch 8 17 Auto Start up CAUTION Before connecting this generator to any building s electrical system a licensed electr
18. TAILLIGHT 1 LIGHTS ARE ORIENTED FROM THE DRIVER S SEAT PAGE 18 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK TRAILER BRAKE TROUBLESHOOTING Table 5 Electric Brake Troubleshooting Symptom Brake drums scored or grooved Machine or replace Brakes synchronized Correct Locking Brakes Brake components loose bent or Replace components broken Weak Brakes or Brakes Grease or oil on magnets or linings Clean or replace Pull to One Side Connections corroded Clean and correct cause of corrosion DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 19 DCA 400SSK TRAILER BRAKE TROUBLESHOOTING Table 6 Hydraulic Brake Troubleshooting Seton Weak Brakes or Brakes Pull to Dragging Brakes Brake lining thickness correct or in right Install new shoes and wrong position linings Enough brake fluid or correct fluid Replace rubber parts fill with dot4 fluid PAGE 20 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK OPERATION AND SAFETY DECALS Machine Safety Decals The DCA 400SSK generator is equipped with a number of safety decals These decals are provided for operator safety and maintenance information The illustration below and on the preceding pages shows the decals as they appear on the machine Should any of these decals become unreada
19. The following safety guidelines should always be used when operating the DCA 400SSK portable generator GENERAL SAFETY DO NOT operate or service this equipment before reading this entire manual This equipment should not be operated persons under 18 years of age E NEVER operate this equipment without proper protective clothing shatterproof glasses steel toed boots and other protective devices required by the job NEVER operate this equipment when not feeling well due to fatigue illness or taking medicine NEVER operate this equipment under the influence or drugs or alcohol NEVER use accessories or attachments which are not recommended by MQ Power for this equipment Damage to the equipment and or injury to user may result Manufacturer does not assume responsibility for any accident due to equipment modifications E Whenever necessary replace nameplate operation and safety decals when they become difficult read Always check the machine for loosened threads or bolts before starting MNEVER touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or generator E High Temperatures Allow the engine to cool before adding fuel or performing service and maintenance functions Contact with hot components can cause serious burns The engine of this generator requires an adequate free flow of cooling air Never operate the g
20. the generator AUTO MANUAL OFF RESET LOW OIL PRESSURE During cranking cycle The engine controller will attempt to crank the engine for 10 seconds before disengaging HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING POWER igure 9 Engine Controller Module If the engine does not engage start by the third attempt the engine will be shutdown by the engine controller s Over Crank Protection mode If the engine engages at speed RPM s that is not safe the engine controller will shutdown the engine by initializing the Over Speed Protection mode Also the engine controller will shutdown the generator in the event of low oil pressure high coolant temperature low coolant level and loss of magnetic pickup These conditions can be observed by monitoring the LED status indicators on the front of the engine controller module A Switch This switch controls the running of the generator If this switch is left in the OFF position the generator will not run When this switch is set to the manual position the generator will start immediately If the generator is to be connected to a building s AC power source via a transfer switch isolation place the switch in the auto position In this position the generator will monitor the AC line output from the building s power source B Low Oil Pressure Indicates the engine pressure has fallen bel
21. 3692434 5 3696509 C3454201032 SPLASHER PANEL S N3696510 3700679 3454201042 SPLASHER PANEL d aate S N3700680 TO 3706720 C3454202002 SPEASHER PANEL pe 5 3706721 2 0019108065 HEX HEAD BOLT 6 0042308000 LOCK WASHER 6 0042408000 PLAIN WASHER 6 3 C3454101203 SIDE PANEL 1 C3494404704 LINING 1 4 C3454101303 SIDE PANEL 1 C3494404704 LINING 1 5 C3454101903 SIDE PANEL 1 C3494406304 LINING 1 6 C3454100703 SIDE PANEL 1 C3494402204 LINING 1 7 C3454700504 LOUVER PANELL 3 8 C3454301004 DUCT 3 C3494404804 LINING 3 9 0207006000 HEX NUT 27 10 C3454003103 SIDE DOOR 1 C3494406604 LINING 1 11 C3454003003 SIDE DOOR 1 C3494406404 LINING 1 12 C3454002103 SIDE DOOR 1 C3494404504 LINING 1 13 C3454001603 SIDE DOOR 1 C3494402704 LINING 1 14 8195151004 LOUVER PANEL 4 15 8215151004 LOUVER PANEL 1 16 0207006000 HEX NUT 30 17 C3454301403 DUCT 1 C3494406704 LINING 1 18 C3454301304 DUCT 2 3494406504 LINING 2 19 C3454300904 DUCT 1 C3494404604 LINING 1 20 0207006000 HEX NUT 35 21 B9114000002 DOOR HANDLE 3 23 0021806016 MACHINE SCREW 28 0030006000 HEX NUT 16 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 101 DCA 400SSK ENCLOSURE 3 ASSY ENCLOSURE 3 ASSY THE DEFAULT PART NUMBER FOR THE COLOR ORANGE PLEASE INDICATE COLOR WHEN ORDERING MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED PAGE 102 DCA 400SSK PARTS AND O
22. 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 113 PARTS AND OPERATION MANUAL HERE S HOW GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING PARTS DEPARTMENT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SERVICE DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 WARRANTY DEPARTMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 MAIN 800 421 1244 or 310 537 3700 FAX 310 537 3927 Manufactured for Multiquip Inc DENYO MANUFACTURING USA MU LTIQUIP INC POST OFFICE BOX 6254 CARSON CA 90749 lt 310 537 3700 800 421 1244 FAX 310 537 3927 E MAIL multiquip com POWER WWW multiquip com Atlanta Boise Dallas Houston Newark Quebec Canada Manchester UK Rio De Janiero BR Guadalajara MX
23. Air cleaner clogged Clean or change Deficient nozzle injection Repair or replace the nozzle Deficient output Incorrect injection timing Adjust Engine s moving parts seem to be seizing Repair or replace Uneven fuel injection Repair or replace the injection pump Deficient nozzle injection Repair or replace the nozzle Compression leak Replace head gasket tighten cylinder head bolt glow plug and nozzle holder DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 63 DCA 400SSK TROUBLESHOOTING GENERATOR ENGINE Practically all breakdowns can be prevented by proper diagnosis based on the Engine and Radiator Troubleshooting handling and maintenance inspections but in the event ofa Table 17 If the problem cannot be remedied consult our breakdown use the tables shown for company s business office or service plant TABLE 17 GENERATOR TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION No Voltage Output Voltmeter defective Check output voltage using a voltmeter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Low Voltage Output Is engine speed correct Turn engine throttle lever to High Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary
24. Brake Troubleshooting Tables Use the following definitions with reading Table 1 1 Fuel Cell Provides an adequate amount of fuel for the equipment in use Fuel cells must be empty when transporting equipment 2 Braking System System employed in stopping the trailer Typical braking systems are electric surge hy draulic hydraulic surge and air 3 GVWR Gross Vehicle Weight Rating GVWR is the maximum number of pounds the trailer can carry in cluding the fuel cell empty 4 Frame Length This measurement is from the ball hitch to the rear bumper reflector 5 Frame Width This measurement is from fender to fender 6 Jack Stand Trailer support device with maximum pound requirement from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing Usually consists of chains and ball or eye 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and the width in millimeters 175 185 205 etc The tire diameter must match the diameter of the tire rim 9 Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc 10 Wheel Hub The wheel hub is connected to the trailer s axle 11 Tire Rim Tires mounted on a tire rim The tire rim must match the size of the tire 12 Lug Nuts Used to secure the wheel to the wheel hub Always use a torque wrench to tighten down the lug nuts See Table 4 and Figure 5 or lug nut tightening an
25. Control Panel The Engine Control Panel is provided with the following Auto Start Stop Controller S N 3696510 Tachometer Water Temperature Gauge Oil Pressure Gauge Charging Ammeter Gauge Engine Warning Lamp Module Engine Speed Switch S N3701667 Pre Heat Button Pre Heat Lamp Emergency Stop Button Battery Switch Starter Switch Up to S N3696509 Generator Control Panel The Generator Control Panel is provided with the following Output Voltage Adjustment Knob Frequency Meter Hz AC Ammeter Amps AC Voltmeter Volts Ammeter Change Over Switch Voltmeter Change Over Switch Panel Light Auto On Off Engine Controller Panel Light Switch Pilot Lamp Output Terminal Panel The Output Terminal Panel is provided with the following Three120 240V output receptacles 50 amp Two 120V receptacles 20 amp 3 Circuit Breakers 240V 50 amps 2GFCI Circuit Breakers 125V 20amps Control Box The Control is provided with the following Main Circuit Breaker 1060 amps Over Current Relay High Idle Adjust Trimmer Current Transformer Automatic Voltage Regulator Open Delta Excitation System The 40055 generator is equipped with the state of the art Open Delta excitation system The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four leads A B C and D During light loads the
26. HEX HEAD BOLT 14 5 C3424001204 FRONT FRAME 1 C3494100903 5 3692434 3701676 3494101703 EINING 5 3701677 6 C342400103 FRONT FRAME 1 C3494100903 UNING 5 3692434 3701676 3494101703 EINING Tass S N3701677 7 C3424000202 FRONT FRAME 1 C3494100903 5 3692434 3701676 3494101703 UNING perm 5 3701677 8 3424000302 FRONT FRAME 1 C3494100903 S N3692434 TO 3701676 3494101703 pom 5 3701677 9 0017108020 HEX HEAD BOLT 20 10 C3424300403 GUIDE PANEL ee S N3692434 3701676 C3424300603 GUIDE PANEL AIR scita Fe s S N3701677 C3494100903 5 3692434 3701676 3494101703 LINING Lade N3701677 11 C3424300303 GUIDE PANEL AIR 1 C3494100903 EINING 5 3692434 3701676 3494101703 LINING 5 3701677 12 0019208020 HEX HEAD BOLT 24 13 0019210025 HEX HEAD BOLT 8 14 C3424201403 COVER FRONT FRAME 1 15 C3424201304 COVER FRONT FRAME 1 C3494101004 LINING 1 16 0019208020 HEX HEAD BOLT 28 THE DEFAULT PART NUMBER FOR THE COLOR ORANGE PLEASE INDICATE COLOR WHEN ORDERING MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED DCA 400SSK PARTS AND
27. OPERATION MANUAL STD REV 3 09 17 01 PAGE 93 ASSY LLI CC gt o o 2 LLI x 27 Hp c 4 Q PAGE 94 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 ENCLOSURE 1 ASSY ENCLOSURE 1 ASSY NO 17 18 19 20 21 22 23 24 25 26 28 29 30 DCA 400SSK ENCLOSURE 1 ASSY PART NO PART NAME QTY REMARKS 0845042703 FILLER BRACKET 1 0019208020 HEX HEAD BOLT 4 C3424201503 COVER FRONT FRAME 1 0019208020 HEX HEAD BOLT 14 0600500090 EMBLEM 1 0021106020 MACHINE SCREW 2 C3434000202 CENER FRAME 1 0010120070 HEX HEAD BOLT 6 0030020000 HEX NUT 6 0040020000 LOCK WASHER 6 0041220000 PLAIN WASHER 12 0010120060 HEX HEAD BOLT 8 0030020000 HEX NUT 8 0040020000 LOCK WASHER 8 0041220000 PLAIN WASHER 16 C3464100102 ROOF PANEL 1 0800251701 FILLER COVER 1 0025006015 MACHINE SCREW 2 0042306000 LOCK WASHER 2 0042406000 PLAIN WASHER 2 0019208020 HEX HEAD BOLT 28 C3464501004 BRAGKET EE 5 3707481 THE DEFAULT PART NUMBER FOR THE COLOR ORANGE PLEASE INDICATE COLOR WHEN ORDERING MQW WHITE MQGRN GREEN THE SERIAL NUMBER MAY BE REQUIRED DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 95 DCA 400SSK ENCLOSURE 2 ASSY ENCLOSURE 2 ASSY THE DEFAULT PART NUMBER FOR THE COLOR ORANGE PLEASE INDICATE COLOR WHEN ORDERING MQW WHITE MQGRN GREEN
28. available PAGE 66 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK SUGGESTED SPARE PARTS DCA 400SSK W KOMATSU SA6D140E 2 DIESEL ENGINE 1 to 5 Units Qty P N Description 6125817051 AIR FILTER 10 6003117111 FUEL FILTER 10 6002111231 OIL FILTER JE 6004111171 CARTRIDGE CORROSION RESISTOR Lune 0601804887 CIRCUIT UPTO S N3706720 0601807514 CIRCUIT BREAKER 5 3706721 0601810575 PILOT LAMP ENGINE TROUBLE 0601810576 PILOT LAMP ENGINE TROUBLE 0412122258 ENGINE FAN BELT 6008155390 SWITCH STARTER UPTO S N3696509 Buan KEY SET STARTER SWITCH 2 S N3696509 0602122281 OIL SWITCH Inde 6212619610 RADIATOR HOSE UPPER ER 6212616930 RADIATOR HOSE LOWER Lander 0605505030 FUEL 061820625 VOLTAGE REGULATOR 0601807307 MAIN CIRCUIT BREAKER Tersan 0601805840 CIRCUIT BREAKER 0601802525 HANDLE MAIN CIRCUIT BREAKER UP TO S N3706720 0601840073 VOLTAGE REGULATOR RHEOSTAT Tiisin 0601840009 BHEOSTA Guarda areal S N3701677 0601840121 KNOB VOLTAGE REGULATOR EEE 0601810072 PILOT LAMP
29. connecting cables are securely connected to the generators output terminals insufficient tightening of the terminal connections may cause damage to the generator and electrical shock DO NOT touch or open any of the below mentioned components while the generator is running Always allow sufficient time for the engine and generator to cool before performing maintenance Radiator 1 Radiator Cap Removing the radiator cap while the engine is hot will result in high pressurized boiling water to spew 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 to flow out of the coolant drain plug therefore causing severe scalding to any persons in the general area of the generator Engine Oil Drain Plug Removing the engine oil drain plug while the engine is hot will result in hot oil to flow out of the oil drain plug therefore causing severe scalding to any persons in the general area of the generator DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 7 RULES FOR SAFE OPERATION CAUTION Never over fill the battery with water above the upper limit The battery contains acids that can cause injury to the eyes and skin To avoid eye irritation always wear safety glasses Use well insulated gloves when picking up the battery Use the
30. nuts in sequence See Figure 5 DO NOT LUG NUTS torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 4 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically 9 Table 4 Tire Torque Requirements Wheel Size First Pass Second Pass Third Pass FT LBS FT LBS FT LBS 20 25 35 40 50 65 PNEUMATIC 20 25 35 40 50 65 AIR GUN TORQUE WRENCH Figure 5 Wheel Lug Nuts Tightening Sequence 20 25 50 60 90 120 NOTE NEVER use an pneumatic air gun to tighten wheel lug nuts DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 17 DCA 400SSK TRAILER WIRING DIAGRAM TOWING TRAILER SIDE VEHICLE SIDE DOUBLE FILAMENT BULB CONNECT TO CHASSIS TAIL LIGHT a SINGLE ae YELLOW BROWN i GREEN STOP amp TURN LEFT LICENSE LIGHT 1 t DOUBLE FILAMENT i BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR i MATING CONNECTOR LEFT TAIL LIGHT i i 1 I 1 1 1 DOUBLE FILAMENT i BULB 1 TO CHASSIS RIGHT GROUND TAIL LIGHT Cu 1 WHITE WHITE COMMON GROUND SINGLE 1 BLUE TURN RIGHT FILAMENT 1 7 1 GREEN TAIL amp LICENSE BULB 1 YELLOW STOP RED TURN LEFT LIGENSE TAIL LIGHT i 1 1 DOUBLE i FILAMENT BULB FLAT 5 PIN ROUND FLAT 5 PIN ROUND CONNECTOR t LEFT 1
31. power to the Automatic Voltage Regulator AVR is supplied from the leads parallel connections of B amp C When loads increase the AVR switches and accepts power from leads A amp D The output of leads A amp D increase proportionally with load This of adding the voltages to each phase provides better voltage response during heavy loads The connections of the AVR to the AC output windings are for sensing only No power is required from these windings The open delta design provides virtually unlimited excitation current offering maximum motor starting capabilities The excitation does not have a fixed ceiling and responds according the demands of the required load Engine Controller Alarm System The DCA 400SSK generator is equipped with various alarms and LED status indicators These alarms and status indicators are provided to add safety to the generator when operating under normal conditions The DCA 400SSK generator is designed to shutdown in the event of low oil high coolant temperature low battery and other operation conditions that may cause severe damage to the generator PAGE 24 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK GENERAL INFORMATION Engine The DCA 400SSK is powered by a 4 cycle water cooled turbocharged KOMATSU Model SA6D140E 2 diesel engine This engine is designed to meet every performance requirement for the generator Reference Table 1 page 16 for engine s
32. the output terminal panel see page 35 Figure 14 To gain access to the output terminals lift the UVW cover Make sure to tighten terminal nuts securely to prevent load wires from slipping out AC OUTPUT TERMINALS amp 55 hd Bw c CORRECT INCORRECT Figure 34 Engine Enclosure Doors 5 Setthe battery ON OFF switch Figure 35 to the ON position Figure 32 UVW Terminal Lugs Load 3 Connect the negative battery cable BLACK to the negative post on the battery Figure 33 Figure 35 Battery ON OFF Switch 6 Whenstartingthe generator in COLD weather conditions press and hold the engine preheat button Figure 36 until the preheat lamp Figure 37 is lit ON Figure 33 Battery Connections Figure 37 Engine Pre Heat Lamp PAGE 48 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 7 8 The generator s frequency meter Figure 39 displays 11 9 DCA 400SSK GENERATOR START UP PROCEDURE KEY SWITCH If the generator is equipped with a ignition switch turn the key to Start position Figure 38 Once the engine Starts release the key to the on position lt STOP HF LT Alo lt Figure 38 Engine Ignition Switch the 60 cycle output frequency in HERTZ Figure 39 Frequency Meter Hz The generator s voltage meter Figure 40 displays the 120 VAC in VOLTS If the voltage is not within the specified
33. with clean cloth or cloth tape 3 Clean the inside of the body Remove air connector opening protection 4 Install a new inner cylinder element to the cylinder and tighten the nut 5 Install element 6 Afterreplacing the element press the button of the dust indicator to return the red piston to its original position Fuel Addition Add diesel fuel the grade may vary according to season and locations Always pour through the mesh filter Removing Water from the Tank After prolonged use water and other impurities accumulate in the bottom of the tank Occasionally remove the drain cock and drain the contents During cold weather the greater the empty volume inside the tank the easier it is for water to condense This can be reduced by always keeping the tank as full as possible Air Removal If air enters the fuel injection system of a diesel engine starting becomes impossible After running out of fuel or after disassembling the fuel system bleed the system according to the following procedure To restart after running out of fuel turn the key switch to the START position for 15 30 seconds Try again if needed This unit is equipped with an automatic air bleeding system Service Daily If engine is operating in very dusty and dry grass conditions a clogged air cleaner will result in high fuel consumption loss of power and excessive carbon buildup in the combustion chamber Cleaning the Fuel Strainer Clean the fue
34. 0 REPLACES 0602041146 4 6003117111 CARTRIDGE FUEL FILTER REPLACES 0602042157 5 6004111171 CARTRIDGE CORROSION RESISTOR REPLACES 0602045144 6 0602040678 DUST SENSOR 1 7 C3304200104 ENGINE FOOT 1 8 0010118060 HEX HEAD BOLT 2 9 0030018000 HEX NUT 2 10 0040018000 LOCK WASHER 2 11 0041218000 PLAIN WASHER 4 12 0605000061 RUBBER SUSPENSION 4 13 0030016000 HEX NUT 8 14 0040016000 LOCK WASHER 8 15 6212619902 RADIATOR Gaio orem REPLACES 060201 1943 2016012191 RADIATOR CAP 1 16 6995619230 RUBBER ER REPLACES 0605000085 17 0010120055 HEX HEAD BOLT 4 18 0040020000 LOCK WASHER 4 19 0041220000 PLAIN WASHER 4 20 C3311100204 BRACKET RADIATOR 2 21 0010112025 HEX HEAD BOLT 4 22 0040012000 LOCK WASHER 4 23 0041212000 PLAIN WASHER 4 24 6212619610 RADIATOR HOSE Dots REPLACES 0602013962 25 6212616930 RADIATOR HOSE Lis REPLACES 0602014467 26 0726102612 RADIATOR HOSE REPLACES 0602013963 27 6138619260 RADIATOR HOSE REPLACES 0602013062 28 0728100909 HOSE BAND REPLACES 0602014056 29 0728101029 HOSE BAND es em REPLACES 0602014350 30 0728100489 HOSE BAND es ME REPLACES 0602014351 31 0728100167 HOSE BAND AR REPLACES 0602014059 32 0802081003 RESERVE TANK 1 33 0802010900 CAP RESERVE TANK
35. 0603 FUEL TANK 1 2 0605505030 FUEL TANK pe Trati REPLACES 0605505005 0601850590 re REPLACES 0601850505 3 0810105400 FUEL FILTER 1 4 0264100385 HOSE FUEL GAUGE 1 5 0605515079 HOSE BAND 2 6 0605503020 FUEL SENSOR 1 7 0802120604 PACKING 1 8 0605501050 UNIT FUEL une ETER 52000 KA9810 9 0602021155 PACKING 52391 KW3700 10 0027104010 MACHINE SCREW 5 11 8225523104 TANK BAND 2 12 0805003414 PAD TANK BAND 4 13 0017108020 HEX HEAD BOLT 2 14 0037908000 HEX NUT 2 15 0222100300 TANK SHEET 6 16 0130206000 STREET ELBOW 1 17 3515512014 DRAIN PIPE 1 18 0603325011 VALVE 1 19 0132006000 PLUG 1 20 0845039604 RUBBER SEAL 1 21 0191303000 SUCTION HOSE 1 22 0191303000 RETURN HOSE 1 23 0191004200 RETURN HOSE 1 24 0605515019 HOSE BAND 4 25 0605515013 HOSE BAND 2 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 91 ASSY EE meet LLI oc 5 LLI e 7 Y lt PAGE 92 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 ENCLOSURE 1 ASSY DCA 400SSK ENCLOSURE 1 ASSY ENCLOSURE 1 ASSY NO PART PART NAME QTY REMARKS 1 03414000202 une S N3692434 3701676 3414001902 reif td OD Luger 5 3701677 2 C3414100104 FLOOR PANEL 1 3 C3414100004 FLOOR PANEL 1 4 0019208020
36. 0647804 DECAL EMERGENCY STOP anus S N3696510 3701676 54100 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 109 DCA 400SSK NAME PLATE AND DECALS BONNET GROUP 9 PLATE AND DECALS PAGE 110 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK NAME PLATE AND DECALS NAME PLATE ASSY NO 16 17 18 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 PART NO 6360610304 B9504000404 B9504100104 0840614104 0840619904 B4551000103 1551000803 89511100304 89511100404 B9531 100504 0551000404 9039209064 0800689404 0800689504 9505300004 9504200004 9511100204 1320620904 6360620004 9504500004 1320610603 1320621504 0840625902 9504000304 3561101003 3561100903 3561100604 3561100803 3561100104 C3561100703 C3561100203 PART NAME QTY REMARKS ENGINE amp RADIATOR GROUP WATER Tissu 5 1880 DECAL WARNING pe AER B90400040 DECAL WARNING Lundi Lend B90410010 OUTPUTTERMINAL GROUP DECAL GROUND 556 Vatne 5 2635 DECAL DANGER Videre 52731 DECAL RECEPTACLE amp CIRCUIT BREAK 1 S N3692434 TO 3706720 845100010 DECAL RECEPTACLE amp CIRCUIT BREAK 1 5 3706721 15100080 DECAL WARNING nnn
37. 18 0019112045 HEX HEAD BOLT 2 19 0042412000 PLAIN WASHER 2 20 0805015604 STAY RUBBER 2 21 0205012000 HEX NUT 2 22 0845043704 SPRING 2 23 C3237100214 COVER 1 24 0017108020 HEX HEAD BOLT 7 25 C0237101504 COVER OUTPUT TERMINAL 1 26 0805015604 STAY RUBBER 1 27 0845054204 COLLAR 2 28 0017110040 HEX HEAD BOLT 2 29 0601815324 TERMINAL BOARD ee 5 3696510 30 0027104020 MACHINE SCREW EE S N3696510 31 0601850275 GBOMMET dir less S N3696510 32 0601851780 GROMMET 2 S N3700680 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 83 BATTERY ASSY DCA 400SSK BATTERY ASSY 5 cp gt oc 1 am HL lt 5 z lt z lt CC TT an N lt a x N 77 T lt a amp DCA 400SSK BATTERY ASSY BATTERY ASSY NO PART NO 1 0168719052 2 0805018904 3 0805006404 4 0805006504 5 0037808000 6 0040008000 7 0041208000 8 C3347600004 9 C3347600104 10 C3347600304 11 C3347600204 12 C3347200004 13 0010010030 14 0030010000 15 0845040114 16 0845041004 17 0845040214 18 0845041104 19 0602220205 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 85 PART NAME BATTERY BATTERY SHEET BATTERY BAND BATTERY BOLT WING NUT LOCK WASHER PLAIN WASHER BATTERY CABLE BATTERY CABLE BATTERY CABLE
38. 24504 DECAL CIRCUIT T o 5 3031 7 0840624604 DECAL PANEL LIGHT SWITCH Liens 5 3032 8 0840624704 DECAL PILOT LAMP S 3033 9 0840624804 DECAL VOLTAGE REGULATOR 5 3034 10 9531100604 DECAL WARNING B93110060 11 C0551000903 DECAL OUTPUT VOLTAGE SETTING doe C05100090 12 C2551000004 DECAL SAFTETY INSTRUCTIONS Toss C25100000 13 C3561101103 DECAL WHISPERWATT 400 36110110 14 9502400004 DECAL HIGH IDLE SPEED S N3701677 C9024000 15 0600500091 DECAL ENGINE CONTROLLER S N3696510 ENGINE OPERATING PANEL GROUP 19 0840625004 DECAL PREHEAT LANP 5 3692434 3701676 S 3036 C1552000013 DECAL OPERATING PANEL Vgs 5 3701677 C15200001 20 0840625104 DECAL STARTER SWITCH S N3692434 3696509 5 3037 9501400304 DECAL PREHEAT Tonia S N3696510 TO 3701676 C90140030 21 C0551000504 DECAL BATTERY SWITCH 05100050 22 0551000704 DECAL LOW HIGH S N3692434 TO 3696509 C05100070 23 C0551000804 DECAL STOP BUTTON pe T ses S N3692434 TO 3696509 C05100080 084
39. 32 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK ENGINE OPERATING PANEL The definitions below describe the controls and functions of the DCA 400SSK Engine Operating Panel Figure 10 1 Throttle Handle up to S N 3701676 This handle controls the speed of the engine low or high 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 Engine Warning Display Module This module display s the following engine failures Overheat Lamp This lamp goes ON when the cooling water temperature rises abnormally If the lamp goes ON during normal operation of the generator the emergency shutdown device will stop the engine automatically Low Oil Pressure Lamp During normal operation of the generator this lamp should remain OFF When the Auto OFF Reset Manual switch is set to the Manual position to start the engine the lamp will be lit After the oil pressure rises after start up the lamp will go OFF If this lamp is ever lit ON during normal operation of the generator the emergency shutdown device will stop the engine automatically 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
40. 605010502 SNAP PIN E iuueni S N3692434 TO 3701676 21 0602100049 STARTER SWITCH ds aus 5 3692434 3696509 6008155390 0601830448 PREHEAT BUTTON Maiin S N3696510 AH25FB10 22 0602104045 STOP BUTTON S N3692434 TO 3701676 0806410000 0601831557 EMERGENCY STOP BUTTON S N3701677 AR22V2R01R 23 0602102055 PRHEAT LAMP Punk 6008153730 24 0602120054 TACHOMETER iee 25000KX4110 25 0602120156 GABLE TACHOMETER 62500KA4210 L 3000 26 0602122060 OIL PRESSURE GAUGE 42000KX1410 27 0602122200 UNIT OIL PRESSURE Viskan 53000AC0101 28 0602123061 WATER TEMPERATURE GAUGE 40000KX0910 29 0602123206 UNIT WATER TEMPERATURE lade 41400KS0600 30 0602121052 CHARGING AMMETER Line 43000KV0300 31 0602125060 41000KW0110 32 0602115014 MONITOR Ro dantes V3376600000 33 C3484000103 SET FRAME 1 34 0010110030 HEX HEAD BOLT 2 0030010000 HEX NUT 2 0040010000 LOCK WASHER 2 0041210000 PLAIN WASHER 4 35 0601830710 ENGINE SPEED SWITCH S N3701677 S301T DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 81 OUTPUT TERMINAL ASSY 400 DCA OUTPUT TERMINAL ASSY 5 cp gt
41. 7 01 PAGE 61 DCA 400SSK TROUBLESHOOTING ENGINE Practically all breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown use the tables shown for diagnosis based on the Engine Troubleshooting Table 16 If the problem cannot be remedied consult our company s business office or service plant TABLE 16 ENGINE TROUBLESHOOTING SYMPTOM POSSIBLE PROBLEM SOLUTION Engine does not start No fuel Replenish fuel Air in the fuel system Bleed system Water in the fuel system Remove water from fuel tank Fuel pipe clogged Clean fuel pipe Fuel filter clogged Clean or change fuel filter Excessively high viscosity of fuel or engine oil at low temperature Use the specified fuel or engine oil Fuel with low cetane number Use the specified fuel Fuel leak due to loose injection pipe retaining nut Tighten nut Incorrect injection timing Adjust Fuel cam shaft worn Replace Injection nozzle clogged Clean injection nozzle Injection pump malfunctioning Repair or replace Seizure of crankshaft camshaft piston cylinder liner or bearing Repair or replace Compression leak from cylinder Replace head gasket tighten cylinder head bolt glow plug and nozzle holder Improper valve timing Correct or replace timing gear Piston ring and liner worn Replace
42. 804 19 0040016000 20 0041416000 21 0801830704 22 8201852504 23 0040012000 24 0041412000 25 0017110030 26 C3261500023 C3621501103 27 0017108020 28 0602201911 29 0027106015 30 0602200446 HEX HEAD BOLT TERMINAL PLATE CHANGE PLATE HEX HEAD BOLT LOCK WASHER PLAIN WASHER HEX HEAD BOLT HEX HEAD BOLT LOCK WASHER PLAIN WASHER HEX HEAD BOLT SET PANEL ELECTRIC PARTS SET PANEL ELECTRIC PARTS HEX HEAD BOLT UNIT BATTERY SENSOR MACHINE SCREW 1 EMERGENCY RELAY Tames S N3692434 TO 3701676 6008151252 5 3692434 3696509 5 3696510 7038 0000 31 0017106015 HEX HAD BOLT dias 5 3692434 TO 3701676 32 0601824542 EE ER 625 DC24V 33 0027103010 MACHINE SCREW 4 34 C3224001303 CONTROL PANEL 1 35 C3224001203 CONTROL PANEL ott Um 5 3692434 TO 3706720 C3224002403 CONTROL PANEL premiene Visser 8 3706721 36 0228800100 RUBBER SEAL S N3692434 3706720 0228800110 RUBBER SEM EN 5 3706721 37 0228800124 RUBBER SEAL 5 3692434 3706720 0228800165 RUBBER SEAR 5 3706721 38 0605011211 2 39 0601807622 FREQUENCY Passet RSC 80F 45 65Hz 220V 40 0601806987 AMMETER inc tet her ER loses RSS80 0 750A 0 1500A 41 0601801040 CHANGE OVER SW AMMETER SL2AS 42 0601806887
43. ASSEMBLY 7 CONTROL PANEL ASSEMB OPERATING PAN Figure 6 Major Components PAGE 26 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 NOTE PAGE DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 27 DCA 400SSK DIMENSIONS TOP AND SIDE REAR VIEW CONTROL PANEL VIEW 2100 mm 82 68 in 1400 mm 55 11 in FRONT VIEW Dry weight 4270kg 9413 641 1320 mm 51 97 in Wet weight 4800kg 10582 08 Ib Figure 7a Dimensions PAGE 28 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK DIMENSIONS FRONT AND REAR SIDE VIEW 600 39 37 39 37 23 62 BOLT HOLE LOCATION 4200 mm 165 35 in TOP VIEW 460mm 18 11in lt gt A lt gt 805mm 31 69in Figure 7b Dimensions DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 29 DCA 400SSK CONTROL PANEL 6 AMMETER CHANGE OVER SWITCH LIGHT PANEL SWITCH VOLTAGE REGULATOR ENGINE CONTROLLER S N 3696510 11 CIRCUIT BREAKER Figure 8 Control Panel PAGE 30 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK CONTROL PANEL The definitions belo
44. CA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 51 DCA 400SSK GENERATOR SHUTDOWN PROCEDURE Engine Shutdown To shutdown the generator use the following procedure 1 Place both the MAIN GFCI and LOAD circuit breakers to the OFF position Let the engine cool by running it for 3 5 minutes with no load applied Place the Off Manual Auto Switch Figure 52 in the OFF position AUTO MANUAL OFF RESET Figure 52 Off Manual Auto Switch OFF 4 Verify that the Engine Running status LED Figure 53 on the microprocessor Engine Controller display is OFF not lit AUTO 6 MANUAL OFF RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING Figure 53 Engine Controller Running Status LED OFF 5 Remove the load from the UVWO terminal strip Figure 18 on page 48 Emergency Stop 1 To stop the engine in the event of an emergency PUSH the emergency stop button Figure 54 inward This button is located on the generator s engine operating panel see page 30 Figure 11 Figure 54 Emergency Stop Button CAUTION NEVER stop the engine suddenly except in an emergency DO NOT use the emergency stop switch a as method of shutting down the engine This switch is ONLY to be used in the event of an emergency PAGE 52 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01
45. DCA 400SSK CONTROL BOX ASSY CONTROL BOX ASSY 47272 if PAGE 72 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK CONTROL BOX ASSY CONTROL BOX ASSY NO PART NO PART NAME QTY REMARKS 1 C3214000912 CONTROL BOX issir Panser 5 3692434 3706720 63214001502 CONTROL BOX speed 5 3706721 2 0601801170 CURRENT TRANSFORMER Sor CW 5L 750 5A 3 0027106016 MACHINE SCREW 6 4 0601807307 CIRCUIT BREAKER 51200 1060A 5 3692434 3706720 0601807514 CIRCUIT BREAKER 57 1000 5 3706721 C0244300003 5 0601802525 HANDLE CIRCUIT BREAKER 5 3692434 3706720 6 63214600004 BRACKET CIRCUIT BREAKER EN S N3692434 TO 3706720 7 0017108020 HEX HEAD d sss 5 3692434 TO 3706720 8 0021008045 MACHINE SCREW 5 3692434 3706720 0040008000 LOCK WASHER uci 5 3692434 3706720 0041208000 PLAIN WASHER o hte 5 3692434 3706720 9 0601820625 AUTOMATIC VOLTAGE REGULATOR 2 10 0027105016 MACHINE SCREW 4 11 0601820892 OVER CURRENT RELAY THN20HZ 12 0027104016 MACHINE SCREW 2 13 C3274000003 CHANGE OVER BOARD VOLTAGE 1 14 8221852104 CHANGE TERMINAL 15 0017108030 16 2277200004 17 8221853104 18 0801830
46. E PHASE power at 240V After hooking up the hard wires to the lugs as shown in figure 20 below 240V will be the voltage output Voltage Change over Board must be set at 240V Set TO LOAD TO GROUND FIGURE 20 Hard Wire Hookup for Three Phase 240V Single Phase 240 Volt The following connection with the voltage change over board set into the 240V set position See Figure 19 can offer SINGLE PHASE power at 240V After hooking up the hard wires to the lugs as shown in figure 21 below 240V will be the voltage output Voltage Change over Board must be set at 240V Set TO GROUND LOAD LOAD LOAD FIGURE 21 Hard Wire Hookup for Single Phase 240V Single Phase 139 Volt The following connection with the voltage change over board set into the 240V set position See Figure 19 can offer SINGLE PHASE power at 139V After hooking up the hard wires to the lugs as shown in figure 22 below 139V will be the voltage output Voltage Change over Board must be set at 240V Set TOLOAD TOLOAD TO LOAD TO GROUND FIGURE 22 Hard Wire Hookup for Single Phase 139V PAGE 38 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK OUTPUT TERMINAL PANEL OVERVIEW 480 Volt Set position The voltage change over board 480V set position uses all 6 plates in 3 different connection places There are 2 plates at every position Every plate is used See figure 23 below FIGURE 23 Voltag
47. F 4 WIRE LOOM 3 EYE BIAS 3 4 TRLR 85 125 ADJUSTABLE 2 5 6 ST225 75R15D 146 2 6000Ibs 6 3 EYE RADIAL TRLR 150XF 3 BALL EYE 750 16 E 16 X7 2 6000Ibs BIAS 4 5 5 b 4 2 b TRLR 220XF 3 EYE ADJUSTABLE ST235 85R16E 16 X7 2 7000lb RADIAL 4 2 b 3 6 4 TRLR 300XF 3 EYE ADJUSTABLE ST235 85R16E 16 X7 2 6000 RADIAL 6 TRLR 400XF 3 EYE ADJUSTABLE ST235 85R16E 16 X7 3 7000Ibs 8 RADIAL 6 TRLR 600XF 5TH WHEEL ST215 75R17 5H 16 X7 3 1000065 8 RADIAL 8 TRLR 800AR 5TH WHEEL ST215 75R17 5H 16 X7 3 10000Ibs AIR RIDE 6 WIRE LOOM RADIAL 8 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 13 40055 TRAILER SAFETY GUIDELINES Brakes If your trailer has a braking system the brakes should be inspected the first 200 miles of operation This will allow the brake shoes and drums to seat properly After the first 200 mile interval inspect the brakes every 3 000 miles If driving over rough terrain inspect the brakes more frequently Electric Brakes Electrically actuated brakes Figure 2 are similar to hydraulic brakes The basic difference is that hydraulic brakes are actuated by an electromagnet Listed below are some of the advantages that electric brakes have over hydraulic brakes Brake system can be manually adjusted to provide the corrected braking capability for varying road and load conditions Brake s
48. FLAT PAD 2000LB FLAT PAD 76 20001 8 FLAT PAD 200018 FLAT PAD 5000 LB FLAT PAD 83 5000 LB FLAT PAD 83 5000 LB FLAT PAD 83 5000 LB FLAT PAD 5000 LB FLAT PAD 5000 LB FLAT PAD 77 PAGE 12 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK TRAILER SPECIFICATIONS Table 1 Specifications Con t MODEL COUPLER TIRES WHEELS AXLE HUBS SUSPENSION ELECTRICAL TRLR 10W 2 BALL CLASS 175 13C 13 X4 50 2200 2X2 5 LUG 3 LEAF 4 WIRE LOOM W 2 ADJUSTABLE 4 POLE FLAT TRLR 10 2 BALL CLASS 175 13C 13 X4 5 2200 2 2 5 LUG 3 LEAF 4 POLE FLAT 2 ADJUSTABLE LUG 4 POLE FI TRLR 10XF 2 BALL CLASS 175 130 13 X4 5 2200 2 2 2 ADJUSTABLE 2 BALL CLASS 175 13B 13X4 5 2200 2 2 5 LUG Q FLEX 4 POLE FLAT TRLR BLW 400 2 BALL CLASS 175 13C 13 X 4 5 2200 2 2 5 4 POLE FLAT 2 ADJUSTABLE TRLR 50X 2 BALL CLASS B78 13LRC 13 4 50 3500Ibs 5 4 POLE RUBBER FLAT 2 3 TRLR 50XF 2 BALL CLASS B78 13LRC 13 4 50 3500Ibs 4 POLE RUBBER FLAT 2 3 8 TRLR 70W 2 BALL CLASS 205 14C 14 5 3500008 5 LUG 5 LEAF 4 POLE RUBBER FLAT 3 ADJUSTABLE BIAS 4 3 TRLR 70X 2 BALL CLASS 205 14C 14 X5 3500Ibs 5 LUG 5 LEAF 4 POLE RUBBER FLAT 3 ADJUSTABLE AS 4 3 14C 5 4 5 TRLR 70XF 2 BALL CLASS 205 1 14 X5 35001 5 LUG 5 LEAF 4 POLE RUBBER FLAT 3 ADJUSTABLE BIA 3 TRLR 100XF ADJUSTABLE 2 5 6 OPT 205 15C 14 X5 5 3500Ib 5 LUG 5 LEA
49. G HUB BALANCING PLATE HEX HEAD BOLT LOCK WASHER BALANCING WEIGHT KIT BEARING FLANGE BEARING COUPLING RING HEX HEAD BOLT LOCK WASHER HEX HEAD BOLT LOCK WASHER STATOR ASSY RUBBER SEAL CLAMPER RUBBER SEAL CLAMPER RUBBER SEAL HEX HEAD BOLT PLAIN WASHER COVER RUBBER SEAL RUBBER SEAL HEX HEAD BOLT GROMMET END BRACKET FIELD ASSY EXCITER HEX HEAD BOLT LOCK WASHER PLAIN WASHER RB A CE PPD a Ooo DID REMARKS RM50TC 24 40055 GENERATOR ASSY DCA GENERATOR ASSY rr gt LU 1 HL lt D lt lt LU a CD lt x CD 72 T lt LU DCA 400SSK GENERATOR ASSY GENERATOR ASSY NO PART NO PART NAME QTY REMARKS 34 0017112045 HEX HEAD BOLT 8 35 C3154300104 COVER BEARING 1 35 C3154300004 GASKET BEARING 1 37 0010106060 HEX HEAD BOLT 4 0040006000 LOCK WASHER 4 0041206000 PLAIN WASHER 4 38 C3154400003 SUCTION COVER 1 39 0017106016 HEX HEAD BOLT 8 40 0012112035 HEX HEAD BOLT 16 0042512000 LOCK WASHER 16 41 C3132300003 COVER FAN 1 42 0010106030 HEX HEAD BOLT 1 0041206000 PLAIN WASHER 1 43 0605000061 RUBBER SUSPENSION 4 44 0030016000 HEX NUT 8 0040016000 LOCK WASHER 8 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 71
50. Guidelines 11 17 Trailer Wiring Diagram ee 18 Electric Brake Troubleshooting 19 Hydraulic Brake Troubleshooting 20 Operation And Safety 21 22 Specification sau iore pa Oda apr un aia Re 23 General Information 24 25 Major Components ps 26 Dimensions Top Side And 28 29 Control 30 31 Engine Operating 32 33 Output Terminal Panel Overview 34 39 Installation 40 41 lt 42 45 Load Application 46 Generator Start Up Procedure Key Switch 47 50 Generator Start Up Procedure Controller 51 Generator Shut Down Procedure 52 Maintenance ede 54 57 Generator Wiring 58 Engine Wiring Diagram 60 Troubleshooting Engine 62 63 Troubleshooting Generator 64 Troubleshooting Engine Controller 65 Explanation Of Codes In Remarks Column 66 Suggested Spare 67 MQ Power DCA 400SS
51. HEOSTAT VOLT REGULATOR Tecate RA20A2SE102BJ 2W 1K OHM KNOB 1 PANEL LIGHT parer V325070 HEX NUT 2 PANEL LIGHT SWITCH 1 HEX HEAD BOLT 2 LOCK WASHER 2 PLAIN WASHER 2 SNAP RING 2 HEX HEAD BOLT 4 STOPPER CONTROL PANEL 1 PLAIN WASHER 1 SNAP PIN 1 COVER CONTROL BOX 1 HEX HEAD BOLT 8 SIDE PANEL CONTROL BOX 1 HEX HEAD BOLT 4 PANEL CONTROL BOX 1 HEX HEAD BOLT 8 HEX HEAD BOLT 4 HEX NUT 4 ENGINE STOP UNIT 1 2 5 3696510 3701676 MACHINE SCREW 2542 S N3696510 3701676 RECTIFIER uden fee S N3696510 3701676 DE4503 MACHINE SCREW 05222 S N3696510 3701676 LOCK Gu S N3696510 TO 3701676 PLAIN WASHER e 422 5 3696510 3701676 FUSE 10A NE S N3696510 3701676 FUSE RIGHT 5 3701677 FUSE LEFT 15 Peer S N3701677 HOLDER FUSE anden de S N3696510 MACHINE 5 S N3696510 aN er S N3696510 TO 3701676 REPLACES 0601823732 NE EG uos S N3699150 REPLACES 0601827655 SOCKET eine nt PE S N3696510 REPLACES 0601823109 HOLDER urne S N3696510 1 MACHINE SCREW en DS N3696510 RELAY fe S N3696510 MACHINE 5
52. K AC Generator Generator Assembly 68 71 Control Box 72 75 Engine Radiator Assembly 76 79 Engine Operating Panel Assembly 80 81 Output Terminal Assembly 82 83 Battery Assembly 84 85 Actuator Assembly pp 86 87 Muffler Assembly pe 88 89 Fuel Tank Assembly 90 91 Enclosure 1 Assembly 92 95 Enclosure 2 Assembly 96 99 Enclosure 3 100 103 Enclosure Rubber Seals 104 105 Oil Piping Assembly 106 107 Name Plate and Decals 108 111 Terms and Conditions Of Sale Parts 112 NOTE Specification and part number are subject to change without notice PAGE 4 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PARTS ORDERING PROCEDURES Dealer account number Dealer name and address Shipping address if different than billing address Return fax number Applicable model number Quantity part number and description of each part Specify preferred method of shipment UPS Ground UPS Second Day or T
53. OPERATING PANEL 5 3696510 3701676 2352100223 OPERATING PANEL Toinn S N3701677 2 0017106015 HEX HEAD BOLT 8 3 0207006000 HEX NUT 4 4 0602101000 BATTERY doro 9827300090 5 0021008080 MACHINE SCREW 2 0030008000 HEX NUT 2 0040008000 LOCK WASHER 2 0041208000 PLAIN WASHER 2 6 0800250300 THROTTLE HANDLE iioii ted codes Loggen 5 3692434 3701676 7 3355100304 LINK GOVERNOR ROD Toss S N3692434 TO 3701676 8 C3355200004 BRAGKET S N3692434 TO 3701676 9 0017110025 HEX HEAD BOLT 2 uoa S N3692434 TO 3701676 10 0010010035 HEX HEAD BOLT S N3692434 3701676 11 0030010000 HEX NUT 5 3692434 3701676 12 0041210000 PLAIN WASHER S N3692434 TO 3701676 13 C3355300204 GOVERNOR ROD S N3692434 3701676 14 C3355300304 GOVERNOR ROD dicitis S N3692434 3701676 15 0602180106 BALL JOINT desire itid as tecta Pan S N3692434 TO 3701676 16 0030008000 HEX NU TS ke aedi o Pd epa AN 5 3692434 3701676 17 0207006000 HEX eee S N3692434 TO 3701676 18 0041206000 PLAIN WASHER e S N3692434 3701676 19 0041206000 PLAIN WASHER S N3692434 3701676 20 0
54. PERATION MANUAL STD REV 3 09 17 01 ENCLOSURE 3 ASSY NO PART NO 24 0845046904 0845045004 25 0845047004 0845045004 26 0019208020 27 0601850097 28 0021008025 29 0019108065 0042308000 0042408000 30 0845031504 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 103 PART NAME HINGE WASHER HINGE WASHER HEX HEAD BOLT STOPPER MACHINE SCREW HEX HEAD BOLT LOCK WASHER PLAIN WASHER CAP DCA 400SSK ENCLOSURE 3 ASSY QTY REMARKS DCA 400SSK RUBBER SEAL ASSY PAGE 104 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK RUBBER SEAL ASSY RUBBER SEAL ASSY NO PART NO PART NAME QTY REMARKS 1 0228901390 RUBBER SEAL 6 2 0228900825 RUBBER SEAL 8 3 0228900790 RUBBER SEAL 2 4 0229201400 RUBBER SEAL 2 5 0228800795 RUBBER SEAL aa pm S N3692434 TO 3701676 0221200795 RUBBER 24 54 5 3701677 6 0228801240 RUBBER SEAL 2 7 0229201340 RUBBER SEAL 1 8 0228100120 RUBBER SEAL 4 9 0228100510 RUBBER SEAL 4 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 105 DCA 400SSK OIL PIPING ASSY OIL PIPING ASSY OILPAN gt gt D PAGE 106 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK OIL PIPING ASSY OIL PIPING ASSY NO PAR
55. Ser ous injury or death may result without this transfer switch B91110030 P N C0551000404 3 Phase output term nal 139 277 4 Keep the loads balancing when us ng plura 5 ngle loads 240 480 C05100040 B9511100304 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 21 DCA 400SSK OPERATION AND SAFETY DECALS HANDLING PROCEDURES 1 CHECK TO OPERAT NG 6 Adjust the VOLTAGE REGULATOR tothe rated vo tage Pro to operat ng the engine be sure to check the fol ow ng 6 tu n on the CIRCUIT BREAKER to supp y e ectic power items to prevent trouble and acc dents to the load 1 Check lub cating ol cool ng water and diese fue 3 OPERATING PRECAUTIONS 2 Check the tension of the fan belt and charging 1 Whi e operating do not turn the BATTERY SWITCH generator dr v ng belt OFF to protect the charg ng gene ator and eng 3 Check the CRCUT BREAKER stu ned OFF circu t aga nst damage 4 Set the vo tage change over boa d to the ated vo tage 2 When the C RCU T BREAKER is tipped OFF for over ony Dua votage typer cur ent or sho t circuit check the trouble cause and defect ve parts 2 STARTING AND OPERAT NG The RCUIT BREAKER cannot be reset unless it is 1 Turn the battery sw tch to pos tion once turned OFF and next turned 2 Turn the STARTER SWITCH to PREHEAT pos ton 4 STOPP NG THE ENG NE for 0 30 seconds 1 Turn the C cut saker
56. T NO 1 0602023040 2 8215191013 3 0017106025 4 7522054204 5 0131506000 6 0120006005 7 0602022202 8 3972054104 9 3972054304 10 0265801650 11 0605515074 12 0193301200 13 0605515004 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 107 PART NAME PUMP BRACKET PUMP HEX HEAD BOLT BUSHING NIPPLE VALVE HOSE JOINT HOSE JOINT PACKING HOSE HOSE BAND HOSE HOSE BAND QTY 1 1 5 1 1 1 1 1 1 1 2 1 1 REMARKS DCA 400SSK NAME PLATE AND DECALS NAME PLATE AND DECALS CONTROL BOX GROUP Llc ENGINE OPERATING PANEL GROUP PAGE 108 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK NAME PLATE AND DECALS NAME PLATE ASSY NO PART NO PART NAME QTY J REMARKS 1 0800655603 DECAL HANDLING PROCEDURES 5 2763 S N3692434 3696509 C1551000503 DECAL HANDLING PROCECURES 15100050 5 3696510 3701676 1552000403 DECAL HANDLING PROCDURES Tasas C15200040 S N3701677 2 B1552000103 DECAL CAUTION es 15200010 S N UP TO 3701676 C9522100003 DECAL CAUTION es 92210000 5 3701677 CONTROL BOX GROUP 3 0800520100 PLATE ON OF AT 202 4 0800520904 PLATE AMMETER CHNG OVER SWTH 1 N 2438 5 0800520814 PLATE VOLTMETER CHNG OVER SWTH 1 N 2439 6 08406
57. THE SERIAL NUMBER MAY BE REQUIRED PAGE 96 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 ENCLOSURE 2 ASSY NO PART 1 C3444000903 8195151204 C3454700104 8175151204 0207006000 C3444000402 8225940104 0017108020 0019210025 0017110025 0 C3444300703 C3494300604 11 8195151004 12 0207006000 13 C3444300804 C3494300704 14 0017108020 15 0019208020 16 C3444200503 17 C3444200903 18 8225147004 19 0037906000 20 B9114500104 21 0207006000 22 B9114000102 23 0021806016 0030006000 24 8225146204 25 8225146304 26 0845050704 27 0207006000 28 0805011304 29 0805011204 30 0207006000 31 M9110100204 0845045004 32 0845047204 0845045004 33 0019208020 34 0601850097 35 0021008025 36 0845031504 ON REAR FRAME LOUVER PANEL LOUVER PANEL LOUVER PANEL HEX NUT REAR FRAME LINING HEX HEAD BOLT HEX HEAD BOLT HEX HEAD BOLT COVER REAR FRAME LINING LOUVER PANEL HEX NUT DUCT COVER LINING HEX HEAD BOLT HEX HEAD BOLT DOOR REAR FRAME DOOR REAR FRAME WINDOW PLATE HEX NUT DOOR POCKET HEX NUT DOOR HANDLE MACHINE SCREW HEX NUT DOOR ROD DOOR ROD STAY HEX NUT STOPPER DOOR STOPPER DOOR HEX NUT HINGE iiec ra esto ciat WASHER HINGE WASHER HEX HEAD BOLT STOPPER MACHINE SCREW CAP QTY DCA 400SSK ENCLOSURE 2 ASSY REMARKS oo RS Rg ck
58. Voltage Regulator on the control panel is necessary See the table below Table 8 for a list of available voltages the generator is able to supply TABLE 8 VOLTAGES AVAILABLE MODEL DCA400SSK 3 PHASE VOLTAGE RECONNECTABLE SINGLE PHASE ADJUSTABLE 208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT 120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT CAUTION NEVER attempt to change the Voltage Change over board while the engine is engaged Over Current Relay An over current relay is connected to the circuit breaker In an over current situation both the circuit breaker and the over current relay may trip If the circuit breaker can not be reset the reset button on the over current relay must be pressed The over current relay is located in the control box Maximum Amps The following table show the maximum amps the entire generator can provide Do not exceed the maximum amps listed See Table 9 Table 9 Maximum Amps inge Ang 120 8889 amps 4 wire Single Phase 240 444 4 amps 4 wire Volt Three Phase 1 962 3 amps Three Phase pes 481 1 amps PAGE 36 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK OUTPUTTERMINAL PANEL OVERVIEW How to read the output terminal gauges The gauges and knobs on the control panel DO NOT effect the generator output in any fashion They are there to simply help the operator observe h
59. ash the breather in diesel fuel or flushing oil blow dry with compressed air then reinstall it Inspect the hose and if there is any deteriorated oil stuck inside the hose Replace hose if necessary Greasing Using a grease pump grease the fan hub 1 place and tension pulley 2 places Generator Storage For storage of the generator for over 30 days the following is required Fill the fuel tank completely lubricate and change oil Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately If the ambient temperature is expected to drop below 0 add antifreeze to the radiator Removal from long term storage Apply oil to the engine valve and rocker arms and examine the operating condition of the valves Remove the oil filler pipe from the turbocharger oil inlet port add 0 5 1L 0 13 0 26gal of oil to the turbocharger reinstall the oil filler pipe Change the oil in engine oil pan Replace all the filters Flush the inside of the cooling system Drain the water from the fuel tank and bleed the air from the fuel system If the engine has not been started for more than one year contact your Komatsu distributor to have engine overhauled PAGE 56 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK MAINTENANCE TABLE 15 INSPECTION MAINTENANCE 10Hrs 250Hrs 500Hrs 1000 Hrs ENGINE DAILY Protection L
60. ble replacements can be obtained from your dealer OIL DRAIN PLUG BATTERY SWITCH DON T TURN THE SWITCH 5 2635 OFF DURING OPERATION P N 0840614104 C05100050 GROUND 63606 20204 ELECTRIC SHOCK HAZARD h L 400 HOT COOLANT can cause Always complete the grounding SMILE me n severe burns path from the ground terminal on this genset to an externa feli 0773 grounding source See nstruct on UN e Do not remove cap if manua for deta s radiator is hot B91110040 890410010 P N B9511100404 Eng Ma N Ensure the AUTO OFF RESET MANUAL switch is in the OFF RESET position It is not when the battery cables are connected the engine will crank and 240 1 39 VO LT attemptto start Ci 5100040 P N C1551000404 P N C9505300004 AWARNING Onlyoperate machine FUEL in well ventilated areas Donotinhale exhaust DRAIN PLUG DANGEROUS GAS P N 6360620004 ELECTRIC SHOCK HAZARD CAUTION e Do not touch output MOVING PARTS can cause severe Injury termina s while this Ls machine is operating Do not operate with Turn power off before doors open servicing 893110050 Stop engine before servicing B9531100504 Me030000 WARNING Before connecting this generator to any bu Id ng s electrical system licensed electrician must nstall P N M9503000004 an solation transfer switch
61. ccounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE A 20 00 to 50 00 surcharge willbe added to the invoice for special handling including bus shipments insured parcel post or in cases where Multiquip must personally deliver the parts tothe carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable here under for damages in excess ofthe purchase price of the itemwithrespecttowhich damages are claimed andinnoeventshall 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 manufactured by Multiquip Such warranties made in connection with the sale of new complete units are made exclusively by a statement of warranty packaged with such units and Multiquip neither assumes not authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products A part from such written statement of warranty there areno warranties express impliedorstatutory which extend beyond the description of the products onthe face hereof PAGE 112 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 NOTE PAGE DCA
62. cover that can be secured in the close position by a pad lock See Figure 11 FIGURE 11 Output Terminal Cover 120 Volt Recetacle Two GFCI Duplex Nema 5 20R 120V 20 Amp recepacle is provided on the output terminal This receptacle can be used anytime the generator is in operation The receptacle is controlled by the circuit breaker located on the control panel Pressing the reset button resets the receptacle after being tripped Pressing the Test Button See Figure 12 in the center of this receptacle will check the GFCI function The receptacle should be tested at least once a month FIGURE 12 GFCI Test Button PAGE 34 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 Connecting Load Loads can be connected to the generator by the UVWO Lugs or the convenience receptacles See figure 13 Make sure to read the operation manual before attempting to connect a load to the generator AC OUTPUT TERMINALS FIGURE 13 Connecting Load Circuit Breakers To protect the generator from an overload a 3 pole 1000 amp main circuit breaker is provided to protect the UVW output terminals from overload In addition two single pole 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload Three 50 amp load circuit breakers have also been provided to protect the load side of the generator from overload Make sure to switch ALL circuit breakers to the OFF position prior to s
63. ctrical system ALWAYS consult with licensed electrician PAGE 40 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK INSTALLATION WZ GROUND ROD FOR EARTH GROUND CONNECT TO BUILDING GROUND GROUND CABLE 8 FT MINIMUM REFERENCE NEC250 2 C Figure 27 Typical Generator Grounding Application DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 41 DCA 400SSK PRE SETUP General Inspection Prior to Operation The DCA 400SSK generator has been thoroughly inspected and accepted prior to shipment from the factory However be sure to check for damaged parts or components or loose nuts and bolts which could have occurred in transit Extension Cable When electric power is to be provided to various tools or loads at some distance from the generator extension cords are normally used Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use load is held to a minimum Use the Cable Selection Guide Table 10 as a guide for selecting proper cable size Circuit Breakers To protect the generator from an overload a 3 pole 1000 amp main circuit breaker is provided to protect the UVW output terminals from overload In addition two single pole 20 amp GFCI circuit breakers are provided to protect the receptacles from overload Three 50 amp load circuit breakers hav
64. cy DO NOT use this button as a means of stopping the engine EMERGENCY STOP BUTTON Q STOP RUNNING Use this switch to preheat the Pr engine and turn on the generator This feature will not be on the unit if it is equipped with engine controller see Control Panel STARTER SWITCH 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 ON a BATTERY SWITCH Engine Speed Switch S N 3701677 This switch controls the speed of the engine high low DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 33 DCA 400SSK OUTPUT TERMINAL PANEL OVERVIEW OUTPUTTERMINAL FAMILIARIZATION The Output Terminal Panel is provided with the following Two 120V GFCI receptacles 20 amp Three 120 240V output receptacles 50 amp Two 120V output receptacles 20 amp optional 3 Circuit Breakers 240V 50 amps 2 GFCI Circuit Breakers 125V 9 20 amps Control Box The Control Box is provided with the following Main Circuit Breaker 1000 amps Over Current Relay Output Terminal Panel The Output Control Panel See Figure 14 is located on the right hand side left from control panel of the generator The UVWO lugs are protected by a face plate
65. d sequence 13 Axle Indicates the maximum weight the axle can sup port in pounds and the diameter of the axle expressed in inches see Table 3 Please not that some trailers have a double axle This will be shown as 2 6000 Ibs meaning two axles with a total weight capacity of 6000 pounds Suspension Protects the trailer chassis from shocks transmitted through the wheels Types of suspension used are leaf Q flex and air ride 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 gt DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 11 DCA 400SSK TRAILER SPECIFICATIONS Table 1 Specifications MODEL APPLICATION FUEL CELL BRAKE SYSTEM GVWR FRAME LENGTH TRLR 10W SDW225 LBS SGW250 TLW300 FRAME JACK WIDTH STAND 15 50 FULL TILT WHEEL 50 800LB FULL TILT WHEE 50 800LB FULL TILT WHEE TRLR 10XF DCA10 TLG 12 52 GAL LBS DCA15 TLW 300 TRLR 225W WELDERS NO 2200LBS 85 42 800LB DA7000SS FULL TILT WHEE TRLR BLW400 BLW 400 NO ELECTRIC 2700LBS W MAST 154 55 800LB W O 124 78 TALL LL TILT WHEE TRLR 50X DCA 25 NO 2700LBS 124 55 800LB FULL TILT WHEE TRLR 50XF DCA 25 41 GAL 2700LBS 124 55 800LB FULL TILT WHEE 2000LB FLAT PAD 2000LB
66. e Change over Board 480V set position 3 Phase 480 Volt The following connection with the voltage change over board set into the 480V set position See Figure 23 can offer THREE PHASE power at 480V After hooking up the hard wires to the lugs as shown in figure 24 below 480V will be the voltage output Voltage Change over Board must be set at 480V Set TO LOAD TO GROUND FIGURE 24 Hard Wire Hookup for Three Phase 480V Single Phase 480 Volt The following connection with the voltage change over board set into the 480V set position See Figure 23 can offer SINGLE PHASE power at 480V After hooking up the hard wires to the lugs as shown in figure 25 below 480 will be the voltage output Voltage Change over Board must be set at 480V Set TO LOAD TO LOAD TO LOAD FIGURE 25 Hard Wire Hookup for Single Phase 480V Single Phase 277 Volt The following connection with the voltage change over board set into the 480V set position See Figure 23 can offer SINGLE PHASE power at 277V After hooking up the hard wires to the lugs as shown in figure 26 below 277V will be the voltage output Voltage Change over Board must be set at 480V Set TO LOAD TO LOAD TO LOAD TO GROUND FIGURE 26 Hard Wire Hookup for Single Phase 277V DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 39 DCA 400SSK INSTALLATION Outdoor Installation Install the generator in a location where it
67. e also been provided to protect the load side of the generator from overload Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine NOTE ALWAYS consult with a licensed electrician for correct extension cord wire size PAGE 42 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK PRE SETUP Lubrication Oil Fuel Fill the engine crankcase with lubricating oil through the filler Fill the fuel tank with clean and fresh diesel fuel DO NOT hole but do not overfill Make sure the generator is level fill the tank beyond capacity With the dipstick inserted all the way but without being screw Pay attention to the fuel tank capacity when replenishing into the filler hole verify that the oil level is maintained fyel Refer to the fuel tank capacity listed on page 23 between the two notches Figure 28 on the dipstick See Specification Table 7 Table 11 for proper selection of engine oil 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 UPPER LIMIT CAUTION I Never fill the fuel tank while the engine is running or in the dark Diesel spillage on a hot engine can cause a fire or explosion If diesel spillage occurs wipe up the spilled diesel completely to prevent fire hazards LOWER D Coolant Use on
68. ed shelf life such as gaskets seals O rings and other rubber parts that were purchased more than six months prior tothe return date c Anylineitemwithan extended dealer netprice of less than 5 00 d Special order items Electrical components f Paint chemicals and lubricants g Decalsandpaper products h Items purchased in kits The sender will be notified of any material receivedthatis not acceptable Such material will be held for 5 working days from notification pending instructions If a reply is not received within 5 days the material will be returned to the sender at his expense Credit on returned parts will be issued at dealer net price at time of the original purchase lessa 15 restocking charge In cases where an item is accepted for which the original purchase document can not be determined the price will be based on the list price that was effective twelve months prior to the RMA date Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changesare effective ona specific date andallorders received on orafter that date will be billed at the revised price Rebates for price declines and added charges for price increases will notbe made for stock on hand at the time of any price change Multiquip reserves the right to quote and sell directto Government agencies and Original Equipment Manufacturer a
69. enerator in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people The generator engine gives off DEADLY carbon monoxide gas CAUTION Always refuel in a well ventilated area away from sparks and open flames Always use extreme caution when working with flammable liquids When refueling stop the engine and allow it to cool DO NOT smoke around or near the machine Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine NEVER operate the generator in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death Topping off to filler port is dangerous as it tends to spill fuel PAGE 6 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 RULES FOR SAFE OPERATION CAUTION CAUTION NEVER touch output terminals during operation This is extremely dangerous Always stop the machine when contact with the output terminals GAUTION Backfeed to 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 CAUTION Never use damaged or worn cables when connecting power tools or equipment to the generator Make sure power
70. evel GENERATOR Insulation Resistance Over 3M ohm 1 Replace engine anf filter at 100 hours first time only 2 Replace fuel filter at 250 Hours first time only DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 57 DCA 400SSK GENERATOR WIRING DIAGRAM DCA4008SK GENERATOR WIRE DIAGRAM CONTROL BOX CONTROL PANEL SETTING FOR OUTPUT VOLTAGE 240 MARK NAME Re RECTIFIER CONTROL PANEL SIDE 0 750 15004 CONNECTOR VE veg OVER SUTTON WIRE SIZE COLOR CODE 2 21244 2 12402 12 020 mr Leow ly from zo Emm v violet o 2 1 PAGE 58 DCA 400SSK PARTS AND OPERATION MANUAL 570 REV 3 09 17 01 NOTE PAGE DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 59 DCA 400SSK ENGINE WIRING DIAGRAM KEY SWITCH DCAA00SSK ENGINE WIRE DIAGRAM MONITOR SOLEnoID EMERGENCY EATER RELAY cb 5 A AIR HEATER PREHEAT LAMP 8 CONTROL BOX LEVEL FUEL GAGE UNIT C BR 1 G o WATER CHARGING AMMETER OIL FILTER E SW 5 I WIRE SIZE COLOR CODE RENE INSIDE CONNECTION
71. following guidelines when handling the battery BATTERY 1 DO NOT drop the battery There is the possibility of risk that the battery may explode 2 DO NOT expose the battery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come in contact with a flame or spark an explosion could occur 3 Always keep the battery charged If the battery is not charged a buildup of combustible gas will occur 4 Always keep battery charging and booster cables in good working condition Repair or replace all worn cables 5 Always recharge the battery an open air environment to avoid risk of a dangerous concentration of combustible gases 6 case the battery liquid dilute sulfuric acid comes in contact with clothing or skin rinse skin or clothing immediately with plenty of water 7 In case the battery liquid dilute sulfuric acid comes contact with your eyes rinse eyes immediately with plenty of water then contact the nearest doctor or hospital and seek medical attention MNEVER Run engine without air filter Severe engine damage may occur W Always service air cleaner frequently to prevent carburetor malfunction Always disconnect the battery before performing service on the generator Always be sure the operator is familiar with proper safety precautions and operations techniques before using generator Always store equipmen
72. 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 willbe accepted and credit will be allowed subject to the following provisions 1 A Returned Material Authorization must beapproved by Multiquip priorto shipment 2 Toobtain a Return Material Authorization alistmustbe provided to Multiquip Parts Sales that defines item numbers quantities and descriptions ofthe itemsto be returned Theparts numbers and descriptions must match the current parts price list b The listmustbe typed or computer generated c Thelistmuststate the reason s for the return d list must reference the sales order s or invoice s under which theitems were originally purchased Thelistmustinclude the name and phone number of the person requestingthe 3 copy of the Return Material Authorizationmustaccompany the return shipment 10 11 Freight is at the sender s expense All parts mustbe returned freight prepaid to Multiquip s designated receiving point Parts must be in new and resalable condition inthe original Multiquip package ifany and with Muiltiquip part numbers clearly marked The following items are not returnable Obsolete parts If an item is listed in the parts price book as being replaced by another item itis obsolete b Any parts with a limit
73. frequency tolerance use the voltage adjustment control knob Figure 41 to increase or decrease the desired voltage Figure 40 Voltage Meter Volts INCREASE DECREASE Figure 41 Voltage Adjust Control Knob 10 12 The ammeter Figure 42 will indicate zero amps with no load applied When a load is applied this meter will indicate the amount of current that the load is drawing from the generator s alternator Figure 42 Ammeter No Load The engine oil pressure gauge Figure 43 will indicate the oil pressure kg cm of the engine Under normal Operating conditions the oil pressure should be approximately 25 psi Figure 43 Oil Pressure Gauge The coolant temperature gauge Figure 44 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 165 and 215 degrees Fahrenheit Figure 44 Coolant Temperature Gauge DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 49 DCA 400SSK GENERATOR STARTUP PROCEDURE KEY SWITCH 13 The tachometer Figure 45 will indicate the speed of 16 Observe the generator s ammeter Figure 48 and verify the engine when the generator is operating Under normal that it reads the anticipated amount of current with operating conditions this speed should be approximately respect to the load Remember the ammeter will only 1800 RPM s display a current reading if the load is in use
74. h the system watch carefully the water inlet hose does not come out of the radiator filler port After flushing stop the engine open drain plug and drain the water then close drain plugs After draining the water flush the system with a flushing agent See instructions on flushing agent label After flushing open drain plugs and drain out all the water then close drain plugs and add tap water so the water level is near the mouth of the water filler When the water level is near the mouth of the water filler open drain plugs and start the engine run at low idling and continue to flush the system until clean water comes out Adjust the flow of the water flowing in and draining out to ensure the radiator is always full during the flushing operation When clean water comes out stop the engine drain all the water then close drain plugs Remove the corrosion resistor if equipped and open valve Supply water until it flows over the water filler Drain the water inside reserve tank clean the inside of the reserve tank then fill with coolant water mixture to between the full and low lines Stop the engine wait for 3 minutes add tap water until the water level reaches near the water filer port then tighten the radiator cap Check Electric Heater If equipped Before starting in cold weather once a year please contact your Komatsu distributor for inspection Remove electric heater from the engine intake manifold a
75. h the trailer s bumper to prevent tipping while parked Use the trailers hand winch to adjust the height of the trailer then insert locking pin to lock wheel stand in place while parked Avoid sudden stops and starts This can cause skidding or jackknifing Smooth gradual starts and stops will improve gas milage Avoid sharp turns to prevent rolling Remove wheel stand when transporting DO NOT transport generator with fuel in tank CHOCKED BLOCK PREVENT ROLLING SUPPORT BLOCKS Generator with Trailer PAGE 10 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK TRAILER SAFETY GUIDELINES GAUTION ALWAYS make sure the trailer is in good operating condition Check the tires for proper inflation and wear Also check the wheel lug nuts for proper tightness Explanation of Chart This section is intended to provide the user with trailer ser vice and maintenance information The service and mainte nance guidelines referenced in this section apply wide range of trailers Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent dam age to the equipment and personal injury It is the purpose of this section to cover the major mainte components of the trailer The following trailer com ponents will be discussed in this section Brakes B Tires B Lug Nut Torquing Suspension B Electrical
76. hird Day UPS Next Day Federal Express Priority One please provide us with your Federal Express account number Airborne Express Truck or parcel post Normally shipped the same day the order is received if prior to 2PM west coast time Earn Extra Discounts when you order by FAX All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts Number of line items ordered Additional Discount 1 9 items 3 10 items 5 Get special freight allowances when you order 10 or more line items via FAX Now Direct TOLL FREE access UPS Ground Service at no charge for freight to our Parts Department PS Third Day Service at one half of actual freight cost Toll free nationwide No other allowances on freight shipped by any other carrier Ll our cd Common nuts bolts and washers all items under 1 00 list price 800 421 1244 do not count towards the 10 line items Toll free FAX DISCOUNTS ARE SUBJECT TO CHANGE 800 6 PARTS 7 800 672 7877 Fax order discount and UPS special programs revised June 1 1995 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 5 RULES FOR SAFE OPERATION CAUTION Failure to follow instructions in this manual may lead to serious injury or even death This equipment is to be operated by trained and qualified personnel only This equipment is for industrial use only
77. iator 16 9 Gal 64 0 Liters Reserve Tank 2 Quarts 1 9 Liters Operation in Freezing Weather When operating in freezing weather be certain the proper amount of antifreeze Table 13 has been added Table 13 Anti Freeze Operating Temperatures Freezing Point Boiling Point Vol Anti Freeze i When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with compressed air Cleaning inside the machine is dangerous So clean only with the engine turned off and the battery disconnected Air Cleaner Periodic cleaning replacement is necessary See maintenance section for instruction to cleaning replacing air cleaner Fan Belt Tension slack fan belt may contribute to overheating or to insufficient charging of the battery Inspect the fan belt for damage and wear See maintenance section on replacing belts To adjust tension 1 Insert bar between alternator and the cylinder block to fix alternator in position When fixing the alternator in position insert a wooden block between the bar and alternator to prevent damage to the alternator 2 Loosen bolts and nuts located on the alternator 3 Move alternator with the bar so the deflection of the belt is approx 8mm 4 Tighten the bolt and nuts to fix the alterna
78. ician must install an isolation transfer switch Serious injury or death may result without this transfer switch CAUTION When connecting the generator to a isolation transfer switch ALWAYS have power applied to the generator s internal battery charger This will ensure that the engine will not fail due to a dead battery Starting the generator in the AUTO mode is similar to starting the generator in the MANUAL mode with few exceptions CAUTION When running the generator in the AUTO mode remember the generator can start up at any time without warning NEVER attempt to perform any maintenance when the generator is in the auto mode When starting generator in Auto mode use the Manual Start up procedure except where noted see below 1 Perform steps 1 through 6 Before Starting page 47 48 as outlined in the manual starting procedure 2 Apply commercial power to the internal battery charger receptacle to ensure good starting via commercial power An external power cord will be required 3 Apply commercial power to the jacket water heater receptacle not necessary for warm climates via commercial power An external power cord will be required 4 Place the Off Manual Auto switch Figure 51 in the AUTO position MANUAL OFF RESET Figure 51 Off Manual Auto Switch AUTO 5 Continue to follow the steps outline in the manual start up procedure start at step 11 page 49 D
79. l strainer if it contains dust or water Remove dust or water in the strainer cap and wash it in diesel Securely fasten the fuel strainer cap so that fuel will not leak Check the fuel strainer every 200 hours of operation or once a month Check Oil Level Check the crankcase oil level prior to each use or when the fuel tank is filled Insufficient oil may cause severe damage to the engine Make sure the generator is level The oil level must be between the two notches on the dipstick as shown in Figure 28 page 43 Flushing Out Radiator and Changing Coolant 1 Stop the engine and allow to cool Tighten valve of the corrosion resistor if equipped Turn water filer cap slowly and remove it Prepare a container to catch the coolant then open drain plug of the radiator or heat exchanger and drain plug of the engine and drain the coolant 4 After draining the coolant close drain plugs and fill with tap water PAGE 54 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK MAINTENANCE 5 10 11 12 13 14 15 When the water level is near the mouth of the water filler open drain plugs and start the engine and run at low idling Keep the engine running at low idling and flush the radiator for about 10 minutes Adjust the flow of the water flowing and draining out to ensure that the radiator is always full during the flushing operation While flushing water throug
80. le 11 on page 43 3 Check the coolant level in the radiator and subtank Replenish with antifreeze as necessary Always maintain the coolant level between the FULL and LOW markings on the coolant container Be sure the radiator cap is fastened securely 4 Check the fuel level on the fuel gauge If fuel is low fill the fuel tank with clean fresh unleaded automotive diesel If diesel spillage occurs completely wipe up the spilled fuel immediately Before Starting Generator and Control Panel CAUTION NEVER start the engine with the main or load circuit breakers in the ON position 1 Be sure to disconnect the electrical load and switch the main load and G F C I circuit breakers Figure 31 to the OFF position prior to starting the engine CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER MAIN RECEPTACLE OUTPUT RECEPTACLES Figure 31 Main GFCI and Load Circuit Breakers Jacket Water Heater and Internal Battery Charger 120 VAC Output Receptacles OPTIONAL This generator is equipped with two 120 VAC 20 amp output receptacles located on the output terminal panel page 43 Figure 14 The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal battery charger These receptacles will ONLY function when commercial power has been supplied to them Figure 31 To apply commercial power to these receptacles a power cord of adequate size will be re
81. ly drinkable tap water If hard water or water with many impurities is used the inside of the engine and radiator may become coated with deposits and cooling efficiency Figure 28 Engine Oil Dipstick will be reduced When checking the engine oil be sure to check if the oil is clean and viscous If the oil is not clean drain the oil by removing the oil drain plug and with the specified amount of oil as outlined in the Komatsu Engine Owner s Manual An anticorrosion additive added to the water will help prevent deposits and corrosion in the cooling system See the engine manual for further details Table 11 Recommended Motor Oil Temperature Range Type Oil 104 F 23 F 40 C 5 C FEN 23 5 5 C 2 15 20 or SAE 10W 30 Below 5 15 SAE 10W or SAE 10W 30 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 43 DCA 400SSK PRE SETUP CAUTION When adding coolant or antifreeze to the radiator do not remove the radiator cap until the unit has completely cooled Day to day addition of coolant is done from the reserve tank When adding coolant to the radiator DO NOT remove the radiator cap until the unit has completely cooled See Table 12 for engine radiator and reserve tank coolant capacities Make sure the coolant level in the reserve tank is always between the and the L markings Table 12 Coolant Capacity Engine and Rad
82. nd check for disconnections or dirt When checking or installing the electric heater replace the gasket with a new part Changing Oil 1 2 Make sure the oil is cool before changing Set a container directly under the drain plug of the oil pan Loosen the drain plug slowly Check the drained oil for excessive metal particles or foreign material Contact the distributor if there is metal particles or foreign material Using a filter wrench turn filter cartridge to the left to remove it If the filter cartridge is filled with a large amount of oil wait 10 minutes or so before removing Make sure there is no old gasket stuck on the filter holder Tighten drain plug Clean the filter holder fill the new filter cartridge with clean engine oil coat the packing and thread of the new filter cartridge with engine oil then install it to the filter holder Tighten until the gasket surface contacts the seal surface of the filter holder then tighten it a further 3 4 to 1 turn Add engine oil through oil filler until the oil level is between the H and L marks on the dipstick Run the engine at idling for a short time then stop the engine Recheck the oil level and fill as necessary Replacing fuel filter 1 2 Set the container under the filter cartridge to catch fuel Using a filter wrench turn the filter cartridge to the left to remove it Clean the filter holder fill the new filter cartridge with fuel coat the packi
83. ng of the generator and create other malfunctions Wiring Inspect the entire generator for bad or worn electrical wiring or connections If any wiring or connections are exposed insulation missing replace wiring immediately Piping and Hose Connection Inspect all piping oil hose and fuel hose connections for wear and tightness Tighten all hose clamps and check hoses for leaks If any hose fuel or oil lines are defective replace them immediately Battery This unit is of negative ground DO NOT connect in reverse Always maintain battery fluid level between the specified marks Battery life will be shortened if the fluid level is not properly maintained Add only distilled water when replenishment is necessary The battery is sufficiently charged if the specific gravity of the battery fluid is 1 28 at 68 F If the specific gravity should fall to 1 245 or lower it indicates the battery is discharged and needs to be recharged or replaced Check to see whether the battery cables are loose Poor contact may result in poor starting or malfunctions Always keep the terminals firmly tightened Coating the terminals with a thin film of grease will help inhibit corrosion DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 45 DCA 400SSK LOAD APPLICATION Single Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage amperage and frequency req
84. ng surface of the filter cartridge with engine oil then install the cartridge to the filter holder When installing tighten until the packing surface contacts the seal surface of the filter holder then tighten a further 2 3 of a turn If the filter cartridge is tighten too much the packing will be damaged and will cause fuel leakage Fuel leakage will occur if the filter cartridge is not tightened enough Always tighten to the correct angle After replacing filter cartridge loosen air bleed plug Loosen the knob of feed pump and pump it up and down until no bubbles come our with the fuel from air bleed plug DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 55 DCA 400SSK MAINTENANCE 13 After bleeding the air tighten air bleed plug then push in the knob of feed pump and lock it in position Replace Corrosion resistor cartridge if equipped Screw in valves at the top of the corrosion resistor Using a filter wrench turn the cartridge to the left to remove it Coat the seal surface of the new cartridge with engine oil and install it to the filter holder Tighten until he packing surface contacts the seal surface of the filter holder then tighten a further 2 3 of a turn Open valves Cleaning breather element 1 Loosen the clamp then remove the hose and take out breather Wipe off the dirt around the breather Check the O ring and replace if necessary W
85. oss of chamber or overloading n Check bearing adjustment Cupping and balance tires Wheel lockup amp Avoid sudden stops when vie Flat Spots tire skidding possible and adjust brakes Suspension The leaf suspension springs and associated components Figure 4 should be visually inspected every 6 000 miles for signs of excessive wear elongation of bolt holes and loosening of fasteners Replace all damaged parts suspension immediately Torqued suspension components as detailed in Table 3 SHACKLE SUPPORT BRACKET IS WELDED TO FRAME SHACKLE HANGER SUPPORT BRACKET IS WELDED SHACKLE TO FRAME BOLTS LEAF SUSPENSION FRONT HANGER NUT FRONT U BOLT HANGER BOLT LOCKING TIE PLATE Figure 4 Major Suspension Components PAGE 16 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK TRAILER SAFETY GUIDELINES Table 3 Suspension Torque Requirements SNUG FIT ONLY PARTS MUST ROTATE FREELY LOCKING SHACKLE BOLT SPRING EYE BOLT NUTS OR COTTER PINS ARE PROVIDED TO RETAIN NUT BOLT ASSEMBLY SHOULDER TYPE MIN 30 MAX 50 SHACKLE BOLT Lug Nut Torque Requirements It 5 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 5 LUG NUTS 8 LUG NUTS 1 Start all wheel lug nuts by hand 2 Torque all lug
86. our x S N3696510 TERMINAL fr 5 3696510 TS144P MACHINE 5 ER S N3696510 ENGINE CONTROLLER e S N3696510 TO 3699149 ENGINE NN S N3699150 REPLACES 0602202545 SWITCH RA Pune S N3696510 TO 3698125 82608DPDT SWITCH eo er 15 58 S N3698126 S303T SPEED SENSOR Tee S N3696510 DYNT 11200 SEALED CABLE S N3696510 TEHN23670201 CONTROLLER ss S N3701677 MACHINE 5 5 3701677 oe PNE S N3701677 RA20ASE502BJ BRAGE he S N3701677 HEX HEAD BOLT gt 5 3701677 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 75 DCA 400SSK ENGINE amp RADIATOR ASSY ENGINE amp RADIATOR ASS DO 9 NESS AUNT PAGE 76 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK ENGINE amp RADIATOR ASSY ENGINE amp RADIATOR ASSY NO PART PART NAME QTY REMARKS 1 C3924200054 ENGINE 5 3692434 3701676 KOMATSU SA6D 140 2 C3925200004 d 5 3701677 SA6D140E 2 2 6125817051 ELEMENT AIR REPLACES 0602040157 3 6002111231 CARTRIDGE OIL 15420
87. ow 15 psi The oil pressure is detected using variable resistive values from the oil pressure sending unit This is considered major fault C High Coolant Temperature Indicates the engine temperature has exceeded 215 F The engine temperature is detected using variable resistive values from the temperature sending unit This is considered a major fault D Overcrank Shutdown Indicates the unit has attempted to start a pre programmed number of times and has failed to start The number of cycles and duration are programmable Typical programmable start settings is 3 cycles with a 10 second duration This is considered a 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 11 Main Circuit Breaker This three pole 1000 amp main breaker is provided to protect the UVW voltage output terminals from overload DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 31 DCA 400SSK ENGINE OPERATING PANEL ENGINE THROTTLE TACHOMETER ENGINE WARNING DISPLAY LED OIL PRESSURE GAUGE 6 ACAMMETER GAUGE 8 9 PREHEATBUTTON EMERGENCY STOP BUTTON STARTER SWITCH BATTERY SWITCH ENGINE SPEED SWITCH td 4 5 6 D 2 10 Engine Operating Panel PAGE
88. ow much power is being supplied produced at the UVWO legs To read the output of the W U legs for example place the Voltmeter Change over switch to the W U position and the AC ammeter Change over Switch to the U or W position to read the output on the selected leg OFF FIGURE 15 AC Voltmeter FIGURE 16 AC Voltmeter Change over switch Gauge Reading the W U leg on i A the output terminal panel NO rpad ing orug V FIGURE 17 AC Ammeter FIGURE 18 AC Ammeter Change over Switch Amp reading on U lug Reading the U leg on the output terminal panel DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 37 DCA 400SSK OUTPUT TERMINAL PANEL OVERVIEW Voltage Change over Board The voltage change over board changes the available voltages of the output terminal panel UVWO lugs The voltage change over board is located on the control box behind the control panel There are six 6 plates that can be set into two set positions to get six different voltages Unless specified differently the generator comes from the factory in the 240V position 240 Volt Set position The voltage change over board 240V set position uses all 6 plates in 6 different connection places See figure 19 below FIGURE 19 Voltage Change over Board 240V set position 3 Phase 240 Volt The following connection with the voltage change over board set into the 240V set position See Figure 19 can offer THRE
89. pecifications Electronic Governor System The electronic governor system replaces the standard mechanical governor system The frequency regulation improves from 3 0 regulation with the mechanical governor to 0 25 regulation with the electronic governor system Jacket Water Heater OPTIONAL The jacket water heater is a 1500 watt heater designed to keep the coolant warm in the engine block for fast starts and load acceptance The heater is thermostatically controlled and once an acceptable engine temperature is achieved it will cycle on and off operating only about 1 3 of the time which makes it more efficient than the direct block type heater It is designed to keep the engine coolant between 100 and 120 degrees Fahrenheit Under normal conditions 20 to 15 minutes is required to raise the engine temperature of a cold engine to 100 degrees Fahrenheit Battery Charger The battery charger will operate in a BOOST mode until the battery s current acceptance falls to 70 of the charger s rating The charger will then go into a FLOAT mode where it discharges a lower voltage until an AC failure or the battery is discharged DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 25 DCA 400SSK MAJOR COMPONENTS O 504 DESCRIPTION MUFFLER ASSEMBLY ENGINE amp RADIATOR ASSEMBLY ENCLOSURE ASSEMBLY CONTROL BOX ASSEMBLY OUTPUT TERMINAL ASSEMBLY 6 GENERATOR
90. quired When using the generator in hotclimates there is no reason to apply power to jacket water heater However if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size If the generator will be used daily the battery should normally not require charging If the generator will be idle not used for long periods of time apply power to the battery charger receptacle via commercial power using an power cord of adequate size When connecting the generator to a isolation transfer switch ALWAYS have power applied to the generator s internal battery charger This will ensure that the engine will not fail due to a dead battery CAUTION ALWAYS have power applied to the generator s internal battery charger when connecting the generator to a isolation transfer switch Remember before connecting this generator to any buildings electrical system have a licensed electrician perform the installation of the transfer switch DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 47 DCA 400SSK GENERATOR START UP PROCEDURE KEY SWITCH 2 Connect the load to the UVW terminals as shown in 4 Close all engine enclosure doors Figure 34 Figure 32 These terminals can be found on
91. s 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 CAUTION An electric shock may happen when vibrators are used Pay close attention to handling when operating vibrators and always use rubber boots and gloves to insulate the body from electrical shock Generator Grounding 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 mm or larger b Aluminum 8 AWG 8 4 mm or larger 2 When grounding the generator Figure 27 connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully Connect the other end of the ground cable to earth ground 3 NEC article 250 52 c specifies that the earth ground should be buried minimum of 8 ft into the ground NOTE When connecting the generator to any buildings ele
92. t properly when not in use Equipment should be stored in a clean dry location out of the reach of children NOT leave the generator running in the manual mode unattended NOT allow unauthorized people to operate this equipment M Always read understand and follow procedures in Operator s Manual before attempting to operate equipment Mi Refer to the Komatsu Engine Owner s Manual for engine technical questions or information Loading and Unloading Crane Before lifting make sure the generator s lifting hook 15 secure and that there is no apparent damage to the generator itself loose screws nuts and bolts If any part is loose or damaged please take corrective action before lifting Always drain fuel prior to lifting Make sure the crane or lifting device has been properly secured to the hook of guard frame on generator NEVER lift the machine while the engine is running Use adequate lifting cable wire or straps of sufficient strength When lifting the generator always use the balanced center point suspension hook and lift straight upwards NEVER allow any person or animal to stand underneath the machine while lifting When loading the generator on a truck be sure to use the front and back frame bars as a means to secure the generator during transport PAGE 8 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 RULES FOR SAFE OPERATION Transpor
93. tarting the engine Maximum Output The entire load connected to the UVWO Lugs all four slots in the duplex receptacles and the must not exceed 352 kW in standby or 320 in prime output Twist Lock Dual Voltage Receptacles Three 5 6369 auxiliary power receptacles have been provided to supply 208 120V The voltage regulator knob on the control panel may need to be used to adjust the voltage to 208 or 416V Input Receptacles Two 120 volt 20 amp input receptacles are provided to supply power to accessories such as the battery charger optional or jacket water heater optional DCA 400SSK OUTPUT TERMINAL PANEL OVERVIEW CIRCUIT BREAKERS FOR OUTPUT AND GFCI RECEPTACLES 120 20 RECEPTACLES OUTPUT TERMINAL PANEL AUX POWER RECEPTACLES 139 240V 50 AMPS POWER OUTPUT GROUND TERMINALS TERMINAL NOTE AD FIGURE 14 Output Terminal Panel Legs 0 and Ground are L2 y 11 considered Bonded Grounds 5 6369 TWIST LOCK DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 35 DCA 400SSK OUTPUTTERMINAL PANEL OVERVIEW Output Terminal Panel Available Voltages A wide range of voltages are available to supply load to many different applications Voltages may be selected by using the voltage change over board and how you hookup your hard wire connection to the generator To obtain some of the voltages listed fine adjustment with the
94. ting Always shutdown engine before transporting Tighten fuel tank cap securely Drain fuel when transporting generator over long distances or deteriorated roads Always tie down the generator during transportation by securing the generator generator is mounted on a trailer make sure trailer complies with all local and state safety transportation laws See page 10 for basic towing procedures Emergencies Always know the location of the nearest fire extinguisher and first aid kit Know the location of the nearest telephone Also know the phone numbers of the nearest ambulance doctor and fire department Maintenance Safety NEVER lubricate components or attempt service on a running machine Always allow the machine a proper amount of time to cool before servicing Keep the proper running condition Fix damage to the machine immediately and always replace broken parts Dispose of hazardous waste properly Examples of potentially hazardous waste are used motor oil coolant fuel and fuel filters DO NOT use plastic containers to dispose of hazardous waste DO NOT pour waste oil coolant or fuel directly onto the ground down drain or into any water source DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 9 DCA 400SSK TOWING Towing Safety Precautions CAUTION Check with your county or state safety towing regulations depar
95. tment before towing your generator To reduce the possibility of an accident while transporting the generator on public roads always make sure the trailer Figure 1 that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound The following list of suggestions should be used when towing your generator Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating GVWR ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings chains etc Check the tire air pressure on both towing vehicle and trailer Also check the tire tread wear on both vehicles ALWAYS make sure the trailer is equipped with a Safety Chain HAND WINCH ADJUSTS TRAILER HEIGHT S VN WHEEL STAND LOCKING PIN Figure 1 ALWAYS attach trailer s safety chain to bumper of towing vehicle ALWAYS make sure the vehicle and trailer directional backup brake and trailer lights are connected and working properly The maximum speed unless otherwise posted for highway towing is 55 MPH It is not recommended for off road towing However if necessary do not exceed 15 MPH or less depending on type of terrain to prevent damage to the axles Place chocked blocks underneath wheel to prevent rolling while parked Place support blocks underneat
96. to OFF P eset the STARTER SWITCH to START POS TION Rotate the THROTTLE HANDLE TO THE Low Speed s de to start the eng ne Coo down the engine for about 5 m nutes When the engne starts release the STARTER SW 2 Depress the STOP BUTTON 8 Warm up the eng ne for about 5 m nutes the eng ne stops completely tu n OFF STARTER 4 Rotate the THROTTLE HANDLE to GH SPEED and SWITCH and BATTERY SW TCH ad eng ne speed according to the fol ow ng tab 60 Hz operat on Approx 62 5 Hz 1875 C15200040 P N C1552000403 HOT PARTS can burn skin Do not touch until the machine has sufficiently cooled ui 6 B90400030 P N B9504000304 DIESEL FUEL can cause fire or explosion e Stop engine before fueling Keep cigarettes sparks and flame away P N B9504500004 WHISPERWATT 400 MQ POWER CORP WHISPERWATT 400 POWER 400 KVA AC GENERATOR MODEL DCA 400SSK C36110110 B90450000 P N C3561101103 WATER OIL CHECK AND FILL DAILY C05100040 C0551000404 DIESEL FUEL 1756 P N 1320620904 SAFETY INSTRUCTIONS Improper operat on of this machine can cause severe njury or death eRead the nstruction manual carefully before operating or servicing This machine shou d on y be operated by a person with sufficient knowledge and skill to ensure safe operation H gh voltage circuits are located ins de the ou
97. to expand the brake shoes 5 Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn 6 Rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag 7 Replace the adjusting hole cover and lower the trailer to the ground 8 Repeat steps 1 through 6 on the remaining brakes PAGE 14 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 40055 TRAILER SAFETY GUIDELINES Retractor Spring Hold Down Washer Self Adjusting Cable Adjuster Spring Adjuster Lever Adjuster Assembly Figure 2 Electrical Brake Components Hydraulic Air Surge Brakes Hydraulic brakes Figure 3 should not require any special attention with the exception of routine maintenance such as shoe and lining replacement These brakes can be adjusted in the same manner as electric brakes Brake lines should be periodically checked for cracks kinks or blockage Figure 3 below displays the major hydraulic air surge brake Anchor Post Retractor Springs Plate Adjuster Spring components that will require inspection and maintenance Please inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section Hold Down Spring Primary Shoe Adjuster Assembly Figure 3 Hydraulic Brake Components DCA 400SSK PARTS AND OPERATION MANUAL
98. tor back to position The fan belt tension is proper if the fan belt bends 7 to 10 mm Figure 29 when depressed with the thumb as shown below 7 10 MM DEFLECTION Figure 29 Fan Belt Tension CAUTION Never place hands near the belts or fan while the generator set is running PAGE 44 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK PRE SETUP Battery Cable Installation ALWAYS be sure the battery cables Figure 30 are properly connected to the battery terminals as shown below The RED cable is connected to the positive terminal of the battery and the BLACK cable is connected to the negative terminal of the battery POSITIVE NEGATIVE BATTERY Figure 30 Battery Connections CAUTION If the battery cable is connected incorrectly electrical damage to the generator will occur Pay close attention to the polarity of the battery when connecting the battery When connecting battery do the following 1 DO NOT connect the battery cables to the battery terminals when the Off Manual Auto switch is in either the manual or auto position ON ALWAYS make sure that the Off Manual Auto switch is in the OFF position when connecting the battery 2 Place a small amount of grease around both battery terminals This will ensure a good connection and will help prevent corrosion around the battery terminals CAUTION Inadequate battery connections may cause poor starti
99. tput termina cover and control panel e Close the cover and contro pane before operat ng Moving parts and hot surfaces are contained w thin the enc osure Close al doors and lock them before operat ng C251 00000 P N C2551000004 __ WARNING ELECTRIC SHOCK HAZARD 9 Do not touch nternal wiring or connections while this machine is operating Turn power off before servicing B93110060 P N B9531100604 CIRCUIT BREAKER 5 3031 08406 24504 PILOT LAMP 5 3033 P N 0840624704 SUPPORT HOOK Never use it for lifting the unit Use the LIFT HOOK on the roof for lifting S 2257 P N 13206 21504 P N 0840625902 PAGE 22 DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 DCA 400SSK SPECIFICATIONS Generator Specifications Engine Specifications 20 4gal 77 5L hr at full load 15 8gal 59 8L hr at 3 4 load Fuel Consumption 11 0gal 41 6L hr at 1 2 load 6 6gal 25 0L hr at 1 4 load Battery 12V 200 AH x 2 Fuel 2 Diesel Fuel DCA 400SSK PARTS AND OPERATION MANUAL STD REV 3 09 17 01 PAGE 23 DCA 400SSK GENERAL INFORMATION DCA 400SSK FAMILIARIZATION Generator The Power Model DCA 400SSK is 320 kW generator that is designed as high quality portable requires a trailer for transport power source for telecom sites lighting facilities power tools submersible pumps and other industrial and construction machinery Engine
100. uirements are satisfactorily supplied by the generator for operating the equipment Generally the wattage listed on the nameplate of the equipment is its rated output Equipment may require 130 150 more wattage than the rating on the nameplate as the wattage is influenced by the efficiency power factor and starting system of the equipment NOTE If wattage is not given on the equipment s name plate approximate may be determined by multiplying nameplate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 14 below when connecting loads Table 14 Power Factor By Load Type Of Load Single phase induction motors Power Factor 0 4 0 75 Electric heaters incandescent 1 0 lamps Fluorescent lamps mercury lamps Electronic devices communication equipment Three Phase Load When calculating the power requirements for 3 phase power use the following equation VOLTAGE X AMPERAGE X 3 1 732 1000 KVA CAUTION Motors and motor driven equipment draw much greater current for starting than during operation An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable 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
101. w describe the controls and functions of the DCA 400SSK Control Panel Figure 8 1 Pilot Lamp Indicates that the generator is working properly 2 Panel Light Normally used in dark areas or at night time When activated panel lights will illuminate When the generator is not in use be sure to turn the panel light switch to the OFF position 3 Frequency Meter Indicates the output frequency in hertz Hz Normally 60 Hz 1 Hz 4 AC Ammeter Indicates the amount of current the load is drawing from the generator 5 AC Voltmeter Indicates the single phase output voltage present at the UVW terminals 6 Ammeter Change Over Switch This switch allows the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals or to be switched off 7 Voltmeter Change Over Switch This switch allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off 8 Panel Light Switch When activated will turn on control panel light 9 Voltage Regulator Control Allows manual adjustment of the generator s output voltage 10 Engine Controller for S N 3696510 The engine controller as a vertical row of status LED s Figure 9 that when lit indicate that an engine malfunction fault has been detected When a fault has been detected the engine controller will evaluate the fault and if the fault is major will shutdown
102. will not be exposed to rain or sunshine Make sure the generator is on secure level ground so that it cannot slide or shift around Also install the generator in manner 0 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 Pay close attention to ventilation when operating the generator inside tunnels and caves The engine exhaust contains noxious elements Engine exhaust must be routed to a ventilated area Indoor Installation Exhaust gases from diesel engines are extremely poisonous Whenever an engine is installed indoors the exhaust fumes must be vented to the outside The engine should be installed at least two feet from any outside wall Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves Mounting The generator must be mounted on 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 inche
103. ystem can be modulated to provide more or less braking force thus easing the brake load on the towing vehicle Brake system has very little lag time between the time the vehicle s brakes are actuated and the trailer s brakes are actuated Brake system can provide an independent emergency brake system Remember in order to properly synchronize the tow vehicle s braking to the trailer s braking can only be accomplished by road testing Brake lockup grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under adjusted brakes Before any brake synchronizations adjustments can be made the trailer brakes should be burnished in by applying the brakes 20 30 times with approximately 20 m p h decrease in speed e g 40 m p h to 20 m p h Allow ample time for brakes to cool between application This allows the brake shoes to slightly be seated into the brake drum surface Figure 2 displays the major electric brake components that will require inspection and maintenance Please inspect these components as required Electric Brake Adjustment 1 Place the trailer on jack stands Make sure the jack stands are placed on secure level ground 2 Check the wheel and drum for free rotation 3 Remove the adjusting hole cover from the adjusting slot at the bottom brake backing plate 4 With a screwdriver or standard adjusting tool rotate the star wheel of the adjuster assembly

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