Page 3 - HERE'S HOW TO GET HELP
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 3 HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBERON-HAND WHEN CALLING P P P P PAR AR AR AR ARTS DEP TS DEP TS DEP TS DEP TS DEPAR AR AR AR ARTMENT TMENT TMENT TMENT TMENT 800/427-1244 or 310/537-3700FAX: 800/672-7877 ...
Page 4 - TABLE OF CONTENTS; NOTE
PAGE 4 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) Here's How To Get Help ............................................. 3Table Of Contents ...................................................... 4Rules For Safe Operation ...................................... 6-9Towing ................
Page 5 - PARTS ORDERING PROCEDURES; at no charge for freight; at one-half of actual freight cost; UPS; Earn Extra Discounts when; to our Parts Department!; Extra Fax Discount
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 5 PARTS ORDERING PROCEDURES Get special freight allowanceswhen you order 10 or moreline items via FAX!** ■ UPS Ground Service at no charge for freight ■ PS Third Day Service at one-half of actual freight cost No other allowances on ...
Page 9 - RULES FOR SAFE OPERATION
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 9 Transporting ■ Always shutdown engine before transporting. ■ Tighten fuel tank cap securely. ■ Drain fuel when transporting generator over long distancesor bad roads. ■ Always tie-down the generator during transportation bysecurin...
Page 10 - Figure 1. Generator with Trailer
PAGE 10 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) To reduce the possibility of an accident while transportingthe generator on public roads, always make sure the trailer(Figure 1) that supports the generator and the towing vehicleare in good operating condition and both units arem...
Page 14 - DCA-400SPK — TRAILER SAFETY GUIDELINES; Brakes
PAGE 14 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — TRAILER SAFETY GUIDELINES Brakes If your trailer has a braking system, the brakes should beinspected the first 200 miles of operation. This will allow thebrake shoes and drums to seat properly. After the first 200mile...
Page 15 - Figure 2. Electrical Brake Components
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 15 DCA-400SPK — TRAILER SAFETY GUIDELINES Hydraulic/Air/Surge Brakes Hydraulic brakes (Figure 3) should not require any specialattention with the exception of routine maintenance such asshoe and lining replacement. These brakes can ...
Page 16 - Figure 4. Major Suspension Components; Suspension
PAGE 16 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) Tires/Wheels/Lug Nuts T i r e s a n d w h e e l s a r e a ver y i m p o r t a n t a n d c r i t i c a lcomponents of the trailer. When specifying or replacing thetrailer wheels it is important the wheels, tires, and axle areproper...
Page 17 - Lug Nut Torque Requirements; After first road use, retorque all lug nuts in sequence.; Figure 5. Wheel Lug Nuts Tightening Sequence
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 17 s t n e m e r i u q e R e u q r o T n o i s n e p s u S . 3 e l b a T m e t I ) . s b L - . t F ( e u q r o T T L O B - U " 8 / 3 5 3 - X A M 0 3 - N I M T L O B - U " 6 1 / 7 0 6 - X A M 5 4 - N I M T L O B - U " 2 /...
Page 19 - DCA-400SPK — TRAILER-BRAKE TROUBLESHOOTING
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 19 g n i t o o h s e l b u o r T e k a r B c i r t c e l E . 5 e l b a T m o t p m y S e s u a C e l b i s s o P n o i t u l o S t n e t t i m r e t n I r o s e k a r B o N s e k a r B ? s e r i w n e k o r b r o s t i u c r i c n e...
Page 21 - Machine Safety Decals; DCA-400SPK — OPERATION AND SAFETY DECALS
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 21 Machine Safety Decals The DCA-400SPK generator is equipped with a number of safety decals. These decals are provided for operator safety andmaintenance information. The illustration below and on the preceding pages shows the deca...
Page 23 - DCA-400SPK — SPECIFICATIONS; if
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 23 DCA-400SPK — SPECIFICATIONS s n o it a c if i c e p S . 7 e l b a T s n o it a c if i c e p S r o t a r e n e G l e d o M K P S 0 0 4 - A C D e p y T r o t a r e n e g s u o n o r h c n y s e p y t d e t c e t o r p n e p o , d e...
Page 24 - DCA-400SPK — GENERAL INFORMATION
PAGE 24 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — GENERAL INFORMATION DCA-400SPK FAMILIARIZATION Generator The MQ Power Model DCA-400SPK is a 320 kW gener gener gener gener generator ator ator ator ator that is designed as a high quality portable (requires a trailerf...
Page 25 - Mechanical Governor System; The
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 25 DCA-400SPK — GENERAL INFORMATION Mechanical Governor System The mechanical governor system control the RPM of theengine. When the engine demands increase or decrease,the mechanical governor system regulates the frequencyvariation...
Page 26 - DCA-400SPK — MAJOR COMPONENTS; Figure 6. Major Components
PAGE 26 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — MAJOR COMPONENTS Figure 6. Major Components
Page 27 - NOTE PAGE
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 27 NOTE PAGE
Page 28 - Figure 7a. Dimensions
PAGE 28 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — DIMENSIONS (TOP AND SIDE) Figure 7a. Dimensions
Page 29 - Figure 7b. Dimensions
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 29 DCA-400SPK — DIMENSIONS (FRONT AND REAR) Figure 7b. Dimensions
Page 30 - DCA-400SPK — CONTROL PANEL; Figure 8. Control Panel
PAGE 30 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — CONTROL PANEL Figure 8. Control Panel
Page 31 - Figure 9. MPEC Module
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 31 DCA-400SPK — CONTROL PANEL The definitions below describe the controls and functions ofthe DCA-400SPK " Control Panel Control Panel Control Panel Control Panel Control Panel " (Figure 8). 1. Pilot Lamp – Indicates that th...
Page 32 - DCA-400SPK — ENGINE OPERATING PANEL; Figure 10. Engine Operating Panel
PAGE 32 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — ENGINE OPERATING PANEL Figure 10. Engine Operating Panel
Page 34 - DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW; FIGURE 12. GFCI Test Button
PAGE 34 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW Circuit Breakers To protect the generator from an overload, a 3-pole, 1000amp, main main main main main circuit breaker is provided to protect the UVW output terminals from overload. In ...
Page 35 - FIGURE 14. Output Terminal Panel
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 35 DCA-400SPK — OUTPUT TERMINAL PANEL OVERVIEW L e g s O a n d G r o u n d a r econsidered Bonded Grounds. NOTE FIGURE 14. Output Terminal Panel
Page 36 - attempt to change the Voltage; Over Current Relay
PAGE 36 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) E L B A L I A V A S E G A T L O V . 8 E L B A T L E D O M K S S 0 0 4 A C D E G A T L O V E S A H P 3 ) E L B A T C E N N O C E R ( T L O V 8 0 2 T L O V 0 2 2 T L O V 0 4 2 T L O V 6 1 4 T L O V 0 4 4 T L O V 0 8 4 E S A H P E L ...
Page 37 - How to read the output terminal gauges.; The gauges and knobs on the control panel; DO NOT; effect
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 37 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 tosimply help the operator observe how much power is beingsupplied produced at th...
Page 38 - FIGURE 20. Hard Wire Hookup for Three Phase 240V; power at 139V. After hooking up
PAGE 38 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) 3 Phase, 240 Volt The following connection, with the voltage change-overboard set into the 240V set position (See Figure 19), canoffer THREE PHASE power at 240V. After hooking up the hard wires to the lugs as shown in figure 20 be...
Page 39 - FIGURE 24. Hard Wire Hookup for Three Phase 480V; power at 277V. After hooking up
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 39 480 Volt Set position The voltage change-over board 480V set position uses all6 plates in 3 different connection places. There are 2plates at every position (Every plate is used). See figure23 below. FIGURE 23. Voltage Change-ove...
Page 40 - C A U T I O N; Generator Grounding; EARTH; Use one of the following wire types to connect the; DCA-400SPK — INSTALLATION; ALWAYS; consult with a licensed; Outdoor Installation; noxious elements. Engine exhaust must; Mounting
PAGE 40 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) C A U T I O N : An electric shock may happen whenvibrators are used. Pay close attention tohandling when operating vibrators andalways use rubber boots and gloves toinsulate the body from electrical shock. Generator Grounding To g...
Page 41 - Figure 27. Typical Generator Grounding Application
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 41 Figure 27. Typical Generator Grounding Application DCA-400SPK — INSTALLATION
Page 43 - Fill the fuel tank with clean and fresh diesel fuel.; DO; fill the tank beyond capacity.; Figure 28. Engine Oil Dipstick; If diesel spillage occurs, wipe up the; Coolant
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 43 Lubrication Oil Fill the engine crankcase with lubricating oil through the fillerhole, but do not overfill. Make sure the generator is level.With the dipstick inserted all the way, but without being screwinto the filler hole, ver...
Page 44 - il; Cleaning the Radiator; Figure 29. Fan Belt Tension
PAGE 44 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — PRE-SETUP 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 Table12 for engine, radiator, and re...
Page 45 - Figure 30. Battery Connections
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 45 DCA-400SPK — PRE-SETUP Battery Cable InstallationALWAYS be sure the battery cables (Figure 30) are properly connected to the battery terminals as shown below. TheRED RED RED RED RED cable is connected to the positive terminal of ...
Page 46 - DCA-400SPK — LOAD APPLICATION; Single Phase Load; An inadequate size connecting cable which; I f w a t t a g e i s n o t g i v e n o n t h e; Three Phase Load
PAGE 46 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — LOAD APPLICATION Single Phase Load Always be sure to check the nameplate on the generatorand equipment to insure the wattage, amperage andfrequency requirements are satisfactorily supplied by thegenerator for operatin...
Page 47 - Load Circuit Breakers
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 47 W A R N I N G : Before Starting Engine 1. Check the lubricating oil level prior to starting the engine. Make sure the generator is level. The oil level must bemaintained between two notches on the dipstick. 2. When there is not e...
Page 48 - Figure 34. Engine Enclosure Doors; Connect the load to the UVW terminals as shown in; BATTER; Figure 33. Battery Connections; When starting the generator in; COLD
PAGE 48 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) 4. Close all engine enclosure doors (Figure 34). Figure 34. Engine Enclosure Doors 5. Set the battery ON/OFF switch (Figure 35) to the ON position. Figure 35. Battery ON/OFF Switch 2. Connect the load to the UVW terminals as shown...
Page 49 - the 60 cycle output frequency in; HERTZ; . If the voltage is not within the; Figure 43. Voltage Adjust Control; Engine Running; Figure 39. MPEC Engine Running Status LED; MANUAL; Figure 40. Engine Ignition Switch; If the generator is equipped with a ignition switch, turn
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 49 10. The generator's frequency meter (Figure 41) displays the 60 cycle output frequency in HERTZ . Figure 41. Frequency Meter (Hz) Figure 42. Voltage Meter (Volts) 11. The generator's voltage meter (Figure 42) displays the 120 VAC...
Page 50 - Figure 48. Main and GFCI Circuit Breakers; Turn the MAIN, GFCI and LOAD circuit breakers to their; Figure 47. Engine Tachometer; of the engine. Under normal; Figure 46. Coolant Temperature Gauge
PAGE 50 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) 17. Observe the generator's ammeter (Figure 49) and verify that it reads the anticipated amount of current withrespect to the load. Remember the ammeter will onlydisplay a current reading if the load is in use. 18. The generator w...
Page 52 - Figure 52. MPEC Engine Running; Figure 53. Emergency Stop Button; DCA-400SPK — GENERATOR SHUTDOWN PROCEDURE
PAGE 52 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) Figure 52. MPEC Engine Running Status LED (OFF) NEVER stop the engine suddenly except i n a n e m e r g e n c y. D O N OT u s e t h e emergency stop switch a as method ofshutting down the engine. This switch is ONLY to be used in ...
Page 54 - DCA-400SPK — MAINTENANCE
PAGE 54 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — MAINTENANCE General Inspection Prior to each use, the generating set should be cleaned andinspected for deficiencies. Check for loose, missing ordamaged nuts, bolts or other fasteners. Also check for fuelor oil leaks....
Page 55 - Changing Oil
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 55 DCA-400SPK — MAINTENANCE 5. When the water level is near the mouth of the water filler, open drain plugs and start the engine, and run atlow idling. Keep the engine running at low idling andflush the radiator for about 10 minutes...
Page 58 - DCA-400SPK — GENERATOR WIRING DIAGRAM
PAGE 58 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — GENERATOR WIRING DIAGRAM
Page 60 - DCA-400SPK — ENGINE WIRING DIAGRAM
PAGE 60 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — ENGINE WIRING DIAGRAM
Page 66 - Items Found In the “Remarks” Column; Where indicated, this indicates a serial; Items Found In the “Items Number” Column; All par ts with same symbol in the number column,; EXPLANATION OF CODE IN REMARKS COLUMN
PAGE 66 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) How to read the marks and remarks used in this partsbook. Items Found In the “Remarks” Column Serial Numbers- Where indicated, this indicates a serial number range (inclusive) where a par ticular part is used. Model Number- Where ...
Page 67 - DCA-400SPK — SUGGESTED SPARE PARTS; Description; Part number on this Suggested Spare
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 67 DCA-400SPK DCA-400SPK DCA-400SPK DCA-400SPK DCA-400SPK W/K W/K W/K W/K W/KOMA OMA OMA OMA OMATSU SA6D140E-2 TSU SA6D140E-2 TSU SA6D140E-2 TSU SA6D140E-2 TSU SA6D140E-2 DIESEL ENGINE DIESEL ENGINE DIESEL ENGINE DIESEL ENGINE DIESE...
Page 80 - ENGINE OPERATING PANEL ASSY.
PAGE 80 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SSKENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY.
Page 81 - DCA-400SPK ENGINE OPERATING PANEL ASSY.; PART NO
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 81 DCA-400SPK ENGINE OPERATING PANEL ASSY. ENGINE OPERATING PANEL ASSY. NO PART NO PART NAME QTY. REMARKS 1 9039211283 OPERATING PANEL 1 2 0017106016 HEX. HEAD BOLT 12 3 0602101000 BATTERY SWITCH 1 9827300090 4 0021008080 MACHINE SC...
Page 102 - DCA-400SPK — NAME PLATE AND DECALS; NAME PLATE AND DECALS; CONTROL BOX GROUP
PAGE 102 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — NAME PLATE AND DECALS NAME PLATE AND DECALS CONTROL BOX GROUP ENGINE OPERATING PANEL GROUP
Page 103 - PART NAME
DCA-400SPK — PARTS AND OPERATION MANUAL — REV. #0 (06/19/01) — PAGE 103 DCA-400SPK — NAME PLATE AND DECALS NAME PLATE ASSY. NO. PART NO. PART NAME QTY. REMARKS CONTROL BOX GROUP 2-1 0800520100 PLATE: ON-OFF .............................................. 1 ......... AT-202 2-2 0800520904 PLATE: AMMET...
Page 104 - DCA-400SPK — NAME PLATE AND DECALS; BONNET GROUP
PAGE 104 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) DCA-400SPK — NAME PLATE AND DECALS NAME PLATE AND DECALS BONNET GROUP BATTERY GROUP ENGINE AND RADIATOR GROUP
Page 106 - TERMS AND CONDITIONS OF SALE — PARTS
PAGE 106 — DCA-400SPK — PARTS AND OPERATION MANUAL— REV. #0 (06/19/01) PAYMENT TERMS Terms of payment for parts are net 10 days. FREIGHT POLICY All parts orders will be shipped collect orprepaid with the charges added to the invoice.All shipments are F.O.B. point of origin.Multiquip’s responsibility...
Page 108 - PARTS AND OPERATION MANUAL
HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBERON-HAND WHEN CALLING P P P P PAR AR AR AR ARTS DEP TS DEP TS DEP TS DEP TS DEPAR AR AR AR ARTMENT TMENT TMENT TMENT TMENT 800/427-1244 or 310/537-3700FAX: 800/672-7877 or 310/637-3284 SER SER SER SER SERVICE DEP VICE DEP VICE DEP VICE DEP...
