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Circuit Breakers
To protect the generator from an overload, a 3-pole, 600 amp, main circuit breaker is provided to protect the U,V, and W OutputTerminals 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 auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level. and verify that the oil level is maintained between the two notches (Figure 29) on the dipstick. See Table 11 for proper selection of engine oil.
DCA-400SSV— PRE-SETUP
Fuel Check
DANGER - EXPLOSION/FIRE HAZARDS
Fuel spillage on a hot engine can cause a fire or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.
Refilling the Fuel System
CAUTION - REFUELINGTHE GENERATOR
ONLY properly trained personel who have read and understand this section should refill the fuel tank system.
Figure 29. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the Volvo Engine Owner's Manual. Oil should be warm before draining.
Other types of motor oils may be substituted if they meet the following requirements:
■API Service Classification CC/SC
■API Service Classification CC/SD
■API Service Classification CC/SE
■API Service Classification CC/SF
This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 30). ALWAYS fill the fuel tanks with clean fresh #2 diesel fuel. DO NOT fill the fuel tanks beyond their capacities.
Pay attention to the fuel tank capacity when replenishing fuel.The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.
Figure 30. Internal Fuel Tank System
PAGE 32 — DCA-400SSV— OPERATION AND PARTS MANUAL — REV. #0 (04/19/06)
Parts List NO. C3871301004
Model DCA-400SSV
2 DCA-400SSV- Operation and Parts Manual REV. #0 04/19/06
Heres HOW to GET Help
Wilmington Ave Carson, CA
Table of Contents
Parts Ordering Procedures
When ordering parts Please supply the following information
DCA-400SSV- Specifications
DCA-400SSV- Dimensions TOP, Side and Front
DCA-400SSV- Safety Message Alert Symbols
You can be injured if you do not follow directions
DCA-400SSV- Safety Message Alert Symbols
This generator, other property, or
General Safety
DCA-400SSV- Rules for Safe Operation
Electrical Safety
Generator Grounding
Maintenance Safety
Battery Safety
Towing &Transporting Safety
Emergencies
DCA-400SSV- Generator Decals
Generator Decals
DCA-400SSV- Generator Decals
Generator Decals Cont inued
DCA-400SSV- Installation
Typical Generator Grounding Application
Outdoor Installation
Indoor Installation
When connecting the generator
Mounting
Generator
Engine Operating Panel
Generator Control Panel
Output Terminal Panel
DCA-400SSV- Major Components
Major Components
Auto On/Off Engine Controller Mpec
DCA-400SSV- Generator Control Panel
Pilot Lamp Indicates
DCA-400SSV- Generator Control Panel
DCA-400SSV- Engine Operating Panel
DCA-400SSV- Operation and Parts Manual REV. #0 04/19/06
DCA-400SSV- Output Terminal Panel Familiarization
Output Terminal Familiarization
120VAC Gfci Receptacles
F.C.I. Receptacle
Connecting Loads
Over Current Relay
Single Phase Load
Three Phase Load
DCA-400SSV- Load Application
Motors and motor-driven
Generator Amperage
Generator OutputVoltages
Voltage Change-Over Board
How to Read the Output Terminal Gauge
Change-Over Switch
DCA-400SSV- Generator OUTPUTS/ Gauge Reading
Maximum Amps
DCA-400SSV- Output Terminal Panel Connections
Uvwo Terminal Output Voltages
3Ø-240V Uvwo Terminal Output Voltages
1Ø-240V Uvwo Terminal Output Voltages
1Ø-277V Uvwo Terminal Output Voltages
3Ø-480V Uvwo Terminal Output Voltages
1Ø-480V Uvwo Terminal Output Voltages
DCA-400SSV- PRE-SETUP
Circuit Breakers
Lubrication Oil
Fuel Check
Refueling Procedure
Refueling
Cleaning the Radiator
Air Cleaner Fan Belt Tension
Coolant Antifreeze/Summer Coolant/Water
Operation FreezingWeather
Battery
Battery Cable Installation
Wiring
Alternator
Place the engine speed switch in the LOW down position
Before Starting
Engines exhaust contains harmful emissions
Direct exhaust away from nearby personnel
Coolant Temperature Gauge
No Load
Place the Mpec Control Switch in the Auto position
Starting Auto Mode
Place the engine speed switch in the High position
Normal Shutdown Procedure
Emergency Shutdown Procedure
DCA-400SSV- Maintenance
General Inspection Air Cleaner
Air Cleaner with Dust Indicator
Air filter should not be
Service Daily
Cleaning Inside the Fuel Tank
Cleaning the Fuel Strainer
Fuel Addition
Radiator Cleaning
Air Removal
Check Oil Level
Replacing Oil Filter
Battery Charger JacketWater Heater Power Connections
To ensure adequate starting
Coupler Type of hitch used on the trailer for towing
DCA-400SSV-TRAILER Maintenance
Trailer Maintenance
DCA-400SSV-TRAILER Maintenance
Brake Adjustment
Brakes
Check the wheel and drum for free rotation
Suspension
Tires/Wheels/Lug Nuts
TireWear/Inflation
Lug Nut Torque Requirements
Start all wheel lug nuts by hand
DCA-400SSV-TRAILERWIRING Diagram
DCA-400SSV- Generatorwiring Diagram
DCA-400SSV Enginewiring Diagram S/N 3722759 and below
DCA-400SSV Enginewiring Diagram S/N 3722760 and Above
DCA-400SSV-TROUBLESHOOTING Generator
Generator Troubleshooting
DCA-400SSV-TROUBLESHOOTING Engine Controller
DCA-400SSV-TROUBLESHOOTING Diagnostic Lamp
Example Error Code
Method of Operation
For a complete understanding
DCA-400SSV- Operation and Parts Manual REV. #0 04/19/06
Sample Parts List
DCA-400SSV- Explanation of Code in Remarks Column
Part number on this Suggested Spare Parts list
RING, SENSOR, Coolant Temp
Sensor OIL, Pressure & Temp
RING, Sensor OIL, Pressure & Temp
DCA-400SSV- Generator Assy
Generator Assy
Balancing Weight KIT
Rotor Assy Field Assy
Resistor 80W 300K
RECTIFIER, RM50TC-24
DCA-400SSV- Generator ASSY.
Generator ASSY.
Suction Cover
Coupling Adapter
SPACER, Bearing
BEARING, 6208ZZ
DCA-400SSV- Engine Operating Panel Assy
Engine Operating Panel Assy
Engine Speed Switch
Alarm Lamp
COVER, AIR Cleaner
Operating Panel
DCA-400SSV- Control BOX Assy
Control BOX Assy
TIMER, DC/AC24V
Switch Bracket
Control BOX
Circuit BREAKER, 1000A
DCA-400SSV- Control BOX ASSY.
Control BOX ASSY.
DCA-400SSV- Control BOX ASSY.
DCA-400SSV- Engine and Radiator Assy
Engine and Radiator Assy
AIR CLEANER, Complete
Connector
Includes Items W
Engine Foot
70 DCA-400SSV- Operation and Parts Manual REV. #0 04/19/06
SENSOR, OIL Temperature
GASKET, OIL Temperature
Plug
Ring
DCA-400SSV- Outputterminal Assy
Output Terminal Assy
Output Terminal
Circuit BREAKER, 20A
Circuit BREAKER, 50A
BRACKET, Circuit Breaker
DCA-400SSV- Battery Assy
Battery Assy
Battery
Battery Sheet
Battery Band
Battery Bolt
DCA-400SSV- Muffler Assy
Muffler Assy
Seal Clamp
Muffler
Exhaust Pipe
DCA-400SSV- Fueltank Assy
Fuel Tank Assy
Fuel Tank
CAP, Fuel Tank
KEY
Fuel Filter
DCA-400SSV- Enclosure #1 Assy
Enclosure #1 Assy
Base
Floor Panel
Front Frame
Lining
DCA-400SSV- Enclosure #2 Assy
Rear Frame
Louver Panel
COVER, Rear Frame
Duct Cover
DCA-400SSV- Enclosure #2 ASSY.
Enclosure #2 ASSY.
Stay
STOPPER, Door
Hinge
Stopper
DCA-400SSV- Enclosure #3 Assy
Enclosure #3 Assy
Splasher Panel
Side Panel
Duct
Side Door
DCA-400SSV- Enclosure #3 ASSY.
3875151304
C3454303104
19A C3494409804
C3454303204
DCA-400SSV- Rubber Seals Assy
Rubber Seals Assy
0228901390
0228901075
0228900825
0228901410
DCA-400SSV- Nameplate and Decals Assy
Nameplate and Decals Assy
Name Plate Assy
Control BOX Group
Engine & Radiator Group
Engine Operating Panel Group
94 DCA-400SSV- Operation and Parts Manual REV. #0 04/19/06
Battery Group
Name Plate and Decals Assy
Muffler Group
Fuel Tank Group
Terms and Conditions of Sale Parts
DCA-400SSV- Operation and Parts Manual REV. #0 04/19/06
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