PARTS AND OPERATION MANUAL
PARTS AND OPERATION MANUAL
MQ POWER
MODEL DCA-500SSK
TM
WHISPERWATT
GENERATOR
(Standard)
PARTS LIST NO C4872300004
Revision #1 (06/04/01)
MULTIQUIPINC.
PARTS DEPARTMENT:
18910 WILMINGTON AVE.
800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244
SERVICE DEPARTMENT:
800-835-2551
FAX:310-537-3927
FAX:310-638-8046
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HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN 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-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 3
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TABLE OF CONTENTS
Here's How To Get Help ............................................ 3 Generator Assembly .......................................... 70-73
Table Of Contents ..................................................... 4 Control Box Assembly ........................................ 74-79
Parts Ordering Procedures ....................................... 5 Engine Radiator Assembly................................. 80-83
Rules For Safe Operation ...................................... 6-9 Engine Operating Panel Assembly .................... 84-85
Towing ..................................................................... 10 Output Terminal Assembly ................................. 86-89
Trailer Safety Guidelines .................................... 11-17 Battery Assembly ............................................... 90-91
Trailer Wiring Diagram............................................. 18 Muffler Assembly ............................................... 92-93
Air Brake Troubleshooting ....................................... 19 Fuel Tank Assembly ........................................... 94-95
Operation And Safety Decals............................. 20-24 Enclosure #1 Assembly...................................... 96-97
Specifications .......................................................... 26 Enclosure #2 Assembly.................................... 98-101
General Information ................................................ 27 Enclosure #3 Assembly.................................. 102-103
Enclosure (Rubber Seals).............................. 104-105
Name Plate and Decals ................................. 106-109
MQ Power DCA-500SSK
ACGenerator
Terms and Conditions Of Sale — Parts ................ 110
Major Components ................................................. 28
Dimensions (Top, Side, Front, and Rear) .......... 30-31
Control Panel...................................................... 32-33
Engine Operating Panel ..................................... 34-35
Output Terminal Panel ........................................ 36-41
Installation .......................................................... 42-43
Pre-Setup ........................................................... 44-47
Load Application ..................................................... 48
Generator Start-Up Procedure (Manual)........... 49-52
Generator Start-Up Procedure (Auto) .................... 53
Generator Shut-Down Procedure ........................... 54
Maintenance ...................................................... 56-59
Generator Wiring Diagram ...................................... 60
Engine Wiring Diagram ...................................... 62-63
Troubleshooting (Engine)................................... 64-65
Troubleshooting (Engine/Generator) ...................... 66
Troubleshooting MPEC ........................................... 67
Explanation Of Codes In Remarks Column ............ 68
Suggested Spare Parts ........................................... 69
NOTE
Specification and part
number are subject to
change without notice.
PAGE 4 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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PARTS ORDERING PROCEDURES
I Dealer account number
I Dealer name and address
I Shipping address (if different than billing address)
I Return fax number
I Applicable model number
I Quantity, part number and description of each part
I Specify preferred method of shipment:
UPS Ground
•
UPS Second Day or Third Day*
•
UPS Next Day*
•
Federal Express Priority One (please provide us with your Federal
Express account number)*
•
Airborne Express*
•
Truck or parcel post
•
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered
Additional Discount
1-9 items
3%
10+ items**
5%
only
s
der
ed or
x
a
f
For
Get special freight allowances
when you order 10 or more
line items via FAX!**
Now! Direct TOLL-FREE access
to our Parts Department!
I
UPS Ground Service at no charge for freight
I
PS Third Day Service at one-half of actual freight cost
Toll-free nationwide:
800-421-1244
No other allowances on freight shipped by any other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
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-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 5
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RULES FOR SAFE OPERATION
CAUTION:
I
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only!This equipment is for
industrial use only.
The following safety guidelines should always be used when
operating the DCA-500SSK portable generator:
I
I
HighTemperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions.
Contact with hot components can cause serious burns.
GENERAL SAFETY
I
I
I
DONOToperateorservicethisequipmentbeforereading
thisentiremanual.
The engine of this generator requires an adequate free flow
of cooling air. Never operate the generator in any enclosed or
narrow area where free flow of the air is restricted. If the air
flow is restricted it will cause serious damage to the generator
or engine and may cause injury to people. The generator
engine gives off DEADLY carbon monoxide gas.
This equipment should not be operated by
persons under 18 years of age.
NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel-
toed boots and other protective devices required
by the job.
CAUTION:
Always refuel in a well-ventilated area, away
from sparks and open flames.
I
I
I
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.
I
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 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.
I
I
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.
I
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Manufacturer does not assume responsibility for any accident
due to equipment modifications.
Topping-off to filler port is dangerous, as it tends to spill fuel.
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Always check the machine for loosened threads or bolts before
starting.
PAGE 6 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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RULES FOR SAFE OPERATION
CAUTION:
CAUTION:
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
NEVER touch output terminals during operation. This is 1. Radiator Cap - Removing the radiator cap while the
I
extremely dangerous. Always stop the machine when
contact with the output terminals.
engine is hot will result in high pressurized, boiling
water to gush out of the radiator, therefore causing
severe scalding to any persons in the general area
of the generator.
CAUTION:
2. Coolant Drain Plug - Removing the coolant drain
plug while the engine is hot will result in hot coolant
to gush out of the coolant drain plug, therefore
causing severe scalding to any persons in the
general area of the generator.
3. Engine Oil Drain Plug - Removing the engine oil
drain plug while the engine is hot will result in hot oil
to gush out of the oil drain plug, therefore causing
severe scalding to any persons in the general area
of the generator.
I
Backfeed to a utility system can cause electrocution
and/or property damage. Do not connect to any
building's electrical system except through an
approved device or after building main switch is
opened.
CAUTION:
Never use damaged or worn cables when
connecting power tools or equipment to the
generator.Make sure power connecting cables
are securely connected to the generator’s
output terminals, insufficient tightening of the
terminal connections may cause damage to
the generator and electrical shock.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 7
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RULES FOR SAFE OPERATION
I
I
I
I
I
NEVER Run engine without air filter.Severe engine damage
Battery
may occur.
CAUTION:
Always service air cleaner frequently to prevent carburetor
malfunction.
Never over fill the battery with water above
the upper limit.
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.
The battery contains acids that can cause injury to the eyes and
skin. To avoid eye irritation, always wear safety glasses. Use
well insulated gloves when picking up the battery. Use the
following guidelines when handling the battery:
Always store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the
reach of children.
I
I
I
I
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DO NOT leave the generator running in the manual mode
unattended.
DO NOT allow unauthorized people to operate this
equipment.
Always read, understand, and follow procedures in Operator’s
Manual before attempting to operate equipment.
1. DO NOT drop the battery. There is the possibility of risk
Always be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.
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.
Refer to the Komatsu Engine Owner's Manual for engine
technical questions or information.
Loading and Unloading (Crane)
I
Before lifting, make sure the generator's lifting hook is secure
and that there is no apparent damage to the generator itself
(loose screws, nuts and bolts). If any part is loose or damaged,
please take corrective action before lifting.
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.
I
I
Always drain fuel prior to lifting.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
Always make sure crane or lifting device has been properly
secured to the hook of guard frame on generator.
I
I
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NEVER lift the machine while the engine is running.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
Use adequate lifting cable (wire or rope) of sufficient strength.
When lifting the generator, always use the balanced center-
point suspension hook and lift straight upwards.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.
I
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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-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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RULES FOR SAFE OPERATION
Transporting
Maintenance Safety
I
I
I
Always shutdown engine before transporting.
I
NEVER lubricate components or attempt service on a running
machine.
Tighten fuel tank cap securely.
I
Always allow the machine a proper amount of time to cool
before servicing.
Drain fuel when transporting generator over long distances
or bad roads.
I
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Keep the machinery in proper running condition.
I
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Always tie-down the generator during transportation by
securing the generator.
Fix damage to the machine immediately and always replace
broken parts.
If generator is mounted on a trailer, make sure trailer complies
with all local and state safety transportation laws. See page
10 for basic towing procedures.
I
I
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Dispose of hazardous waste properly.Examples of potentially
hazardous waste are used motor oil, fuel, and fuel filters.
Emergencies
DO NOT use plastic containers to dispose of hazardous
waste.
I
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.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 9
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DCA-500SSK —TOWING
I
I
ALWAYS attach trailer's safety chain to bumper of towing
Towing Safety Precautions
vehicle.
CAUTION :
ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and working
properly.
Check with your county or state safety towing
regulations department before towing your
generator.
I
Remember the maximum speed unless otherwise posted for
highway towing is 45 MPH. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of terrain.
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.
I
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Place chocked blocks underneath wheel to prevent rolling,
while parked.
Place support blocks underneath the trailer's bumper to
prevent tipping, while parked.
The following list of suggestions should be used when towing
your generator:
Use the trailer's hand winch to adjust the height of the trailer,
then insert locking pin to lock wheel stand in place, while
parked.
I
Make sure the hitch and coupling of the towing vehicle are
rated equal to, or greater than the trailer "gross vehicle weight
rating" (GVWR).
I
Avoid sudden stops and starts.This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gas milage.
I
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ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
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Avoid sharp turns to prevent rolling.
Check the tire air pressure on both the towing vehicle and
the trailer.Also check the tire tread wear on both vehicles.
Remove wheel stand when transporting.
DO NOT transport generator with fuel in tank.
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 1. Generator and Trailer
PAGE 10 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — TRAILER-SAFETY GUIDELINES
4. Frame Length - This measurement is from the ball
CAUTION:
hitch to the rear bumper (reflector).
ALWAYS make sure the trailer is in good
5. Frame Width - This measurement is from fender to
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
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.
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.
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 a 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.
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. SeeTable 4 and Figure 5 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please not that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
„
„
„
„
„
„
Brakes
Tires
Lug NutTorquing
Suspension
Electrical
Brake Troubleshooting Tables
Use the following definitions with reading Table 1.
1. Fuel Cell - Provides an adequate amount of fuel for the
equipment in use. Fuel cells must be empty when trans-
porting 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).
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 11
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DCA-500SSK —TRAILER-SPECIFICATIONS
Table 1. Specifications
MODEL
APPLICATION
FUEL
CELL
BRAKE
SYSTEM
GVWR
FRAME
LENGTH
FRAME
WIDTH
JACK
STAND
TRLR-10W
TRLR-10
SDW225,
SGW250,TLW300
NO
NO
1900LBS
1900LBS
1900LBS
2200LBS
2700LBS
2700LBS
2700LBS
7000LBS
7000LBS
7000LBS
7000LBS
10000LBS
11160LBS
14000LBS
18000LBS
18000LBS
30000LBS
30000LBS
96"
96"
96"
85"
50"
50"
50"
42"
800LB.
FULL TILT WHEEL
DCA10, TLG12,
DCA-15
NO
NO
800LB.
FULL TILT WHEEL
TRLR-10XF
TRLR-225W
TRLR-BLW400
TRLR-50X
DCA10, TLG-12,
DCA15, TLW-300
52 GAL
NO
NO
NO
800LB.
FULL TILT WHEEL
WELDERS,
DA7000SS
800LB.
FULL TILT WHEEL
BLW-400
NO
ELECTRIC
NO
W/MAST 154"
W/O 124"
55"
(78" TALL)
800LB.
FULL TILT WHEEL
DCA-25
NO
124"
124"
186"
138"
138"
190"
186"
204"
222"
238"
238"
384"
384"
55"
55"
77"
66"
66"
76"
77"
84"
83"
83"
83"
96"
96"
800LB.
FULL TILT WHEEL
TRLR-50XF
TRLR-70W
DCA-25
41 GAL
NO
NO
800LB.
FULL TILT WHEEL
DCA-45, -60, 70
DCA-45, -60, 70
DCA-45, -60, 70
DCA-100, 125
SURGE
2000LB.
FLAT PAD
TRLR-70X
OPT
SURGE
2000LB.
FLAT PAD
TRLR-70XF
TRLR-100XF
TRLR-85/125
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800SX
53 GAL
150 GAL
145 GAL
200 GAL
250 GAL
250 GAL
350 GAL
550 GAL
550 GAL
SURGE
2000LB.
FLAT PAD
HYDRAULIC SURGE
HYDRAULIC
HYDRAULIC SURGE
HYDRAULIC SURGE
HYDRAULIC SURGE
ELECTRIC
AIR
2000LB.
FLAT PAD
DCA-85, 100,
125
2000LB.
FLAT PAD
DCA-150, 180
5000 LB.
FLAT PAD
DCA-220
5000 LB.
FLAT PAD
DCA-300
5000 LB.
FLAT PAD
DCA-400
5000 LB.
FLAT PAD
DCA-600, 800
DCA-600, 800
5000 LB.
FLAT PAD
AIR
5000 LB.
FLAT PAD
PAGE 12 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK —TRAILER-SPECIFICATIONS
Table 1. Specifications (Con't)
MODEL
COUPLER
TIRES
WHEELS
AXLE
HUBS SUSPENSION
ELECTRICAL
TRLR-10W
2" BALL CLASS
2 ADJUSTABLE
175-13C
13"X4.50"
2200# 2X2
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
5 LUG
6 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
8 LUG
3 LEAF
3 LEAF
3 LEAF
Q FLEX
3 LEAF
4 LEAF
4 LEAF
5 LEAF
5 LEAF
5 LEAF
5 LEAF
7 LEAF
7 LEAF
Q FLEX
Q FLEX
Q FLEX
7 LEAF
AIR-RIDE
4 WIRE LOOM W/
4 POLE FLAT
TRLR-10
TRLR-10XF
TRLR-225W
2"BALL CLASS
2 ADJUSTABLE
175-13C
175-13C
13"X4.5"
13"X4.5"
13X4.5"
13 X 4.5"
13"X4.50"
13"X4.50"
14"X5"
2200#2X2
2200#2X2
2200#2X2
2200#2X2
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
4 POLE FLAT
2"BALL CLASS
2 ADJUSTABLE
2"BALL CLASS
2 ADJUSTABLE
175-13B
TRLR-BLW
400
2"BALL CLASS
2 ADJUSTABLE
175-13C
TRLR-50X
TRLR-50XF
TRLR-70W
TRLR-70X
TRLR-70XF
2" BALL CLASS
B78-13LRC
B78-13LRC
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3500lbs.
2-3/8"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
3500lbs.
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs
3"
4 POLE RUBBER
FLAT
2" BALL CLASS
3" ADJUSTABLE
205-14C
BIAS (4)
14"X5"
3500lbs.
3"
4 POLE RUBBER
FLAT
TRLR-100XF ADJUSTABLE 2-5/6
205-15C
BIAS (4)
14"X5.5"
14"x6"
3500lbs
3"
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
4 WIRE LOOM
6 WIRE LOOM
6 WIRE LOOM
OPT 3" EYE
TRLR-85/125 ADJUSTABLE 2-5/6
ST225/75R15D
RADIAL (4)
(2)-6000lbs
(2)-6000lbs
(2)-7000lbs
(2)-6000lbs
(3)-7000lbs.
(3)-10000lbs
(3)-10000lbs
OPT 3" EYE
TRLR-150XF
TRLR-220XF
TRLR-300XF
TRLR-400XF
TRLR-600XF
TRLR-800AR
3" BALL EYE
750-16 E
BIAS (4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(4)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
3" EYE
ADJUSTABLE
ST235/85R16E
RADIAL(6)
16"X7"
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
5TH WHEEL
ST215/75R17.5H
RADIAL (8)
16"X7"
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 13
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DCA-500SSK —TRAILER SAFETY GUIDELINES
Brakes
Before any brake synchronizations adjustments can be made,
If your trailer has a braking system, the brakes should be the trailer brakes should be burnished-in by applying the
inspected the first 200 miles of operation. This will allow the brakes 20-30 times with approximately a 20 m.p.h. decrease
brake shoes and drums to seat properly. After the first 200 in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for
mile interval, inspect the brakes every 3,000 miles. If driving brakes to cool between application. This allows the brake
over rough terrain, inspect the brakes more frequently.
shoes to slightly be seated into the brake drum surface.
Electric Brakes
Figure 2 displays the major electric brake components that
Electrically actuated brakes (Figure 2) are similar to hydraulic will require inspection and maintenance. Please inspect these
brakes. The basic difference is that hydraulic brakes are components as required.
actuated by an electromagnet.
Listed below are some of the advantages that electric brakes Electric Brake Adjustment
have over hydraulic brakes:
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
„
„
„
„
Brake system can be manually adjusted to provide the
corrected braking capability for varying road and load 2. Check the wheel and drum for free rotation.
conditions
Brake system can be modulated to provide more or less
braking force, thus easing the brake load on the towing 4. With a screwdriver or standard adjusting tool, rotate the
vehicle
Brake system has very little lag time between the time
the vehicle’s brakes are actuated and the trailer’s brakes 5. Adjust the brake shoes outward until the pressure of the
are actuated
Brake system can provide an independent emergency
brake system
3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.
star wheel of the adjuster assembly to expand the brake
shoes.
lining against the wheel drum makes the wheel difficult
to turn.
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
Remember in order to properly synchronize the tow vehicle’s 7. Replace the adjusting hole cover and lower the trailer to
braking to the trailer’s braking, can only be accomplished by the ground.
road testing. Brake lockup, grabbiness or harshness is due 8. Repeat steps 1 through 6 on the remaining brakes.
to lack of synchronization between the tow vehicle and the
trailer being towed or under-adjusted brakes.
PAGE 14 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK —TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
Hydraulic/Air/Surge Brakes
components that will require inspection and maintenance.
Hydraulic brakes (Figure 3) should not require any special Please inspect these components as required using steps 1
attention with the exception of routine maintenance such as through 6 as referenced in the electric brake adjustments
shoe and lining replacement. These brakes can be adjusted section.
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
Figure 3. Hydraulic Brake Components
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 15
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DCA-500SSK —TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer. When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the
rim is cracked, the air pressure in the
inner tube may cause pieces of the rim
to explode (break off) with great force
and cause serious eye or bodily injury.
Suspension
The leaf suspension springs and associated components
(Figure 4) should be visually inspected every 6,000 miles for
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.
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:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.
Figure 4. Major Suspension Components
PAGE 16 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK —TRAILER SAFETY GUIDELINES
Table 3. Suspension Torque Requirements
Item
Torque (Ft.-Lbs.)
3/8" U-BOLT
7/16" U-BOLT
1/2" U-BOLT
MIN-30 MAX-35
MIN-45 MAX-60
MIN-45 MAX-60
SNUG FIT ONLY
LOCKING NUTS OR COTTER PINS ARE PROVIDED
TO RETAIN NUT-BOLT ASSEMBLY
.
PARTS MUST ROTATE FREELY
.
SHACKLE BOLT
SPRING EYE BOLT
.
SHOULDER TYPE
SHACKLE BOLT
MIN-30 MAX-50
Lug NutTorque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 5. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined byTable 4.
3.
After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
Table 4. Tire Torque Requirements
Second
Pass
FT-LBS
First Pass
FT-LBS
Third Pass
FT-LBS
Wheel Size
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 5. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 17
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DCA-500SSK —TRAILER-WIRING DIAGRAM
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DCA-500SSK —TRAILER BRAKESTROUBLESHOOTING
Table 6. Air Brake Troubleshooting
Symptom
Possible Cause
Brake line broken or kinked?
Brake lining glazed?
Solution
No Brakes
Repair or replace.
Reburnish or replace.
Correct weight.
Weak Brakes or Brakes
Pull to One Side
Trailer overloaded?
Brake drums scored or grooved?
Tire pressure correct?
Machine or replace.
Inflate all tires equally.
Match tires.
Tires unmatched on the same axle?
Locking Brakes
Brake components loose, bent or
broken?
Replace components.
Brake drums out-of-round?
System lubricated?
Replace.
Lubricate.
Noisy Brakes
Brake components correct?
Replace and correct.
Dragging Brakes
Brake lining thickness correct or in Install new shoes and
right wrong position? linings.
Enough brake fluid or correct fluid? Replace rubber parts
fill with dot4 fluid.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 19
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DCA-500SSK — OPERATION AND SAFETY DECALS
Machine Safety Decals
The DCA-500SSK generator is equipped with a number of safety decals.These decals are provided for operator safety
and maintenance information.The illustrations below and on the preceding pages shows the decals as they appear on the
machine.Should any of these decals become unreadable, replacements can be obtained from your dealer.
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DCA-500SSK — OPERATION AND SAFETY DECALS
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 21
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DCA-500SSK — OPERATION AND SAFETY DECALS
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DCA-500SSK — OPERATION AND SAFETY DECALS
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 23
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DCA-500SSK — OPERATION AND SAFETY DECALS
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DCA-500SSK -- NOTES PAGE
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 25
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DCA-500SSK — SPECIFICATIONS
Table 7. Specifications
Generator Specifications
Model
Type
DCA-500SSK
Revolving field,self-ventilated, 4-pole, drip-proof, single
bearing
Excitation
Phase
Brushless with AVR
3
Standby Output
Prime Output
440KVA (550 KW)
400 KVA (500 KW)
208,220,240,416,440,480 reconnectable (3 phase)
120,127,139,240,254,277 adjustable (single phase)
Voltage
Frequency
Speed
60 Hz
1800 rpm
Power Factor
Sound Level dB(A)
0.8
69 (full load at 23 feet)
Engine Specifications
KOMATSU SA6D170BE
direct injection, turbo-charged with after-cooler
6 cylinders
Model
Type
No. of Cylinders
Bore x Stroke
Rated Output
Displacement
Starting
6.8 in. x 6.8 in. (170 mm x 170 mm)
572 HP/1800 rpm
1411.5 cu. in. (23150 cc)
Electric
Coolant Capacity
Lube Oil Capacity
31.4 gal. (118.8 liters)
28.5 gal. (108 liters)
29 gal. (109.7L)/hr at full
22.3 gal. (84L)/hr at 3/4
Fuel Consumption
load
load
16.5 gal. (62L)/hr at 1/2
10.6gal/(40L)/hr at 1/4
load
load
Battery
Fuel
12V- 200 AH x 2 (24 Volt system)
#2 Diesel Fuel
PAGE 26 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — GENERAL INFORMATION
DCA-500SSK FAMILIARIZATION
Generator
Open Delta Excitation System
The DCA-500SSK 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.
The MQ Power Model DCA-500SSK is a 550 kW generator
that has been designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
There are four leads: A, B, C and D. During light loads, the
power to the Automatic Voltage Regulator (AVR) is supplied
from the leads parallel connections of B&C. When loads
increase, the AVR switches and accepts power from leads
A&D. The output of leads A&D increase proportionally with
load. This of adding the voltages to each phase provides
better voltage response during heavy loads.
Engine Control Panel
The “Engine Control Panel” is provided with the following:
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Tachometer
WaterTemperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
EngineWarning Lamp Module
Throttle Lever
Engine Speed Switch
Pre-Heat Button
Pre-Heat Lamp
Emergency Stop Button
Battery Switch
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
Generator Control Panel
The DCA-500SSK is powered by a 4 cycle, water cooled,
turbocharged KOMATSU Model SA6D170BE diesel engine.
This engine is designed to meet every performance
requirement for the generator. Reference Table 7, page 23
for engine specifications.
The “Generator Control Panel”is provided with the following:
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Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Panel Light
Panel Light Switch
MPEC Module
Pilot Lamp
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
The basic controls and indicators for the DCA-500SSK
generator are addressed on the following pages.
Electronic Governor System
Microprocessor Controlled Alarm System
The electronic governor system is made up of two parts, an
electronic controller that monitors frequency variation as the
load increases and decreases, and an electronic actuator
that controls the engine throttle. The frequency is regulated
at 0.25 to help protect sensitive equipment.
The DCA-500SSK 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-500SSK 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.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 27
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DCA-500SSK — MAJOR COMPONENTS
Figure 6. Major Components
PAGE 28 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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NOTE PAGE
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 29
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DCA-500SSK — DIMENSIONS (TOP AND SIDE)
Figure 7a. Dimensions
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DCA-500SSK — DIMENSIONS (FRONT AND REAR)
Figure 7b. Dimensions
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 31
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DCA-500SSK — CONTROL PANEL
Figure 8. Control Panel
PAGE 32 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — CONTROL PANEL
The definitions below describe the controls and functions of If the engine does not engage (start) by the third attempt,
the DCA-500SSK " Control Panel " (Figure 8).
the engine will be shutdown by the MPEC's " Over Crank
Protection" mode. If the engine engages at a speed (RPM's)
that is not safe, the MPEC will shutdown the engine by
initializing the "Over Speed Protection" mode.
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
lit this light will make it easier to read the meters and
gauges. When the generator is not in use be sure to
turn the panel light switch to the OFF position.
Also the MPEC 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 MPEC module.
3. Frequency Meter – Indicates the output frequency in
A. Off/Manual/Auto Switch – This switch controls the
running of the generator.If this switch is left in the "OFF"
position, the generator will not run. When this switch is
set to the manual position, the generator will start
immediately.
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. .
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. The generator will engage when
commercial power falls below a preset level.
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
B. Low Oil Pressure – Indicates the engine pressure
has fallen below 15 psi. The oil pressure is detected
using variable resistive values from the oil pressure
sending unit. This is considered a major fault and will
shut down the generator.
8. Panel Light Switch – When activated, this switch will
turn on the luminate the control panel.
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 and will shut down the generator.
9. Voltage Regulator Control – Allows manual
adjustment of the generator’s output voltage
10. Main Circuit Breaker – This three-pole, 1400 amp main
breaker is provided to protect the UVW voltage output
terminals from overload.
D. Overcrank Shutdown – Indicates the unit has
attempted to be started 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 and will shut down
the generator.
11. MPEC – Microprocessor
Engine Control Module –
(MPEC) has 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
E. Overspeed Shutdown – Indicates that the engine is
running at an unsafe speed.This is considered a major
fault.
MPEC will evaluate the fault
and if the fault is major will
shutdown the generator.
During cranking cycle ,The MPEC will attempt to crank the
engine for 10 seconds before disengaging.
Figure 9. MPEC
Module
F. Engine Running – Indicates that engine is running at
a safe operating speed.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 33
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DCA-500SSK — ENGINE OPERATING PANEL
Figure 10. Engine Operating Panel
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DCA-500SSK — ENGINE OPERATING PANEL
The definitions below describe the controls and functions of the
DCA-500SSK " Engine Operating Panel " (Figure 10).
4.
Oil Pressure Gauge –During normal operation this gauge
be should read in the “GREEN” zone. 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
the green zone.
1.
Throttle Handle- Use this handle to adjust the RPMs when
the engine is idling (no load).
2.
Tachometer – Indicates engine speed in RPM’s for 60 Hz
operation.This meter should indicate 1800 RPM’s when
the rated load is applied. In addition a built in hour meter
will record the number of operational hours that the
generator has been in use.
5.
6.
Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.
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.
3.
EngineWarning Display (LED) Module – This module
display’s the following engine failures:
7.
8.
Fuel Level Gauge – Indicates amount of diesel fuel
remaining.
A. Overheat Lamp – This lamp goes ON when
the cooling water temperature rises abnormally.
If the lamp goes ON during normal operation of
the generator, the emergency shutdown device
will stop the engine automatically.
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
B. 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 illuminate. After
the oil pressure rises after start-up the lamp
will go OFF. If this lamp is ever illuminated (ON) during
normal operation of the generator, the emergency
shutdown device will stop the engine automatically.
9.
Ignition Switch- Use this switch to start the engine in
manual mode (see instructions on starting generator.)
10. Pre-Heat Lamp – Indicates that the glow
plugs of the diesel engine are hot and the
engine is ready to be started.
11. Preheat Switch –Turn this switch on to heat
C. Low Fuel Level Lamp – When this lamp is
ON, it is time to stop the engine and add fuel.
Remember to let the engine cool before adding
fuel.
diesel engine in cold weather conditions.
12. Emergency Stop Button – Push this button inward to
stop the engine in the event of an emergency. DO NOT
use this button as a normal means of stopping the engine.
13. Engine Speed Switch – This switch changes the engine
D. Low Battery Fluid Lamp – This lamp goes
ON when the battery fluid is low. If this lamp
goes ON during normal operation of the
generator, stop the engine and fill the battery
with distilled water to the specified level.
speed from idle to normal.
E. Clogged Air Filter Lamp – This lamp goes
ON when the air filter is clogged. If this lamp
goes ON during normal operation of the
generator, stop the engine and replace the air
filter.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 35
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DCA-500SSK — OUTPUTTERMINAL
600SSK FAMILIARIZATION
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.
The “Output Terminal Panel” is provided with the following:
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Two 120V GFCI receptacles, 20 amp
Three 240/139V output receptacles, 50 amp
Two 120V input receptacles, 20 amp (optional)
3 Load Circuit Breakers 265V @65 amps
2 Load GFCI Circuit Breakers 265V@ 20amps
Control Box
The “Control Box” is provided with the following:
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Main Circuit Breaker 1400 amps
Over-Current Relay
Output Terminal Panel
Figure 13. Connection Receptacles
Circuit Breakers
The Output Control Panel (See Figure 14) is located on the
right hand side (left from control panel) of the generator.
The UVWO lugs are protected by a face plate cover that
can be secured in the close position by a pad lock. (See
Figure 11).
To protect the generator from an overload, a 3-pole, 1400
amp, main circuit breaker is provided to protect the UVWO
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 starting the engine.
Maximum Output
The entire load connected to the UVWO Lugs, all four slots in
the duplex receptacles, and the must not exceed 500 kW in
standby or 550 kW in prime output.
Figure 11. Output Terminal Cover
120Volt 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.
Twist Lock DualVoltage Receptacles
Three CS-6369 auxiliary power receptacles have been
provided to supply 208/120V. The voltage regulator knob
on the control panel may need to be used to adjust the
voltage to 208 or 416V.
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.
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).
Figure 12. GFCI Test/Reset Button
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DCA-500SSK — OUTPUTTERMINAL
Figure 14. Output Terminal Panel Location
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DCA-500SSK — OUTPUTTERMINAL
Output Terminal Panel Available Voltages
CAUTION:
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 to hookup the
hard wire connection to the voltages listed, fine adjustment
with theVoltage 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.
NEVER attempt to change the Voltage
Change-Over Board with the engine is
running.
TABLE 8. VOLTAGES AVAILABLE
DCA500SSK
MODEL
3 PHASE VOLTAGE
(RECONNECTABLE)
208 VOLT 220 VOLT 240 VOLT 416 VOLT 440 VOLT 480 VOLT
120 VOLT 127 VOLT 139 VOLT 240 VOLT 254 VOLT 277 VOLT
SINGLE PHASE
(ADJUSTABLE)
Over Current Relay
Maximum Amps
An over current relay is connected to the circuit breaker.
During 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 on the control
box.
The following table below shows the maximum amps the
generator can provide Do not exceed the maximum amps
listed below.
Table 9. Maximum Amps
Model:
DCA500SSK
Maximum Amps
1111.1 amps (4 wire)
555.6 amps (4 wire)
1202.8 amps
Rated
Voltage
Single Phase
120 Volt
Single Phase
240 Volt
Three Phase
240 Volt
Three Phase
480 Volt
601.4 amps
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DCA-500SSK — OUTPUTTERMINAL
Reading the OutputTerminal Gauges
The gauges and knobs on the control panel DO NOT effect
the generator output. They are to help the operator observe
how much power supply is produced at the UVWO legs.
To read the output at the U-W legs, place the AC Voltmeter
Change-over switch to theW-U position and the AC ammeter
Change-over Switch to the U orW position to read the output
on the selected leg.
Figure 16. AC
Voltmeter Gauge
(Voltage reading on
W-U lug)
Figure 15. AC Voltmeter
Change-Over Switch
(Reading the W-U leg
on the output terminal
Panel
Figure 17. AC Ammeter
Change-Over Switch
(Reading the W-U leg
on the output terminal
Panel
Figure 18. AC
Ammeter Gauge
(Amp reading on U
lug)
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 39
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DCA-500SSK — OUTPUTTERMINAL
Voltage Change-over Board
Single Phase, 240 Volt
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.
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.
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 21. Hard Wire Hookup for Single Phase 240V
FIGURE 19. Voltage Change-over Board 240V set position.
3 Phase, 240 Volt
Single Phase, 139 Volt
The following connection, with the voltage change-over
board set into the 240V set position (See Figure 19), can
offer THREE PHASE power at 240V. After hooking up the
hard wires to the lugs as shown in figure 20 below, 240V
will be the voltage output.
The following connection, with the voltage change-over
board set into the 240V set position (See Figure 19), can
offer SINGLE PHASE power at 139V. After hooking up
the hard wires to the lugs as shown in figure 22 below,
139V will be the voltage output.
FIGURE 22. Hard Wire Hookup for Single Phase 139V
FIGURE 20. Hard Wire Hookup for Three Phase 240V
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DCA-500SSK — OUTPUTTERMINAL
480 Volt Set position
Single Phase, 480 Volt
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.
The following connection, with the voltage change-over
board set into the 480V set position (See Figure 23), can
offer SINGLE PHASE power at 480V. After hooking up
the hard wires to the lugs as shown in figure 25 below,
480V will be the voltage output.
FIGURE 23. Voltage Change-over Board 480V set position.
FIGURE 25. Hard Wire Hookup for Single Phase 480V
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.
Single Phase, 277 Volt
The following connection, with the voltage change-over
board set into the 480V set position (See Figure 23), can
offer SINGLE PHASE power at 277V. After hooking up
the hard wires to the lugs as shown in figure 26 below,
277V will be the voltage output.
FIGURE 26. Hard Wire Hookup for Single Phase 277V
FIGURE 24. Hard Wire Hookup for Three Phase 480V
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 41
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DCA-500SSK — INSTALLATION
CAUTION :
Outdoor Installation
Install the generator in a location where it will not be
exposed to rain or sunshine. Make sure the generator is
on secure level ground so that it cannot slide or shift around.
Also install the generator in a manner so the exhaust will
not be discharged in the direction of nearby homes.
An electric shock will 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
The installation site must be free from excessive moisture
and dust. All electrical equipment must be protected from
excessive moisture.Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
To prevent 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 the
cable ground shall be connected to the grounding system of
the building as close to the point of cable entry as practical.
Foreign materials such as dust, sand, lint and abrasive
materials will cause excessive wear to the engine and
alternator parts.
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.
CAUTION :
a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.
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.
2. When grounding the generator (Figure 27) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully.Connect the other
end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.
Indoor Installation
Exhaust gases from diesel engines are extremely
poisonous. If the generator is installed indoors, the exhaust
fumes must be vented to the outside.The engine must be
installed at least two feet from any outside wall. Using an
exhaust pipe that is too long or too small will cause
excessive back pressure resulting in engine overheating.
Eliminate the danger of deadly carbon monoxide gas.
Exhaust fumes from any diesel engine are very poisonous
if discharged in a closed room, but harmless if allowed to
mix with the outside air.
NOTE
When connecting the generator
to any buildings electrical system
ALWAYS consult with a licensed
electrician.
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DCA-500SSK — INSTALLATION
Figure 27. Typical Generator Grounding Application
CAUTION :
Always check Local, State, and Federal
Laws before grounding generator.
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DCA-500SSK — PRE-SETUP
General Inspection Prior to Operation
Circuit Breakers
The DCA-500SSK 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.
To protect the generator from an overload, a 3-pole,1400
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 starting the engine.
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 8) for selecting proper cable
size.
NOTE
ALWAYS consult with a licensed
electrician for correct extension
cord wire size.
Table 10. Cable Selection (60 Hz, Single Phase Operation)
Load In Watts
Maximum Allowable Cable Length
Current
in
Amperes
At
At 120
240
#10 Wire
#12 Wire
#14 Wire
#16 Wire
Volts
Volts
2.5
5
300
600
600
1000 ft.
500 ft.
350 ft.
250 ft.
150 ft.
125 ft.
600 ft.
300 ft.
200 ft.
150 ft.
100 ft.
75 ft.
375 ft.
200 ft.
125 ft.
100 ft.
65 ft.
250 ft.
125 ft.
100 ft.
1200
1800
2400
3600
4800
7.5
10
15
20
900
1200
1800
2400
50 ft.
CAUTION: Equipment damage can result from low voltage.
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DCA-500SSK — PRE-SETUP
Fuel
Lubrication Oil
Fill the fuel tank with clean and fresh diesel fuel. DO
NOT fill the tank beyond capacity.
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way, but without being screw
into the filler hole, verify that the oil level is maintained
between the two notches (Figure 28) on the dipstick. See
Table 9 for proper selection of engine oil.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 26,
Specification Table 7.
The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does
not have a spout, use a funnel.Wipe up any spilled fuel
immediately.
CAUTION :
Never fill the fuel tank while the engine
is running or in the dark. Diesel spillage
on a hot engine can cause a fire or
explosion. If diesel spillage occurs,
wipe up the spilled diesel completely
to prevent fire hazards.
Coolant
Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and
radiator may become coated with deposits and cooling
efficiency will be reduced.
Figure 28. Engine Oil Dipstick
An anticorrosion additive added to the water will help
prevent deposits and corrosion in the cooling system.
See the engine manual for further details.
When checking the engine oil, be sure to check if the oil
is clean and viscous. If the oil is not clean, drain the oil
by removing the oil drain plug, and refill with the specified
amount of oil as outlined in the Komatsu Engine
Owner's Manual.
Table 11. Recommended Motor Oil
Temperature
Range
Type Oil
104° F ~ 23° F
(40° C ~ -5°C)
SAE 30
23° F ~ 5° F
(-5° C ~ -15°C)
SAE 20 or SAE 10W-30
SAE 10W or SAE 10W-30
Below 5° C (-15°)
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 45
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DCA-500SSK — PRE-SETUP
Cleaning the Radiator
CAUTION :
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.
When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.
Day-to-day addition of coolant is done from the reserve tank.
When adding coolant to the radiator, DO NOT remove the
radiator cap until the unit has completely cooled. See Table
12 for engine, radiator, and reserve tank coolant capacities.
Make sure the coolant level in the reserve tank is always
between the "H" and the "L" markings.
Air Cleaner
Periodic cleaning/replacement is necessary. See
maintenance section for instruction to cleaning/replacing air
cleaner.
Fan BeltTension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear. See maintenance section on replacing
belts. To adjust tension:
Table 12. Coolant Capacity
1. Insert a bar between alternator and the cylinder block to
fix alternator in position. When fixing the alternator in
position, insert a wooden block between the bar and
alternator to prevent damage to the alternator.
2. Loosen bolts and nuts located on the alternator.
3. Move alternator with the bar so the deflection of the belt
is approx. 8mm.
31.4Gal. (119.0
Engine and Radiator
Liters)
Reserve Tank
2 Quarts (1.9 Liters)
4. Tighten the bolt and nuts to fix the alternator back to
position.
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
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.
Table 13. Anti-Freeze Operating Temperatures
Freezing Point
Boiling Point
Vol %
Anti-Freeze
°C
-24
-37
°F
°C
°F
40
50
-12
-34
106
108
222
226
Figure 29. Fan Belt Tension
CAUTION
:
NOTE
Never place hands near the belts or fan
while the generator set is running.
When the antifreeze is mixed with
water, the antifreeze mixing ratio must
be less than 50%.
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DCA-500SSK — PRE-SETUP
Battery Cable Installation
CAUTION
:
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.
Inadequate battery connections may cause
poor starting 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.
Figure 30. Battery Connections
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.
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.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 47
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DCA-500SSK — LOAD APPLICATION
Single Phase Load
CAUTION:
Motors and motor-driven equipment
draw much greater current for
starting than during operation.
Always be sure to check the nameplate on the
generator and equipment to insure the wattage,
amperage and frequency requirements are
satisfactorily supplied by the generator for operating
the equipment.
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.
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.
z
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.
NOTE
If wattage is not given on the
equipment's name plate, approximate
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.
z
z
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.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table
14. below when connecting loads.
CAUTION:
Table 14. Power Factor By Load
Type Of Load
Power Factor
When connecting ordinary power tools,
a capacity of up to the generating set’s
rated output (kW) multiplied by 0.8 can
be used.
Single-phase induction
motors
0.4 - 0.75
Electric heaters,
incandescent lamps
1.0
0.4 - 0.9
1.0
Fluorescent lamps, mercury
lamps
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.
Electronic devices,
communication equipment
Three Phase Load
When calculating the power requirements for 3-phase
power use the following equation:
NOTE
If output (kVA) is not given on the equipment
nameplate, approximate output may be
determined by multiplying voltage by
amperage by
.
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DCA-500SSK — GENERATOR START-UP PROCEDURE (MANUAL)
2. Connect the load to the UVW terminals as shown in
WARNING:
Figure 32.These terminals can be found on the output
terminal panel, see page 37, Figure 14. To gain
access to the output terminals lift the UVW cover.
Tighten the terminal nuts securely to prevent load
wires from slipping out.
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 Table 9 on page 41).
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.
Figure 32. UVW Terminal Lugs (Load)
3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 33).
4. Check the fuel level on the fuel gauge. If fuel is low, fill
the fuel tank with clean fresh diesel fuel. 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, GFCI or load circuit breakers
in the ON position.
Y
TTER
BA
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.
Figure 33. Battery Connections
Figure 31. Main, GFCI and
Load Circuit Breakers
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DCA-500SSK — GENERATOR START-UP PROCEDURE (MANUAL)
4. Close all engine enclosure doors (Figure 34).
7. Place the Off/Manual/Auto switch (Figure 38) in
the MANUAL position (down). Observe that the
engine begins to crank.
Figure 34. Engine Enclosure Doors
Figure 38. Off/Manual/Auto Switch (Manual)
5. Set the battery ON/OFF switch (Figure 35) to the ON
position.
8. After engine starts, verify that the "Engine Running"
status LED (Figure 39) on the Microprocessor Engine
Control Module (MPEC) display is "ON" (lit).
Figure 35. Battery ON/OFF Switch
6. When starting the generator in COLD weather
conditions, press and hold the engine preheat button
(Figure 36) until the preheat lamp (Figure 37) is lit
(ON).
Figure 39. MPEC Engine Running Status LED
9. The generator's frequency meter (Figure 40) displays
the 60 cycle output frequency in HERTZ.
Figure 36. Engine Pre-Heat Button
Figure 40. Frequency Meter (Hz)
Figure 37. Engine Pre-Heat Lamp
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DCA-500SSK — GENERATOR START-UP PROCEDURE (MANUAL)
10. The generator's voltage meter (Figure 41) displays
12. The engine oil pressure gauge (Figure 44) will
indicate the oil pressure (kg/ cm2) of the engine.
Under normal operating conditions the oil pressure
should be approximately 25 psi.
the 120 VAC in VOLTS. If the voltage is not within
the specified frequency tolerance, use the voltage
adjustment control knob (Figure 42) to increase or
decrease the desired voltage.
Figure 44. Oil Pressure Gauge
Figure 41. Voltage Meter (Volts)
13. The coolant temperature gauge (Figure 45) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature
should be between 165 and 215 degrees Fahrenheit
(Green Zone).
Figure 42. Voltage Adjust Control
Knob
WATER TEMP
11. The ammeter (Figure 43) 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 45. Coolant Temperature Gauge
40
20
60
0
75
A
Figure 43. Ammeter (No Load)
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 51
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DCA-500SSK — GENERATOR START-UP PROCEDURE (MANUAL)
14. Set the engine speed switch (Figure 46) to low to idle
17. Observe the generator's ammeter (Figure 49) and
verify that it reads the anticipated amount of current
with respect to the load. Remember the ammeter
will only display a current reading if the load is in
use.
engine, set to high when a load is being applied.
40
20
60
0
75
Figure 46. Engine Speed Switch
A
15. The tachometer (Figure 47) will indicate the speed of
the engine when the generator is operating. Under
normal operating conditions this speed should be
approximately 1800 RPM’s.
Figure 49. Ammeter (Load)
18. The generator will run until manually stopped or an
abnormal condition occurs.
Figure 47. Engine Tachometer
16. Turn the MAIN, GFCI and LOAD circuit breakers to
their ON position (Figure 48).
Figure 48. Main and GFCI Circuit Breakers
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DCA-500SSK — GENERATOR START-UP PROCEDURE (AUTO)
When starting generator in Auto mode use the "Manual Start-
up" procedure except where noted (see below).
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.
1. Perform steps 1 through 6 (Before Starting, page 49-50)
as outlined in the manual starting procedure.
2. Place the Off/Manual/Auto switch (Figure 50) in the
AUTO position (up). Observe that the engine begins to
crank.
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.
Figure 50. Off/Manual Auto Switch (AUTO)
3. Continue to follow the steps outline in the manual start-
up procedure (start at step 9, page 50).
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 53
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DCA-500SSK — GENERATOR SHUTDOWN PROCEDURE
Engine Shutdown
To shutdown the generator use the following procedure:
Emergency Stop
1. Place both the MAIN, GFCI and LOAD circuit breakers
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 control panel, see page 34,
Figure 10.
to the "OFF position"
2. Set the engine speed switch (Figure 51) to the idle (low)
position (If optional part installed).
Figure 54. Emergency Stop Button
CAUTION
:
NEVER stop the engine suddenly
except in an emergency. DO NOT use
the emergency stop switch as a method
of shutting down the engine.This switch
is ONLY to be used in the event of an
emergency.
Figure 51. Engine Speed Switch
3. Let the engine cool by running it for 3-5 minutes with no
load applied.
4. Place the Off/Manual/Auto Switch (Figure 52) in the "OFF/
RESET" position
Figure 52. Off/Manual Auto Switch (OFF)
5. Verify that the "Engine Running" status LED (Figure
53) on the Microprocessor Engine Control Module
(MPEC) display is "OFF" (not lit).
Figure 53. MPEC Engine Running
Status LED (OFF)
6. Remove the load from the UVW terminal strip (Figure 32
page 49).
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DCA-500SSK — MAINTENANCE
General Inspection
Fuel Addition
Prior to each use, the generating set should be cleaned and Add diesel fuel (the grade may vary according to season
inspected for deficiencies. Check for loose, missing or and locations). Always pour through the mesh filter.
damaged nuts, bolts or other fasteners. Also check for fuel Removing Water from theTank
or oil leaks.
Air Cleaner
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
Every 50 hours: If dust indicator is red, clean the air cleaner cock and drain the contents. During cold weather, the greater
element.
Outer Element:
the empty volume inside the tank, the easier it is for water to
condense. This can be reduced by always keeping the tank
1. Loosen wing bolt, remove dust cup, then remove wing as full as possible.
nut and take out element. Air Removal
2. Clean the inside of the body and cover using a damp If air enters the fuel injection system of a diesel engine,
cloth.
starting becomes impossible. After running out of fuel, or
3. Blow dry with compressed air (0.69Mpa [7kgf.cm2, after disassembling the fuel system, bleed the system
99.4 PSI] maximum) against the side of the element according to the following procedure.
along the pleats. Then blow dry against outside along To restart after running out of fuel, turn the key switch to the
the pleats, then against inside again.
4. Remove one seal each time the element is cleaned.
“START” position for 15-30 seconds. Try again, if needed.
This unit is equipped with an automatic air bleeding system.
5. Replace the outer element after cleaning it 6 times or Service Daily
after one year. Replace the outer element if indicator is If engine is operating in very dusty and dry grass conditions,
red even after cleaning it.
a clogged air cleaner will result in high fuel consumption,
6. Check the inner cylinder element clamping nut for loss of power and excessive carbon buildup in the
looseness, and retighten if necessary.
7. If seal washer is damaged or the threads of wing nut are
damaged, replace.
8. Remove evacuator valve and clean it with compressed
air. Reinstall.
Inner element (if equipped)
1. Remove the cover and outer element, then remove the
inner element.
2. Cover the air connector opening (outer side) with clean
cloth or cloth tape.
3. Clean the inside of the body. Remove air connector
opening protection.
4. Install a new inner cylinder element to the cylinder and
tighten the nut.
5. Install element.
combustion chamber.
Cleaning the Fuel Strainer
Clean the fuel strainer if it contains dust or water. Remove
dust or water in the strainer cap and wash it in diesel. Securely
fasten the fuel strainer cap so that fuel will not leak. Check
the fuel strainer every 200 hours of operation or once a month.
Check Oil Level
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level.The oil level
must be between the two notches on the dipstick as shown
in Figure 14, page 39.
Flushing Out Radiator and Changing Coolant
6. After replacing the element, press the button of the dust
indicator to return the red piston to its original position.
1. Stop the engine and allow to cool. Tighten valve of the
corrosion resistor (if equipped).
2. Turn water filer cap slowly and remove it.
3. Prepare a container to catch the coolant, then open drain
plug of the radiator or heat exchanger and drain plug of
the engine, and drain the coolant.
4. After draining the coolant, close drain plugs and fill with
tap water.
PAGE 56 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — MAINTENANCE
5. When the water level is near the mouth of the water Changing Oil
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.
1. Make sure the oil is cool before changing.
2. Set a container directly under the drain plug of the oil
pan. Loosen the drain plug slowly.
6. Adjust the flow of the water flowing in and draining out to
ensure that the radiator is always full during the flushing
operation, While flushing water through the system,
watch carefully the water inlet hose does not come out
of the radiator filler port.
3. Check the drained oil for excessive metal particles or
foreign material. Contact the distributor if there is metal
particles or foreign material.
4. Using a filter wrench, turn filter cartridge to the left to
remove it. If the filter cartridge is filled with a large
amount of oil, wait 10 minutes or so before removing.
Make sure there is no old gasket stuck on the filter holder.
7. After flushing, stop the engine, open drain plug and drain
the water, then close drain plugs.
8. After draining the water, flush the system with a flushing
agent. See instructions on flushing agent label.
5. Tighten drain plug. Clean the filter holder, fill the new
filter cartridge with clean engine oil, coat the packing
and thread of the new filter cartridge with engine oil,
then install it to the filter holder. Tighten until the gasket
surface contacts the seal surface of the filter holder,
then tighten it a further 3/4 to 1 turn.
9. After flushing, open drain plugs and drain out all the
water, then close drain plugs and add tap water so the
water level is near the mouth of the water filler.
10. When the water level is near the mouth of the water
filler, open drain plugs and start the engine, run at low
idling and continue to flush the system until clean water
comes out. Adjust the flow of the water flowing in and
draining out to ensure the radiator is always full during
the flushing operation.
6. Add engine oil through oil filler until the oil level is between
the H and L marks on the dipstick.
7. Run the engine at idling for a short time, then stop the
engine. Recheck the oil level and fill as necessary.
Replacing fuel filter
11. When clean water comes out, stop the engine, drain all
the water, then close drain plugs.
1. Set the container under the filter cartridge to catch fuel.
2. Using a filter wrench, turn the filter cartridge to the left
to remove it.
12. Remove the corrosion resistor (if equipped) and open
valve.
3. Clean the filter holder, fill the new filter cartridge with
fuel, coat the packing surface of the filter cartridge with
engine oil, then install the cartridge to the filter holder.
13. Supply water until it flows over the water filler.
14. Drain the water inside reserve tank, clean the inside of
the reserve tank, then fill with coolant/water mixture to
between the full and low lines.
4. When installing, tighten until the packing surface
contacts the seal surface of the filter holder then tighten
a further 2/3 of a turn. If the filter cartridge is tighten too
much, the packing will be damaged and will cause fuel
leakage. Fuel leakage will occur if the filter cartridge is
not tightened enough. Always tighten to the correct
angle.
15. Stop the engine, wait for 3 minutes, add tap water until
the water level reaches near the water filer port, then
tighten the radiator cap.
Check Electric Heater (If equipped)
Before starting in cold weather (once a year), please contact
your Komatsu distributor for inspection. Remove electric
heater from the engine intake manifold and check for
disconnections or dirt. When checking or installing the electric
heater, replace the gasket with a new part.
5. After replacing filter cartridge, loosen air bleed plug.
6. Loosen the knob of feed pump, and pump it up and down
until no bubbles come our with the fuel from air bleed
plug.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 57
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DCA-500SSK — MAINTENANCE
7. After bleeding the air, tighten air bleed plug, then push in Generator Storage
the knob of feed pump and lock it in position.
8. Replace Corrosion resistor cartridge (if equipped)
9. Screw in valves at the top of the corrosion resistor.
For storage of the generator for over 30 days, the following
is required:
z
z
Fill the fuel tank completely, lubricate and change oil.
10. Using a filter wrench, turn the cartridge to the left to
remove it.
Disconnect the negative terminals of the battery and
cover it, or remove it from the machine and store it
separately.
11. Coat the seal surface of the new cartridge with engine
oil and install it to the filter holder.
z
If the ambient temperature is expected to drop below
0oC, add antifreeze to the radiator.
12. Tighten until he packing surface contacts the seal
surface of the filter holder, then tighten a further 2/3 of a
turn.
Removal from long term storage:
13. Open valves.
z
Apply oil to the engine valve and rocker arms, and
examine the operating condition of the 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.
z
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.
2. Wash the breather in diesel fuel or flushing oil, blow dry
with compressed air, then reinstall it.
z
z
z
z
Change the oil in engine oil pan.
Replace all the filters.
3. Inspect the hose and if there is any deteriorated oil stuck
inside the hose. Replace hose if necessary.
Flush the inside of the cooling system.
Drain the water from the fuel tank and bleed the air from
the fuel system.
Greasing
Using a grease pump, grease the fan hub (1 place) and
tension pulley (2 places).
z
If the engine has not been started for more than one
year, contact your Komatsu distributor to have engine
overhauled.
PAGE 58 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — MAINTENANCE
TABLE 15.
10 Hrs
DAILY
250 Hrs
500 Hrs 1000 Hrs
INSPECTION / MAINTENANCE
Check Engine Fluid Levels
Check Air Cleaner
X
X
X
X
X
X
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter *1
Clean Air Filter
X
X
X
X
ENGINE
Drain Bottom of Fuel Tank
Clean Unit, Inside and Outside
Change Fuel Filter *2
X
X
Clean Radiator and Check Coolant
Protection Level
Replace Air Filter Element
Change Corrosion Resistor
Check all Hoses and Clamps
Clean Inside of Fuel Tank
X
X
X
X
Measure Insulation Resistance Over
3M ohms
X
GENERATOR
*1 Replace engine oil anf filter at 100 hours, first time only.
*2 Replace fuel filter at 250 Hours, first time only.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 59
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DCA-500SSK—GENERATORWIRING DIAGRAM
RING DIAG
PAGE 60 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK—ENGINEWIRING DIAGRAM
RAM
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 61
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DCA-500SSK —TROUBLESHOOTING (ENGINE)
All breakdowns can be prevented by proper handling and on the EngineTroubleshooting (Table 16) information shown
maintenance inspections, but in the event of a breakdown, below and on the proceeding page. If the problem cannot be
please take a remedial action following the diagnosis based remedied, consult our company's business office or service
plant.
TABLE 16. ENGINE TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
No fuel?
SOLUTION
Replenish fuel.
Bleed system.
Air in the fuel system?
Water in the fuel system?
Fuel pipe clogged?
Remove water from fuel tank.
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.
Tighten nut.
Fuel leak due to loose
injection pipe retaining nut?
Engine does not start.
Incorrect injection timing?
Fuel cam shaft worn?
Adjust.
Replace.
Injection nozzle clogged?
Clean injection nozzle.
Injection pump
malfunctioning?
Repair or replace.
Repair or replace.
Seizure of crankshaft,
camshaft, piston, cylinder
liner or bearing?
Compression leak from
cylinder?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
Improper valve timing?
Correct or replace timing gear.
Replace.
Piston ring and liner worn?
Excessive valve clearance? Adjust.
Battery discharged?
Charge battery.
Repair or replace.
Starter malfunctioning?
Starter does not run.
Key switch malfunctioning? Repair or replace.
Wiring disconnected? Connect wiring.
PAGE 62 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK —TROUBLESHOOTING (ENGINE)
TABLE 16. ENGINE TROUBLESHOOTING (CONTINUED)
SYMPTOM
POSSIBLE PROBLEM
Fuel filter clogged or dirty?
Air cleaner clogged?
SOLUTION
Clean or change.
Clean or change.
Fuel leak due to loose
injection pipe retaining nut?
Tighten nut.
Injection pump
malfunctioning?
Repair or replace.
Adjust.
Engine revolution is not
smooth.
Incorrect nozzle opening
pressure?
Injection nozzle stuck or
clogged?
Repair or replace.
Fuel over flow pipe
clogged?
Clean.
Governor malfunctioning?
Excessive engine oil?
Repair.
Reduce to the specified level.
Repair or replace.
Piston ring and liner worn
or stuck?
Either white or blue exhaust
gas is observed.
Incorrect injection timing?
Deficient compression?
Overload?
Adjust.
Adjust top clearance.
Lessen the load.
Use the specified fuel.
Clean or change.
Clean or change.
Repair or replace the nozzle.
Adjust.
Low grade fuel used?
Fuel filter clogged?
Either black or dark gray
exhaust gas is observed.
Air cleaner clogged?
Deficient nozzle injection?
Incorrect injection timing?
Engine's moving parts
seem to be seizing?
Repair or replace.
Deficient output.
Uneven fuel injection?
Repair or replace the injection pump.
Repair or replace the nozzle.
Deficient nozzle injection?
Replace head gasket, tighten cylinder head bolt, glow
plug and nozzle holder.
Compression leak?
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 63
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DCA-500SSK —TROUBLESHOOTING (GENERATOR/ENGINE)
All breakdowns can be prevented by proper handling and on the Engine and Generator Troubleshooting (Table 17)
maintenance inspections, but in the event of a breakdown, information shown below. If the problem cannot be remedied,
please take a remedial action following the diagnosis based consult our company's business office or service plant.
TABLE 17. GENERATOR TROUBLESHOOTING
SYMPTOM
POSSIBLE PROBLEM
AC Voltmeter defective?
Is wiring connection loose?
Is AVR defective?
SOLUTION
Check output voltage using a voltmeter.
Check wiring and repair.
No Voltage Output
Replace if necessary.
Defective Rotating Rectifier?
Is engine speed correct?
Is wiring connections loose?
Defective AVR?
Check and replace.
Turn engine throttle lever to "High".
Check wiring and repair.
Low Voltage Output
High Voltage Output
Replace if necessary.
Is wiring connections loose?
Defective AVR?
Check wiring and repair.
Replace if necessary.
Short Circuit in load?
Check load and repair.
Over current?
Confirm load requirements and reduce.
Check and replace.
Circuit Breaker Tripped
Defective circuit breaker?
Over current Relay actuated?
Confirm load requirement and replace.
PAGE 64 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK —TROUBLESHOOTING (MPEC)
All breakdowns can be prevented by proper handling and on the MPECTroubleshooting (Table 18) information shown
maintenance inspections, but in the event of a breakdown, below. If the problem cannot be remedied, consult our
please take a remedial action following the diagnosis based company's business office or service plant.
TABLE 18. MPEC TROUBLESHOOTING
Sympton
Possible Cause
Low oil level?
Solution
Fill oil level.
Oil pressure sending unit failure?
Time delay malfuntion in MPEC?
Wire shorted?
Replace oil pressure sending unit.
Refer to dealer.
Low oil pressure
light is on.
Inspect/repair wire.
Fill coolant level.
Low coolant level?
Low coolant level
light is on.
Sending unit failure?
Replace sending unit.
Replace/charge battery.
Tighten/replace fan belt.
Low battery voltage?
Fan belt tension incorrect?
Air flow is not circulation through
radiator?
Clean/repair radiator grill.
Doors open?
Close doors.
High coolant
temperture light is
on.
Exhaust leaking?
Replace/repair gaskets or faulty part.
Check/reduce load.
Replace thermostat.
Clear all air intakes.
Replace temperature switch.
Fill fuel level.
Generator being overloaded?
Thermostat failure?
Air intake blocked?
Temperature switch failure?
No or low Fuel?
Overcrank light is
on.
MPEC needs to be calibrated?
RPM engine speed too high?
Refer to dealer.
Adjust RPM.
Governor actuator needs to be adjusted? Adjust governor actuator.
Overspeed light is
on.
Governor controller needs to be
Adjust governor controller.
adjusted?
MPEC needs to be calibrated?
Magnetic pick up out of adjustment?
Magnetic pick up dirty?
Refer to dealer.
Adjust magnetic pick up.
Clean magnetic pick up.
Loss of MPU
light(s) or on.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 65
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EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts
book.
Items Found In the “Remarks” Column
Serial Numbers-Where indicated, this indicates a serial
number range (inclusive) where a particular part is used.
Model Number-Where indicated, this shows that the
corresponding part is utilized only with this specific model
number or model number variant.
Items Found In the“Items Number”Column
All parts with same symbol in the number column, , #,
or , belong to the same assembly or kit.
+, %,
*
I
Note: If more than one of the same reference number is
listed, the last one listed indicates newest (or latest) part
available.
PAGE 66 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — SUGGESTED SPARE PARTS
DCA-500SSK w/SA6D170AE-1 KOMATSU ENGINE
1 to 5 Units
Description
Qty. P/N
20 .....6125817032... AIR FILTER
30 .....6003117111... FUEL FILTER
30 .....6002111231... OIL FILTER
2 .......6004111030... CARTRIDGE, CORROSION RESISTOR
1 .......0601804887... CIRCUIT BREAKER
1 .......0601810575... PILOT LAMP, ENGINE TROUBLE
1 .......0601810576... PILOT LAMP, ENGINE TROUBLE
1 .......0412222568... ENGINE FAN BELT
1 .......6008155390... SWITCH STARTER
3 .......615 ................ KEY SET, STARTER SWITCH (2)
2 .......0602122281... OIL SWITCH
1 .......6995621691... RADIATOR HOSE (UPPER)
1 .......6162639650... RADIATOR HOSE (LOWER)
1 .......0605505030... FUEL CAP
1 .......0601820625... AUTOMATICVOLTAGE REGULATOR
1 .......0601807030... MAIN CIRCUIT BREAKER
1 .......0601805840... CIRCUIT BREAKER
1 .......0601802525... HANDLE, MAIN CURRENT BREAKER
1 .......0601840073... VOLTAGE REGULATOR (RHEOSTAT)
2 .......0601840121... KNOB, VOLTAGE REGULATOR
1 .......0601810072... PILOT LAMP
2 .......0601810261... BULB PILOT LAMP
1 .......23S0311150M CAP, RADIATOR
1 .......0602122203... UNIT OIL PRESSURE
1 .......0602123206... UNIT, WATER TEMPERATURE
1 .......0602121052... CHARGING AMMETER
NOTE
Part number on this Suggested Spare
Parts List may super cede/replace the
P/N shown in the text pages of this
book.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 67
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DCA-500SSK — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 68 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — GENERATOR ASSY.
GENERATOR ASSY.
NO.
1
PART NO.
PART NAME
QTY.
1
1
4
6
6
1
1
6
6
1
1
1
12
12
1
2
4
4
4
6
6
1
1
1
1
6
6
1
4
4
2
4
4
REMARKS
8471000002
ROTOR ASSY.
1-1
1-2
1-3
1-4
1-5
1-6
1-7
FIELD ASSY.
RESISTOR
INSULATORWASHER
INSULATORWASHER
FAN
0601842366
8171020004
8171020504
8461070002
8461614003
0010312025
0042512000
416310004
COUPLING RING
HEX. HEAD BOLT
LOCKWASHER
COUPLING DISK ASSY.
WASHER, COUPLING HUB
BALANCING PLATE
HEX. HEAD BOLT
LOCKWASHER
SET PLATE, RECTIFIER
RECTIFIER
HEX. SOCKET HEAD COP SCREW
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
LOCKWASHER
BALANCING WEIGHT KIT
BEARING FLANGE
BEARING
1-8
1-9
8461612004
8461015003
0012120055
0042620000
8461026023
0601823282
0018205020
0040005000
0041205000
0010112020
0040012000
0601000209
7431014003
0070106321
0080000105
0012116060
0042516000
C4130200003
7431323003
3871323123
7431323204
0016310080
0030010000
0040010000
0041210000
0017110020
8461315002
C4137000003
0012110075
0042610000
0845044904
0010116045
0040016000
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
1-18
1-19
1-20
2
SNAP RING
HEX. HEAD BOLT
LOCKWASHER
STRATOR ASSY.
CLAMPER
CLAMPER
CLAMPER
3
3-1
3-2
3-3
3-7
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
END BRACKET
FIELD ASSY. EXCITER
HEX. HEAD BOLT
LOCKWASHER
GROMMET
8
4
8
1
1
6
6
1
3-5
4
5
6
7
8
HEX. HEAD BOLT
LOCKWASHER
8
8
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 69
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DCA-500SSK — GENERATOR ASSY.
GENERATOR ASSY.
PAGE 70 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — GENERATOR ASSY.
GENERATOR ASSY.
NO
9
10
11
PART NO
PART NAME
QTY.
REMARKS
7431310003
8461312004
0010108095
0040008000
0041208000
0010110016
0803000104
8461335004
8461334003
0017106012
0017106050
8461333003
0017106012
0012112040
0042512000
8461332003
0017106050
0605000012
0030020000
0040020000
COVER, BEARNG
GASKET, BEARING
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
PACKING
1
2
3
3
3
1
1
1
1
4
2
1
2
16
16
1
1
4
8
8
12
13
14
15
16
17
18
19
20
BRACKET, COVER
COVER, STATOR
HEX. HEAD BOLT
HEX. HEAD BOLT
COVER, EXCITER
HEX. HEAD BOLT
HEX. HEAD BOLT
LOCKWASHER
COVER, FAN
21
22
23
24
HEX. HEAD BOLT
RUBBER SUSPENSION
HEX. NUT
LOCKWASHER
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 71
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DCA-500SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 72 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO
1
PART NO
PART NAME
QTY.
1
REMARKS
8481812502
0601801194
0017108020
C4261501303
0017108030
0601820625
0027105016
0601820892
0027104016
0601823706
0027104014
0601823861
0027104014
0601802133
0601802164
0601802149
0601802218
0021004020
0040004000
0041204000
0601823757
PYF08A
CONTROL BOX
2
CURRENT TRANSFORMER, AMMETER
HEX. HEAD BOLT
SET PANEL, ELECTRIC PARTS
HEX. HEAD BOLT
AUTOMATIC VOLTAGE REGULATOR
MACHINE SCREW
OVER CURRENT RELAY
MACHINE SCREW
RELAY
3
CW-40LM 1000/5A
3
6
4
1
5
8
6
1
NTA5A2T
7
4
8
1
THN20HZKP
9
2
10
11
12
13
14
1
MACHINE SCREW
ENGINE STOP UNIT
MACHINE SCREW
FUSE, LEFT SIDE
FUSE
2
1
MSA9014
2
1
5A
1
30A
FUSE, RIGHT SIDE
HOLDER, FUSE
1
10A
1
F7111SP
15
16
17
MACHINE SCREW
LOCK WASHER
3
3
PLAIN WASHER
3
RELAY
1
MY2DC24V
SOCKET
1
REPLACES 0601823143
REPLACES 0601824400
REPLACES 0601823759
REPLACES 0601823146
REPLACES 0601824400
PYCA1
HOLDER
1
MY4DC24V
PYF14A
RELAY
2
SOCKET
2
PYCA1
HOLDER
2
18
19
20
21
22
23
24
25
25-1
26
27
28
29
0027104016
0602201246
0017105016
0602201911
0017106020
0602200446
0017106016
0601807031
0601802525
7971816104
7971816304
0017108020
0021008045
0030008000
0040008000
0041208000
7461861113
7431852104
0017108035
7971852504
7431853104
0801832504
0040020000
0041420000
0010110040
0030010000
0040010000
0041210000
MACHINE SCREW
RELAY
6
1
1750733520
C7038A0000
6008151252
HEX. HEAD BOLT
UNIT, BATTERY SENSOR
HEX. HEAD BOLT
EMERGENCY RELAY
HEX. HEAD BOLT
CIRCUIT BREAKER
HANDLE, CIRCUIT BREAKER
BRACKET, CIRCUIT BREAKER
BRACKET, CIRCUIT BREAKER
HEX. HEAD BOLT
MACHINE SCREW
HEX. NUT
2
1
1
1
4
1
XS1600NA1400A
XHA9
1
1
1
4
4
4
LOCK WASHER
PLAIN WASHER
4
4
30
31
32
33
34
35
36
37
38
CHANGE-OVER BOARD, VOLTAGE
CHANGE TERMINAL
HEX. HEAD BOLT
TERMINAL PLATE
CHANGE PLATE
HEX. HEAD BOLT
LOCK WASHER
1
10
20
7
7
17
20
20
4
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
4
LOCK WASHER
4
PLAIN WASHER
4
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 73
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DCA-500SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
PAGE 74 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO
PART NO
PART NAME
QTY. REMARKS
39
40
0602201245
0010010040
0040010000
0041210000
C4224001403
7971822603
0228800124
0228800100
0605011211
0601800480
0601800780
0601801040
0601800252
0601801041
0601810072
0601810261
061840073
APS UNIT
1
4
4
4
1
1
2
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
2
2
2
2
2
2
2
2
1
10
1
1
12
1
1
15
5
3
3
6008153600
HEX.HEAD BOLT
LOCK WASHER
PLAIN WASHER
CONTROL PANEL
CONTROL PANEL
RUBBER SEAL
41
42
42-1
42-2
43
RUBBER SEAL
PIN
44
FREQUENCY METER
AC AMMETER
PAL100 220V 45~65Hz
PSK100 0~1000A 0~2000A
SL2AS
45
46
CHANGE OVER SWITCH, AMMETER
AC VOLTMETER
CHANGE OVER SWITCH, VOLTMETER
PILOT LAMP
47
PCK100 0~600V
SL2VS
48
49
LP132DC 220V
BULB
50
51
52
53
54
RHEOSTAT
RA20A2SE102BJ
0601840121
0601827395
061831340
KNOB
ENGINE CONTROLLER
SWITCH
ECU88LG24
82608DPDT
V325070
0601810161
0601810214
0207004000
0601830710
C9221100004
0040008000
0041208000
0080200007
C9221100004
0040008000
0041208000
0080200007
3871824004
0041206000
0605010502
8481814503
0017108020
8481812104
7971812104
0017108020
8481825104
8481825304
0017108020
0017110030
0017108020
0801830904
PANEL LIGHT
BULB
55
56
57
HEX. NUT
SWITCH, PANEL LIGHT
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
SNAP RING
S301T
58
HEX. HEAD BOLT
LOCK WASHER
PLAIN WASHER
SNAP RING
STOPPER, CONTROL PANEL
PLAIN WASHER
SNAP PIN
COVER, CONTROL BOX
HEX. HEAD BOLT
SIDE PANEL, CONTROL BOX
SIDE PANEL, CONTROL BOX
HEX. HEAD BOLT
PANEL, CONTROL BOX
PANEL, CONTROL BOX
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. HEAD BOLT
59
60
61
62
63
64
65
66
67
68
39
70
71
72
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 75
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DCA-500SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 76 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO
1
2
2-1
3
4
5
6
7
8
PART NO
PART NAME
QTY. REMARKS
C4925200004
0602011985
0602011058
0605000085
0010120100
0030020000
0040020000
0041220000
8485123004
0010112025
0040012000
0041212000
0017110025
0602013955
0602014649
0602013305
0602012054
0602014541
0602013954
0602014350
0602014058
0602014351
0602040156
0602040647
0602041146
0602042146
0602045149
7435112004
8485112004
0010118060
0030018000
0040018000
0041218000
0605000012
0030020000
0040020000
0602023160
0010108025
0041208000
0207008000
ENGINE ..................................................... 1 .......KOMATSU SA6D170BE-1
RADIATOR .................................................. 1 .......6162639151
CAP, RADIATOR......................................... 1 .......23S0311150
RUBBER SHEET........................................ 2 .......6995619230
HEX. HEAD BOLT ...................................... 4
HEX. NUT ................................................... 8
LOCKWASHER ......................................... 4
PLAIN WASHER......................................... 8
BRACKET, RADIATOR ............................... 2
HEX. HEAD BOLT ...................................... 4
PLAIN WASHER......................................... 4
PLAIN WASHER......................................... 4
HEX. HEAD BOLT ...................................... 4
RADIATOR HOSE ...................................... 1 .......6995621450
RADIATOR HOSE ...................................... 1 .......6162639650
RADIATOR PIPE ........................................ 1 .......6162639640
DRAIN VALVE ............................................ 1 .......07730500004
RADIATOR HOSE ...................................... 1 .......0726120911
RADIATOR HOSE ...................................... 1 .......6128619650
HOSE BAND .............................................. 8 .......0728101029
HOSE BAND .............................................. 2 .......0728100197
HOSE BAND .............................................. 2 .......0728100489
ELEMENT, AIR CLEANER ......................... 2 .......6125817032
DUST SENSOR ......................................... 1 .......6008157930
CARTRIDGE, OIL FILTER ......................... 2 .......6002111231
CARTRIDGE, FUEL FILTER ...................... 3 .......6003118293
CARTRIDGE, CORROSION RESISTOR.... 1 .......6004111161
ENGINE FOOT ........................................... 1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
ENGINE FOOT ........................................... 2
HEX. HEAD BOLT ...................................... 6
HEX. NUT ................................................... 6
LOCKWASHER ......................................... 6
PLAIN WASHER......................................... 6
RUBBER SUSPENSION ............................ 4
HEX. NUT ................................................... 8
LOCKWASHER ......................................... 8
PUMP ......................................................... 1 .......GM2524H
HEX. HEAD BOLT ...................................... 4
PLAIN WASHER......................................... 4
HEX. NUT ................................................... 4
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 77
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DCA-500SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
PAGE 78 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENGINE & RADIATOR ASSY.
ENGINE & RADIATOR ASSY.
NO
40
41
42
43
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
PART NO
PART NAME
QTY. REMARKS
0131710060
0131708060
0130206000
0602022202
0802024004
0191601350
0605515134
0602010230
8482082103
0229200700
0017106030
0017108020
0199601100
0194001600
0605515013
0602014648
0194201000
0605515014
8482256304
8482256104
0010118040
0040018000
0041218000
0017110025
0017112025
C4494600004
BUSHING ................................................... 1
BUSHING ................................................... 1
STREET ELBOW ....................................... 3
HOSE JOINT.............................................. 1
PACKING.................................................... 1
HOSE ......................................................... 1
HOSE BAND .............................................. 2
RESERVE TANK ........................................ 1 .......0228104860
BRACKET, RESERVE TANK ...................... 1
RUBBER CUSHION ................................... 1
HEX. HEAD BOLT ...................................... 1
HEX. HEAD BOLT ...................................... 2
HOSE ......................................................... 1
HOSE ......................................................... 1
HOSE BAND .............................................. 3
HOSE ......................................................... 1 .......0727061510
HOSE ......................................................... 1
HOSE BAND .............................................. 2
CLAMPER ROD ......................................... 1
CLAMPER ROD ......................................... 1
HEX. HEAD BOLT ...................................... 2
LOCKWASHER ......................................... 2
PLAIN WASHER......................................... 2
HEX. HEAD BOLT ...................................... 1
HEX. HEAD BOLT ...................................... 1
RUBBER SEAL .......................................... 1
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 79
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DCA-500SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 80 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO
1
2
PART NO
PART NAME
QTY.
1
REMARKS
8485312002
0010012035
0030012000
0040012000
0041212000
0017110025
C4352100403
0017108020
0017108020
8085182004
8085183004
0017106020
0602101012
0805008804
0805008704
0020008070
0040008000
0041208000
0840201200
8482181103
0017110030
0207010000
7472181003
0017112030
8482152104
8482152004
8482152204
0602180106
0030008000
0207006000
0041206000
0802100704
0207006000
0041208000
0041206000
SUPPORT LEG
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
4
4
4
4
2
1
4
6
2
2
12
1
1
2
2
2
2
1
1
2
2
1
2
1
1
1
3
3
3
3
1
3
2
PLAIN WASHER
HEX. HEAD BOLT
OPERATING PANEL
HEX. HEAD BOLT
HEX. HEAD BOLT
RUBBER COVER
SET FRAME, RUBBER COVER
HEX. HEAD BOLT
BATTERY SWITCH
SET PLATE, BATTERY SWITCH
STAY, BATTERY SWITCH
MACHINE SCREW
LOCKWASHER
PLAIN WASHER
THROTTLE HANDLE
LINK, GOVERNOR ROD
HEX. HEAD BOLT
HEX. NUT
LINK, GOVERNOR ROD
HEX. HEAD BOLT
GOVERNOR ROD
GOVERNOR ROD
GOVERNOR ROD
BALL JOINT
3
4
5
6
7
8
9
10
11
12
13
0315262002
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
HEX. NUT
HEX. NUT
PLAIN WASHER
PIN BOLT
HEX. NUT
PLAIN WASHER
PLAIN WASHER
1
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 81
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DCA-500SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
PAGE 82 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENGINE OPERATING PANEL ASSY.
ENGINE OPERATING PANEL ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
0027105016
0602180105
0030008000
0207008000
0041208000
0602100049
0602104045
0602103043
0602120054
0602120165
0602122060
0602122203
0602123061
0602123206
0602121052
0602125060
0602115014
0601830715
0602210649
0601850267
0602210809
8492233004
0027106012
0017108025
0207008000
0802100204
0802101204
8482159304
00171010025
3335048004
MACHINE SCREW
BALL JOINT
HEX. NUT
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
2
2
1
1
1
2
1
HEX. NUT
PLAIN WASHER
STARTER SWITCH
EMERGENCY STOP BUTTON
PREHEAT INDICATOR
TACHOMETER
CABLE, TACHOMETER
OIL PRESSURE GAUGE
UNIT, OIL PRESSURE
WATERTEMPERATURE GAUGE
UNIT, WATERTEMPERATURE
CHARGINE AMMETER
FUEL GAUGE
6008155390
0804610000
0814721200
25000KX4110
62500KA8610
42000KX1410
53600KX0501
4000KX0910
51400KS0600
43000KV0300
41000KW0110
V3376600000
S332T
OK MONITOR
ENGINE SPEED SWITCH
PREHEATING SWTICH
GROMMET
CONTROLLER
BRACKET
MACHINE SCREW
HEX. HEAD BOLT
HEX. NUT
JOINT
SPRING
0806130070
SG30A
181900193Z
54
55
56
57
58
BRACKET
HEX. HEAD BOLT
SPRING
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 83
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DCA-500SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
PAGE 84 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO
1
2
3
4
PART NO
PART NAME
QTY. REMARKS
C4231700603
7521860504
7521850504
0010112040
0030012000
0040012000
0041212000
0010112045
0030012000
0040012000
0041212000
0010112040
0030012000
0040012000
0041212000
0801830404
0801830904
0039320000
0040020000
0041420000
0010112050
0030012000
0040012000
0041212000
0601850275
0601815324
0027104020
C4237101304
7971867114
7521865804
0019106020
0042306000
0042406000
0605010660
0207006000
0010112045
0041212000
0805009804
0030012000
7521865603
SET BOARD, OUTPUT TERMINAL
OUTPUTTERMINAL
BRACKET, OUTPUT TERMINAL
HEX. HEAD BOLT
HEX. NUT
1
4
4
8
8
8
16
8
8
8
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
TERMINAL
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
GROMMET
TERMINAL BOARD
MACHINE SCREW
COVER, OUTPUT TERMINAL
RUBBER SHEET
SET PANEL, RUBBER SHEET
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
KNOB
5
6
8
24
24
24
48
1
1
2
3
4
6
6
7
8
9
10
11
12
6
12
1
1
13
14
15
16
17
18
19
TS22P
2
1
1
1
5
5
5
2
20
21
22
23
24
25
26
KMM21xM6
HEX. NUT
2
4
4
4
4
1
HEX. HEAD BOLT
PLAIN WASHER
STAY RUBBER
HEX. NUT
STOPPER
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 85
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DCA-500SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
PAGE 86 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — OUTPUTTERMINAL ASSY.
OUTPUT TERMINAL ASSY.
NO
PART NO
PART NAME
QTY. REMARKS
27
0010108030
0030008000
0041208000
C4237100504
0017108020
0601805313
0601805840
C4261601203
0223300200
0017106030
0601812597
0601812565
0027104015
0030004000
0041204000
C4237101203
HEX. HEAD BOLT
HEX. NUT
PLAIN WASHER
COVER
HEX. HEAD BOLT
CIRCUIT BREAKER
CIRCUIT BREAKER
BRACKET, CIRCUIT BREAKER
RUBBER CUSHION
HEX. HEAD BOLT
RECEPTACLE
RECEPTACLE
MACHINE SCREW
HEX. NUT
PLAIN WASHER
COVER
1
1
2
1
5
2
3
1
1
2
2
28
29
30
31
32
32-1
33
34
35
36
KM51 265V 20A
KM52 265V 50A
GF5352
CS6369
3
10
10
10
1
37
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 87
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DCA-500SSK — BATTERY ASSY.
BATTERY ASSY.
PAGE 88 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — BATTERY ASSY.
BATTERY ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
2
REMARKS
190H52
0168719052
0805018904
0805007804
0805006504
0037808000
0040008000
0041208000
8482280104
8482280304
7432280504
7432280904
7432281104
0347010030
0208110000
0845040114
0845041004
0602220205
BATTERY
BATTERY SHEET
BATTERY BAND
BATTERY BOLT
WING NUT
LOCKWASHER
PLAIN WASHER
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
BATTERY CABLE
EARTH CABLE
HEX. HEAD BOLT
HEX. NUT
2
2
4
4
4
4
1
1
1
1
1
4
4
2
2
1
9
10
11
12
13
14
15
16
17
TERMINAL CAP (+)
TERMINAL CAP (-)
BATTERY SENSOR
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 89
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DCA-500SSK — MUFFLER ASSY.
MUFFLER ASSY.
PAGE 90 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — MUFFLER ASSY.
MUFFLER ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
1
REMARKS
8482311002
0019210020
7432356504
7432356604
7432356704
0019110030
0042310000
0042410000
0019108030
0042308000
0042408000
C4334000513
0010116060
0010116050
0040016000
0041216000
7472355003
C3334200704
0010112050
0030012000
0040012000
0041212000
8225125604
0017108020
0207008000
C4334200504
MUFFLER
HEX. HEAD BOLT
PACKING
PACKING
4
2
1
1
14
14
14
8
8
8
1
8
8
16
24
1
1
4
PACKING
HEX. HEAD BOLT
LOCKWASHER
HEX. HEAD BOLT
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
EXHAUST PIPE
HEX. HEAD BOLT
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
OUTLET PIPE
GASKET
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
COVER
HEX. HEAD BOLT
HEX. NUT
GASKET
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
4
4
8
2
4
4
2
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 91
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DCA-500SSK — FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 92 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — FUELTANK ASSY.
FUEL TANK ASSY.
NO
1
1-1
PART NO
PART NAME
FUEL TANK
CAP, FUEL TANK
KEY
FUEL FILTER
HOSE, FUEL GAUGE
HOSE BAND
TANK BAND
PAD, TANK BAND
HEX. HEAD BOLT
HEX. NUT
TANK SHEET
STREET ELBOW
DRAIN PIPE
BRACKET
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
VAVE
QTY.
1
1
1
1
1
2
2
4
2
2
6
1
1
1
2
2
2
4
1
3
2
2
1
1
2
1
1
1
1
6
2
1
1
1
1
5
1
REMARKS
C4364000713
0605505005
0601850505
0810105400
0264100425
0605515079
7435523104
0805003414
0017108020
0207308000
0221006000
0130206000
7435517114
7525516504
0019108030
0205008000
0042308000
0042408000
0603325011
0132006000
7435512104
0605511033
0602022209
0602022203
7435514304
0191403850
0191301100
0191104000
0191001800
0605515073
0605515000
0605503009
0802120604
0605501050
0602021155
0022905015
0845039604
1-2
1-3
1-4
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
BBS7715 PT1/2
PLUG
LONG NIPPLE
THREE WAY VALVE
HOSE JOINT
HOSE JOINT
HOSE JOINT
SUCTION HOSE
SUCTION HOSE
RETURN HOSE
RETURN HOSE
HOSE BAND
HOSE BAND
FUEL SENSOR
PACKING
400 PT1/2
KH135
KH131
UNIT, FUEL
PACKING
MACHINE SCREW
RUBBER SEAL
52000KA9810
52391KW3700
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 93
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DCA-500SSK — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
6 -CATERPILLARYELLOW
7 -CATO GOLD
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN
8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 94 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
NO
1
2
3
4
5
6
7
PART NO
PART NAME
BASE
QTY.
1
1
1
18
1
4
1
1
1
1
1
1
1
1
28
1
1
1
1
1
1
30
8
1
1
1
32
1
4
1
6
1
12
1
2
REMARKS
8485111002
3875116304
7435116104
0017108020
8485118004
0017108020
C4424002303
C4494100103
C4424000503
C4494100103
C4424000702
C4494100103
C4424000602
C4494100103
0017108020
C4424700004
C4494100103
C4424300303
C4494100103
C4424300003
C4494100103
0017108020
0019210025
8485125203
8485125104
8465924104
0019208020
0845042703
0019208020
7525125304
0019206016
C442420003
0019208020
0600500090
0021106020
C4434000112
FOOR PANEL
FLOOR PANEL
HEX. HEAD BOLT
GUIDE PANEL, AIR
HEX. HEAD BOLT
FRONT FRAME
LINING
FRONT FRAME
LINING
FRONT FRAME
LINING
FRONT FRAME
LINING
HEX. HEAD BOLT
GUIDE PANEL, AIR
LINING
GUIDE PANEL, AIR
LINING
GUIDE PANEL, AIR
LINING
HEX. HEAD BOLT
HEX. HEAD BOLT
COVER, FRONT FRAME
COVER, FRONT FRAME
LINING
HEX. HEAD BOLT
FILLER BRACKET
HEX. HEAD BOLT
COVER
HEX. HEAD BOLT
COVER, FRONT FRAME
HEX. HEAD BOLT
EMBLEM
MACHINE SCREW
CENTER FRAME
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
1
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 95
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DCA-500SSK — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
PAGE 96 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENCLOSURE #1 ASSY.
ENCLOSURE #1 ASSY.
NO
PART NO
PART NAME
HEX. HEAD BOLT
HEX.NUT
LOCKWASHER
PLAIN WASHER
HEX. HEAD BOLT
HEX. NUT
LOCKWASHER
PLAIN WASHER
COVER
HEX. HEAD BOLT
HEX. NUT
ROOF PANEL
ROOF PANEL
ROOF PANEL
HEX. NUT
FILLER COVER
HEX. HEAD BOLT
HEX. HEAD BOLT
QTY. REMARKS
29
0010120075
0030020000
0040020000
0041220000
0010120065
0030020000
0040020000
0041220000
C4434200013
0017108020
0207008000
8485161103
C4464100203
C4464100303
0207008000
0800251701
0019206016
0019208020
6
6
6
12
8
8
8
16
2
12
12
1
1
1
14
1
2
30
31
32
33
34
35
36
37
38
39
30
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 97
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DCA-500SSK — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
6 -CATERPILLARYELLOW
7 -CATO GOLD
8 -RED
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 98 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
NO
1
2
PART NO
PART NAME
QTY. REMARKS
C4444000003
3875151004
0205006000
0042306000
0042406000
C4444000103
C4444000203
C4444000303
0017110025
0017108020
0019210025
7975155003
3875944104
3875151104
0205006000
0042306000
0042406000
7975156004
8495946104
0017108020
0019208020
C4444300703
3875165803
0019208020
7975143003
7975143113
3875147204
3875147304
0207306000
B9114000102
0021806016
7975146004
7975146104
0845050704
0207006000
REAR FRAME
LOUVER PANEL
HEX. NUT
1
1
3
21
21
21
1
1
1
18
5
4
1
1
LOCKWASHER
PLAIN WASHER
REAR FRAME
REAR FRAME
REAR FRAME
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. HEAD BOLT
COVER, REAR FRAME
LINING
LOUVER PANEL
HEX.NUT
LOCKWASHER
PLAIN WASHER
DUCT COVER
LINING
4
5
6
7
8
9
10
11
12
1
16
16
16
1
13
1
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
HEX. HEAD BOLT
HEX. HEAD BOLT
VISOR
17
23
1
1
12
1
1
1
1
VISOR
HEX. HEAD BOLT
DOOR, REAR FRAME
DOOR, REAR FRAME
WINDOW PLATE
WINDOW PLATE
HEX. NUT
DOOR HANDLE
MACHINE SCREW
DOOR ROD
12
1
4
1
1
4
8
139LKDNUSA
DOOR ROD
STAY
HEX. NUT
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 99
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DCA-500SSK — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
PAGE 100 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENCLOSURE #2 ASSY.
ENCLOSURE #2 ASSY.
NO
PART NO
PART NAME
QTY.
REMARKS
30
0805011304
STOPPER, DOOR
1
31
32
33
0805011204
0207006000
0845047104
0845045004
0845047204
0845045004
0019208020
0845031504
0601850097
0021008025
0600500090
0021106020
C4464200303
8485960104
C4464200403
8485960104
C4464200503
8485960104
C4464500304
C4464500204
8485960104
0207008000
C4464500404
00171008020
8485166004
8485968104
0017108020
0019208020
0019210025
B9114500104
0207006000
STOPPER, DOOR
HEX. NUT
HINGE
WASHER
HINGE
WASHER
HEX. HEAD BOLT
CAP
STOPPER
MACHINE SCREW
EMBLEM
MACHINE SCREW
ROOF PANEL
LINING
ROOF PANEL
LINING
ROOF PANEL
LINING
GUIDE
PANEL
LINING
HEX. NUT
PANEL
1
4
2
2
2
2
6
4
2
2
1
2
1
1
1
1
1
1
1
1
1
27
1
11
1
1
9
30
4
1
4
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
HEX. HEAD BOLT
COVER, ROOF PANEL
LINING
HEX. HEAD BOLT
HEX. HEAD BOLT
HEX. HEAD BOLT
DOOR POCKET
HEX.NUT
50
51
52
53
54
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
6 -CATERPILLARYELLOW
7 -CATO GOLD
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN
8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 101
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DCA-500SSK — ENCLOSURE #3 ASSY.
ENCLOSURE #3 ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE
COLOR OF UNIT:
5 -BLACK
6 -CATERPILLARYELLOW
7 -CATO GOLD
1-ORANGE
2-WHITE
3 -SPECTRUM GRAY
4 -SUNBELT GREEN
8 -RED
THE SERIAL NUMBER MAY BE REQUIRED.
PAGE 102 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENCLOSURE #3 ASSY.
ENCLOSURE #3 ASSY.
NO
1
2
PART NO
PART NAME
SPASHER PANEL
HEX. HEAD BOLT
LOCKWASHER
PLAIN WASHER
SIDE PANEL
LINING
SIDE PANEL
LINING
SIDE PANEL
LINING
SIDE PANEL
LINING
LOUVER PANEL
LOUVER PANEL
HEX. NUT
LOCKWASHER
PLAIN WASHER
DUCT
QTY. REMARKS
C4454201603
0019110070
0042310000
0042410000
8485172003
8485972104
8485172103
8485972304
8485172203
8485972503
8485172303
8485972704
7525151004
7525151104
0205006000
0042306000
0042406000
8215176004
8485976704
8485176104
8485976304
0017108020
0019108070
0042308000
0042408000
8485171003
8485970103
8485171103
8485970303
7975171403
8485970503
7975171203
7975970704
1
6
6
6
1
1
1
1
1
1
1
1
1
3
4
5
6
7
8
9
1
16
16
16
1
1
1
10
11
LINING
DUCT
LINING
1
12
13
HEX. HEAD BOLT
HEX.HEAD BOLT
LOCKWASHER
PLAIN WASHER
SIDE DOOR
LINING
SIDE DOOR
LINING
SIDE DOOR
LINING
12
16
16
16
1
1
1
1
1
1
1
14
15
16
17
SIDE DOOR
LINING
1
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 103
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DCA-500SSK — ENCLOSURE #3 ASSY.
ENCLOSURE #3 ASSY.
PAGE 104 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — ENCLOSURE #3 ASSY.
ENCLOSURE #3 ASSY.
NO
PART NO
PART NAME
QTY. REMARKS
18
19
20
21
7525151504
7525151404
7975151004
0205006000
0042306000
0042406000
8485176004
7865976104
0017108020
0825007362
0021806016
0845046904
0845045004
0845047004
0845045004
0019208020
0845031504
0601850097
0021008025
0021008020
B9114000002
LOUVER PANEL
LOUVER PANEL
LOUVER PANEL
HEX. NUT
LOCKWASHER
PLAIN WASHER
DUCT
1
1
1
28
28
28
1
1
22
3
28
8
8
8
8
39
16
10
9
1
4
22
LINING
25
26
27
28
HEX. HEAD BOLT
DOOR HANDLE
MACHINE SCREW
HINGE
WASHER
HINGE
WASHER
HEX. HEAD BOLT
CAP
29
30
31
32
33
34
35
STOPPER
MACHINE SCREW
MACHINE SCREW
DOOR HANDLE
039LKDNUSA
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 105
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DCA-500SSK — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
PAGE 106 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — RUBBER SEAL ASSY.
RUBBER SEAL ASSY.
NO
1
2
3
4
5
6
7
8
PART NO
PART NAME
QTY.
6
REMARKS
0228901640
0228900970
0228901100
0228900990
0229201650
0228800860
0228801380
0229200780
0229201490
0229200595
0229201490
0228100280
0228100520
0228100150
0228100580
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
4
4
2
2
2
2
2
1
2
1
2
2
2
2
9
10
11
12
13
14
15
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 107
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DCA-500SSK — NAMEPLATE AND DECALS
NAME PLATE AND DECALS
PAGE 108 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — NAMEPLATE AND DECALS
NAME PLATE AND DECALS
NO
PART NO
PART NAME
CONTROL BOX GROUP
QTY.
REMARKS
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
0800520100
0800520904
0800520814
0840624504
0840624604
0840624704
0840624804
PLATE; ON-OFF........................................................ 1 ........ AT-202
PLATE; AMMETER CHANGE-OVER SWITCH .......... 1 ........ N-2438
PLATE; VOLTMETER CHANGE-OVER SWITCH ....... 1 ........ N-2439
DECAL; CIRCUIT BREAKER ..................................... 1 ........ S-3031
DECAL; PANEL LIGHT............................................... 1 ........ S-3032
DECAL; PILOT LAMP ................................................ 1 ........ S-3033
DECAL;VOLTAGE REGULATOR................................ 1 ........ S-3034
B9531100604 DECAL;WARNING ELECTRIC SHOCK HAZARD ..... 1 ........ B93110060
C9521203003 DECAL; SETTING FOR OUTPUT VOLTAGE ............. 1 ........ C92120300
C4561101803 DECAL;WHISPERWATT 600 ..................................... 1 ........ C46110180
ENGINE OPERATING PANEL GROUP
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
0800588004
0800682004
0800686004
0840625004
0840631204
9039208694
9039208704
0840655004
0840655804
DECAL: THROTTLE LEVER ..................................... 1 ........ N-3808
DECAL: BATTERY SWITCH ..................................... 1 ........ S-874
DECAL: STOP BUTTON ........................................... 1 ........ S-878
DECAL: PREHEAT LAMP ......................................... 1 ........ S-3036
DECAL: RED CIRCLE ............................................... 1 ........ S-3346
DECAL: HIGH-LOW .................................................. 1 ........ S-4451
DECAL: ENGINE SPEED ......................................... 1 ........ S-4452
DECAL: HEATER SWITCH ....................................... 1 ........ S-4506
DECAL: STARTER SWITCH ..................................... 1 ........ S-4515
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 109
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DCA-500SSK — NAMEPLATE AND DECALS
NAME PLATE AND DECALS
PAGE 110 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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DCA-500SSK — NAMEPLATE AND DECALS
NAME PLATE AND DECALS
NO
1-1
1-2
PART NO
PART NAME
QTY.
REMARKS
C4551001002 DECAL: HANDLING PROCEDURES .............................. 1 .......... C45100100
8490611303
DECAL: PROCEDURES FOR START UP ...................... 1 .......... S-4519
ENGINE & RADIATOR GROUP
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
0800616204
0800689204
6360610304
0840611903
B9504000404
B9504100104
0966810000
6162937111
DECAL: WATER DRAIN COCK ....................................... 1 .......... S-705
DECAL: COOLING WATER ............................................. 1 .......... S-961
DECAL: WATER ............................................................... 1 .......... S-1880
DECAL: PRECAUTIONS ON HANDLING ....................... 1 .......... S-2570
DECAL: WARNING MOVING PARTS .............................. 2 .......... B90400040
DECAL: WARNING HOT COOLANT .............................. 1 .......... B90410010
DECAL: WARNING .......................................................... 1 .......... REPLACES 0600501100
DECAL: FUEL PRIMING .................................................. 1 .......... REPLACES 0600500011
OUTPUT TERMINAL GROUP
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
C0551000404 DECAL; 3-PHASE OUTPUT TERMINAL .......................... 1 .......... C05100040
0840614104
9039202064
0840655704
B4551000103
B9511100304
B9511100404
B9531100504
DECAL; GROUND ............................................................ 1 .......... S-2635
DECAL; START CONTACT .............................................. 1 .......... S-4468
DECAL; TERMINAL COVER STOPPER .......................... 1 .......... S-4516
DECAL; RECEPTACLE & CIRCUIT BREAKER ............... 1 .......... B45100010
DECAL; WARNING ........................................................... 1 .......... B91110030
DECAL; WARNING ELECTRIC SHOCK HAZARD .......... 1 .......... B91110040
DECAL; WARNING ELECTRIC SHOCK HAZARD .......... 1 .......... B93110050
C1551000404 DECAL; 240/139 VOLT ..................................................... 2 .......... C15100040
BATTERY GROUP
DECAL: + .......................................................................... 2 .......... S-2090
DECAL: - ........................................................................... 1 .......... S-2091
6-1
6-2
0800689404
0800689504
MUFFLER ASSY.
7-1
7-2
B9504200004
B9511100204
DECAL; WARNING ENGINE EXHAUST .......................... 1 .......... B90420000
DECAL: CAUTION HOT SURFACES .............................. 1 .......... B91110020
FUEL TANK GROUP
8-1
8-2
8-3
8-4
8-5
8-6
0800688404
0800688504
1320620904
6360620004
0840607104
B9504500004
DECAL; FUEL INLET ........................................................ 1 .......... S-1344
DECAL; FUEL OUTLET.................................................... 1 .......... S-1345
DECAL; DIESEL FUEL...................................................... 1 .......... S-1756
DECAL; FUEL DRAIN PLUG ............................................ 1 .......... S-1883
DECAL; FUEL GAUGE ..................................................... 1 .......... S-2365
DECAL; WARNING DIESEL FUEL ................................... 1 .......... B90450000
ENCLOSURE GROUP
9-1
0800615102
1320610603
1320621504
0840625902
B9504000304
B9521100404
B9531100604
DECAL; CAUTION AGAINST OIL AND ............................ 1 .......... S-544A
DECAL; WATER-OIL ......................................................... 1 .......... S-1760
DECAL; SUPPORT HOOK ............................................... 2 .......... S-2257
DECAL; MQ ....................................................................... 1 .......... S-3057
DECAL; CAUTION HOT PARTS....................................... 1 .......... B90400030
DECAL; SAFETY INSTRUCTIONS .................................. 1 .......... B92110040
DECAL; WARNING ELECTRIC SHOCK HAZARD .......... 1 .......... B93110060
9-2
9-3
9-4
9-5
9-6
9-7
9-8
C4561101603 STRIPE
C4561101503 STRIPE
C4561101303 STRIPE
C4561101204 STRIPE
C4561101704 STRIPE
C4561101104 STRIPE
C4561101403 STRIPE
C4561101003 STRIPE
C4561100904 STRIPE
1
1
1
2
2
2
1
1
2
9-9
9-10
9-11
9-12
9-13
9-14
9-15
9-16
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 111
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Effective: July 1, 2000
TERMS AND CONDITIONS OF SALE — PARTS
PAYMENT TERMS
4. Freight is at the sender’s expense. All PRICINGANDREBATES
partsmustbereturnedfreightprepaidto
Multiquip’sdesignatedreceivingpoint.
Terms of payment for parts are net 10 days.
Prices are subject to change without prior
notice.Pricechangesareeffectiveonaspecific
5. Parts must be in new and resalable dateandallordersreceivedonorafterthatdate
condition,intheoriginalMultiquippackage willbebilledattherevisedprice. Rebatesfor
(ifany),andwithMuiltiquippartnumbers price declines and added charges for price
FREIGHTPOLICY
All parts orders will be shipped collect or
prepaidwiththechargesaddedtotheinvoice.
All shipments are F.O.B. point of origin.
Multiquip’sresponsibilityceaseswhenasigned
manifest has been obtained from the carrier,
andanyclaimforshortageordamagemustbe
settledbetweentheconsigneeandthecarrier.
clearlymarked.
increaseswillnotbemadeforstockonhandat
thetimeofanypricechange.
6. Thefollowingitemsarenotreturnable:
Multiquip reserves the right to quote and sell
directtoGovernmentagencies,andtoOriginal
Equipment Manufacturer accounts who use
our products as integral parts of their own
products.
a. Obsolete parts. (If an item is listed
inthepartspricebookasbeing
replaced by another item, it is
obsolete.)
b. Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
andotherrubberparts)thatwere
purchasedmorethansixmonths
priortothereturndate.
MINIMUMORDER
SPECIALEXPEDITINGSERVICE
TheminimumchargeforordersfromMultiquip
is $15.00 net. Customers will be asked for
instructionsregardinghandlingofordersnot
meetingthisrequirement.
A$20.00to$50.00surchargewillbeaddedto
theinvoiceforspecialhandlingincludingbus
c. Anylineitemwithanextendeddealer shipments, insured parcel post or in cases
netpriceoflessthan$5.00.
where Multiquip must personally deliver the
partstothecarrier.
d. Special order items.
RETURNEDGOODSPOLICY
e. Electricalcomponents.
Returnshipmentswillbeacceptedandcredit
will be allowed, subject to the following
provisions:
LIMITATIONSOFSELLER’SLIABILITY
f.
Paint,chemicals,andlubricants.
Multiquip shall not be liable here under for
damagesinexcessofthepurchasepriceofthe
itemwithrespecttowhichdamagesareclaimed,
andinnoeventshallMultiquipbeliableforloss
of profit or good will or for any other special,
consequentialorincidentaldamages.
g. Decalsandpaperproducts.
h. Itemspurchasedinkits.
1. AReturnedMaterialAuthorizationmust
beapprovedbyMultiquippriortoshipment.
7. Thesenderwillbenotifiedofanymaterial
receivedthatisnotacceptable.
2. ToobtainaReturnMaterialAuthorization,
alistmustbeprovidedtoMultiquipParts
Sales that defines item numbers,
quantities,anddescriptionsoftheitemsto
bereturned.
8. Such material will be held for 5 working
days from notification, pending
instructions. If a reply is not received
within5days,thematerialwillbereturned
tothesenderathisexpense.
LIMITATIONOFWARRANTIES
a. Thepartsnumbersanddescriptions
mustmatchthecurrentpartsprice
list.
Nowarranties,expressorimplied,aremadein
connection with the sale of parts or trade
accessories nor as to any engine not
manufacturedbyMultiquip.Suchwarranties
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
connectionwiththesaleofitsproducts.Apart
fromsuchwrittenstatementofwarranty,there
arenowarranties,express,impliedorstatutory,
which extend beyond the description of the
productsonthefacehereof.
9. Creditonreturnedpartswillbeissuedat
dealer net price at time of the original
purchase,lessa15%restockingcharge.
b. The list must be typed or computer
generated.
10. In cases where an item is accepted for
which the original purchase document
can not be determined, the price will be
basedonthelistpricethatwaseffective
twelvemonthspriortotheRMAdate.
c. Thelistmuststatethereason(s)for
thereturn.
d. The list must reference the sales
order(s)orinvoice(s)underwhich
theitemswereoriginallypurchased.
11. Credit issued will be applied to future
purchasesonly.
e. Thelistmustincludethenameand
phonenumberoftheperson
requestingtheRMA.
3. A copy of the Return Material
Authorizationmustaccompanythereturn
shipment.
PAGE 112 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)
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NOTE PAGE
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 113
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PARTS AND OPERATION MANUAL
HERE'S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HANDWHEN 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.
by
DENYO MANUFACTURING, CO., USA
MULTIQUIP INC.
POST OFFICE BOX 6254
CARSON, CA 90749
310-537-3700 • 800-421-1244
FAX:310-537-3927
WWW:multiquip.com
Atlanta • Boise • Dallas • Houston • Newark
Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX
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