MQ POWER MODEL DCA-500SSK WHISPERWATTTM GENERATOR
PARTS AND OPERATION MANUAL
SERVICE DEPARTMENT
Standard
Page
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
HERES HOW TO GET HELP
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
TABLE OF CONTENTS
MQ Power DCA-500SSK
AC Generator
Now! Direct TOLL-FREE access to our Parts Department
PARTS ORDERING PROCEDURES
Extra
Discount
GENERAL SAFETY
RULES FOR SAFE OPERATION
RULES FOR SAFE OPERATION
Radiator
CAUTIONCAUTION
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
Battery
RULES FOR SAFE OPERATION
Loading and Unloading Crane
Maintenance Safety
RULES FOR SAFE OPERATION
Transporting
Emergencies
Towing Safety Precautions
DCA-500SSK -TOWING
Figure 1. Generator and Trailer
Explanation of Chart
DCA-500SSK - TRAILER-SAFETY GUIDELINES
Table 1. Specifications
DCA-500SSK -TRAILER-SPECIFICATIONS
MODEL
APPLICATION
Table 1. Specifications Cont
DCA-500SSK -TRAILER-SPECIFICATIONS
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
MODEL
Electric Brake Adjustment
DCA-500SSK -TRAILER SAFETY GUIDELINES
Brakes
Electric Brakes
Hydraulic/Air/Surge Brakes
DCA-500SSK -TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
Figure 3. Hydraulic Brake Components
Tire Wear/Inflation
Tires/Wheels/Lug Nuts
Suspension
DCA-500SSK -TRAILER SAFETY GUIDELINES
Table 3. Suspension Torque Requirements
DCA-500SSK -TRAILER SAFETY GUIDELINES
Torque Ft.-Lbs
Lug Nut Torque Requirements
DCA-500SSK -TRAILER-WIRING DIAGRAM
Table 6. Air Brake Troubleshooting
DCA-500SSK -TRAILER BRAKESTROUBLESHOOTING
Symptom
Solution
Machine Safety Decals
DCA-500SSK - OPERATION AND SAFETY DECALS
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - OPERATION AND SAFETY DECALS
DCA-500SSK - OPERATION AND SAFETY DECALS
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - OPERATION AND SAFETY DECALS
DCA-500SSK - OPERATION AND SAFETY DECALS
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK -- NOTES PAGE
Table 7. Specifications
DCA-500SSK - SPECIFICATIONS
Generator Specifications
Engine Specifications
DCA-500SSK - GENERAL INFORMATION
Microprocessor Controlled Alarm System
DCA-500SSK FAMILIARIZATION Generator
Engine Control Panel
Figure 6. Major Components
DCA-500SSK - MAJOR COMPONENTS
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
NOTE PAGE
Figure 7a. Dimensions
DCA-500SSK - DIMENSIONS TOP AND SIDE
DCA-500SSK - DIMENSIONS FRONT AND REAR
Figure 7b. Dimensions
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
Figure 8. Control Panel
DCA-500SSK - CONTROL PANEL
D. Overcrank Shutdown - Indicates the unit has
DCA-500SSK - CONTROL PANEL
Figure 9. MPEC Module
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
Figure 10. Engine Operating Panel
DCA-500SSK - ENGINE OPERATING PANEL
DCA-500SSK - ENGINE OPERATING PANEL
7. Fuel Level Gauge - Indicates amount of diesel fuel remaining
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - OUTPUTTERMINAL
Connecting Load
600SSK FAMILIARIZATION
Control Box
Figure 14. Output Terminal Panel Location
DCA-500SSK - OUTPUTTERMINAL
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
Legs O and Ground are considered Bonded Grounds
Over Current Relay
Output Terminal Panel Available Voltages
Maximum Amps
Maximum Amps
Change-Over Switch
Reading the Output Terminal Gauges
Change-Over Switch
DCA-500SSK - OUTPUTTERMINAL
3 Phase, 240 Volt
Single Phase, 240 Volt
Single Phase, 139 Volt
Voltage Change-over Board
3 Phase, 480 Volt
Single Phase, 480 Volt
Single Phase, 277 Volt
DCA-500SSK - OUTPUTTERMINAL
Outdoor Installation
DCA-500SSK - INSTALLATION
Always check Local, State, and Federal
DCA-500SSK - INSTALLATION
Laws before grounding generator
Figure 27. Typical Generator Grounding Application
Table 10. Cable Selection 60 Hz, Single Phase Operation
DCA-500SSK - PRE-SETUP
#10 Wire
#12 Wire
Owners Manual
Table 11. Recommended Motor Oil
Type Oil
Range
Air Cleaner
Cleaning the Radiator
Operation in Freezing Weather
Fan Belt Tension
Wiring
Battery Cable Installation
Piping and Hose Connection
DCA-500SSK - PRE-SETUP
Single Phase Load
Three Phase Load
DCA-500SSK - LOAD APPLICATION
DCA-500SSK - GENERATOR START-UP PROCEDURE MANUAL
Before Starting Engine
Before Starting Generator and Control Panel
4. Close all engine enclosure doors Figure
DCA-500SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 41. Voltage Meter Volts Figure 42. Voltage Adjust Control Knob
DCA-500SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 45. Coolant Temperature Gauge
Figure 44. Oil Pressure Gauge
Figure 46. Engine Speed Switch
DCA-500SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 49. Ammeter Load
Figure 47. Engine Tachometer
DCA-500SSK - GENERATOR START-UP PROCEDURE AUTO
Figure 50. Off/Manual Auto Switch AUTO
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - GENERATOR SHUTDOWN PROCEDURE
Engine Shutdown
Emergency Stop
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
NOTE PAGE
Service Daily
DCA-500SSK - MAINTENANCE
Cleaning the Fuel Strainer
General Inspection
Check Electric Heater If equipped
DCA-500SSK - MAINTENANCE
Changing Oil
Replacing fuel filter
Greasing
Cleaning breather element
Generator Storage
DCA-500SSK - MAINTENANCE
ENGINE
INSPECTION / MAINTENANCE
GENERATOR
DCA-500SSK - MAINTENANCE
DCA-500SSK-GENERATORWIRING DIAGRAM
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK-ENGINEWIRING DIAGRAM
TABLE 16. ENGINE TROUBLESHOOTING
DCA-500SSK -TROUBLESHOOTING ENGINE
TABLE 16. ENGINE TROUBLESHOOTING CONTINUED
DCA-500SSK -TROUBLESHOOTING ENGINE
SYMPTOM
POSSIBLE PROBLEM
TABLE 17. GENERATOR TROUBLESHOOTING
DCA-500SSK -TROUBLESHOOTING GENERATOR/ENGINE
TABLE 18. MPEC TROUBLESHOOTING
DCA-500SSK -TROUBLESHOOTING MPEC
Solution
Sympton
EXPLANATION OF CODE IN REMARKS COLUMN
How to read the marks and remarks used in this parts book
Items Found In the “Remarks” Column
Items Found In the “Items Number” Column
DCA-500SSK w/SA6D170AE-1 KOMATSU ENGINE
DCA-500SSK - SUGGESTED SPARE PARTS
1 to 5 Units
Description
GENERATOR ASSY
DCA-500SSK - GENERATOR ASSY
PART NAME
DCA-500SSK - GENERATOR ASSY
HEX. SOCKET HEAD COP SCREW
DCA-500SSK - GENERATOR ASSY
DCA-500SSK - GENERATOR ASSY
QTY. REMARKS
PART NAME
CONTROL BOX ASSY
DCA-500SSK - CONTROL BOX ASSY
DCA-500SSK - CONTROL BOX ASSY
REMARKS
PART NAME
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - CONTROL BOX ASSY
CHANGE OVER SWITCH, VOLTMETER
CHANGE OVER SWITCH, AMMETER
DCA-500SSK - CONTROL BOX ASSY
PART NAME
ENGINE & RADIATOR ASSY
DCA-500SSK - ENGINE & RADIATOR ASSY
DCA-500SSK - ENGINE & RADIATOR ASSY
PART NAME
REMARKS
DCA-500SSK - ENGINE & RADIATOR ASSY
DCA-500SSK - ENGINE & RADIATOR ASSY
PART NAME
REMARKS
ENGINE OPERATING PANEL ASSY
DCA-500SSK - ENGINE OPERATING PANEL ASSY
DCA-500SSK - ENGINE OPERATING PANEL ASSY
SET PLATE, BATTERY SWITCH
PART NAME
SET FRAME, RUBBER COVER
DCA-500SSK - ENGINE OPERATING PANEL ASSY
WATER TEMPERATURE GAUGE
UNIT, WATER TEMPERATURE
DCA-500SSK - ENGINE OPERATING PANEL ASSY
PART NAME
OUTPUT TERMINAL ASSY
DCA-500SSK - OUTPUTTERMINAL ASSY
PART NAME
DCA-500SSK - OUTPUTTERMINAL ASSY
SET BOARD, OUTPUT TERMINAL
OUTPUT TERMINAL ASSY
DCA-500SSK - OUTPUTTERMINAL ASSY
DCA-500SSK - OUTPUTTERMINAL ASSY
PART NAME
REMARKS
BATTERY ASSY
DCA-500SSK - BATTERY ASSY
PART NAME
DCA-500SSK - BATTERY ASSY
MUFFLER ASSY
DCA-500SSK - MUFFLER ASSY
PART NAME
DCA-500SSK - MUFFLER ASSY
FUEL TANK ASSY
DCA-500SSK - FUELTANK ASSY
PART NAME
DCA-500SSK - FUELTANK ASSY
REMARKS
52000KA9810
ENCLOSURE #1 ASSY
DCA-500SSK - ENCLOSURE #1 ASSY
DCA-500SSK - ENCLOSURE #1 ASSY
PART NAME
QTY. REMARKS
DCA-500SSK - ENCLOSURE #1 ASSY
PART NAME
DCA-500SSK - ENCLOSURE #1 ASSY
QTY. REMARKS
ENCLOSURE #1 ASSY
ENCLOSURE #2 ASSY
DCA-500SSK - ENCLOSURE #2 ASSY
PART NAME
DCA-500SSK - ENCLOSURE #2 ASSY
REMARKS
ENCLOSURE #2 ASSY
DCA-500SSK - ENCLOSURE #2 ASSY
DCA-500SSK - ENCLOSURE #2 ASSY
PART NAME
QTY. REMARKS
ENCLOSURE #3 ASSY
DCA-500SSK - ENCLOSURE #3 ASSY
PART NAME
DCA-500SSK - ENCLOSURE #3 ASSY
QTY. REMARKS
SPASHER PANEL
DCA-500SSK - ENCLOSURE #3 ASSY
PART NAME
DCA-500SSK - ENCLOSURE #3 ASSY
REMARKS
039LKDNUSA
RUBBER SEAL ASSY
DCA-500SSK - RUBBER SEAL ASSY
PART NAME
DCA-500SSK - RUBBER SEAL ASSY
NAME PLATE AND DECALS
DCA-500SSK - NAMEPLATE AND DECALS
ENGINE OPERATING PANEL GROUP
CONTROL BOX GROUP
DCA-500SSK - NAMEPLATE AND DECALS
PART NAME
DCA-500SSK - NAMEPLATE AND DECALS
DCA-500SSK - NAMEPLATE AND DECALS
BATTERY GROUP
PART NAME
REMARKS
Effective July 1
TERMS AND CONDITIONS OF SALE - PARTS
11. Credit issued will be applied to future purchases only
SPECIAL EXPEDITING SERVICE
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
NOTE PAGE
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
HERES HOW TO GET HELP
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