SERVICE DEPARTMENT
PARTS AND OPERATION MANUAL
MQ POWER MODEL DCA-500SSK WHISPERWATTTM GENERATOR
Standard
Page
SERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046
HERES HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046
MQ Power DCA-500SSK
TABLE OF CONTENTS
AC Generator
Extra
PARTS ORDERING PROCEDURES
Now! Direct TOLL-FREE access to our Parts Department
Discount
RULES FOR SAFE OPERATION
GENERAL SAFETY
CAUTIONCAUTION
Radiator
RULES FOR SAFE OPERATION
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
RULES FOR SAFE OPERATION
Battery
Loading and Unloading Crane
Transporting
RULES FOR SAFE OPERATION
Maintenance Safety
Emergencies
DCA-500SSK -TOWING
Towing Safety Precautions
Figure 1. Generator and Trailer
DCA-500SSK - TRAILER-SAFETY GUIDELINES
Explanation of Chart
MODEL
DCA-500SSK -TRAILER-SPECIFICATIONS
Table 1. Specifications
APPLICATION
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK -TRAILER-SPECIFICATIONS
Table 1. Specifications Cont
MODEL
Brakes
DCA-500SSK -TRAILER SAFETY GUIDELINES
Electric Brake Adjustment
Electric Brakes
Figure 2. Electrical Brake Components
DCA-500SSK -TRAILER SAFETY GUIDELINES
Hydraulic/Air/Surge Brakes
Figure 3. Hydraulic Brake Components
Suspension
Tires/Wheels/Lug Nuts
Tire Wear/Inflation
DCA-500SSK -TRAILER SAFETY GUIDELINES
Torque Ft.-Lbs
DCA-500SSK -TRAILER SAFETY GUIDELINES
Table 3. Suspension Torque Requirements
Lug Nut Torque Requirements
DCA-500SSK -TRAILER-WIRING DIAGRAM
Symptom
DCA-500SSK -TRAILER BRAKESTROUBLESHOOTING
Table 6. Air Brake Troubleshooting
Solution
DCA-500SSK - OPERATION AND SAFETY DECALS
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 -- NOTES PAGE
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
Generator Specifications
DCA-500SSK - SPECIFICATIONS
Table 7. Specifications
Engine Specifications
DCA-500SSK FAMILIARIZATION Generator
Microprocessor Controlled Alarm System
DCA-500SSK - GENERAL INFORMATION
Engine Control Panel
DCA-500SSK - MAJOR COMPONENTS
Figure 6. Major Components
NOTE PAGE
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - DIMENSIONS TOP AND SIDE
Figure 7a. Dimensions
Figure 7b. Dimensions
DCA-500SSK - DIMENSIONS FRONT AND REAR
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - CONTROL PANEL
Figure 8. Control Panel
Figure 9. MPEC Module
DCA-500SSK - CONTROL PANEL
D. Overcrank Shutdown - Indicates the unit has
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - ENGINE OPERATING PANEL
Figure 10. Engine Operating Panel
7. Fuel Level Gauge - Indicates amount of diesel fuel remaining
DCA-500SSK - ENGINE OPERATING PANEL
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
600SSK FAMILIARIZATION
Connecting Load
DCA-500SSK - OUTPUTTERMINAL
Control Box
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - OUTPUTTERMINAL
Figure 14. Output Terminal Panel Location
Legs O and Ground are considered Bonded Grounds
Maximum Amps
Output Terminal Panel Available Voltages
Over Current Relay
Maximum Amps
Change-Over Switch
Reading the Output Terminal Gauges
Change-Over Switch
DCA-500SSK - OUTPUTTERMINAL
Single Phase, 139 Volt
Single Phase, 240 Volt
3 Phase, 240 Volt
Voltage Change-over Board
Single Phase, 277 Volt
Single Phase, 480 Volt
3 Phase, 480 Volt
DCA-500SSK - OUTPUTTERMINAL
DCA-500SSK - INSTALLATION
Outdoor Installation
Laws before grounding generator
DCA-500SSK - INSTALLATION
Always check Local, State, and Federal
Figure 27. Typical Generator Grounding Application
#10 Wire
DCA-500SSK - PRE-SETUP
Table 10. Cable Selection 60 Hz, Single Phase Operation
#12 Wire
Type Oil
Table 11. Recommended Motor Oil
Owners Manual
Range
Operation in Freezing Weather
Cleaning the Radiator
Air Cleaner
Fan Belt Tension
Piping and Hose Connection
Battery Cable Installation
Wiring
DCA-500SSK - PRE-SETUP
Three Phase Load
Single Phase Load
DCA-500SSK - LOAD APPLICATION
Before Starting Engine
DCA-500SSK - GENERATOR START-UP PROCEDURE MANUAL
Before Starting Generator and Control Panel
DCA-500SSK - GENERATOR START-UP PROCEDURE MANUAL
4. Close all engine enclosure doors Figure
Figure 45. Coolant Temperature Gauge
DCA-500SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 41. Voltage Meter Volts Figure 42. Voltage Adjust Control Knob
Figure 44. Oil Pressure Gauge
Figure 49. Ammeter Load
DCA-500SSK - GENERATOR START-UP PROCEDURE MANUAL
Figure 46. Engine Speed Switch
Figure 47. Engine Tachometer
Figure 50. Off/Manual Auto Switch AUTO
DCA-500SSK - GENERATOR START-UP PROCEDURE AUTO
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
Engine Shutdown
DCA-500SSK - GENERATOR SHUTDOWN PROCEDURE
Emergency Stop
NOTE PAGE
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
Cleaning the Fuel Strainer
DCA-500SSK - MAINTENANCE
Service Daily
General Inspection
Changing Oil
DCA-500SSK - MAINTENANCE
Check Electric Heater If equipped
Replacing fuel filter
Generator Storage
Cleaning breather element
Greasing
DCA-500SSK - MAINTENANCE
GENERATOR
INSPECTION / MAINTENANCE
ENGINE
DCA-500SSK - MAINTENANCE
DCA-500SSK-GENERATORWIRING DIAGRAM
DCA-500SSK-ENGINEWIRING DIAGRAM
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK -TROUBLESHOOTING ENGINE
TABLE 16. ENGINE TROUBLESHOOTING
SYMPTOM
DCA-500SSK -TROUBLESHOOTING ENGINE
TABLE 16. ENGINE TROUBLESHOOTING CONTINUED
POSSIBLE PROBLEM
DCA-500SSK -TROUBLESHOOTING GENERATOR/ENGINE
TABLE 17. GENERATOR TROUBLESHOOTING
Solution
DCA-500SSK -TROUBLESHOOTING MPEC
TABLE 18. MPEC TROUBLESHOOTING
Sympton
Items Found In the “Remarks” Column
How to read the marks and remarks used in this parts book
EXPLANATION OF CODE IN REMARKS COLUMN
Items Found In the “Items Number” Column
1 to 5 Units
DCA-500SSK - SUGGESTED SPARE PARTS
DCA-500SSK w/SA6D170AE-1 KOMATSU ENGINE
Description
DCA-500SSK - GENERATOR ASSY
GENERATOR ASSY
DCA-500SSK - GENERATOR ASSY
PART NAME
HEX. SOCKET HEAD COP SCREW
DCA-500SSK - GENERATOR ASSY
QTY. REMARKS
DCA-500SSK - GENERATOR ASSY
PART NAME
DCA-500SSK - CONTROL BOX ASSY
CONTROL BOX ASSY
PART NAME
REMARKS
DCA-500SSK - CONTROL BOX ASSY
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
DCA-500SSK - CONTROL BOX ASSY
DCA-500SSK - CONTROL BOX ASSY
CHANGE OVER SWITCH, AMMETER
CHANGE OVER SWITCH, VOLTMETER
PART NAME
DCA-500SSK - ENGINE & RADIATOR ASSY
ENGINE & RADIATOR ASSY
PART NAME
DCA-500SSK - ENGINE & RADIATOR ASSY
REMARKS
DCA-500SSK - ENGINE & RADIATOR ASSY
PART NAME
DCA-500SSK - ENGINE & RADIATOR ASSY
REMARKS
DCA-500SSK - ENGINE OPERATING PANEL ASSY
ENGINE OPERATING PANEL ASSY
PART NAME
SET PLATE, BATTERY SWITCH
DCA-500SSK - ENGINE OPERATING PANEL ASSY
SET FRAME, RUBBER COVER
DCA-500SSK - ENGINE OPERATING PANEL ASSY
DCA-500SSK - ENGINE OPERATING PANEL ASSY
UNIT, WATER TEMPERATURE
WATER TEMPERATURE GAUGE
PART NAME
DCA-500SSK - OUTPUTTERMINAL ASSY
OUTPUT TERMINAL ASSY
SET BOARD, OUTPUT TERMINAL
DCA-500SSK - OUTPUTTERMINAL ASSY
PART NAME
OUTPUT TERMINAL ASSY
DCA-500SSK - OUTPUTTERMINAL ASSY
PART NAME
DCA-500SSK - OUTPUTTERMINAL ASSY
REMARKS
DCA-500SSK - BATTERY ASSY
BATTERY ASSY
DCA-500SSK - BATTERY ASSY
PART NAME
DCA-500SSK - MUFFLER ASSY
MUFFLER ASSY
DCA-500SSK - MUFFLER ASSY
PART NAME
DCA-500SSK - FUELTANK ASSY
FUEL TANK ASSY
REMARKS
DCA-500SSK - FUELTANK ASSY
PART NAME
52000KA9810
DCA-500SSK - ENCLOSURE #1 ASSY
ENCLOSURE #1 ASSY
PART NAME
DCA-500SSK - ENCLOSURE #1 ASSY
QTY. REMARKS
DCA-500SSK - ENCLOSURE #1 ASSY
QTY. REMARKS
DCA-500SSK - ENCLOSURE #1 ASSY
PART NAME
ENCLOSURE #1 ASSY
DCA-500SSK - ENCLOSURE #2 ASSY
ENCLOSURE #2 ASSY
REMARKS
DCA-500SSK - ENCLOSURE #2 ASSY
PART NAME
ENCLOSURE #2 ASSY
DCA-500SSK - ENCLOSURE #2 ASSY
PART NAME
DCA-500SSK - ENCLOSURE #2 ASSY
QTY. REMARKS
DCA-500SSK - ENCLOSURE #3 ASSY
ENCLOSURE #3 ASSY
QTY. REMARKS
DCA-500SSK - ENCLOSURE #3 ASSY
PART NAME
SPASHER PANEL
DCA-500SSK - ENCLOSURE #3 ASSY
REMARKS
DCA-500SSK - ENCLOSURE #3 ASSY
PART NAME
039LKDNUSA
DCA-500SSK - RUBBER SEAL ASSY
RUBBER SEAL ASSY
DCA-500SSK - RUBBER SEAL ASSY
PART NAME
DCA-500SSK - NAMEPLATE AND DECALS
NAME PLATE AND DECALS
DCA-500SSK - NAMEPLATE AND DECALS
CONTROL BOX GROUP
ENGINE OPERATING PANEL GROUP
PART NAME
DCA-500SSK - NAMEPLATE AND DECALS
PART NAME
BATTERY GROUP
DCA-500SSK - NAMEPLATE AND DECALS
REMARKS
11. Credit issued will be applied to future purchases only
TERMS AND CONDITIONS OF SALE - PARTS
Effective July 1
SPECIAL EXPEDITING SERVICE
NOTE PAGE
DCA-500SSK - PARTS AND OPERATION MANUAL STD- REV. #1 04/14/01 - PAGE
SERVICE DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046
HERES HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
WARRANTY DEPARTMENT 800/835-2551 or 310/537-3700 FAX 310/638-8046