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DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 47

DCA-500SSK — PRE-SETUP

Battery Cable Installation
ALWAYS

be sure the battery cables (Figure 30) are properly

connected to the battery terminals as shown below. The
RED

RED

RED

RED

RED cable is connected to the positive terminal of the battery,
and the

BLACK

cable is connected to the negative terminal

of the battery.

When connecting battery do the following:

1.

DO NOT

connect the battery cables to the battery

terminals when the Off/Manual/Auto

Off/Manual/Auto

Off/Manual/Auto

Off/Manual/Auto

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.

CAUTION

:

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

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.

CAUTION

:

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.

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Summary of Contents for WHISPERWATT DCA-500SSK

Page 1: ...WILMINGTON AVE 800 427 1244 CARSON CALIFORNIA 90746 FAX 800 672 7877 310 537 3700 SERVICE DEPARTMENT 800 421 1244 800 835 2551 FAX 310 537 3927 FAX 310 638 8046 E mail mq multiquip com www multiquip com MQ POWER MODEL DCA 500SSK WHISPERWATTTM GENERATOR Standard PARTS AND OPERATION MANUAL PARTS LIST NO C4872300004 ...

Page 2: ...PAGE 2 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 ...

Page 3: ...NT 800 427 1244 or 310 537 3700 FAX 800 672 7877 or 310 637 3284 SER SER SER SER SERVICE DEP VICE DEP VICE DEP VICE DEP VICE DEPAR AR AR AR ARTMENT TMENT TMENT TMENT TMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 W W W W WARRANTY DEP ARRANTY DEP ARRANTY DEP ARRANTY DEP ARRANTY DEPAR AR AR AR ARTMENT TMENT TMENT TMENT TMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 MAIN MAIN MAIN MAIN MAIN...

Page 4: ...am 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 Specification and part Specification and part Specification and part Specification and part number are subject to number are subject to number are subject to number are subject to nu...

Page 5: ...lude 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 Now Direct TOLL FREE access to our Parts Department Toll free nationwide 800 421 1244 Toll free FAX 800 6 PARTS 7 800 672 7877 Dealer account number Dealer name and address Shipping address if different than billing address Return fax ...

Page 6: ...pment 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 NEVERoperatethisequipmentwhennotfeeling wellduetofatigue illnessor taking medicine NEVER operate this equipment under the influence or drugs or alcohol NEVER use accessories or attachment...

Page 7: ...ow sufficient time for the engine and generator to cool before performing maintenance Radiator 1 Radiator Cap Removing the radiator cap while the 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 2 Coolant Drain Plug Removing the coolant drain plug while the engine is hot wil...

Page 8: ...ing Useadequateliftingcable wireorrope ofsufficientstrength When lifting the generator always use the balanced center point suspension hook and lift straight upwards 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 frontandbackframebarsasameanstosecurethegenerator during transport Battery Never over fill the bat...

Page 9: ...irst aid kit first aid kit Know the location of the nearest telephone Also know the phone numbers of the nearest ambulance ambulance ambulance ambulance ambulance doctor doctor doctor doctor doctor and fire department fire department fire department fire department fire department RULES FOR SAFE OPERATION Maintenance Safety NEVERlubricatecomponentsorattemptserviceonarunning machine Always allow th...

Page 10: ...parked Place support blocks underneath the trailer s bumper to prevent tipping tipping tipping tipping tipping while parked 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 Avoid sudden stops and starts This can cause skidding or jackknifing Smooth gradual starts and stops will improve gas milage Avoid sharp turns to...

Page 11: ...rt 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 whe...

Page 12: ... 0 7 0 6 5 4 A C D O N E G R U S S B L 0 0 0 7 6 8 1 7 7 B L 0 0 0 2 D A P T A L F X 0 7 R L R T 0 7 0 6 5 4 A C D T P O E G R U S S B L 0 0 0 7 8 3 1 6 6 B L 0 0 0 2 D A P T A L F F X 0 7 R L R T 0 7 0 6 5 4 A C D L A G 3 5 E G R U S S B L 0 0 0 7 8 3 1 6 6 B L 0 0 0 2 D A P T A L F F X 0 0 1 R L R T 5 2 1 0 0 1 A C D L A G 0 5 1 E G R U S C I L U A R D Y H S B L 0 0 0 7 0 9 1 6 7 B L 0 0 0 2 D A...

Page 13: ... B B U R E L O P 4 T A L F X 0 7 R L R T S S A L C L L A B 2 E L B A T S U J D A 3 C 4 1 5 0 2 4 S A I B 5 X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 R E B B U R E L O P 4 T A L F F X 0 7 R L R T S S A L C L L A B 2 E L B A T S U J D A 3 C 4 1 5 0 2 4 S A I B 5 X 4 1 s b l 0 0 5 3 3 G U L 5 F A E L 5 R E B B U R E L O P 4 T A L F F X 0 0 1 R L R T 6 5 2 E L B A T S U J D A E Y E 3 T P O C 5 1 5 0 2 4...

Page 14: ...nly be accomplished by road testing Brake lockup grabbiness or harshness is due to lack of synchronization between the tow vehicle and the trailer being towed or under adjusted brakes Beforeanybrakesynchronizationsadjustmentscanbemade the trailer brakes should be burnished in by applying the brakes 20 30 times with approximately a 20 m p h decrease in speed e g 40 m p h to 20 m p h Allow ample tim...

Page 15: ...replacement These brakes can be adjusted 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 components that will require inspection and maintenance Please inspect these components as required using steps 1 through 6 as referenced in the electric brake adjustments section Figure 2 ...

Page 16: ...t 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 Failur...

Page 17: ... 2 0 4 5 3 5 6 0 5 3 1 5 2 0 2 0 4 5 3 5 6 0 5 4 1 5 2 0 2 0 6 0 5 0 2 1 0 9 5 1 5 2 0 2 0 6 0 5 0 2 1 0 9 6 1 5 2 0 2 0 6 0 5 0 2 1 0 9 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...

Page 18: ...PAGE 18 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK TRAILER WIRING DIAGRAM ...

Page 19: ...l a u q e s e r i t l l a e t a l f n I e l x a e m a s e h t n o d e h c t a m n u s e r i T s e r i t h c t a M s e k a r B g n i k c o L r o t n e b e s o o l s t n e n o p m o c e k a r B n e k o r b s t n e n o p m o c e c a l p e R d n u o r f o t u o s m u r d e k a r B e c a l p e R s e k a r B y s i o N d e t a c i r b u l m e t s y S e t a c i r b u L t c e r r o c s t n e n o p m o c e ...

Page 20: ...h 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 DCA 500SSK OPERATION AND SAFETY DECALS ...

Page 21: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 21 DCA 500SSK OPERATION AND SAFETY DECALS ...

Page 22: ...PAGE 22 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK OPERATION AND SAFETY DECALS ...

Page 23: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 23 DCA 500SSK OPERATION AND SAFETY DECALS ...

Page 24: ...PAGE 24 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK OPERATION AND SAFETY DECALS ...

Page 25: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 25 DCA 500SSK NOTES PAGE ...

Page 26: ...o t c a F r e w o P 8 0 A B d l e v e L d n u o S t e e f 3 2 t a d a o l l l u f 9 6 s n o i t a c i f i c e p S e n i g n E l e d o M E B 0 7 1 D 6 A S U S T A M O K e p y T r e l o o c r e t f a h t i w d e g r a h c o b r u t n o i t c e j n i t c e r i d s r e d n i l y C f o o N s r e d n i l y c 6 e k o r t S x e r o B m m 0 7 1 x m m 0 7 1 n i 8 6 x n i 8 6 t u p t u O d e t a R m p r 0 0 ...

Page 27: ...tion system The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section There are four leads A B C and D During light loads the powertothe A A A A Automatic utomatic utomatic utomatic utomatic V V V V Voltage Regulator oltage Regulator oltage Regulator oltage Regulator oltage Regulator AVR issupplied from the leads parallel connecti...

Page 28: ...PAGE 28 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK MAJOR COMPONENTS Figure 6 Major Components ...

Page 29: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 29 NOTE PAGE ...

Page 30: ...PAGE 30 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK DIMENSIONS TOP AND SIDE Figure 7a Dimensions ...

Page 31: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 31 Figure 7b Dimensions DCA 500SSK DIMENSIONS FRONT AND REAR ...

Page 32: ...PAGE 32 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK CONTROL PANEL Figure 8 Control Panel ...

Page 33: ... ual ual ual ual position the generator will start immediately 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 auto auto auto auto position In this position the generator will monitor the AC line output from the building spowersource Thegeneratorwillengagewhen commercial power falls below a preset level B Low Oil Pres...

Page 34: ...PAGE 34 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK ENGINE OPERATING PANEL Figure 10 Engine Operating Panel ...

Page 35: ...tor stop the engine and fill the battery with distilled water to the specified level 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 10 Pre Heat Lamp Indicates that the glow plugs of the diesel engine are hot and the engine is ready to be started 12 Emergency Stop But...

Page 36: ...e secured in the close position by a pad lock See Figure 11 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 Pressing the reset button resets the receptacle after being tripped Pressing the Test Butto...

Page 37: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 37 Legs O and Ground are considered Bonded Grounds NOTE DCA 500SSK OUTPUTTERMINAL Figure 14 Output Terminal Panel Location ...

Page 38: ...ver current relay is located on the control box Maximum Amps The following table below shows the maximum amps the generator can provide Do not exceed the maximum amps listed below E L B A L I A V A S E G A T L O V 8 E L B A T L E D O M K S S 0 0 5 A C D E G A T L O V E S A H P 3 E L B A T C E N N O C E R T L O V 8 0 2 T L O V 0 2 2 T L O V 0 4 2 T L O V 6 1 4 T L O V 0 4 4 T L O V 0 8 4 E S A H P ...

Page 39: ...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 DCA 500SSK OUTPUTTERMINAL 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 16 AC Voltm...

Page 40: ...ase 139V FIGURE 21 Hard Wire Hookup for Single Phase 240V Single Phase 139 Volt 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 Voltage Change over Board The voltage change over board changes the availa...

Page 41: ...gs as shown in figure 24 below 480V will be the voltage output Single Phase 480 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 480V After hooking up the hard wires to the lugs as shown in figure 25 below 480V will be the voltage output FIGURE 24 Hard Wire Hookup for Three Phase 480V FIGURE 26 Hard Wire H...

Page 42: ...n 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 CAUTION 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 elect...

Page 43: ...SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 43 Figure 27 Typical Generator Grounding Application DCA 500SSK INSTALLATION CAUTION Always check Local State and Federal Laws before grounding generator ...

Page 44: ...GFCI GFCI GFCI circuit breakers are provided to protect the GFCI receptacles from overload Three 50 amp load load load load load circuit breakers have also been provided to protecttheloadsideofthegeneratorfromoverload Make sure to switch ALL ALL ALL ALL ALL circuit breakers to the OFF position prior to starting the engine DCA 500SSK PRE SETUP n o i t a r e p O e s a h P e l g n i S z H 0 6 n o i t...

Page 45: ...ION Never fill the fuel tank while the engine isrunningorinthedark 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 w...

Page 46: ...e less than 50 be less than 50 be less than 50 be less than 50 NOTE y t i c a p a C t n a l o o C 2 1 e l b a T r o t a i d a R d n a e n i g n E 0 9 1 1 l a G 4 1 3 s r e t i L k n a T e v r e s e R s r e t i L 9 1 s t r a u Q 2 CAUTION Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris Periodically clean the radiator fins with compressed air ...

Page 47: ...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 If the battery cable is connected incorrectly el...

Page 48: ...ate approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage WATTS VOLTAGE x AMPERAGE The power factor of this generator is 0 8 See Table 14 below when connecting loads Before connecting this generator to any building s electrical system a licensed electrician must install anisolation transfer switch Seriousinjuryordeath may result without this transfer swit...

Page 49: ...t the electrical load and switch the MAIN LO MAIN LO MAIN LO MAIN LO MAIN LOAD AD AD AD AD and G F G F G F G F G F C C C C C I I I I I circuit breakers Figure 31 to the OFF position prior to starting the engine NEVER start the engine with the main main main main main GFCI GFCI GFCI GFCI GFCI or load load load load load circuit breakers in the ON position The engine s exhaust contains harmful emiss...

Page 50: ...on the Microprocessor Engine Control Module MPEC display is ON lit DCA 500SSK GENERATOR START UP PROCEDURE MANUAL Figure 39 MPEC Engine Running Status LED 7 Place the Off Manual Auto switch Figure 38 in the MANUAL position down Observe that the engine begins to crank 6 When starting the generator in COLD weather conditions press and hold the engine preheat button Figure 36 until the preheat lamp F...

Page 51: ...kg cm2 of the engine Under normal operating conditions the oil pressure should be approximately 25 psi 13 The coolant temperature gauge Figure 45 will indicate the coolant temperature Under normal operating conditions the coolant temperature shouldbebetween165and215degreesFahrenheit Green Zone WATER TEMP Figure 45 Coolant Temperature Gauge A 0 40 60 75 20 Figure 43 Ammeter No Load Figure 44 Oil Pr...

Page 52: ...ading if the load is in use 18 The generator will run until manually stopped or an abnormal condition occurs DCA 500SSK GENERATOR START UP PROCEDURE MANUAL Figure 48 Main and GFCI Circuit Breakers Figure 46 Engine Speed Switch 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 R...

Page 53: ... begins to crank 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 Before connecting this generator to any building s electrical system a licensed electrician must install an isolation transfer switch Serious injury injury injury injury injury or death death death death death may result without this transfer switch...

Page 54: ...ch as a method of shutting down the engine This switch is ONLY to be used in the event of an emergency 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 Emergency Stop CAUTION Figure 54 Emergency Stop Button 4 Place the Off Manual Auto Switch Figure 52 in the OFF RESET positi...

Page 55: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 55 NOTE PAGE ...

Page 56: ...inthestrainercapandwashitindiesel Securely fasten the fuel strainer cap so that fuel will not leak Check thefuelstrainerevery200hoursofoperationoronceamonth 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 dipsti...

Page 57: ...er from the engine intake manifold and check for disconnectionsordirt Whencheckingorinstallingtheelectric heater replace the gasket with a new part Changing Oil 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 3 Check the drained oil for excessive metal particles or foreign material Contact the distributor if th...

Page 58: ...as not been started for more than one year contact your Komatsu distributor to have engine overhauled 7 After bleeding the air tighten air bleed plug then push in 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 10 Using a filter wrench turn the cartridge to the left to remove it 11 Coat the seal...

Page 59: ... e l C X k n a T l e u F f o m o t t o B n i a r D X e d i s t u O d n a e d i s n I t i n U n a e l C X r e t l i F l e u F e g n a h C 2 X t n a l o o C k c e h C d n a r o t a i d a R n a e l C l e v e L n o i t c e t o r P X t n e m e l E r e t l i F r i A e c a l p e R X r o t s i s e R n o i s o r r o C e g n a h C X s p m a l C d n a s e s o H l l a k c e h C X k n a T l e u F f o e d i s n...

Page 60: ...PAGE 60 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK GENERATORWIRING DIAGRAM DCA 500SSK ENGINE WIRING DIAG ...

Page 61: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 61 RAM DCA 500SSK ENGINEWIRING DIAGRAM ...

Page 62: ...e t h g i T g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n r o w t f a h s m a c l e u F e c a l p e R d e g g o l c e l z z o n n o i t c e j n I e l z z o n n o i t c e j n i n a e l C p m u p n o i t c e j n I g n i n o i t c n u f l a m e c a l p e r r o r i a p e R t f a h s k n a r c f o e r u z i e S r e d n i l y c n o t s i p t f a h s m a c g n i r a e b r o r e n i l e c ...

Page 63: ... i f i c e p s e h t o t e c u d e R n r o w r e n i l d n a g n i r n o t s i P k c u t s r o e c a l p e r r o r i a p e R g n i m i t n o i t c e j n i t c e r r o c n I t s u j d A n o i s s e r p m o c t n e i c i f e D e c n a r a e l c p o t t s u j d A y a r g k r a d r o k c a l b r e h t i E d e v r e s b o s i s a g t s u a h x e d a o l r e v O d a o l e h t n e s s e L d e s u l e u f...

Page 64: ...i t c e f e d R V A s I y r a s s e c e n f i e c a l p e R r e i f i t c e R g n i t a t o R e v i t c e f e D e c a l p e r d n a k c e h C t u p t u O e g a t l o V w o L t c e r r o c d e e p s e n i g n e s I h g i H o t r e v e l e l t t o r h t e n i g n e n r u T e s o o l s n o i t c e n n o c g n i r i w s I r i a p e r d n a g n i r i w k c e h C R V A e v i t c e f e D y r a s s e c e ...

Page 65: ...p e R d e d a o l r e v o g n i e b r o t a r e n e G d a o l e c u d e r k c e h C e r u l i a f t a t s o m r e h T t a t s o m r e h t e c a l p e R d e k c o l b e k a t n i r i A s e k a t n i r i a l l a r a e l C e r u l i a f h c t i w s e r u t a r e p m e T h c t i w s e r u t a r e p m e t e c a l p e R s i t h g i l k n a r c r e v O n o l e u F w o l r o o N l e v e l l e u f l l i F ...

Page 66: ...icular 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 Allpartswithsamesymbolinthenumbercolumn or belong to the same assembly or kit Note If more than one of the same reference number is listed the last one listed indicates newest or latest part available...

Page 67: ...5 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...

Page 68: ...PAGE 68 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 GENERATOR ASSY DCA 500SSK GENERATOR ASSY ...

Page 69: ...R 1 1 14 0601823282 RECTIFIER 2 1 15 0018205020 HEX SOCKET HEAD COP SCREW 4 0040005000 LOCKWASHER 4 0041205000 PLAINWASHER 4 1 16 0010112020 HEX HEAD BOLT 6 0040012000 LOCKWASHER 6 1 17 0601000209 BALANCING WEIGHT KIT 1 1 18 7431014003 BEARING FLANGE 1 1 19 0070106321 BEARING 1 1 20 0080000105 SNAP RING 1 2 0012116060 HEX HEAD BOLT 6 0042516000 LOCKWASHER 6 3 C4130200003 STRATOR ASSY 1 3 1 7431323...

Page 70: ...PAGE 70 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK GENERATOR ASSY GENERATOR ASSY ...

Page 71: ... 0041208000 PLAINWASHER 3 12 0010110016 HEX HEAD BOLT 1 13 0803000104 PACKING 1 14 8461335004 BRACKET COVER 1 15 8461334003 COVER STATOR 1 16 0017106012 HEX HEAD BOLT 4 17 0017106050 HEX HEAD BOLT 2 18 8461333003 COVER EXCITER 1 19 0017106012 HEX HEAD BOLT 2 20 0012112040 HEX HEAD BOLT 16 0042512000 LOCKWASHER 16 21 8461332003 COVER FAN 1 22 0017106050 HEX HEAD BOLT 1 23 0605000012 RUBBER SUSPENSI...

Page 72: ...PAGE 72 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK CONTROL BOX ASSY CONTROL BOX ASSY ...

Page 73: ...S 0601823143 PYCA1 HOLDER 1 REPLACES 0601824400 17 MY4DC24V RELAY 2 REPLACES 0601823759 PYF14A SOCKET 2 REPLACES 0601823146 PYCA1 HOLDER 2 REPLACES 0601824400 18 0027104016 MACHINE SCREW 6 19 0602201246 RELAY 1 1750733520 20 0017105016 HEX HEAD BOLT 2 21 0602201911 UNIT BATTERY SENSOR 1 C7038A0000 22 0017106020 HEX HEAD BOLT 1 23 0602200446 EMERGENCY RELAY 1 6008151252 24 0017106016 HEX HEAD BOLT ...

Page 74: ...PAGE 74 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK CONTROL BOX ASSY CONTROL BOX ASSY ...

Page 75: ...840073 RHEOSTAT 1 RA20A2SE102BJ 51 0601840121 KNOB 1 52 0601827395 ENGINE CONTROLLER 1 ECU88LG24 53 061831340 SWITCH 1 82608DPDT 54 0601810161 PANEL LIGHT 1 V325070 0601810214 BULB 1 55 0207004000 HEX NUT 2 56 0601830710 SWITCH PANEL LIGHT 1 S301T 57 C9221100004 HEX HEAD BOLT 2 0040008000 LOCK WASHER 2 0041208000 PLAIN WASHER 2 0080200007 SNAP RING 2 58 C9221100004 HEX HEAD BOLT 2 0040008000 LOCK ...

Page 76: ...PAGE 76 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK ENGINE RADIATOR ASSY ENGINE RADIATOR ASSY ...

Page 77: ...RADIATOR PIPE 1 6162639640 16 0602012054 DRAIN VALVE 1 07730500004 17 0602014541 RADIATOR HOSE 1 0726120911 18 0602013954 RADIATOR HOSE 1 6128619650 19 0602014350 HOSE BAND 8 0728101029 20 0602014058 HOSE BAND 2 0728100197 21 0602014351 HOSE BAND 2 0728100489 22 0602040156 ELEMENT AIR CLEANER 2 6125817032 23 0602040647 DUST SENSOR 1 6008157930 24 0602041146 CARTRIDGE OIL FILTER 2 6002111231 25 060...

Page 78: ...PAGE 78 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK ENGINE RADIATOR ASSY ENGINE RADIATOR ASSY ...

Page 79: ...0230 RESERVE TANK 1 0228104860 49 8482082103 BRACKET RESERVE TANK 1 50 0229200700 RUBBER CUSHION 1 51 0017106030 HEX HEAD BOLT 1 52 0017108020 HEX HEAD BOLT 2 53 0199601100 HOSE 1 54 0194001600 HOSE 1 55 0605515013 HOSE BAND 3 56 0602014648 HOSE 1 0727061510 57 0194201000 HOSE 1 58 0605515014 HOSE BAND 2 59 8482256304 CLAMPER ROD 1 60 8482256104 CLAMPER ROD 1 61 0010118040 HEX HEAD BOLT 2 62 00400...

Page 80: ...PAGE 80 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY ...

Page 81: ...HEX HEAD BOLT 12 10 0602101012 BATTERY SWITCH 1 0315262002 11 0805008804 SET PLATE BATTERY SWITCH 1 12 0805008704 STAY BATTERY SWITCH 2 13 0020008070 MACHINE SCREW 2 0040008000 LOCKWASHER 2 0041208000 PLAINWASHER 2 14 0840201200 THROTTLE HANDLE 1 15 8482181103 LINK GOVERNOR ROD 1 16 0017110030 HEX HEAD BOLT 2 0207010000 HEX NUT 2 17 7472181003 LINK GOVERNOR ROD 1 18 0017112030 HEX HEAD BOLT 2 19 8...

Page 82: ...PAGE 82 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK ENGINE OPERATING PANEL ASSY ENGINE OPERATING PANEL ASSY ...

Page 83: ...2500KA8610 40 0602122060 OIL PRESSURE GAUGE 1 42000KX1410 41 0602122203 UNIT OIL PRESSURE 1 53600KX0501 42 0602123061 WATERTEMPERATURE GAUGE 1 4000KX0910 43 0602123206 UNIT WATERTEMPERATURE 1 51400KS0600 44 0602121052 CHARGINE AMMETER 1 43000KV0300 45 0602125060 FUEL GAUGE 1 41000KW0110 46 0602115014 OK MONITOR 1 V3376600000 47 0601830715 ENGINE SPEED SWITCH 1 S332T 48 0602210649 PREHEATING SWTICH...

Page 84: ...PAGE 84 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSY ...

Page 85: ...ASHER 24 0041212000 PLAINWASHER 48 7 0801830404 TERMINAL 1 8 0801830904 HEX HEAD BOLT 1 9 0039320000 HEX NUT 2 10 0040020000 LOCKWASHER 3 11 0041420000 PLAINWASHER 4 12 0010112050 HEX HEAD BOLT 6 0030012000 HEX NUT 6 0040012000 LOCKWASHER 6 0041212000 PLAINWASHER 12 13 0601850275 GROMMET 1 14 0601815324 TERMINAL BOARD 1 TS22P 15 0027104020 MACHINE SCREW 2 16 C4237101304 COVER OUTPUTTERMINAL 1 17 7...

Page 86: ...PAGE 86 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 OUTPUT TERMINAL ASSY DCA 500SSK OUTPUTTERMINAL ASSY ...

Page 87: ...ER 2 28 C4237100504 COVER 1 29 0017108020 HEX HEAD BOLT 5 30 0601805313 CIRCUIT BREAKER 2 KM51 265V 20A 31 0601805840 CIRCUIT BREAKER 3 KM52 265V 50A 32 C4261601203 BRACKET CIRCUIT BREAKER 1 32 1 0223300200 RUBBER CUSHION 1 33 0017106030 HEX HEAD BOLT 2 34 0601812597 RECEPTACLE 2 GF5352 35 0601812565 RECEPTACLE 3 CS6369 36 0027104015 MACHINE SCREW 10 0030004000 HEX NUT 10 0041204000 PLAINWASHER 10...

Page 88: ...PAGE 88 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK BATTERY ASSY BATTERY ASSY ...

Page 89: ...BATTERY BAND 2 4 0805006504 BATTERY BOLT 4 5 0037808000 WING NUT 4 6 0040008000 LOCKWASHER 4 7 0041208000 PLAINWASHER 4 8 8482280104 BATTERY CABLE 1 9 8482280304 BATTERY CABLE 1 10 7432280504 BATTERY CABLE 1 11 7432280904 BATTERY CABLE 1 12 7432281104 EARTH CABLE 1 13 0347010030 HEX HEAD BOLT 4 14 0208110000 HEX NUT 4 15 0845040114 TERMINAL CAP 2 16 0845041004 TERMINAL CAP 2 17 0602220205 BATTERY ...

Page 90: ...PAGE 90 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK MUFFLER ASSY MUFFLER ASSY ...

Page 91: ...042410000 HEX HEAD BOLT 14 9 0019108030 HEX HEAD BOLT 8 10 0042308000 LOCKWASHER 8 11 0042408000 PLAINWASHER 8 12 C4334000513 EXHAUST PIPE 1 13 0010116060 HEX HEAD BOLT 8 14 0010116050 HEX HEAD BOLT 8 16 0040016000 LOCKWASHER 16 17 0041216000 PLAINWASHER 24 18 7472355003 OUTLET PIPE 1 19 C3334200704 GASKET 1 20 0010112050 HEX HEAD BOLT 4 21 0030012000 HEX NUT 4 22 0040012000 LOCKWASHER 4 23 004121...

Page 92: ...PAGE 92 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK FUELTANK ASSY FUEL TANK ASSY ...

Page 93: ...516504 BRACKET 1 10 0019108030 HEX HEAD BOLT 2 11 0205008000 HEX NUT 2 12 0042308000 LOCKWASHER 2 13 0042408000 PLAINWASHER 4 14 0603325011 VAVE 1 BBS7715 PT1 2 15 0132006000 PLUG 3 16 7435512104 LONG NIPPLE 2 17 0605511033 THREE WAY VALVE 2 400 PT1 2 18 0602022209 HOSE JOINT 1 KH135 19 0602022203 HOSE JOINT 1 KH131 20 7435514304 HOSE JOINT 2 21 0191403850 SUCTION HOSE 1 22 0191301100 SUCTION HOSE...

Page 94: ...0SSK ENCLOSURE 1 ASSY ENCLOSURE 1 ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GRAY 4 SUNBELT GREEN 5 BLACK 6 CATERPILLARYELLOW 7 CATO GOLD 8 RED THE SERIAL NUMBER MAY BE REQUIRED ...

Page 95: ...INING 1 11 0017108020 HEX HEAD BOLT 28 12 C4424700004 GUIDE PANEL AIR 1 C4494100103 LINING 1 13 C4424300303 GUIDE PANEL AIR 1 C4494100103 LINING 1 14 C4424300003 GUIDE PANEL AIR 1 C4494100103 LINING 1 15 0017108020 HEX HEAD BOLT 30 16 0019210025 HEX HEAD BOLT 8 17 8485125203 COVER FRONT FRAME 1 18 8485125104 COVER FRONT FRAME 1 8465924104 LINING 1 19 0019208020 HEX HEAD BOLT 32 20 0845042703 FILLE...

Page 96: ...PAGE 96 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK ENCLOSURE 1 ASSY ENCLOSURE 1 ASSY ...

Page 97: ...KWASHER 6 0041220000 PLAINWASHER 12 30 0010120065 HEX HEAD BOLT 8 0030020000 HEX NUT 8 0040020000 LOCKWASHER 8 0041220000 PLAINWASHER 16 31 C4434200013 COVER 2 32 0017108020 HEX HEAD BOLT 12 0207008000 HEX NUT 12 33 8485161103 ROOF PANEL 1 34 C4464100203 ROOF PANEL 1 35 C4464100303 ROOF PANEL 1 36 0207008000 HEX NUT 14 37 0800251701 FILLER COVER 1 38 0019206016 HEX HEAD BOLT 2 39 0019208020 HEX HE...

Page 98: ...0SSK ENCLOSURE 2 ASSY ENCLOSURE 2 ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GRAY 4 SUNBELT GREEN 5 BLACK 6 CATERPILLARYELLOW 7 CATO GOLD 8 RED THE SERIAL NUMBER MAY BE REQUIRED ...

Page 99: ... 3875944104 LINING 1 11 3875151104 LOUVER PANEL 1 12 0205006000 HEX NUT 16 0042306000 LOCKWASHER 16 0042406000 PLAINWASHER 16 13 7975156004 DUCT COVER 1 8495946104 LINING 1 14 0017108020 HEX HEAD BOLT 17 15 0019208020 HEX HEAD BOLT 23 16 C4444300703 VISOR 1 17 3875165803 VISOR 1 18 0019208020 HEX HEAD BOLT 12 19 7975143003 DOOR REAR FRAME 1 20 7975143113 DOOR REAR FRAME 1 21 3875147204 WINDOW PLAT...

Page 100: ...PAGE 100 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK ENCLOSURE 2 ASSY ENCLOSURE 2 ASSY ...

Page 101: ...WASHER 2 34 0845047204 HINGE 2 0845045004 WASHER 2 35 0019208020 HEX HEAD BOLT 6 36 0845031504 CAP 4 37 0601850097 STOPPER 2 38 0021008025 MACHINE SCREW 2 39 0600500090 EMBLEM 1 40 0021106020 MACHINE SCREW 2 41 C4464200303 ROOF PANEL 1 8485960104 LINING 1 42 C4464200403 ROOF PANEL 1 8485960104 LINING 1 43 C4464200503 ROOF PANEL 1 8485960104 LINING 1 44 C4464500304 GUIDE 1 45 C4464500204 PANEL 1 84...

Page 102: ...00SSK ENCLOSURE 3 ASSY ENCLOSURE 3 ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT 1 ORANGE 2 WHITE 3 SPECTRUM GRAY 4 SUNBELT GREEN 5 BLACK 6 CATERPILLARYELLOW 7 CATO GOLD 8 RED THE SERIAL NUMBER MAY BE REQUIRED ...

Page 103: ...03 SIDE PANEL 1 8485972704 LINING 1 7 7525151004 LOUVER PANEL 1 8 7525151104 LOUVER PANEL 1 9 0205006000 HEX NUT 16 0042306000 LOCKWASHER 16 0042406000 PLAINWASHER 16 10 8215176004 DUCT 1 8485976704 LINING 1 11 8485176104 DUCT 1 8485976304 LINING 1 12 0017108020 HEX HEAD BOLT 12 13 0019108070 HEX HEAD BOLT 16 0042308000 LOCKWASHER 16 0042408000 PLAINWASHER 16 14 8485171003 SIDE DOOR 1 8485970103 L...

Page 104: ...PAGE 104 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK ENCLOSURE 3 ASSY ENCLOSURE 3 ASSY ...

Page 105: ... NUT 28 0042306000 LOCKWASHER 28 0042406000 PLAINWASHER 28 22 8485176004 DUCT 1 7865976104 LINING 1 25 0017108020 HEX HEAD BOLT 22 26 0825007362 DOOR HANDLE 3 27 0021806016 MACHINE SCREW 28 28 0845046904 HINGE 8 0845045004 WASHER 8 29 0845047004 HINGE 8 0845045004 WASHER 8 30 0019208020 HEX HEAD BOLT 39 31 0845031504 CAP 16 32 0601850097 STOPPER 10 33 0021008025 MACHINE SCREW 9 34 0021008020 MACHI...

Page 106: ...PAGE 106 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK RUBBER SEAL ASSY RUBBER SEAL ASSY ...

Page 107: ...901100 RUBBER SEAL 4 4 0228900990 RUBBER SEAL 2 5 0229201650 RUBBER SEAL 2 6 0228800860 RUBBER SEAL 2 7 0228801380 RUBBER SEAL 2 8 0229200780 RUBBER SEAL 2 9 0229201490 RUBBER SEAL 1 10 0229200595 RUBBER SEAL 2 11 0229201490 RUBBER SEAL 1 12 0228100280 RUBBER SEAL 2 13 0228100520 RUBBER SEAL 2 14 0228100150 RUBBER SEAL 2 15 0228100580 RUBBER SEAL 2 DCA 500SSK RUBBER SEAL ASSY ...

Page 108: ...PAGE 108 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK NAMEPLATE AND DECALS NAME PLATE AND DECALS ...

Page 109: ...LTAGE REGULATOR 1 S 3034 2 8 B9531100604 DECAL WARNING ELECTRIC SHOCK HAZARD 1 B93110060 2 9 C9521203003 DECAL SETTING FOR OUTPUT VOLTAGE 1 C92120300 2 10 C4561101803 DECAL WHISPERWATT 600 1 C46110180 ENGINE OPERATING PANEL GROUP 4 1 0800588004 DECAL THROTTLE LEVER 1 N 3808 4 2 0800682004 DECAL BATTERY SWITCH 1 S 874 4 3 0800686004 DECAL STOP BUTTON 1 S 878 4 4 0840625004 DECAL PREHEAT LAMP 1 S 30...

Page 110: ...PAGE 110 DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 DCA 500SSK NAMEPLATE AND DECALS NAME PLATE AND DECALS ...

Page 111: ...ARNING ELECTRIC SHOCK HAZARD 1 B91110040 5 8 B9531100504 DECAL WARNING ELECTRIC SHOCK HAZARD 1 B93110050 5 9 C1551000404 DECAL 240 139 VOLT 2 C15100040 BATTERY GROUP 6 1 0800689404 DECAL 2 S 2090 6 2 0800689504 DECAL 1 S 2091 MUFFLER ASSY 7 1 B9504200004 DECAL WARNING ENGINE EXHAUST 1 B90420000 7 2 B9511100204 DECAL CAUTION HOT SURFACES 1 B91110020 FUEL TANK GROUP 8 1 0800688404 DECAL FUEL INLET 1...

Page 112: ...iquip shall not be liable here under for damagesinexcessofthepurchasepriceofthe itemwithrespecttowhichdamagesareclaimed andinnoeventshallMultiquipbeliableforloss of profit or good will or for any other special consequentialorincidentaldamages LIMITATIONOFWARRANTIES Nowarranties expressorimplied aremadein connection with the sale of parts or trade accessories nor as to any engine not manufacturedby...

Page 113: ...DCA 500SSK PARTS AND OPERATION MANUAL STD REV 1 04 14 01 PAGE 113 NOTE PAGE ...

Page 114: ... 537 3700 FAX 310 638 8046 W W W W WARRANTY DEP ARRANTY DEP ARRANTY DEP ARRANTY DEP ARRANTY DEPAR AR AR AR ARTMENT TMENT TMENT TMENT TMENT 800 835 2551 or 310 537 3700 FAX 310 638 8046 MAIN MAIN MAIN MAIN MAIN 800 421 1244 or 310 537 3700 FAX 310 537 3927 PARTS AND OPERATION MANUAL Manufactured for Multiquip Inc by DENYO MANUFACTURING CO USA MULTIQUIP INC POST OFFICE BOX 6254 CARSON CA 90749 310 5...

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