MQ Power WHISPERWATT DCA-500SSK Parts And Operation Manual

PARTS AND OPERATION MANUAL

PARTS AND OPERATION MANUAL

MQ POWER

MODEL DCA-500SSK

TM

WHISPERWATT

GENERATOR

(Standard)

© COPYRIGHT 2001, MULTIQUIP INC.

PARTS LIST NO C4872300004

Revision #1 (06/04/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
800-421-1244 800-835-2551
FAX: [phone] FAX: [phone]

E-mail:[e-mail] • www:multiquip.com

SERVICE DEPARTMENT:

PAGE 2 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING

PP

ARAR

TS DEPTS DEP

P

AR

TS DEP

PP

ARAR

TS DEPTS DEP
800/427-1244 or 310/537-3700
FAX: [phone] or 310/637-3284

SERSER

VICE DEPVICE DEP

SER

VICE DEP

SERSER

VICE DEPVICE DEP
800/835-2551 or 310/537-3700
FAX: [phone]

WW

ARRANTY DEPARRANTY DEP

W

ARRANTY DEP

WW

ARRANTY DEPARRANTY DEP
800/835-2551 or 310/537-3700
FAX: [phone]

ARAR

TMENTTMENT

AR

TMENT

ARAR

TMENTTMENT

ARAR

AR

ARAR

TMENTTMENT

TMENT

TMENTTMENT

ARAR

TMENTTMENT

AR

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MAINMAIN

MAIN

MAINMAIN
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

TABLE OF CONTENTS

Here's How To Get Help ............................................ 3

Table Of Contents ..................................................... 4

Parts Ordering Procedures ....................................... 5

Rules For Safe Operation ...................................... 6-9

Towing ..................................................................... 10

Trailer Safety Guidelines .................................... 11-17

Trailer Wiring Diagram ............................................. 18

Air Brake Troubleshooting ....................................... 19

Operation And Safety Decals ............................. 20-24

Specifications .......................................................... 26

General Information ................................................ 27

MQ Power DCA-500SSK
AC Generator

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

Generator Assembly .......................................... 70-73

Control Box Assembly ........................................ 74-79

Engine Radiator Assembly ................................. 80-83

Engine Operating Panel Assembly .................... 84-85

Output Terminal Assembly ................................. 86-89

Battery Assembly ............................................... 90-91

Muffler Assembly ............................................... 92-93

Fuel Tank Assembly ........................................... 94-95

Enclosure #1 Assembly...................................... 96-97

Enclosure #2 Assembly.................................... 98-101

Enclosure #3 Assembly.................................. 102-103

Enclosure (Rubber Seals) .............................. 104-105

Name Plate and Decals ................................. 106-109

Terms and Conditions Of Sale — Parts ................ 110

NOTE

PAGE 4 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

Specification and partSpecification and part

Specification and part

Specification and partSpecification and part
number are subject tonumber are subject to

number are subject to

number are subject tonumber are subject to
change without noticechange without notice

change without notice

change without noticechange without notice

..

.

..

PARTS ORDERING PROCEDURES

■ Dealer account number

■ Dealer name and address

■ Shipping address (if different than billing address)

■ Return fax number

■ Applicable model number

■ Quantity, part number and description of each part

■ 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%

Get special freight allowances
when you order 10 or more
line items via FAX!**

■

UPS Ground Service at no charge for freight

■

PS Third Day Service at one-half of actual freight cost

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.

Extra Fax Discount

for Domestic USA

Dealers Only

UPS

Special

For faxed orders only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

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

800/6-PARTS-7 • 800-672-7877

CAUTION:

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.

RULES FOR SAFE OPERATION

■

NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.

The following safety guidelines should always be used when
operating the DCA-500SSK portable generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading
this entire manual.

■

This equipment should not be operated by
persons under 18 years of age.

■

NEVER operate this equipment without proper
protective clothing, shatterproof glasses, steel­toed boots and other protective devices required
by the job.

■

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.

■

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.

■

High Temperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions.
Contact with

■

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.

CAUTION:

hot

components can cause serious burns.

Always refuel in a well-ventilated area, away
from sparks and open flames.

■

Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool. DO NOT
machine. Fire or explosion could result from
fuel vapors, or if fuel is spilled on a hot
engine.

smoke around or near the

■

Manufacturer does not assume responsibility for any accident
due to equipment modifications.

■

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)

■

NEVER operate the generator in an explosive atmosphere or
near combustible materials. An explosion or fire could result
causing severe

■

Topping-off to filler port is dangerous, as it tends to spill fuel.

bodily harm or even death.

RULES FOR SAFE OPERATION

CAUTION:

■

NEVER touch output terminals during operation. This is
extremely dangerous.
contact with the output terminals.

Always stop the machine when

CAUTION:

■

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:

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

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 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.

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

■

Battery

CAUTION:

Never over fill the battery with water above
the upper limit.

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:

1. DO NOT drop the battery. There is the possibility of risk
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.

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.

5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.

6. In case the battery liquid (dilute sulfuric acid) comes in
contact with
immediately with plenty of water.

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.

clothing or skinclothing or skin

clothing or skin

clothing or skinclothing or skin

, rinse skin or clothing

NEVER Run engine without air filter. Severe engine damage
may occur.

■

Always service air cleaner frequently to prevent carburetor
malfunction.

■

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.

■

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.

■

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.

■

Always be sure the operator is familiar with proper safety
precautions and operations techniques before using generator.

■

Refer to the
technical questions or information.

Loading and Unloading (Crane)

■

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.

■

Always drain fuel prior to lifting.

■

Always make sure crane or lifting device has been properly
secured to the hook of guard frame on generator.

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or rope) of sufficient strength.

■

When lifting the generator, always use the balanced center­point 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
front and back frame bars as a means to secure the generator
during transport.

RULES FOR SAFE OPERATION

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PAGE 8 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

RULES FOR SAFE OPERATION

Transporting

■

Always shutdown engine before transporting.

■

Tighten fuel tank cap securely.

■

Drain fuel when transporting generator over long distances
or bad roads.

■

Always tie-down the generator during transportation by
securing the generator.

■

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.

Emergencies

■

Always know the location of the nearest

first aid kitfirst aid kit

and

first aid kit

first aid kitfirst aid kit

Also know the phone numbers of the nearest

doctordoctor

doctor

and

doctordoctor

. Know the location of the nearest telephone.

fire departmentfire department

fire department

fire departmentfire department

.

fire extinguisherfire extinguisher

fire extinguisher

fire extinguisherfire extinguisher

ambulanceambulance

ambulance

ambulanceambulance

Maintenance Safety

■

■

■

■

■

■

■

,

NEVER lubricate components or attempt service on a running
machine.

Always allow the machine a proper amount of time to cool
before servicing.

Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace

broken parts.
Dispose of hazardous waste properly. Examples of potentially

hazardous waste are used motor oil, fuel, and fuel filters.
DO NOT use plastic containers to dispose of hazardous

waste.
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

■

Towing Safety Precautions

CAUTION :

Check with your county or state safety towing
regulations department before towing your
generator.

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.

The following list of suggestions should be used when towing
your generator:

■

Make sure the hitch and coupling of the towing vehicle are
rated equal to, or greater than the trailer "gross vehicle weight
rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both the towing vehicle and
the trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety
Chain".

ALWAYS attach trailer's safety chain to bumper of towing

vehicle.

■

ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and working
properly.

■

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.

■

Place
while parked.

■

Place
prevent

■

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 prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

DCA-500SSK — TOWING

chocked blocks

support blocks

tippingtipping

tipping

tippingtipping

underneath wheel to prevent

underneath the trailer's bumper to

, while parked.

rolling rolling

rolling,

rolling rolling

Figure 1. Generator and Trailer

PAGE 10 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — TRAILER-SAFETY GUIDELINES

CAUTION:

ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer ser­vice and maintenance information. The service and mainte­nance 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 dam­age to the equipment and personal injury.

It is the purpose of this section to cover the major mainte­nance components of the trailer. The following trailer com­ponents will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



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 trans­porting equipment.

2. Braking System - System employed in stopping the
trailer. Typical braking systems are electric, surge, hy­draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in­cluding the fuel cell (empty).

4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to
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.

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. See Table 4 and Figure 5 or lug nut tightening and
sequence.

13. Axle - Indicates the maximum weight the axle can sup­port 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.

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

DCA-500SSK — TRAILER-SPECIFICATIONS

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PAGE 12 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — TRAILER-SPECIFICATIONS

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DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 13

DCA-500SSK — TRAILER SAFETY GUIDELINES

Brakes

If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow the
brake shoes and drums to seat properly. After the first 200
mile interval, inspect the brakes every 3,000 miles. If driving
over rough terrain, inspect the brakes more frequently.

Electric Brakes

Electrically actuated brakes (Figure 2) are similar to hydraulic
brakes. The basic difference is that hydraulic brakes are
actuated by an electromagnet.
Listed below are some of the advantages that electric brakes
have over hydraulic brakes:



Brake system can be manually adjusted to provide the

corrected braking capability for varying road and load
conditions



Brake system can be modulated to provide more or less

braking force, thus easing the brake load on the towing
vehicle



Brake system has very little lag time between the time

the vehicle’s brakes are actuated and the trailer’s brakes
are actuated



Brake system can provide an independent emergency

brake system

Remember in order to properly synchronize the tow vehicle’s
braking to the trailer’s braking, can only 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.

Before any brake synchronizations adjustments can be made,
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 time for
brakes to cool between application. This allows the brake
shoes to slightly be seated into the brake drum surface.

Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect these
components as required.

Electric Brake Adjustment

1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot
at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the
star wheel of the adjuster assembly to expand the brake
shoes.

5. Adjust the brake shoes outward until the pressure of the
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.

7. Replace the adjusting hole cover and lower the trailer to
the ground.

8. Repeat steps 1 through 6 on the remaining brakes.

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

DCA-500SSK — TRAILER SAFETY GUIDELINES

Figure 2. Electrical Brake Components

Hydraulic/Air/Surge Brakes

Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such as
shoe and lining replacement. These brakes can be adjusted

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.

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

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 15

Figure 3. Hydraulic Brake Components

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

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.

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.

CAUTION:

NOTE

ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.

PAGE 16 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

Figure 4. Major Suspension Components

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"2/106-XAM54-NIM

SHACKLE BOLT

SPRING EYE BOLT

DCA-500SSK — TRAILER SAFETY GUIDELINES

TLOB-U"61/706-XAM54-NIM

.

SNUG FIT ONL Y

LOC K ING NUTS OR C OTTE R P INS A RE P RO VID ED

TO RE TAIN NUT

PARTS MUST ROTATE FREELY

-

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.

SHOULDER TYPE

SHACKLE BOLT

05-XAM03-NIM

Lug Nut Torque 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 by Table 4.

3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.

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"5152-0206-05021-09

"6152-0206-05021-09

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 17

Figure 5. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

DCA-500SSK — TRAILER-WIRING DIAGRAM

PAGE 18 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — TRAILER BRAKES TROUBLESHOOTING

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motpmyS esuaCelbissoP noituloS

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sekarBrosekarBkaeW

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sekarBgnikcoLrotneb,esoolstnenopmocekarB

?nekorb

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.sgninil

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DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 19

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.

PAGE 20 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — OPERATION AND SAFETY DECALS

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 21

DCA-500SSK — OPERATION AND SAFETY DECALS

PAGE 22 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — OPERATION AND SAFETY DECALS

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 23

DCA-500SSK — OPERATION AND SAFETY DECALS

PAGE 24 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK -- NOTES PAGE

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 25

DCA-500SSK — SPECIFICATIONS

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daol

PAGE 26 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — GENERAL INFORMATION

DCA-500SSK FAMILIARIZATION
Generator

genergener

The MQ Power Model DCA-500SSK is a 550 kW
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.

Engine Control Panel

The “Engine Control Panel” is provided with the following:

z

Tachometer

z

Water Temperature Gauge

z

Oil Pressure Gauge

z

Charging Ammeter Gauge

z

Engine Warning Lamp Module

z

Throttle Lever

z

Engine Speed Switch

z

Pre-Heat Button

z

Pre-Heat Lamp

z

Emergency Stop Button

z

Battery Switch

Generator Control Panel

The “Generator Control Panel” is provided with the following:

z

Output Voltage Adjustment Knob

z

Frequency Meter (Hz)

z

AC Ammeter (Amps)

z

AC Voltmeter (Volts)

z

Ammeter Change-Over Switch

z

Voltmeter Change-Over Switch

z

Panel Light

z

Panel Light Switch

z

MPEC Module

z

Pilot Lamp

Microprocessor Controlled Alarm System

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.

gener

genergener

atorator

ator

atorator

Open Delta Excitation System

The DCA-500SSK generator is equipped with the state of
the art "
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
power to the
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.

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 "
according the demands of the required load.

Engine

The DCA-500SSK is powered by a 4 cycle, water cooled,
turbocharged KOMATSU Model SA6D170BE diesel
This engine is designed to meet every performance
requirement for the generator. Reference Table 7, page 23
for engine specifications.

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

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.

Open-DeltaOpen-Delta

Open-Delta

Open-DeltaOpen-Delta

AA

utomatic utomatic

A

utomatic

AA

utomatic utomatic

" excitation system. The open delta

VV

oltage Regulator oltage Regulator

V

oltage Regulator

VV

oltage Regulator oltage Regulator

fixed ceilingfixed ceiling

fixed ceiling

fixed ceilingfixed ceiling

(AVR) is supplied

" and responds

engine.

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 27

DCA-500SSK — MAJOR COMPONENTS

PAGE 28 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

Figure 6. Major Components

NOTE PAGE

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 29

DCA-500SSK — DIMENSIONS (TOP AND SIDE)

PAGE 30 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

Figure 7a. Dimensions

DCA-500SSK — DIMENSIONS (FRONT AND REAR)

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 31

Figure 7b. Dimensions

DCA-500SSK — CONTROL PANEL

Figure 8. Control Panel

PAGE 32 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — CONTROL PANEL

The definitions below describe the controls and functions of
the DCA-500SSK "

Control Panel Control Panel

Control Panel

Control Panel Control Panel

" (Figure 8).

1. Pilot Lamp – Indicates that the generator is working

properly.

If the engine does not engage (start) by the third attempt,
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.

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

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. .

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

8. Panel Light Switch – When activated, this switch will

turn on the luminate the control panel.

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.

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
MPEC will evaluate the fault
and if the fault is major will

Figure 9. MPEC

Module

shutdown the generator.

crcr

During
engine for 10 seconds before disengaging.

anking cycleanking cycle

cr

anking cycle

crcr

anking cycleanking cycle

, The MPEC will attempt to crank the

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
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
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.

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
shut down the generator.

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

major major

a

major

major major

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
the generator.

E. Overspeed Shutdown – Indicates that the engine is

running at an unsafe speed. This is considered a
fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

manman

ualual

man

ual

manman

position, the generator will start

ualual

autoauto

auto

position. In this position the

autoauto

major major

major

fault and will

major major

fault and will shut down the generator.

major major

major

major major

fault and will shut down

majormajor

major

majormajor

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 33

DCA-500SSK — ENGINE OPERATING PANEL

Figure 10. Engine Operating Panel

PAGE 34 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the

Engine Operating Panel Engine Operating Panel

DCA-500SSK "

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.

3. Engine Warning Display (LED) Module – This module

display’s the following engine failures:

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.

B. Low Oil Pressure Lamp – During normal

operation of the generator this lamp should
remain OFF. When the Auto-OFF/Reset­Manual 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.

Engine Operating Panel

Engine Operating Panel 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.

5. Water Temperature Gauge – During normal operation
this gauge be should read in the “GREEN” zone.

6. 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.

7. Fuel Level Gauge – Indicates amount of diesel fuel
remaining.

8. 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

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.

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.

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.

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

11. Preheat Switch – Turn this switch on to heat

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
speed from idle to normal.

DCA-500SSK — OUTPUT TERMINAL

600SSK FAMILIARIZATION

The “Output Terminal Panel” is provided with the following:

z

Two 120V GFCI receptacles, 20 amp

z

Three 240/139V output receptacles, 50 amp

z

Two 120V input receptacles, 20 amp (optional)

z

3 Load Circuit Breakers 265V @65 amps

z

2 Load GFCI Circuit Breakers 265V@ 20amps

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.

Control Box

The “Control Box” is provided with the following:

z

Main Circuit Breaker 1400 amps

z

Over-Current Relay

Output Terminal Panel

Figure 13. Connection Receptacles

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).

Circuit Breakers

To protect the generator from an overload, a 3-pole, 1400

main main

amp,

main

main main

output terminals from overload. In addition two single-pole,
20 amp
GFCI receptacles from overload. Three 50 amp
breakers have also been provided to protect the load side of
the generator from overload. Make sure to switch
breakers to the "OFF" position prior to starting the engine.

circuit breaker is provided to protect the UVWO

GFCIGFCI

GFCI

circuit breakers are provided to protect the

GFCIGFCI

loadload

load

circuit

loadload

ALLALL

ALL

circuit

ALLALL

Maximum Output

Figure 11. Output Terminal Cover

The entire load connected to the UVWO Lugs, all four slots in
the duplex receptacles, and the must not exceed 500 kW in

120 Volt Recetacle

standby or 550 kW in prime output.

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 Dual Voltage 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

Pressing the reset button resets the receptacle after being

voltage to 208 or 416V.
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

PAGE 36 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — OUTPUT TERMINAL

NOTE

Legs O and Ground are
considered Bonded Grounds.

Figure 14. Output Terminal Panel Location

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 37

DCA-500SSK — OUTPUT TERMINAL

Output Terminal Panel Available Voltages

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 the Voltage 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.

LEDOMKSS005ACD

EGATLOVESAHP3

)ELBATCENNOCER(

ESAHPELGNIS

)ELBATSUJDA(

TLOV802TLOV022TLOV042TLOV614TLOV044TLOV084

TLOV021TLOV721TLOV931TLOV042TLOV452TLOV772

CAUTION:

NEVER attempt to change the Voltage
Change-Over Board with the engine is
running.

ELBALIAVASEGATLOV.8ELBAT

Over Current Relay

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.

:ledoMKSS005ACD

detaR

egatloV

tloV021

tloV042

tloV042

Maximum Amps

The following table below shows the maximum amps the

generator can provide Do not exceed the maximum amps

listed below.

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esahPelgniS

esahPeerhT

spmAmumixaM.9elbaT

spmAmumixaM

)eriw4(spma1.1111

)eriw4(spma6.555

spma8.2021

PAGE 38 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

esahPeerhT

tloV084

spma4.106

DCA-500SSK — OUTPUT TERMINAL

Reading the Output Terminal 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 the W-U position and the AC ammeter
Change-over Switch to the U or W position to read the output
on the selected leg.

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

Voltmeter Gauge

(Voltage reading on

W-U lug)

Figure 18. AC

Ammeter Gauge

(Amp reading on U

lug)

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 39

DCA-500SSK — OUTPUT TERMINAL

Voltage Change-over Board

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.

Single Phase, 240 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 240V. After hooking up
the hard wires to the lugs as shown in figure 21 below,

240V will be the voltage output.
Unless specified differently, the generator comes from the
factory in the 240V position.

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

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.

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.

FIGURE 20. Hard Wire Hookup for Three Phase 240V

PAGE 40 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

FIGURE 22. Hard Wire Hookup for Single Phase 139V

DCA-500SSK — OUTPUT TERMINAL

480 Volt Set position

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.

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 23. Voltage Change-over Board 480V set position.

3 Phase, 480 Volt

FIGURE 25. Hard Wire Hookup for Single Phase 480V

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 24. Hard Wire Hookup for Three Phase 480V

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 41

FIGURE 26. Hard Wire Hookup for Single Phase 277V

DCA-500SSK — INSTALLATION

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.

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.

Foreign materials such as dust, sand, lint and abrasive
materials will cause excessive wear to the engine and
alternator parts.

CAUTION :

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.

CAUTION :

Generator 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.

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.

a. Copper - 10 AWG (5.3 mm2) or larger.
b. Aluminum - 8 AWG (8.4 mm2) or larger.

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.

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.

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.

3. NEC article 250-52(c) specifies that the earth ground
rod should be buried a minimum of 8 ft. into the ground.

NOTE

When connecting the generator
to any buildings electrical system
ALWAYS consult with a licensed
electrician.

PAGE 42 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — INSTALLATION

CAUTION :

Always check Local, State, and Federal
Laws before grounding generator.

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 43

Figure 27. Typical Generator Grounding Application

DCA-500SSK — PRE-SETUP

General Inspection Prior to Operation

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.

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

Circuit Breakers

To protect the generator from an overload,

amp,
UVW output terminals from overload. In addition two
single-pole, 20 amp
to protect the GFCI receptacles from overload. Three 50
amp
protect the load side of the generator from overload. Make
sure to switch
prior to starting the engine.

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.

a 3-pole,1400

main main

main

circuit breaker is provided to protect the

main main

GFCIGFCI

circuit breakers are provided

GFCI

GFCIGFCI

loadload

load

circuit breakers have also been provided to

loadload

ALLALL

ALL

circuit breakers to the "OFF" position

ALLALL

NOTE

ALWAYS consult with a licensed

electrician for correct extension
cord wire size.

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PAGE 44 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — PRE-SETUP

Lubrication Oil

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.

Fuel

Fill the fuel tank with clean and fresh
NOT fill the tank beyond capacity.

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 fillin
Handle fuel in a safety container. If the container does
not have a spout, use a funnel. Wipe up any spilled fuel
immediately.

CAUTION :

diesel fuel. diesel fuel.

diesel fuel.

diesel fuel. diesel fuel.

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.

DO

g.

Coolant

Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and

Figure 28. Engine Oil Dipstick

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.

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radiator may become coated with deposits and cooling
efficiency will be reduced.

An anticorrosion additive added to the water will help
prevent deposits and corrosion in the cooling system.
See the engine manual for further details.

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DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 45

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DCA-500SSK — PRE-SETUP

CAUTION :

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.

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Operation in Freezing Weather

When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.

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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. Cleaning inside the machine is
dangerous, so clean only with the engine turned off and the
battery disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. See
maintenance section for instruction to cleaning/replacing air
cleaner.

Fan Belt Tension

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:

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.

4. Tighten the bolt and nuts to fix the alternator back to
position.

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.

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CAUTION

NOTE

When the antifreeze is mixed withWhen the antifreeze is mixed with

When the antifreeze is mixed with

When the antifreeze is mixed withWhen the antifreeze is mixed with
ww

aterater

, the antifreez, the antifreez

w

ater

, the antifreez

ww

aterater

, the antifreez, the antifreez

be less than 50%.be less than 50%.

be less than 50%.

be less than 50%.be less than 50%.

PAGE 46 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

e mixing re mixing r

e mixing r

e mixing re mixing r

atio matio m

atio m

atio matio m

ustust

ust

ustust

Figure 29. Fan Belt Tension

:

Never place hands near the belts or fan
while the generator set is running.

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

cable is connected to the positive terminal of the battery,

RED RED

and the BLACK cable is connected to the negative terminal
of the battery.

Figure 30. Battery Connections

CAUTION

When connecting battery do the following:

1. DO NOT connect the battery cables to the battery
terminals when the
the manual or auto position (ON). ALWAYS make sure
that the Off/Manual/Auto switch is in the OFF position
when connecting the battery.

:

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.

Off/Manual/Auto Off/Manual/Auto

Off/Manual/Auto

Off/Manual/Auto Off/Manual/Auto

switch is in either

CAUTION

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.

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.

:

Inadequate battery connections may cause
poor starting of the generator, and create
other malfunctions.

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

DCA-500SSK — LOAD APPLICATION

Single Phase Load

CAUTION:

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.

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.

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.

WATTS = VOLTAGE x AMPERAGE

which cannot carry the required load can cause a
voltage drop which can burn out the appliance or tool
and overheat the cable.

z

z

z

Motors and motor-driven equipment
draw much greater current for
starting than during operation.

An inadequate size connecting cable

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.

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.

The power factor of this generator is 0.8. See Table

14. below when connecting loads.

CAUTION:

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Three Phase Load

When calculating the power requirements for 3-phase
power use the following equation:

57.0-4.0

0.1

9.0-4.0

Before connecting this generator to any building’s

0.1

electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious injury or death
may result without this transfer switch.

When connecting ordinary power tools,
a capacity of up to the generating set’s
rated output (kW) multiplied by 0.8 can
be used.

NOTE

If output (kVA) is not given on the equipment
nameplate, approximate output may be
determined by multiplying voltage by
amperage by .

PAGE 48 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — GENERATOR START-UP PROCEDURE (MANUAL)

WARNING:

The engine's exhaust contains harmful

ALAL

WW

AA

W

WW

YS YS

A

YS

ventilate the

AA

YS YS

emissions.
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.

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.

AL

ALAL

2. Connect the load to the UVW terminals as shown in
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.

3. Connect the negative battery cable (BLACK) to the
negative post on the battery (Figure 33).

Figure 32. UVW Terminal Lugs (Load)

Before Starting

Generator and Control Panel

CAUTION:

NEVER start the engine with the

main,main,

GFCI GFCI

main,

GFCI

main,main,

GFCI GFCI

in the ON position.

1. Be sure to disconnect the electrical load and switch the

MAIN LOMAIN LO

MAIN LO

MAIN LOMAIN LO

to the “OFF” position prior to starting the engine.

AD AD

AD

AD AD

Figure 31. Main, GFCI and

G.FG.F

.C.C

G.F

G.FG.F

.C

.C.C

.I..I.

.I.

.I..I.

and

Load Circuit Breakers

loadload

or

load

circuit breakers

loadload

circuit breakers (Figure 31)

NEGATIVE

POSTIVE

BATTERY

Figure 33. Battery Connections

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 49

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 36. Engine Pre-Heat Button

Figure 37. Engine Pre-Heat Lamp

Figure 39. MPEC Engine Running Status LED

9. The generator's frequency meter (Figure 40) displays
the 60 cycle output frequency in HERTZ.

Figure 40. Frequency Meter (Hz)

PAGE 50 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

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

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 41. Voltage Meter (Volts)

13. The coolant temperature gauge (Figure 45) will

indicate the oil pressure (kg/ cm

2)

of the engine.
Under normal operating conditions the oil pressure
should be approximately 25 psi.

Figure 44. Oil Pressure Gauge

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

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.

40

20

0

60

75

A

Figure 43. Ammeter (No Load)

WATER

TEMP

Figure 45. Coolant Temperature Gauge

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 51

DCA-500SSK — GENERATOR START-UP PROCEDURE (MANUAL)

14. Set the engine speed switch (Figure 46) to low to idle
engine, set to high when a load is being applied.

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.

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 RPM’s.

18. The generator will run until manually stopped or an
abnormal condition occurs.

Figure 47. Engine Tachometer

40

20

0

60

75

A

Figure 49. Ammeter (Load)

16. Turn the MAIN, GFCI and LOAD circuit breakers to
their ON position (Figure 48).

Figure 48. Main and GFCI Circuit Breakers

PAGE 52 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — GENERATOR START-UP PROCEDURE (AUTO)

When starting generator in Auto mode use the "Manual Start­up" procedure except where noted (see below).

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:

CAUTION:

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).

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.

Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious
may result without this transfer switch.

injuryinjury

injury

injuryinjury

or

deathdeath

death

deathdeath

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 53

DCA-500SSK — GENERATOR SHUTDOWN PROCEDURE

Engine Shutdown

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers
to the "OFF position"

2. Set the engine speed switch (Figure 51) to the idle (low)
position (If optional part installed).

Emergency Stop

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.

CAUTION

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 54. Emergency Stop Button

:

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 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).

PAGE 54 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

NOTE PAGE

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 55

DCA-500SSK — MAINTENANCE

General Inspection

Prior to each use, the generating set should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for fuel
or oil leaks.

Air Cleaner

Every 50 hours: If dust indicator is red, clean the air cleaner
element.

Outer Element:

1. Loosen wing bolt, remove dust cup, then remove wing
nut and take out element.

2. Clean the inside of the body and cover using a damp
cloth.

3. Blow dry with compressed air (0.69Mpa [7kgf.cm

99.4 PSI] maximum) against the side of the element
along the pleats. Then blow dry against outside along
the pleats, then against inside again.

4. Remove one seal each time the element is cleaned.

5. Replace the outer element after cleaning it 6 times or
after one year. Replace the outer element if indicator is
red even after cleaning it.

6. Check the inner cylinder element clamping nut for
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.

6. After replacing the element, press the button of the dust
indicator to return the red piston to its original position.

Fuel Addition

Add diesel fuel (the grade may vary according to season
and locations). Always pour through the mesh filter.

Removing Water from the Tank

After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the greater
the empty volume inside the tank, the easier it is for water to
condense. This can be reduced by always keeping the tank
as full as possible.

Air Removal

If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel, or

2

,

after disassembling the fuel system, bleed the system
according to the following procedure.
To restart after running out of fuel, turn the key switch to the
“START” position for 15-30 seconds. Try again, if needed.
This unit is equipped with an automatic air bleeding system.

Service Daily

If engine is operating in very dusty and dry grass conditions,
a clogged air cleaner will result in high fuel consumption,
loss of power and excessive carbon buildup in the
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

1. Stop the engine and allow to cool. Tighten valve of the
corrosion resistor (if equipped).

PAGE 56 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

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.

DCA-500SSK — MAINTENANCE

5. When the water level is near the mouth of the water
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.

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.

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.

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.

11. When clean water comes out, stop the engine, drain all
the water, then close drain plugs.

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 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.

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.

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

1. Set the container under the filter cartridge to catch fuel.

12. Remove the corrosion resistor (if equipped) and open
valve.

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.

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.

2. Using a filter wrench, turn the filter cartridge to the left
to remove it.

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.

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.

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

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.

10. Using a filter wrench, turn the cartridge to the left to
remove it.

11. Coat the seal surface of the new cartridge with engine
oil and install it to the filter holder.

12. Tighten until he packing surface contacts the seal

For storage of the generator for over 30 days, the following
is required:

z

Fill the fuel tank completely, lubricate and change oil.

z

Disconnect the negative terminals of the battery and
cover it, or remove it from the machine and store it
separately.

z

If the ambient temperature is expected to drop below

o

0

C, add antifreeze to the radiator.

surface of the filter holder, then tighten a further 2/3 of a
turn.

13. Open 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.

2. Wash the breather in diesel fuel or flushing oil, blow dry
with compressed air, then reinstall it.

3. Inspect the hose and if there is any deteriorated oil stuck
inside the hose. Replace hose if necessary.

Greasing

Using a grease pump, grease the fan hub (1 place) and
tension pulley (2 places).

Removal from long term storage:

z

Apply oil to the engine valve and rocker arms, and
examine the operating condition of the valves.

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.

z

Change the oil in engine oil pan.

z

Replace all the filters.

z

Flush the inside of the cooling system.

z

Drain the water from the fuel tank and bleed the air from
the fuel system.

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)

DCA-500SSK — MAINTENANCE

.51ELBAT

ECNANETNIAM/NOITCEPSNI

srH01

YLIAD

srH052 srH005 srH0001

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

1

*retliFdnaliOenignEecalpeR

X

retliFriAnaelC X

ENIGNE

knaTleuFfomottoBniarD X

edistuOdnaedisnI,tinUnaelC X

2

*retliFleuFegnahC

tnalooCkcehCdnarotaidaRnaelC

X

X

leveLnoitcetorP

tnemelEretliFriAecalpeR X

rotsiseRnoisorroCegnahC X

spmalCdnasesoHllakcehC X

knaTleuFfoedisnInaelC X

ROTARENEG

*

*

smhoM3

1

2

revOecnatsiseRnoitalusnIerusaeM

.ylnoemittsrif,sruoH052taretlifleufecalpeR

X

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 59

DCA-500SSK—GENERATOR WIRING DIAGRAM

DCA-500SSK — ENGINE WIRING DIAG

PAGE 60 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

RAM

DCA-500SSK—ENGINE WIRING DIAGRAM

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 61

DCA-500SSK — TROUBLESHOOTING (ENGINE)

All breakdowns can be prevented by proper handling and
maintenance inspections, but in the event of a breakdown,
please take a remedial action following the diagnosis based

on the Engine Troubleshooting (Table 16) information shown
below and on the proceeding page. If the problem cannot be
remedied, consult our company's business office or service
plant.

MOTPMYS MELBORPELBISSOP NOITULOS

?leufoN .leufhsinelpeR

?metsysleufehtniriA .metsysdeelB

?metsysleufehtniretaW .knatleufmorfretawevomeR

?deggolcepipleuF .epipleufnaelC

?deggolcretlifleuF .retlifleufegnahcronaelC

ytisocsivhgihylevissecxE

?erutarepmet

?rebmun

woltalioenigneroleuffo

enatecwolhtiwleuF

GNITOOHSELBUORTENIGNE.61ELBAT

.lioenigneroleufdeificepsehtesU

.leufdeificepsehtesU

esooloteudkaelleuF

?tungniniaterepipnoitcejni

.tratstonseodenignE

pmupnoitcejnI

?gninoitcnuflam

?gniraebrorenil

?rednilyc

?gnimitnoitcejnitcerrocnI .tsujdA

?nrowtfahsmacleuF .ecalpeR

?deggolcelzzonnoitcejnI .elzzonnoitcejninaelC

,tfahsknarcfoeruzieS

rednilyc,notsip,tfahsmac

morfkaelnoisserpmoC

?gnimitevlavreporpmI .raeggnimitecalperrotcerroC

?nrowrenildnagnirnotsiP .ecalpeR

?ecnaraelcevlavevissecxE .tsujdA

?degrahcsidyrettaB .yrettabegrahC

?gninoitcnuflamretratS .ecalperroriapeR

.tunnethgiT

.ecalperroriapeR

.ecalperroriapeR

wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

.redlohelzzondnagulp

.nurtonseodretratS

?gninoitcnuflamhctiwsyeK .ecalperroriapeR

PAGE 62 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

?detcennocsidgniriW .gniriwtcennoC

DCA-500SSK — TROUBLESHOOTING (ENGINE)

MOTPMYS MELBORPELBISSOP NOITULOS

?ytridrodeggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

)DEUNITNOC(GNITOOHSELBUORTENIGNE.61ELBAT

esooloteudkaelleuF

?tungniniaterepipnoitcejni

pmupnoitcejnI

?gninoitcnuflam

.htooms

tonsinoituloverenignE

?erusserp

?deggolc

?deggolc

.devresbosisag

tsuahxeeulbroetihwrehtiE

?kcutsro

?daolrevO .daolehtnesseL

gninepoelzzontcerrocnI

rokcutselzzonnoitcejnI

epipwolfrevoleuF

?gninoitcnuflamronrevoG .riapeR

?lioenigneevissecxE .leveldeificepsehtotecudeR

nrowrenildnagnirnotsiP

?gnimitnoitcejnitcerrocnI .tsujdA

?noisserpmoctneicifeD .ecnaraelcpottsujdA

.tunnethgiT

.ecalperroriapeR

.tsujdA

.ecalperroriapeR

.naelC

.ecalperroriapeR

?desuleufedargwoL .leufdeificepsehtesU

yargkradrokcalbrehtiE

.devresbosisagtsuahxe

.tuptuotneicifeD

?deggolcretlifleuF .egnahcronaelC

?deggolcrenaelcriA .egnahcronaelC

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?gnimitnoitcejnitcerrocnI .tsujdA

strapgnivoms'enignE

?gniziesebotmees

?noitcejnileufnevenU .pmupnoitcejniehtecalperroriapeR

?noitcejnielzzontneicifeD .elzzonehtecalperroriapeR

?kaelnoisserpmoC

.ecalperroriapeR

.redlohelzzondnagulp

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 63

wolg,tlobdaehrednilycnethgit,teksagdaehecalpeR

DCA-500SSK — TROUBLESHOOTING (GENERATOR/ENGINE)

All breakdowns can be prevented by proper handling and
maintenance inspections, but in the event of a breakdown,
please take a remedial action following the diagnosis based

MOTPMYS MELBORPELBISSOP NOITULOS

?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

tuptuOegatloVoN

?evitcefedRVAsI .yrassecenfiecalpeR

?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

tuptuOegatloVwoL

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH

?RVAevitcefeD .yrassecenfiecalpeR

on the Engine and Generator Troubleshooting (Table 17)
information shown below. If the problem cannot be remedied,
consult our company's business office or service plant.

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

GNITOOHSELBUORTROTARENEG.71ELBAT

?daolnitiucriCtrohS .riaperdnadaolkcehC

deppirTrekaerBtiucriC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

PAGE 64 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — TROUBLESHOOTING (MPEC)

All breakdowns can be prevented by proper handling and
maintenance inspections, but in the event of a breakdown,
please take a remedial action following the diagnosis based

on the MPEC Troubleshooting (Table 18) information shown
below. If the problem cannot be remedied, consult our
company's business office or service plant.

notpmySesuaCelbissoPnoituloS

?levelliowoL.levelliolliF

erusserpliowoL

.nosithgil

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

leveltnaloocwoL

.nosithgil

?rotaidar

?eruliaftinugnidneS.tinugnidnesecalpeR

?egatlovyrettabwoL.yrettabegrahc/ecalpeR

?eruliaftinugnidneserusserpliO .tinugnidneserusserplioecalpeR

?CEPMninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF.tlebnafecalper/nethgiT

hguorhtnoitalucrictonsiwolfriA

GNITOOHSELBUORTCEPM.81ELBAT

.llirgrotaidarriaper/naelC

?neposrooD.sroodesolC

tnaloochgiH

sithgilerutrepmet

.no

sithgilknarcrevO

.no

sithgildeepsrevO

.no

?detsujda

UPMfossoL

.noro)s(thgil

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliaftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliafhctiwserutarepmeT.hctiwserutarepmetecalpeR

?leuFwolrooN.levelleuflliF

?detarbilacebotsdeenCEPM.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG.rotautcaronrevogtsujdA

ebotsdeenrellortnocronrevoG

?detarbilacebotsdeenCEPM.relaedotrefeR

?tnemtsujdafotuopukcipcitengaM.pukcipcitengamtsujdA

?ytridpukcipcitengaM.pukcipcitengamnaelC

.rellortnocronrevogtsujdA

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 65

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,

■

, belong to the same assembly or kit.

or

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)

DCA-500SSK — SUGGESTED SPARE PARTS

DCA-500SSK w/SA6D170AE-1 KOMATSU ENGINE

1 to 5 Units1 to 5 Units

1 to 5 Units

1 to 5 Units1 to 5 Units

Qty. P/N Description

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 ... AUTOMATIC VOLTAGE 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

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 67

NOTE

Part number on this Suggested Spare
Parts List may super cede/replace the
P/N shown in the text pages of this
book.

GENERATOR ASSY.

DCA-500SSK — GENERATOR ASSY.

PAGE 68 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 8471000002 ROTOR ASSY. 1
1-1 FIELD ASSY. 1
1-2 0601842366 RESISTOR 4
1-3 8171020004 INSULATOR WASHER 6
1-4 8171020504 INSULATOR WASHER 6
1-5 8461070002 FAN 1
1-6 8461614003 COUPLING RING 1
1-7 0010312025 HEX. HEAD BOLT 6

0042512000 LOCK WASHER 6
1-8 416310004 COUPLING DISK ASSY. 1
1-9 8461612004 WASHER, COUPLING HUB 1
1-10 8461015003 BALANCING PLATE 1
1-11 0012120055 HEX. HEAD BOLT 12
1-12 0042620000 LOCK WASHER 12
1-13 8461026023 SET PLATE, RECTIFIER 1
1-14 0601823282 RECTIFIER 2
1-15 0018205020 HEX. SOCKET HEAD COP SCREW 4

0040005000 LOCK WASHER 4

0041205000 PLAIN WASHER 4
1-16 0010112020 HEX. HEAD BOLT 6

0040012000 LOCK WASHER 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 LOCK WASHER 6
3 C4130200003 STRATOR ASSY. 1
3-1 7431323003 CLAMPER 4
3-2 3871323123 CLAMPER 4
3-3 7431323204 CLAMPER 2
3-7 0016310080 HEX. HEAD BOLT 4

0030010000 HEX. NUT 4

0040010000 LOCK WASHER 8

0041210000 PLAIN WASHER 4
3-5 0017110020 HEX. HEAD BOLT 8
4 8461315002 END BRACKET 1
5 C4137000003 FIELD ASSY. EXCITER 1
6 0012110075 HEX. HEAD BOLT 6

0042610000 LOCK WASHER 6
7 0845044904 GROMMET 1
8 0010116045 HEX. HEAD BOLT 8

0040016000 LOCK WASHER 8

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 69

GENERATOR ASSY.

DCA-500SSK — GENERATOR ASSY.

PAGE 70 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — GENERATOR ASSY.

GENERATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

9 7431310003 COVER, BEARNG 1
10 8461312004 GASKET, BEARING 2
11 0010108095 HEX. HEAD BOLT 3

0040008000 LOCK WASHER 3

0041208000 PLAIN WASHER 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 LOCK WASHER 16
21 8461332003 COVER, FAN 1
22 0017106050 HEX. HEAD BOLT 1
23 0605000012 RUBBER SUSPENSION 4
24 0030020000 HEX. NUT 8

0040020000 LOCK WASHER 8

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 71

CONTROL BOX ASSY.

DCA-500SSK — CONTROL BOX ASSY.

PAGE 72 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

1 8481812502 CONTROL BOX 1
2 0601801194 CURRENT TRANSFORMER, AMMETER 3 CW-40LM 1000/5A
3 0017108020 HEX. HEAD BOLT 6
4 C4261501303 SET PANEL, ELECTRIC PARTS 1
5 0017108030 HEX. HEAD BOLT 8
6 0601820625 AUTOMATIC VOLTAGE REGULATOR 1 NTA5A2T
7 0027105016 MACHINE SCREW 4
8 0601820892 OVER CURRENT RELAY 1 THN20HZKP
9 0027104016 MACHINE SCREW 2
10 0601823706 RELAY 1
11 0027104014 MACHINE SCREW 2
12 0601823861 ENGINE STOP UNIT 1 MSA9014
13 0027104014 MACHINE SCREW 2
14 0601802133 FUSE, LEFT SIDE 1 5A

0601802164 FUSE 1 30A
0601802149 FUSE, RIGHT SIDE 1 10A
0601802218 HOLDER, FUSE 1 F7111SP

15 0021004020 MACHINE SCREW 3

0040004000 LOCK WASHER 3
0041204000 PLAIN WASHER 3

16 0601823757 RELAY 1 MY2DC24V

PYF08A SOCKET 1 REPLACES 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 4
25 0601807031 CIRCUIT BREAKER 1 XS1600NA1400A
25-1 0601802525 HANDLE, CIRCUIT BREAKER 1 XHA9
26 7971816104 BRACKET, CIRCUIT BREAKER 1
27 7971816304 BRACKET, CIRCUIT BREAKER 1
28 0017108020 HEX. HEAD BOLT 4
29 0021008045 MACHINE SCREW 4

0030008000 HEX. NUT 4

0040008000 LOCK WASHER 4

0041208000 PLAIN WASHER 4
30 7461861113 CHANGE-OVER BOARD, VOLTAGE 1
31 7431852104 CHANGE TERMINAL 10
32 0017108035 HEX. HEAD BOLT 20
33 7971852504 TERMINAL PLATE 7
34 7431853104 CHANGE PLATE 7
35 0801832504 HEX. HEAD BOLT 17
36 0040020000 LOCK WASHER 20
37 0041420000 PLAIN WASHER 20
38 0010110040 HEX. HEAD BOLT 4

0030010000 HEX. NUT 4

0040010000 LOCK WASHER 4

0041210000 PLAIN WASHER 4

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 73

CONTROL BOX ASSY.

DCA-500SSK — CONTROL BOX ASSY.

PAGE 74 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO PART NO PART NAME QTY. REMARKS

39 0602201245 APS UNIT 1 6008153600
40 0010010040 HEX.HEAD BOLT 4

0040010000 LOCK WASHER 4

0041210000 PLAIN WASHER 4
41 C4224001403 CONTROL PANEL 1
42 7971822603 CONTROL PANEL 1
42-1 0228800124 RUBBER SEAL 2
42-2 0228800100 RUBBER SEAL 2
43 0605011211 PIN 4
44 0601800480 FREQUENCY METER 1 PAL100 220V 45~65Hz
45 0601800780 AC AMMETER 1 PSK100 0~1000A 0~2000A
46 0601801040 CHANGE OVER SWITCH, AMMETER 1 SL2AS
47 0601800252 AC VOLTMETER 1 PCK100 0~600V
48 0601801041 CHANGE OVER SWITCH, VOLTMETER 1 SL2VS
49 0601810072 PILOT LAMP 1 LP132DC 220V

0601810261 BULB 1
50 061840073 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 WASHER 2

0041208000 PLAIN WASHER 2

0080200007 SNAP RING 2
59 3871824004 STOPPER, CONTROL PANEL 2
60 0041206000 PLAIN WASHER 2
61 0605010502 SNAP PIN 2
62 8481814503 COVER, CONTROL BOX 1
63 0017108020 HEX. HEAD BOLT 10
64 8481812104 SIDE PANEL, CONTROL BOX 1
65 7971812104 SIDE PANEL, CONTROL BOX 1
66 0017108020 HEX. HEAD BOLT 12
67 8481825104 PANEL, CONTROL BOX 1
68 8481825304 PANEL, CONTROL BOX 1
39 0017108020 HEX. HEAD BOLT 15
70 0017110030 HEX. HEAD BOLT 5
71 0017108020 HEX. HEAD BOLT 3
72 0801830904 HEX. HEAD BOLT 3

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 75

ENGINE & RADIATOR ASSY.

DCA-500SSK — ENGINE & RADIATOR ASSY.

PAGE 76 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4925200004 ENGINE ..................................................... 1 .......KOMATSU SA6D170BE-1

2 0602011985 RADIATOR .................................................. 1 ....... 6162639151

2-1 0602011058 CAP, RADIATOR ......................................... 1 .......23S0311150

3 0605000085 RUBBER SHEET........................................ 2 ....... 6995619230

4 0010120100 HEX. HEAD BOLT ...................................... 4

5 0030020000 HEX. NUT ................................................... 8

6 0040020000 LOCK WASHER ......................................... 4

7 0041220000 PLAIN WASHER ......................................... 8

8 8485123004 BRACKET, RADIATOR ............................... 2

9 0010112025 HEX. HEAD BOLT ...................................... 4

10 0040012000 PLAIN WASHER ......................................... 4

11 0041212000 PLAIN WASHER ......................................... 4

12 0017110025 HEX. HEAD BOLT ...................................... 4

13 0602013955 RADIATOR HOSE ...................................... 1 ....... 6995621450

14 0602014649 RADIATOR HOSE ...................................... 1 ....... 6162639650

15 0602013305 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 0602042146 CARTRIDGE, FUEL FILTER ...................... 3 .......6003118293

26 0602045149 CARTRIDGE, CORROSION RESISTOR.... 1 .......6004111161

27 7435112004 ENGINE FOOT ........................................... 1

28 8485112004 ENGINE FOOT ........................................... 2

29 0010118060 HEX. HEAD BOLT ...................................... 6

30 0030018000 HEX. NUT ................................................... 6

31 0040018000 LOCK WASHER ......................................... 6

32 0041218000 PLAIN WASHER ......................................... 6

33 0605000012 RUBBER SUSPENSION ............................ 4

34 0030020000 HEX. NUT ................................................... 8

35 0040020000 LOCK WASHER ......................................... 8

36 0602023160 PUMP ......................................................... 1 ....... GM2524H

37 0010108025 HEX. HEAD BOLT ...................................... 4

38 0041208000 PLAIN WASHER ......................................... 4

39 0207008000 HEX. NUT ................................................... 4

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 77

ENGINE & RADIATOR ASSY.

DCA-500SSK — ENGINE & RADIATOR ASSY.

PAGE 78 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — ENGINE & RADIATOR ASSY.

ENGINE & RADIATOR ASSY.

NO PART NO PART NAME QTY. REMARKS

40 0131710060 BUSHING ................................................... 1

41 0131708060 BUSHING ................................................... 1

42 0130206000 STREET ELBOW ....................................... 3

43 0602022202 HOSE JOINT .............................................. 1

45 0802024004 PACKING .................................................... 1

46 0191601350 HOSE ......................................................... 1

47 0605515134 HOSE BAND .............................................. 2

48 0602010230 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 0040018000 LOCK WASHER ......................................... 2

63 0041218000 PLAIN WASHER ......................................... 2

64 0017110025 HEX. HEAD BOLT ...................................... 1

65 0017112025 HEX. HEAD BOLT ...................................... 1

66 C4494600004 RUBBER SEAL .......................................... 1

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 79

ENGINE OPERATING PANEL ASSY.

DCA-500SSK — ENGINE OPERATING PANEL ASSY.

PAGE 80 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 8485312002 SUPPORT LEG 1
2 0010012035 HEX. HEAD BOLT 4

0030012000 HEX. NUT 4
0040012000 LOCK WASHER 4

0041212000 PLAIN WASHER 4
3 0017110025 HEX. HEAD BOLT 2
4 C4352100403 OPERATING PANEL 1
5 0017108020 HEX. HEAD BOLT 4
6 0017108020 HEX. HEAD BOLT 6
7 8085182004 RUBBER COVER 2
8 8085183004 SET FRAME, RUBBER COVER 2
9 0017106020 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 LOCK WASHER 2

0041208000 PLAIN WASHER 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 8482152104 GOVERNOR ROD 1
20 8482152004 GOVERNOR ROD 1
21 8482152204 GOVERNOR ROD 1
22 0602180106 BALL JOINT 3
23 0030008000 HEX. NUT 3
24 0207006000 HEX. NUT 3
25 0041206000 PLAIN WASHER 3
26 0802100704 PIN BOLT 1
27 0207006000 HEX. NUT 3
28 0041208000 PLAIN WASHER 2
29 0041206000 PLAIN WASHER 1

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 81

ENGINE OPERATING PANEL ASSY.

DCA-500SSK — ENGINE OPERATING PANEL ASSY.

PAGE 82 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — ENGINE OPERATING PANEL ASSY.

ENGINE OPERATING PANEL ASSY.

NO PART NO PART NAME QTY. REMARKS

30 0027105016 MACHINE SCREW 1
31 0602180105 BALL JOINT 2
32 0030008000 HEX. NUT 2
33 0207008000 HEX. NUT 2
34 0041208000 PLAIN WASHER 2
35 0602100049 STARTER SWITCH 1 6008155390
36 0602104045 EMERGENCY STOP BUTTON 1 0804610000
37 0602103043 PREHEAT INDICATOR 1 0814721200
38 0602120054 TACHOMETER 1 25000KX4110
39 0602120165 CABLE, TACHOMETER 1 62500KA8610
40 0602122060 OIL PRESSURE GAUGE 1 42000KX1410
41 0602122203 UNIT, OIL PRESSURE 1 53600KX0501
42 0602123061 WATER TEMPERATURE GAUGE 1 4000KX0910
43 0602123206 UNIT, WATER TEMPERATURE 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 1 0806130070
49 0601850267 GROMMET 1 SG30A
50 0602210809 CONTROLLER 1 181900193Z
51 8492233004 BRACKET 1
52 0027106012 MACHINE SCREW 3
53 0017108025 HEX. HEAD BOLT 2

0207008000 HEX. NUT 2
54 0802100204 JOINT 1
55 0802101204 SPRING 1
56 8482159304 BRACKET 1
57 00171010025 HEX. HEAD BOLT 2
58 3335048004 SPRING 1

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 83

OUTPUT TERMINAL ASSY.

DCA-500SSK — OUTPUT TERMINAL ASSY.

PAGE 84 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4231700603 SET BOARD, OUTPUT TERMINAL 1
2 7521860504 OUTPUT TERMINAL 4
3 7521850504 BRACKET, OUTPUT TERMINAL 4
4 0010112040 HEX. HEAD BOLT 8

0030012000 HEX. NUT 8

0040012000 LOCK WASHER 8

0041212000 PLAIN WASHER 16
5 0010112045 HEX. HEAD BOLT 8

0030012000 HEX. NUT 8

0040012000 LOCK WASHER 8

0041212000 PLAIN WASHER 8
6 0010112040 HEX. HEAD BOLT 24

0030012000 HEX. NUT 24

0040012000 LOCK WASHER 24

0041212000 PLAIN WASHER 48
7 0801830404 TERMINAL 1
8 0801830904 HEX. HEAD BOLT 1
9 0039320000 HEX. NUT 2
10 0040020000 LOCK WASHER 3
11 0041420000 PLAIN WASHER 4
12 0010112050 HEX. HEAD BOLT 6

0030012000 HEX. NUT 6

0040012000 LOCK WASHER 6

0041212000 PLAIN WASHER 12
13 0601850275 GROMMET 1
14 0601815324 TERMINAL BOARD 1 TS22P
15 0027104020 MACHINE SCREW 2
16 C4237101304 COVER, OUTPUT TERMINAL 1
17 7971867114 RUBBER SHEET 1
18 7521865804 SET PANEL, RUBBER SHEET 1
19 0019106020 HEX. HEAD BOLT 5

0042306000 LOCK WASHER 5

0042406000 PLAIN WASHER 5
20 0605010660 KNOB 2 KMM21xM6
21 0207006000 HEX. NUT 2
22 0010112045 HEX. HEAD BOLT 4
23 0041212000 PLAIN WASHER 4
24 0805009804 STAY RUBBER 4
25 0030012000 HEX. NUT 4
26 7521865603 STOPPER 1

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 85

OUTPUT TERMINAL ASSY.

DCA-500SSK — OUTPUT TERMINAL ASSY.

PAGE 86 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO PART NO PART NAME QTY. REMARKS

27 0010108030 HEX. HEAD BOLT 1

0030008000 HEX. NUT 1

0041208000 PLAIN WASHER 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 PLAIN WASHER 10
37 C4237101203 COVER 1

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 87

BATTERY ASSY.

DCA-500SSK — BATTERY ASSY.

PAGE 88 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — BATTERY ASSY.

BATTERY ASSY.

NO PART NO PART NAME QTY. REMARKS

1 0168719052 BATTERY 2 190H52
2 0805018904 BATTERY SHEET 2
3 0805007804 BATTERY BAND 2
4 0805006504 BATTERY BOLT 4
5 0037808000 WING NUT 4
6 0040008000 LOCK WASHER 4
7 0041208000 PLAIN WASHER 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 SENSOR 1

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 89

MUFFLER ASSY.

DCA-500SSK — MUFFLER ASSY.

PAGE 90 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — MUFFLER ASSY.

MUFFLER ASSY.

NO PART NO PART NAME QTY. REMARKS

1 8482311002 MUFFLER 1
2 0019210020 HEX. HEAD BOLT 4
3 7432356504 PACKING 2
4 7432356604 PACKING 1
5 7432356704 PACKING 1
6 0019110030 HEX. HEAD BOLT 14
7 0042310000 LOCK WASHER 14
8 0042410000 HEX. HEAD BOLT 14
9 0019108030 HEX. HEAD BOLT 8
10 0042308000 LOCK WASHER 8
11 0042408000 PLAIN WASHER 8
12 C4334000513 EXHAUST PIPE 1
13 0010116060 HEX. HEAD BOLT 8
14 0010116050 HEX. HEAD BOLT 8
16 0040016000 LOCK WASHER 16
17 0041216000 PLAIN WASHER 24
18 7472355003 OUTLET PIPE 1
19 C3334200704 GASKET 1
20 0010112050 HEX. HEAD BOLT 4
21 0030012000 HEX. NUT 4
22 0040012000 LOCK WASHER 4
23 0041212000 PLAIN WASHER 8
24 8225125604 COVER 2
25 0017108020 HEX. HEAD BOLT 4
26 0207008000 HEX. NUT 4
27 C4334200504 GASKET 2

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 91

FUEL TANK ASSY.

DCA-500SSK — FUEL TANK ASSY.

PAGE 92 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — FUEL TANK ASSY.

FUEL TANK ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4364000713 FUEL TANK 1
1-1 0605505005 CAP, FUEL TANK 1

0601850505 KEY 1
1-2 0810105400 FUEL FILTER 1
1-3 0264100425 HOSE, FUEL GAUGE 1
1-4 0605515079 HOSE BAND 2
2 7435523104 TANK BAND 2
3 0805003414 PAD, TANK BAND 4
4 0017108020 HEX. HEAD BOLT 2
5 0207308000 HEX. NUT 2
6 0221006000 TANK SHEET 6
7 0130206000 STREET ELBOW 1
8 7435517114 DRAIN PIPE 1
9 7525516504 BRACKET 1
10 0019108030 HEX. HEAD BOLT 2
11 0205008000 HEX. NUT 2
12 0042308000 LOCK WASHER 2
13 0042408000 PLAIN WASHER 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 1
23 0191104000 RETURN HOSE 1
24 0191001800 RETURN HOSE 1
25 0605515073 HOSE BAND 6
26 0605515000 HOSE BAND 2
27 0605503009 FUEL SENSOR 1
28 0802120604 PACKING 1
29 0605501050 UNIT, FUEL 1 52000KA9810
30 0602021155 PACKING 1 52391KW3700
31 0022905015 MACHINE SCREW 5
32 0845039604 RUBBER SEAL 1

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 93

ENCLOSURE #1 ASSY.

DCA-500SSK — ENCLOSURE #1 ASSY.

PAGE 94 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

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

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

DCA-500SSK — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO PART NO PART NAME QTY. REMARKS

1 8485111002 BASE 1
2 3875116304 FOOR PANEL 1
3 7435116104 FLOOR PANEL 1
4 0017108020 HEX. HEAD BOLT 18
5 8485118004 GUIDE PANEL, AIR 1
6 0017108020 HEX. HEAD BOLT 4
7 C4424002303 FRONT FRAME 1

C4494100103 LINING 1
8 C4424000503 FRONT FRAME 1

C4494100103 LINING 1
9 C4424000702 FRONT FRAME 1

C4494100103 LINING 1
10 C4424000602 FRONT FRAME 1

C4494100103 LINING 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 FILLER BRACKET 1
21 0019208020 HEX. HEAD BOLT 4
22 7525125304 COVER 1
23 0019206016 HEX. HEAD BOLT 6
24 C442420003 COVER, FRONT FRAME 1
25 0019208020 HEX. HEAD BOLT 12
26 0600500090 EMBLEM 1
27 0021106020 MACHINE SCREW 2
28 C4434000112 CENTER FRAME 1

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 95

ENCLOSURE #1 ASSY.

DCA-500SSK — ENCLOSURE #1 ASSY.

PAGE 96 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

DCA-500SSK — ENCLOSURE #1 ASSY.

ENCLOSURE #1 ASSY.

NO PART NO PART NAME QTY. REMARKS

29 0010120075 HEX. HEAD BOLT 6

0030020000 HEX.NUT 6

0040020000 LOCK WASHER 6

0041220000 PLAIN WASHER 12
30 0010120065 HEX. HEAD BOLT 8

0030020000 HEX. NUT 8

0040020000 LOCK WASHER 8

0041220000 PLAIN WASHER 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. HEAD BOLT 30

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 97

ENCLOSURE #2 ASSY.

DCA-500SSK — ENCLOSURE #2 ASSY.

PAGE 98 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)

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

THE SERIAL NUMBER MAY BE REQUIRED.

5 -BLACK
6 -CATERPILLAR YELLOW
7 -CATO GOLD
8 -RED

DCA-500SSK — ENCLOSURE #2 ASSY.

ENCLOSURE #2 ASSY.

NO PART NO PART NAME QTY. REMARKS

1 C4444000003 REAR FRAME 1
2 3875151004 LOUVER PANEL 1
3 0205006000 HEX. NUT 21

0042306000 LOCK WASHER 21

0042406000 PLAIN WASHER 21
4 C4444000103 REAR FRAME 1
5 C4444000203 REAR FRAME 1
6 C4444000303 REAR FRAME 1
7 0017110025 HEX. HEAD BOLT 18
8 0017108020 HEX. HEAD BOLT 5
9 0019210025 HEX. HEAD BOLT 4
10 7975155003 COVER, REAR FRAME 1

3875944104 LINING 1
11 3875151104 LOUVER PANEL 1
12 0205006000 HEX.NUT 16

0042306000 LOCK WASHER 16

0042406000 PLAIN WASHER 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 PLATE 1
22 3875147304 WINDOW PLATE 1
23 0207306000 HEX. NUT 12
24 B9114000102 DOOR HANDLE 1 139LKDNUSA
25 0021806016 MACHINE SCREW 4
26 7975146004 DOOR ROD 1
27 7975146104 DOOR ROD 1
28 0845050704 STAY 4
29 0207006000 HEX. NUT 8

DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 99

ENCLOSURE #2 ASSY.

DCA-500SSK — ENCLOSURE #2 ASSY.

PAGE 100 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01)