Page 3 - HERE'S HOW TO GET HELP
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 3 HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBERON-HAND WHEN CALLING P P P P PAR AR AR AR ARTS DEP TS DEP TS DEP TS DEP TS DEPAR AR AR AR ARTMENT TMENT TMENT TMENT TMENT 800/427-1244 or 310/537-3700FAX: 800/672-...
Page 4 - TABLE OF CONTENTS; NOTE
PAGE 4 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) TABLE OF CONTENTS Here's How To Get Help ............................................ 3Table Of Contents ..................................................... 4Parts Ordering Procedures .........................................
Page 5 - PARTS ORDERING PROCEDURES; at no charge for freight; at one-half of actual freight cost; UPS; Earn Extra Discounts when; to our Parts Department!; Extra Fax Discount
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 5 PARTS ORDERING PROCEDURES Get special freight allowanceswhen you order 10 or moreline items via FAX!** ■ UPS Ground Service at no charge for freight ■ PS Third Day Service at one-half of actual freight cost No other allowance...
Page 6 - RULES FOR SAFE OPERATION
PAGE 6 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) RULES FOR SAFE OPERATION ■ NEVER touch the hot exhaust manifold, muffler or cylinder. Allowthese parts to cool before servicingengine or generator. ■ The engine of this generator requires an adequate free flowof cooling air....
Page 7 - Never; Radiator; Removing the radiator cap while the; Coolant Drain Plug -; Removing the coolant drain; Engine Oil Drain Plug -; Removing the engine oil; NEVER; touch output terminals during operation. This is
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 7 RULES FOR SAFE OPERATION CAUTION: CAUTION: ■ Backfeed to a utility system can cause electrocutionand/or property damage. Do not connect to anybuilding's electrical system except through anapproved device or after building mai...
Page 8 - Battery; DO NOT
PAGE 8 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) ■ NEVER Run engine without air filter. Severe engine damage may occur. ■ Always service air cleaner frequently to prevent carburetormalfunction. ■ Always disconnect the battery before performing service onthe generator. ■ Al...
Page 10 - Towing Safety Precautions; Figure 1. Generator and Trailer
PAGE 10 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) To reduce the possibility of an accident while transportingthe generator on public roads, always make sure the trailer(Figure 1) that supports the generator and the towing vehicleare in good operating condition and both uni...
Page 14 - DCA-500SSK — TRAILER SAFETY GUIDELINES; Brakes
PAGE 14 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — TRAILER SAFETY GUIDELINES Brakes If your trailer has a braking system, the brakes should beinspected the first 200 miles of operation. This will allow thebrake shoes and drums to seat properly. After the first ...
Page 15 - Figure 2. Electrical Brake Components
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 15 DCA-500SSK — TRAILER SAFETY GUIDELINES Hydraulic/Air/Surge Brakes Hydraulic brakes (Figure 3) should not require any specialattention with the exception of routine maintenance such asshoe and lining replacement. These brakes...
Page 16 - Figure 4. Major Suspension Components; Suspension
PAGE 16 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) Tires/Wheels/Lug Nuts T i r e s a n d w h e e l s a r e a ver y i m p o r t a n t a n d c r i t i c a lcomponents of the trailer. When specifying or replacing thetrailer wheels it is important the wheels, tires, and axle ar...
Page 17 - Lug Nut Torque Requirements; After first road use, retorque all lug nuts in sequence.; Figure 5. Wheel Lug Nuts Tightening Sequence
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 17 s t n e m e r i u q e R e u q r o T n o i s n e p s u S . 3 e l b a T m e t I ) . s b L - . t F ( e u q r o T T L O B - U " 8 / 3 5 3 - X A M 0 3 - N I M T L O B - U " 6 1 / 7 0 6 - X A M 5 4 - N I M T L O B - U "...
Page 19 - DCA-500SSK — TRAILER BRAKES TROUBLESHOOTING
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 19 g n i t o o h s e l b u o r T e k a r B r i A . 6 e l b a T m o t p m y S e s u a C e l b i s s o P n o i t u l o S s e k a r B o N ? d e k n i k r o n e k o r b e n il e k a r B . e c a l p e r r o r i a p e R s e k a r B r...
Page 20 - Machine Safety Decals; DCA-500SSK — OPERATION AND SAFETY DECALS
PAGE 20 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) Machine Safety Decals The DCA-500SSK generator is equipped with a number of safety decals. These decals are provided for operator safetyand maintenance information. The illustrations below and on the preceding pages shows t...
Page 26 - DCA-500SSK — SPECIFICATIONS
PAGE 26 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — SPECIFICATIONS s n o i t a c i f i c e p S . 7 e l b a T s n o i t a c i f i c e p S r o t a r e n e G l e d o M K S S 0 0 5 - A C D e p y T e l g n i s , f o o r p - p i r d , e l o p - 4 , d e t a l i t n e v...
Page 27 - DCA-500SSK — GENERAL INFORMATION
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 27 DCA-500SSK — GENERAL INFORMATION DCA-500SSK FAMILIARIZATION Generator The MQ Power Model DCA-500SSK is a 550 kW gener gener gener gener generator ator ator ator ator that has been designed as a high quality portable (require...
Page 28 - DCA-500SSK — MAJOR COMPONENTS; Figure 6. Major Components
PAGE 28 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — MAJOR COMPONENTS Figure 6. Major Components
Page 29 - NOTE PAGE
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 29 NOTE PAGE
Page 30 - Figure 7a. Dimensions
PAGE 30 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — DIMENSIONS (TOP AND SIDE) Figure 7a. Dimensions
Page 31 - Figure 7b. Dimensions
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 31 Figure 7b. Dimensions DCA-500SSK — DIMENSIONS (FRONT AND REAR)
Page 32 - 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 Figure 8. Control Panel
Page 33 - Module
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 33 DCA-500SSK — CONTROL PANEL The definitions below describe the controls and functions ofthe DCA-500SSK " Control Panel Control Panel Control Panel Control Panel Control Panel " (Figure 8). 1. Pilot Lamp – Indicates th...
Page 34 - 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 Figure 10. Engine Operating Panel
Page 36 - Figure 11. Output Terminal Cover; DCA-500SSK — OUTPUT TERMINAL; Figure 13. Connection Receptacles
PAGE 36 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) Circuit Breakers To protect the generator from an overload, a 3-pole, 1400amp, main main main main main circuit breaker is provided to protect the UVWO output terminals from overload. In addition two single-pole,20 amp GFCI...
Page 37 - Figure 14. Output Terminal Panel Location
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 37 L e g s O a n d G r o u n d a r econsidered Bonded Grounds. NOTE DCA-500SSK — OUTPUT TERMINAL Figure 14. Output Terminal Panel Location
Page 38 - attempt to change the Voltage
PAGE 38 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) Output Terminal Panel Available Voltages A wide range of voltages are available to supply load tomany different applications. Voltages may be selected byusing the voltage change-over board and how to hookup thehard wire con...
Page 39 - Reading the Output Terminal Gauges; The gauges and knobs on the control panel; effect
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 39 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 observehow much power supply is produced at the UVWO legs. To read the output at ...
Page 40 - power at 240V. After hooking up the; FIGURE 20. Hard Wire Hookup for Three Phase 240V; power at 139V. After hooking up
PAGE 40 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — OUTPUT TERMINAL 3 Phase, 240 Volt The following connection, with the voltage change-overboard set into the 240V set position (See Figure 19), canoffer THREE PHASE power at 240V. After hooking up the hard wires ...
Page 41 - power at 480V. After hooking up the; FIGURE 24. Hard Wire Hookup for Three Phase 480V; power at 277V. After hooking up
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 41 DCA-500SSK — OUTPUT TERMINAL 480 Volt Set position The voltage change-over board 480V set position uses all6 plates in 3 different connection places. There are 2plates at every position (Every plate is used). See figure23 be...
Page 42 - Outdoor Installation; be routed to a ventilated area.; extremely; Generator Grounding; EARTH; Use one of the following wire types to connect the; DCA-500SSK — INSTALLATION; ALWAYS; consult with a licensed
PAGE 42 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) Outdoor Installation Install the generator in a location where it will not beexposed to rain or sunshine. Make sure the generator ison secure level ground so that it cannot slide or shift around.Also install the generator i...
Page 43 - Figure 27. Typical Generator Grounding Application
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 43 Figure 27. Typical Generator Grounding Application DCA-500SSK — INSTALLATION CAUTION : Always check Local, State, and FederalLaws before grounding generator.
Page 44 - To protect the generator from an overload,
PAGE 44 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) General Inspection Prior to Operation The DCA-500SSK generator has been thoroughlyinspected and accepted prior to shipment from the factory.However, be sure to check for damaged par ts orcomponents, or loose nuts and bolts,...
Page 45 - DO; fill the tank beyond capacity.; Figure 28. Engine Oil Dipstick; Komatsu Engine
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 45 Lubrication Oil Fill the engine crankcase with lubricating oil through the fillerhole, but do not overfill. Make sure the generator is level.With the dipstick inserted all the way, but without being screwinto the filler hole...
Page 46 - il; C A U T I O N; Cleaning the Radiator; Figure 29. Fan Belt Tension
PAGE 46 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — PRE-SETUP 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 Table12 for engine, radiator,...
Page 47 - Figure 30. Battery Connections
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 47 DCA-500SSK — PRE-SETUP Battery Cable InstallationALWAYS be sure the battery cables (Figure 30) are properly connected to the battery terminals as shown below. TheRED RED RED RED RED cable is connected to the positive termina...
Page 48 - DCA-500SSK — LOAD APPLICATION; Single Phase Load; WATTS = VOLTAGE x AMPERAGE; Three Phase Load; An inadequate size connecting cable
PAGE 48 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — LOAD APPLICATION Single Phase Load Always be sure to check the nameplate on thegenerator and equipment to insure the wattage,a m p e r a g e a n d f r e q u e n c y r e q u i r e m e n t s a r esatisfactorily s...
Page 49 - Load Circuit Breakers; BATTER; Figure 33. Battery Connections
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 49 WARNING: Before Starting Engine 1. Check the lubricating oil level prior to starting the engine. Make sure the generator is level. The oil level must bemaintained between two notches on the dipstick. 2. When there is not eno...
Page 50 - the 60 cycle output frequency in; HERTZ; Figure 34. Engine Enclosure Doors; Engine Running; Figure 39. MPEC Engine Running Status LED; the; MANUAL; engine begins to crank.; COLD; weather
PAGE 50 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) 9. The generator's frequency meter (Figure 40) displays the 60 cycle output frequency in HERTZ . Figure 40. Frequency Meter (Hz) 4. Close all engine enclosure doors (Figure 34). Figure 34. Engine Enclosure Doors Figure 38. ...
Page 51 - VOLTS; . If the voltage is not within; 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) Figure 41. Voltage Meter (Volts) 10. The generator's voltage meter (Figure 41) displays the 120 VAC in VOLTS . If the voltage is not within the specified frequency tolerance...
Page 52 - Figure 48. Main and GFCI Circuit Breakers; Turn the MAIN, GFCI and LOAD circuit breakers to; Figure 47. Engine Tachometer
PAGE 52 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) 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 currentwith res...
Page 54 - DCA-500SSK — GENERATOR SHUTDOWN PROCEDURE; Figure 51. Engine Speed Switch; Figure 54. Emergency Stop Button
PAGE 54 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — GENERATOR SHUTDOWN PROCEDURE Figure 52. Off/Manual Auto Switch (OFF) Engine Shutdown To shutdown the generator use the following procedure: Figure 51. Engine Speed Switch Figure 53. MPEC Engine Running Status L...
Page 56 - DCA-500SSK — MAINTENANCE
PAGE 56 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — MAINTENANCE General Inspection Prior to each use, the generating set should be cleaned andinspected for deficiencies. Check for loose, missing ordamaged nuts, bolts or other fasteners. Also check for fuelor oil...
Page 57 - Changing Oil
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 57 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 atlow idling. Keep the engine running at low idling andflush the radiator for about 10 mi...
Page 60 - DCA-500SSK—GENERATOR WIRING DIAGRAM; DCA-500SSK — ENGINE WIRING DIAG
PAGE 60 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK—GENERATOR WIRING DIAGRAM DCA-500SSK — ENGINE WIRING DIAG
Page 61 - RAM; DCA-500SSK—ENGINE WIRING DIAGRAM
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 61 RAM DCA-500SSK—ENGINE WIRING DIAGRAM
Page 66 - Items Found In the “Remarks” Column; Where indicated, this indicates a serial; All parts with same symbol in the number column,; EXPLANATION OF CODE IN REMARKS COLUMN
PAGE 66 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) How to read the marks and remarks used in this partsbook. 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- ...
Page 67 - Description; DCA-500SSK — SUGGESTED SPARE PARTS
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 67 NOTE DCA-500SSK w/SA6D170AE-1 KOMATSU ENGINE 1 to 5 Units 1 to 5 Units 1 to 5 Units 1 to 5 Units 1 to 5 Units Qty. P/N Description 20 ..... 6125817032 ... AIR FILTER30 ..... 6003117111 ... FUEL FILTER30 ..... 6002111231 ... ...
Page 80 - DCA-500SSK — ENGINE OPERATING PANEL ASSY.; 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.
Page 81 - PART NO
DCA-500SSK — PARTS AND OPERATION MANUAL (STD)— REV. #1 (04/14/01) — PAGE 81 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 PLAI...
Page 84 - 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.
Page 86 - OUTPUT TERMINAL ASSY.
PAGE 86 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) OUTPUT TERMINAL ASSY. DCA-500SSK — OUTPUT TERMINAL ASSY.
Page 108 - DCA-500SSK — NAMEPLATE AND DECALS; NAME PLATE AND DECALS
PAGE 108 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) DCA-500SSK — NAMEPLATE AND DECALS NAME PLATE AND DECALS
Page 112 - TERMS AND CONDITIONS OF SALE — PARTS
PAGE 112 — DCA-500SSK — PARTS AND OPERATION MANUAL (STD) — REV. #1 (04/14/01) PAYMENT TERMS Terms of payment for parts are net 10 days. FREIGHT POLICY All parts orders will be shipped collect orprepaid with the charges added to the invoice.All shipments are F.O.B. point of origin.Multiquip’s respons...
Page 114 - PARTS AND OPERATION MANUAL
HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBERON-HAND WHEN CALLING P P P P PAR AR AR AR ARTS DEP TS DEP TS DEP TS DEP TS DEPAR AR AR AR ARTMENT TMENT TMENT TMENT TMENT 800/427-1244 or 310/537-3700FAX: 800/672-7877 or 310/637-3284 SER SER SER SER SERVICE DEP VICE DEP VICE DEP VICE DEP...
