OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA800SSK2
60HZ GENERATOR (STD.)
(KOMATSU SAA6D170E-3 DIESEL ENGINE)
PARTS LIST NO. C5871301004
Revision # (09/03/09)
To fi nd the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
Diesel engine exhaust and some of
PAGE 2 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffi c Safety Administration (NHTSA) in addition to notifying Multiquip at
18004211244.
If NHTSA receives similar complaints, it may open an investigation, and if it
fi nds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip.
To contact NHTSA, you may either call the Vehicle Safety Hotline tollfree at
18883274236 (TTY: 18004249153), go to http://www.nhtsa.dot.gov; or write
to:
Administrator
NHTSA
1200 New Jersey Avenue S.E.
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safecar.gov.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 3
TABLE OF CONTENTS
DCA800SSK2
60 Hz Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects ......................................... 3
Table Of Contents .................................................... 4
Parts Ordering Procedures ...................................... 5
Safety Information ..............................................6-11
Specifi cations ........................................................ 12
Dimensions ............................................................ 13
Installation ........................................................ 14-15
General Information ............................................... 16
Major Components ................................................ 17
Generator Control Panel ................................... 18-19
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization .............. 22-23
Load Application .................................................... 24
Generator Outputs ................................................. 25
Generator Outputs/Gauge Reading ....................... 26
Output Terminal Panel Connections ................. 27-28
Inspection/Setup ............................................... 29-32
Generator StartUp Procedure (Manual) .......... 34-35
Generator StartUp Procedure (Auto Mode) ........... 36
Generator ShutDown Procedures ......................... 37
Maintenance ..................................................... 38-41
Trailer Maintenance .......................................... 42-45
Trailer Wiring Diagram ........................................... 46
Generator Wiring Diagram ..................................... 47
Engine Wiring Diagram .......................................... 48
Controller Wiring Diagram ..................................... 49
Controller Wiring Diagram (Main Breaker) ............. 49
Troubleshooting (Generator) .................................. 50
Troubleshooting (MPEC) ....................................... 51
Troubleshooting (Engine Controller) ...................... 52
Explanation Of Code In Remarks Column............. 54
Suggested Spare Parts ......................................... 55
Component Drawings
Generator Assembly ......................................... 56-59
Control Panel Assembly ................................... 60-61
Control Box Assembly ...................................... 62-65
Engine Assembly ............................................. 66-69
Radiator Assembly ...........................................70-71
Alternator Assembly .........................................72-73
Thermostat Assembly ....................................... 74-75
Water Pump Assembly ..................................... 76-77
Starter Assembly .............................................. 78-79
Engine Operating Panel Assembly ................... 80-81
Output Terminal Assembly ................................ 82-85
Battery Assembly.............................................. 86-87
Muffl er Assembly .............................................. 88-89
Fuel Tank Assembly ......................................... 90-91
Enclosure Assembly #1 .................................... 92-95
Enclosure Assembly #2 .................................... 96-99
Enclosure Assembly #3 ................................ 100-103
Rubber Seals Assembly ............................... 104-105
Nameplate and Decals Assembly ................ 106-111
Terms and Conditions Of Sale — Parts ............... 112
PAGE 4 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
N View Parts Diagrams
N Order Parts
N Print Specification Information
Goto www.multiquip.com and click on
Order Parts
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
to log in and save!
Order via Phone:
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
When ordering parts, please supply:
R Dealer Account Number
R Dealer Name and Address
R Shipping Address (if different than billing address)
R Return Fax Number
R Applicable Model Number
R Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
R Specify Preferred Method of Shipment:
UPS/Fed Ex DHL
N Priority One Tr uck
N Ground
N Next Day
N Second/Third Day
www.mqpower.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 5
SAFETY INFORMATION
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
PAGE 6 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
SAFETY INFORMATION
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
ALWAYS check the equipment for loosened threads or
bolts before starting.
DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NEVER use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fi re department. This information will be invaluable in
the case of an emergency.
GENERATOR SAFETY
DANGER
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
bodily harm or even death.
WARNING
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
NEVER disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
NEVER lubricate components or attempt service on a
running machine.
NOTICE
ALWAYS ensure generator is on level ground before use.
ALWAYS keep the machine in proper running condition.
Fix damage to machine and replace any broken parts
immediately.
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 and unauthorized personnel
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 7
SAFETY INFORMATION
ENGINE SAFETY
DANGER
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
The engine of this equipment
requires an adequate free
fl ow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
DO NOT place hands or fingers inside engine
compartment when engine is running.
NEVER operate the engine with heat shields or
guards removed.
Keep fi ngers, hands hair and clothing away
from all moving parts to prevent injury.
DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
suffi cient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak effi ciency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or fl ames
from the engine exhaust. Spark arresters are qualifi ed
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
PAGE 8 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
SAFETY INFORMATION
FUEL SAFETY
DANGER
DO NOT start the engine near spilled fuel or combustible
fl uids. Diesel fuel is extremely fl ammable and its vapors
can cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DO NOT overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
Refer to MQ Power trailer manual for additional safety
information.
In order to reduce the possibility of an accident while
transporting the generator on public roads, ALWAYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
ALWAYS shutdown engine before transporting
Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
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 towing vehicle and
trailer. Trailer tires should be infl ated to 50 psi cold.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a safety
chain.
ALWAYS properly attach trailer’s safety chains to towing
vehicle.
ALWAYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
DOT Requirements include the following:
• Connect and test electric brake operation.
• Secure portable power cables in cable tray with tie
wraps.
The maximum speed for highway towing is 55 MPH unless
posted otherwise. Recommended off-road towing is not to
exceed 15 MPH or less depending on type of terrain.
Avoid sudden stops and starts. This can cause skidding,
or jack-knifi ng. Smooth, gradual starts and stops will
improve towing.
Avoid sharp turns to prevent rolling.
Trailer should be adjusted to a level position at all times
when towing.
Raise and lock trailer wheel stand in up position when
towing.
Place chock blocks underneath wheel to prevent rolling
while parked.
Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 9
SAFETY INFORMATION
ELECTRICAL SAFETY
DANGER
DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
NEVER insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
ALWAYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
NEVER use gas piping as an electrical ground.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power from the
generator is being transferred to a load.
NEVER use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
PAGE 10 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
SAFETY INFORMATION
BATTERY SAFETY
DANGER
DO NOT drop the battery. There is a possibility that the
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
Use well-insulated gloves when picking up the battery.
ALWAYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
ENVIRONMENTAL SAFETY
NOTICE
Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel fi lters.
DO NOT use food or 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.
ALWAYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the NEGATIVE battery terminal
before performing service on the generator.
ALWAYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 11
Generator Specifi cationsTable 1.
Model DCA800SSK2 (Standard)
Type
Armature Connection Star with Neutral
Phase
Standby Output
Prime Output
Revolving fi eld, self ventilated,
open protected type synchronous generator
3
880 kVA (704 kW)
800 kVA (640 kW)
SPECIFICATIONS
Voltage - 1 Ø
Voltage - 3 Ø
Frequency
Speed
Power Factor
Aux. AC Power
Aux. Voltage/Output
Dry Weight
Wet Weight
Model
Type
No. of Cylinders
Bore x Stroke
Displacement
Rated Output
Starting
Coolant Capacity
Lube Oil Capacity
Fuel Type
Fuel Tank Capacity
Fuel Consumption
Battery
120, 127, 139, 240, 254, 277V Adjustable
208, 220, 240, 416, 440, 480V Reconnectable
60 Hz
1800 rpm
0.8
Single Phase, 60 Hz
4.8 Kw (2.4 kW x 2)
23,634 lbs. (10,720 kg.)
25,308 lbs. (11,479 kg.)
Engine Specifi cationsTable 2.
KOMATSU SAA6D170E3
4 cycle, watercooled, direct injection, turbocharged
airtoair intercooled
6 cylinders
6.69in. x 6.69 in. (170 mm x 170 mm)
1413 cu. in. (23,150 cc)
1008 HP/1800 RPM
Electric 24 VDC
40.4 gal. (153 liters)
37.2 gal. (141 liters)
#2 Diesel Fuel
129.5 gal. (490 liters)
41.3 gal. (156.5 L)/hr at full load 30.8 gal. (116.4 L)/hr at 75% load
22.6 gal. (85.9 L)/hr at 50% load 14.5 gal. (54.9 L)/hr at 25% load
12V 200Ah x 4 (24V System)
PAGE 12 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
DIMENSIONS
DimensionsFigure 1.
DimensionsTable 3.
Reference
Letter
A 43.31 in. (1,100 mm.) H 32.68 in. (830 mm.)
B 36.22 in. (920 mm.) I 39.37 in. (1000 mm.)
C 27.17 in. (690 mm.) J 29.53 in. (750 mm.)
D 43.31 in. (1,100 mm.) K 240.54 in. (6110 mm.)
E 29.53 in. (750 mm.) L 98.43 in. (2500 mm.)
F 39.37 in. (1000 mm.) M 76.77 in. (1950 mm.)
G 32.68 in. (830 mm.)
Dimension in. (mm) Reference Letter Dimension in. (mm)
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 13
INSTALLATION
Typical Generator Grounding ApplicationFigure 2.
PAGE 14 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
INSTALLATION
OUTDOOR INSTALLATION
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. 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
that the exhaust will not be discharged in the direction of
nearby homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should 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 have a tendency to cause excessive wear to
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.
GENERATOR GROUNDING
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground (Figure 2).
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifi es that 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 25064(b) and 25066 set the following
grounding requirements:
Use one of the following wire types to connect the 1.
generator to earth ground.
Copper 10 AWG (5.3 mm2) or larger.a.
Aluminum 8 AWG (8.4 mm2) or larger.b.
When grounding the generator (Figure 2) connect the 2.
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.
INDOOR INSTALLATION
Exhaust gases from diesel engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
MOUNTING
The generator must be mounted on a solid foundation (such
as concrete) and set fi rmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the fl oor or grade level (in
accordance to NFPA 110, Chapter 54.1). DO NOT remove
the metal skids on the bottom of the generator. They are
to resist damage to the bottom of the generator and to
maintain alignment.
NEC article 25052(c) specifi es that the earth ground rod 3.
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 15
GENERAL INFORMATION
GENERATOR
The MQ Power Model DCA800SSK2 is a 640 kW generator
(Figure 3) that is 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 OPERATING PANEL
The “Engine Operating Panel” is provided with the following:
Tachometer
Emergency Stop Switch
Water Temperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Fuel Level Gauge
Pilot Lamp
PreHeat Lamp
Engine Speed Switch
Battery Switch
Engine Alarm Lamps (6)
GENERATOR CONTROL PANEL
The “Generator Control Panel” is provided with the following:
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter ChangeOver Switch
Voltmeter ChangeOver Switch
Voltage Regulator
Panel Light/Panel Light Switch
3Pole, 2500 amp Main Circuit Breaker
“Control Box” (located behind the Gen. Control Panel)
Automatic Voltage Regulator•
Current Transformer•
OverCurrent Relay•
Voltage Rectifi er•
Starter Relay•
Engine Controller (Computer Controlled)•
Voltage ChangeOver Board•
OUTPUT TERMINAL PANEL
The “Output Terminal Panel” is provided with the following:
Three 240/139V output receptacles (CS6369), 50A
Three auxiliary circuit breakers, 50A
Eight output terminal lugs (3Ø power)
Battery Charger (Optional)
Water Heater (Optional)
OPEN DELTA EXCITATION SYSTEM
The DCA800SSK2 generator is equipped with the state
of the art “OpenDelta” excitation system. The open delta
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectifi ed and are the
excitation current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the confi guration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The opendelta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a “fi xed ceiling” and responds
according the demands of the required load.
ENGINE
The DCA800SSK2 is powered by a 6 cylinder, water
cooled, direct injection, turbocharged airtoair KOMATSU
SAA6D170E3 Diesel Engine. This engine is designed to
meet every performance requirement for the generator.
Reference Table 2 for engine specifi cations.
In keeping with MQ Power’s policy of constantly improving
its products, the specifi cations quoted herein are subject
to change without prior notice.
ELECTRIC GOVERNOR SYSTEM
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
EXTENSION CABLES
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 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 chart (Table 6) as a
guide for selecting proper extension cable size.
PAGE 16 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
MAJOR COMPONENTS
Generator Major ComponentsTable 4.
ITEM NO. DESCRIPTION
1 Air Filter Assembly
2 Muffl er Assembly
3 Fuel Tank Assembly
4 Engine Operating Panel Assembly
5 Battery Assembly
6 Output Terminal Panel Assembly
7 Generator Assembly
8 Generator Control Panel Assembly
9 Engine Control Panel Assembly
Major ComponentsFigure 3.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 17
GENERATOR CONTROL PANEL
Generator Control PanelFigure 4.
The defi nitions below describe the controls and functions of
the DCA800SSK2 Generator Control Panel (Figure 4).
AC Voltmeter 1. — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
Pilot Lamp 2. — Indicates the system is running.
Panel Light 3. — Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
Frequency Meter 4. — Indicates the output frequency
in hertz (Hz). Normally 60 Hz.
AC Ammeter 5. — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phaseselector switch.
Voltmeter ChangeOver Switch 6. — 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.
Ammeter ChangeOver Switch 9. — This switch allows
the AC ammeter to indicate the current fl owing to the load
connected to any phase of the output terminals, or to be
switched off. This switch does not effect the generator
output in any fashion, it is for current reading only.
Circuit Breaker (ON) Switch10. — Press this switch to
place the 2500 amp circuit breaker in the closed (ON)
position.
Circuit Breaker (OFF) Switch11. — Press this switch to
place the 2500 amp circuit breaker in the open (OFF)
position.
CIircuit Breaker (ON) Lamp12. — When the circuit breaker
ON switch is placed in the ON position this lamp willl be
turned ON.
CIircuit Breaker (OFF) Lamp 13. — When the circuit
breaker ON switch is placed in the OFF position this
lamp will be turned ON.
Panel Light Switch 7. — When activated will turn on
control panel light.
Voltage Regulator Control 8. — Allows ±15% manual
adjustment of the generator’s output voltage.
PAGE 18 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR CONTROL PANEL
Auto On/Off Engine Controller (MPEC) 14. — This
controller has a vertical row of status LED’s (inset), that
when lit, indicate that an engine malfunction (fault) has
been detected. When a fault has been detected the
engine controller will evaluate the fault and all major
faults will shutdown the generator. During cranking
cycle, The MPEC will attempt to crank the engine for
10 seconds before disengaging.
If the engine does not engage
(start) by the third attempt, the
engine will be shutdown by the
engine controller’s Over Crank
Protection mode. If the engine
engages at a speed (RPM’s)
that is not safe, the controller will
shutdown the engine by initializing the Over Speed
Protection mode.
Also the engine controller will shut down the engine 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 controller module.
Overcrank Shutdown — Indicates the unit has
attempted to start a pre programmed number of timesand
has failed to start. The number of cycles and duration are
programmable. It is preset at 3 cycles with a 10second
duration. This is considered a major fault.
Overspeed Shutdown — Indicates the engine is running
at an unsafe speed. This is considered a major fault.
Engine Running — Indicates that engine is running at
a safe operating speed.
Located behind the generator control panel is the
Generator Control Box. This box contains some of the
necessary electronic components required to make the
generator function.
The Control Box is equipped with the following major
components:
OverCurrent Relay
Voltage Rectifi er (AVR)
Starter Relay
Current Transformer
MPEC Control Switch — This switch controls the
running of the unit. If this switch is set to the OFF/RESET
position, the unit will not run. When this switch is set to the
manual position, the generator will start immediately.
If the generator is to be connected to a building’s AC
power source via a transfer switch (isolation), place the
switch in the AUTO position. In this position, should an
outage occur, the automatic transfer switch (ATS) will
start the generator automatically via the generator’s
autostart contacts connected to the ATS’s start contacts.
Please refer to your ATS installation manual for further
instructions for the correct installation of the autostart
contacts of the geerator to the ATS.
Low Oil Pressure — Indicates the engine pressure
has fallen below a safe operating level. The oil pressure
is detected using variable resistive values from the
oil pressure sending unit. This is considered a major
fault.
High Coolant Temperature — Indicates the engine
temperature has exceeded a safe operating level. The
engine temperature is detected using variable resistive
values from the temperature sending unit. This is
considered a major fault.
Voltage ChangeOver Board
Three Phase Circuit Breaker
NOTICE
Remember the overcurrent relay monitors the current
fl owing from the U,V, and W Output Terminal Lugs
to the load.
In the event of a short circuit or over current condition,
it will automatically trip the 2500 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 19
ENGINE OPERATING PANEL
L
Engine Operating PanelFigure 5.
The defi nitions below describe the controls and functions
of the DCA800SSK2 Engine Operating Panel (Figure 5).
Battery Switch 1. — 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.
Engine Speed Switch 2. — This switch controls the
speed of the engine (low/high).
PreHeat Lamp 3. — When ECU is placed in AUX
position, preheat lamp will be ON. When preheat cycle
is completed, lamp will turn OFF.
PreHeat Button 4. — Push this button when the engine
is ready for starting during cold weather operating
conditions. Keep pushing until the preheat lamp is
off.
Emergency Stop Button 5. — Push this button inward to
stop the engine in the event of an emergency. DO NOT
use this button as a means of stopping the engine.
Tachometer 6. — 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.
Oil Pressure Gauge 7. — During normal operation this
gauge be should read between 28 to 85 psi. (193~586
kPa). When starting the generator the oil pressure may
read a little higher, but after the engine warms up the oil
pressure should return to the correct pressure range.
Water Temperature Gauge 8. — During normal
operation this gauge be should read between 167°
and 203°F (75°~95°C).
Charging Ammeter Gauge 9. — Indicates the current
being supplied by the engine’s alternator which
provides current for generator’s control circuits and
battery charging system.
Fuel Gauge 10. — Indicates amount of diesel fuel available.
Engine Warning Lamps 11. — There are six engine
warning lamps, they are defi ned as follows:
Overheat Lamp a. — 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.
Low Oil Pressure Lamp b. — During
normal operation of the generator this
lamp should remain OFF. When the
AutoOFF/ResetManual switch is set to
the MANUAL position to start the engine,
the lamp will be lit. When the oil pressure
rises after startup the lamp will go OFF. If this lamp
is ever lit (ON) during normal operation of the
generator, the emergency shutdown device will stop
the engine automatically.
Low Fuel Level Lamp c. — When this lamp
is ON, it is time to stop the engine and
add fuel. Remember to let the engine cool
before adding fuel.
Air Filter Alarm d. — When the air fi lter
element is clogged, this lamp goes ON
indicating the element should be
immediately cleaned or replaced.
Oil Filter Alarm e. — This lamp goes ON
when the coolant level is low. If this lamp
goes ON while the engine is in operation,
the emergency shutdown device will
COOLANT LEVE
automatically stop the engine.
Water Level Lamp f. — This lamp goes ON
when the coolant level is low. If this lamp
goes ON while the engine is in operation,
the emergency shutdown device will
automatically stop the engine.
PAGE 20 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
NOTES
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 21
OUTPUT TERMINAL PANEL FAMILIARIZATION
OUTPUT TERMINAL PANEL
The Output Terminal Panel (Figure 6) shown below is
located on the righthand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.
NOTICE
Terminal legs “O” and “Ground” are considered bonded
grounds.
OUTPUT TERMINAL FAMILIARIZATION
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
Three (3) 120/240V output receptacles @ 50 amp
Three (3) Circuit Breakers @ 50 amps
Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)
Output Terminal PanelFigure 6.
PAGE 22 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
OUTPUT TERMINAL PANEL FAMILIARIZATION
Twist Lock Dual Voltage 240/139 VAC Receptacles
There are three 240/139V, 50 amp auxiliary twistlock
(CS6369) receptacles (Figure 7) provided on the output
terminal panel..
240/139V TwistLock Auxiliary Figure 7.
Receptacles
Each auxiliary receptacle is protected by a 50 amp
circuit breaker. These breakers are located directly above
the auxiliary receptacles. Remember the load output
(current) on all three receptacles is dependent on the load
requirements of the Output Terminal Lugs.
Connecting Loads
Loads can be connected to the generator by the Output
Terminal Lugs or the convenience receptacles (Figure 9).
Make sure to read the operation manual before attempting
to connect a load to the generator.
To protect the output terminals from overload, a 3pole,
2500A main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Connecting LoadsFigure 9.
Over Current Relay
Turn the voltage regulator control knob (Figure 8) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will increase the voltage, turning the knob
counterclockwise will decrease the voltage.
Voltage Regulator Control KnobFigure 8.
An over current relay (Figure 10) is connected to the main
circuit breaker. In the event of an overload, 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 in the control box.
Over Current RelayFigure 10.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 23
LOAD APPLICATION
SINGLE PHASE LOAD
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage 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 infl uenced by the effi ciency, power factor
and starting system of the equipment.
NOTICE
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
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
Power Factor By LoadTable 5.
Type of Load Power Factor
Singlephase induction motors 0.40.75
THREE PHASE LOAD
When calculating the power requirements for 3phase power
use the following equation:
NOTICE
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
Motors and motordriven equipment draw much greater
current for starting than during operation.
An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can
burn out the appliance or tool and overheat the cable. See
Table 6.
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.
Electric heaters, incandescent lamps 1.0
Fluorescent lamps, mercury lamps 0.40.9
Electronic devices, communication
equipment
1.0
Common power tools 0.8
Cable Selection (60 Hz, Single Phase Operation)Table 6.
Current
in
Amperes
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.
5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft.
15 1800 3600 150 ft. 100 ft. 65 ft.
20 2400 4800 125 ft. 75 ft. 50 ft.
Load in Watts Maximum Allowable Cable Length
At 100
Volts
CAUTION: Equipment damage can result from low voltage
At 200
Volts
#10 Wire #12 Wire #14 Wire #16 Wire
When connecting a fl uorescent 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.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
PAGE 24 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR OUTPUTS
GENERATOR OUTPUT VOLTAGES
A wide range of voltages are available to supply voltage
for many different applications. Voltages are selected by
applying jumpers (6) to the voltage changeover board
(Figure 11). To obtain some of the voltages as listed in
Table 7 (see below) will require a fi ne adjustment using
the voltage regulator (VR) control knob located on the
control panel.
Voltage ChangeOver Board
The voltage changeover board (Figure 11) is located on
the control box, behind the generator control panel. This
board has been provided for ease of voltage selection.
Generator Amperage
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed.
Generator Maximum AmpsTable 8.
Rated Voltage Maximum Amps
1Ø 120 Volt 1777.8 amps (4 wire)
1Ø 240 Volt 888.9 amps (4 wire)
3Ø 240 Volt 1924.6 amps
3Ø 480 Volt 962.3 amps
Voltage ChangeOver BoardFigure 11.
CAUTION
NEVER attempt to place jumper plates on the voltage
changeover board while the generator is in operation.
There exist the possibility of electrocution, electrical
shock or burn, which can cause severe bodily harm
or even death!
Voltages AvailableTable 7.
Three Phase
(Switchable)
Single Phase
(Switchable)
208V 220V 240V 416V 440V 480V
120V 1127V 139V 240V 254V 277V
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 25
GENERATOR OUTPUTS/GAUGE READING
HOW TO READ THE AC AMMETER AND AC
VOLTAGE GAUGES
The AC ammeter and AC voltmeter gauges are controlled by
the AC ammeter and AC voltmeter changeover switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
Before taking a reading from either gauge, confi gure the
Voltage ChangeOver Board (Figure 12) which produces
the desired output voltage.
AC Ammeter Gauge Reading
Place the AC Ammeter ChangeOver Switch (Figure 16)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 16). This process can be repeated for
terminals V and W.
AC AmmeterFigure 15.
ChangeOver Switch
(Amp reading on U Lug
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
AC Ammeter Figure 16.
Voltage ChangeOver BoardFigure 12.
240/3
Ø Position
AC Voltmeter Gauge Reading
Place the AC Voltmeter ChangeOver Switch (Figure 13)
in the WU position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 14).
AC Voltmeter Figure 13.
ChangeOver Switch
AC Voltmeter GaugeFigure 14.
(Volt reading on WU Lug
PAGE 26 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO TERMINAL OUTPUT VOLTAGES
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the placement of the jumpers plates (6)
on the Voltage ChangeOver Board (Figure 17) and the
adjustment of the Voltage Regulator Control Knob.
Remember the voltage changeover board determines the
range of the output voltage and can be confi gured in two
different positions that provide 6 different output voltages
at the UVWO output terminals. The generator is shipped
from the factory in the 240V confi guration. The voltage
regulator (VR) allows the user to increase or decrease the
selected voltage.
3Ø-240V UVWO Terminal Output Voltages
Jumper the voltage changeover board for 240V 1.
operation as shown in Figure 17.
Turn the voltage regulator knob (Figure 19) clockwise 3.
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fi ne tuning of the output
voltage is required
Voltage Regulator KnobFigure 19.
1Ø-240V UVWO Terminal Output Voltages
Make sure the voltage changeover board is jumpered 1.
for 240V operation as shown in Figure 17.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 20.
Voltage ChangeOver Board 240V Figure 17.
Confi guration
Connect the load wires to the UVWO terminals as 2.
shown in Figure 18.
UVWO Terminal Lugs 1Ø240V Figure 20.
Connections
1Ø-120V UVWO Terminal Output Voltages
Make sure the voltage changeover board is jumpered 1.
for 240V operation as shown in Figure 17.
Adjust voltage regulator knob (Figure 19) for an output 2.
of 208V to obtain 120V at the UVWO terminals.
Connect the load wires to the UVWO terminals as 3.
shown in Figure 21.
UVWO Terminal LugsFigure 18.
UVWO Terminal Lugs Figure 21. 1Ø139V
Connections
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 27
OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480V UVWO Terminal Output Voltages
Jumper the voltage changeover board for 480V 1.
operation as shown in Figure 22. This confi guration
uses 6 jumper plates in 3 different positions. Remember
there are 2 jumper plates at every position. Every
jumper plate must be used.
Voltage ChangeOver Board 480V Figure 22.
Confi guration
Connect the load wires to the UVWO terminals as 2.
shown in Figure 23.
1Ø-480V UVWO Terminal Output Voltages
Make sure the voltage changeover board is jumpered 1.
for 480V operation as shown in Figure 22.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 24.
UVWO Terminal Lugs 1Ø480V Figure 24.
Connections
1Ø-277V UVWO Terminal Output Voltages
Make sure the voltage changeover board is jumpered 1.
for 480V operation as shown in Figure 22.
UVWO Terminal Lugs 3Ø480V Figure 23.
Connections
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exists, that could cause a fi re.
Connect the load wires to the UVWO terminals as 2.
shown in Figure 25.
UVWO Terminal Lugs 1Ø277V Figure 25.
Connections
PAGE 28 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
INSPECTION/SETUP
CIRCUIT BREAKERS
To protect the generator from an overload, a 3pole, 2500
amp, main circuit breaker is provided to protect the U,V,
and W Output Terminals from overload. In addition, three
50 amp load circuit breakers have been provided to protect
the auxiliary receptacles from overload. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
LUBRICATION OIL
Fill the engine crankcase with lubricating oil through the
fi ller hole, but DO NOT overfi ll. Make sure the generator is
level and verify that the oil level is maintained between the
two notches (Figure 26) on the dipstick. See Table 11 for
proper selection of engine oil.
Engine Oil DipstickFigure 26.
When checking the engine oil, be sure to check if the oil
is clean. If the oil is not clean, drain the oil by removing
the oil drain plug, and refi ll with the specifi ed amount of oil
as outlined in the Komatsu Engine Owner’s Manual. Oil
should be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
FUEL CHECK
DANGER
Fuel spillage on a hot engine can cause
a fi re or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refi lling the Fuel System
CAUTION
ONLY properly trained personnel who have read
and understand this section should refi ll the fuel tank
system.
This generator has an internal fuel tank located inside
the trailer frame and may also be equipped with an
environmental fuel tank (Figure 27). ALWAYS fi ll the fuel
tanks with clean fresh #2 diesel fuel. DO NOT fi ll the fuel
tanks beyond their capacities.
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after fi lling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
API Service Classifi cation CC/SC
API Service Classifi cation CC/SD
API Service Classifi cation CC/SE
API Service Classifi cation CC/SF
Recommended Motor OilTable 9.
Internal Fuel Tank SystemFigure 27.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 29
INSPECTION/SETUP
Refueling Procedure:
WARNING
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
Level Tanks1. — Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 28).
CAUTION
ALWAYS place trailer on fi rm level ground before
refueling to prevent spilling and maximize the amount
of fuel that can be pumped into the tank.
Open cabinet doors on the “right side” of the generator 2.
(from generator control panel position). Remove fuel
cap and fi ll tank (Figure 29).
Fueling the GeneratorFigure 29.
NEVER overfi ll fuel tank3. — It is important to read the
fuel gauge when fi lling trailer fuel tank. DO NOT wait
for fuel to rise in fi ller neck (Figure 30).
Only Fill on Level GroundFigure 28.
NOTICE
ONLY use #2 diesel fuel when refueling.
Full Fuel TankFigure 30.
CAUTION
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 31).
Fuel ExpansionFigure 31.
PAGE 30 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
INSPECTION/SETUP
COOLANT (ANTIFREEZE/SUMMER COOLANT/
WATER)
Komatsu recommends antifreeze/summer coolant for use in
their engines, which can be purchased in concentrate (and
mixed with 50% demineralized water) or prediluted. See the
Komatsu Engine Owner’s Manual for further details.
WARNING
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe burns.
Daytoday addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 10 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the “H” and the “L” markings.
CLEANING THE RADIATOR
The engine may overheat if the radiator fi ns become
overloaded with dust or debris. Periodically clean the
radiator fi ns with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
AIR CLEANER
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the Komatsu Engine Owner’s Manual.
FAN BELT TENSION
A slack fan belt may contribute to overheating, or to
insuffi cient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
Komatsu Engine Owner’s Manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 32) when depressed with the thumb as shown
below.
Coolant CapacityTable 10.
Engine and Radiator 40.4 gal (153.0 liters)
Reserve Tank N/A
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 11) has been added.
AntiFreeze Table 11.
Operating Temperatures
Vol %
AntiFreeze
50 37 34
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
Freezing Point
°C °F
Fan Belt TensionFigure 32.
CAUTION
NEVER place hands near the belts or fan
while the generator set is running.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 31
INSPECTION/SETUP
BATTERY
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fl uid level between the specifi ed
marks. Battery life will be shortened, if the fl uid level are
not properly maintained. Add only distilled water when
replenishment is necessary.
DO NOT over fill. 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 an approved battery
terminal treatment compound. Replace battery with only
recommended type battery.
The battery is suffi ciently charged if the specifi c gravity
of the battery fl uid is 1.28 (at 68° F). If the specifi c gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Battery Cable Installation
When connecting battery do the following:
NEVER1. connect the battery cables to the battery
terminals when the MPEC Control Switch is in either
the MANUAL position. ALWAYS make sure that the
MPEC Control Switch is in the OFF/RESET position
when connecting the battery.
Place a small amount of battery terminal treatment 2.
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
NOTICE
If the battery cable is connected incorrectly, electrical
damage to the generator will occur. Pay close attention to
the polarity of the battery when connecting the battery.
CAUTION
Inadequate battery connections may cause poor starting
of the generator, and create other malfunctions.
ALWAYS be sure the battery cables (Figure 33) are
properly connected to the battery terminals as shown below.
The red cable is connected to the positive terminal of the
battery, and the black cable is connected to the negative
terminal of the battery.
CAUTION
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
Battery ConnectionsFigure 33.
ALTERNATOR
The polarity of the alternator is negative grounding type.
When an inverted circuit connection takes place, the
circuit will be in short circuit instantaneously resulting the
alternator failure.
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrosion and damage the
alternator.
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.
PAGE 32 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR STARTUP PROCEDURE (MANUAL)
BEFORE STARTING
CAUTION
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
WARNING
NEVER manually start the engine with the main, or
auxiliary circuit breakers in the ON (closed) position.
If applicable perform the following:
Apply commercial power to the internal battery charger
receptacle (to ensure good starting) via commercial
power. An external power cord will be required. This
capability is an option.
Apply commercial power to the jacket water heater
receptacle (not necessary for warm climates) via
commercial power. An external power cord will be
required. This capability is an option.
Place the three3. auxiliary circuit breakers (Figure 36) in
the OFF position prior to starting the engine.
Auxiliary Figure 36.
Circuit Breakers (OFF)
Connect the load to the UVWO terminals or auxiliary 4.
receptacles as shown in Figure 37. These load
connection points can be found on the output terminal
panel. To gain access to the UVWO busbar terminals
or other power receptacles, unlock the access cover
and lift the door.
Press the main circuit breaker “OFF” switch (Figure 34).1.
Main Circuit Breaker OFF SwitchFigure 34.
Verify that the 2. main circuit breaker “OFF” lamp (Figure
35) is lit (ON).
Main Circuit Breaker OFF LampFigure 35.
Load ConnectionsFigure 37.
Tighten the UVWO terminal nuts securely to prevent 5.
load wires from slipping out.
Close all engine enclosure doors (Figure 38).6.
INCORRECTCORRECT
Engine Enclosure DoorsFigure 38.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 33
GENERATOR STARTUP PROCEDURE (MANUAL)
STARTING (MANUAL)
Set the 1. battery ON/OFF switch (Figure 39) to the "ON"
position.
Battery Switch (ON)Figure 39.
Place the 2. engine speed switch in the "LOW" position
(Figure 40).
Engine Speed Switch (Low)Figure 40.
Place the 3. MPEC control switch in the MANUAL
position to start the engine (Figure 41).
MPEC Control Switch Figure 41.
(Manual Position)
The generator’s frequency meter (Figure 44) should be 6.
displaying the 60 cycle output frequency in HERTZ.
Frequency MeterFigure 44.
The generator’s ACvoltmeter (Figure 45) will display 7.
the generator’s output in VOLTS..
VoltmeterFigure 45.
If the voltage is not within the specifi ed tolerance, use 8.
the voltage adjustment control knob (Figure 46) to
increase or decrease the desired voltage.
Press and hold the engine pre-heat button (Figure 42). 4.
Verify that the pre-heat lamp is lit. Continue pressing
button until pre-heat cycle is complete. After completion
of the pre-heating cycle, the light will go OFF and the
engine will start up automatically.
Pre-Heat Lamp/Pre-Heat ButtonFigure 42.
Once the engine starts, let the engine run for 12 5.
minutes. Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct
the problem. If the engine is running smoothly, place
the engine speed switch (Figure 43) in the HIGH (up)
position.
Engine Speed Switch (High)Figure 43.
Voltage Adjust Control KnobFigure 46.
Verify that the 9. engine running status LED on the
MPEC module (Figure 47) is lit (ON) after the engine
has started.
Engine Running LED (ON)Figure 47.
The ammeter (Figure 48) will indicate 10. zero amps with
no load applied. When a load is applied, the ammeter
will indicate the amount of current that the load is
drawing from the generator.
PAGE 34 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR STARTUP PROCEDURE (MANUAL)
Press the 14. main circuit breaker "ON" switch (Figure 52).
Main Circuit Breaker ON SwitchFigure 52.
Ammeter (No Load)Figure 48.
The engine oil pressure gauge (Figure 49) will indicate 11.
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 28 to 85
psi. (193~586 kPa).
Oil Pressure GaugeFigure 49.
The 12. coolant temperature gauge (Figure 50) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 167°~203°F (75°~95°C) (Green Zone).
Verify that the main circuit breaker "15. ON" lamp (Figure 53)
is lit (ON).
Main Circuit Breaker ON LampFigure 53.
Place the three 16. auxiliary circuit breakers in the ON
position (Figure 54).
Main, Aux. and GFCI Figure 54.
Circuit Breakers (ON)
Verify that the generator’s ammeter (Figure 55) reads 17.
the anticipated amount of current with respect to the
Coolant Temperature GaugeFigure 50.
The13. tachometer gauge (Figure 51) will indicate the
load. The ammeter will only display a current reading
if a load is in use.
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Ammeter (Load)Figure 55.
Engine Tachometer GaugeFigure 51.
The generator will run until manually stopped or an 18.
abnormal condition occurs.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 35
GENERATOR STARTUP PROCEDURE (AUTO MODE)
CAUTION
When connecting the generator to a isolation (transfer)
switch, ALWAYS have power applied to the generator’s
internal battery charger. This will ensure that the engine
will not fail due to a dead battery.
DANGER
Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
NOTICE
When the generator is set in the AUTO mode, the
generator will automatically start in the event of
commercial power falling below a prescribed level
by means of a contact closure that is generated
automatically by a transfer switch.
STARTING (AUTO MODE)
When starting generator in AUTO mode use the “Manual
Startup” procedure except where noted (see below).
Perform steps 1 through 4 in the Before Starting section 1.
as outlined in the Manual Starting Procedure.
Place the 2. engine speed switch (Figure 56) in the
HIGH position
Engine Speed Switch (High)Figure 56.
Place the 3. MPEC Control Switch (Figure 57) in the
AUTO position.
MPEC Control Switch (AUTO)Figure 57.
Continue operating the generator as outlined in the 4.
Manual Startup procedure (start at step 5).
WARNING
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.
CAUTION
The engine speed switch must be set to the “High”
position when running in the autostart mode. Failing
to set the switch in the proper position can result in
damage to your generator when it turns on.
NOTICE
When the MPEC control switch is placed in the AUTO
position, the engine glow plugs will be warmed and the
engine will start automatically.
PAGE 36 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR SHUTDOWN PROCEDURES
NORMAL SHUTDOWN PROCEDURE
To shutdown the generator, use the following procedure:
Place the three 1. auxiliary circuit breakers in the OFF
position (Figure 36)
Place the engine speed switch (Figure 58) in the “LOW” 2.
(down) position.
Engine Speed Switch (Low)Figure 58.
Let the engine cool by running it at low speed for 3-5 3.
minutes with no load applied.
Place the 4. MPEC Control Switch (Figure 59) to the
OFF/RESET position.
EMERGENCY SHUTDOWN PROCEDURE
To stop the engine in the event of an emergency, 1. PUSH
the emergency stop button (Figure 61) inward. This
button is located on the engine operating panel, see
Figure 5.
Emergency Stop ButtonFigure 61.
MPEC Control Switch (Off/Reset)Figure 59.
Verify that 5. all the status LEDs on the MPEC display
are OFF (not lit).
Set the 6. battery ON/OFF switch (Figure 60) to the
"OFF" position.
Battery Switch (OFF)Figure 60.
Remove all loads from the generator.7.
Inspect entire generator for any damage or loosening 8.
of components that may have occurred during
operation.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 37
MAINTENANCE
Engine
Generator
2
10 Hrs
DAILY
250 Hrs 500 Hrs
X
X
X
Inspection/MaintenanceTable 12.
Check Engine Fluid Levels X
Check Air Cleaner X
Check Battery Acid Level X
Check Fan Belt Condition X
Check for Leaks X
Check for Loosening of Parts X
Replace Engine Oil and Filter *
Clean Air Filter X
Check Fuel Filter/Water Separator Bowl X
Clean Unit, Inside and Outside X
Change Fuel Filter X
Clean Radiator and Check Coolant Protection Level*
Replace Air Filter Element *
Check all Hoses and Clamps *
Clean Inside of Fuel Tank X
Measure Insulation Resistance Over 3M ohms X
Check Rotor Rear Support Bearing X
*1 Replace engine oil and fi lter at 100 hours, fi rst time only.
*2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
*3 Replace primary air fi lter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
with no sags or dips that could collect moisture and/or oil.
1
3
4
1000
Hrs
X
GENERAL INSPECTION
Prior to each use, the generator should be cleaned and
inspected for defi ciencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for
fuel, oil, and coolant leaks. Use Table 12 as a general
maintenance guideline. Engine Side, refer to the Engine
Instruction Manual.
AIR CLEANER
Every 250 hours: Remove air cleaner element (Figure 62)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.
Air Cleaner with Dust Indicator
This indicator (Figure 62) is attached to the air cleaner.
When the air cleaner element is clogged, air intake
NOTICE
The air fi lter should not be changed until the indicator
reads “RED”. Dispose of old air fi lter. It may not be
cleaned or reused.
restriction becomes greater and the dust indicator signal
shows RED meaning the element needs changing or
service. After changing the air element, press the dust
indicator button to reset the indicator.
PAGE 38 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
Air Cleaner/IndicatorFigure 62.
MAINTENANCE
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result. This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber and high fuel consumption. Change air cleaner
more frequently if these conditions exists.
FUEL ADDITION
Add diesel fuel (the grade may vary according to season
and locations).
Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel
tank for water contamination and drain the contents if
required.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
Cleaning Inside the Fuel Tank
If necessary, drain the fuel inside the fuel tank completely.
Using a spray washer (Figure 63) wash out any deposits
or debris that have accumulated inside the fuel tank.
FUEL TANK INSPECTION
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
Rubber Suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
Fuel Hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
Fuel Tank Lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
Replacing Fuel Filter
Replace the fuel fi lter cartridge with new one every 500
hours or so.
Loosen the drain plug at the lower top of the fuel fi lter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
Vent any air
AIR REMOVAL
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel,
or after disassembling the fuel system, bleed the system
according to the following procedure. See the Komatsu
Engine Manual for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 1530 seconds. Try again, if needed.
Fuel Tank CleaningFigure 63.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 39
MAINTENANCE
CHECK OIL LEVEL
Check the crankcase oil level prior to each use, or when the
fuel tank is fi lled. Insuffi cient 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 26.
Replacing Oil Filter
Remove the old oil fi lter.
Apply a fi lm of oil to the gasket on the new oil fi lter.
Install the new oil fi lter.
After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check for
leaks before adding more oil if needed. Clean excessive
oil from engine.
FLUSHING OUT RADIATOR AND REPLACING
COOLANT
Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overfl ow
tank and drain.
Check hoses for softening and kinks. Check clamps for
signs of leakage.
Tighten both cocks and replace the overfl ow tank.
Replace with coolant as recommended by the engine
manufacturer.
Close radiator cap tightly.
Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
WARNING
Allow engine to cool when fl ushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
RADIATOR CLEANING
The radiator (Figure 64) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fi ns or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fi ns and tube.
Radiator CleaningFigure 64.
GENERATOR STORAGE
For long term storage of the generator the following is
recommended:
Drain the fuel tank completely. Treat with a fuel stabilizer
if necessary.
Completely drain the oil from the crankcase and refi ll if
necessary with fresh oil.
Clean the entire generator, internal and external.
Cover the generating set and store in a clean, dry place.
Disconnect the battery.
Make sure engine coolant is at proper level.
If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
PAGE 40 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
MAINTENANCE
JACKET WATER HEATER AND INTERNAL BATTERY
CHARGER 120 VAC INPUT RECEPTACLES
(OPTIONAL)
This generator can be optionally equipped with two 120
VAC, 20 amp input receptacles located on the output
terminal panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 65). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times.
To apply power to the jacket water heater simply apply
power to the jacket water heater receptacle via commercial
power using an power cord of adequate size.
If the generator will be used daily, the battery should
normally not require charging. If the generator will be idle
(not used) for long periods of time, apply power to the
battery charger receptacle via commercial power using a
power cord of adequate size.
NOTICE
To ensure adequate starting capability, always have
power applied to the generator's internal battery
charger.
Battery Charger and Jacket Water Figure 65.
Heater Power Connections
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 41
TRAILER MAINTENANCE
TRAILER MAINTENANCE
This section is intended to provide the user with generic
trailer service and maintenance information. The service
and maintenance guidelines referenced in this section refer
to a wide range of trailers.
Remember periodic inspection of the trailer will ensure safe
towing of the generator and will prevent personal injury and
damage to the equipment.
The definitions below describe some of the major
components of a typical trailer that would be used with
generator.
Fuel Cell 1. — Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
Braking System 2. — System employed in stopping
the trailer. Typical braking systems are electric, surge,
hydraulic, hydraulicsurge and air.
GVWR 3. — Gross Vehicle Weight Rating (GVWR) is
the maximum number of pounds the trailer can carry,
including the fuel cell (empty).
Frame Length 4. — Measurement is from the ball hitch
to the rear bumper (refl ector).
Tire Size 8. — 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.
Tire Ply 9. — The tire ply (layers) number is rated in
letters; 2ply,4ply,6ply, etc.
Wheel Hub 10. — The wheel hub is connected to the
trailer’s axle.
Tire Rim 11. — Tires mounted on a tire rim. The tire rim
must match the size of the tire.
Lug Nuts 12. — Used to secure the wheel to the wheel
hub. Always use a torque wrench to tighten down
the lug nuts. See Table 15 and Figure 68 for lug nut
tightening and sequence.
Axle 13. — Indicates the maximum weight the axle can
support in pounds, and the diameter of the axle
expressed in inches. Please note that some trailers
have a double axle. This will be shown as 26000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
Suspension 14. — Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Qfl ex, and air ride.
Frame Width 5. — Measurement is from fender to
fender
Jack Stand 6. — Trailer support device with maximum
pound requirement from the tongue of the trailer.
Coupler 7. — Type of hitch used on the trailer for
towing.
Electrical 15. — Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
Application 16. — Indicates which units can be employed
on a particular trailer.
PAGE 42 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
TRAILER MAINTENANCE
ELECTRIC BRAKES
Electrically actuated brakes (Figure 66) are similar
tohydraulic 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 underadjusted brakes.
Before any brake synchronizations adjustments can be
made, the trailer brakes should be burnishedin by applying
the brakes 2030 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 66. displays the major electric brake components
that will require inspection and maintenance. Please
inspect these components as required. See Table 13.
Electric Brake Troubleshooting.
Magnets For All Electric Brakes
To make certain an electricallyoperated braking system
will function properly, you must have your dealer inspect
the magnets at least once a year, or each 12,000 miles.
See the brake manual for wear and current inspection
instructions.
Brake Controller
.
Hydraulic Brake ComponentsFigure 66.
Brake Drums (or discs), Linings, and Hoses
Brake drums or discs must not have cracks longer than one
half the width of the friction area. Linings must not be loose,
soaked with oil or grease or be dangerously thin. Mechanical
parts must be in place, not broken or missing. Check that all air
hoses connected to the brake chambers are not worn or cut
due to rubbing.
Air Leaks
Always check for brake air leaks before towing the trailer.
NEVER tow the trailer with an brake air leak problem. The
possibility exists of brake failure.
Symptom Possible Cause Solution
No Brakes or Intermittent Brakes
Weak Brakes or Brakes Pull to
One Side
Locking Brakes
Noisy Brakes
Dragging Brakes Bearings of the wheel adjusted? Adjust.
Electric Brake TroubleshootingTable 13.
Any open circuits or broken wires? Find and correct.
Any short circuits? Find and correct.
Faulty controller? Test and correct.
Any loose connections? Find and repair.
Ground wire secure? Find and secure.
Grease or oil on magnets or
linings?
Connections corroded?
Brake drums scored or grooved? Machine or replace.
Brakes synchronized? Correct.
Brake components loose, bent or
broken?
Brake drums outofround? Replace.
System lubricated? Lubricate.
Brake components correct? Replace and correct.
Clean or replace.
Clean and correct cause of
corrosion.
Replace components.
The electric brake controller is part of the tow vehicle and
is essential in the operation of the electric brakes on the
trailer. The brake controller is not the same
as the safety
breakaway brake system that may be equipped on
the trailer.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 43
TRAILER MAINTENANCE
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
ALWAYS wear safety glasses when
removing or installing force fi tted parts.
Failure to comply may result in serious
injury.
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.
Tire Wear/Infl ation
Suspension
The Torsion axle systems, the suspension takes place
inside the square tube which is fi lled with highly resilient
rubber. It attaches directly to the trailer frame using brackets
which are an integral part of the axle assembly (See Figure
67 below).
Visually inspect the mounting hardware every 6,000 miles
for signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
immediately. Torque torsion axle mounting hardware as
recommended by manufactuer..
Tire infl ation 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 infl ation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 14 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Tire Wear TroubleshootingTable 14.
Wear Pattern Cause Solution
Center Wear Over infl ation.
Edge Wear Under infl ation.
Side Wear
Toe Wear Incorrect toein. Align wheels.
Cupping Outofbalance.
Flat Spots
Loss of camber
or overloading.
Wheel lockup and
tire skidding.
Adjust pressure to particular
load per tire manufacturer.
Adjust pressure to particular
load per tire manufacturer.
Make sure load does not
exceed axle rating.
Align wheels.
Check bearing adjustment
and balance tires.
Avoid sudden stops when
possible and adjust brakes.
Major Suspension ComponentsFigure 67.
PAGE 44 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
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:
Start all wheel lug nuts by hand.1.
Torque all lug nuts in sequence (see Figure 68). 2. DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defi ned
by Table 15.
After fi rst road use, retorque all lug nuts in sequence. 3.
Check all wheel lug nuts periodically.
Tire Torque RequirementsTable 15.
Wheel Size
12" 2025 3540 5065
13" 2025 3540 5065
14" 2025 5060 90120
15" 2025 5060 90120
16" 2025 5060 90120
First Pass
FTLBS
Second Pass
FTLBS
Third Pass
FTLBS
TRAILER MAINTENANCE
Wheel Lug Nuts Figure 68.
Tightening Sequence
NOTICE
NEVER use an pneumatic air gun to tighten wheel
lug nuts.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 45
TRAILER WIRING DIAGRAM
Trailer/Towing Vehicle Wiring DiagramFigure 69.
PAGE 46 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR WIRING DIAGRAM
Generator Wiring DiagramFigure 70.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 47
GENERATOR WIRING DIAGRAM (MAIN BREAKER)
Engine Wiring DiagramFigure 71.
PAGE 48 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ENGINE WIRING DIAGRAM
Controller Wiring DiagramFigure 72.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 49
TROUBLESHOOTING (GENERATOR)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 16 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business offi ce or service plant.
Generator TroubleshootingTable 16.
Symptom Possible Problem Solution
AC Voltmeter defective? Check output voltage using a voltmeter.
Is wiring connection loose? Check wiring and repair.
No Voltage Output
Low Voltage Output
High Voltage Output
Circuit Breaker Tripped
Is AVR defective? Replace if necessary.
Defective Rotating Rectifi er? Check and replace.
Defective Exciter Field? Check for approximately 17.3 ohms across J & K on CN1
Is engine speed correct? Turn engine throttle lever to “High”.
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR? Replace if necessary.
Short Circuit in load? Check load and repair.
Over current? Confi rm load requirements and reduce.
Defective circuit breaker? Check and replace.
Over current Relay actuated? Confi rm load requirement and replace.
PAGE 50 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
TROUBLESHOOTING (ENGINE CONTROLLER)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown,
use Table 17 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller
unit (MPEC). If the problem cannot be remedied, consult our company's business offi ce or service plant.
Engine Controller Troubleshooting (MPEC)Table 17.
Symptom Possible Problem Solution
Low oil level? Fill oil level.
Low oil pressure light is on.
Low coolant level light is on.
(Optionally installed)
High coolant temperature
light is on.
Overcrank light is on.
Oil pressure sending unit failure? Replace oil pressure sending unit.
Time delay malfunction in controller? Refer to dealer.
Wire shorted? Inspect/repair wire.
Low coolant level? Fill coolant level.
Sending unit failure? Replace sending unit.
Low battery voltage? Replace/charge battery.
Fan belt tension incorrect? Tighten/replace fan belt.
Air fl ow is not circulating through radiator? Clean/repair radiator grill.
Doors open? Close doors.
Exhaust leaking? Replace/repair gaskets or faulty part.
Generator being overloaded? Check/reduce load.
Thermostat failure? Replace thermostat.
Air intake blocked? Clean all air intakes.
Temperature switch failure Replace temperature switch.
No or low fuel? Fill fuel level.
Controller needs to be calibrated? Refer to dealer.
RPM engine speed too high? Adjust RPM.
Overspeed light is on.
Loss of MPU light(s) or on.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 51
Governor actuator needs to be adjusted? Adjust governor actuator.
Governor controller needs to be adjusted? Adjust governor controller.
Engine controller needs to be calibrated? Refer to dealer.
Magnetic pick up out of adjustment? Adjust magnetic pick up.
Magnetic pick up dirty? Clean magnetic pick up.
TROUBLESHOOTING (ENGINE CONTROLLER)
This generator is equipped with an electronic governor for
unit injection system. The engine controller (Figure 73),
consists of a display, switches, trimmer, etc., for monitoring
and for controlling the engine.
Komatsu Engine ControllerFigure 73.
The defi nitions below describe the controls and functions
of the Engine Controller (Figure 73).
Display 1. — Displays engine malfunctions. When the
engine starts and the controller turns ON, various
engine parameters will be checked within about 10
seconds. If the engine system is normal and working
correctly the display will show "00".
If the engine controller detects an engine malfunction
(parameter abnormality) an "E" will be displayed
followed by the error code and the type of failure.
NOTICE
For a complete understanding of error codes and
troubleshooting procedures, refer to the enclosed
engine instruction manual.
Reset Button 2. — To clear the display after a fault or
abnormal parameter has occured, press and hold this
button for one second. This will reset the display.
PAGE 52 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
NOTES
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 53
EXPLANATION OF CODE IN REMARKS COLUMN
r
r
The following section explains the different symbols and
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice. Multiquip
does not guarantee the availability of the parts listed.
SAMPLE PARTS LIST
NO. PART NO. PART NAME QTY. REMARKS
1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%
2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY
2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY
3 12348 HOSE ..................A/R ...MAKE LOCALLY
4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE
NO. Column
Unique Symbols — All items with same unique
symbol
QTY. Column
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or othe
parts that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
REMARKS Column
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Duplicate Item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific Model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model numbe
variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“Make/Obtain Locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items. Examples include battery cables, shims,
and certain washers and nuts.
“Not Sold Separately” — Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
PAGE 54 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
SUGGESTED SPARE PARTS
DCA800SSK2 WHISPERWATT GENERATOR WITH
KOMATSU SAA6D170E3 DIESEL ENGINE
1 to 3 units
QTY. P/N DESCRIPTION
12..........0602046653 .......... AIR FILTER, ELEMENT, OUTER
6............0602046653-1 ......AIR FILTER, ELEMENT, INNER
12..........6003193320 .......... FUEL FILTER, ENGINE
24..........6002111231 .......... CARTRIDGE OIL FILTER
6............6004111171 .......... CARTRIDGE, CORROSION RESISTOR
6............0810105400 .......... FUEL FILTER, FUEL TANK
2............6240613821 .......... FAN BELT, ENGINE
2............6240816180 .......... ALTERNATOR BELT, ENGINE
4............6162144810 .......... RADIATOR HOSE (UPPER)
1............6240611950 .......... RADIATOR HOSE (UPPER-INNER)
1............6162639651 .......... RADIATOR HOSE (LOWER)
1............1140348160 ..........CAP, RADIATOR
1............0601820625 ..........AUTOMATIC VOLTAGE REGULATOR
3............0601808804 .......... CIRCUIT BREAKER, 50 AMP
1............0601840073 ..........RHEOSTAT, (VO LTAG E REGULATOR)
2............0601840100 ..........KNOB, RHEOSTAT
1............0601810072 ..........PILOT LAMP
2............0601810261 .......... BULB, PILOT LAMP
1............0602122272 .......... UNIT, OIL PRESSURE, FOR GAUGE
1............0602123267 .......... UNIT, WATER TEMPERATURE, FOR GAUGE
1............0601810261 .......... CIRCUIT BREAKER BULB, ON/OFF LAMP
1............0601802149 .......... FUSE, 10 AMP
1............6008158280 .......... SWITCH, OIL PRESSURE
1............6216849140 .......... SENSOR ASSY., COOLANT TEMPERATURE
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 55
GENERATOR ASSY.
PAGE 56 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C5110000402 ROTOR ASSY. ........................................ 1 ...........INCLUDES ITEM W/#
1-1# FIELD ASSY. 1
1-2# 0601842366 RESISTOR, 80W 50K 4
1-3# 8171020004 INSULATOR WASHER 6
1-4# 8171020504 INSULATOR WASHER 6
1-5# C5111100002 FAN 1
1-6# C5163400003 COUPLING RING 1
1-7# 0010312025 HEX HEAD BOLT 2
1-7A# 0042512000 WASHER, LOCK 2
1-8# C5163100104 COUPLING DISK ASSY. 1
1-9# C5163200004 COUPLING HUB WASHER 1
1-10# C5111300003 BALANCING PLATE ............................... 1 ...........PURCHASE ITEM 1-17 AS A SET
1-11# 0012724060 HEX HEAD BOLT 10
1-12# 0042524000 WASHER, LOCK 10
1-13# 8461026023 RECTIFIER SET PLATE ......................... 1 ...........PURCHASE ITEM1-17 AS A SET
1-14# 0601823282 RECTIFIER 2
1-15# 0018205020 HEX SOCKET HEAD CAP SCREW 4
1-15A# 0040005000 WASHER, LOCK 4
1-15B# 0041205000 WASHER, FLAT 4
1-16# 0010112020 HEX HEAD BOLT 6
1-16A# 0040012000 WASHER, LOCK 6
1-17# 0601000209 BALANCING WEIGHT KIT 1
1-18 C5111500003 BEARING FLANGE 1
1-19 0072906322 BEARING 1
1-20 0080000110 SNAP RING 1
1-21# C5153300104 BEARING GASKET 1
2 0012116065 HEX HEAD BOLT 10
2A 0042516000 WASHER, LOCK 10
3 C5130000003 STARTER ASSY. 1
31 C5131200404 CLAMPER 4
32 C5131200014 CLAMPER 4
33 C5131200504 CLAMPER 2
34 0016310090 HEX HEAD BOLT 4
34A 0030010000 HEX NUT 4
34B 0040010000 WASHER, LOCK 8
34C 0041210000 WASHER, FLAT 4
35 0017110020 HEX HEAD BOLT 8
4 C5153000002 END BRACKET 1
5 C4137000003 EXCITER FIELD ASSY 1
6 0012110075 HEX HEAD BOLT 6
6A 0042610000 WASHER, LOCK 6
6B 0041210000 WASHER, FLAT 6
7 0845044904 GROMMET 1
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 57
GENERATOR ASSY. (CONTINUED)
PAGE 58 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
GENERATOR ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
8 0016316045 HEX HEAD BOLT 8
8A 0040016000 WASHER, LOCK 8
8B 0041216000 WASHER, FLAT 8
9 C5153300003 BEARING COVER 1
10 C5153300104 BEARING GASKET 1
11 0016308095 HEX HEAD BOLT 3
11A 0040008000 WASHER, LOCK 3
11B 0041208000 WASHER, FLAT 3
12 0010110016 HEX HEAD BOLT 1
13 0803000104 PACKING 1
14 8461335004 COVER BRACKET 1
15 C5131300103 STATOR COVER 1
16 0017106012 HEX HEAD BOLT 4
17 0017106050 HEX HEAD BOLT 2
18 8461333003 EXCITER COVER 1
19 0017106012 HEX HEAD BOLT 2
20 0012112040 HEX HEAD BOLT 16
20A 0042512000 WASHER, LOCK 16
21 C5131300003 FAN COVER 1
22 0017106050 HEX HEAD BOLT 1
23 0605000012 RUBBER SUSPENSION 4
24 0030020000 HEX NUT 8
24A 0040020000 WASHER, LOCK 8
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 59
CONTROL PANEL ASSY.
PAGE 60 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
CONTROL PANEL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C5224002303 CONTROL PANEL 1
2 C5224002103 CONTROL PANEL 1
3 0605011211 PIN 4
4 0601810476 CIRCUIT BREAKER OFF LAMP 1
4A 0601810235 BULB 1
5 0601810467 CIRCUIT BREAKER ON LAMP 1
5A 0601810235 BULB 1
6 0601830498 CIRCUIT BREAKER OFF SWITCH 1
7 0601831224 CIRCUIT BREAKER ON SWITCH 1
8 0601800480 FREQUENCY METER, 220V 45 ~ 65Hz 1
9 0601800795 AC AMMETER, 0~1500A 0~3000A 1
10 0601801040 AMMETER CHANGE OVER SWITCH 1
11 0601800252 AC VOLTMETER, ~ 600V 1
12 0601801041 VOLTMETER CHANGE OVER SWITCH 1
13 0601810072 PILOT LAMP 1
13A 0601810261 BULB 1
14 0601840073 RHEOSTAT (VOLTAGE REGULATOR) 1
15 0601840100 KNOB 1
16 ECU99888N600/800 ENGINE CONTROLLER .............................1 ................REPLACES P/N 0602202545
17 0601830765 SWITCH 1
18 0601810161 PANEL LIGHT 1
18A 0601810214 BULB 1
19 0207004000 HEX NUT 2
20 0601830710 PANEL LIGHT SWITCH 1\
21 C9221100004 HEX. HEAD BOLT 4
21A 0040008000 WASHER, LOCK 4
21B 0041208000 WASHER, FLAT 4
21C 0080200007 SNAP RING 4
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 61
CONTROL BOX ASSY.
PAGE 62 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
CONTROL BOX ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C5214001602 CONTROL BOX 1
2 0601806166 AMMETER CURRENT TRANSFORMER 3
3 0017108020 HEX HEAD BOLT 6
4 C5261503703 ELECTRIC PARTS SET PANEL 1
5 C5261503503 ELECTRIC PARTS SET PANEL 1
6 0017108020 HEX HEAD BOLT 14
7 0601820625 AUTOMATIC VOLTAGE REGULATOR 1
8 0027105016 MACHINE SCREW 4
9 0601820892 OVER CURRENT RELAY 1
10 0027104016 MACHINE SCREW 2
11 0601815402 TERMINAL BOARD 1
12 0027104020 MACHINE SCREW 2
13 0601823240 RECTIFIER 1
14 0027105020 MACHINE SCREW 1
15 7818529500 CONTROLLER ............................................1 ................REPLACES P/N 0602202615
15A 6240815300 PANEL .........................................................1 ................REPLACES P/N 0602129110
15B 6240815400 WIRE HARNESS .........................................1 ................REPLACES P/N 0602202431
16 0017106015 HEX HEAD BOLT 6
17 0601842468 RESISTOR, 5W 150 OHM 1
18 0027103010 MACHINE SCREW 2
19 0601828533 RELAY, DC24V 1
20 0027104016 MACHINE SCREW 2
21 0601826022 RELAY, DC24V 1
22 0027103010 MACHINE SCREW 2
23 0601802149 FUSE, 10A 1
23A 0601802211 FUSE HOLDER 1
24 0027504020 MACHINE SCREW 2
25 0601823706 RELAY, DC24V 1
26 0027104016 MACHINE SCREW 2
27 LY2DC24V RELAY .........................................................1 ................REPLACES P/N 0601823732
27A PTF08A SOCKET ......................................................1 ................REPLACES P/N 0601823109
27B PYCA1 HOLDER 1 REPLACES P/N 0601824400
28 LY2DDC24V RELAY .........................................................1 ................REPLACES P/N 0601827655
28A PTF08A SOCKET ......................................................1 ................REPLACES P/N 0601823109
28B PYCA1 HOLDER .....................................................1 ................REPLACES P/N 0601824400
29 0601823759 RELAY 2
29A PYF14A SOCKET ......................................................2 ................REPLACES P/N 0601823146
29B PYCA1 HOLDER .....................................................2 ................REPLACES P/N 0601824000
30 0027104016 MACHINE SCREW 8
31 M7080041000Q CIRCUIT BREAKER, S8V 2500A ...............1 ................REPLACES P/N C5244300003
32 0010308050 HEX HEAD BOLT 8
32A 0042508000 WASHER, LOCK 8
32B 0041208000 WASHER, FLAT 8
33 7521861303 VOLTAGE CHANGEOVER BOARD 1
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 63
CONTROL BOX ASSY. (CONTINUED)
PAGE 64 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
CONTROL BOX ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
34 C5277200004 CHANGE TERMINAL 10
35 0017108035 HEX HEAD BOLT 20
36 C5277200004 TERMINAL PLATE 10
37 C5277300004 CHANGE PLATE 6
38 0801832504 HEX HEAD BOLT 20
39 0040020000 WASHER, LOCK 20
40 0041420000 WASHER, FLAT 20
41 0010110040 HEX HEAD BOLT 4
41A 0040010000 WASHER, LOCK 4
41B 0041210000 WASHER, FLAT 4
42 3871824004 CONTROL PANEL STOPPER 2
43 0041206000 WASHER, FLAT 2
44 0605010502 SNAP PIN 2
45 C5214500303 CONTROL BOX COVER 1
46 0017106016 HEX HEAD BOLT 14
47 C5214300304 CONTROL BOX SIDE PANEL 1
48 0601850349 EMBEDDED PULLS 1
49 C5214300404 CONTROL BOX SIDE PANEL 1
50 0017106016 HEX HEAD BOLT 24
51 C5214400203 CONTROL BOX PANEL 1
52 0017106016 HEX HEAD BOLT 15
53 7521811904 BRACKET 2
54 0017110025 HEX HEAD BOLT 4
55 0017108020 HEX HEAD BOLT 3
56 0017110030 HEX HEAD BOLT 4
56A 0207010000 HEX NUT 4
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 65
ENGINE ASSY.
PAGE 66 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ENGINE ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C5924200134 ENGINE, KOMATSU SAA170E3 1
1-1 0602046653 AIR CLEANER ELEMENT OUTER 2
1-1A 0602046653-1 AIR CLEANER ELEMENT, INNER 2
1-2 6002111231 OIL FILTER CARTRIDGE ...........................2 ................REPLACES P/N 0602041146
1-3 6004111171 CORROSION RESISTOR CARTRIDGE .....1 ................REPLACES P/N 0602045144
1-4 6008711220 DUST SENSOR ..........................................1 ................REPLACES P/N 060204043
1-4A 6240613821 FAN BELT ....................................................1 ................REPLACES P/N 0602015227
2 C5304200504 ENGINE FOOT 2
3 C5304200604 ENGINE FOOT 2
4 0010118070 HEX HEAD BOLT 8
5 0030018000 HEX NUT 8
6 0040018000 WASHER, LOCK 8
7 0041618000 WASHER, FLAT 8
8 0605000012 RUBBER SUSPENSION 4
9 0030020000 HEX NUT 8
10 0040020000 WASHER, LOCK 8
13 6995619380 CUSHION ....................................................2 ................REPLACES P/N 0605000498
14 0010118100 HEX HEAD BOLT 8
15 0030018000 HEX NUT 16
16 0041618000 WASHER, FLAT 16
17 C5311100104 RADIATOR BRACKET 2
18 0017112025 HEX HEAD BOLT 4
19 0017110025 HEX HEAD BOLT 4
20 0199603100 HOSE 1
21 0605515170 HOSE CLIP 1
22 6162637810 RESERVE TANK .........................................1 ................REPLACES P/N 0602010207
23 C2317100503 RESERVE TANK BRACKET 1
24 6212617210 RESERVE TANK .........................................1 ................REPLACES P/N 0602010206
25 C5317100003 RESERVE TANK BRACKET 1
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 67
ENGINE ASSY. (CONTINUED)
PAGE 68 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ENGINE ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
26 0017108020 HEX HEAD BOLT 4
27 0017106030 HEX HEAD BOLT 2
28 0194200840 HOSE 1
29 0605515019 HOSE BAND 1
30 0602022294 HOSE JOINT 2
31 0605515074 HOSE BAND
32 0265800560 HOSE 1
33 0603325017 VALVE 1
34 C0321200004 DRAIN JOINT 1
35 C0321300004 CAP 1
36 0019208025 HEX HEAD BOLT 2
37 C5322600304 CLAMPER ROD 1
38 C5358300904 CLAMPER ROD 1
39 0010118030 HEX HEAD BOLT 1
40 0040018000 WASHER, LOCK 1
41 0041618000 WASHER, FLAT 1
42 C5358300804 CLAMPER ROD 1
43 6216849140 SENSOR ASSY., COOLANT TEMP. ............1 ................S/N 316346 AND ABOVE
43A 6735211930 O-RING 1
44 6008158280 SWITCH, OIL PRESSURE ..........................1 ................S/N 316346 AND ABOVE
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 69
RADIATOR ASSY. (S/N 316346 AND ABOVE)
PAGE 70 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
RADIATOR ASSY. (S/N 316346 AND ABOVE)
NO. PART NO. PART NAME QTY. REMARKS
1 6240619300 RADIATOR ASSY. .......................................1 ......... REPLACES P/N 0602012734
1A 1140348160 RADIATOR CAP ..........................................1 ......... REPLACES P/N 0602011021
2 6995619380 CUSHION 2
18 6240611950 HOSE, RADIATOR, UPPER, INNER 1
19 0728101029 CLAMP 4
20 6240612010 TUBE 1
21 6240612020 BRACKET 2
22 0101081020 BOLT 8
23 0164331032 WASHER 8
24 0728101029 CLAMP 4
25 6240611960 HOSE 1
26 6240612080 CONNECTOR 1
27 6693629242 GASKET 1
28 0101081025 BOLT 4
29 0164331032 WASHER 4
36 6162639651 HOSE, RADIATOR, LOWER 1
37 0728101029 CLAMP 4
38 0726120913 HOSE 1
39 0728100197 CLAMP 2
40 0803400536 BAND 2
41 0704200617 PLUG 1
42 6240112550 TUBE 1
43 6162144810 HOSE 2
44 0729900120 CLAMP 8
45 6240112560 TUBE 1
46 6162144810 HOSE 2
47 0728900120 CLAMP 8
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 71
ALTERNATOR ASSY. (S/N 311209 AND ABOVE)
PAGE 72 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ALTERNATOR ASSY. (S/N 311209 AND ABOVE)
NO. PART NO. PART NAME QTY. REMARKS
1 6240816150 PULLEY, NON HARDENING 1
2 6240816180 BELT, ALTERNATOR 1
3 6008253161 ALTERNATOR, ASSY 1
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 73
THEROMOSTAT ASSY. (S/N 316346 AND ABOVE)
PAGE 74 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
THEROMOSTAT ASSY. (S/N 316346 AND ABOVE)
NO. PART NO. PART NAME QTY. REMARKS
1 6240116410 HOUSING, THERMOSTAT 1
2 6240116470 GASKET 1
3 0101081095 BOLT 5
4 0704230108 PLUG 2
5 6240116480 PLATE 1
6 6222116820 GASKET 1
7 0101081035 BOLT 2
8 0164331032 WASHER 2
9 0704200415 PLUG 1
10 6004216630 THERMOSTAT 2
11 6162136440 SEAL, THERMOSTAT ?
12 6240611761 TUBE 1
13 6162136481 GASKET 1
14 0101081030 BOLT 4
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 75
WATER PUMP ASSY.
PAGE 76 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
WATER PUMP ASSY.
NO. PART NO. PART NAME QTY. REMARKS
A 6240611302 WATER PUMP ASSY. ......... 1 .........S/N 315602 AND ABOVE INCLUDES ITEMS W/$
1$ BODY ................................. 1 .........S/N 315602 AND ABOVE
2$ 6162631515 SEAL, WATER .................... 1 .........S/N 311819 AND ABOVE
3$ 0634006305 BEARING, BALL ................ 1 .........S/N 310007 AND ABOVE
4$ 0603006205 BEARING, BALL ................ 1 .........S/N 310007 AND ABOVE
5$ 6240611470 SPACER ............................. 1 .........S/N 310007 AND ABOVE
6$ 6240611440 RING .................................. 1 .........S/N 310007 AND ABOVE
7$ 07012D0022 SEAL, OIL .......................... 1 .........S/N 310007 AND ABOVE
8$ 6240611321 SHAFT ................................ 1 .........S/N 311819 AND ABOVE
9$ 6240611210 IMPELLER .......................... 1 .........S/N 310007 AND ABOVE
10$ 6240611410 GEAR ................................. 1 .........S/N 310007 AND ABOVE
11$ 6240611150 COVER ............................... 1 .........S/N 310007 AND ABOVE
12$ 0704370211 PLUG .................................. 1 .........S/N 310007 AND ABOVE
13$ 07000G2140 O-RING .............................. 1 .........S/N 310007 AND ABOVE
14$ 07000G2012 O-RING .............................. 1 .........S/N 310007 AND ABOVE
15$ 0101081030 BOLT .................................. 4 .........S/N 310007 AND ABOVE
16$ 0164331032 WASHER ............................ 4 .........S/N 310007 AND ABOVE
17 0700072095 O-RING .............................. 1 .........S/N 310007 AND ABOVE
18 0101181215 BOLT .................................. 4 .........S/N 310007 AND ABOVE
19 6240611560 TUBE .................................. 1 .........S/N 310007 AND ABOVE
20 07000A3039 O-RING .............................. 2 .........S/N 310007 AND ABOVE
21 6150215720 BRACKET .......................... 1 .........S/N 310007 AND ABOVE
22 0101080812 BOLT .................................. 1 .........S/N 310007 AND ABOVE
23 0164020816 WASHER ............................ 1 .........S/N 310007 AND ABOVE
25 07000G2075 O-RING .............................. 1 .........S/N 310007 AND ABOVE
29 6162631270 NIPPLE ............................... 1 .........S/N 310007 AND ABOVE
30 0728500180 CLIP ................................... 1 .........S/N 310007 AND ABOVE
31 0728701410 HOSE ................................. 1 .........S/N 310007 AND ABOVE
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 77
STARTER ASSY. (S/N 316346 AND ABOVE)
PAGE 78 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
STARTER ASSY. (S/N 316346 AND ABOVE)
NO. PART NO. PART NAME QTY. REMARKS
1 6008133512 STARTING MOTOR ASSY. (7.5 KW) 2
2 6221816810 GASKET 2
3 0101061645 BOLT 6
4 0164331645 WASHER 6
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 79
ENGINE OPERATING PANEL ASSY.
PAGE 80 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ENGINE OPERATING PANEL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C5484001202 SUPPORT LEG 1
2 0017112045 HEX HEAD BOLT 4
2A 0030012000 HEX NUT 4
2B 0041212000 WASHER, FLAT 4
3 0019210025 HEX HEAD BOLT 2
3A 0205010000 HEX NUT 2
3B 0042412000 WASHER, FLAT 2
4 C5352101303 OPERATING PANEL 1
5 0019208020 HEX HEAD BOLT 4
6 C5352100213 OPERATING PANEL COVER 1
7 0019208020 HEX HEAD BOLT 8
8 0226900460 RUBBER SEAL 1
9 8085182004 RUBBER COVER 1
10 8085183004 RUBBER COVER SET FRAME 1
11 0019206020 HEX HEAD BOLT 6
12 0602101016 BATTERY SWITCH 1
13 7522258304 BATTERY SWITCH BRACKET 2
14 0017106030 HEX HEAD BOLT 4
14A 0207006000 HEX NUT 4
15 0019206015 HEX HEAD BOLT 4
16 0601830710 ENGINE SPEED SWITCH 1
17 K6008153730 PREHEAT INDICATOR ................................1 ................REPLACES P/N 0602102055
18 0601830448 PREHEAT BUTTON 1
19 0601831927 EMERGENCY STOP BUTTON 1
20 0602120095 TACHOMETER 1
21 0602122093 OIL PRESSURE GAUGE 1
22 0601842450 VOLTAGE DIVIDER 1
23 0602123092 WATER TEMPERATURE GAUGE 1
24 0602121080 CHARGING AMMETER 1
25 0602125091 FUEL GAUGE 1
26 0602103090 ALARM LAMP 6
26A 0601810244 BULB, DC28V 6
27 0602122272 OIL PRESSURE UNIT FOR GAUGE 1
28 0602123267 WATER TEMP. UNIT FOR GAUGE 1
28A 0602021109 PACKING 1
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 81
OUTPUT TERMINAL ASSY.
PAGE 82 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
OUTPUT TERMINAL ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C5231700003 OUTPUT TERMINAL SET BOARD 1
2 7521860504 OUTPUT TERMINAL 4
3 7521850504 OUTPUT TERMINAL BRACKET 4
4 0010112040 HEX HEAD BOLT 8
4A 0030012000 HEX NUT 8
4B 0040012000 WASHER, LOCK 8
4C 0041212000 WASHER, FLAT 16
5 0010112060 HEX HEAD BOLT 8
5A 0030012000 HEX NUT 8
5B 0040012000 WASHER, LOCK 8
5C 0041212000 WASHER, FLAT 16
6 00101112040 HEX HEAD BOLT 24
6A 0030012000 HEX NUT 24
6B 0040012000 WASHER, LOCK 24
6C 0041212000 WASHER, FLAT 48
7 C5234000004 TERMINAL 1
8 0801830904 HEX HEAD BOLT 1
9 0039320000 HEX NUT 2
10 0040020000 WASHER, LOCK 3
11 0041420000 WASHER, FLAT 4
12 0019112050 HEX HEAD BOLT 6
12A 0042312000 WASHER, LOCK 6
12B 0042412000 WASHER, FLAT 6
13 0601850275 GROMMET 1
14 0601815324 TERMINAL BOARD 1
15 0027104020 MACHINE SCREW 2
16 C4237101304 OUTPUT TERMINAL COVER 1
17 7971867114 RUBBER SHEET 1
18 7521865804 RUBBER SHEET SET PLATE 1
19 0019206020 HEX HEAD BOLT 5
20 0605010660 KNOB 2
21 0207006000 HEX NUT 2
22 0019212040 HEX HEAD BOLT 4
23 0041212000 WASHER, FLAT 4
24 0805009804 RUBBER STAY 4
25 0030012000 HEX NUT 4
26 7521865603 STOPPER 1
27 0010108030 HEX HEAD BOLT 1
27A 0030008000 HEX NUT 1
27B 0041208000 WASHER, FLAT 2
28 C4237100504 COVER 1
29 0017108020 HEX HEAD BOLT 5
30 0601808804 CIRCUIT BREAKER, 50A 3
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 83
OUTPUT TERMINAL ASSY (CONTINUED).
PAGE 84 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
OUTPUT TERMINAL ASSY. (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
31 C5261600204 CIRCUIT BREAKER BRACKET 1
311 0221200110 RUBBER CUSHION 1
32 0017106030 HEX HEAD BOLT 2
33 0601811034 RECEPTACLE 3
34 0027104015 MACHINE SCREW 6
34A 0030004000 HEX NUT 6
34B 0041204000 WASHER, FLAT 6
35 C4237101203 COVER 1
36 0601851780 GROMMET 2
37 C4237102804 COVER 1
38 C4237400804 BRACKET 1
39 0017106016 HEX HEAD BOLT 2
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 85
BATTERY ASSY.
PAGE 86 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
BATTERY ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 0165719052 BATTERY 4
2 C9109100704 BATTERY SHEET 4
3 0805006404 BATTERY BAND 1
4 0805007804 BATTERY BAND 2
5 0805006504 BATTERY BOLT 6
6 0037808000 WING NUT 6
7 0040008000 WASHER, LOCK 6
8 0041608000 WASHER, FLAT 6
9 C5347800504 BATTERY CABLE 1
10 C5347800404 BATTERY CABLE 1
11 7522280904 BATTERY CABLE 2
12 C5347601404 BATTERY CABLE 1
13 C5347400104 EARTH CABLE 1
14 0347010030 HEX HEAD BOLT 8
15 0208110000 HEX NUT 8
16 0845040114 TERMINAL CAP (+) 4
17 0845041004 TERMINAL CAP (-) 4
18 C5347601304 BATTERY CABLE 1
19 C5347601204 BATTERY CABLE 1
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 87
MUFFLER ASSY.
PAGE 88 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
MUFFLER ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C5331100302 MUFFLER 1
2 0019212030 HEX HEAD BOLT 4
3 C5334200704 PACKING 2
4 C5335200204 PACKING 1
5 C5335200304 PACKING 1
6 0019210035 HEX HEAD BOLT 26
7 C5334000403 EXHAUST PIPE 2
8 0010116070 HEX HEAD BOLT 8
8A 0030016000 HEX NUT 8
8B 0040016000 WASHER, LOCK 8
8C 0041616000 WASHER, FLAT 16
9 0010116050 HEX HEAD BOLT 8
9A 0040016000 WASHER, LOCK 8
9B 0041616000 WASHER, FLAT 8
10 C5334101503 OUTLET PIPE 1
11 C5335200004 GASKET 1
12 0010116070 HEX HEAD BOLT 4
12A 0030016000 HEX NUT 4
12B 0040016000 WASHER, LOCK 4
12C 0041616000 WASHER, FLAT 8
13 C5331300304 COVER 1
14 0019208020 HEX HEAD BOLT 4
15 C5331400104 COVER 2
16 0019208020 HEX HEAD BOLT 8
17 C4334200504 GASKET 2
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 89
FUEL TANK ASSY.
PAGE 90 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
FUEL TANK ASSY.
NO. PART NO. PART NAME QTY. REMARKS
1 C5364001003 FUEL TANK 1
11 0845500104 FUEL TANK CAP 1
12 0810105400 FUEL FILTER 1
13 0264100525 FUEL GAUGE HOSE 1
14 0605515079 HOSE BAND 2
2 0605503023 FUEL SENSOR 1
3 0802120604 PACKING 1
4 0605501093 FUEL UNIT 1
5 0022905015 PACKING 1
6 0605516090 MACHINE SCREW 5
7 C6364200104 TANK BAND 2
8 0805003414 TANK BAND PAD 4
9 0017108020 HEX HEAD BOLT 2
10 0207308000 HEX NUT 2
11 0222100600 TANK SHEET 6
12 0130206000 STREET ELBOW 1
13 0134306370 DRAIN PIPE 1
14 0603325026 VALVE 1
15 0132006000 PLUG 1
16 C1367700304 LOCK PLATE 1
17 0019208020 HEX HEAD BOLT 2
18 0130008000 ELBOW 2
19 0602022225 HOSE JOINT 6
20 0605515074 HOSE BAND 6
21 0265803400 SUCTION HOSE 1
22 0265801900 SUCTION HOSE 1
23 6240715690 RETURN HOSE ..........................................1 ................REPLACES P/N 0605514120
24 0265803900 RETURN HOSE 1
25 0845039604 RUBBER SEAL 1
26 0010110100 HEX HEAD BOLT 3
27 0040010000 WASHER, LOCK 3
28 0041610000 WASHER, FLAT 3
29 0131108000 SOCKET 4
30 6003193320 FUEL FILTER CARTRIDGE ........................2 ................REPLACES P/N 0602042583
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 91
ENCLOSURE ASSY.#1
PAGE 92 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ENCLOSURE ASSY. #1
NO. PART NO. PART NAME QTY. REMARKS
1 C5414001502 BASE 1
2 C5414100204 FLOOR PANEL 1
3 0019208020 HEX HEAD BOLT 4
4 C5414100104 FLOOR PANEL 1
5 0019208020 HEX HEAD BOLT 12
6 C5414600403 AIR GUIDE PANEL 1
7 0019208020 HEX HEAD BOLT 4
8 C5414600503 BASE DUCT 1
8A C5494000204 LINING 1
9 0019208020 HEX HEAD BOLT 6
10 C5424002803 FRONT FRAME 1
10A C5494100603 LINING 1
11 C5424003003 FRONT FRAME 1
11A C5494100603 LINING 1
12 C5424002903 FRONT FRAME 1
13 0019208020 HEX HEAD BOLT 6
14 C5424002402 FRONT FRAME 1
14A C5494100603 LINING 1
15 C5424002502 FRONT FRAME 1
15A C5494100603 LINING 1
16 0019208020 HEX HEAD BOLT 28
17 C5424002603 AIR GUIDE PANEL 1
17A C5494100603 LINING 1
18 0019208020 HEX HEAD BOLT 18
19 C5424002704 GUSSET 2
20 0019210025 HEX HEAD BOLT 8
21 C5327100504 BREATHER PIPE 1
22 0016908020 HEX HEAD BOLT 1
23 0019210025 HEX HED BOLT 8
24 C5424201803 FRONT FRAME COVER 1
25 C5424202103 FRONT FRAME COVER 1
25A C5494100704 LINING 1
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 93
ENCLOSURE ASSY. #1 (CONTINUED)
PAGE 94 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ENCLOSURE ASSY.#1 (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
26 0019208020 HEX HEAD BOLT 36
27 0845042703 FILLER BRACKET 1
28 0019208020 HEX HEAD BOLT 4
29 C4424204604 COVER 1
30 0019206020 HEX HEAD BOLT 6
31 C5424201903 FRONT FRAME COVER 1
32 C5424202003 FRONT FRAME COVER 1
33 0019208020 HEX HEAD BOLT 16
34 C5434000702 CENTER FRAME 1
35 0010120075 HEX HEAD BOLT 16
35A 0040030000 HEX NUT 16
35B 0040020000 WASHER, LOCK 16
35C 0041620000 WASHER, FLAT 16
36 C5434200003 COVER 2
37 0207008000 HEX NUT 8
38 C2367700404 COVER 1
39 0019208020 HEX HEAD BOLT 2
40 C5464101603 ROOF PANEL 1
41 C5464101703 ROOF PANEL 1
42 C5464101403 ROOF PANEL 1
43 C5464101503 ROOF PANEL 1
44 0207108000 HEX NUT 16
45 8452023004 FILLER COVER 1
46 0019208020 HEX HEAD BOLT 2
47 0019208020 HEX HEAD BOLT 12
48 0019210025 HEX HEAD BOLT 22
49 0600500090 EMBLEM 1
50 0021106016 MACHINE SCREW 2
51 C5464500304 BRACKET 2
52 0019206020 HEX HEAD BOLT 6
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 95
ENCLOSURE ASSY. #2
PAGE 96 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ENCLOSURE ASSY. #2
NO. PART NO. PART NAME QTY. REMARKS
1 C5444001403 REAR FRAME 1
1A C5494300104 LINING 1
2 7525151004 LOUVER PANEL 5
3 0207106000 HEX NUT 40
4 C5444001303 REAR FRAME 1
4A C5494300604 LINING 1
5 C5444001103 REAR FRAME 1
5A C5494300604 LINING 1
6 C5444001203 REAR FRAME 1
6A C5494300604 LINING 1
7 0017110020 HEX HEAD BOLT 21
8 0019110025 HEX HEAD BOLT 4
9 C5444300703 REAR FRAME COVER 1
9A C5494300704 LINING 1
10 7525151804 LOUVER PANEL 1
11 0207106000 HEX NUT 21
12 C5444300804 DUCT COVER 1
12A C5494300804 LINING 1
13 0017108020 HEX HEAD BOLT 15
14 0019208020 HEX HEAD BOLT 21
15 C5444300303 VISOR 1
16 7525165603 VISOR 1
17 0019208020 HEX HEAD BOLT 13
18 C5444200503 REAR DOOR FRAME 1
19 C5444200003 REAR DOOR FRAME 1
20 7525147014 WINDOW PLATE 1
21 7525147114 WINDOW PLATE 1
22 0207306000 HEX NUT 14
23 B9114000102 DOOR HANDLE 1
24 0021806016 MACHINE SCREW 4
25 7525146404 DOOR ROD 1
26 7525146504 DOOR ROD 1
27 0845050704 STAY 4
28 0207106000 HEX NUT 8
29 0805011304 DOOR STOPPER 1
30 0805011204 DOOR STOPPER 1
31 0207106000 HEX NUT 4
32 0845047104 HINGE 2
32A 0845045004 WASHER 2
33 0845047204 HINGE 2
33A 0845045004 WASHER 2
34 0019208020 HEX HEAD BOLT 4
35 0845031504 CAP 4
36 0601850097 STOPPER 4
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 97
ENCLOSURE ASSY. #2 (CONTINUED)
PAGE 98 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
ENCLOSURE ASSY. #2 (CONTINUED)
NO. PART NO. PART NAME QTY. REMARKS
37 0025408025 MACHINE SCREW 4
38 C5464201403 ROOF PANEL 1
38A C5494500503 LINING 1
39 C5464201503 ROOF PANEL 1
39A C5494500503 LINING 1
40 C5464201603 ROOF PANEL 1
40A C5494500503 LINING 1
41 0207008000 HEX NUT 18
42 C5464200504 PANEL 1
42A C5494500503 LINING 1
43 C5464200604 GUIDE 1
44 0207008000 HEX NUT 20
45 0017108020 HEX HEAD BOLT 4
46 C5464200404 PANEL 1
46A C5494500503 LINING 1
47 C5464200304 PANEL 1
47A C5494500503 LINING 1
48 0207008000 HEX NUT 10
49 0017108020 HEX HEAD BOLT 4
50 C5464400004 ROOF PANEL COVER 1
50A C5494500604 LINING 1
51 0017108020 HEX HEAD BOLT 12
52 0019210030 HEX HEAD BOLT 34
53 0019212030 HEX HEAD BOLT 4
54 0600500090 EMBLEM 1
55 0021106016 MACHINE SCREW 2
57 0207106000 HEX NUT 4
58 C5464500404 BRACKET 1
59 C5464500504 BRACKET 1
DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09) — PAGE 99
ENCLOSURE ASSY. #3
PAGE 100 — DCA800SSK2 60 HZ GENERATOR • OPERATION AND PARTS MANUAL — REV. #0 (09/03/09)
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