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 ![](/images/new-backgrounds/1098502/9850219xi3.webp)
![](/images/new-backgrounds/1098502/9850219xi4.webp)
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)
Model DCA800SSK2
This Manual Must Accompany the Equipment AT ALL Times
Proposition 65 Warning
Administrator
Reporting Safety Defects
Nhtsa
Table of Contents
DCA800SSK2
Parts Ordering Procedures
Ordering parts has never been easier
Safety Information
Safety Messages
Generator Safety
General Safety
Always know the location of the nearest
Engine Safety
Before servicing equipment
Never use fuel as a cleaning agent
Fuel Safety
Towing Safety
From fuel vapors or if fuel is spilled on a hot engine
Power Cord/Cable Safety
Electrical Safety
Grounding Safety
Device. All installations should be
Battery Safety
Environmental Safety
Specifications
Komatsu SAA6D170E3
Dimensions
Dimensions
Installation
Typical Generator Grounding Application
Mounting
Outdoor Installation
Indoor Installation
Generator Grounding
General Information
Major Components
Item no
Generator Control Panel
Pilot Lamp Indicates the system is running
Owing from the U,V, and W Output Terminal Lugs to the load
Air Filter Alarm When the air fi lter
Engine Operating Panel
Page
Output Terminal Familiarization
Output Terminal Panel Familiarization
Terminal legs O and Ground are considered bonded grounds
Connecting Loads
Over Current Relay
Three Phase Load
Single Phase Load
Load Application
Voltage ChangeOver Board
Generator Outputs
Generator Output Voltages
Generator Amperage
AC Voltmeter Gauge Reading
HOW to Read the AC Ammeter and AC Voltage Gauges
Generator OUTPUTS/GAUGE Reading
AC Ammeter Gauge Reading
3Ø-240V Uvwo Terminal Output Voltages
Output Terminal Panel Connections
Uvwo Terminal Output Voltages
1Ø-240V Uvwo Terminal Output Voltages
1Ø-480V Uvwo Terminal Output Voltages
3Ø-480V Uvwo Terminal Output Voltages
1Ø-277V Uvwo Terminal Output Voltages
Lubrication OIL
INSPECTION/SETUP
Circuit Breakers
Fuel Check
Refueling Procedure
Only use #2 diesel fuel when refueling
Coolant ANTIFREEZE/SUMMER COOLANT/ Water
Cleaning the Radiator
AIR Cleaner FAN Belt Tension
Operation in Freezing Weather
Wiring
Battery
Battery Cable Installation
Alternator
Engine’s exhaust contains harmful emissions
Generator Startup Procedure Manual
Before Starting
Is lit on
Place the engine speed switch in the LOW position Figure
Starting Manual
Verify that the main circuit breaker on lamp is lit on
Ammeter No Load
Before connecting this generator to any
Generator Startup Procedure Auto Mode
Starting Auto Mode
Place the engine speed switch in the High position
Normal Shutdown Procedure
Generator Shutdown Procedures
Emergency Shutdown Procedure
General Inspection AIR Cleaner
Maintenance
Air Cleaner with Dust Indicator
Fuel Tank Inspection
Fuel Addition
AIR Removal
Replacing Oil Filter
Radiator Cleaning
Check OIL Level
Flushing OUT Radiator and Replacing Coolant
Battery Charger and Jacket Water Heater Power Connections
Trailer Maintenance
Trailer Maintenance
Coupler Type of hitch used on the trailer for towing
Brake Drums or discs, Linings, and Hoses
Electric Brakes
Air Leaks
Tire Wear/Inflation
TIRES/WHEELS/LUG Nuts
Suspension
Lug Nut Torque Requirements
Never use an pneumatic air gun to tighten wheel lug nuts
Trailer Wiring Diagram
Trailer/Towing Vehicle Wiring Diagram
Generator Wiring Diagram
Generator Wiring Diagram
Generator Wiring Diagram Main Breaker
Engine Wiring Diagram
Engine Wiring Diagram
Controller Wiring Diagram
Troubleshooting Generator
Adjust governor actuator
Troubleshooting Engine Controller
Clean/repair radiator grill
Adjust governor controller
Komatsu Engine Controller
Page
Sample Parts List
Explanation of Code in Remarks Column
Suggested Spare Parts
To 3 units
Generator Assy
RESISTOR, 80W 50K Ω
Balancing Weight KIT
Field Assy
Insulator Washer
Generator Assy
Cover Bracket
Bearing Cover
Packing
Stator Cover
Control Panel Assy
Panel Light Switch
Circuit Breaker on Switch
Switch
Control Panel
Control BOX Assy
Electric Parts SET Panel
Control BOX
Ammeter Current Transformer
Machine Screw
Control BOX Assy
Change Plate
Change Terminal
Terminal Plate
Snap PIN
Engine Assy
Radiator Bracket
ENGINE, Komatsu SAA170E3
Engine Foot
Hose
Engine Assy
Valve
Hose Band
Hose Joint
Drain Joint
Radiator ASSY. S/N 316346 and Above
Clamp
Connector
Cushion
Tube
Alternator ASSY. S/N 311209 and Above
BELT, Alternator
PULLEY, NON Hardening
ALTERNATOR, Assy
Theromostat ASSY. S/N 316346 and Above
Thermostat
HOUSING, Thermostat
Plate
SEAL, Thermostat
Water Pump Assy
6162631515
6240611302
315602 and Above
311819 and Above
Starter ASSY. S/N 316346 and Above
0101061645
6008133512
6221816810
0164331645
Engine Operating Panel Assy
Engine Speed Switch
Battery Switch
Battery Switch Bracket
Alarm Lamp
Output Terminal Assy
Terminal
Output Terminal
Output Terminal Bracket
Output Terminal Cover
Output Terminal Assy
Rubber Cushion
Receptacle
Battery Assy
Battery Band
Battery
Battery Sheet
Battery Bolt
Muffler Assy
Exhaust Pipe
Muffler
Outlet Pipe
Fuel Tank Assy
Fuel Filter
Fuel Tank
Fuel Tank CAP
Fuel Gauge Hose
Enclosure ASSY.#1
Enclosure ASSY. #1
Enclosure ASSY. #1
Roof Panel
Filler Bracket
Center Frame
Filler Cover
Enclosure ASSY. #2
Rear Frame Cover
Rear Frame
Louver Panel
Duct Cover
Enclosure ASSY. #2
Guide
Panel
Roof Panel Cover
Enclosure ASSY. #3
Side Door
Splasher Panel
Side Panel
Duct
Enclosure ASSY. #3
C5454300904
C5454300604
21A C5494405904
22A C5494405904
Rubber Seals Assy
0228901800
0228901750
0228901780
0228901690
Nameplate and Decals Assy
Decal Fuel Priming Engine Operating Panel Group
Control Panel & BOX Group
Engine & Radiator Group
Output Terminal Group
Nameplate and Decals Assy
Fuel Tank Group
Battery Group
Muffler Group
Bonnet Group
Nameplate and Decals Assy
C1552000403
Terms and Conditions of Sale Parts
Freight Policy
Page
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