MQ Power Whisperwatt DCA180SSI, Operation And Parts Manual

Page 1: ...ision of this publication visit our website at www mqpower com Whisperwatt Series MODEL dca180SSI MODEL dca180SSIU 60hz generators isuzu 6HK1X DIESEL ENGINE PARTS LIST NO C0870301604 Dca180SSSI PARTS LIST NO M3870301404 Dca180SSIU Revision 1 08 02 10 Operation and Parts Manual ...

Page 2: ...page 2 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 proposition 65 warning Diesel engine exhaust and some of ...

Page 3: ...t may open an investigation and if it finds 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 toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www nhtsa dot gov or write to Administrator ...

Page 4: ... Procedure Auto Mode 36 Generator Shut Down Procedures 37 Maintenance 38 41 Trailer Maintenance 42 45 TTrailer Wiring Diagram 46 Generator Wiring Diagram 47 Engine Wiring Diagram 48 Controller Wiring Diagram 49 Troubleshooting Generator 50 Troubleshooting Engine Controller 51 Troubleshooting Diagnostic Lamp 52 Explanation of Code in Remarks Column 54 Suggested Spare Parts 55 Component Drawings Gen...

Page 5: ...bsite View Parts Diagrams Order Parts Print Specification Information Note Discounts Are Subject To Change Goto www multiquip com and click on Order Parts to log in and save Use the internet and qualify for a 5 Discount on Standard orders for all orders which include complete part numbers order via Fax Dealers only All customers are welcome to order parts via Fax Domestic uS Customers dial 1 800 6...

Page 6: ...he safety messages specifically 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 Indicates a hazardous situation which if not avoided CoulD result in DeaTh or SerIouS InJurY CauTIon Indicates a hazardous situat...

Page 7: ...re 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 fire extinguisher alWaYS know the location of the nearest first 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 fire department This information will b...

Page 8: ...nction 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 sufficient load less than 40 of the rated output it will n...

Page 9: ...d 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 inflated...

Page 10: ... applicable laws and electrical codes Failure to do so could result in electrical shock or burn causing serious injury or even death 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 ...

Page 11: ...e battery in a well ventilated environmenttoavoidtheriskofadangerousconcentration 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 hospit...

Page 12: ...Single Phase 60 Hz Aux Voltage Output 4 8 Kw 2 4 kW x 2 DryWeight 6 373 lbs 2890 kg WetWeight 7211 lbs 3270 kg Table 2 Engine Specifications Model ISUZU 6HK1X Type 4 cycle water cooled direct injection turbo charged No of Cylinders 6 cylinders Bore x Stroke 4 53in x 4 92 in 115 mm x 125 mm Displacement 475 25 cu in 7 790 cc Rated Output 219 HP 1800 RPM Starting Electric Coolant Capacity 6 6 gal 25...

Page 13: ... page 13 Dimensions Figure 1 Dimensions Table 3 Dimensions Reference Letter Dimension in mm Reference Letter Dimension in mm A 41 33 in 1 050 mm F 137 8 in 3 500 mm B 41 33 in 1050 mm G 67 in 1 700 mm C 37 00 in 940 mm H 48 8 in 1 240 mm D 41 33 in 1050 mm E 37 00 in 940 mm ...

Page 14: ...page 14 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 Installation Figure 2 Typical Generator Grounding Application ...

Page 15: ...vibration of the generator when it is running The generator must set at least 6 inches above the floor or grade level in accordance to NFPA 110 Chapter 5 4 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 CAUTION Pay close attention to ventilation when operating the generator inside tunnels and caves T...

Page 16: ...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 rectified 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 configuration of the open delta to the series connection of B t...

Page 17: ...EM NO DESCRIPTION 1 Muffler Assembly 2 Air Filter Assembly 3 Generator Assembly 4 Output Terminal Panel Assembly 5 Battery Assembly 6 Output Receptacles Assembly 7 Engine and Radiator Assembly 8 Fuel Tank Assembly 9 Circuit Breaker Assembly 10 Engine Operating Panel Assembly 11 Generator Control Panel Assembly Figure 3 Major Components ...

Page 18: ...allows the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off 5 ACVoltmeter Indicates the output voltage present at the U V and W Output Terminal Lugs 6 AC Ammeter Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase selector switch 7 Frequency Meter Indicates the output freque...

Page 19: ...DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 page 19 Notes ...

Page 20: ...page 20 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 ENGINE OPERATING PANEL Figure 5 Engine Operating Panel ...

Page 21: ...ault has been detected the engine controller will evaluate the fault and all major faults will shutdown the generator During cranking cycle the ECU 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...

Page 22: ...e generator Lift up on the cover to gain access to receptacles and terminal lugs NOTICE Terminal legs O and Ground are considered bonded grounds OutputTerminal Familiarization The Output Terminal Panel Figure 6 is provided with the following Three 120 240V output receptacles 50 amp Three Circuit Breakers 50 amps Two 120V GFCI receptacles 20 amp Two GFCI Circuit Breakers 20 amps Five Output Termina...

Page 23: ...xiliary twist lock CS 6369 receptacles Figure 8 provided on the output terminal panel These receptacles can be accessed in any voltage change over board position Figure 8 120 240V Twist Lock Auxiliary Receptacles Each auxiliary receptacle is protected by a 50 amp circuit breaker These breakers are located directly above the GFCI receptacles Remember the load output current on all three receptacles...

Page 24: ...utput terminals from overload a 3 pole 500A main circuit breaker is provided Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine Figure 11 Connecting Loads Over Current Relay An over current relay Figure 12 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 ca...

Page 25: ... wattage may be determined by multiplying nameplate voltage by the nameplate amperage Table 5 Power Factor By Load Type of Load Power Factor Single phase induction motors 0 4 0 75 Electric heaters incandescent lamps 1 0 Fluorescent lamps mercury lamps 0 4 0 9 Electronic devices communication equipment 1 0 Common power tools 0 8 NOTICE Motors and motor driven equipment draw much greater current for...

Page 26: ...um amps as listed CAUTION NEVER attempt to place jumper plates on the voltage change over 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 Table 7 Voltages Available Three Phase Switchable 208V 220V 240V 416V 440V 480V Single Phase Switchable 120V 1127V 139V 240V 254V 277V Table 8 Genera...

Page 27: ...ted on the ACVoltmeter Gauge Figure 16 Figure 15 ACVoltmeter Change Over Switch Figure 16 ACVoltmeter Gauge AC Ammeter Gauge Reading Place the AC AmmeterChange Over Switch Figure 17 to the U position and observe the current reading load drain at the U terminal as indicated on the AC Ammeter Gauge Figure 18 This process can be repeated for terminals V and W Figure 17 AC Ammeter Change Over Switch F...

Page 28: ...er board for 240V operation as shown in Figure 19 Figure 19 Voltage Change Over Board 240V Configuration 2 Connect the load wires to the UVWO terminals as shown in Figure 20 Figure 20 UVWO Terminal Lugs 3Ø 240 139V Connections 3 Turn the voltage regulator knob Figure 21 clockwise to increase voltage output turn counterclockwise to decrease voltage output Use voltage regulator adjustment knob whene...

Page 29: ...gure 25 Figure 25 UVWO Terminal Lugs 3Ø 480V 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 fire 1Ø 480V UVWOTerminal OutputVoltages 1 Make sure the voltage change over board is jumpered for 480V operation as shown in Figure 24 2 Connect the load wires to the UVWO terminals as shown in Figure 2...

Page 30: ...l with the specified amount of oil as outlined in the ISUZU Engine Owner s Manual Oil should be warm before draining Other types of motor oils may be substituted if they meet the following requirements API Service Classification CC SC API Service Classification CC SD API Service Classification CC SE API Service Classification CC SF Table 9 Recommended Motor Oil Fuel Check Refilling the Fuel System...

Page 31: ...e the amount of fuel that can be pumped into the tank NOTICE ONLY use 2 diesel fuel when refueling Figure 31 Fueling the Generator 3 NEVER overfill fuel tank It is important to read the fuel gauge when filling trailer fuel tank DO NOT wait for fuel to rise in filler neck Figure 32 Figure 32 Full Fuel Tank Figure 33 Fuel Expansion Coolant Antifreeze Summer Coolant Water ISUZU recommends ISUZU antif...

Page 32: ... Inspect the fan belt for Table 10 Coolant Capacity Engine and Radiator 2 88 gal 10 9 liters Reserve Tank 2 quarts 1 9 liters Table 11 Anti Freeze OperatingTemperatures Vol Anti Freeze Freezing Point C F 50 37 34 NOTICE When the antifreeze is mixed with water the antifreeze mixing ratio must be less than 50 damage and wear and adjust it in accordance with the ISUZU Engine Owner s Manual The fan be...

Page 33: ...als This will ensure a good connection and will help prevent corrosion around the battery terminals CAUTION ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST NOTICE If the battery cable is connected incorrectly electrical damagetothegeneratorwilloccur Paycloseattentionto the polarity of the battery when connecting the battery CAUTION Inadequate battery connections ...

Page 34: ...he 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 GFCI or auxiliary circuit breakers in the ON closed position INCORRECT CORRECT Figure 39 MPEC Control Switch Manual Position 3 Depending on the temperature of the coolant cold weather conditions the pre heat l...

Page 35: ... the oil pressure of the engine Under normal operating conditions the oil pressure is approximately 42 to 71 psi 290 490 kPa Figure 47 Oil Pressure Gauge 11 The coolant temperature gauge Figure 48 will indicate the coolant temperature Under normal operating conditions the coolant temperature should be between 167 203 F 75 95 C Green Zone Figure 48 Coolant Temperature Gauge 12 The tachometer gauge ...

Page 36: ...re that the engine will not fail due to a dead battery 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 WARNING When running the generator in the AUTO mode rememberthegeneratorcanstartupatanytimewithout warning ...

Page 37: ...and LOAD circuit breakers as shown in Figure 54 to the OFF position Figure 54 Main GFCI and Load Circuit Breakers Off WARNING NEVER stop the engine suddenly except in an emergency 2 Place the engine speed switch Figure 55 in the LOW down position Figure 55 Engine Speed Switch Low 3 Let the engine cool by running it at low speed for 3 5 minutes with no load applied 4 Place the MPEC Control Switch F...

Page 38: ... X Check all Hoses and Clamps 4 X Clean Inside of Fuel Tank X Generator Measure Insulation Resistance Over 3M ohms X Check Rotor Rear Support Bearing X Maintenance General Inspection Prior to each use the generator should be cleaned and inspected for deficiencies 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 mai...

Page 39: ...deposits or debris that have accumulated inside the fuel tank Figure 59 Fuel Tank Cleaning FuelTank 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 an...

Page 40: ...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 flushing out radiator Flushing the radiator while hot could cause serious burns from water or steam Radiator Cleaning The radiator Figure 60 should be spray...

Page 41: ...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 Figure 61 ...

Page 42: ...ximum pound requirement from the tongue of the trailer 7 Coupler Type of hitch used on the trailer for towing 8 Tire Size Indicates the diameter of the tire in inches 10 12 14 etc and the width in millimeters 175 185 205 etc The tire diameter must match the diameter of the tire rim 9 Tire Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply etc 10 Wheel Hub The wheel hub is connect...

Page 43: ...ic surge brakes Figure 62 should not require any special attention with the exception of routine maintenance such as shoe and lining replacement Brake lines should be periodically checked for cracks kinks or blockage Figure 62 Hydraulic Brake Components Actuator Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer Remember the surge or push of the trailer t...

Page 44: ...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 Table 14 TireWearTroubleshooting Wear Pattern Cause Solution Center Wear Over inflation Adjust pressure to particular load per tire manufacturer Edge Wear Under inflation Adjust pressure to ...

Page 45: ... in 3 separate passes as defined by Table 16 3 After first road use retorque all lug nuts in sequence Check all wheel lug nuts periodically Table 16 TireTorque Requirements Wheel Size First Pass FT LBS Second Pass FT LBS Third Pass FT LBS 12 20 25 35 40 50 65 13 20 25 35 40 50 65 14 20 25 50 60 90 120 15 20 25 50 60 90 120 16 20 25 50 60 90 120 Figure 64 Wheel Lug Nuts Tightening Sequence NOTICE N...

Page 46: ...page 46 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 Trailer Wiring Diagram Figure 65 Trailer Towing Vehicle Wiring Diagram ...

Page 47: ...DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 page 47 Generator Wiring Diagram Figure 66 Generator Wiring Diagram ...

Page 48: ...page 48 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 Engine Wiring Diagram Figure 67 Engine Wiring Diagram ...

Page 49: ...DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 page 49 controller Wiring Diagram Figure 68 Controller Wiring Diagram ...

Page 50: ...tmeter Is wiring connection loose Check wiring and repair Is AVR defective Replace if necessary Defective Rotating Rectifier Check and replace Defective Exciter Field Check for approximately 17 3 ohms across J K on CN1 Low Voltage Output Is engine speed correct Turn engine throttle lever to High Is wiring connections loose Check wiring and repair Defective AVR Replace if necessary High Voltage Out...

Page 51: ...evel Fill coolant level Sending unit failure Replace sending unit Low battery voltage Replace charge battery High coolant temperature light is on Fan belt tension incorrect Tighten replace fan belt Air flow 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 Thermos...

Page 52: ...dimly lit when the MPEC Control Switch is placed in the MANUAL position 2 If engine trouble occurs the diagnostic lamp will be brightly lit as long as the control switch is left in the manual position 3 The diagnostic lamp will indicate that an engine malfunction has occurred NOTICE For a complete understanding of error codes and troubleshooting procedures refer to the enclosed engine instruction ...

Page 53: ...DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 page 53 notes ...

Page 54: ...oes not guarantee the availability of the parts listed 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 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 other parts that are sold in bulk and cut to length A blank entry ...

Page 55: ...1 m3310503703 radiator hose lower 1 0810105400 FUEL FILTER TANK dCA180SSI 3 8980714010 fuel filter FEED PUMP 3 8980088400 filter fuel element main 3 8980758540 filter fuel element pre 1 0602122272 UNIT OIL PRESSURE 1 0602123260 UNIT WATER TEMPERATURE 1 0601808803 CIRCUIT BREAKER 1P 20 AMP 1 0601808804 CIRCUIT BREAKER 2P 50 AMP 1 0601820601 AUTOMATIC VOLTAGE REGULATOR 1 LY2DUS24VDC RELAY 1 06018066...

Page 56: ...page 56 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 GENERATOR ASSY 1 4 1 4A 1 4B 10B 10A 10 14 14B 14A 19 20B 20A 20 22A 22 ...

Page 57: ...ING PLATE 1 PURCHASE 1 11 AS A SET 1 9 0012116045 HEX HEAD BOLT 8 1 10 0042616000 WASHER LOCK 8 1 11 0601000209 BALANCING WEIGHT KIT 1 1 12 C1112500004 BEARING FLANGE 1 1 13 0071906314 BEARING 1 2 C0164400503 COUPLING RING 1 DCA180SSI 2 M3163400603 COUPLING RING 1 DCA180SSIU 3 0010310050 HEX HEAD BOLT 8 4 0042510000 WASHER LOCK 8 5 0010312040 HEX HEAD BOLT 8 6 0042512000 WASHER LOCK 8 7 C013000090...

Page 58: ...page 58 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 GENERATOR ASSY CONTINUED 1 4 1 4A 1 4B 10B 10A 10 14 14B 14A 19 20B 20A 20 22A 22 ...

Page 59: ...2000 WASHER LOCK 12 19 C1132300114 COVER FAN 1 20 0010106030 HEX HEAD BOLT 1 20A 0041206000 WASHER FLAT 1 20B 0600815000 NUT 1 21 0605000012 RUBBER SUSPENSION 2 DCA180SSI 21 0605000013 RUBBER SUSPENSION 2 DCA180SSIU 22 0030020000 HEX NUT 4 DCA180SSI 22 0030016000 HEX NUT 4 DCA180SSIU 22A 0040020000 WASHER LOCK 4 DCA180SSI 22A 0040016000 WASHER LOCK 4 DCA180SSIU 23 C0164600003 COUPLING ADAPTER 1 DC...

Page 60: ...page 60 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 control box ASSY ...

Page 61: ...LATE 6 DCA180SSI 10 M3276300004 CHANGE OVER PLATE 6 DCA180SSIU 11 8131852504 TIE BOLT 20 DCA180SSI 11 M4276100004 TIE BOLT 20 DCA180SSIU 12 0040010000 WASHER LOCK 20 13 0041410000 WASHER FLAT 20 14 0017110040 HEX HEAD BOLT 3 15 0207010000 HEX NUT 3 16 0016908030 HEX HEAD BOLT 4 17 0601820601 AUTOMATIC VOLTAGE REGULATOR 1 18 0027105016 MACHINE SCREW 4 19 0601820847 OVER CURRENT RELAY 1 20 060182084...

Page 62: ...page 62 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 control box ASSY continued ...

Page 63: ...05016 MACHINE SCREW 2 47 5825500300 RELAY 1 REPLACES P N 0602201222 48 0027105016 MACHINE SCREW 1 49 8944607060 RELAY GLOW PLUG 1 REPLACES P N 0602202683 50 0027105016 MACHINE SCREW 2 51 3871824004 STOPPER CONTROL PANEL 1 DCA180SSI 51 M4213600104 STOPPER CONTROL PANEL 1 DCA180SSIU 52 0041206000 WASHER FLAT 1 53 0605010502 SNAP PIN 1 54 M4213500104 COVER CONTROL BOX 1 55 0016908020 HEX HEAD BOLT 8 ...

Page 64: ...page 64 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 control box ASSY continued ...

Page 65: ...GAUGE 1 80 0602103090 ALARM LAMP 3 80A 0601810244 BULB 3 81 0601810171 PANEL LIGHT 1 82 0027104020 MACHINE SCREW 2 83 0601831330 SWITCH PANEL LIGHT 1 84 0601831557 EMERGENCY STOP BUTTON 1 DCA180SSI 84 0601831589 EMERGENCY STOP BUTTON 1 DCA180SSIU 85 0845056404 SET SCREW 2 DCA180SSI 85 M9220100004 SET SCREW 2 DCA180SSIU 85A 0080200007 SNAP RING 2 86 0602122272 UNIT OIL PRESSURE 1 87 M9200100004 ADA...

Page 66: ...page 66 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 ENGINE AND RADIATOR ASSY ...

Page 67: ...M9200101004 ADAPTER 1 10 0150000016 O RING 1 11 0602123290 COOLANT LEVEL SWITCH 1 12 0016908020 HEX HEAD BOLT 16 13 M3310503903 RADIATOR HOSE 1 14 M3310503703 RADIATOR HOSE 1 15 0605515137 HOSE BAND 1 DCA180SSI 15 0605515148 HOSE BAND 2 DCA180SSIU 16 0605515137 HOSE BAND 1 DCA180SSI 16 0605515148 HOSE BAND 1 DCA180SSIU 17 0605515141 HOSE BAND 1 DCA180SSI 17 0605515146 HOSE BAND 1 DCA180SSIU 18 135...

Page 68: ...page 68 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 ENGINE AND RADIATOR ASSY continued ...

Page 69: ... 2 DCA180SSIU 33 0016908025 HEX HEAD BOLT 4 34 0207008000 HEX NUT 4 35 M3373101603 HOSE AIR CLEANER 1 36 M3373101703 HOSE AIR CLEANER 1 37 M3326100304 BLOWBY PIPE 1 38 0605515211 HOSE BAND 1 DCA180SSI 38 0605515200 HOSE BAND 1 DCA180SSIU 39 0605515260 HOSE BAND 3 DCA180SSI 39 0605515202 HOSE BAND 3 DCA180SSIU 40 0191701230 BLOWBY HOSE 1 41 0605515068 HOSE BAND 2 DCA180SSI 41 0605515149 HOSE BAND 2...

Page 70: ...page 70 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 ENGINE AND RADIATOR ASSY continued ...

Page 71: ...RESERVE TANK 1 DCA180SSIU 60 0602010900 CAP RESERVE TANK 1 61 M3316100604 BRACKET RESERVE TANK 1 62 0016908020 HEX HEAD BOLT 2 63 0199901150 HOSE 1 64 0193601450 HOSE 1 65 0193600650 HOSE 1 66 0605515106 HOSE BAND 3 67 M3357300004 HARNESS CLAMP 1 68 0017108025 HEX HEAD BOLT 1 DCA180SSI 68 0017108020 HEX HEAD BOLT 1 DCA180SSIU 69 0017110020 HEX HEAD BOLT 1 70 M3357300104 HARNESS CLAMP 1 71 00171080...

Page 72: ...page 72 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 OUTPUT TERMINAL ASSY 4 5 6 12 29 29A 29 29A 13C 13 13A 11 12A 11B 11A 13B 10 ...

Page 73: ...1203000 WASHER FLAT 4 12 0027103015 MACHINE SCREW 4 12A 003003000 HEX NUT 4 13 M9220100404 SET SCREW 2 DCA180SSI 13 M9220100804 SET SCREW 2 DCA180SSIU 13A 0040006000 WASHER LOCK 2 13B 0041806000 WASHER FLAT 2 13C 0080200005 RETAINING RING 2 14 0016906016 HEX HEAD BOLT 2 15 0016906016 HEX HEAD BOLT 2 16 M4236400004 CABLE OUTLET COVER 1 17 M4236400104 SUPPORTER CABLE OUTLET COVER 1 18 0016906020 HEX...

Page 74: ...page 74 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 OUTPUT TERMINAL ASSY continued 4 5 6 12 29 29A 29 29A 13C 13 13A 11 12A 11B 11A 13B 10 ...

Page 75: ... 29 0027104016 MACHINE SCREW 10 29A 0207004000 HEX NUT 10 30 M4236400204 COVER 1 31 0016906016 HEX HEAD BOLT 8 32 M4236100303 TERMINAL COVER 1 33 0010112045 HEX HEAD BOLT 2 34 0041212000 WASHER FLAT 4 35 0805009804 STAY RUBBER 2 DCA180SSI 35 M9310200004 STAY RUBBER 2 DCA180SSIU 36 0030012000 HEX NUT 2 37 0605011505 STAY 1 38 0027105016 HEX HEAD BOLT 4 39 M4236100604 COVER 1 40 M4236400304 BRACKET ...

Page 76: ...page 76 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 BATTERY ASSY DCA180SSI ...

Page 77: ...RY BOLT 2 5 0037808000 WING NIUT 2 6 0040008000 WASHER LOCK 2 7 0041608000 WASHER FLAT 2 8 C0346400804 BATTERY CABLE 1 9 C0346401004 BATTERY CABLE 1 10 C0346400904 BATTERY CABLE 1 11 EARTH CABLE 1 12 0602220310 TERMINAL ASSY 2 13 0602220311 TERMINAL ASSY 2 14 0845040414 TERMINAL CAP 2 15 0845041304 TERMINAL CAP 2 16 0017112025 HEX HEAD BOLT 1 17 0040512000 TOOTHED WASHER 1 18 0016908020 HEX HEAD B...

Page 78: ...page 78 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 BATTERY ASSY DCA180SSIU ...

Page 79: ... M9310500014 BATTERY SHEET 2 3 M9103000804 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 M3346901904 BATTERY CABLE 1 6 M3346902104 BATTERY CABLE 1 7 M3346902204 BATTERY CABLE 1 8 EARTH CABLE 1 9 0017112025 HEX HEAD BOLT 1 10 0040512000 TOOTHED WASHER 1 11 0016908020 HEX HEAD BOLT 1 12 0040508000 TOOTHED WASHER 1 BATTERY ASSY DCA180SSIU ...

Page 80: ...page 80 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 Muffler Assy ...

Page 81: ...2311102 TAPE INSULATING 9 DCA180SSI 3A 0602311130 TAPE INSULATING 9 DCA180SSIU 4 1141451920 GASKET 1 REPLACES P N 0602311130 5 7502356004 GASKET 1 DCA180SSI 5 4333200004 GASKET 1 DCA180SSIU 6 0030710000 HEX NUT 8 7 0017110050 HEX HEAD BOLT 4 8 C1331300104 COVER 2 DCA180SSI 8 M4330300004 COVER 2 DCA180SSIU 9 0016908020 HEX HEAD BOLT 4 10 M4333300304 BRACKET 1 11 0016908020 HEX HEAD BOLT 4 12 060232...

Page 82: ...page 82 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 FUEL TANK ASSY DCA180SSI ...

Page 83: ...5 17 8980758550 FUEL FILTER PRE 1 REPLACES P N 0602042405 17A 8980758540 ELEMENT FUEL FILTER 1 REPLACES P N 0602042516 18 8973834270 JOINT PIPE 4 REPLACES P N 0602042661 19 1096750951 JOINT BOLT 4 REPLACES P N 0602042621 20 1096300860 PACKING 8 REPLACES P N 0602042641 21 0015310045 HEX SOCKET HEAD CAP SCREW 4 21A 0040010000 WASHER LOCK 4 21B 0041210000 WASHER FLAT 4 22 0010110080 HEX HEAD BOLT 2 2...

Page 84: ...page 84 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 2 3 FUEL TANK ASSY DCA180SSIU ...

Page 85: ... P N 0602042515 19 8980758551 FUEL FILTER PRE 1 REPLACES P N 0602042405 19A 8980758540 ELEMENT FUEL FILTER 1 REPLACES P N 0602042516 20 8973834270 JOINT PIPE 4 REPLACES P N 0602042661 21 1096750951 JOINT BOLT 4 REPLACES P N 0602042621 22 1096300860 PACKING 8 REPLACES P N 0602042641 23 0015310045 HEX SOCKET HEAD CAP SCREW 4 23A 0040010000 WASHER LOCK 4 23B 0041210000 WASHER FLAT 4 24 0010110080 HEX...

Page 86: ...page 86 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 ENCLOSURE ASSY ...

Page 87: ... M3310203503 SUPPORTER RADIATOR 1 12A M3493600504 ACOUSTIC SHEET 1 13 M9910203403 SUPPORTER RADIATOR 1 13A M3493600504 ACOUSTIC SHEET 1 14 M4310600304 RUBBER SHEET 2 15 0017112055 HEX HEAD BOLT 4 16 M3310202504 BRACKET RADIATOR 2 17 0016910025 HEX HEAD BOLT 4 18 0016910025 HEX HEAD BOLT 2 19 M3310203703 BRACKET INTER COOLER 2 20 0016910025 HEX HEAD BOLT 8 21 0016910025 HEX HEAD BOLT 8 22 M33103051...

Page 88: ...ion and parts manual rev 1 08 02 10 ENCLOSURE ASSY continued 5A 4A 8A 12A 13A 30A 31C 31 31B 32 32A 33A 36 36A 42A 34 43 44 44A 49A 52A 53A 63A 64A 64 60A 62A 67A 66A 68A 69A 71A 62 70A 82 82A 81A 81 77 75A 75A 75 43A 47 75 32B 32C 31A 88A 88 65A ...

Page 89: ... DOOR HANDLE ASSY 1 DCA180SSI 42 M9114000002 DOOR HANDLE ASSY 1 DCA180SSIU 42A C9312500004 SEAL RUBBER 1 43 0021806015 MACHINE SCREW 4 DCA180SSI 43 0021806016 MACHINE SCREW 4 DCA180SSIU 43A 0030006000 HEX NUT 4 44 0845047104 HINGE 2 DCA180SSI 44 9110100204 HINGE 2 DCA180SSIU 44A 0845045004 WASHER 2 DCA180SSI 44A 9116100004 WASHER 2 DCA180SSIU 45 0019208020 HEX HEAD BOLT 3 46 0845031504 BLIND PLUG ...

Page 90: ...ion and parts manual rev 1 08 02 10 ENCLOSURE ASSY continued 5A 4A 8A 12A 13A 30A 31C 31 31B 32 32A 33A 36 36A 42A 34 43 44 44A 49A 52A 53A 63A 64A 64 60A 62A 67A 66A 68A 69A 71A 62 70A 82 82A 81A 81 77 75A 75A 75 43A 47 75 32B 32C 31A 88A 88 65A ...

Page 91: ...COUSTIC SHEET 1 64 M3453006003 SIDE DOOR 1 64A M3493431404 ACOUSTIC SHEET 1 65 M3453006303 SIDE DOOR 1 65A M3493431504 ACOUSTIC SHEET 1 66 M3453303604 DUCT 1 66A M3493432004 ACOUSTIC SHEET 1 67 M3453303704 DUCT 1 67A M3493432104 ACOUSTIC SHEET 1 68 M3453303804 DUCT 1 68A M3493432204 ACOUSTIC SHEET 1 69 M3453303904 DUCT 1 69A M3493432304 ACOUSTIC SHEET 1 70 M3453304204 DUCT 1 70A M3493432504 ACOUST...

Page 92: ...page 92 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 ENCLOSURE ASSY continued ...

Page 93: ...04 HINGE 6 DCA180SSI 81 M9110100804 HINGE 6 DCA180SSIU 81A 0845045004 WASHER 8 DCA180SSI 81A M9116100004 WASHER 8 DCA180SSIU 82 0845047004 HINGE 5 DCA180SSI 82 M9110100904 HINGE 5 DCA180SSIU 82A 0845045004 WASHER 5 DCA180SSI 82A M9116100004 WASHER 5 DCA180SSIU 83 0019208020 HEX HEAD BOLT 25 84 0601850097 STOPPER 9 85 0025408025 MACHINE SCREW 9 86 0845031504 BLIND PLUG 11 DCA180SSI 86 M9310000004 B...

Page 94: ...page 94 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 RUBBER SEALS ASSY ...

Page 95: ...40 SEAL RUBBER 4 2 0228900945 SEAL RUBBER 4 3 0228901200 SEAL RUBBER 3 4 0228901260 SEAL RUBBER 3 5 0228901055 SEAL RUBBER 4 6 0228900580 SEAL RUBBER 1 7 0228900640 SEAL RUBBER 1 8 0229201130 SEAL RUBBER 1 9 0228801050 SEAL RUBBER 2 10 0228800550 SEAL RUBBER 1 11 0228800590 SEAL RUBBER 1 12 0228100560 SEAL RUBBER 2 13 0228100370 SEAL RUBBER 2 ...

Page 96: ...page 96 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 NAMEPLATE AND DECALS ASSY DCA180SSI ...

Page 97: ...ECAL DIAGNOSTIC BUTTON 1 C92002770 ENGINE RADIATOR GROUP 3 1 6360620204 DECAL OIL DRAIN PLUG 1 S 1885 3 2 6360610304 DECAL WATER 1 S 1880 3 3 B9504000404 DECAL WARNING MOVING PARTS 2 B90400040 3 4 1320610603 DECAL WATER OIL CHECK 1 S 1760 3 5 B9504100104 DECAL WARNING HOT COOLANT 1 B90410010 3 6 B9504000304 DECAL CAUTION HOT PARTS 1 B90400030 3 7 C9501100004 DECAL INTER COOLER DRAIN 1 C90110000 OU...

Page 98: ...page 98 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 NAMEPLATE AND DECALS ASSY cont DCA180SSI ...

Page 99: ...7 8 2 0600500090 EMBLEM 2 8 2A 0021106016 MACHINE SCREW 4 8 3 C1560100303 STRIPE 1 8 4 C0560100403 STRIPE 1 8 5 M3560104803 STRIPE 1 8 6 C1560100004 STRIPE 3 8 7 M3560104703 STRIPE 1 8 8 C0560100303 STRIPE 1 8 9 1320621504 DECAL SUPPORT HOOK 2 S 2257 8 10 M3550002204 DECAL CAUTION 1 M35000220 8 11 M9510000104 DECAL DOCUMENT BOX LOCATED 1 M91000010 8 12 A9504000014 DECAL DANGER EXHAUST GAS 1 A90400...

Page 100: ...page 100 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 NAMEPLATE AND DECALS ASSY DCA180SSIU ...

Page 101: ... 1 M92200050 ENGINE RADIATOR GROUP 3 1 M9500000004 DECAL OIL DRAIN PLUG 1 M90000000 3 2 M9500100004 DECAL WATER 1 M90010000 3 3 M9501000304 DECAL INTER COOLER DRAIN 1 M90010030 3 4 M9503000004 DECAL WARNING MOVING PARTS 2 M90300000 3 5 M9503000103 DECAL WATER OIL CHECK 1 M90300010 3 6 M9503100004 DECAL WARNING HOT COOLANT 1 M90310000 3 7 M9510100004 DECAL CAUTION HOT PARTS 1 M91010000 OUTPUT TERMI...

Page 102: ...page 102 DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 NAMEPLATE AND DECALS ASSY cont DCA180SSIU ...

Page 103: ...8 2A 0021106016 MACHINE SCREW 4 8 3 M4560101103 STRIPE 1 8 4 M3560104703 STRIPE 1 8 5 M3560104803 STRIPE 1 8 6 M4560100704 STRIPE 3 8 7 M4560101003 STRIPE 1 8 8 M4560101203 STRIPE 1 8 9 M3550002204 DECAL CAUTION 1 M35000220 8 10 M3550002204 DECAL DANGER EXHAUST GAS 1 M90320010 8 11 M9510000104 DECAL DOCUMENT BOX LOCATED 1 M91000010 8 12 A9504000014 DECAL SUPPORT HOOK 2 M91200000 8 13 M9504200004 D...

Page 104: ...paper products h Items purchased in kits 7 The sender will be notified of any material received that is not acceptable 8 Such material will be held for five working days from notification pending instructions If a reply is not received within five days the material will be returned to the sender at his expense 9 Credit on returned parts will be issued at dealer net price at time of the original pu...

Page 105: ...DCA180SSI dca180ssiu 60 hz Gen operation and parts manual rev 1 08 02 10 page 105 notes ...

Page 106: ...echnical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Further MQ Power disclaims any warranties or guaranties expressed or implied with regards to the information...