MQ Power WHISPERWATT DCA-180SSV Parts Manual

Download

Page 1

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

SERIES

MODEL DCA-180SSV

60 Hz GENERATOR

PARTS LIST NO. C0870301204

Serial Number 3770213~

Revision #1 (04/14/10)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

Page 2

Diesel engine exhaust and some of

PAGE 2 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 3

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 3

Page 4

MQ POWER DCA-180SSVMQ POWER DCA-180SSV

MQ POWER DCA-180SSV

MQ POWER DCA-180SSVMQ POWER DCA-180SSV

TMTM

WHISPERWHISPER

WHISPER

WHISPERWHISPER

California Proposition 65 Warning ..................................... 2

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

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

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

Specifications ................................................................... 6

Dimensions (Top, Side, Front) ........................................... 7

Safety Message Alert Symbols .................................... 8-9

Rules for Safe Operation ........................................... 10-13

Generator Decals....................................................... 14-15

Installation ................................................................. 16-17

General Information ........................................................ 18

Major Components ......................................................... 19

Generator Control Panel ............................................ 20-21

Engine Operating Panel .................................................. 22

Output Terminal Panel Familiarization ........................ 24-26

Load Application ............................................................. 27

Generator Outputs .......................................................... 28

Gauge Reading ............................................................... 29

Output Terminal Panel Connections ........................... 30-31

Setup ......................................................................... 32-35

Generator Start-up Procedure (Manual) ..................... 36-37

Generator Start-up Procedure (Auto Mode) .................... 38

Generator Shut-Down Procedure .................................... 39

Maintenance (Engine) ................................................ 40-42

Jacket Water Heater/battery Charger (Option) ................ 43

Maintenance (Trailer) ................................................. 44-47

Trailer Wiring Diagram .....................................................48

Generator Wiring Diagram ............................................... 49

Engine Wiring Diagram ................................................... 50

Generator Troubleshooting .............................................. 51

Engine Controller Troubleshooting ................................... 52

Troubleshooting Diagnostic Lamp ................................... 53

Explanation of Code in Remarks Column ....................... 54

Suggested Spare Parts .................................................. 55

TTTT

TMTM

GENERATORGENERATOR

GENERATOR

GENERATORGENERATOR

TABLE OF CONTENTS

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly .................................................. 56-57

Control Panel Assembly ............................................ 58-59

Control Box Assembly ............................................... 60-63

Engine and Radiator Assembly ................................. 64-65

Output Terminal Assembly ......................................... 66-67

Battery Assembly ...................................................... 68-69

Muffler Assembly ...................................................... 70-71

Fuel Tank Assembly .................................................. 72-73

Enclosure Assembly ................................................. 74-77

Rubber Seals Assembly ............................................ 78-79

Nameplate and Decals .............................................. 80-81

Terms and Condition of Sale — Parts ............................ 82

NOTE

Specification and part number are subject to change without notice.

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 5

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

, 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 Par ts

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.

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

www.mqpower.com

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 5

When ordering parts, please supply:

R Specify Preferred Method of Shipment: UPS/Fed Ex DHL

N Priority One Truck  N Ground N Next Day N Second/Third Day

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

Page 6

DCA-180SSV— SPECIFICATIONS

Table 1. Generator Specifications

Model DCA-180SSV

Typ e

Armature Connection Star with Neutral

Phase

Standby Output

Prime Output

Volt a g e — 1Ø

Volt a g e — 3Ø

Frequency

Speed

Power Factor

Aux. AC Power

Aux. Voltage/Output

Dry Weight

Wet Weight

Revolving field, self ventilated,

open protected type synchronous generator

198 KVA (158 KW)

180 KVA (144 KW)

120, 127, 139, 240, 254, and 277V

208, 220, 240, 416, 440, and 480V

60 Hz

1800 rpm

0.8

Single Phase, 60 Hz

120 VAC/ 4.8 Kw (2.4 kW x 2)

11,136 lbs. (5,050 kg.)

12,260 lbs. (5,560 kg.)

Model

Typ e

No. of Cylinders

Bore x Stroke

Displacement

Starting

Coolant Capacity

Lube Oil Capacity

Fuel Type

Fuel Tank Capacity

Fuel Consumption

Battery

Table 2. Engine Specifications

VOLVO TAD722GE

4 cycle, water-cooled, direct injection, turbo-charged

6 cylinders

5.15 in. x 5.90 in. (131 mm x 150 mm)

740.2 cu. in. (12,130 cc)

Electric 24 VDC

11.6 gal. (44 liters)

9.2 gal. (35 liters)

#2 Diesel Fuel

129 gal. (490 liters)

11.2 gal. (42.2 L)/hr at full load 8.5 gal. (32.0 L)/hr at 3/4 load

5.9 gal. (22.4 L) at 1/2 load 3.7 gal (14.0 L) at 1/4 load

12V-150 Ah x 2

PAGE 6 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 7

Figure 1. Dimensions

DCA-180SSV— DIMENSIONS (TOP, SIDE AND FRONT)

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 7

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm049(.ni00.73F ).mm055,3(.ni7.931

B).mm04

C).mm050,1(.ni33.14H ).mm002,1(.ni42.74

D).mm050,1(.ni33.14

E).mm050,1(.ni33.14

9(.ni00.73G ).mm008,1(.ni89.07

).mm(.ninoisnemiDretteLecnerefeR).mm(.ninoisnemiD

Page 8

DCA-180SSV— SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

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.

This Owner's Manual has been

NOTE

developed to provide complete instructions for the safe and efficient operation of the MQ Power

Model DCA-180SSV

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " appear throughout this manual, and will be referenced in conjunction with Safety "

WARNING - LETHAL EXHAUST GASES

Whisperwatt™ Generator.

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

equipment in a confined area or enclosed structure that does not provide ample free flow air.

WARNING - EXPLOSIVE FUEL

DO NOT overfill tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

Hazard Symbols

Message Alert Symbols

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

DEATH

if inhaled. NEVER operate this

Gasoline

its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

is extremely flammable, and

" which

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

electrical shock or burn, severe bodily harm

electrocution,

which can cause

or even

DEATH!

Page 9

DCA-180SSV— SAFETY MESSAGE ALERT SYMBOLS

WARNING - ROTATING PARTS

NEVER operate equipment with covers,

or guards removed. Keep

hair

and clothing away from all moving

parts to prevent injury.

CAUTION - ACCIDENTAL STARTING

ALWAYS place the Engine ON/OFF

switch in the OFF position and remove the ignition key when the pump is not in use.

CAUTION - OVER-SPEED CONDITIONS

NEVER tamper with the factory settings

of the engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

fingers, hands

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

ALWAYS wear approved protection.

ALWAYS wear approved

hearing

protection.

respiratory

eye

and

NOTE

This generator, other property, or the surrounding environment could be damaged if you do not follow instructions.

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 9

Page 10

DCA-180SSV— RULES FOR SAFE OPERATION

■

DANGER - READ THIS MANUAL!

Failure to follow instructions in this manual may lead to

serious injury

operated by trained and qualified personnel only! This equipment is for industrial use only.

The following safety guidelines should always be used when operating the

General Safety:

■

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

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

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

■

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

or even

DEATH

! This equipment is to be

DCA-180SSVWhisperwatt™ AC Generator.

ALWAYS check the machine for loosened threads or bolts

before starting.

■

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

■

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

■

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

hot!

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

bodily harm or even death.

NEVER

operate the generator in any

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

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

DO NOT leave the generator running in the unattended.

Refer to the technical questions or information.

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.

VOLVO Engine Owner's Manual

manual mode

for engine

PAGE 10 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 11

DCA-180SSV— RULES FOR SAFE OPERATION

Generator Grounding

DANGER - ELECTROCUTION HAZARDS

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

During operation of this generator, there exists the possibility of

electrical shock or burn,

Article 250 (Grounding) of the

National Electrical Code

severe bodily harm

(NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

The following safety recommendations should also be followed:

To avoid these hazards:

NEVER use damaged or worn cables when connecting equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

DEATH!

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

ungrounded generator.

■

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

and electrical shock.

NEVER grab or touch a live power cord with wet hands.

NEVER touch output terminals

during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

electrocution,

which can cause

or even

DEATH!

POWER

CORD

(POWER ON)

WET

HANDS

Electrical Safety

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

ALWAYS make sure generator installation is accordance with the

National Electrical Code

(NEC) and local codes

before operating generator.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.

■

NEVER power cables or cords

■

NEVER

stand in water

while AC power from the generator

lay in wate

is being transfer to a load.

Backfeed to a utility system can cause

electrocution

and or property

damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened. ALWAYS have a licensed electrician perform the installation

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 11

Page 12

DCA-180SSV— RULES FOR SAFE OPERATION

Maintenance Safety

■

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn all circuit breakers OFF before performing maintenance on the generator.

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator.

■

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

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace broken parts.

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

Radiator Cap - Removing the radiator cap while the

engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■

Coolant Drain Plug - Removing the coolant drain plug

while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

NEGATIVE battery terminal

Battery Safety

Use the following guidelines when handling the battery:

■

■■

■

■■

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, glasses.

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid

DO NOT drop the battery. There is the possibility of risk that the battery may explode.

DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible gas will occur.

ALWAYS keep battery charging and cables in good working condition. Repair or replace all worn cables.

ALWAYS recharge the battery in an vented air environment, to avoid risk of a dangerous concentration of combustible gases.

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

In case the battery liquid (dilute sulfuric acid) comes in contact with your plenty of water and contact the nearest doctor or hospital to seek medical attention.

always

wear safety

severe injury

clothing or skin

EYES

, rinse skin or clothing

, rinse eyes immediately with

DEATH:

■

Engine Oil Drain Plug - Removing the engine oil drain

plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

PAGE 12 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 13

DCA-180SSV— RULES FOR SAFE OPERATION

■

Towing & Transporting Safety

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 in good operating condition and both units are mechanically sound.

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

Transportation

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

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.

(DOT)

Safety Towing Regulations

Towing & Transporting Safety

Department of

, before

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.

■

Place while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

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.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

Emergencies

chock blocks

support blocks

underneath wheel to prevent rolling,

underneath the trailer’s bumper to

■

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

■

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

■

ALWAYS attach trailer’s safety chains to towing vehicle properly.

■

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

■

DOT Requirements include the following:

 

Trailer tires should be inflated to 50 psi cold.

Connect and test electric brake operation. Secure portable power cables in cable tray with tie wraps.

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 13

■

ALWAYS know the location of the nearest

ALWAYS know the location of the nearest and

ALWAYS know the location of the nearest phone or

the job site,

ALWAYS have easy access to the phone

numbers of the nearest and be invaluable in the case of an emergency.

fire extinguisher

first aid kit

keep a phone on

in case of emergencies.

Fire Department

Ambulance, Doctor

. This information will

Page 14

DCA-180SSV— GENERATOR DECALS

The DCA-180SSVgenerator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 14 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Figure 2. Generator Decals

Page 15

DCA-180SSV— GENERATOR DECALS

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 15

Figure 3. Generator Decals (Cont inued)

Page 16

DCA-180SSV— INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 17

DCA-180SSV— 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 - EXHAUST HAZARD

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.

Indoor Installation

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies 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 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 4) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

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

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 firmly on the foundation to isolate 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.

NOTE

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

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 17

Page 18

DCA-180SSV— GENERAL INFORMATION

DCA-180SSVWhisperwatt™ Series Familiarization Generator

The MQ Power Model DCA-180SSVis a 158 kW

generator

(Figure 5) 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.

Open Delta Excitation System

The DCA-180SSVgenerator is equipped with the state of the art "

Open-Delta

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,

Engine Operating Panel

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

Tachometer Water Temperature Gauge Oil Pressure Gauge Charging Ammeter Gauge Fuel Level Gauge Pre-Heat Button Engine Speed Switch Coolant Level Alarm Lamp

Generator Control Panel

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

■■

■

Frequency Meter (Hz)

■■

■

AC Ammeter (Amps)

■■

■

AC Voltmeter (Volts)

■■

■

Ammeter Change-Over Switch

■■

■

Voltmeter Change-Over Switch

■■

■

Voltage Regulator

■■

■

Panel Light/Panel Light Switch

■■

■

3-Pole, 500 amp Main Circuit Breaker

■■

■

“Control Box” (located behind the Gen. Control Panel)

■■

■

Automatic Voltage Regulator

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifer

■■

■

Starter Relay

■■

■

Engine Controller (Computer Controlled)

■■

■

Voltage Change-over Board

■■

Output Terminal Panel

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

■■

■

Three 120/240V output receptacles (CS-6369), 50A

■■

■

Three auxilliary circuit breakers, 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Five output terminal lugs (3Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

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 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 open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a " according the demands of the required load.

Engine

The DCA-180SSVis powered by a 6 cylinder, water cooled, direct injection, turbocharged

TAD722GEGE Diesel Engine

meet every performance requirement for the generator. Reference Table 1 for engine specifications.

In keeping with MQ Power's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

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.

" excitation system. The open delta system

fixed ceiling

" and responds

VOLVO Model PENTA

. This engine is designed to

PAGE 18 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 19

DCA-180SSV— MAJOR COMPONENTS

4elbaT. stnenopmoCrojaMrotareneG

.ONMETINOITPIRCSED

1ylbmessArelffuM

2ylbmessAretliFriA

3ylbmessArotareneG

4ylbmessAlenaPlanimreTtuptuO

5ylbmessA

6ylbmessAselcatpeceRtuptuO

7ylbmessArotaidaRdnaenignE

8ylbmessAknaTleuF

9ylbmessArekaerBtiucriC

01ylbme

11ylbmessAlenaPlortnoCrotareneG

Figure 5. Major Components

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 19

yrettaB

ssAlenaPlgnitarepOenignE

Page 20

NOTE PAGE

PAGE 20 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 21

DCA-180SSV— GENERATOR CONTROL PANEL

Figure 6. Generator Control Panel

The definitions below describe the controls and functions of the DCA-180SSVU

Generator Control Panel

(Figure 6).

1. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz.

2. AC Ammeter – Indicates the amount of current the load

is drawing from the generator per leg selected by the ammeter phase-selector switch.

3. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading

Located behind the generator control panel is the

Control Box

electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■■

■

Over-Current Relay

■■

■

Voltage Rectifer (AVR)

■■

■

Starter Relay

■■

■

Current Transformer

■■

■

Voltage Selector Board

■■

■

Three Phase Circuit Breaker

■■

only.

4. Voltage Regulator Control – Allows ±15% manual

NOTE

adjustment of the generator’s output voltage.

5. AC Voltmeter – Indicates the output voltage present at

the

U,V, and W Output Terminal Lugs

6. Voltmeter Change-Over Switch – This switch allows

the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

7. Main Circuit Breaker – This three-pole, 600A main

breaker is provided to protect the the

Terminal Lugs

from overload.

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 21

U,V, and W Output

In the event of a short circuit or over current condition, it will automatically trip the 600 amp main breaker.

To restore power to the

reset

button on the overcurrent relay and place the

circuit breaker in the

Generator

. This box contains some of the necessary

Remember the

relay

monitors the current

flowing from the

Output Terminal Lugs

overcurrent

U,V, and W

to the

load.

Output Terminal Panel

, press the

main

closed

position (ON).

Page 22

DCA-180SSV— ENGINE OPERATING PANEL

PAGE 22 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Figure 7. Engine Operating Panel

Page 23

DCA-180SSV— ENGINE OPERATING PANEL

The definitions below describe the controls and functions of the DCA-220SSVU

1. Panel Light – 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.

2. Panel Light Switch – When activated will turn on control

panel light.

3. Oil Pressure Gauge – During normal operation this

gauge be should read between 44 to 73 psi. (303~503 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.

4. Water Temperature Gauge – During normal operation

this gauge be should read between 189° and 216°F.

5. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

8. Coolant Alarm Lamp – This lamp will illuminate when

the coolant level falls below a safe operating level and the engine will stop.

9. Auto On/Off Engine Controller (MPEC) –

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

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

Crank Protection

(RPM's) that is not safe, the controller will shutdown the engine by initializing the

Engine Operating Panel

(Figure 7).

cranking

Over

mode. If the engine engages at a speed

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.

A. 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 an automatic 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 auto-start contacts connected to the ATS’s start contacts. Please refer to your ATS installation manual for further instructions for the correct installation of the auto-start contacts of the generator to the ATS.

B. Low Oil Pressure – Indicates the engine pressure has

fallen below 29 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a

C. High Coolant Temperature – Indicates the engine

temperature has exceeded 235°F. The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a

major

D. Overcrank Shutdown – Indicates the unit has

attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. It is pre-set at 3 cycles with a 10 second duration. This is considered a fault.

E. Overspeed Shutdown – Indicates the engine is running

at an unsafe speed. This is considered a

F. Engine Running – Indicates that engine is running at

a safe operating speed.

fault.

major

fault.

major

fault.

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 23

Page 24

DCA-180SSV— OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The

Output Terminal Panel

(Figure 8) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles and terminal

Output Terminal Familiarization

The “

Output Terminal Panel

following:

■■

■

Three (3) 120/240V output receptacles @ 50 amp

■■

lugs.

■■

■

Three (3) Circuit Breakers @ 50 amps

■■

Two (2) 100V GFCI receptacles @ 20 amp

■

■■

Two (2) GFCI Circuit Breakers @ 20 amps

■

■■

■

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

■■

NOTE

Terminal legs “O” and “Ground” are considered

bonded grounds

” (Figure 8) is provided with the

Figure 8. Output Terminal Panel

PAGE 24 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 25

DCA-180SSV— OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) recepacles provided on the output terminal panel. These receptacles can be accessed in any position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the being tripped. Pressing the the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

reset

button resets the GFCI receptacle after

voltage selector switch

Test Button

(See Figure 9) in

Each auxilliary 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 is dependent on the load requirements of the

Output Terminal Lugs

Turn the control panel to obtain the desired voltage. Turning the knob clockwise will clockwise will

voltage regulator control knob

increase

decrease

Figure 11. Voltage Regulator Control Knob

the voltage, turning the knob counter-

the voltage.

(Figure 11) on the

Figure 9. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxilliary twist-lock (CS-6369) recepacles (Figure 10) provided on the output terminal panel.These receptacles can when the voltage selector switch is placed in the

only

be accessed

single-

phase 240/120 position.

Figure 10. 120/240V Twist-Lock

Auxiliary Receptacles

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 25

Page 26

DCA-180SSV— OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

Terminal Lugs

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 1000A to switch ALL circuit breakers to the OFF position prior to starting the engine.

or the convienience receptacles (Figure 12).

main

circuit breaker is provided. Make sure

Ouput

Over Current Relay

over current relay

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 rent relay must be pressed. The over current relay is located in the control box.

(Figure 13) is connected to the main

reset button

Figure 13. Over Current Relay

on the over cur-

Figure 12. Connecting Loads

PAGE 26 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 27

DCA-180SSV— LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage,

frequency

Three Phase Load

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

, 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 influenced by the efficiency, power factor and

NOTE

starting system of the equipment.

If wattage is not given on the equipment's name plate,

NOTE

approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

NOTE

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out

daoLyBrotcaFrewoP.5elbaT

daoLfOepyTrotcaFrewoP

srotomnoitcudniesahp-elgniS57.0-4.0

tnecsednacni,sretaehcirtcelE

spmal

m,spmaltnecseroulF9.0-4.0

tnempiuqe

slootrewopnommoC8.0

spmalyrucre

noitacinummoc,secivedcinortcelE

0.1

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.

■■

■

When connecting a fluorescent or mercury lamp, a

■■

capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

■■

■

When connecting an electric drill or other power tools,

■■

pay close attention to the required starting current capacity.

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

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

nitnerruC

serepmA

5.20

50060021.tf005.tf003.tf002.tf521

5.70090081.tf053.tf002.tf521.tf001

0100210042.tf052.tf051.tf00

5100810063.tf051.tf001.tf56

0200420084.tf521.tf57.tf05

sttaWnIdaoLhtgneLelbaCelbawollAmumixaM

001tA

stloV

03006.tf0001.tf006.tf573.tf052

002tA

stloV

eriW01#eriW21#eriW41#eriW61#

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 27

)noitarepOesahPelgniS,zH06(noitceleSelbaC.6elbaT

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 - ELECTRICAL SYSTEM HAZARDS

.egatlovwolmorftlusernacegamadtnempiuqE:NOITUAC

Before connecting this generator to any building’s electrical system, a

(transfer) switch

licensed electrician

must install an

. Serious damage to the building’s

isolation

electrical system may occur without this transfer switch.

Page 28

DCA-180SSV — GENERATOR OUTPUTS

sgnitaRerepmArotareneG.9elbaT

⎯⎯⎯⎯⎯3∅∅∅∅∅

AVKV042V084

028442

046984

0644127

0829169

001142021

021982441

041733861

061483291

)xaM(081334612

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 change-over board

(Figure 14).

Generator Amperage

Tables 8 and 9 describe the generator’s current output capability for both 1Ø-phase and 3Ø phase applications.

To obtain some of the voltages as listed in Table 6 (see below) will require a fine adjustment using the

lator

(VR)

control knob

located on the control panel.

voltage regu-

Voltage Change-Over Board

The

voltage change-over board

(Figure 14) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection.

WkV021V042

8105157

83613851

85384762

87056632

89718294

811389913

831051,1575

)xaM(851713,1856

sgnitaRerepmArotareneG.8elbaT

⎯⎯⎯⎯⎯1∅∅∅∅∅

Figure 14. Voltage Change-Over Board

CAUTION - CHANGING VOLTAGES

NEVER attempt to place jumper plates on the

change-over board

There exist the possibility of

while the generator is in operation.

electrocution, electrical

voltage

shock or burn, which can cause severe bodily harm or even death

elbaliavAsegatloV.7elbaT

esahPeerhT )elbahctiwS(

esahPelgniS )elbahctiwS(

V802V022V042V614V044V084

V021V721V931V042V452V772

PAGE 28 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 29

DCA-180SSV— GENERATOR OUTPUTS/ GAUGE READING

Maximum Amps

Table 10 shows the vide. DO NOT exceed the maximum amps as listed.

maximum

ledoMUVSS022ACD

amps the generator can pro-

egatloVdetaRspmAmumixaM

spmAmumixaMrotareneG.01elbaT

esahPelgniS

tloV021

elgniS

esahP

tloV042

esahPeerhT

tloV042

esahPeerhT

tloV084

)eriw4(spma004

)eriw4(spma002

Figure 16. AC Voltmeter

Change-Over Switch

spma334

spma612

How to Read the Output Terminal Gauge.

The AC ammeter and AC voltmeter change-over switches on the control panel DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

When the voltage change-over board is jumpered for 3Ø, 240V operation (See Figures 16 and17), place the

meter Change-Over Switch

W-U position and the

(See Figures 18 and 19) to the

AC Ammeter Change-Over Switch

AC Volt-

Figure 18. AC Ammeter

Change-Over Switch

(Figure 18) to the U or W position to read the output on the selected leg.

Figure 17. AC Voltmeter Gauge

(Volt reading on W-U Lug)

Figure 19. AC Ammeter (Amp reading on U lug)

Figure 15. Voltage Change-Over Board

240V Configuration

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 29

NOTE

The

ammeter

gauge will only

show a reading when the

Output Terminal Lugs

are

connected to a load and in use.

Page 30

DCA-180SSV— 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 Change-Over Board Voltage Regulator Control Knob

and the adjustment of the

Figure 22. Voltage Regulator Knob

Remember the voltage change-over board determines the

range

of the output voltage and can be configured 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 configuration. The voltage regulator (VR) allows the user to increase or decrease the selected

1Ø-240V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 20 .

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 20.

Figure 20. Voltage Change-Over Board

240V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 21.

1Ø-139V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 20.

2. Connect the load wires to the UVWO terminals as shown in Figure 24.

Figure 23. UVWO Terminal Lugs

1Ø-240V Connections

Figure 21. UVWO Terminal Lugs

3Ø-240V Connections

3. Turn the voltage regulator knob (Figure 22) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required

PAGE 30 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Figure 24. UVWO Terminal Lugs

1Ø-139V Connections

Page 31

DCA-180SSV— OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation

as shown in Figure 25. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate

must

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 25.

2. Connect the load wires to the UVWO terminals as shown in Figure 27.

be used.

Figure 25. Voltage Change-Over Board

480V Configuration

2. Connect the load wires to the UVWO terminals as shown in Figure 26.

1Ø-277V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 25.

Figure 27. UVWO Terminal Lugs

1Ø-480V Connections

NOTE

Figure 26. UVWO Terminal Lugs

3Ø-480V Connections

ALWAYS make sure that the

connections to the UVWO terminals are The possibility of arcing exists, that could cause a fire.

secure

2. Connect the load wires to the UVWO terminals as shown in Figure 28.

Figure 28. UVWO Terminal Lugs

1Ø-277V Connections

and tight.

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 31

Page 32

DCA-180SSV— SETUP

Circuit Breakers

Fuel Check

To protect the generator from an overload, a 3-pole, 600 amp,

main

circuit breaker is provided to protect the

Output Terminals

20 amp

GFCI

from overload. In addition two single-pole,

circuit breakers are provided to protect the

GFCI receptacles from overload. Three 50 amp

U,V, and W

load

circuit

breakers have also been provided to protect the auxiliary

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

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 filler hole, but DO NOT overfill. Make sure the generator is level. and verify that the oil level is maintained between the two notches (Figure 29) on the dipstick. See Table 11 for proper selection of engine oil.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

Figure 29. Engine Oil Dipstick

This generator has an internal fuel tank located inside the

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 refill with the specified amount of oil as outlined in the Volvo 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

■■

trailer frame and may also be equipped with an environmental fuel tank (Figure 30). fresh

#2 diesel fuel.

capacities.

Pay attention to the fuel tank capacity when replenishing fuel.The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

hot

engine can cause a

ALWAYS

fill the fuel tanks with clean

fire

explosion

DO NOT fill the fuel tanks beyond their

PAGE 32 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Figure 30. Internal Fuel Tank System

Page 33

DCA-180SSV— SETUP

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks – 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 31).

CAUTION - REFUELING THE GENERATOR

ALWAYS

to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

place trailer on firm level ground before refueling

3. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and fill tank (Figure 32).

Figure 32. Fueling the Generator

Figure 31. Only Fill on Level Ground

NOTE

ONLY! use

refueling.

#2 diesel fuel

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 33).

when

Figure 33. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 34).

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 33

Figure 34. Fuel Expansion

Page 34

DCA-180SSV— SETUP

Coolant (Antifreeze/Summer Coolant/Water)

VOLVO recommends VOLVO antifreeze/summer coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the VOLVO Engine Owner's Manual for further details.

Cleaning the Radiator

The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the

negative

WARNING - BURN HAZARDS

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in

If adding coolant/antifreeze mix to the

accordance with the VOLVO Engine Owner's Manual.

radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of

hot!

coolant exists which

can cause severe burns.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the VOLVO

Day-to-day 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 12 for engine, radiator, and recovery tank coolant

Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 35) when depressed with the thumb as shown below.

capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

battery terminal disconnected.

yticapaCtnalooC.21elbaT

rotaidaRdnaenignE)sretil81(.laG8.4

knaTevreseR)sretil9.1(strauQ2

Operation Freezing Weather

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

ezeerF-itnA.31elbaT

serutarepmeTgnitarepO

tnioPgnizeerF

NOTE

%loV

ezeerF-itnA

C°F°

0573-43-

When the antifreeze is mixed with water, the antifreeze mixing ratio

must be

less than 50%.

Figure 35. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

PAGE 34 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 35

DCA-180SSV— SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level 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. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates 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

ALWAYS be sure the battery cables (Figure 36) 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 - BATTERY SERVICING SAFETY

Always

keep the terminals firmly tightened.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the the MANUAL position. ALWAYS make sure that the

Control Switch

connecting the battery.

2. Place a small amount of battery terminal treatment

compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTE

CAUTION - BATTERY SERVICING SAFETY

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

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.

MPEC Control Switch

is in either

MPEC

is in the OFF/RESET position when

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.

ALWAYS

reconnect negative terminal LAST.

disconnect the negative terminal FIRST and

Figure 36. Battery Connections

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 35

DO NOT put water directly on the alternator. Entry of water

into the alternator can cause corrision 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 ( immediately.

fuel

oil

) lines are defective replace them

Page 36

DCA-180SSV— GENERATOR START-UP PROCEDURE (MANUAL)

Before Starting

CAUTION - LETHAL EXHAUST HAZARD

The engine's exhaust contains harmful emissions.

ALWAYS have adequate ventilation when operating

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

NEVER!

1. Place the

manually start the engine with the

auxiliary

(Figure 37) in the OFF position prior to starting the engine.

circuit breakers in the ON (closed) position.

main, G.F.C.I.,

and

aux.

main, GFCI

circuit breakers

Starting (Manual)

1. Place the engine speed switch (Figure 39) in the “ (down) position.

2. Once the engine glow plugs have been warmed, place the start the engine (Figure 40).

3. Once the engine starts, let it engine run for 1-2 minutes. Listen for any abnormal noises. If any abnormalities exists shutdown the engine and correct the problem. If the engine is running smoothly, place the engine speed switch (Figure 41) in the “

LOW

Figure 39. Engine Speed Switch (Low)

MPEC Control Switch

Figure 40. MPEC Control Switch

(Manual Position)

in the MANUAL position to

HIGH

” (up) position.

”

Figure 37. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the the been configured for the desired output voltage.

3. Connect the load to the

terminal lugs

connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

4. Tighten terminal nuts securely to prevent load wires from slipping out.

5. Close all engine enclosure doors (Figure 38).

voltage change-over board

receptacles or

as shown in Figure 12. These load

the

has

output

4. Verify that the Engine Running

status LED on the MPEC unit (Figure 42) is ON (lit) after the engine has been started.

Figure 41. Engine Speed Switch (High)

Figure 42. Engine Running LED (ON)

Figure 38. Engine Enclosure Doors

PAGE 36 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 37

DCA-180SSV— GENERATOR START-UP PROCEDURE (MANUAL)

5. The generator's frequency meter (Figure 43) should be

displaying the 60 cycle output frequency in HERTZ.

Figure 43. Frequency Meter (Hz)

6. The generator's AC-voltmeter (Figure 44) will display the

generator’s output in VOLTS. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 45) to increase or decrease the desired voltage.

9. The (Figure 48) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 189 and 216 degrees Fahrenheit (

10. The will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1600 RPM’s.

11. Place the

ON position (Figure 50).

coolant temperature gauge

Green Zone

tachometer gauge

main, GFCI

Temperature Gauge

(Figure 49)

, and

aux

. circuit breakers in the

Figure 48. Coolant

Figure 49. Engine

Tachometer Gauge

Figure 44. Voltmeter

Figure 45. Voltage Adjust Control Knob

7. The ammeter (Figure 46) will indicate applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

8. The engine oil pressure gauge (Figure 47) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 44 to 73 psi. (303~503 kPa). When starting the genera

zero amps

with no load

Figure 46. Ammeter

(No Load)

Figure 47. Oil

Pressure Gauge

Figure 50. Main, Aux. and GFCI

Circuit Breakers (ON)

12. Observe the generator's ammeter (Figure 51) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 51. Ammeter

(Load)

13. The generator will run until manually stopped or an

abnormal condition occurs.

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 37

Page 38

DCA-180SSV— GENERATOR START-UP PROCEDURE (AUTO MODE)

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

electrician (transfer) switch

building’s electrical system may occur without this transfer switch.

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.

NOTE

must install an

. Serious damage to the

CAUTION - BACKUP GENERATOR USE

When the generator is set in the

AUTO mode, the generator will

automically start

comercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

licensed

isolation

in the event of

When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below).

1. Perform steps 1 through 5 in the as outlined in the

2. Place the position

3. Place the position

4. Continue operating the generator as outlined in the

Manual Start-up

Manual

Before Starting

Manual Starting Procedure

engine speed switch

Figure 52. Engine Speed Switch (High)

MPEC Control Switch

Figure 53. MPEC Control Switch (AUTO)

procedure (start at step 5).

(Figure 53) in the HIGH

(Figure 54) in the AUTO

section .

WARNING - AUTO MODE MAINTENANCE

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 - ENGINE SPEED SWITCH

The

Engine Speed Switch

position when running in the set the switch in the proper position can result in damage to your generator when it turns on.

NOTE

must be set to the “High”

Auto-Start

When the MPEC is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically.

mode. Failing to

Control Switch

PAGE 38 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 39

DCA-180SSV— GENERATOR SHUT-DOWN PROCEDURES

WARNING -

NEVER stop the engine suddenly except in an emergency.

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 38 to the OFF position.

2. Place the engine speed switch (Figure 54) in the “

(down) position.

Figure 54. 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

OFF/RESET position.

SHUTTING DOWN THE GENERATOR

MPEC Control Switch

(Figure 55) in the

LOW

Emergency Shutdown Procedure

1. To stop the engine in the event of an emergency place the OFF/RESET position.

”

MPEC Control Switch

(Figure 55) in the

Figure 55. MPEC Control Switch (Off/Reset)

5. Verify that the

are OFF (not lit).

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening of components that may have occured during operation.

all

status LED on the MPEC display

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 39

Page 40

DCA-180SSV— MAINTENANCE

ECNANETNIAM/NOITCEPSNI.41ELBAT

sleveLdiulFenignEkcehC X

renaelCriAkcehC X

leveLdicAyrettaBkcehC X

noitidnoCtleBnaFkcehC X

skaeLrofkcehC X

straPfogninesooLrofkcehC X

*retliFdnaliOenignEecalpeR

ENIGNE

ROTARENEG

retliFriAnaelC X

lwoBrotarepeSretaW/retliFleuFkcehC X

edistuOdnaedisnI,tinUnaelC X

retliFleuFegnahC X

*leveLnoitcetorPtnalooCkcehCdnarotaidaRnaelC

*tnemelEretliFriAecalpeR

*spmalCdnasesoHllakcehC

knaTleuFfoedisnInaelC X

smhoM3revOecnatsiseRnoitalusnIerusaeM X

gniraeBtroppuSraeRrotoRkcehC X

naerutsiomtcellocdluoctahtspidrosgason

.lioro/d

srH01

YLIAD

.ylnoemittsrif,sruoh001taretliffnalioenigneecalpeR1*

srH052 srH005 srH0001

.tnaloocenigneehtegrahcerot")S'ACS(sevitaddAtnalooClatnemelppuS"ddA2*

H.ni52(mm526fomuccavaswohsrotacidninoitcirtsernehwtnemeleretlifriayramirpecalpeR3*

.)0

htiw,toofrephcni2/1atsaeltasiesohybolbehtfoepolsehttahterusne,decalperebotsdeenesohybwolbfI4*

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 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element (Figure 56) 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 58) is attached to the air cleaner. When

NOTE

the air cleaner element is clogged, air intake 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 40 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Figure 56. Air Cleaner/Indicator

The air filter should not be

changed until the indicator reads “RED”. Dispose of old air filter it may not be cleaned or reused.

Page 41

DCA-180SSV— MAINTENANCE

Service Daily

If the engine is operating in very 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

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

Drain the fuel inside the fuel tank completely. Using a spray washer (Figure 57) wash out any deposits or debris that have accumulated inside the fuel tank.

if these conditions exists.

dusty

dry grass

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, deteration and hardning.

Fuel Tank Lining – inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Replacing Fuel Filter



Replace the fuel filter cartridge with new one every 500 hours or so.



Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.

Figure 57. Fuel Tank Cleaning



Vent any air

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 41

Page 42

DCA-180SSV— MAINTENANCE

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

Manual

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

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 30.

Replacing Oil Filter



for details.

Remove the old oil filter.

Apply a film of oil to the gasket on the new oil filter.

Install the new oil filter.

VOLVO Engine

WARNING - BURN HAZARDS

Allow engine to radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Radiator Cleaning



The radiator (Figure 58) should be sprayed (cleaned) with a high pressure washer when excessive amouts of dirt and debris have accumulated on the cooling fins 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 fins and tube.

cool

when flushing out



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 overflow tank and drain.



Check hoses for softening and kinks. Check clamps for signs of leakage.



Tighten both cocks and replace the overflow tank.



Replace with coolant as recommended by the engine manufaturer.



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.

Figure 58. Air Cleaner/Indicator

Generator Storage

For longe term storage of the generator the following is recommended:



Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.



Completely drain the oil from the crankcase and refill 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.

PAGE 42 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)



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 43

DCA-180SSV— 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

battery charger

These receptacles will ONLY function when commercial power has been supplied to them (Figure 59). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in to apply power to jacket water heater. However, if the generator will be used in 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.

jacket water heater

hot

climates there is no reason

cold

climates it is always a good

and

internal

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 an power cord of adequate size.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

internal battery charger

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 43

Figure 59. Battery Charger &

Jacket Water Heater Power Connections

Page 44

DCA-180SSV— 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 the DCA180SSV

1. Fuel Cell - Provides an adequate amount of fuel for the

2. Braking System - System employed in stopping the

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the

4. Frame Length - Measurement is from the ball hitch to

5. Frame Width - Measurement is from fender to fender

Whisperwatt

equipment in use. Fuel cells must be empty when transporting equipment.

trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

maximum number of pounds the trailer can carry, including the fuel cell (empty).

the rear bumper (reflector).

™

Generator.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;

2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s

axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must

match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.

Always use a torque wrench to tighten down the lug nuts. See Table 18 and Figure 62 for lug nut tightening and sequence.

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

port 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 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

14. Suspension - Protects the trailer chassis from shocks

transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

6. Jack Stand - Trailer support device with maximum pound

requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

15. Electrical - Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed

on a particular trailer.

PAGE 44 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 45

DCA-180SSV— TRAILER MAINTENANCE

Brakes

Trailer brakes should be inspected the

first 200 miles

operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes

every 3,000 miles

. If driving over rough terrain, inspect the

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 60) 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.

brakes more frequently.

Figure 60 displays the major hydraulic surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 15 as listed below:

Brake Adjustment

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

2. Check the wheel and drum for free rotation.

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

4. With a screwdriver or standard adjusting tool, rotate the

Figure 60. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

Actuator

5. Adjust the brake shoes outward until the pressure of the lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction until the wheel rotates freely with slight lining drag.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder, supplying

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

hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “

8. Repeat steps 1 through 7 on the remaining brakes.

sure that it is functioning correctly. Never use an undersize actuator.

motpmyS esuaCelbissoP noituloS

sekarBoN?deknikronekorbenilekarB.ecalperroriapeR

rB.ecalperrohsinrubeR

ediSenO

otlluPsekarBrosekarBkaeW

sekarBgnikcoL

sekarBysioN

sekarBgniggarD

tsujda

?dezalggninileka

?dedaolrevoreliarT.thgiewtcerroC

?tcerroc

erusserperiT.yllauqeseritllaetalfnI

oolstnenopmocekarB.stnenopmocecalpeR

?detacirbulmetsyS.etacirbu

?yltcerrocde

gnitoohselbuorTekarBciluardyH.51elbaT

?devoorgroderocssmurdekarB.ecalperroenihcaM

?elxaemasehtnodehctamnuseriT.serithctaM

?nekorbrotneb,es

?dnuor-fo-tuosmurdekarB.ecalpeR

?tcerrocstnenopmocekarB.tcerrocdnaecalpeR

tonrotcerrocnissenkcihtgninilekarB

?diulftcerrocrodiulfekarbhguonE

surge

push

actuator

dnaseohswenllatsnI

.sgninil

straprebburecalpeR

.diulf4todhtiwllif

” to make

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 45

Page 46

DCA-180SSV— 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.

Suspension

The

leaf suspension

(Figure 61) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately. Torqued suspension components

CAUTION - EYESIGHT HAZARD

ALWAYS

wear safety glasses when

as detailed in Table 17.

removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

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.

springs and associated components

Figure 61. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are

hot!

. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 16 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

SNUG FIT ONLY

LOCKING NUTS OR COTTER PINS ARE PROVIDED

TO RETAIN NUT

stnemeriuqeReuqroTnoisnepsuS.71elbaT

PARTS MUST ROTATE FREELY

BOLT ASSEMBLY

05-XAM03-NIM

PAGE 46 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 47

DCA-180SSV— TRAILER MAINTENANCE

Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 62). DO NOT

torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 18.

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

stnemeriuqeReuqroTeriT.81elbaT

eziSleehWssaPtsriF

SBL-TF

"2152-0204-5356-05

152-0204-5356-05

"4152-0206-05021-09

"5152-0206-05021-09

"6152-0206-05021-09

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 47

NOTE

Figure 64. Wheel Lug Nuts

Tightening Sequence

NEVER

use an pneumatic air

gun to tighten wheel lug nuts.

Page 48

DCA-180SSV— TRAILER WIRING DIAGRAM

Figure 63. Trailer/Towing Vehicle Wiring Diagram

PAGE 48 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 49

DCA-180SSV— GENERATOR WIRING DIAGRAM

Figure 64. Generator Wiring Diagram

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 49

Page 50

DCA-180SSV — ENGINE WIRING DIAGRAM

Figure 65. Engine Wiring Diagram

PAGE 50 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 51

DCA-180SSV— TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant.

GNITOOHSELBUORTROTARENEG.91ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

tuptuOegatloVoN ?evitcefedretemtloVCA .retemtlovagnisuegatlovtuptuokcehC

?esoolnoitcennocgniriwsI .riaperdnagniriwkcehC

?evitcefedRVAsI .yrassecenfiecalpeR

?reifitceRgnitatoRevitcefeD .ecalperdnakcehC

?dleiFreticxEevitcefeD 1NCnoK&Jssorcasmho3.71rofkcehC

tuptuOegatloVwoL ?tcerrocdeepsenignesI ."hgiH"otrevelelttorhtenignenruT

?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

tuptuOegatloVhgiH ?esoolsnoitcennocgniriwsI .riaperdnagniriwkcehC

?RVAevitcefeD .yrassecenfiecalpeR

deppirTrekaerBtiucriC ?daolnitiucriCtrohS .riaperdnadaolkcehC

?tnerrucrevO .ecuderdnastnemeriuqerdaolmrifnoC

?rekaerbtiucricevitcefeD .ecalperdnakcehC

?detautcayaleRtnerrucrevO .ecalperdnatnemeriuqerdaolmrifnoC

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 51

Page 52

DCA-180SSV— TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 20 (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 office or service plant.

)CEPM(GNITOOHSELBUORTRELLORTNOCENIGNE.02ELBAT

MOTPMYS MELBORPELBISSOP NOITULOS

?levelliowoL.levelliolliF

sithgilerusserpliowoL

.no

?detrohseriW.eriwriaper/tcepsnI

?leveltnaloocwoL.leveltnalooclliF

ltnaloocwoL

.nosithgil

sithgilleve )dellatsnIyllanoitpO(.no

erutrepmettnaloochgiH

?eruliaftinugnidneS .tinugnidnesecalpeR

?egatlovyrettabwoL .yrettabegrahc/ecalpeR

?neposrooD.srood

?gnikaeltsuahxE .trapytluafrosteksagriaper/ecalpeR

?eruli

aftatsomrehT.tatsomrehtecalpeR

?dekcolbekatniriA.sekatniriallaraelC

?eruliaftinugnidneserusserpliO .tinugnidneseru

?rellortnoCninoitnuflamyaledemiT.relaedotrefeR

?tcerrocninoisnettlebnaF .t

?rotaidarhguorhtnoitalucrictonsiwolfriA .llirgrotaidarriaper/naelC

esolC

?dedaolrevogniebrotareneG.daolecuder/kcehC

?eruliafhctiwserutarepmeT .hctiwseruta

sserplioecalpeR

lebnafecalper/nethgiT

repmetecalpeR

.nosithgilknarcrevO

nosithgildeepsrevO

E.relaedotrefeR

ro)s(thgilUPMfossoL

.no

tengaM .pukcipcitengamnaelC

PAGE 52 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

?leuFwolrooN.levelleuflliF

?detarbilacebotsdeenrellortnoC.relaedotrefeR

?hgihootdeepsenigneMPR.MPRtsujdA

?detsujdaebotsdeenrotautcaronrevoG .rotautcaronrevogt

?detsujdaebotsdeenrellortnocronrevoG .rellortnocronrevogtsujdA

?detarbilacebotsdeenrellortnoCenign

?tnemtsujdafotuopukcipcitengaM .pukcipcitengamtsujdA

?ytridpukcipci

sujdA

Page 53

DCA-180SSV— TROUBLESHOOTING (DIAGNOSTIC LAMP)

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself. The malfunction can be determined by examining the flashing pattern of the diagnostic lamp (Figure 66) located in the control box.

Figure 66. Diagnostic Panel

Method of Operation

1. Normally, the diagnostic lamp will be

MPEC Control Switch

position.

2. If engine trouble occurs, the diagnostic lamp will be

brightly

manual position.

3. The diagnostic lamp will indicate an error code via a flashing pattern on the lamp. This pattern will become visible once the the reset button on the control box has been pushed and released. The error code consists of a series of flashes by the lamp. The error codes are defined as follows:

lit as long as the control switch is left in the

is placed in the MANUAL

dimly

lit when the

Example Error Code 2.

Figure 68 displays the error code for

Figure 68. Error Code High Temperature Intake

NOTE

4. In a situation where several engine malfunctions occur simultaneously, the code for each malfunction will flash one after another in sucession.

5. After all engine related malfunctions have been diagnosed and corrected, and the generator is operating in a normal maner the following code (Figure 69) should be displayed once the reset button is pressed and released

high temp intake

The error code will flash each time the reset button is pressed and released until the problems have been corrected.

Figure 69. Normal Operating Code

Example Error Code 1.

Figure 67 displays the error code for

Figure 67. Error Code Low Radiator Coolant

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 53

low radiator coolant

NOTE

For a complete understanding of error codes and troubleshooting procedures, refer to the enclosed engine instruction manual.

When the

Switch

position, the same error codes will apply. Codes will not be active until the unit is activated.

MPEC Control

is placed in the AUTO

Page 54

DCA-180SSV— EXPLANATION OF CODE IN REMARKS COLUMN

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.

The contents and part numbers listed in the parts section are subject to change guarantee the availibility of the parts listed.

Sample Parts List:

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ....................... 1 .... INCLUDES ITEMS W/

2*12347 WASHER, 3/8 IN. ....1 ....

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

, #, +, %, 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 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.

NOTE

without notice

WASHER, 1/4 IN. ...........

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.

. Multiquip does not

NOT SOLD SEPARATELY MQ-45T ONLY

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 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

symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

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

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 number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

- All items on the parts list with the same unique

- Used to list an effective serial number

- Indicates that the part is used

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 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.

PAGE 54 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

“Make/Obtain Locally”

purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately”

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.

- Indicates that the part can be

- Indicates that an item cannot be

Page 55

DCA-180SSV— SUGGESTED SPARE PARTS

DCA-180SSV WHISPER WATT GENERATOR

W/VOLVO PENTA TAD1241GE DIESEL ENGINE

1 TO 3 UNITS

Qty. P/N Description

1 ........ 0601820625 ..................... AUTOMATIC VOLTAGE REGULATOR

1 ........ 0601840073 ..................... RHEOSTAT, VOLTAGE REGULATOR

1 ........ 0601840121 ..................... KNOB, RHEOSTAT

1 ........ V20797199 ......................V-BELT, ALTERNATOR

1 ........ V20585207 ......................V-BELT, FAN, SET OF TWO

1 ........ V976490 ..........................V-BELT, FUEL PUMP

20 ...... V3831236 ........................OIL FILTER

20 ...... V3825133 ........................FUEL FILTER

10 ...... V24424482 ......................AIR ELEMENT

1 ........ V20585572 ......................RADIATOR HOSE, UPPER

1 ........ V20585573 ......................RADIATOR HOSE, LOWER

1 ........ 0602103090 ..................... LAMP, PILOT ALARM

1 ........ 0601810244 ..................... BULB, PILOT LAMP

1 ........ V20543720 ......................WATER TEMPERATURE SWITCH

1 ........ V20585158 ......................OIL PRESSURE UNIT

1 ........ 0845500104 ..................... FUEL TANK CAP

2 ........ 0601808803 ..................... CIRCUIT BREAKER, QOU120B 20A

3 ........ 0601808804 ..................... CIRCUIT BREAKER, QOU250B 50A

3 ........ V20549350 ......................FILTER, WATER SEPARATOR

Part numbers on this Suggested Spare Parts list

NOTE

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 55

may supersede/replace the P/N shown in the text pages of this book.

Page 56

GENERATOR ASSY.

DCA-180SSV— GENERATOR ASSY.

PAGE 56 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 57

DCA-180SSV— GENERATOR ASSY.

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0110000502 ROTOR ASSY. 1

1-1 FIELD ASSY. ................................................. 1 ........ INCLUDES ITEMS W/

1-2*0601842334 RESISTOR, SMRK 80W 100 K 1 1-3*0601823282 RECTIFIER, RM50TC-24 1 1-4*0018205020 HEX. SOCKET HEAD CAP SCREW 2 1-4A*0040005000 LOCK WASHER 2 1-4B*0041205000 FLAT WASHER 2 1-5*8171070002 FAN 1 1-6*8171611003 COUPLING DISK 9 1-7*C1164200004 WASHER, COUPLING HUB 1

1-8*8171015003 BALANCING PLATE ....................................... 1 ........ ALSO PURCAHSE 1-11

1-9*0012116045 HEX. HEAD BOLT, S=38 8 1-10*0042616000 LOCK WASHER 8 1-11*0601000209 BALANCING WEIGHT KIT 1 1-12*C1112500004 BEARING FLANGE 1 1-13*0071906314 BEARING, 6314DDU C3 1 2 C0163400103 COUPLING RING 1 3 0012110100 HEX. HEAD BOLT, S=26 8 4 0042510000 LOCK WASHER 8 5 0012112040 HEX. HEAD BOLT, S=30 8 6 0042512000 LOCK WASHER 8

7 C0130100003 STATOR ASSY. .............................................. 1 ........ INCLUDES ITEMS W/#

7-1# 0845041804 GROMMET 2 7-2# 0601850144 GROMMET, G-45 1 8 C1154000002 END BRACKET 1 9 C1138000003 FIELD ASSY., EXCITER 1 10 0012110065 HEX. HEAD BOLT, S=26 4 10A 0042610000 LOCK WASHER 4 10B 0041210000 FLAT WASHER 4 11 0017112045 HEX. HEAD BOLT 6 12 C1154400004 COVER. BEARING 1 13 C1154300004 GASKET, BEARING 1 14 0010106060 HEX. HEAD BOLT 4 14A 0040006000 FLAT WASHER 4 14B 0041206000 FLAT WASHER 4 15 C1154400103 SUCTION COVER 1 16 0017106015 HEX. HEAD BOLT 8 17 0012110035 HEX. HEAD BOLT, S=26 11 18 0042510000 LOCK WASHER 11 19 C0132300014 COVER, FAN 1 20 0010106030 HEX. HEAD BOLT 1 20A 0041206000 FLAT WASHER 1 20B 0600815000 NUT, USN-6001 1 21 0605000012 RUBBER SUSPENSION, EA1013 2 22 0030020000 HEX. NUT 4 22A 0040020000 LOCK WASHER 4 23 0070506207 BEARING, 6207ZZ 1

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 57

Page 58

CONTROL PANEL ASSY.

DCA-180SSV— CONTROL PANEL ASSY.

PAGE 58 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 59

DCA-180SSV— CONTROL PANEL ASSY.

CONTROL PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0223002303 CONTROL PANEL 1 2 C0223002404 CONTROL PANEL 1 3 0605011211 PIN, B-99-2 2 4 0017108035 HEX. HEAD BOLT 4 5 0601807622 FREQUENCY METER, RSC-80F 45~65HZ 200V 1 6 0601806967 AC AMMETER, RSS-80 300/600A 1 7 0601801040 CHANGE-OVER SWITCH, AMMETER SL-2 AS 1 8 0601806887 AC VOLTMETER, RSR-80 0~600V 1 9 0601801041 CHANGE-OVER SWITCH, VOLTMETER SL-2-VS 1 10 0601840073 RHEOSTAT, VOLT. REG. RA20ASE102BJ 2W 1k 1 11 0601840121 KNOB, 25N 1

12 ECU9988N180V CONTROLLER ............................................................. 1 ....... REPLACES P/N 0602202545

13 0601830765 SWITCH, S-303T 1 14 0027104035 MACHINE SCREW 2 14A 0207004000 HEX. NUT 2 15 0602120096 TACHOMETER, 103678 1 16 0602122097 OIL PRESSURE GAUGE, 100728 1 16A V20585158 OIL PRESSURE SWITCH 1 17 0602123094 WATER TEMPERATURE GAUGE, 111930 1 17A V20543720 WATER TEMPERATURE SWITCH 1 18 0602121080 CHARGING AMMETER, 100158 1 19 0602125091 FUEL GAUGE, 101584 1 20 0602103090 ALARM LAMP, PL-05 1 20A 0601810244 BULB, E-10 T-10 DC28V 1 21 0601810161 PANEL LIGHT, V325070 DC24V 1 21A 0601810214 BULB 1 22 0207004000 HEX. NUT 2 23 0601830710 SWITCH, PANEL LIGHT S-301T 1 24 0845056404 SET SCREW 2 24A 0080200007 SNAP RING, S-7 2 25 0601842450 VOLTAGE DIVIDER, 062900 1 26 C0246700804 WIRE HARNESS, GENERATOR 1 27 C0357200402 WIRE HARNESS, ENGINE 1

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 59

Page 60

CONTROL BOX ASSY.

DCA-180SSV— CONTROL BOX ASSY.

PAGE 60 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 61

DCA-180SSV— CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0213002802 CONTROL BOX 1 2 0601809666 CURRENT TRANSFORMER, COM-5-30D 300/5A 3 3 0027106016 MACHINE SCREW 6 4 0601870421 CIRCUIT BREAKER, L13500S2 500A 1 5 0601815168 REAR CONNECTOR KIT, 6636C35G01 1 6 C0213601304 SET PANEL. CIRCUIT BREAKER 1 7 0016908035 HEX. HEAD BOLT 4 8 C0274000003 TERMINAL BOARD, VOLTAGE CHANGE-OVER 1 9 8131852104 CHANGE TERMINAL 10 10 0017106025 HEX. HEAD BOLT 20 11 C0277200004 TERMINAL PLATE 3 12 8131853104 CHANGE-OVER PLATE 6 13 8131852504 TIE BOLT 20 14 0040010000 LOCK WASHER 20 15 0041410000 FLAT WASHER 20 16 0017108035 HEX. HEAD BOLT 4 17 0601820625 AUTOMATIC VOLTAGE REGULATOR, NTA-5A-2T 1 18 0027105016 MACHINE SCREW 4 19 0601820892 OVER CURRENT RELAY, TH-N20HZ KP3. 6A 1 20 0027104016 MACHINE SCREW 2

21 CONTROL UNIT, VOLVO EDC4 .................................... 1 ....... CONTACT VOLVO

22 0027105020 MACHINE SCREW 4 23 C0260502903 SET PANEL, ELECTRIC PARTS 1 24 0017108020 HEX. HEAD BOLT 4 25 C3261601004 SWITCH BRACKET 1 26 0017106016 HEX. HEAD BOLT 4 27 0601831205 RESET SWITCH, SB-221N/O 1 28 0601810575 DIAGNOSTIC LAMP, KRE-108-4R DC24V 1 29 C0266600004 RESISTIR UNIT, 1/4W 91 1/4 68 1 30 0027105020 MACHINE SCREW 1 30A 0030006000 HEX. NUT 1 31 0601830710 CHANGE-OVER SWITCH, FREQUENCY S-301T 1 32 0601823240 RECTIFIER, DE45 2 33 0027104020 MACHINE SCREW 2 34 0601842468 RESISTOR, GG5W 151J 5W 150 1 35 0027103010 MACHINE SCREW 2 36 0602202690 GLOW RELAY, VOLVO 20715645 1 37 0017104020 HEX. HEAD BOLT 2

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 61

Page 62

CONTROL BOX ASSY. (CONT.)

DCA-180SSV— CONTROL BOX ASSY. (CONT)

PAGE 62 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 63

DCA-180SSV— CONTROL BOX ASSY. (CONT)

CONTROL BOX ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

38 0601806671 FUSE, LEFT SIDE F-1065 15A 1 38A 0601802149 FUSE, RIGHT SIDE F-1065 10A 1 38B 0601802218 HOLDER, FUSE F-7111 3P 1 39 0027103020 MACHINE SCREW 2 40 0601827684 RELAY, AHE1232 DC24V 1 41 0027104020 MACHINE SCREW 2 42 0601840073 RHEOSTAT, RA20ASE102BJ 2W 1k 1 43 C3262600004 BRACKET 1 44 0017106016 HEX. HEAD BOLT 2 45 0601815462 TERMINAL BOARD, TK-152 15P 1 46 0027104020 MACHINE SCREW 2

47 LY2DDC24V RELAY....................................................................... 2 ....... REPLACES P/N 0601827655

47A PTF08A RELAY BASE............................................................ 2 ....... REPLACES P/N 0601823109

47B PYCA1 RELAY CLIP .............................................................. 2 ....... REPLACES P/N 0601824400

48 0027104020 MACHINE SCREW 4 49 3871824004 STOPPER, CONTROL PANEL 1 50 0041206000 FLAT WASHER 1 51 0605010502 SNAP PIN, SSP-6 1 52 C0213500104 COVER, CONTROL BOX 1 53 0017108020 HEX. HEAD BOLT 8 54 C0213300104 SIDE PANEL, CONTROL BOX 1 55 0017108020 HEX. HEAD BOLT 4 56 C0213400204 BACK PANEL, CONTROL BOX 1 57 0017108020 HEX. HEAD BOLT 8 58 0017110025 HEX. HEAD BOLT 4

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 63

Page 64

ENGINE AND RADIATOR ASSY.

DCA-180SSV— ENGINE AND RADIATOR ASSY.

PAGE 64 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 65

DCA-180SSV— ENGINE AND RADIATOR ASSY.

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C092320144 ENGINE & RADIATOR SET, (VOLVO TAD722GE) .................... 1 ........ INCLUDES ITEMS W/

1-1*V24424482 ELEMENT, AIR CLEANER .......................................................... 1 ........ REPLACES P/N 0602046624

1-2 1-3 1-4 2 C0303200004 ENGINE FOOT 1 3 C0303200104 ENGINE FOOT 1 4 0012116045 HEX. HEAD BOLT 4 5 0042516000 LOCK WASHER 4 6 0041616000 FLAT WASHER 4 7 0605000011 RUBBER SUSPENSION, EA1012 2 8 0030016000 HEX.NUT 4 9 0040016000 LOCK WASHER 4 10 C0310100704 BRACKET. REDIATOR 1 11 C0310100804 BRACKET, RADIATOR 1 12 0017108020 HEX. HEAD BOLT 4 13 0017110025 HEX. HEAD BOLT 4 14 0602022568 ADAPTER, 10-M22X1.5 F80X-S 1 15 0602022792 HOSE JOINT, 30682-10-10 1 16 0603306590 CONNECTOR, 10WFTX-S 1 17 0603300285 ROCKNUT, 10WLN 1 18 0605511395 VALVE, XV500P-8 1 19 0603306395 HOSE JOINT, 30182-8-10 1 20 0602021070 CAP, 10FNTX-S 1 21 0269200280 DRAIN HOSE 1

22 V969011 PACKING .....................................................................................1 ........ REPLACES P/N 0602012340

23 C9200000104 ADAPTOR 1 24 0603306487 STREET ELBOW, 2102-6-6 1 25 0605511397 VALVE, MV608-6 1 26 0602022991 HOSE JOINT, 30182-6-6 1 27 0194801000 DRAIN HOSE 1 28 0605515107 HOSE BAND, RS-8007 1 29 0194700700 DRAIN HOSE 1 30 C0357300104 CLAMPER ROD 1 31 0017112020 HEX. HEAD BOLT 1 32 0017108020 HEX. HEAD BOLT 1 33 0602120486 SPEED SENSOR, DYNT-17200 1 34 C0354200104 BRACKET, SPEED SENSOR 1 35 0017106020 HEX. HEAD BOLT 1 36 0228800200 SEAL RUBBER 1

V3831236 CARTRIDGE, OIL FILTER .......................................................... 1 ........ REPLACES P/N 0602041277

V3825133 CARTRIDGE, FUEL FILTER ...................................................... 1 ........ REPLACES P/N 0602042560

V20405872 INDICATOR, AIR CLEANER ....................................................... 1 ........ REPLACES P/N 0602040606

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 65

Page 66

OUTPUT TERMINAL ASSY.

DCA-180SSV— OUTPUT TERMINAL ASSY.

THE PART NUMBERS LISTED INDICATE DEFAULT COLOR OF ORANGE. PLEASE ADD THE FOLLOWING LETTERS AFTER THE PART NUMBER WHEN ORDERING ANY OTHER PAINTED PANEL TO INDICATE COLOR OF UNIT:

MQW - WHITE

MQGR - GRAY

MQGRN - GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 66 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 67

DCA-180SSV— OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0231700003 SET BOARD, OUTPUT TERMINAL 1 2 0801830404 OUTPUT TERMINAL 5 3 0801830904 HEX. HEAD BOLT 5 4 0039320000 HEX. NUT 10 5 0040020000 LOCK WASHER 15 6 0041420000 FLAT WASHER 20 7 0019208040 HEX. HEAD BOLT 5 8 0601808803 CIRCUIT BREAKER, QOU120B 1P 20A 2 9 0601808804 CIRCUIT BREAKER, QOU250B 2P 50A 3

10 C3261600704 BRACKET, CIRCUIT BREAKER ........................................ 1 ....... INCLUDES ITEM W/

10-1*0221200150 RUBBER CUSHION 1 11 0017106020 HEX. HEAD BOLT 2 12 0601812598 RECEPTACLE, GF-530EM 20A 2 13 0601812565 RECEPTACLE, CS-6369 50A 2 14 0027104016 MACHINE SCREW 10 14A 0030004000 HEX. NUT 10 14B 0041204000 FLAT WASHER 10 15 C0237101313 COVER, OUTPUT TERMINAL 1 16 0010112045 HEX. HEAD BOLT 2 17 0041412000 FLAT WASHER 2 18 0805015604 STAY RUBBER 2 19 003001200 HEX. NUT 2 20 0845043704 SPRING 2 21 C0236101904 COVER 1 22 0017108020 HEX. HEAD BOLT 7 23 C0237101504 COVER 1 24 0017110040 HEX. HEAD BOLT 2 25 0845054204 COLLAR 1 26 0805015604 STAY RUBBER 1 27 0601815324 TERMINAL BOARD, TS-2 2P 1 28 0027104020 MACHINE SCREW 2 29 0601850275 GROMMET, SG-14A 1 30 0601851780 GROMMET, MV-45 2 31 C2237101504 COVER 1 32 C2237400104 BRACKET 1 33 0017106020 HEX. HEAD BOLT 2

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 67

Page 68

BATTERY ASSY.

DCA-180SSV— BATTERY ASSY.

PAGE 68 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 69

DCA-180SSV— BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0168614551 BATTERY, 145G51 2 2 C9109100604 BATTERY SHEET 2 3 0805000904 BATTERY BAND 2 4 0805002904 BATTERY BOLT 4 5 0037808000 WING NUT 4 6 0040008000 LOCK WASHER 4 7 0041608000 FLAT WASHER 4 8 C0346600004 BATTERY CABLE 1 9 C3347601504 BATTERY CABLE 1 10 C0346600104 BATTERY CABLE 1 11 C4347200204 EARTH CABLE 1 12 0347010003 HEX. HEAD BOLT 4 13 0208110000 HEX. NUT 4 14 0845040414 TERMINAL CAP, + 2 15 0845041304 TERMINAL CAP, - 2 16 0017112025 HEX. HEAD BOLT 1 17 0040512000 TOOTHED WASHER 1 18 0040520000 TOOTHED WASHER 1

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 69

Page 70

MUFFLER ASSY.

DCA-180SSV— MUFFLER ASSY.

PAGE 70 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 71

DCA-180SSV— MUFFLER ASSY.

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0330101102 MUFFLER 1 2 0017110025 HEX. HEAD BOLT 4 3 C0333001403 EXHAUST PIPE 1

4 V20405969 GASKET ........................................................................ 1 ....... REPLACES P/N 0602320197

5 C1334200304 GASKET 1 6 0017110030 HEX. HEAD BOLT 4 7 0017112055 HEX. HEAD BOLT 4 8 C1331300104 COVER 2 9 0017108020 HEX. HEAD BOLT 4 10 C1331400204 BRACKET 1 11 0017108020 HEX. HEAD BOLT 4 12 0603320129 U BOLT SET 1 13 0207310000 HEX. NUT 2

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 71

Page 72

FUEL TANK ASSY.

DCA-180SSV— FUEL TANK ASSY.

PAGE 72 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 73

DCA-180SSV— FUEL TANK ASSY.

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0363001503 FUEL TANK 1 1-1 0845500104 CAP. FUEL TANK 1 1-2 0810105400 FUEL FILTER 1 2 06055010191 SENDER, FUEL GAUGE 1 2A 0605506090 GASKET 1 3 0027104016 MACHINE SCREW 5 4 8305523104 TANK BAND 2 5 0805003414 SUPPORTER SHEET 4 6 0017108020 HEX. HEAD BOLT 2 7 0207308000 HEX. NUT 2 8 0222100150 RUBBER SHEET 2 9 0222100200 RUBBER SHEET 2 10 0130206000 STREET ELBOW, 1/2 1 11 8085512104 LONG NIPPLE 1 12 0603325011 VALVE, BBS-77-15 1/2 1 13 0132006000 PLUG, 1/2 1

14 V20549342 WATER SEPARATOR ......................................................... 1 ....... 0602042267

14A V20549350 ELEMENT .......................................................................... 1 ....... 0602042767

15 0017110040 HEX. HEAD BOLT 2 16 0602023200 FUEL HAND PUMP, (20450901) 1 17 0017106045 HEX. HEAD BOLT 2 18 0602022567 90° ELBOW, 8-M16X1.5 C80X-S 2 19 0602022980 SWIVEL, 30682-8-8 2 20 019142400 SUCTION HOSE 1 21 0191400250 SUCTION HOSE S1 22 0191401700 SUCTION HOSE 1 23 019303200 RETURN HOSE 1 24 0605515073 HOSE BAND, HS-10 6 25 0605515132 HOSE BAND, HS-8 2

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 73

Page 74

ENCLOSURE ASSY.

DCA-180SSV— ENCLOSURE ASSY.

THE PART NUMBERS LISTED INDICATE DEFAULT COLOR OF ORANGE. PLEASE ADD THE FOLLOWING LETTERS AFTER THE PART NUMBER WHEN ORDERING ANY OTHER PAINTED PANEL TO INDICATE COLOR OF UNIT:

MQW - WHITE

MQGR - GRAY

MQGRN - GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 74 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 75

DCA-180SSV— ENCLOSURE ASSY.

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0413005502 BASE 1 2 C3414100104 COVER 1 3 0019208020 HEX. HEAD BOLT 4 4 C0423001702 FRONT FRAME 1 4A C0493100203 ACOUSTIC SHEET 1 5 C0423001602 FRONT FRAME 1 5A C0493100203 ACOUSTIC SHEET 1 6 0017110030 HEX. HEAD BOLT 13 7 0017110030 HEX. HEAD BOLT 8 8 C0423201604 COVER, FRONT FRAME 1 8A C0493100304 ACOUSTIC SHEET 1 9 0019208020 HEX. HEAD BOLT 21 10 C0423201703 OVER COVER, FRONT FRAME 1 11 0019208020 HEX. HEAD BOLT 14 12 C0433001002 CENTER FRAME 1 13 0010114050 HEX. HEAD BOLT 4 13A 0030014000 HEX. NUT 4 13B 0040014000 LOCK WASHER 4 13C 0041214000 FLAT WASHER 8 14 0010120045 HEX. HEAD BOLT 4 14A 0030020000 HEX.NUT 4 14B 0040020000 LOCK WASHER 4 14C 0041220000 FLAT WASHER 8 15 C044300502 REAR FRAME 1 15A C0493300004 ACOUSTIC SHEET 1 16 0017110030 HEX. HEAD BOLT 4 17 C0443300603 COVER, REAR FRAME 1 17A C0493300104 ACOUSTIC SHEET 1 18 C0443300703 DUCT 1 18A C0493300204 ACOUSTIC SHEET 1 19 0207008000 HEX. NUT 12 20 0019208020 HEX. HEAD BOLT 17 21 C0443200503 DOOR, REAR FRAME 1 22 8165157004 WINDOW PLATE 1 23 0207306000 HEX. NUT 10 23A 0041206000 FLAT WASHER 10 24 B9114000002 DOOR HANDLE 1 25 0021806016 MACHINE SCREW 4 25A 0030006000 HEX. NUT 4 26 0845047104 HINGE 2 26A 0845045004 WASHER 2 27 0019208020 HEX. HEAD BOLT 3 28 0845031504 BLIND PLUG 2 29 C0463100502 ROOF PANEL 1 29A C0493500104 ACOUSTIC SHEET 1 30 8452023004 COVER 1

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 75

Page 76

ENCLOSURE ASSY. (CONT.)

DCA-180SSV— ENCLOSURE ASSY. (CONTINUED)

THE PART NUMBERS LISTED INDICATE DEFAULT COLOR OF ORANGE. PLEASE ADD THE FOLLOWING LETTERS AFTER THE PART NUMBER WHEN ORDERING ANY OTHER PAINTED PANEL TO INDICATE COLOR OF UNIT:

MQW - WHITE MQGR - GRAY

MQGRN - GREEN

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 76 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 77

DCA-180SSV— ENCLOSURE ASSY. (CONTINUED)

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

31 0019208020 HEX. HEAD BOLT 2 32 C0463200402 ROOF PANEL 1 32A C0493500204 ACOUSTIC SHEET 1 33 0009208020 HEX. HEAD BOLT 36 34 C0453201402 SPLASHER PANEL 1 34A C0493401004 ACOUSTIC SHEET 1 35 0019108065 HEX. HEAD BOLT 6 35A 0042308000 LOCK WASHER 6 35B 0042408000 FLAT WASHER 6 36 C0453002003 SIDE DOOR 1 36A C0493401104 ACOUSTIC SHEET 1 37 C04523002103 SIDE DOOR 1 37A C0493401204 ACOUSTIC SHEET 1 38 C0453002203 SIDE DOOR 1 38A C0493401404 ACOUSTIC SHEET 1 39 C0453002303 SIDE DOOR 1 39A C0493401504 ACOUSTIC SHEET 1 40 C0453300304 DUCT 1 40A C0493401304 ACOUSTIC SHEET 1 41 C0453300404 DUCT 1 41A C0493401604 ACOUSTIC SHEET 1 42 0207008000 HEX. NUT 14 43 B9114000002 DOOR HANDLE 4 44 0825007362 DOOR HANDLE 3 45 0021806016 MACHINE SCREW 28 45A 0030006000 HEX. NUT 28 46 C0453600104 CUTTER 2 47 0019206020 HEX. HEAD BOLT 6 48 0845046904 HINGE 6 48A 0845045004 WASHER 6 49 0845047004 HINGE 5 49A 0845045004 WASHER 5 50 0019208020 HEX. HEAD BOLT 25 51 0601850097 STOPPER 9 52 0027208025 MACHINE SCREW 9 53 0845031504 BLIND PLUG 11 54 C0483003503 SUPPORT LEG 1 55 0017110035 HEX. HEAD BOLT 4 55A 0030010000 HEX. NUT 4 55B 0041210000 FLAT WASHER 4

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 77

Page 78

RUBBER SEALS ASSY.

DCA-180SSV— RUBBER SEALS ASSY.

PAGE 78 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 79

DCA-180SSV— RUBBER SEALS ASSY.

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0229201200 RUBBER SEAL 4 2 0228900945 RUBBER SEAL 4 3 0228901300 RUBBER SEAL 3 4 0028901360 RUBBER SEAL 3 5 0228901055 RUBBER SEAL 4 6 0228900650 RUBBER SEAL 1 7 0228900710 RUBBER SEAL 1 8 0229201140 RUBBER SEAL 1 9 0228801050 RUBBER SEAL 2 10 0228800640 RUBBER SEAL 1 11 0228800680 RUBBER SEAL 1 12 0228100540 RUBBER SEAL 2 13 0228100370 RUBBER SEAL 2

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 79

Page 80

NAMEPLATE AND DECALS ASSY.

DCA-180SSV— NAMEPLATE AND DECALS ASSY.

PAGE 80 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 81

DCA-180SSV— NAMEPLATE AND DECALS ASSY.

NAMEPLATE AND DECALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1-1 C0550000603 DECAL: OPERATING PROCEDURES ............................... 1 ....... 005000060

1-2 C9521100404 DECAL: SAFETY INSTRUCTIONS .................................... 1 ....... B92110040

1-3 C9522100003 DECAL: CAUTION .............................................................. 2 ....... C9221000

2-1 C0550000502 DECAL: CONTROL PANEL ................................................ 1 ....... C05000050

2-2 0800520904 PLATE: AMMETER CHANGE-OVER SWITCH .................. 1 ....... N-2438

2-3 0800520814 PLATE; VOLTMETER CHANGE-OVER SWITCH ............... 1 ....... N-2439

2-4 B9531100604 DECAL: WARNING ELECTRIC SHOCK HAZARD ............. 2 ....... B93110060

2-5 C9520200904 DECAL: OVER CURRENT RELAY ..................................... 1 ....... C92020090

2-6 C0551000903 DECAL: SETTING FOR OUTPUT VOLTAGE ..................... 1 ....... 005100090

2-7 W9522000504 DECAL: CIRCUIT BREAKER ............................................. 1 ....... M92200050

2-8 C9502400004 DECAL: HIGH IDLE SPEED .............................................. 1 ....... C90240000

2-9 C3551001004 DECAL: DIAGNOSTIC LAMP ............................................. 1 ....... C35100100

2-10 C9521007504 DECAL: DIAGNOSTIC SWITCH ........................................ 1 ....... 092100750

2-11 Z0110001504 DECAL: RESET .................................................................. 1 ....... Z01000150

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 B9524111304 DECAL: CAUTION HOT PARTS ......................................... 1 ....... B90400030

3-7 C9503100404 DECAL: MIN COLD ............................................................ 1 ....... C90310040

4-1 C1551000803 DECAL: RECEPTACLE & CIRCUIT BREAKER ................. 1 ....... C15100080

4-2 0840614104 DECAL: GROUND .............................................................. 1 ....... S-2635

4-3 9039209064 DECAL: START CONTACT ................................................. 1 ....... S-4468

4-4 M9520000704 DECAL: 3-PHASE OUTPUT TERMINAL ............................ 1 ....... M92000070

4-5 080619904 DECAL: DANGER HIGH VOLTAGE .................................... 1 ....... S-2731

4-6 M9520100503 DECAL: WARNING ............................................................. 1 ....... W92010050

5-1 0800689504 DECAL: - ............................................................................ 1 ....... S-2091

5-2 0800689404 DECAL: + ........................................................................... 1 ....... S-2090

5-3 C9505300004 DECAL: CAUTION .............................................................. 1 ....... C90530000

6-1 B9504200004 DECAL: WARNING ENGINE EXHAUST ............................. 1 ....... B90420000

7-1 1320620904 DECAL: DIESEL FUEL ....................................................... 1 ....... S-1756

7-2 6360620004 DECAL: FUEL DRAIN PLUG .............................................. 1 ....... S-1883

8-1 0840625902 DECAL: MQ ........................................................................ 1 ....... S-3057

8-2 0600500090 EMBLEM 2 8-2A 0021106016 MACHINE SCREW 4 8-3 C1561100503 STRIPE 1 8-4 C0560100403 STRIPE 1 8-5 C1561100304 STRIPE 2 8-6 C0560100103 STRIPE 1 8-7 C0560100204 STRIPE 2 8-8 C0560100003 STRIPE 1

8-9 C0560100303 STRIPE

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 81

Page 82

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 30 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

A Returned Material Authorization 1. must be approved by Multiquip prior to shipment.

To obtain a Return Material Authorization, 2. a list must be provided to Multiquip Parts Sales that deﬁnes item numbers, quantities, and descriptions of the items to be returned.

The parts numbers and descriptions a. must match the current parts price list.

The list must be typed or computer b. generated.

The list must state the reason(s) c. for the return.

The list must reference the sales d. order(s) or invoice(s) under which the items were originally purchased.

The list must include the name e. and phone number of the person requesting the RMA.

A copy of the Return Material Authorization 3. must accompany the return shipment.

Freight is at the sender’s expense. All 4. parts must be returned freight prepaid to Multiquip’s designated receiving point.

Parts must be in new and resalable 5. condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked.

The following items are not returnable:6.

Obsolete parts. (If an item is in the a. price book and shows as being replaced by another item, it is obsolete.)

Any parts with a limited shelf life b. (such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

Any line item with an extended c. dealer net price of less than $5.00.

Special order items.d.

Electrical components.e.

Paint, chemicals, and lubricants.f.

Decals and paper products.g.

Items purchased in kits.h.

The sender will be notiﬁed of any material 7. received that is not acceptable.

Such material will be held for five 8. 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.

Credit on returned parts will be issued 9. at dealer net price at time of the original purchase, less a 15% restocking charge.

In cases where an item is accepted, for 10. which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

Credit issued will be applied to future 11. purchases only.

PRICING AND REBATES

Prices are subject to change without prior notice. Price changes are effective on a speciﬁc date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

Multiquip reserves the right to quote and sell direct to Government agencies, and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products.

SPECIAL EXPEDITING SERVICE

A $35.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable hereunder fo damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of proﬁt or good will or for any other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. Apart from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.

Effective: February 22, 2006

PAGE 82 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)

Page 83

NOTE PAGE

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 83

Page 84

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

MULTIQUIP CORPORATE OFFICE

18910 Wilmington Ave Tel. (800) 421-1244 Carson, CA 90746 Fax (800) 537- 3927 Contact: mq@multiquip.com Web: www.multiquip.com

MQ Power

1800 Water Ridge Rd. Tel. (800) 883-2551 Suite 500/600 Fax (972) 315-1847 Lewisville, TX 75057 Contact: mqpower@multiquip.com Web: www.mqpower.com

MQ Parts Department

800-427-1244 Fax: 800-672-7877 310-537-3700 Fax: 310-637-3284

Service/Tech Support/Warranty

800-835-2551 Fax: 310-638-8046

MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

This manual

The information and speciﬁcations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical 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 contained in this manual.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

Manufactured for

Multiquip Inc.

Your Local Dealer is:

DENYO CO., LTD, JAPAN

MQ Power WHISPERWATT DCA-180SSV Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual