Multiquip DCA180SSIU User Manual

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OPERATION AND PARTS MANUAL

WHISPERWATT™ SERIES

MODEL DCA180SSI

MODEL DCA180SSIU

60HZ GENERATORS

(ISUZU 6HK1X DIESEL ENGINE)

PARTS LIST NO. C0870301604 DCA180SSSI

PARTS LIST NO. M3870301404 DCA180SSIU

Revision #1 (08/02/10)

To ﬁnd the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

REPORTING SAFETY DEFECTS

If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Trafﬁc Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244.

If NHTSA receives similar complaints, it may open an investigation, and if it ﬁnds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

You can also obtain information about motor vehicle safety from http://www.safecar.gov.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 3

TABLE OF CONTENTS

DCA180SSI/DCA180SSIU 60 Hz Generators

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

Reporting Safety Defects ......................................... 3

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

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

Safety Information .............................................. 6-11

Speciﬁcations ........................................................ 12

Dimensions ............................................................ 13

Installation ........................................................14-15

General Information ............................................... 16

Major Components ................................................ 17

Generator Control Panel ........................................ 18

Engine Operating Panel .................................... 20-21

Output Terminal Panel Familiarization .............. 22-24

Load Application .................................................... 25

Generator Outputs ................................................. 26

Generator Outputs/Gauge Reading ....................... 27

Output Terminal Panel Connections .................28-29

Inspection/Setup ............................................... 30-33

Generator Start-Up Procedure (Manual) ......... 34-35

Generator Start-Up Procedure (Auto Mode) .......... 36

Generator Shut-Down Procedures ........................ 37

Maintenance ..................................................... 38-41

Trailer Maintenance .......................................... 42-45

TTrailer Wiring Diagram ......................................... 46

Generator Wiring Diagram ..................................... 47

Engine Wiring Diagram .......................................... 48

Controller Wiring Diagram ..................................... 49

Troubleshooting (Generator) .................................. 50

Troubleshooting (Engine Controller) ...................... 51

Troubleshooting (Diagnostic Lamp) ....................... 52

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

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

Component Drawings

Generator Assembly ......................................... 56-59

Control Box Assembly ...................................... 60-65

Engine And Radiator Assembly ........................ 66-71

Output Terminal Assembly ................................ 72-75

Battery Assembly (DCA180SSI) ....................... 76-77

Battery Assembly (DCA180SSIU) .................... 78-79

Mufﬂer Assembly .............................................. 80-81

Fuel Tank Assembly (DCA180SSI) .................. 82-83

Fuel Tank Assembly (DCA180SSIU) ...............84-85

Enclosure Assembly ......................................... 86-93

Rubber Seals Assembly ................................... 94-95

Nameplate and Decals Assy. (DCA180SSI) ....96-99

Nameplate and Decals Assy.(DCA180SSIU) .100-103

Terms And Conditions Of Sale — Parts .............. 104

PAGE 4 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

If you have an MQ Account, to obtain a Username

Effective:

Choose from three easy options:

January 1st, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

■ View Parts Diagrams

■ Order Parts

■ Print Speciﬁ cation Information

Goto www.multiquip.com and click on

Order Parts

to log in and save!

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)

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

and Password, E-mail us at: parts@multiquip.

com.

To ob ta in an MQ Acc ou nt, co nt a ct yo ur 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.*

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

Note: Discounts Are Subject To Change

When ordering parts, please supply:

❒ Dealer Account Number ❒ Dealer Name and Address ❒ Shipping Address (if different than billing address) ❒ Return Fax Number ❒ Applicable Model Number ❒ Quantity, Part Number and Description of Each Part

NOTICE

All orders are treated as Standard Orders and will

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

❒ Specify Preferred Method of Shipment: ✓ UPS/Fed Ex ✓ DHL

■ Priority One ✓ Truck

■ Ground

■ Next Day

■ Second/Third Day

www.mqpower.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 5

SAFETY INFORMATION

Do not operate or service the equipment before reading the

Potential hazards associated with the operation of this

entire manual. Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages speciﬁ cally address the level of exposure to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION or NOTICE.

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING

equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

Indicates a hazardous situation which, if not avoided,

COULD result in DEATH or SERIOUS INJURY.

CAUTION

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

PAGE 6 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by MQ Power for this equipment. Damage

Also, know the

and

This information will be invaluable in

emergency or safety devices.

Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these

ensure generator is on level ground before use.

keep the machine in proper running condition.

store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel

CAUTION

 NEVER operate this equipment without proper protective

clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.

NEVER operate this equipment under the inﬂ uence of

drugs or alcohol.

ALWAYS check the equipment for loosened threads or bolts before starting.

DO NOT use the equipment for any purpose other than

its intended purposes or applications.

to the equipment and/or injury to user may result.

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest

phone or keep a phone on the job site. phone numbers of the nearest ambulance, doctor

ﬁ re department.

the case of an emergency.

GENERATOR SAFETY

DANGER

 NEVER operate the equipment in an explosive

atmosphere or near combustible materials. An explosion or ﬁ re could result causing severe

bodily harm or even death.

WARNING

NOTICE

This equipment should only be operated by trained and qualiﬁ ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and

safety decals when they become difﬁ cult read.

Manufacturer does not assume responsibility for any

accident due to equipment modiﬁ cations. Unauthorized equipment modiﬁ cation will void all warranties.

 NEVER disconnect any

These devices are intended fo r operator safety.

devices will void all warranties.

CAUTION

 NEVER lubricate components or attempt service on a

running machine.

NOTICE

 ALWAYS

 Fix damage to machine and replace any broken parts

immediately.

 ALWAYS

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 7

ENGINE SAFETY



NOTICE

run engine without an air ﬁ lter or with a dirty air

ﬁ lter. Severe engine damage may occur. Service air ﬁ lter

Wet stacking is a common problem with diesel engines

no load applied. When a diesel engine operates without sufﬁ cient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow

In order for a diesel engine to operate at peak efﬁ ciency,

it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine

applied to relieve the condition. It can reduce the system

Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed

from the engine exhaust. Spark arresters are qualiﬁ ed

SAFETY INFORMATION

DANGER

 The engine fuel exhaust gases contain poisonous carbon

monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine of this equipment requires an adequate free ﬂ ow of cooling air. NEVER operate this equipment in any enclosed or narrow area where free ﬂ ow of the air is restricted. If the air ﬂ ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

WARNING

 DO NOT place hands or fingers ins i de engine

compartment when engine is running.

 NEVER operate the engine with heat shields or

guards removed.

Keep ﬁ ngers, hands hair and clothing away

from all moving parts to prevent injury.

DO NOT remove the radiator cap while the

engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator.

 DO NOT remove the coolant drain plug while the engine

is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator.

 NEVER

frequently to prevent engine malfunction.

 NEVER tamper with the factory settings

of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable.



which are operated for extended periods with light or

unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce the operating performance.

to completely burn all of the fuel.

Wet stacking does not usually cause any permanent

damage and can be alleviated if additional load is

performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several hours to burn off the accumulated unburned fuel.

 State Health Safety Codes and Public Resources

 DO NOT remove the engine oil drain plug while the

engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator.

CAUTION

NEVER touch the hot exhaust manifold,

mufﬂ er or cylinder. Allow these parts to cool before servicing equipment.

PAGE 8 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

to prevent accidental discharge of sparks or ﬂ ames

and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.

FUEL SAFETY

DANGER

 Make sure the hitch and coupling of the towing vehicle

NEVER

tow a trailer with defective hitches, couplings, chains, etc.

Trailer tires should be inﬂ ated to 50 psi cold.

safety

attach trailer’s safety chains to towing

make sure the vehicle and trailer directional,

unless

posted otherwise. Recommended off-road towing is not to

Avoid sudden stops and starts. This can cause skidding,

Trailer should be adjusted to a level position at all times

rolling

underneath the trailer’s bumper

Use the trailer’s swivel jack to adjust the trailer height to

SAFETY INFORMATION

are rated equal to, or greater than the trailer “gross vehicle weight rating.”

 DO NOT start the engine near spilled fuel or combustible

ﬂ uids. Diesel fuel is extremely ﬂ ammable and its vapors can cause an explosion if ignited.

 ALWAYS refuel in a well-ventilated area, away from

sparks and open ﬂ ames.

 ALWAYS use extreme caution when working with

ﬂ ammable liquids.

 DO NOT ﬁ ll the fuel tank while the engine is running

or hot.

 DO NOT overﬁ ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system.

 Store fuel in appropriate containers, in well-ventilated

areas and away from sparks and ﬂ ames.

 NEVER use fuel as a cleaning agent.

 DO NOT sm oke around or ne ar the

equipment. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

TOWING SAFETY

 Check with your local county or state safety

towing regulations, in addition to meeting

Depar tment of Transportation (DOT) Safety Towing Regulations, before towing

your generator.

 Refer to MQ Power trailer manual for additional safety

information.

 In order to reduce the possibility of an accident while

transporting the generator on public roads, ALWAYS make sure the trailer that supports the generator and the towing vehicle are mechanically sound and in good operating condition.

 ALWAYS shutdown engine before transporting

CAUTION

 ALWAYS inspect the hitch and coupling for wear.

 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

chain.

 ALWAYS properly

vehicle.

 ALWAYS

backup, brake and trailer lights are connected and working properly.

 DOT Requirements include the following:

• Connect and test electric brake operation.

• Secure portable power cables in cable tray with tie wraps.

 The maximum speed for highway towing is 55 MPH

exceed 15 MPH or less depending on type of terrain.



or jack-kniﬁ ng. Smooth, gradual starts and stops will improve towing.

 Avoid sharp turns to prevent rolling.



when towing.

 Raise and lock trailer wheel stand in up position when

towing.

 Place chock blocks underneath wheel to prevent

while parked.

 Place support blocks

to prevent tipping while parked.



a level position while parked.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 9

ELECTRICAL SAFETY

DANGER



 Make sure power cables are securely connected to the

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

make sure that electrical circuits are properly

Severe injury or death by

can result from operating an ungrounded

DO NOT touch output terminals during operation. Contact with output terminals during operation can cause electrocution,

electrical shock or burn.

SAFETY INFORMATION

generator’s output receptacles. Incorrect connections may cause electrical shock and damage to the generator.

NOTICE

 ALWAYS

The electrical vo ltage required to

operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.

NEVER insert any objects into the output

receptacles during operat ion. This is extremely dangerous. The possibility exists of electrical shock, electrocution or death.

Backfeed to a utility system can cause

electrocution and/or property damage. NEVER connect the generator to a

building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn, causing serious

injury or even death.

Chart in this manual.

Grounding Safety

DANGER

 ALWAYS

grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator.

electrocution

generator.

 NEVER use gas piping as an electrical ground.

Power Cord/Cable Safety

DANGER

 NEVER let power cords or cables lay in water.

 NEVER stand in water while AC power from the

generator is being transferred to a load.

 NEVER use damaged or worn cables or cords when

connecting equipment to generator. Inspect for cuts in the insulation.

NEVER grab or touch a live power

cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.

PAGE 10 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

SAFETY INFORMATION

BATTERY SAFETY

ENVIRONMENTAL SAFETY

pour waste, oil or fuel directly onto the ground,

DANGER

 DO NOT drop the battery. There is a possibility that the

battery will explode.

 DO NOT expose the battery to open ﬂ ames,

sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a ﬂ ame or spark, an explosion could occur.

WARNING

 ALWAYS wear safety glasses when handling

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

 Use well-insulated gloves when picking up the battery.

 ALWAYS keep the battery charged. If the battery is not

charged, combustible gas will build up.

 ALWAYS recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration of combustible gasses.

NOTICE

 Dispose of hazardous waste properly.

Examples of potentially hazardous waste are used motor oil, fuel and fuel ﬁ lters.

 DO NOT use food or plastic containers to

dispose of hazardous waste.

 DO NOT

down a drain or into any water source.

 If the battery liquid (dilute sulfuric acid) comes into

contact with clothing or skin, rinse skin or clothing immediately with plenty of water.

 If the battery liquid (dilute sulfuric acid) comes into

contact with eyes, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

CAUTION

 ALWAYS disconnect the NEGATIVE battery terminal

before performing service on the generator.

 ALWAYS keep battery cables in good working condition.

Repair or replace all worn cables.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 11

Table 1. Generator Speciﬁcations

Model DCA-180SSI/DCA-180SSIU

Type

Armature Connection Star with Neutral

Phase

Standby Output

Prime Output

Revolving ﬁeld, self ventilated,

open protected type synchronous generator

198 KVA (158 kW)

180 kVA (144 KW)

SPECIFICATIONS

Voltage - 1 Ø

Voltage - 3 Ø

Frequency

Speed

Power Factor

Aux. AC Power

Aux. Voltage/Output

Dry Weight

Wet Weight

Model

Type

No. of Cylinders

Bore x Stroke

Displacement

Rated Output

Starting

Coolant Capacity

Lube Oil Capacity

Fuel Type

Fuel Tank Capacity

Fuel Consumption

Battery

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

208, 220, 240, 415, 440, 480V Reconnectable

60 Hz

1800 rpm

0.8

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

6,373 lbs. (2890 kg.)

7211 lbs. (3270 kg.)

Table 2. Engine Speciﬁcations

ISUZU 6HK1X

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

6 cylinders

4.53in. x 4.92 in. (115 mm x 125 mm)

475.25 cu. in. (7,790 cc)

219 HP/1800 RPM

Electric

6.6 gal. (25 liters)

10.6 gal. (40.0 liters)

#2 Diesel Fuel

100 gal. (380 liters)

10.6 gal. (40.0 L)/hr at full load 8.0 gal. (30.1 L)/hr at 75% load

6.1 gal. (23.1 L)/hr at 50% load 3.7 gal. (14.0 L)/hr at 25% load

27(CCA O degF -800A) X 2

PAGE 12 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

DIMENSIONS

Figure 1. Dimensions

Table 3. Dimensions

Reference

Letter

A 41.33 in. (1,050 mm.) F 137.8 in. (3,500 mm.)

B 41.33 in. (1050 mm.) G 67 in. (1,700 mm.)

C 37.00 in. (940 mm.) H 48.8 in. (1,240 mm.)

D 41.33 in. (1050 mm.)

E 37.00 in. (940 mm.)

Dimension in. (mm) Reference Letter Dimension in. (mm)

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 13

INSTALLATION

Figure 2. Typical Generator Grounding Application

PAGE 14 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

INSTALLATION

OUTDOOR INSTALLATION

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

GENERATOR GROUNDING

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

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 2) 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.

INDOOR INSTALLATION

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

MOUNTING

The generator must be mounted on a solid foundation (such as concrete) and set 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.

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

NOTICE

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

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 15

GENERAL INFORMATION

GENERATOR

These MQ Power generators (Figure 3) are a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

ENGINE OPERATING PANEL

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

 Tachometer  Water Temperature Gauge  Warning Lamp  Pre-Heat Lamp  Oil Pressure Gauge  Charging Ammeter Gauge  Fuel Level Gauge  Panel Light/Panel Light Switch  ECU Controller  Engine Speed Switch

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  3-Pole, 500 amp Main Circuit Breaker  “Control Box” (located behind the Gen. Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Voltage Rectiﬁer

• 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 auxiliary 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)

OPEN DELTA EXCITATION SYSTEM

Each generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist

of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then 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 “ﬁxed ceiling” and responds according the demands of the required load.

ENGINE

These generators are powered by a 6 cylinder, water cooled, direct injection, turbocharged ISUZU 6JK1X diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 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.

PAGE 16 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

MAJOR COMPONENTS

Table 4. Generator Major Components

ITEM NO. DESCRIPTION

1 Mufﬂer Assembly

2 Air Filter Assembly

3 Generator Assembly

4 Output Terminal Panel Assembly

5 Battery Assembly

6 Output Receptacles Assembly

7 Engine and Radiator Assembly

8 Fuel Tank Assembly

9 Circuit Breaker Assembly

10 Engine Operating Panel Assembly

11 Generator Control Panel Assembly

Figure 3. Major Components

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 17

INCREASE

GENERATOR CONTROL PANEL

DECREASE

OFF

AUTO

MANUAL

V-W

W-U

U-V

OFF

1000

2000

3000

RP M

OFF/RESET

LOWOIL PRESSURE HIGHCOOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINERUNNING

MOOOOO-20001Q

Figure 4. Generator Control Panel

The deﬁnitions below describe the controls and functions of the DCA180SSIU Generator Control Panel (Figure 4).

1. Voltage Regulator Control — Allows ±15% manual adjustment of the generator’s output voltage.

2. Main Circuit Breaker — This three-pole, 500A main breaker is provided to protect the the U,V, and W Output Terminal Lugs from overload.

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 only.

4. 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.

5. AC Voltmeter — Indicates the output voltage present at the U,V, and W Output Terminal Lugs.

6. AC Ammeter — Indicates the amount of current the load is drawing from the generator per leg selected by the ammeter phase-selector switch.

7. Frequency Meter — Indicates the output frequency in hertz (Hz). Normally 60 Hz.

Located behind the generator control panel is the Generator Control Box. This box contains some of the necessary electronic components required to make the generator function.

The Control Box is equipped with the following major components:

 Over-Current Relay

 Automatic Voltage Regulator (AVR)

 Starter Relay

 Current Transformer

 Voltage Selector Switch

 Three Phase Breaker

NOTICE

Remember the overcurrent relay monitors the current ﬂowing from the U,V, and W Output Terminal Lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 500 amp main breaker.

To restore power to the Output Terminal Panel, press the reset button on the overcurrent relay and place the

main circuit breaker in the closed position (ON).

PAGE 18 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

NOTES

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 19

ENGINE OPERATING PANEL

Figure 5. Engine Operating Panel

PAGE 20 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

ENGINE OPERATING PANEL

The deﬁnitions below describe the controls and functions of the Engine Control Panel (Figure 5).

1. Panel Light Switch — When activated will turn on control panel light

2. 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.

3. Preheat Lamp — As the engine cranks, this lamp will illuminate to indicate automatic preheating of the engine glow plugs. When the lamp turns off, this indicates that the preheat cycle is complete and the engine will start automatically.

4. Warning Lamp — This lamp will illuminate whe a critical engine fault has occured.

5. Coolant Alarm Lamp — This lamp will illuminate when the coolant level falls below a safe operating level and the engine will stop.

6. Oil Pressure Gauge — During normal operation this gauge should read between 42 ~71 psi. (290~490 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.

7. Water Temperature Gauge — During normal operation this gauge be should read between 167°~203°F (75°~95°C).

8. 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.

9. Fuel Gauge — Indicates amount of diesel fuel available.

10. 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.

11. Engine Speed Switch — This switch controls the speed of the engine (low/high).

12. Emergency Stop Button — Push this button inward to stop the engine in the event of an emergency. DO NOT use this button as a means of stopping the engine.

13. Au t o S TART/STO P Eng i n e Co n t r o l l e r ( E C U ) — T h i s

controller has a ver tical row of status LED's (inse t), tha t when lit, indicate that an engine ma lfun ction (fault ) has been detected. When a fault has been detected the engine controller will evaluate the fault and all major

faults will shutdown the generator. During cranking cycle, the ECU will attempt to crank the engine for 10 seconds before disengaging.

If the engine does not engage (start) by the third

attempt, the engine will be shutdown by the engine controller’s Over Crank Protection mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the Over Speed Protection mode.

Also the engine controller will shut down the engine in

the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the controller module.

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 15 psi (103 kPa). The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a major fault.

C. High Coolant Temperature — Indicates the engine

temperature has exceeded 230°F (110°C). The engine temperature is detected using variable resistive values from the temperature sending unit. This is considered a major fault.

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 major fault.

E. Overspeed Shutdown — Indicates the engine is

running at an unsafe speed. This is considered a major fault.

F. Engine Running — Indicates that engine is running

at a safe operating speed.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 21

OUTPUT TERMINAL PANEL FAMILIARIZATION

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 6) 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 lugs.

NOTICE

Terminal legs “O” and “Ground” are considered bonded grounds.

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel ” (Figure 6) is provided with the following:

 Three 120/240V output receptacles @ 50 amp

 Three Circuit Breakers @ 50 amps

 Two 120V GFCI receptacles @ 20 amp

 Two GFCI Circuit Breakers @ 20 amps

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

Figure 6. Output Terminal Panel

PAGE 22 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage selector switch 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 reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 7) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the Output Terminal Lugs.

Turn the voltage regulator control knob (Figure 9) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 9. Voltage Regulator Control Knob

Removing the Plastic Face Plate (Hard Wire

Hookup Panel)

The Output Terminal Lugs are protected by a plastic face plate cover (Figure 10). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

Figure 7. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 120/240V, 50 amp auxiliary twist-lock (CS-

6369) receptacles (Figure 8) provided on the output

terminal panel. These receptacles can be accessed in any voltage change-over board position.

Figure 8. 120/240V Twist-Lock Auxiliary

Receptacles

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

Figure 10. Plastic Face Plate (Output Terminal

Lugs)

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 23

OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 11).

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, 500A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Over Current Relay

An over current relay (Figure 12) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

Figure 12. Over Current Relay

Figure 11. Connecting Loads

PAGE 24 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

LOAD APPLICATION

SINGLE PHASE LOAD

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, as the wattage is inﬂuenced by the efﬁciency, power factor and starting system of the equipment.

NOTICE

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

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

approximate wattage may be determined by multiplying

when connecting loads.

nameplate voltage by the nameplate amperage.

Single-phase induction motors 0.4-0.75

Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4-0.9

Electronic devices, communication equipment

Common power tools 0.8

WATTS = VOLTAGE x AMPERAGE

Table 5. Power Factor By Load

Type of Load Power Factor

1.0

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 6.

 When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

 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.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

Table 6. Cable Selection (60 Hz, Single Phase Operation)

Current

Amperes

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.

7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.

10 1200 2400 250 ft. 150 ft. 100 ft.

15 1800 3600 150 ft. 100 ft. 65 ft.

20 2400 4800 125 ft. 75 ft. 50 ft.

Load in Watts Maximum Allowable Cable Length

At 100

Volts

CAUTION: Equipment damage can result from low voltage

At 200

Volts

#10 Wire #12 Wire #14 Wire #16 Wire

THREE PHASE LOAD

NOTICE

When calculating the power requirements for 3-phase

NOTICE

power use the following equation:

If 3Ø load (kVA) is not given on the equipment Motors and motor-driven equipment draw much greater

nameplate, approximate 3Ø load may be determined current for starting than during operation.

by multiplying voltage by amperage by 1.732.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 25

GENERATOR OUTPUTS

GENERATOR OUTPUT VOLTAGES

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by applying jumpers (6) to the voltage change-over board (Figure 13). To obtain some of the voltages as listed in Table 7 (see below) will require a ﬁne adjustment using the voltage regulator (VR) control knob located on the control panel.

Voltage Change-Over Board

The voltage change-over board (Figure 13) is located on the control box, behind the generator control panel. This board has been provided for eae of voltage selection.

HOW TO READ THE OUTPUT TERMINAL GAUGE

The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches,

Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe the phase to phase voltage and the current ﬂowing to the load at the UVWO terminals lugs.

Observe that the voltage change-over board (Figure 14) has been conﬁgured for 3Ø, 240V operation.

Figure 13. Voltage Change-Over Board.

Generator Amperage

CAUTION

NEVER attempt to place jumper plates on the voltage

Three Phase

change-over board while the generator is in operation.

(Switchable)

There exist the possibility of electrocution, electrical

Single Phase

(Switchable)

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

Table 7. Voltages Available

208V 220V 240V 416V 440V 480V

120V 1127V 139V 240V 254V 277V

Table 8. Generator Maximum Amps

Table 8 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed..

Rated Voltage Maximum Amps

1Ø 120 Volt 400 amps (4 wire)

1Ø 240 Volt 200 amps (4 wire)

3Ø 240 Volt 433 amps

3Ø 480 Volt 216 amps

PAGE 26 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

GENERATOR OUTPUTS/GAUGE READING

Figure 14. Voltage Change-Over Board

3Ø 240V Conﬁguration

AC Voltmeter Gauge Reading

Place the AC Voltmeter Change-Over Switch (Figure 15) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge (Figure 16)

Figure 15. AC Voltmeter Change-Over Switch

NOTICE

The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use.

Figure 16. AC Voltmeter Gauge

AC Ammeter Gauge Reading

Place the AC AmmeterChange-Over Switch (Figure 17) to the U position and observe the current reading (load drain) at the U terminal as indicated on the AC Ammeter Gauge (Figure 18). This process can be repeated for terminals V and W.

Figure 17. AC Ammeter

Change-Over Switch

Figure 18. AC Ammeter

(Amp Reading on U Lug)

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 27

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 and the adjustment of the Voltage Regulator Control 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 voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 19.

3. Turn the voltage regulator knob (Figure 21) 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

Figure 21. Voltage Regulator Knob

1Ø-240V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 19.

2. Connect the load wires to the UVWO terminals as shown in Figure 22.

Figure 19. Voltage Change-Over Board 240V

Conﬁguration

2. Connect the load wires to the UVWO terminals as shown in Figure 20..

Figure 20. UVWO Terminal Lugs

3Ø-240/139V Connections

Figure 22. UVWO Terminal Lugs 1Ø-240V

Connections

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

Figure 23. UVWO Terminal Lugs

3Ø-208/1Ø-120V Connections Connections

NOTICE

To achieve a 3Ø 208V output the voltage selector switch must be in the 3Ø-240/139 position and the voltage regulator must be adjusted to 208V..

PAGE 28 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation as shown in Figure 24. This conﬁguration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used.

Figure 24. Voltage Change-Over Board 480V

Conﬁguration

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 24.

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

Figure 26. UVWO Terminal Lugs 1Ø-480V

Connections

1Ø-277V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 24.

Figure 25. UVWO Terminal Lugs 3Ø-480V

Connections

NOTICE

ALWAYS make sure that the connections to the UVWO terminals are secure and tight. The possibility of arcing exists, that could cause a ﬁre.

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

Figure 27. UVWO Terminal Lugs 1Ø-277V

Connections

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 29

INSPECTION/SETUP

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 500 amp, main circuit breaker is provided to protect the U,V, and W Output Terminals from overload. In addition two single-pole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

LUBRICATION OIL

Fill the engine crankcase with lubricating oil through the 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 28) on the dipstick. See Table 9 for proper selection of engine oil.

FUEL CHECK

DANGER

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

Reﬁlling the Fuel System

CAUTION

ONLY properly trained personnel who have read

and understand this section should reﬁll the fuel tank system.

This generator has an internal fuel tank located inside the trailer frame and may also be equipped with an environmental fuel tank (Figure 29). ALWAYS ﬁll the fuel tanks with clean fresh #2 diesel fuel. DO NOT ﬁll the fuel tanks beyond their capacities.

Figure 28. Engine Oil Dipstick

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 ISUZU Engine Owner’s Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:

 API Service Classiﬁcation CC/SC  API Service Classiﬁcation CC/SD  API Service Classiﬁcation CC/SE  API Service Classiﬁcation CC/SF

Table 9. Recommended Motor Oil

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.

Figure 29. Internal Fuel Tank System

PAGE 30 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

INSPECTION/SETUP

Refueling Procedure:

WARNING

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 30).

CAUTION

ALWAYS place trailer on firm level ground before

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

Figure 30. Only Fill on Level Ground

NOTICE

Diesel fuel and its vapors are dangerous to your health an d the surro unding environment. Avoid skin contact and/or inhaling fumes.

Figure 31. Fueling the Generator

3. NEVER overﬁll fuel tank — It is important to read the fuel gauge when ﬁlling trailer fuel tank. DO NOT wait for fuel to rise in ﬁller neck (Figure 32).

Figure 32. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 33).

ONLY use #2 diesel fuel when refueling.

2. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and ﬁll tank (Figure 31).

Figure 33. Fuel Expansion

COOLANT (ANTIFREEZE/SUMMER COOLANT/

WATER)

ISUZU recommends ISUZU 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 ISUZU Engine Owner’s Manual for further details.

WARNING

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 31

INSPECTION/SETUP

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 10 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings.

Table 10. Coolant Capacity

Engine and Radiator 2.88 gal (10.9 liters)

Reserve Tank 2 quarts (1.9 liters)

Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 11) has been added.

Table 11. Anti-Freeze

Operating Temperatures

Vol %

Anti-Freeze

50 -37 -34

Freezing Point

°C °F

damage and wear and adjust it in accordance with the

ISUZU Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 34) when depressed with the thumb as shown below.

Figure 34. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan while the generator set is running.

BATTERY

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

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 battery terminal disconnected.

AIR CLEANER

Periodic cleaning/replacement is necessary. Inspect it in accordance with the ISUZU Engine Owner’s Manual.

FAN BELT TENSION

A slack fan belt may contribute to overheating, or to insufﬁcient charging of the battery. Inspect the fan belt for

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. Always keep the ter minals firmly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery.

The battery is sufﬁciently charged if the speciﬁc gravity

PAGE 32 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

INSPECTION/SETUP

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 35) are

properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery.

CAUTION

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

ALTERNATOR

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

WIRING

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

PIPING AND HOSE CONNECTION

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose (fuel or oil) lines are defective replace them immediately.

Figure 35. Battery Connections

When connecting battery do the following:

1. NEVER connect the battery cables to the battery terminals when the MPEC Control Switch is in either the MANUAL position. ALWAYS make sure that the MPEC Control Switch is in the OFF/RESET position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent

NOTICE

corrosion around the battery terminals.

CAUTION

If the battery cable is connected incorrectly, electrical Inadequate battery connections may cause poor

damage to the generator will occur. Pay close attention to starting of the generator, and create other malfunctions.

the polarity of the battery when connecting the battery.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 33

GENERATOR START-UP PROCEDURE (MANUAL)

INCORRECT

BEFORE STARTING

CAUTION

1. Place the main, G.F.C.I., and aux. circuit breakers (Figure

36) in the OFF position prior to starting the engine.

The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel.

WARNING

NEVER manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

Figure 36. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been conﬁgured for the desired output voltage.

3. Connect the load to the receptacles or the output terminal lugs as shown in Figure 10. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

Figure 39. MPEC Control Switch

(Manual Position)

3. Depending on the temperature of the coolant (cold weather conditions), the pre-heat lamp (Figure 40) will light (ON) and remain on until the pre-heating cycle has been completed. After completion of the pre-heating cycle, the light will go OFF and the engine will start up automatically.

Figure 40. Pre-Heat Lamp

4. Once the engine starts, let the engine run for 1-2 minutes. Listen for any abnormal noises. If any abnormalities exist, shut down the engine and correct the problem. If the engine is running smoothly, place the engine speed switch (Figure 41) in the HIGH (up) position.

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

5. Close all engine enclosure doors (Figure 37).

CORRECT

Figure 37. Engine Enclosure Doors

STARTING (MANUAL)

1. Place the engine speed switch (Figure 38) in the LOW (down) position.

Figure 38. Engine Speed Switch (Low)

2. Place the MPEC control switch in the MANUAL position to start the engine (Figure 39).

Figure 41. Engine Speed Switch (High)

5. Verify that the engine running status LED on the MPEC module (Figgure 42) is lit (ON) after the engine has started.

Figure 42. Engine Running LED (ON)

6. The generator’s frequency meter (Figure 43) should be displaying the 60 cycle output frequency in HERTZ.

PAGE 34 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

GENERATOR START-UP PROCEDURE (MANUAL)

Figure 43. Frequency Meter

7. The generator’s AC-voltmeter (Figure 44) will display the generator’s output in VOLTS.

Figure 44. Voltmeter

8. If the voltage is not within the speciﬁed tolerance, use the voltage adjustment control knob (Figure 45) to increase or decrease the desired voltage.

Figure 45. Voltage Adjust Control Knob

9. The ammeter (Figure 46) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 47. Oil Pressure Gauge

11. The coolant temperature gauge (Figure 48) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 167°~203°F (75°~95°C) (Green Zone).

Figure 48. Coolant Temperature Gauge

12. The tachometer gauge (Figure 49) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 49. Engine Tachometer Gauge

13. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 50).

Figure 46. Ammeter (No Load)

10. The engine oil pressure gauge (Figure 47) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 42 to 71 psi. (290~490 kPa).

Figure 50. Main, Aux. and GFCI

Circuit Breakers (ON)

14. 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.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 35

GENERATOR START-UP PROCEDURE (AUTO MODE)

Figure 51. Ammeter (Load)

15. The generator will run until manually stopped or an abnormal condition occurs.

STARTING (AUTO MODE)

DANGER

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

electrician must install an isolation (transfer) switch. Serious damage to

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

CAUTION

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator’s internal battery charger. This will ensure that the engine

NOTICE

will not fail due to a dead battery.

CAUTION

WARNING

When the generator is set in the AUTO mode, the

NOTICE

generator will automatically start in the event of The engine speed switch must be set to the “High”

When running the generator in the AUTO mode, commercial power falling below a prescribed level

position when running in the auto-start mode. Failing

When the MPEC control switch is placed in the AUTO

remember the generator can start up at any time without by means of a contact closure that is generated

to set the switch in the proper position can result in

position, the engine glow plugs will be warmed and the

warning. NEVER attempt to perform any maintenance automatically by a transfer switch.

damage to your generator when it turns on.

engine will start automatically.

when the generator is in the auto mode.

PAGE 36 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

GENERATOR SHUT-DOWN PROCEDURES

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

1. Perform steps 1 through 5 in the Before Starting section

as outlined in the Manual Starting Procedure.

2. Place the engine speed switch (Figure 52) in the

HIGH position

Figure 52. Engine Speed Switch (High)

3. Place the MPEC Control Switch (Figure 53) in the

AUTO position.

Figure 53. MPEC Control Switch (AUTO)

4. Continue operating the generator as outlined in the

Manual Start-up procedure (start at step 5).

WARNING

NEVER stop the engine suddenly except in an

emergency.

2. Place the engine speed switch (Figure 55) in the “LOW” (down) position.

Figure 55. Engine Speed Switch (Low)

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the MPEC Control Switch (Figure 56) to the OFF/RESET position.

Figure 56. MPEC Control Switch (Off/Reset)

5. Verify that all the status LEDs on the MPEC display 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 occurred dur ing operation.

EMERGENCY SHUTDOWN PROCEDURE

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 54 to the OFF position..

Figure 54. Main, GFCI and Load

Circuit Breakers Off

1. To stop the engine in the event of an emergency, PUSH the emergency stop button (Figure 57) inward. This button is located on the engine operating panel, see Figure 5.

Figure 57. Emergency Stop Button

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 37

MAINTENANCE

Engine

Generator

10 Hrs

DAILY

250 Hrs 500 Hrs

Table 12. Inspection/Maintenance

Check Engine Fluid Levels X

Check Air Cleaner X

Check Battery Acid Level X

Check Fan Belt Condition X

Check for Leaks X

Check for Loosening of Parts X

Replace Engine Oil and Filter *

Clean Air Filter X

Check Fuel Filter/Water Separator Bowl X

Clean Unit, Inside and Outside X

Change Fuel Filter X

Clean Radiator and Check Coolant Protection Level*

Replace Air Filter Element *

Check all Hoses and Clamps *

Clean Inside of Fuel Tank X

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

*1 Replace engine oil and ﬁlter at 100 hours, ﬁrst time only.

*2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.

*3 Replace primary air ﬁlter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).

*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,

with no sags or dips that could collect moisture and/or oil.

1000

Hrs

GENERAL INSPECTION

Prior to each use, the generator should be cleaned and inspected for deﬁciencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 12 as a general maintenance guideline. Engine Side, refer to the Engine Instruction Manual.

AIR CLEANER

Every 250 hours: Remove air cleaner element (Figure 58) 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 the air cleaner element is clogged, air intake

NOTICE

The air ﬁlter should not be changed until the indicator reads “RED”. Dispose of old air ﬁlter. It may not be

cleaned or reused. restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the air element, press the dust indicator button to reset the indicator.

PAGE 38 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

Figure 58. Air Cleaner/Indicator

MAINTENANCE

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exists.

FUEL ADDITION

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

Cleaning Inside the Fuel Tank

If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 59) wash out any deposits or debris that have accumulated inside the fuel tank.

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following components should be inspected for wear:

 Rubber Suspension — look for signs of wear or

deformity due to contact with oil. Replace the rubber suspension if necessary.

 Fuel Hoses — inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

 Fuel Tank Lining — inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

Replacing Fuel Filter

 Replace the fuel 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.

 Vent any air

AIR REMOVAL

If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the ISUZU Engine Manual for details.

To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed.

Figure 59. Fuel Tank Cleaning

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 39

MAINTENANCE

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 28.

Replacing Oil Filter

 Remove the old oil ﬁlter.

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

 Install the new oil ﬁlter.

 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

manufacturer.

 Close radiator cap tightly.

 Flush the radiator by running clean tap water through

radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

WARNING

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

RADIATOR CLEANING

The radiator (Figure 60) should be sprayed (cleaned) with a high pressure washer when excessive amounts 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.

Figure 60. Radiator Cleaning

GENERATOR STORAGE

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

 Drain the fuel tank completely. Treat with a fuel stabilizer

if necessary.

 Completely drain the oil from the crankcase and 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.

 If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block and completely remove the tires.

PAGE 40 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

MAINTENANCE

JACKET WATER HEATER AND INTERNAL BATTERY CHARGE R 120 VAC IN P UT RECEPTACLE S (OPTIONAL)

This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the jacket water heater and internal

battery charger.

These receptacles will ONLY function when commercial power has been supplied to them (Figure 61). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in hot climates there is no reason to apply power to jacket water heater. However, if the generator will be used in cold climates it is always a good idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using a power cord of adequate size.

NOTICE

To ensure adequate starting capability, always have power applied to the generator's internal battery charger.

Figure 61. Battery Charger and Jacket Water

Heater Power Connections

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 41

TRAILER MAINTENANCE

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with generator.

1. Fuel Cell — Provides an adequate amount of fuel for

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

2. Braking System — System employed in stopping

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

3. GVWR — Gross Vehicle Weight Rating (GVWR) is

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

4. Frame Length — Measurement is from the ball hitch

to the rear bumper (reﬂector).

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 16 and Figure 64 for lug nut tightening and sequence.

13. Axle — Indicates the maximum weight the axle can suppor t 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.

5. Frame Width — Measurement is from fender to fender

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 42 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

TRAILER MAINTENANCE

BRAKES

Trailer brakes should be inspected the ﬁrst 200 miles of 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 brakes more frequently.

Figure 62 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 13 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 star wheel of the adjuster assembly to expand the brake shoes.

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.

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

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

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 62) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

Figure 62. Hydraulic Brake Components

Actuator

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the surge or push of the trailer 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 hydraulic pressure to the trailer brakes.

Periodically check and test the surge “actuator” to make sure that it is functioning correctly. Never use an undersize actuator.

Table 13. Hydraulic Brake Troubleshooting

Symptom Possible Cause Solution

No Brakes Brake line broken or kinked? Repair or replace.

Brake lining glazed? Reburnish or replace.

Weak Brakes or Brakes Pull to

One Side

Locking Brakes

Noisy Brakes

Dragging Brakes

Trailer overloaded? Correct weight.

Brake drums scored or grooved? Machine or replace.

Tire pressure correct? Inﬂate all tires equally.

Tires unmatched on the same axle? Match tires.

Brake components loose, bent or

broken?

Brake drums out-of-round? Replace.

System lubricated? Lubricate.

Brake components correct? Replace and correct.

Brake lining thickness incorrect or

not adjusted correctly?

Enough brake ﬂuid or correct ﬂuid?

Replace components.

Install new shoes and

linings.

Replace rubber parts

ﬁll with dot 4 ﬂuid.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 43

TRAILER MAINTENANCE

TIRES/WHEELS/LUG NUTS

Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.

Tire Wear/Inﬂation

CAUTION

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.

CAUTION

tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Table 14 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Wear Pattern Cause Solution

ALWAYS wear safety glasses when

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

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

Table 14. Tire Wear Troubleshooting

Center Wear Over inﬂation.

Adjust pressure to particular load per tire manufacturer.

as detailed in Table 15.

Figure 63. Major Suspension Components

Table 15. Suspension Torque Requirements

Item Torque (Ft.-Lbs.)

3/8" U-Bolt Min-30 Max-35

7/16" U-Bolt Min-45 Max-60

1/2" U-Bolt Min-45 Max-60

Shackle Bolt

Spring Eye Bolt

Shoulder Type

Shackle Bolt

Snug ﬁt only. Parts must rotate freely.

Locking nuts or cotter pins are

provided to retain nut-bolt assembly.

Min-30 Max-50

Edge Wear Under inﬂation.

Side Wear

Loss of camber or overloading.

Adjust pressure to particular load per tire manufacturer.

Make sure load does not exceed axle rating. Align wheels.

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

Toe Wear Incorrect toe-in. Align wheels.

Cupping Out-of-balance.

Flat Spots

Wheel lockup and tire skidding.

Check bearing adjustment and balance tires.

Avoid sudden stops when possible and adjust brakes.

procedure for attachment of the wheels is as follows:

Suspension

The leaf suspension springs and associated components (Figure 63) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged par ts (suspension) immediately. Torqued suspension components

PAGE 44 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

TRAILER MAINTENANCE

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence (see Figure 64). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as deﬁned by Table 16.

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

Table 16. Tire Torque Requirements

Wheel Size

12" 20-25 35-40 50-65

13" 20-25 35-40 50-65

14" 20-25 50-60 90-120

15" 20-25 50-60 90-120

16" 20-25 50-60 90-120

First Pass

FT-LBS

Second Pass

FT-LBS

Third Pass

FT-LBS

Figure 64. Wheel Lug Nuts

Tightening Sequence

NOTICE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 45

TRAILER WIRING DIAGRAM

Figure 65. Trailer/Towing Vehicle Wiring Diagram

PAGE 46 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

GENERATOR WIRING DIAGRAM

Figure 66. Generator Wiring Diagram

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 47

ENGINE WIRING DIAGRAM

Figure 67. Engine Wiring Diagram

PAGE 48 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

CONTROLLER WIRING DIAGRAM

Figure 68. Controller Wiring Diagram

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 49

TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 17 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business ofﬁce or service plant.

Table 17. Generator Troubleshooting

Symptom Possible Problem Solution

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is AVR defective? Replace if necessary.

Defective Rotating Rectiﬁer? Check and replace.

Defective Exciter Field? Check for approximately 17.3 ohms across J & K on CN1

Is engine speed correct? Turn engine throttle lever to “High”.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Short Circuit in load? Check load and repair.

Over current? Conﬁrm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Conﬁrm load requirement and replace.

PAGE 50 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

TROUBLESHOOTING (ENGINE CONTROLLER)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 (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.

Table 18. Engine Controller Troubleshooting (MPEC)

Symptom Possible Problem Solution

Low oil level? Fill oil level.

Low oil pressure light is on.

Low coolant level light is on. (Optionally installed)

High coolant temperature light is on.

Overcrank light is on.

Oil pressure sending unit failure? Replace oil pressure sending unit.

Time delay malfunction in controller? Refer to dealer.

Wire shorted? Inspect/repair wire.

Low coolant level? Fill coolant level.

Sending unit failure? Replace sending unit.

Low battery voltage? Replace/charge battery.

Fan belt tension incorrect? Tighten/replace fan belt.

Air ﬂow is not circulating through radiator? Clean/repair radiator grill.

Doors open? Close doors.

Exhaust leaking? Replace/repair gaskets or faulty part.

Generator being overloaded? Check/reduce load.

Thermostat failure? Replace thermostat.

Air intake blocked? Clean all air intakes.

Temperature switch failure Replace temperature switch.

No or low fuel? Fill fuel level.

Controller needs to be calibrated? Refer to dealer.

RPM engine speed too high? Adjust RPM.

Overspeed light is on.

Loss of MPU light(s) or on.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 51

Governor actuator needs to be adjusted? Adjust governor actuator.

Governor controller needs to be adjusted? Adjust governor controller.

Engine controller needs to be calibrated? Refer to dealer.

Magnetic pick up out of adjustment? Adjust magnetic pick up.

Magnetic pick up dirty? Clean magnetic pick up.

TROUBLESHOOTING (DIAGNOSTIC LAMP)

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself. Press the diagnostic button (Figure 69) on the diagnostic panel to determine if an engine malfunction has occurred.

Figure 69. Diagnostic Panel

METHOD OF OPERATION

1. Normally, the diagnostic lamp will be dimly lit when the MPEC Control Switch is placed in the MANUAL position.

2. If engine trouble occurs, the diagnostic lamp will be brightly lit as long as the control switch is left in the manual position.

3. The diagnostic lamp will indicate that an engine malfunction has occurred.

NOTICE

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

NOTICE

If the engine is cranked while the diagnostic switch is in the “ON” position, the engine will not be stopped even if the starter switch is turned to the “OFF” position. In such case, turn the diagnostic switch to the “OFF” position.

PAGE 52 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

NOTES

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 53

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and

PART NO. Column

QTY. Column

— Item quantity can be indicated by a

A/R (As Required) is generally used for hoses or other

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁ ed in the “Remarks”

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed

same unique symbol will be included when this item is

— Used to list an effective serial

— Indicates that the part

part is NOT used on a speciﬁ c model or model number

available items. Examples include battery cables, shims,

— Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available

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.

Numbers Used

number, a blank entry, or A/R.

NOTICE

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

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

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTICE

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

parts that are sold in bulk and cut to length.

Column.

REMARKS Column

to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the

purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

Serial Number Break

number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Speciﬁ c Model Number Use

is used only with the speciﬁ c model number or model number variant listed. It can also be used to show a

variant.

Indicated by:

Numbers Used — Part numbers can be indicated by a number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clariﬁ ed in the “Remarks” Column.

PAGE 54 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

“XXXXX ONLY” “NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can be purchased at any hardware shop or made out of

and certain washers and nuts.

“Not Sold Separately”

for sale through Multiquip.

DC A 1 8 0S S I / DC A 1 8 0S S I U WH IS P E RWATT GENERATORS WITH ISUZU 6HK1X DIESEL ENGINE

1 to 3 units

QTY. P/N DESCRIPTION

5............1132402322 ..........OIL FILTER, CARTRIDGE

3............0602046682 ..........ELEMENT, AIR (OUTER)

3............0602046683 ..........ELEMENT, AIR (INNER)

1............1136715160 ..........BELT, FAN

1............M3310503903 .......RADIATOR HOSE, UPPER

1............M3310503703 .......RADIATOR HOSE, LOWER

1............0810105400 ..........FUEL FILTER, TANK (DCA180SSI)

3............8980714010 ..........FUEL FILTER, FEED PUMP

3............8980088400 ..........FILTER FUEL, ELEMENT MAIN

3............8980758540 ..........FILTER FUEL, ELEMENT PRE

1............0602122272 ..........UNIT, OIL PRESSURE

1............0602123260 ..........UNIT, WATER TEMPERATURE

1............0601808803 ..........CIRCUIT BREAKER, 1P, 20 AMP

1............0601808804 ..........CIRCUIT BREAKER, 2P 50 AMP

1............0601820601 ..........AUTOMATIC VOLTAGE REGULATOR

1............LY2DUS24VDC ..... RELAY

1............0601806644 ..........FUSE, 30 AMP

1............0601806640 ..........FUSE, 65 AMP

SUGGESTED SPARE PARTS

NOTICE

Part number on this Suggested Spare Parts list may supersede/replace the P/N shown in the text pages of this book.

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 55

1-4B

GENERATOR ASSY.

1-4

1-4A

10A

10B

20A

20B

22A

14B

14A

page 56 — DCa180SSI/DCa180SSIu 60 hz gen. • operatIon anD partS manual — rev. #1 (08/02/10)

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 C0110100902 ROTOR ASSY 1 1-1 FIELD ASSY 1 1-2 0601842334 RESISTOR, 80W 100K W 1 1-3 0601823282 RECTIFIER 1 1-4 0018205020 HEX SOCKET HEAD CAP SCREW 2 1-4A 0040005000 WASHER, LOCK 2 1-4B 0041205000 WASHER, FLAT 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 ................PURCHASE 1 - 11 AS A SET

1-9 0012116045 HEX HEAD BOLT 8 1-10 0042616000 WASHER, LOCK 8 1-11 0601000209 BALANCING WEIGHT KIT 1 1-12 C1112500004 BEARING FLANGE 1 1-13 0071906314 BEARING 1

2 C0164400503 COUPLING RING ........................................1 ................DCA180SSI

2 M3163400603 COUPLING RING ........................................1 ................DCA180SSIU

3 0010310050 HEX HEAD BOLT 8 4 0042510000 WASHER, LOCK 8 5 0010312040 HEX HEAD BOLT 8 6 0042512000 WASHER, LOCK 8 7 C0130000903 STATOR ASSY 1 7-1 0845041804 GROMMET 2 8 C1154000002 END BRACKET 1 9 C1138000003 FIELD ASSY EXCITER 1

10 0012110065 HEX HEAD BOLT 4 10A 0042610000 WASHER, LOCK 4

10B 0041210000 WASHER,FLAT 4 11 0017112045 HEX HEAD BOLT 6 12 C1154400004 COVER, BEARING 1

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 57

1-4B

GENERATOR ASSY. (CONTINUED)

1-4

1-4A

10A

10B

20A

20B

22A

14B

14A

PAGE 58 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

GENERATOR ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 13 C1154300004 GASKET, BEARING 1

14 0010106060 HEX HEAD BOLT 4 14A 0040006000 WASHER, LOCK 4

14B 0041206000 WASHER,FLAT 4 15 C1154400103 SUCTION COVER 1 16 0017106016 HEX HEAD BOLT 8 17 0010312040 HEX HEAD BOLT 12 18 0042512000 WASHER, LOCK 12 19 C1132300114 COVER, FAN 1 20 0010106030 HEX HEAD BOLT 1 20A 0041206000 WASHER, FLAT 1 20B 0600815000 NUT 1

21 0605000012 RUBBER SUSPENSION .............................2 ................DCA180SSI

21 0605000013 RUBBER SUSPENSION .............................2 ................DCA180SSIU

22 0030020000 HEX NUT .....................................................4 ................DCA180SSI

22 0030016000 HEX NUT .....................................................4 ................DCA180SSIU

22A 0040020000 WASHER, LOCK .........................................4 ................DCA180SSI

22A 0040016000 WASHER, LOCK .........................................4 ................DCA180SSIU

23 C0164600003 COUPLING ADAPTER ................................1 ................DCA180SSI

23 M3163600103 COUPLING ADAPTER ................................1 ................DCA180SSIU

24 0010310030 HEX HEAD BOLT 12 25 0042510000 WASHER, LOCK 12

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 59

CONTROL BOX ASSY.

PAGE 60 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M3213002002 CONTROL BOX 1 1-1 0330000215 EDGING 1 2 0601809666 CURRENT TRANSFORMER, 300/5A 3 3 0027106016 MACHINE SCREW 6 4 0601870423 CIRCUIT BREAKER, 500A 1 4-1 0021006045 MACHINE SCREW 4 4-1A 0207006000 HEX NUT 4 5 0601815168 REAR CONNECTOR KIT 1

6 C0274000003 TER. BOARD, VOLT. CHANGE- OVER ........1 ................DCA180SSI

6 M3273000003 TER. BOARD, VOLT. CHANGE- OVER ........1 ................DCA180SSIU

7 8131852104 CHANGE TERMINAL .................................10 ...............DCA180SSI

7 M3276400004 CHANGE TERMINAL .................................10 ...............DCA180SSIU

8 0017106025 HEX HEAD BOLT 20

9 C0277200004 TERMINAL PLATE ......................................3 ................DCA180SSI

9 M4276200004 TERMINAL PLATE ......................................3 ................DCA180SSIU

10 8131853104 CHANGE-OVER PLATE ..............................6 ................DCA180SSI

10 M3276300004 CHANGE-OVER PLATE ..............................6 ................DCA180SSIU

11 8131852504 TIE BOLT ....................................................20 ...............DCA180SSI

11 M4276100004 TIE BOLT ....................................................20 ...............DCA180SSIU

12 0040010000 WASHER, LOCK 20 13 0041410000 WASHER,FLAT 20 14 0017110040 HEX HEAD BOLT 3 15 0207010000 HEX NUT 3 16 0016908030 HEX HEAD BOLT 4 17 0601820601 AUTOMATIC VOLTAGE REGULATOR 1 18 0027105016 MACHINE SCREW 4 19 0601820847 OVER CURRENT RELAY 1 20 0601820848 OVER CURRENT RELAY, 25A 1

21 0027104020 MACHINE SCREW......................................2 ................DCA180SSI

21 0027104016 MACHINE SCREW......................................2 ................DCA180SSIU

21A 0207004000 HEX NUT 2 22 0601842468 RESISTOR 1 23 0027103010 MACHINE SCREW 2 24 0601802218 HOLDER, FUSE 3P 1 24A 0601806671 FUSE, 15A 3 25 0027103020 MACHINE SCREW 2 26 0601815153 TERMINAL 1 27 0027104016 MACHINE SCREW 2

28 812146-8300 SENSOR, INLET AIR TEMP. .......................1 ................REPLACES P/N 0603210240

29 M3260500703 SET PANEL, ELECTRIC PARTS 1 30 0016906016 HEX HEAD BOLT 4

31 8981264350 CONTROLLER ............................................1 ................REPLACES P/N 0602202678

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 61

CONTROL BOX ASSY. (CONTINUED)

PAGE 62 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

CONTROL BOX ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS

32 C3260503104 BRACKET....................................................1 ................DCA180SSI

32 M3260500604 BRACKET....................................................1 ................DCA180SSIU

33 0016906016 HEX HEAD BOLT 4 34 0601831205 PUSH BUTTON SWITCH 1 35 0601831330 DIAGNOSTIC SWITCH 1 36 0016906016 HEX HEAD BOLT 4 37 0601823240 RECTIFIER 1 38 0027104020 MACHINE SCREW 1 39 LY2DUS24VDC RELAY 3 REPLACES P/N 0601827655

39A PTF08A BASE ...........................................................3 ................REPLACES P/N 0601823109

39B PYCA1 CLIP ............................................................3 ................REPLACES P/N 0601824400

40 0027104020 MACHINE SCREW 6

41 8972177780 SENSOR, BAROMETRIC PRESSURE ......1 ................REPLACES P/N 0602130220

42 0027104016 MACHINE SCREW 2

43 8980056310 RELAY, STARTER .......................................1 ................REPLACES P/N 0602201401

44 0027106016 MACHINE SCREW 2

45 8980137900 RELAY .........................................................2 ................REPLACES P/N 0602202682

46 0027105016 MACHINE SCREW 2

47 5825500300 RELAY .........................................................1 ................REPLACES P/N 0602201222

48 0027105016 MACHINE SCREW 1

49 8944607060 RELAY, GLOW PLUG ..................................1 ................REPLACES P/N 0602202683

50 0027105016 MACHINE SCREW 2

51 3871824004 STOPPER, CONTROL PANEL ....................1 ................DCA180SSI

51 M4213600104 STOPPER, CONTROL PANEL ....................1 ................DCA180SSIU

52 0041206000 WASHER,FLAT 1 53 0605010502 SNAP PIN 1 54 M4213500104 COVER, CONTROL BOX 1 55 0016908020 HEX HEAD BOLT 8 56 M4213400104 BACK PANEL, CONTROL BOX 1 57 0016908020 HEX HEAD BOLT 8 58 0016908020 HEX HEAD BOLT 8 59 0016908020 HEX HEAD BOLT 6 60 M4223000303 CONTROL PANEL 1 61 M4223000404 CONTROL PANEL 1 61-1 0222100100 SEAL RUBBER 2 61-2 0222100165 SEAL RUBBER 2 62 0605011211 PIN 2 63 0017108040 HEX HEAD BOLT 4 64 0601807642 FREQUENCY METER, 240V 1 65 0601817000 AC AMMETER, 0~ 300A/600A:5A 1 66 0601801040 CHANGE- OVER SWITCH, AMMETER 1 67 0601800275 AC VOLTMETER, 600V 1 68 0601801041 CHANGE- OVER SWITCH, VOLTMETER 1 69 0601840073 RHEOSTAT (VOLTAGE REGULATOR) 1 70 0601840121 KNOB 1 71 0602202641 CONTROLLER 1

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 63

CONTROL BOX ASSY. (CONTINUED)

PAGE 64 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

CONTROL BOX ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS

72 0027104035 MACHINE SCREW......................................2 ................DCA180SSI

72 0021004040 MACHINE SCREW......................................2 ................DCA180SSIU

72A 0207004000 HEX NUT 2 73 0601831340 SWITCH 1 74 0601831395 ENGINE SPEED SWITCH 1 75 0602120098 TACHOMETER 1 76 0602122093 OIL PRESSURE GAUGE 1 77 0602123090 WATER TEMPERATURE GAUGE 1 78 0602121081 CHARGING AMMETER 1 79 0602125091 FUEL GAUGE 1 80 0602103090 ALARM LAMP 3 80A 0601810244 BULB 3 81 0601810171 PANEL LIGHT 1 82 0027104020 MACHINE SCREW 2 83 0601831330 SWITCH, PANEL LIGHT 1

84 0601831557 EMERGENCY STOP BUTTON ...................1 ................DCA180SSI

84 0601831589 EMERGENCY STOP BUTTON ...................1 ................DCA180SSIU

85 0845056404 SET SCREW ...............................................2 ................DCA180SSI

85 M9220100004 SET SCREW ...............................................2 ................DCA180SSIU

85A 0080200007 SNAP RING 2 86 0602122272 UNIT, OIL PRESSURE 1 87 M9200100004 ADAPTER 1 88 0602123260 UNIT, WATER TEMPERATURE 1

89 9095720140 PACKING .....................................................1 ................REPLACES P/N 0602021109

90 0601806644 FUSE, 30A 1 91 0601806640 FUSE, 65A 1 92 M3246702604 WIRE HARNESS, GENERATOR 1 93 M3357202402 WIRE HARNESS, ENGINE 1 94 M3357202202 WIRE HARNESS, CONTROLLER 1

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 65

ENGINE AND RADIATOR ASSY.

PAGE 66 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 M3923200174 ENGINE, 6HK1X 1

1A 1136715160 FAN BELT ....................................................1 ................REPLACES P/N 0602015275

2 M3303200803 ENGINE FOOT 2 3 0010310025 HEX HEAD BOLT 8 4 0042510000 WASHER, LOCK 8 5 0605000011 RUBBER SUSPENSION 2 6 0030016000 HEX NUT 2 7 0040016000 WASHER, LOCK 2 8 C0923200164 RADIATOR 1

8-1 1026000620 CAP .............................................................1 ................REPLACES P/N 0602011029

8-2 M3493600604 RUBBER SEAL 2 9 M9200101004 ADAPTER 1 10 0150000016 O-RING 1 11 0602123290 COOLANT LEVEL SWITCH 1 12 0016908020 HEX HEAD BOLT 16 13 M3310503903 RADIATOR HOSE 1 14 M3310503703 RADIATOR HOSE 1

15 0605515137 HOSE BAND ...............................................1 ................DCA180SSI

15 0605515148 HOSE BAND ...............................................2 ................DCA180SSIU

16 0605515137 HOSE BAND ...............................................1 ................DCA180SSI

16 0605515148 HOSE BAND ...............................................1 ................DCA180SSIU

17 0605515141 HOSE BAND ...............................................1 ................DCA180SSI

17 0605515146 HOSE BAND ...............................................1 ................DCA180SSIU

18 1350001140 INTER COOLER .........................................1 ................REPLACES P/N M3923200124

18-1 0132004000 PLUG 1 19 M3310504103 INTER COOLER HOSE 1 20 M3310400803 INTER COOLER PIPE 1 21 M3310504003 INTER COOLER HOSE 1 22 M3310504203 INTER COOLER HOSE 1 23 0605515236 HOSE BAND 2 24 0605515214 HOSE BAND 2 25 0605515206 HOSE BAND 1

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 67

ENGINE AND RADIATOR ASSY. (CONTINUED)

PAGE 68 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

ENGINE AND RADIATOR ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 26 0605515238 HOSE BAND 1 27 M3310203303 PIPE BRACKET 1 28 0016908020 HEX HEAD BOLT 2 29 0017112030 HEX HEAD BOLT 1

30 0602046538 AIR CLEANER ............................................1 ................DCA180SSI

30 0602046586 AIR CLEANER ............................................1 ................DCA180SSIU

30A 0602046617 ELEMENT (OUTER), AIR CLEANER .........1 ................DCA180SSI

30A 0602046682 ELEMENT (OUTER), AIR CLEANER 1 DCA180SSIU

30B 0602046618 ELEMENT (INNER), AIR CLEANER ...........1 ................DCA180SSI

30B 0602046683 ELEMENT (INNER), AIR CLEANER ...........1 ................DCA180SSIU

31 0602040690 INDICATOR, AIR CLEANER .......................1 ................DCA180SSI

31 0602040650 INDICATOR, AIR CLEANER .......................1 ................DCA180SSIU

32 0602040559 BAND, AIR CLEANER .................................2 ................DCA180SSI

32 0602040558 BAND, AIR CLEANER .................................2 ................DCA180SSIU

33 0016908025 HEX HEAD BOLT 4 34 0207008000 HEX NUT 4 35 M3373101603 HOSE, AIR CLEANER 1 36 M3373101703 HOSE, AIR CLEANER 1 37 M3326100304 BLOWBY PIPE 1

38 0605515211 HOSE BAND ...............................................1 ................DCA180SSI

38 0605515200 HOSE BAND ...............................................1 ................DCA180SSIU

39 0605515260 HOSE BAND ...............................................3 ................DCA180SSI

39 0605515202 HOSE BAND ...............................................3 ................DCA180SSIU

40 0191701230 BLOWBY HOSE 1

41 0605515068 HOSE BAND ...............................................2 ................DCA180SSI

41 0605515149 HOSE BAND ...............................................2 ................DCA180SSIU

42 0602022581 ADAPTER 1 43 0602022561 90 DEGREE ELBOW 1 44 0603306590 CONNECTOR 1 45 0603300285 ROCKNUT 1 46 0605511395 VALVE 1 47 0603306395 HOSE JOINT 1 48 0602021070 CAP 1

49 0269200400 DRAIN HOSE ..............................................1 ................DCA180SSI

49 0269200800 DRAIN HOSE ..............................................1 ................DCA180SSIU

50 M3323500204 BRACKET, OIL FILTER 1 51 0016910025 HEX HEAD BOLT 2

52 8973243861 OIL FILTER ..................................................1 ................REPLACES P/N 0602041007

52A 1132402322 CARTRIDGE, OIL FILTER ...........................1 ................REPLACES P/N 0602041221

53 0010110120 HEX HEAD BOLT 2 53A 0040010000 WASHER, LOCK 2 53B 0041210000 WASHER, FLAT 2

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 69

ENGINE AND RADIATOR ASSY. (CONTINUED)

PAGE 70 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

ENGINE AND RADIATOR ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 54 0010110150 HEX HEAD BOLT 2 54A 0040010000 WASHER, LOCK 2 54B 0041210000 WASHER,FLAT 2 55 0602022535 ADAPTER 4

56 0603306398 HOSE JOINT ...............................................4 ................DCA180SSIU

57 C0324300504 ENGINE OIL HOSE .....................................1 ................DCA180SSI

57 0379001500 ENGINE OIL HOSE .....................................1 ................DCA180SSIU

58 C0324300604 ENGINE OIL HOSE .....................................1 ................DCA180SSI

58 0379001450 ENGINE OIL HOSE .....................................1 ................DCA180SSIU

58 0802081003 RESERVE TANK ..........................................1 ................DCA180SSI

59 M9300000203 RESERVE TANK ..........................................1 ................DCA180SSIU

60 0602010900 CAP, RESERVE TANK 1 61 M3316100604 BRACKET, RESERVE TANK 1 62 0016908020 HEX HEAD BOLT 2 63 0199901150 HOSE 1 64 0193601450 HOSE 1 65 0193600650 HOSE 1 66 0605515106 HOSE BAND 3 67 M3357300004 HARNESS CLAMP 1

68 0017108025 HEX HEAD BOLT ........................................1 ................DCA180SSI

68 0017108020 HEX HEAD BOLT ........................................1 ................DCA180SSIU

69 0017110020 HEX HEAD BOLT 1 70 M3357300104 HARNESS CLAMP 1

71 0017108025 HEX HEAD BOLT ........................................2 ................DCA180SSI

71 0017108020 HEX HEAD BOLT ........................................2 ................DCA180SSIU

72 8980305320 ELENT., BLOWBY FILTER, DCA180SSIU ..1 ................REPLACES 0602044210

73 0194801300 HOSE ..........................................................1 ................DCA180SSIU

74 3373200304 BRACKET, AIR CLEANER ..........................1 ................DCA180SSIU

75 0016908025 HEX. HEAD BOLT .......................................4 ................DCA180SSIU

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 71

11B

OUTPUT TERMINAL ASSY.

12A

11A

13A

13C

13B

29A

PAGE 72 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

OUTPUT TERMINAL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0231700003 TERMINAL BOARD ....................................1 ................DCA180SSI

1 M3230700113 TERMINAL BOARD ....................................1 ................DCA180SSIU

2 0801830404 OUTPUT TERMINAL BOLT .........................5 ................DCA180SSI

2 M9220100914 OUTPUT TERMINAL BOLT .........................5 ................DCA180SSIU

3 0801830904 TIE BOLT .....................................................5 ................DCA180SSI

3 M9220101004 TIE BOLT .....................................................5 ................DCA180SSIU

4 0039320000 HEX NUT 10 5 0040020000 WASHER, LOCK 15 6 0041420000 WASHER,FLAT 20 7 0016908040 HEX HEAD BOLT 5 8 M4236100403 TERMINAL COVER 1 9 M4236100504 OUTPUT WINDOW 1 10 0605010040 HINGE 2 11 0027103010 MACHINE SCREW 4 11A 0030003000 HEX NUT 4 11B 0041203000 WASHER,FLAT 4 12 0027103015 MACHINE SCREW 4 12A 003003000 HEX NUT 4

13 M9220100404 SET SCREW ...............................................2 ................DCA180SSI

13 M9220100804 SET SCREW ...............................................2 ................DCA180SSIU

13A 0040006000 WASHER, LOCK 2 13B 0041806000 WASHER,FLAT 2 13C 0080200005 RETAINING RING 2 14 0016906016 HEX HEAD BOLT 2 15 0016906016 HEX HEAD BOLT 2 16 M4236400004 CABLE, OUTLET COVER 1 17 M4236400104 SUPPORTER, CABLE OUTLET COVER 1 18 0016906020 HEX HEAD BOLT 8 19 0601815194 TERMINAL BLOCK 1

20 0025304015 MACHINE SCREW......................................2 ................DCA180SSI

20 0027104015 MACHINE SCREW......................................2 ................DCA180SSIU

21 0601850275 GROMMET 1

22 0601851780 BLIND PLUG ...............................................2 ................DCA180SSI

22 0603306775 BLIND PLUG ...............................................2 ................DCA180SSIU

23 0601808803 CIRCUIT BREAKER, 1P 20A 2 24 0601808804 CIRCUIT BREAKER, 2P 50A 3

25 C3261600704 BRACKET, CIRCUIT BREAKER .................1 ................DCA180SSI

25 M3260600104 BRACKET, CIRCUIT BREAKER .................1 ................DCA180SSIU

25-1 0222100150 RUBBER CUSHION 1

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 73

OUTPUT TERMINAL ASSY. (cONTINUEd)

11B

12A

11A

13A

13C

13B

29A

page 74 — DCa180SSI/DCa180SSIu 60 hz gen. • operatIon anD partS manual — rev. #1 (08/02/10)

OUTPUT TERMINAL ASSY (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 26 0016906020 HEX HEAD BOLT 2 27 0601814013 RECEPTACLE, GF-20LA 20A 2

28 0601812565 RECEPTACLE,CS6369 50A ........................3 ................DCA180SSI

28 0601812538 RECEPTACLE, CS6369 50A .......................3 ................DCA180SSIU

29 0027104016 MACHINE SCREW 10 29A 0207004000 HEX NUT 10 30 M4236400204 COVER 1 31 0016906016 HEX HEAD BOLT 8 32 M4236100303 TERMINAL COVER 1 33 0010112045 HEX HEAD BOLT 2 34 0041212000 WASHER,FLAT 4

35 0805009804 STAY RUBBER ............................................2 ................DCA180SSI

35 M9310200004 STAY RUBBER ............................................2 ................DCA180SSIU

36 0030012000 HEX NUT 2 37 0605011505 STAY 1 38 0027105016 HEX HEAD BOLT 4 39 M4236100604 COVER 1 40 M4236400304 BRACKET 1

41 0016906020 HEX HEAD BOLT ........................................2 ................DCA180SSI

41 0016906016 HEX HEAD BOLT ........................................2 ................DCA180SSIU

42 0027104016 MACHINE SCREW 4

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 75

BATTERY ASSY. (DCA180SSI)

PAGE 76 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

BATTERY ASSY. (DCA180SSI)

NO. PART NO. PART NAME QTY. REMARKS 1 0165409541 BATTERY 2 2 6172251004 BATTERY SHEET 1 3 6412250004 BATTERY BAND 1 4 0805002904 BATTERY BOLT 2 5 0037808000 WING NIUT 2 6 0040008000 WASHER, LOCK 2 7 0041608000 WASHER, FLAT 2 8 C0346400804 BATTERY CABLE 1 9 C0346401004 BATTERY CABLE 1 10 C0346400904 BATTERY CABLE 1 11 EARTH CABLE 1 12 0602220310 TERMINAL ASSY 2 13 0602220311 TERMINAL ASSY 2 14 0845040414 TERMINAL CAP (+) 2 15 0845041304 TERMINAL CAP (-) 2 16 0017112025 HEX HEAD BOLT 1 17 0040512000 TOOTHED WASHER 1 18 0016908020 HEX HEAD BOLT 1 19 0040508000 TOOTHED WASHER 1

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 77

BATTERY ASSY. (DCA180SSIU)

PAGE 78 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

BATTERY ASSY. (DCA180SSIU)

NO. PART NO. PART NAME QTY. REMARKS 1 0602220199 BATTERY 2 2 M9310500014 BATTERY SHEET 2 3 M9103000804 BATTERY BAND 1 4 0602220920 BATTERY BOLT SET 2 5 M3346901904 BATTERY CABLE 1 6 M3346902104 BATTERY CABLE 1 7 M3346902204 BATTERY CABLE 1 8 EARTH CABLE 1 9 0017112025 HEX HEAD BOLT 1 10 0040512000 TOOTHED WASHER 1 11 0016908020 HEX HEAD BOLT 1 12 0040508000 TOOTHED WASHER 1

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 79

MUFFLER ASSY.

PAGE 80 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 C0331107302 MUFFLER 1 2 0016910025 HEX HEAD BOLT 4 3 M3333001803 EXHAUST PIPE 1

3A 0602311102 TAPE, INSULATING ....................................9 ................DCA180SSI

3A 0602311130 TAPE, INSULATING ....................................9 ................DCA180SSIU

4 1141451920 GASKET ......................................................1 ................REPLACES P/N 0602311130

5 7502356004 GASKET ......................................................1 ................DCA180SSI

5 4333200004 GASKET ......................................................1 ................DCA180SSIU

6 0030710000 HEX NUT 8 7 0017110050 HEX HEAD BOLT 4

8 C1331300104 COVER ........................................................2 ................DCA180SSI

8 M4330300004 COVER ........................................................2 ................DCA180SSIU

9 0016908020 HEX HEAD BOLT 4 10 M4333300304 BRACKET 1 11 0016908020 HEX HEAD BOLT 4 12 0602326062 U BOLT SET 1

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 81

FUEL TANK ASSY. (DCA180SSI)

PAGE 82 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

FUEL TANK ASSY. (DCA180SSI)

NO. PART NO. PART NAME QTY. REMARKS 1 C1363001403 FUEL TANK 1 1-1 0845500104 CAP, FUEL TANK 1 1-2 0810105400 FUEL FILTER 1 2 0605501092 FUEL SENDER UNIT 1 3 0605516090 GASKET 1 4 0022905015 MACHINE SCREW 5 5 M4363200104 TANK BAND 2 6 0805003414 SUPPORTER SHEET 4 7 0016908020 HEX HEAD BOLT 2 8 0207608000 U NUT 2 9 0222100150 TANK SHEET, 1/2" 4 10 0130206000 STREET ELBOW, 1/2" 1 11 8085512104 LONG NIPPLE, 1/2" 1 12 0603325011 VALVE 1 13 0132006000 PLUG, 1/2" 1 14 M3366700503 FUEL FILTER BRACKET 1 15 0016908020 HEX HEAD BOLT 4

16 8980139861 FUEL FILTER (MAIN) ..................................1 ................REPLACES P/N 0602042426

16A 8980088400 ELEMENT, FUEL FILTER ............................1 ................REPLACES P/N 0602042515

17 8980758550 FUEL FILTER (PRE) ...................................1 ................REPLACES P/N 0602042405

17A 8980758540 ELEMENT, FUEL FILTER ............................1 ................REPLACES P/N 0602042516

18 8973834270 JOINT PIPE .................................................4 ................REPLACES P/N 0602042661

19 1096750951 JOINT BOLT ................................................4 ................REPLACES P/N 0602042621

20 1096300860 PACKING .....................................................8 ................REPLACES P/N 0602042641

21 0015310045 HEX SOCKET HEAD CAP SCREW 4 21A 0040010000 WASHER, LOCK 4 21B 0041210000 WASHER, FLAT 4 22 0010110080 HEX HEAD BOLT 2 22A 0040010000 WASHER, LOCK 2 22B 0041210000 WASHER, FLAT 2

23 8980093970 FUEL FEED PUMP .....................................1 ................REPLACES P/N 0602023241

23A 8980714010 FUEL FILTER ..............................................1 ................REPLACES P/N 0602042517

24 0016906025 HEX HEAD BOLT 2 25 0191302850 SUCTION HOSE 1 26 0191300500 SUCTION HOSE 1 27 0191300580 SUCTION HOSE 1 28 0191300780 SUCTION HOSE 1 29 M3366700703 FUEL COOLER BRACKET 1 30 0016908020 HEX HEAD BOLT 2

31 Y131B40000 FUEL COOLER ...........................................1 ................REPLACES P/N 0605517000

32 0016908020 HEX HEAD BOLT 4 33 0191302160 RETURN HOSE 1 34 0191301870 RETURN HOSE 1 35 0605515145 HOSE BAND 12

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 83

FUEL TANK ASSY. (DCA180SSIU)

PAGE 84 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

FUEL TANK ASSY. (DCA180SSIU)

NO. PART NO. PART NAME QTY. REMARKS 1 M4363000102 FUEL TANK 1 1-1 0605505070 CAP, FUEL TANK 1 2 0605501069 FUEL SENDER UNIT 1 3 0605516090 GASKET 1 4 0027104016 MACHINE SCREW 5 5 M4363200104 TANK BAND 2 6 M9310500104 SUPPORTER SHEET 4 7 0016908020 HEX HEAD BOLT 2 8 0207308000 SUPER LOCK NUT 2 9 0222100150 TANK SHEET 4 10 M9200000003 DRAIN JOINT 1 11 M9200200004 DRAIN BOLT 1 12 0150000018 O'RING 1 13 016906020 HEX HEAD BOLT 2 14 M1363400104 DRAIN HOSE 1 15 0605515198 HOSE BAND 2 16 M33667503 FUEL FILTER BRACKET 1 17 0016908020 HEX HEAD BOLT 1

18 8980139862 FUEL FILTER , MAIN ..................................1 ................REPLACES P/N 0602042426

18A 8980088400 ELEMENT, FUEL FILTER ............................1 ................REPLACES P/N 0602042515

19 8980758551 FUEL FILTER, PRE .....................................1 ................REPLACES P/N 0602042405

19A 8980758540 ELEMENT, FUEL FILTER ............................1 ................REPLACES P/N 0602042516

20 8973834270 JOINT PIPE .................................................4 ................REPLACES P/N 0602042661

21 1096750951 JOINT BOLT ................................................4 ................REPLACES P/N 0602042621

22 1096300860 PACKING .....................................................8 ................REPLACES P/N 0602042641

23 0015310045 HEX SOCKET HEAD CAP SCREW 4 23A 0040010000 WASHER, LOCK 4 23B 0041210000 WASHER,FLAT 4 24 0010110080 HEX HEAD BOLT 2 24A 0040010000 WASHER, LOCK 2 24B 0041210000 WASHER,FLAT 2

25 8980093970 FUEL FEED PUMP .....................................1 ................REPLACES P/N 0602023241

25A 8980714010 FUEL FILTER ..............................................1 ................REPLACES P/N 0602042517

26 0016906025 HEX HEAD BOLT 2 27 0191302850 SUCTION HOSE 1 28 0191300500 SUCTION HOSE 1 29 0191300580 SUCTION HOSE 1 30 0191300780 SUCTION HOSE 1 31 M3366700703 FUEL COOLER BRACKET 1 32 0016908020 HEX HEAD BOLT 2

33 131B40000 FUEL COOLER ...........................................1 ................REPLACES P/N 0605517000

34 0016908020 HEX HEAD BOLT 4 35 0191302160 RETURN HOSE 1 36 0191301870 RETURN HOSE 1 37 0605515145 HOSE BAND 12

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 85

ENCLOSURE ASSY.

PAGE 86 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0413006702 BASE ...........................................................1 ................DCA180SSI

1 M3413002802 BASE ...........................................................1 ................DCA180SSIU

2 M4413400404 COVER 1

3 0019208020 HEX HEAD BOLT ........................................4 ................DCA180SSI

3 0016908020 HEX HEAD BOLT ........................................4 ................DCA180SSIU

4 M3423003202 FRONT FRAME 1 4A M3493116703 ACOUSTIC SHEET 1 5 M3423003302 FRONT FRAME 1 5A M3493116703 ACOUSTIC SHEET 1 6 0016908020 HEX HEAD BOLT 12 7 0019210025 HEX HEAD BOLT 8 8 M3423203004 COVER, FRONT FRAME 1 8A M3493116804 ACOUSTIC SHEET 1 9 0019208020 HEX HEAD BOLT 24 10 M3423203103 OVER COVER, FRONT FRAME 1 11 0019208020 HEX HEAD BOLT 14 12 M3310203503 SUPPORTER, RADIATOR 1 12A M3493600504 ACOUSTIC SHEET 1 13 M9910203403 SUPPORTER, RADIATOR 1 13A M3493600504 ACOUSTIC SHEET 1 14 M4310600304 RUBBER SHEET 2 15 0017112055 HEX HEAD BOLT 4 16 M3310202504 BRACKET, RADIATOR 2 17 0016910025 HEX HEAD BOLT 4 18 0016910025 HEX HEAD BOLT 2 19 M3310203703 BRACKET, INTER COOLER 2 20 0016910025 HEX HEAD BOLT 8 21 0016910025 HEX HEAD BOLT 8 22 M3310305103 FAN SHROUD 1 23 M3310305203 FAN SHROUD 1 24 0016908020 HEX HEAD BOLT 8 25 0016908020 HEX HEAD BOLT 4 26 M3310305403 FAN GUARD 1 27 M3310305303 FAN GUARD 1 28 M3310305503 FAN GUARD 1 29 0016908020 HEX HEAD BOLT 11 30 M3433001602 CENTER FRAME 1 30A M3493201504 ACOUSTIC SHEET 1

31 0010114050 HEX HEAD BOLT ........................................4 ................DCA180SSI

31 0010114040 HEX HEAD BOLT ........................................4 ................DCA180SSIU

31A 0030014000 HEX NUT 4 31B 0040014000 WASHER, LOCK 4 31C 0041214000 WASHER, FLAT 8

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 87

ENCLOSURE ASSY. (CONtiNUEd)

42A

63A

49A

68A

69A

31C

31B

31A

52A

53A

65A

71A

30A

43A

33A

44A

12A

13A

67A

66A

81A

32A

62A

32C

70A

75A

32B

60A

88A

64A

36A

82A

page 88 — DCa180SSI/DCa180SSIu 60 hz gen. • operatIon anD partS manual — rev. #1 (08/02/10)

ENCLOSURE ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS

32 0010120045 HEX HEAD BOLT ........................................4 ................DCA180SSI

32 0010120050 HEX HEAD BOLT ........................................4 ................DCA180SSIU

32A 0030014000 HEX NUT 4 32B 0040020000 WASHER, LOCK 4 32C 0041220000 WASHER,FLAT 8 33 M3443002402 REAR FRAME 1 33A M3493310804 ACOUSTIC SHEET 1 34 0019210025 HEX HEAD BOLT 4

34A 0040510000 TOOTHED WASHER ...................................1 ................DCA180SSI

35 M3443302003 REAR COVER 1 36 M3443302103 DUCT, REAR COVER 1 36A M3493310904 ACOUSTIC SHEET 1 37 0038406000 HEX NUT 12 38 0019208020 HEX HEAD BOLT 19 39 M3443200903 REAR DOOR 1 40 M4443600004 WINDOW PLATE 1 41 0207306000 SUPER LOCK NUT 8 41A 0041206000 WASHER,FLAT 8

42 B9114000002 DOOR HANDLE ASSY ...............................1 ................DCA180SSI

42 M9114000002 DOOR HANDLE ASSY ...............................1 ................DCA180SSIU

42A C9312500004 SEAL RUBBER 1

43 0021806015 MACHINE SCREW......................................4 ................DCA180SSI

43 0021806016 MACHINE SCREW......................................4 ................DCA180SSIU

43A 0030006000 HEX NUT 4

44 0845047104 HINGE .........................................................2 ................DCA180SSI

44 9110100204 HINGE .........................................................2 ................DCA180SSIU

44A 0845045004 WASHER .....................................................2 ...............DCA180SSI

44A 9116100004 WASHER .....................................................2 ................DCA180SSIU

45 0019208020 HEX HEAD BOLT 3

46 0845031504 BLIND PLUG ...............................................2 ................DCA180SSI

46 9310000004 BLIND PLUG ...............................................2 ................DCA180SSIU

47 0600800320 MANUAL PAK 1 48 0021806016 MACHINE SCREW 4 49 M3463101702 ROOF PANEL 1 49A M3493511204 ACOUSTIC SHEET 1 50 M3310600004 COVER 1 51 0019208020 HEX HEAD BOLT 4 52 M4463200202 ROOF PANEL 1 52 A M4493501903 ACOUSTIC SHEET 1 53 M3463202802 DUCT, REAR ROOF 1 53 A M3493512204 ACOUSTIC SHEET 1 54 0016908020 HEX HEAD BOLT 10 55 M4463200304 COVER 2 56 0016906016 HEX HEAD BOLT 12 57 M44635000204 GUTTER 2 58 0019206015 HEX HEAD BOLT 8 59 0019204020 HEX HEAD BOLT 32

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 89

ENCLOSURE ASSY. (CONtiNUEd)

42A

63A

49A

68A

69A

31C

31B

31A

52A

53A

65A

71A

30A

43A

33A

44A

12A

13A

67A

66A

81A

32A

62A

32C

70A

75A

32B

60A

88A

64A

36A

82A

page 90 — DCa180SSI/DCa180SSIu 60 hz gen. • operatIon anD partS manual — rev. #1 (08/02/10)

ENCLOSURE ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS 60 M3453201902 SPLASHER PANEL 1 60A M3493431904 ACOUSTIC SHEET 1 61 0019108065 HEX HEAD BOLT 6 61A 0042308000 WASHER, LOCK 6 61B 0042408000 WASHER,FLAT 6 62 M3453006103 SIDE DOOR 1 62A M3493431604 ACOUSTIC SHEET 1 63 M3453006203 SIDE DOOR 1 63A M3493431704 ACOUSTIC SHEET 1 64 M3453006003 SIDE DOOR 1 64A M3493431404 ACOUSTIC SHEET 1 65 M3453006303 SIDE DOOR 1 65A M3493431504 ACOUSTIC SHEET 1 66 M3453303604 DUCT 1 66A M3493432004 ACOUSTIC SHEET 1 67 M3453303704 DUCT 1 67A M3493432104 ACOUSTIC SHEET 1 68 M3453303804 DUCT 1 68A M3493432204 ACOUSTIC SHEET 1 69 M3453303904 DUCT 1 69A M3493432304 ACOUSTIC SHEET 1 70 M3453304204 DUCT 1 70A M3493432504 ACOUSTIC SHEET 1 71 M3453304004 DUCT 1 71A M3493431804 ACOUSTIC SHEET 1 72 0207008000 HEX NUT 38 73 B9114000002 DOOR HANDLE 4

74 0825007362 DOOR HANDLE ..........................................3 ................DCA180SSI

74 M9113000102 DOOR HANDLE ..........................................3 ................DCA180SSIU

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 91

ENCLOSURE ASSY. (CONTINUED)

PAGE 92 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

ENCLOSURE ASSY. (CONTINUED)

NO. PART NO. PART NAME QTY. REMARKS

75 0021806015 MACHINE SCREW.....................................28 ...............DCA180SSI

75 0021806016 MACHINE SCREW.....................................28 ...............DCA180SSIU

75A 0030006000 HEX NUT 28 76 M3453600404 GUTTER 1 77 M3453600504 GUTTER 2 78 M4453600004 GUTTER 2 79 M3453600604 GUTTER 1 80 0019206015 HEX HEAD BOLT 18

81 0845046904 HINGE .........................................................6 ................DCA180SSI

81 M9110100804 HINGE .........................................................6 ................DCA180SSIU

81A 0845045004 WASHER .....................................................8 ................DCA180SSI

81A M9116100004 WASHER .....................................................8 ................DCA180SSIU

82 0845047004 HINGE .........................................................5 ................DCA180SSI

82 M9110100904 HINGE .........................................................5 ................DCA180SSIU

82A 0845045004 WASHER .....................................................5 ................DCA180SSI

82A M9116100004 WASHER .....................................................5 ................DCA180SSIU

83 0019208020 HEX HEAD BOLT 25 84 0601850097 STOPPER 9 85 0025408025 MACHINE SCREW 9

86 0845031504 BLIND PLUG ..............................................11 ...............DCA180SSI

86 M9310000004 BLIND PLUG ..............................................11 ...............DCA180SSIU

87 0019210025 HEX HEAD BOLT 4

88 0016908020 HEX HEAD BOLT ........................................1 ................DCA180SSIU

88A 0040508000 TOOTHED WASHER ...................................1 ................DCA180SSIU

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 93

RUBBER SEALS ASSY.

PAGE 94 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

RUBBER SEALS ASSY.

NO. PART NO. PART NAME QTY. REMARKS 1 0229201240 SEAL RUBBER 4 2 0228900945 SEAL RUBBER 4 3 0228901200 SEAL RUBBER 3 4 0228901260 SEAL RUBBER 3 5 0228901055 SEAL RUBBER 4 6 0228900580 SEAL RUBBER 1 7 0228900640 SEAL RUBBER 1 8 0229201130 SEAL RUBBER 1 9 0228801050 SEAL RUBBER 2 10 0228800550 SEAL RUBBER 1 11 0228800590 SEAL RUBBER 1 12 0228100560 SEAL RUBBER 2 13 0228100370 SEAL RUBBER 2

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 95

NAMEPLATE AND DECALS ASSY.(DCA180SSI)

PAGE 96 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

NAMEPLATE AND DECALS ASSY.(DCA180SSI)

NO. PART NO. PART NAME QTY. REMARKS

1-1 M4550000303 DECAL : OPERATING PROCEDURES ........................... 1 ...........M45000030

1-2 B9521100404 DECAL : SAFETY INSTRUCTIONS ................................. 1 ...........B92110040

1-3 C9521100003 DECAL : CAUTION .......................................................... 2 ...........C92110000

CONTROL PANEL & BOX GROUP

2-1 M3550004102 DECAL : CONTROL PANEL ............................................. 1 ...........M35000410

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 M9520200404 DECAL : OVER CURRENT RELAY ................................. 1 ...........M92020040

2-6 C0551000903 DECAL : SETTING FOR OUTPUT VOLTAGE .................. 1 ...........C05100090

2-7 M9522000504 DECAL : CIRCUIT BREAKER .......................................... 1 ...........M92200050

2-8 C9521007504 DECAL : DIAGNOSTIC SWITCH ..................................... 1 ...........C92100750

2-9 C9520027704 DECAL : DIAGNOSTIC BUTTON..................................... 1 ...........C92002770

ENGINE & RADIATOR GROUP

3-1 6360620204 DECAL : OIL DRAIN PLUG .............................................. 1 ...........S-1885

3-2 6360610304 DECAL : WATER .............................................................. 1 ...........S-1880

3-3 B9504000404 DECAL : WARNING MOVING PARTS .............................. 2 ...........B90400040

3-4 1320610603 DECAL : WATER - OIL CHECK ........................................ 1 ...........S-1760

3-5 B9504100104 DECAL : WARNING HOT COOLANT ............................... 1 ...........B90410010

3-6 B9504000304 DECAL : CAUTION HOT PARTS ...................................... 1 ...........B90400030

3-7 C9501100004 DECAL : INTER COOLER DRAIN ................................... 1 ...........C90110000

OUTPUT TERMINAL GROUP

4-1 M4550000503 DECAL : RECEPTACLE & CIRCUIT BREAKER .............. 1 ...........M45000050

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 0840619904 DECAL : DANGER HIGH VOLTAGE ................................. 1 ...........S-2731

4-6 M9520100503 DECAL : WARNING ......................................................... 1 ...........M92010050

BATTERY GROUP

5-1 0800689504 DECAL : - ......................................................................... 1

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

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

MUFFLER GROUP

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

FUEL TANK GROUP

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

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

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 97

NAMEPLATE AND DECALS ASSY. (CONT. DCA180SSI)

PAGE 98 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

NAMEPLATE AND DECALS ASSY. (CONT. DCA180SSI)

NO. PART NO. PART NAME QTY. REMARKS ENCLOSURE GROUP

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

8-2 0600500090 EMBLEM 2 8-2A 0021106016 MACHINE SCREW 4 8-3 C1560100303 STRIPE 1 8-4 C0560100403 STRIPE 1 8-5 M3560104803 STRIPE 1 8-6 C1560100004 STRIPE 3 8-7 M3560104703 STRIPE 1 8-8 C0560100303 STRIPE 1

8-9 1320621504 DECAL : SUPPORT HOOK ............................................. 2 ...........S-2257

8-10 M3550002204 DECAL : CAUTION .......................................................... 1 ...........M35000220

8-11 M9510000104 DECAL : DOCUMENT BOX LOCATED ............................ 1 ...........M91000010

8-12 A9504000014 DECAL : DANGER EXHAUST GAS ................................. 1 ...........A90400001

DCA180SSI/DCA180SSIU 60 HZ GEN/ • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10) — PAGE 99

NAMEPLATE AND DECALS ASSY.(DCA180SSIU)

PAGE 100 — DCA180SSI/DCA180SSIU 60 HZ GEN. • OPERATION AND PARTS MANUAL — REV. #1 (08/02/10)

Multiquip DCA180SSIU User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual