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MQ Power DCA-400SSV Operation And Parts Manual

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PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
TM
WHISPERWATT
SERIES
MODEL DCA180SSJU
60HZ GENERATOR
(JOHN DEERE 6068HF485 DIESEL ENGINE)
(PARTS LIST NO. M3870301004)
Revision #3 (02/01/10)
To find the latest revision of this
publication, visit our website at:
www.mqpower.com

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  • Page 1 PARTS AND OPERATION MANUAL OPERATION AND PARTS MANUAL WHISPERWATT SERIES MODEL DCA180SSJU 60HZ GENERATOR (JOHN DEERE 6068HF485 DIESEL ENGINE) (PARTS LIST NO. M3870301004) Revision #3 (02/01/10) To find the latest revision of this publication, visit our website at: www.mqpower.com...

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING PAGE 2 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

  • Page 3: Reporting Safety Defects

    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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS MQ POWER DCA-180SSJU MQ POWER DCA-180SSJU MQ POWER DCA-180SSJU COMPONENT DRA COMPONENT DRA WINGS WINGS MQ POWER DCA-180SSJU MQ POWER DCA-180SSJU COMPONENT DRA COMPONENT DRA COMPONENT DRAWINGS WINGS WINGS WHISPER WHISPER WHISPERW W W W W A A A A A TT...

  • Page 5: Parts Ordering Procedures

    PARTS ORDERING PROCEDURES Ordering parts has never been easier! Choose from three easy options: Effective: January 1 , 2006 Order via Internet (Dealers Only) Best Deal! If you have an MQ Account, to obtain a Username Order parts on-line using Multiquip’s SmartEquip website! and Password, E-mail us at: parts@multiquip.

  • Page 6: Specifications

    SPECIFICATIONS Table 1. Generator Specifications Model DCA-180SSJU Revolving field, self ventilated, open protected type synchronous Type generator Armature Connection Star with Nutreal Phase Standby Output 198 KVA (158 KW) Prime Output 180 KVA (144 KW) 240V or 480V Voltage 60 Hz Frequency Speed 1800 rpm...

  • Page 7: Dimensions (Top, Side And Front)

    DIMENSIONS (TOP, SIDE AND FRONT) Figure 1. Dimensions r e f . t f r e f r e t . t f r e t . n i . n i . n i . n i . n i .

  • Page 8: Safety Message Alert Symbols

    Gasoline engine exhaust gases contain efficient operation of the poisonous carbon monoxide. This gas is MQ Power colorless and odorless, and can cause if inhaled. NEVER operate this Before using this generator, ensure that the operating...
  • Page 9 SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTS CAUTION - RESPIRATORY HAZARDS NEVER operate equipment with covers, ALWAYS wear approved or guards removed. Keep protection. and clothing away from all moving parts to prevent injury. CAUTION - ACCIDENTAL STARTING CAUTION - SIGHT AND HEARING HAZARDS ALWAYS place the MPEC control switch ALWAYS wear approved in the OFF/RESET position when the...

  • Page 10: Rules For Safe Operation

    ■ NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result. ■ Manufacturer does not assume responsibility for any accident due to equipment modifications.
  • Page 11 RULES FOR SAFE OPERATION Generator Grounding DANGER - ELECTROCUTION HAZARDS To guard against electrical shock and possible damage to During operation of this generator, there the equipment, it is important to provide a good EARTH exists the possibility of ground. which can cause Article 250 (Grounding) of the or even...
  • Page 12 RULES FOR SAFE OPERATION Maintenance Safety Battery Safety ■ The electrical voltage required to operate the generator Use the following guidelines when handling the battery: can cause severe injury or even death through physical ■ The battery contains acids that can contact with live circuits.
  • Page 13 RULES FOR SAFE OPERATION ■ The maximum speed for highway towing is 55 MPH unless Towing & Transporting Safety posted otherwise. Recommended off-road towing is not To reduce the possibility of an accident while transporting to exceed 15 MPH or less depending on type of terrain. the generator on public roads, always make sure the trailer ■...

  • Page 14: Generator Decals

    GENERATOR DECALS The DCA-180SSJU generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine.
  • Page 15 GENERATOR DECALS Figure 3. Generator Decals (Cont inued) DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 15...

  • Page 16: Installation

    INSTALLATION Figure 4. Typical Generator Grounding Application PAGE 16 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 17 INSTALLATION Outdoor Installation Generator Grounding Install the generator in a area that is free of debris, To guard against electrical shock and possible damage to bystanders, and overhead obstructions. Make sure the the equipment, it is important to provide a good EARTH generator is on secure level ground so that it cannot slide or ground.

  • Page 18: General Information

    The DCA-180SSJU generator is equipped with the state of the art " " excitation system. The open delta The MQ Power Model DCA-180SSJU is a 180 kW system consist of an electrically independent winding wound (Figure 5) that is designed as a high quality portable (requires among stationary windings of the AC output section.

  • Page 19: Major Components

    MAJOR COMPONENTS Figure 5. Major Components t a r r o j y l b s e l y l b r i A l i F r e t y l b f f u r e l y l b y l b y l b e t t...

  • Page 20: Diagnostic Display

    DIAGNOSTIC DISPLAY Right Arrow Button – Press this button to scroll through the screen either moving the parameter selection toward the right or downward. Enter Key Button – Press this button to select the parameter that is highlighted on the screen. Emergency Stop LED –...
  • Page 21 DIAGNOSTIC DISPLAY First Time Start Up The first seven items of the “Main Menu” will be displayed. Touching the “Arrow Buttons” will scroll When power is first applied to the diagnostic display, through the menu selection. the “Logo” is displayed. GO TO 1-UP DISPLAY LANGUAGES STORED CODES...
  • Page 22 DIAGNOSTIC DISPLAY If the word “MORE” appears above the “Arrow Buttons” The language choices will be displayed. Use the “Arrow” there are more stored fault codes that may be viewed. buttons to scroll through the selections and touch “Enter” Use the “Arrow Buttons” to scroll to the next Stored to make a selection.
  • Page 23 DIAGNOSTIC DISPLAY First Time Start Up The first seven items of the “Main Menu” will be displayed. Touching the “Arrow Buttons” will scroll When power is first applied to the diagnostic display, through the menu selection. the “Logo” is displayed. GO TO 1-UP DISPLAY LANGUAGES STORED CODES...
  • Page 24 DIAGNOSTIC DISPLAY If the word “MORE” appears above the “Arrow Buttons” The language choices will be displayed. Use the “Arrow” there are more stored fault codes that may be viewed. buttons to scroll through the selections and touch “Enter” Use the “Arrow Buttons” to scroll to the next Stored to make a selection.
  • Page 25 DIAGNOSTIC DISPLAY The main menu will pop up on the display. Use the FAULTS AND WARNINGS “Arrow Buttons” to scroll through the menu until the “Engine Configuration” menu item has been Auxiliary Gage Fault highlighted. During normal operation the single or four parameter screen will be displayed.
  • Page 26 DIAGNOSTIC DISPLAY To acknowledge and “Hide” the fault and return to the Indicates Auxiliary Gage Fault Indicates Fault Warning single or four parameter display touch the “Enter Button”. Indicates Derate or Shutdown Condition Fault Touching the “Enter Button” will redisplay the hidden fault.
  • Page 27 DIAGNOSTIC DISPLAY Touching the “Enter Button” once again will hide the Shut Down Codes fault and return the screen to the single or four During normal operation the single or four parameter parameter display. screen will be displayed. SHUTDOWN 1 of x 1000 RPM SPN110 FMI10 LOAD RPM...
  • Page 28 DIAGNOSTIC DISPLAY Once the “Adjust Backlight” menu item has been Contrast Adjustment highlighted touch the “Enter Button” to activate the Starting at the single or four engine parameter display, “Adjust Backlight” function. touch the “Menu Button”. GO TO 1-UP DISPLAY STORED CODES 1000 RPM ENGINE CONF...
  • Page 29 DIAGNOSTIC DISPLAY Select Units Touch the “Enter Button” to select the highlighted units. Starting at the single or four engine parameter display touch the “Menu Button”. ENGLISH METRIC KPA METRIC BAR 1000 RPM ENG RPM 1500 3000 LOAD RPM 1800 RPM 14.2 57 PSI BATT VOLT...
  • Page 30 DIAGNOSTIC DISPLAY Once the “Setup 1-up Display” menu icon has been A message indicating the “Single Engine” parameter highlighted touch the “Enter Button” to access the “Setup display parameters are reset to the factory defaults will 1-up display” function. be displayed, then the display will return to the “Custom Setup”...
  • Page 31 DIAGNOSTIC DISPLAY 11. Touch the “Enter Button” to deselect the selected 16. Touching the “Enter Button” toggles the “Automatic parameter removing it from the list of parameters being Scan” function on. displayed on the 1-up display. USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN ON ENGINE SPEED PERCENT LOAD AT CURRENT RPM...
  • Page 32 DIAGNOSTIC DISPLAY Setup 4-Up Display 5. The “Use Defaults” screen will be displayed during the resetting period then will automatically return to the From the single or four engine parameter display touch “Setup 4- Up Display” menu. the “Menu Button”. 1000 RPM RESTORED TO 1500...
  • Page 33 DIAGNOSTIC DISPLAY The parameter that is highlighted is the selected 14. Touch the “Menu Button” to return to the main menu. parameter for the screen. Use the “Arrow Buttons” to highlight the new parameter to be placed in the quadrant selected in the previous screen.
  • Page 34 DIAGNOSTIC DISPLAY Touch “Select” to enter the “Gage Data” display. When When the gage data has cleared, the display “Gage Data” is selected the PowerView will automatically returns to the “Utilities” menu. Scroll to communicate with the analog gages at a fixed rate of “Software Version”.
  • Page 35 DIAGNOSTIC DISPLAY 11. Touch the “Menu” button to return to “Utilities” menu. Use the “Arrows” to scroll down to and highlight either Touch the “Menu button again to return to the “Main” the “Slave Active or Master Active” modes. Touch the menu.
  • Page 36 DIAGNOSTIC DISPLAY GLOSSARY (Troubleshooting information) CANBUS FAILURE Diagnostic Display has not received any CAN messages for at least 30 seconds. NO DATA Diagnostic Display has not received the particular message being displayed for at least 5 seconds. NOT SUPPORTED Diagnostic Display has received a message from the ECU stating the displayed message is not supported DATA ERROR Diagnostic Display has received an error message from the ECU for the displayed message.

  • Page 37: Generator Control Panel

    GENERATOR CONTROL PANEL INCREASE DECREASE Figure 7. Generator Control Panel Located behind the generator control panel is the The definitions below describe the controls and functions of . This box contains some of the necessary the DCA-180SSJU (Figure 7). electronic components required to make the generator Frequency Meter –...

  • Page 38: Engine Operating Panel

    ENGINE OPERATING PANEL The definitions below describe the controls and functions of the DCA-180SSJU (Figure 8). AUTO MANUAL OFF/RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING MOOOOO-20001Q Figure 8. Engine Operating Panel Panel Light – Normally used in dark areas or at night Charging Ammeter Gauge –...
  • Page 39 ENGINE OPERATING PANEL Pre-Heat Lamp – When lit, indicates engine is in the A. MPEC Control Switch – This switch controls the running of the unit. If this switch is set to the pre-heating mode (for starting during cold weather OFF/RESET position, the unit will not run.

  • Page 40: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Panel Output Terminal Familiarization (Figure 9) shown below is The “ ” (Figure 9) is provided with located on the right-hand side (left from control panel) of the the following: generator. Lift up on the cover to gain access to receptacles ■...
  • Page 41 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles Each auxilliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI There are two 120 VAC, 20 amp GFCI (Duplex Nema 5- receptacles. Remember the load output (current) on all three 20R) recepacles provided on the output terminal panel.
  • Page 42 OUTPUT TERMINAL PANEL FAMILIARIZATION Over Current Relay Connecting Loads (Figure 15) is connected to the main Loads can be connected to the generator by the circuit breaker. In the event of an overload, both the circuit or the convienience receptacles (Figure 14). breaker and the over current relay may trip.

  • Page 43: Load Application

    LOAD APPLICATION Single Phase Load Three Phase Load Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase power and equipment to insure the wattage, amperage, frequency, use the following equation: and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

  • Page 44: Generator Outputs

    GENERATOR OUTPUTS Maximum Amps Generator Output Voltages Table 8 shows the amps the generator can pro- A wide range of voltages are available to supply voltage for vide. DO NOT exceed the maximum amps as listed. many different applications. Voltages are selected by apply- ing jumpers (6) to the (Figure 16).

  • Page 45: Gauge Reading

    GENERATOR OUTPUTS/ GAUGE READING How to Read the AC Ammeter and AC Voltage Gauges. AC Ammeter Gauge Reading The AC ammeter and AC voltmeter gauges are controlled Place the (Figure 20) by the AC ammeter and AC voltmeter change-over switches. to the U position and observe the current reading (load drain) Both of these switches are located on the control panel and on the U terminal as indicated on the...

  • Page 46: Output Terminal Panel Connections

    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 de- pendent on the placement of the jumpers plates (6) on the and the adjustment of the Figure 24.
  • Page 47 OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480 UVWO Output Terminal Voltages 1Ø-480V UVWO Terminal Output Voltages 1. Jumper the voltage change-over board for 480V 1. Make sure the voltage change-over board is jumpered operation as shown in Figure 27. This configuration uses for 480V operation as shown in Figure 27.

  • Page 48: Setup

    SETUP Circuit Breakers Fuel Check To protect the generator from an overload, a 3-pole, 500 DANGER - EXPLOSION/FIRE HAZARDS amp, circuit breaker is provided to protect the from overload. In addition two Fuel spillage on a engine can cause a single-pole, 20 amp circuit breakers are provided to .
  • Page 49 SETUP Refueling Procedure: Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel WARNING - RESPIRATORY HAZARDS cap and fill tank (Figure 34). Diesel fuel and its vapors are dangerous to your health and the surrounding environment.
  • Page 50 SETUP Coolant (Antifreeze) Cleaning the Radiator John Deere recommends Antifreeze/Summer Coolant for use The engine may overheat if the radiator fins become in thier engines, which can be purchased in concentrate (and overloaded with dust or debris. Periodically clean the radiator mixed with 50% demineralized water) or pre-diluted.
  • Page 51 SETUP Battery When connecting battery do the following: This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery Always maintain battery fluid level between the specified terminals when the is in either marks.

  • Page 52: Generator Start-Up Procedure (Manual)

    GENERATOR START-UP PROCEDURE (MANUAL) 3. Make sure the the voltage change-over board Before Starting has been configured for the desired output voltage. CAUTION - LETHAL EXHAUST HAZARD 4. Connect the load to the or the The engine's exhaust contains harmful emissions. as shown in Figure 14.
  • Page 53 GENERATOR START-UP PROCEDURE (MANUAL) When the MPEC Control switch is 8. To restart the engine due to error codes, place the placed in the manual position, in the MANUAL position (Figure 43) NOTE preheating of the glow plugs will begin 9.
  • Page 54 GENERATOR START-UP PROCEDURE (MANUAL) 18. Place the , and . circuit breakers in the ON position (Figure 54). Figure 49. Voltage Adjust Control Knob 14. The ammeter (Figure 50) will indicate with no load applied. When a load is applied, the Figure 54.

  • Page 55: Generator Start-Up Procedure (Auto Mode)

    GENERATOR START-UP PROCEDURE (AUTO MODE) When starting generator in AUTO mode use the " WARNING - AUTO MODE MAINTENANCE Start-up" procedure except where noted (see below). When running the generator in the AUTO mode, remember 1. Perform steps 1 through 6 in the section the generator can start up at any time without warning.

  • Page 56: Generator Shut-Down Procedures

    GENERATOR SHUT-DOWN PROCEDURES Emergency Shutdown Procedure WARNING - SHUTTING DOWN THE To shutdown the generator in the event of an emergency GENERATOR NEVER stop the engine suddenly except in an emergency. use the following procedure: 1. Place the (Figure 59) in the CAUTION - DIAGNOSTIC SWITCH OFF/RESET position.

  • Page 57: Maintenance (Engine)

    MAINTENANCE (ENGINE) 10 Hrs TABLE 12. INSPECTION/MAINTENANCE 250 Hrs 500 Hrs 1000 Hrs DAILY Check Engine Fluid Levels Check Air Cleaner Check Battery Acid Level Check Fan Belt Condition Check for Leaks Check for Loosening of Parts Replace Engine Oil and Filter * Clean Air Filter ENGINE Check Fuel Filter/Water Seperator Bowl...
  • Page 58 MAINTENANCE (ENGINE) Air Removal Flushing Out Radiator and Replacing Coolant  Open both cocks located at the crankcase side and at If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or the lower part of the radiator and drain coolant.

  • Page 59: Maintenance (Heater/Charger)

    MAINTENANCE (HEATER/CHARGER) Jacket Water Heater and Internal Battery Charger If the generator will be used daily, the battery should normally 120 VAC Input Receptacles (OPTIONAL) not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger This generator can be optionally equipped with two 120 VAC, receptacle via commercial power using an power cord of 20 amp input receptacles located on the output terminal...

  • Page 60: Maintenance (Trailer)

    MAINTENANCE (TRAILER) 8. Tire Size - Indicates the diameter of the tire in inches Trailer Maintenance (10,12,14, etc.), and the width in millimeters This section is intended to provide the user with generic trailer (175,185,205, etc.). The tire diameter must match the service and maintenance information.
  • Page 61 MAINTENANCE (TRAILER) Brakes Hydraulic Surge Brakes Trailer brakes should be inspected the Hydraulic surge brakes (Figure 61) should not require any operation. This will allow the brake shoes and drums to seat special attention with the exception of routine maintenance properly.
  • Page 62 MAINTENANCE (TRAILER) Tires/Wheels/Lug Nuts Suspension Tires and wheels are a very important and critical springs and associated components components of the trailer. When specifying or replacing the (Figure 62) should be visually inspected every 6,000 miles trailer wheels it is important the wheels, tires, and axle are for signs of excessive wear, elongation of bolt holes, and properly matched.
  • Page 63 MAINTENANCE (TRAILER) Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows: 1.

  • Page 64: Trailer Wiring Diagram

    TRAILER WIRING DIAGRAM Figure 62. Trailer/Towing Vehicle Wiring Diagram PAGE 64 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

  • Page 65: Generator Wiring Diagram

    GENERATOR WIRING DIAGRAM Figure 63. Generator Wiring Diagram DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 65...

  • Page 66: Engine Wiring Diagram

    DCA-180SSJU — ENGINE WIRING DIAGRAM Figure 64. Engine Wiring Diagram PAGE 66 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

  • Page 67: Troubleshooting (Generator)

    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.

  • Page 68: Troubleshooting (Engine Controller)

    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.
  • Page 69 NOTES DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 69...

  • Page 70: Explanation Of Code In Remarks Column

    EXPLANATION OF CODE IN REMARKS COLUMN The following section explains the different symbols and QTY. Column remarks used in the Parts section of this manual. Use the Numbers Used — Item quantity can be indicated by a help numbers found on the back page of the manual if there number, a blank entry, or A/R.

  • Page 71: Suggested Spare Parts

    SUGGESTED SPARE PARTS DCA-180SSJU WHISPER WATTGENRATOR W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITS Qty. Description 1 ..M4310500803 ..HOSE, RADIATOR UPPER 1 ..M4310500903 ..HOSE, RADIATOR LOWER 1 ..0605505070 ..FUEL CAP 1 ..0602015230 ..V-BELT, FAN 1 ..

  • Page 72: Component Dra Component Drawings Wings Generator Assembly

    GENERATOR ASSY. GENERATOR ASSY. PAGE 72 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 73 GENERATOR ASSY. GENERATOR ASSY. PART NO. PART NAME QTY. REMARKS C0110000602 ROTOR ASSY......1 ..INCLUDES ITEMS W/# 1-1# FIELD ASSY....... 1 ..NOT SOLD SEPARETLY 1-2# 0601842334 RESISTOR, 100K OHM 1-3# 0601823282 RECTIFIER 1-4# 0018205020 HEX. SHCS 1-4A# 0040005000 WASHER, LOCK 1-4B#...
  • Page 74 CONTROL PANEL ASSY. CONTROL PANEL ASSY. PAGE 74 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

  • Page 75: Control Panel Assembly

    CONTROL PANEL ASSY. CONTROL PANEL ASSY. PART NO. PART NAME QTY. REMARKS M4223000303 CONTROL PANEL M4223000404 CONTROL PANEL 022100100 SEAL RUBBER 022100165 SEAL RUBBER 0605011211 0017108040 HEX. HEAD BOLT 0601807642 FREQUENCY METER, 240V 0601817000 AC AMMETER, 0~300A/600A:5A 0601800275 CHANGE- OVER SWITCH, AMMETER 0601800275 AC VOLTMETER, 0~600V 0601801041...
  • Page 76 CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 76 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

  • Page 77: Control Box Assembly

    CONTROL BOX ASSY. CONTROL BOX ASSY. PART NO. PART NAME QTY. REMARKS M3213001302 CONTROL BOX 0601809666 CURRENT TRANSFORMER, 300/5A 0027106018 MACHINE SCREW 0601870423 CIRCUIT BREAKER, 500A 0021006045 MAVHINE SCREW 0207006000 HEX. NUT 0601815168 REAR CONNECTOR KIT M3273000003 TERMINAL BOARD, VOLTAGE CHANGE-OVER 1 M3276400004 CHANGE TERMINAL 0017106025...
  • Page 78 CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 78 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 79 CONTROL BOX ASSY. CONTROL BOX ASSY. ( CONT.) PART NO. PART NAME QTY. REMARKS M4260500003 SET PANEL, ELECTRIC PARTS 0016908020 HEX. HEAD BOLT 0602202592 STARTER RELAY 0030006000 HEX. NUT 0027106016 MACHINE SCREW LY2DUS12VDC RELAY ..............1.... REPLACES P/N 0601827656 PTF08A BASE ..............

  • Page 80: Engine And Radiator Assembly

    ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PAGE 80 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 81 ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PART NO. PART NAME QTY. REMARKS M4923200034 ENGINE 0602015230 FAN BELT RE504836 CARTRIDGE, OIL FILTER ..........1 ....REPLACES P/N 0602041292 RE529643 CARTRIDGE, PRIMARY FUEL FILTER ......1 ....REPLACES P/N 0602042596 RE522878 CARTRIDGE, FINAL FUEL FILTER .......1 ....REPLACES P/N 0602042597 0602060015 BLOWER FAN R81876...
  • Page 82 ENGINE AND RADIATOR ASSY. (CONT) ENGINE AND RADIATOR ASSY. (CONT.) PAGE 82 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 83 ENGINE AND RADIATOR ASSY. (CONT) ENGINE AND RADIATOR ASSY. (CONT.) PART NO. PART NAME QTY. REMARKS 0605515199 HOSE BAND M4310401004 INTER COOLER PIPE M4310501303 INTER COOLER HOSE M4310501003 INTER COOLER HOSE M4310501403 INTER COOLER HOSE 0605515207 HOSE BAND 0605515208 HOSE BAND 0605515209 HOSE BAND M4310600404...

  • Page 84: Output Terminal Assembly

    OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 84 —...
  • Page 85 OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. PART NO. PART NAME QTY. REMARKS M3230700113 TERMINAL BOARD M9220100914 OUTPUT TERMINAL BOLT M9220101004 TIE BOLT 0039320000 HEX. NUT 0040020000 LOCK WASHER 0041420000 WASHER, FLAT 0016908040 HEX. HEAD BOLT M4236100403 TERMINAL COVER M4236100504 OUTPUT WINDOW 0605010040 HINGE 0027103010...
  • Page 86 OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 86 —...
  • Page 87 OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. (CONT.) PART NO. PART NAME QTY. REMARKS M4260600104 BRACKET, CIRCUIT BREAKER 25-1 022100150 RUBBER CUSHION 0019206020 HEX. HEAD BOLT 0601812538 RECEPTACLE, 20A 0601812538 RECEPTACLE, 50A 0025304015 MACHINE SCREW 0207004000 HEX. NUT M4236400204 COVER 0019206015 HEX.

  • Page 88: Battery Assembly

    BATTERY ASSY. BATTERY ASSY. PAGE 88 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 89 BATTERY ASSY. BATTERY ASSY. PART NO. PART NAME QTY. REMARKS 0602220196 BATTERY M9310500404 BATTERY SHEET M9103000504 BATTERY SHEET 0602220921 BATTERY BOLT SET M4346900304 BATTERY CABLE M4346900204 BATTERY CABLE CABLE ..............1.... MAKE LOCALLY 0017116030 HEX. HEAD BOLT 0040516000 TOOTHED WASHER 0040520000 TOOTHED WASHER DCA-180SSJU —...

  • Page 90: Muffler Assembly

    MUFFLER ASSY. MUFFLER ASSY. PAGE 90 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 91 MUFFLER ASSY. MUFFLER ASSY. PART NO. PART NAME QTY. REMARKS M4330100502 MUFFLER 0016910025 HEX. HEAD BOLT M4333000303 EXHAUST PIPE 0602325066 CLAMP M4333200004 GASKET 0017112055 HEX. HEAD BOLT M4330300004 COVER 0016908020 HEX. HEAD BOLT M4333300304 BRACKET 0016908020 HEX. HEAD BOLT 0602326062 U BOLT SET DCA-180SSJU —...
  • Page 92 FUEL TANK ASSY. FUEL TANK ASSY. PAGE 92 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

  • Page 93: Fuel Tank Assembly

    FUEL TANK ASSY. FUEL TANK ASSY. PART NO. PART NAME QTY. REMARKS M4363000102 FUEL TANK 0605505070 CAP. FUEL TANK 0605501069 FUEL SENDER UNIT 0605516090 GASKET 0027104016 MACHINE SCREW M4363200104 TANK BAND M9310500104 SUPPORTER SHEET 0016908020 HEX. HEAD BOLT 0207308000 SUPER LOCK NUT 0222100120 RUBBER SHEET 0222100180...

  • Page 94: Enclosure Assembly

    ENCLOSURE ASSY. ENCLOSURE ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 94 —...
  • Page 95 ENCLOSURE ASSY. ENCLOSURE ASSY. PART NO. PART NAME QTY. REMARKS M4413000302 BASE M1413400004 COVER 0019208020 HEX. HEAD BOLT M4423000312 FRONT FRAME M4493102513 ACOUSTIC SHEET M4423000412 FRONT FRAME M4493102513 ACOUSTIC SHEET 0016908020 HEX. HEAD BOLT 0019210030 HEX. HEAD BOLT M4493102704 ACOUSTIC SHEET 0019208020 HEX.
  • Page 96 ENCLOSURE ASSY. (CONT.) ENCLOSURE ASSY. (CONT.) ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 96 —...
  • Page 97 ENCLOSURE ASSY. (CONT.) ENCLOSURE ASSY. (CONT.) PART NO. PART NAME QTY. REMARKS 0037906000 SELF-LOCKING U NUT 0041206000 WASHER, FLAT M9113000002 DOOR HANDLE 0021806016 MACHINE SCREW 0030006000 HEX. NUT M9110100204 HINGE M9116100004 WASHER 0019208020 HEX. HEAD BOLT M9310000004 BLIND PLUG 0600800320 MANUAL PAK 0021806016 MACHINE SCREW...
  • Page 98 ENCLOSURE ASSY. (CONT.) ENCLOSURE ASSY. (CONT.) ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 98 —...
  • Page 99 ENCLOSURE ASSY. (CONT.) ENCLOSURE ASSY. (CONT.) PART NO. PART NAME QTY. REMARKS M4453001203 SIDE DOOR M4493403804 ACOUSTIC SHEET M4453001303 SIDE DOOR M4493403904 ACOUSTIC SHEET M4453001003 SIDE DOOR M4493403004 ACOUSTIC SHEET M4453001103 SIDE DOOR M4493403104 ACOUSTIC SHEET M4453301004 DUCT M4493404004 ACOUSTIC SHEET M4453300504 DUCT M4493403204...

  • Page 100: Rubber Seals Assembly

    RUBBER SEALS ASSY. RUBBER SEALS ASSY. PAGE 100 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 101 RUBBER SEALS ASSY. RUBBER SEAL ASSY. PART NO. PART NAME QTY. REMARKS 0229201240 RUBBER SEAL 0228900945 RUBBER SEAL 0228901200 RUBBER SEAL 0228901260 RUBBER SEAL 0228901055 RUBBER SEAL 0228900600 RUBBER SEAL 0228900660 RUBBER SEAL 0229201060 RUBBER SEAL 0229200660 RUBBER SEAL 0228801050 RUBBER SEAL 0228800595 RUBBER SEAL...

  • Page 102: Nameplate And Decals Assembly

    NAMEPLATE AND DECALS ASSY. NAMEPLATE AND DECALS ASSY. PAGE 102 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
  • Page 103 NAMEPLATE AND DECALS ASSY. NAME PLATE ASSY. PART NO. PART NAME QTY. REMARKS 0229201240 RUBBER SEAL M4550000303 DECAL; OPERATING PROCEDURES M45000030 M9520100304 DECAL; SAFETY INSTRUCTIONS M92010030 M9520100603 DECAL; CAUTION M92010060 M3550002702 DECAL; CONTROL PANEL M35000270 M9520000104 PLATE; AMMETER CHANGE-OVER SWITCH M92000010 M9520000204 PLATE;...

  • Page 104: Terms And Conditions Of Sale - Parts

    TERMS AND CONDITIONS OF SALE — PARTS PAYMENT TERMS Parts must be in new and resalable Multiquip reserves the right to quote and condition, in the original Multiquip sell direct to Government agencies, and to Terms of payment for parts are net 30 days. package (if any), and with Multiquip part Original Equipment Manufacturer accounts numbers clearly marked.
  • Page 105 NOTES DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 105...
  • Page 106 © COPYRIGHT 2010, MULTIQUIP INC. MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the MQ Power and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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