Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip DCA-150SSJU3 operation manual

Models: DCA-150SSJU3

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PAGE 2 — DCA-150SSJU3— OPERATION AND PARTS MANUAL — REV. #0 (11/14/07)

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Contents

MODEL DCA-150SSJU3 PARTS LIST NO. M3870301104OPERATION AND PARTS MANUAL WHISPERWATTTM SERIESPage SERVICE DEPARTMENT HERES HOW TO GET HELPNUMBER ON-HAND WHEN CALLING WARRANTYDEPARTMENTCOMPONENT DRAWINGS TABLE OF CONTENTSSpecification and part NOTEnumber are subject to change without noticeplease supply the following information PARTS ORDERING PROCEDURESWhen ordering parts Extra DiscountsEngine Specifications DCA-150SSJU3— SPECIFICATIONSTable 1. Generator Specifications FuelTABLE 3. DIMENSIONS DCA-150SSJU3- DIMENSIONS TOP, SIDE AND FRONTFigure 1. Dimensions Dimension ft. mmSAFETY MESSAGE ALERT SYMBOLS DCA-150SSJU3- SAFETY MESSAGE ALERT SYMBOLSHAZARD SYMBOLS Whisperwatt GeneratorCAUTION - ACCIDENTAL STARTING DCA-150SSJU3— SAFETY MESSAGE ALERT SYMBOLSWARNING - ROTATING PARTS CAUTION - OVER-SPEEDCONDITIONSDANGER - READTHIS MANUAL General SafetyDCA-150SSJU3— RULES FOR SAFE OPERATION Generator Grounding Electrical SafetyDCA-150SSJU3— RULES FOR SAFE OPERATION DANGER - ELECTROCUTION HAZARDSDANGER - EXPLOSION HAZARDS Maintenance SafetyBattery Safety DCA-150SSJU3— RULES FOR SAFE OPERATIONDCA-150SSJU3— RULES FOR SAFE OPERATION Towing &Transporting SafetyEmergencies DCA-150SSJU3— GENERATOR DECALS Figure 2. Generator DecalsDCA-150SSJU3— GENERATOR DECALS Figure 3. Generator Decals Cont inuedDCA-150SSJU3- INSTALLATION Figure 4.Typical Generator Grounding ApplicationIndoor Installation DCA-150SSJU3- INSTALLATIONOutdoor Installation CAUTION - EXHAUST HAZARDEngine Operating Panel DCA-150SSJU3— GENERAL INFORMATIONGenerator Generator Control PanelFigure 5. Major Components DCA-150SSJU3— MAJOR COMPONENTSTable 4. Generator Major Components DESCRIPTIONDisplay Parameters DCA-150SSJU3— DIAGNOSTIC DISPLAYFigure 6. Diagnostic Display Panel 1800 RPM DCA-150SSJU3— DIAGNOSTIC DISPLAYFirst Time Start Up Main Menu NavigationDCA-150SSJU3— DIAGNOSTIC DISPLAY Stored Fault CodesEngine Configuration Data 1800 RPM1800 RPM DCA-150SSJU3— DIAGNOSTIC DISPLAYFirst Time Start Up Main Menu NavigationEngine Configuration Data DCA-150SSJU3- DIAGNOSTIC DISPLAYStored Fault Codes 1800 RPM1800 RPM FAULTS ANDWARNINGS Auxiliary Gage FaultDCA-150SSJU3— DIAGNOSTIC DISPLAY 1800 RPM1800 RPM Active Fault CodesDCA-150SSJU3— DIAGNOSTIC DISPLAY 1000 RPMDCA-150SSJU3— DIAGNOSTIC DISPLAY Backlight AdjustmentShut Down Codes 1800 RPM1800 RPM Contrast AdjustmentDCA-150SSJU3— DIAGNOSTIC DISPLAY DCA-150SSJU3- DIAGNOSTIC DISPLAY Setup 1- Up DisplaySelect Units 1800 RPMDCA-150SSJU3— DIAGNOSTIC DISPLAY 3. Once the “Setup 1-upDisplay” menu icon has beenAUTOMATIC SCAN ON DCA-150SSJU3— DIAGNOSTIC DISPLAY1800 RPM AUTOMATIC SCAN OFF1800 RPM Setup 4-UpDisplayDCA-150SSJU3— DIAGNOSTIC DISPLAY 1000 RPM1800 RPM Utilities information and troubleshootingDCA-150SSJU3- DIAGNOSTIC DISPLAY 1000 RPM“Gage Data” is selected the PowerView will DCA-150SSJU3- DIAGNOSTIC DISPLAYWhen the gage data has cleared, the display version currently in the diagnostic displaythrough the menu until the “Modbus Setup” menu is MODBUS SETUPDCA-150SSJU3— DIAGNOSTIC DISPLAY menuDATA ERROR DCA-150SSJU3— DIAGNOSTIC DISPLAYGLOSSARY Troubleshooting information TIMEOUT ECU NOT RESPONDINGDCA-150SSJU3— GENERATOR CONTROL PANEL Figure 7. Generator Control PanelDCA-150SSJU3— ENGINE OPERATING PANEL Figure 8. Engine Operating PanelDCA-150SSJU3— ENGINE OPERATING PANEL 13.Auto On/Off Engine Controller MPEC –Output Terminal Panel Output Terminal FamiliarizationFigure 9. Output Terminal Panel Figure 12. Voltage Regulator Control Knob 120VAC GFCI ReceptaclesFigure 10. G.F.C.I. Receptacle Figure 11. 240/139V Twist-LockOver Current Relay Connecting LoadsFigure 14. Connecting Loads Figure 15. Over Current RelayDCA-150SSJU3— LOAD APPLICATION Single Phase LoadThree Phase Load DANGER - ELECTRICAL SYSTEM HAZARDSGenerator OutputVoltages DCA-150SSJU3— GENERATOR OUTPUTSTable 9. Generator Ampere Ratings ⎯ 3∅ Voltage Change-OverBoardDCA-150SSJU3— GENERATOR OUTPUTS/ GAUGE READING How to Read the Output Terminal GaugeChange-OverSwitch Maximum AmpsDCA-150SSJU3— OUTPUT TERMINAL PANEL CONNECTIONS Three-PhasePositionFigure 25. Voltage Selector Switch 240/139V UVWO Terminal Output Voltages3Ø 480/277 Output Terminal Lug Voltages Figure 27. Voltage Selector Switch 480/277VDCA-150SSJU3— OUTPUT TERMINAL PANEL CONNECTIONS 1Ø 240V/120V Output Terminal Lug VoltagesLubrication Oil DCA-150SSJU3— SETUPCircuit Breakers Fuel CheckFigure 33. Fueling the Generator Refueling ProcedureWARNING - RESPIRATORY HAZARDS Figure 32. Only Fill on Level GroundCoolant Antifreeze Cleaning the RadiatorAir Cleaner Table 12. Coolant CapacityFigure 37. Battery Connections BatteryBattery Cable Installation CAUTION - BATTERY SERVICING SAFETYFigure 42. MPEC Control Switch Manual Position DCA-150SSJU3- GENERATOR START-UPPROCEDURE MANUALFigure 41. Engine Speed Switch Low Before StartingFigure 45. Engine Running LED ON Figure 44. Engine Speed Switch HighFigure 43. Active Fault Code Message Figure 46. Frequency Meter HzNo Load Figure 48. Voltage Adjust Control KnobCAUTION - BACKUP GENERATOR USE Figure 50. OilCAUTION - ENGINE SPEED SWITCH DCA-150SSJU3—GENERATORSTART-UPPROCEDUREAUTOMODEWARNING - AUTO MODE MAINTENANCE Figure 54. Engine Speed Switch HighNormal Shutdown Procedure DCA-150SSJU3— GENERATOR SHUT-DOWNPROCEDURESCAUTION - DIAGNOSTIC SWITCH Figure 56. Engine Speed Switch LowAir Cleaner with Dust Indicator DCA-150SSJU3— MAINTENANCE ENGINETABLE 14. INSPECTION/MAINTENANCE Service DailyCheck Oil Level Cleaning the Fuel StrainerAir Removal Replacing Oil FilterJacketWater Heater Power Connections DCA-150SSJU3— MAINTENANCE HEATER/CHARGERFigure 58. DCA-150SSJU3BatteryCharger & DCA-150SSJU3— MAINTENANCE TRAILER Trailer MaintenanceBrakes DCA-150SSJU3— MAINTENANCE TRAILERBrake Adjustment Hydraulic Surge BrakesTireWear/Inflation Tires/Wheels/Lug NutsCAUTION - EYESIGHT HAZARD SuspensionFigure 61. Wheel Lug Nuts Tightening Sequence DCA-150SSJU3- MAINTENANCE TRAILERLug Nut Torque Requirements Table 18. Tire Torque RequirementsDCA-150SSJU3 —TRAILERWIRINGDIAGRAM Figure 62. Trailer/Towing Vehicle Wiring DiagramDCA-150SSJU3— GENERATORWIRING DIAGRAM Figure 63. Generator Wiring DiagramDCA-150SSJU3— ENGINEWIRING DIAGRAM Figure 64. Engine Wiring DiagramSYMPTOM DCA-150SSJU3 —TROUBLESHOOTINGGENERATORTABLE 19. GENERATOR TROUBLESHOOTING POSSIBLE PROBLEMSYMPTOM DCA-150SSJU3 —TROUBLESHOOTINGENGINE CONTROLLERTABLE 20. ENGINE CONTROLLER TROUBLESHOOTING MPEC POSSIBLE PROBLEMNOTE PAGE QTY. Column NO. ColumnPART NO. Column REMARKS ColumnW/JOHN DEERE 6068HF285TURBO DIESEL ENGINE DCA-150SSJU3— SUGGESTED SPARE PARTSDCA-150SSJU3WHISPERWATTGENRATOR 1TO 3 UNITSDCA-150SSJU3— GENERATOR ASSY GENERATOR ASSYQTY. REMARKS PART NOPART NAME DCA-150SSJU3— GENERATOR ASSYDCA-150SSJU3—CONTROL BOX ASSY CONTROL BOX ASSYPART NO REMARKSDCA-150SSJU3-CONTROL BOX ASSY PART NAMEDCA-150SSJU3—CONTROL BOX ASSY. CONT CONTROL BOX ASSY. CONTPART NO DCA-150SSJU3—CONTROL BOX ASSY. CONTCONTROL BOX ASSY. CONT PART NAMEDCA-150SSJU3—ENGINE AND RADIATOR ASSY ENGINE AND RADIATOR ASSYPART NO DCA-150SSJU3—ENGINE AND RADIATOR ASSYENGINE AND RADIATOR ASSY PART NAMEDCA-150SSJU3—ENGINE AND RADIATOR ASSY. CONT ENGINE AND RADIATOR ASSY. CONTPART NAME DCA-150SSJU3-ENGINE AND RADIATOR ASSY. CONTENGINE AND RADIATOR ASSY. CONT DCA-150SSJU3—OUTPUTTERMINAL ASSY OUTPUT TERMINAL ASSYPART NAME DCA-150SSJU3—OUTPUTTERMINAL ASSYPART NO M3230700003DCA-150SSJU3—BATTERY ASSY BATTERY ASSYPART NO DCA-150SSJU3—BATTERY ASSYBATTERY ASSY PART NAMEDCA-150SSJU3—MUFFLER ASSY MUFFLER ASSYPART NO DCA-150SSJU3—MUFFLER ASSYMUFFLER ASSY PART NAMEDCA-150SSJU3—FUELTANK ASSY FUEL TANK ASSYPART NO DCA-150SSJU3-FUELTANK ASSYFUEL TANK ASSY PART NAMEDCA-150SSJU3—ENCLOSURE ASSY ENCLOSURE ASSYPART NO DCA-150SSJU3—ENCLOSURE ASSYENCLOSURE ASSY PART NAMEDCA-150SSJU3—ENCLOSURE ASSY. CONT ENCLOSURE ASSY. CONTPART NAME DCA-150SSJU3—ENCLOSURE ASSY. CONTPART NO 0041206000DCA-150SSJU3—ENCLOSURE ASSY. CONT 0019206015 DCA-150SSJU3—ENCLOSURE ASSY. CONTPART NAME DCA-150SSJU3—RUBBER SEALS ASSY RUBBER SEALS ASSYPART NAME DCA-150SSJU3—RUBBER SEALS ASSYPART NO 0229201200DCA-150SSJU3—NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSYPART NO DCA-150SSJU3-NAMEPLATE AND DECALS ASSYNAMEPLATE AND DECALS ASSY PART NAMEDCA-150SSJU3—NAMEPLATE AND DECALS ASSY. CONT NAMEPLATE AND DECALS ASSY. CONTPART NO DCA-150SSJU3-NAMEPLATE AND DECALS ASSY. CONTNAMEPLATE AND DECALS ASSY. CONT PART NAMEPAYMENT TERMS SPECIAL EXPEDITING SERVICE2.ToobtainaReturnMaterialAuthorization FREIGHTPOLICYNOTE PAGE SERVICE DEPARTMENT HERES HOW TO GET HELPNUMBER ON-HAND WHEN CALLING WARRANTYDEPARTMENT