Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip DCA180SSJU operation manual Reporting Safety Defects

Models: DCA180SSJU

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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.

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

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Multiquip DCA180SSJU Reporting Safety Defects, DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE

Contents

WHISPERWATTTM SERIES PARTS LIST NO. M3870301004OPERATION AND PARTS MANUAL MODEL DCA180SSJU 60HZ GENERATORPAGE 2 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 PROPOSITION 65 WARNINGDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE REPORTING SAFETY DEFECTSWHISPERWATTTM TABLE OF CONTENTSCOMPONENT DRAWINGS MQ POWER DCA-180SSJUChoose from three easy options PARTS ORDERING PROCEDURESWhen ordering parts, please supply Ordering parts has never been easierPAGE 6 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 SPECIFICATIONSTable 1. Generator Specifications Engine SpecificationsDimension ft. mm DIMENSIONS TOP, SIDE AND FRONTTABLE 3. DIMENSIONS Figure 1. DimensionsDANGER SAFETY MESSAGE ALERT SYMBOLSSAFETY MESSAGE ALERT SYMBOLS HAZARD SYMBOLSCAUTION - SIGHT AND HEARING HAZARDS WARNING - ROTATING PARTSCAUTION - ACCIDENTAL STARTING CAUTION - RESPIRATORY HAZARDSPAGE 10 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 General SafetyRULES FOR SAFE OPERATION DANGER - READ THIS MANUALRULES FOR SAFE OPERATION Electrical SafetyGenerator Grounding NEVERPAGE 12 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Maintenance SafetyBattery Safety DANGER - EXPLOSION HAZARDStowing your generator Towing & Transporting SafetyEmergencies RULES FOR SAFE OPERATIONPAGE 14 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 GENERATOR DECALSGENERATOR DECALS DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEFigure 3. Generator Decals Cont inued INSTALLATION Figure 4.Typical Generator Grounding ApplicationPAGE 16 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Mounting Outdoor InstallationIndoor Installation CAUTION - EXHAUST HAZARDGenerator Control Panel GENERAL INFORMATIONGenerator Engine Operating PanelOutput Receptacles Assembly MAJOR COMPONENTSTable 4. Generator Major Components Output Terminal Panel AssemblyPAGE 20 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAYFigure 6. Diagnostic Display Panel Display Parameters1800 RPM First Time Start Up1800 RPM Main Menu NavigationDIAGNOSTIC DISPLAY Stored Fault CodesEngine Configuration Data PAGE 22 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Main Menu Navigation DIAGNOSTIC DISPLAYFirst Time Start Up 1800 RPMEngine Configuration Data PAGE 24 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIAGNOSTIC DISPLAY Stored Fault Codes1800 RPM FAULTS AND WARNINGS Auxiliary Gage FaultDIAGNOSTIC DISPLAY 1800 RPM1800 RPM Active Fault CodesPAGE 26 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAY1800 RPM Backlight AdjustmentShut Down Codes DIAGNOSTIC DISPLAY1800 RPM Contrast AdjustmentPAGE 28 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAY1800 RPM Setup 1- Up DisplaySelect Units DIAGNOSTIC DISPLAY6. Touch the “Enter Button” to activate the “Use Defaults” function PAGE 30 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIAGNOSTIC DISPLAY 3. Once the “Setup 1-up Display” menu icon has beenNote that the numbers DIAGNOSTIC DISPLAY1800 RPM DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE1800 RPM Setup 4-Up DisplayPAGE 32 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE UtilitiesDIAGNOSTIC DISPLAY 1800 RPMDIAGNOSTIC DISPLAY PAGE 34 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10MODBUS SETUP MODBUS SETUPDIAGNOSTIC DISPLAY SERIAL PORT SETUPNO DATA GLOSSARY Troubleshooting information CANBUS FAILUREDATA ERROR TIMEOUT ECU NOT RESPONDINGDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE GENERATOR CONTROL PANELENGINE OPERATING PANEL PAGE 38 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Figure 8. Engine Operating Panel DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE 13. Auto On/Off Engine Controller MPECENGINE OPERATING PANEL engine by initializing theOutput Terminal Panel OUTPUT TERMINAL PANEL FAMILIARIZATIONOutput Terminal Familiarization PAGE 40 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE Removing the Plastic Face Plate Hard Wire Hookup Panel120 VAC GFCI Receptacles OUTPUT TERMINAL PANEL FAMILIARIZATIONConnecting Loads PAGE 42 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10OUTPUT TERMINAL PANEL FAMILIARIZATION DANGER - ELECTRICAL SYSTEM HAZARDS Single Phase LoadThree Phase Load LOAD APPLICATIONMaximum Amps GENERATOR OUTPUTSGenerator Output Voltages Voltage Change-Over Board3Ø 240V Configuration GENERATOR OUTPUTS/ GAUGE READINGAC Ammeter Gauge Reading AC Voltmeter Gauge Reading1Ø-240V UVWO Terminal Output Voltages OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output Voltages 3Ø-240V UVWO Terminal Output VoltagesFigure 29. UWVO Output Terminal Lugs 1Ø-480V Connections 3Ø-480 UVWO Output Terminal VoltagesFigure 28. Output Terminal Lugs 3Ø-480V Connections 1Ø-480V UVWO Terminal Output VoltagesFuel Check SETUPCircuit Breakers Lubrication OilONLY! use Refueling ProcedureWARNING - RESPIRATORY HAZARDS Figure 34. Fueling the GeneratorTable 10 Coolant Capacity Cleaning the RadiatorAir Cleaner Coolant AntifreezeWiring BatteryBattery Cable Installation CAUTION - BATTERY SERVICING SAFETYCAUTION - LETHAL EXHAUST HAZARD GENERATOR START-UP PROCEDURE MANUALFigure 42. Engine Speed Switch Low Before StartingFigure 48. Voltmeter OFF/RESET positionFigure 45. Engine Speed Switch High Figure 44. Active Fault Code MessageGENERATOR START-UP PROCEDURE MANUAL CAUTION - BACKUP GENERATOR USEStarting Auto Mode PAGE 54 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Figure 56. Engine Speed Switch High GENERATOR START-UP PROCEDURE AUTO MODEWARNING - AUTO MODE MAINTENANCE CAUTION - ENGINE SPEED SWITCHFigure 58. Engine Speed Switch Low GENERATOR SHUT-DOWN PROCEDURESCAUTION - DIAGNOSTIC SWITCH Normal Shutdown ProcedureGeneral Inspection MAINTENANCE ENGINEAir Cleaner with Dust Indicator Service DailyReplacing Oil Filter Cleaning the Fuel StrainerAir Removal Check Oil LevelTo ensure adequate starting MAINTENANCE HEATER/CHARGERcommercial power to theand NOTEcapability, always have power applied to the generatorsMAINTENANCE TRAILER Trailer MaintenancePAGE 60 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Actuator Brake AdjustmentBrakes Hydraulic Surge BrakesSuspension Tires/Wheels/Lug NutsCAUTION - EYESIGHT HAZARD Tire Wear/InflationDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE Lug Nut Torque RequirementsMAINTENANCE TRAILER 1. Start all wheel lug nuts by handTRAILER WIRING DIAGRAM PAGE 64 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Figure 62. Trailer/Towing Vehicle Wiring Diagram GENERATOR WIRING DIAGRAM Figure 63. Generator Wiring DiagramDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE DCA-180SSJU - ENGINE WIRING DIAGRAM PAGE 66 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Figure 64. Engine Wiring Diagram POSSIBLE PROBLEM TROUBLESHOOTING GENERATORTABLE 17. GENERATOR TROUBLESHOOTING SYMPTOMSYMPTOM TROUBLESHOOTING ENGINE CONTROLLERPAGE 68 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 TABLE 18. ENGINE CONTROLLER TROUBLESHOOTING MPECDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE NO. Column EXPLANATION OF CODE IN REMARKS COLUMNPAGE 70 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 SAMPLE PARTS LISTDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE SUGGESTED SPARE PARTSDCA-180SSJU WHISPER WATTGENRATOR W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITSPAGE 72 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 GENERATOR ASSYGENERATOR ASSY PART NAMEQTY. REMARKS BALANCING WEIGHT KITPAGE 74 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 CONTROL PANEL ASSYPART NAME CHANGE- OVER SWITCH, AMMETERCHANGE-OVER SWITCH, VOLTMETER CONTROL PANEL ASSYPAGE 76 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 CONTROL BOX ASSYAUTOMATIC VOLTAGE REGULATOR, 5A CONTROL BOX ASSYPART NAME DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGECONTROL BOX ASSY PAGE 78 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE REMARKSCONTROL BOX ASSY PART NAMEPAGE 80 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ENGINE AND RADIATOR ASSYREMARKS ENGINE AND RADIATOR ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE PART NAMEPAGE 82 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ENGINE AND RADIATOR ASSY. CONTENGINE AND RADIATOR ASSY. CONT DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPART NAME ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER OUTPUT TERMINAL ASSYPAGE 84 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNITSUPPORTER, CABLE OUTLET COVER OUTPUT TERMINAL ASSYPART NAME DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEADD THE FOLLOWING DIGITS AFTER THE PART NUMBER PAGE 86 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT OUTPUT TERMINAL ASSYOUTPUT TERMINAL ASSY PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE PAGE 88 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 BATTERY ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE BATTERY ASSYPART NAME REMARKSPAGE 90 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 MUFFLER ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE MUFFLER ASSYPART NAME REMARKSPAGE 92 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 FUEL TANK ASSYFUEL TANK ASSY PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER ENCLOSURE ASSYPAGE 94 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNITENCLOSURE ASSY PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER ENCLOSURE ASSY. CONTPAGE 96 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNITENCLOSURE ASSY. CONT PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER PAGE 98 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ENCLOSURE ASSY. CONTENCLOSURE ASSY. CONT PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE RUBBER SEALS ASSY RUBBER SEALS ASSYRUBBER SEALS ASSY PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSYPART NAME PLATE AMMETER CHANGE-OVER SWITCHDECAL SETTING FOR OUTPUT VOLTAGE NAMEPLATE AND DECALS ASSYFREIGHT POLICY TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE PAYMENT TERMSDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE Contact mqpower@multiquip.com HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING MQ Power