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DCA180SSJU operation manual Generator Wiring Diagram
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DCA180SSJU
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Troubleshooting
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Trailer Wiring Diagram
Warranty
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Engine Configuration Data
Page 65
Image 65
GENERATOR WIRING DIAGRAM
Figure 63. Generator Wiring Diagram
DCA-180SSJU
— OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 65
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Contents
OPERATION AND PARTS MANUAL
PARTS LIST NO. M3870301004
MODEL DCA180SSJU 60HZ GENERATOR
WHISPERWATTTM SERIES
PAGE 2 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
PROPOSITION 65 WARNING
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
REPORTING SAFETY DEFECTS
COMPONENT DRAWINGS
TABLE OF CONTENTS
MQ POWER DCA-180SSJU
WHISPERWATTTM
When ordering parts, please supply
PARTS ORDERING PROCEDURES
Ordering parts has never been easier
Choose from three easy options
Table 1. Generator Specifications
SPECIFICATIONS
Engine Specifications
PAGE 6 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
TABLE 3. DIMENSIONS
DIMENSIONS TOP, SIDE AND FRONT
Figure 1. Dimensions
Dimension ft. mm
SAFETY MESSAGE ALERT SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
DANGER
CAUTION - ACCIDENTAL STARTING
WARNING - ROTATING PARTS
CAUTION - RESPIRATORY HAZARDS
CAUTION - SIGHT AND HEARING HAZARDS
RULES FOR SAFE OPERATION
General Safety
DANGER - READ THIS MANUAL
PAGE 10 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Generator Grounding
Electrical Safety
NEVER
RULES FOR SAFE OPERATION
Battery Safety
Maintenance Safety
DANGER - EXPLOSION HAZARDS
PAGE 12 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Emergencies
Towing & Transporting Safety
RULES FOR SAFE OPERATION
towing your generator
PAGE 14 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
GENERATOR DECALS
Figure 3. Generator Decals Cont inued
GENERATOR DECALS
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
PAGE 16 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
INSTALLATION
Figure 4.Typical Generator Grounding Application
Indoor Installation
Outdoor Installation
CAUTION - EXHAUST HAZARD
Mounting
Generator
GENERAL INFORMATION
Engine Operating Panel
Generator Control Panel
Table 4. Generator Major Components
MAJOR COMPONENTS
Output Terminal Panel Assembly
Output Receptacles Assembly
Figure 6. Diagnostic Display Panel
DIAGNOSTIC DISPLAY
Display Parameters
PAGE 20 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
1800 RPM
First Time Start Up
Main Menu Navigation
1800 RPM
Engine Configuration Data
Stored Fault Codes
PAGE 22 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
DIAGNOSTIC DISPLAY
First Time Start Up
DIAGNOSTIC DISPLAY
1800 RPM
Main Menu Navigation
DIAGNOSTIC DISPLAY
PAGE 24 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Stored Fault Codes
Engine Configuration Data
DIAGNOSTIC DISPLAY
FAULTS AND WARNINGS Auxiliary Gage Fault
1800 RPM
1800 RPM
PAGE 26 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Active Fault Codes
DIAGNOSTIC DISPLAY
1800 RPM
Shut Down Codes
Backlight Adjustment
DIAGNOSTIC DISPLAY
1800 RPM
PAGE 28 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Contrast Adjustment
DIAGNOSTIC DISPLAY
1800 RPM
Select Units
Setup 1- Up Display
DIAGNOSTIC DISPLAY
1800 RPM
DIAGNOSTIC DISPLAY
PAGE 30 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
3. Once the “Setup 1-up Display” menu icon has been
6. Touch the “Enter Button” to activate the “Use Defaults” function
1800 RPM
DIAGNOSTIC DISPLAY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
Note that the numbers
PAGE 32 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Setup 4-Up Display
DIAGNOSTIC DISPLAY
1800 RPM
DIAGNOSTIC DISPLAY
Utilities
1800 RPM
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
DIAGNOSTIC DISPLAY
PAGE 34 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
DIAGNOSTIC DISPLAY
MODBUS SETUP
SERIAL PORT SETUP
MODBUS SETUP
DATA ERROR
GLOSSARY Troubleshooting information CANBUS FAILURE
TIMEOUT ECU NOT RESPONDING
NO DATA
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
GENERATOR CONTROL PANEL
Figure 8. Engine Operating Panel
ENGINE OPERATING PANEL
PAGE 38 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
ENGINE OPERATING PANEL
13. Auto On/Off Engine Controller MPEC
engine by initializing the
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
Output Terminal Familiarization
OUTPUT TERMINAL PANEL FAMILIARIZATION
PAGE 40 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Output Terminal Panel
120 VAC GFCI Receptacles
Removing the Plastic Face Plate Hard Wire Hookup Panel
OUTPUT TERMINAL PANEL FAMILIARIZATION
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
PAGE 42 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Three Phase Load
Single Phase Load
LOAD APPLICATION
DANGER - ELECTRICAL SYSTEM HAZARDS
Generator Output Voltages
GENERATOR OUTPUTS
Voltage Change-Over Board
Maximum Amps
AC Ammeter Gauge Reading
GENERATOR OUTPUTS/ GAUGE READING
AC Voltmeter Gauge Reading
3Ø 240V Configuration
UVWO Terminal Output Voltages
OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-240V UVWO Terminal Output Voltages
1Ø-240V UVWO Terminal Output Voltages
Figure 28. Output Terminal Lugs 3Ø-480V Connections
3Ø-480 UVWO Output Terminal Voltages
1Ø-480V UVWO Terminal Output Voltages
Figure 29. UWVO Output Terminal Lugs 1Ø-480V Connections
Circuit Breakers
SETUP
Lubrication Oil
Fuel Check
WARNING - RESPIRATORY HAZARDS
Refueling Procedure
Figure 34. Fueling the Generator
ONLY! use
Air Cleaner
Cleaning the Radiator
Coolant Antifreeze
Table 10 Coolant Capacity
Battery Cable Installation
Battery
CAUTION - BATTERY SERVICING SAFETY
Wiring
Figure 42. Engine Speed Switch Low
GENERATOR START-UP PROCEDURE MANUAL
Before Starting
CAUTION - LETHAL EXHAUST HAZARD
Figure 45. Engine Speed Switch High
OFF/RESET position
Figure 44. Active Fault Code Message
Figure 48. Voltmeter
Starting Auto Mode
CAUTION - BACKUP GENERATOR USE
PAGE 54 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
GENERATOR START-UP PROCEDURE MANUAL
WARNING - AUTO MODE MAINTENANCE
GENERATOR START-UP PROCEDURE AUTO MODE
CAUTION - ENGINE SPEED SWITCH
Figure 56. Engine Speed Switch High
CAUTION - DIAGNOSTIC SWITCH
GENERATOR SHUT-DOWN PROCEDURES
Normal Shutdown Procedure
Figure 58. Engine Speed Switch Low
Air Cleaner with Dust Indicator
MAINTENANCE ENGINE
Service Daily
General Inspection
Air Removal
Cleaning the Fuel Strainer
Check Oil Level
Replacing Oil Filter
commercial power to theand
MAINTENANCE HEATER/CHARGER
NOTEcapability, always have power applied to the generators
To ensure adequate starting
PAGE 60 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
MAINTENANCE TRAILER
Trailer Maintenance
Brakes
Brake Adjustment
Hydraulic Surge Brakes
Actuator
CAUTION - EYESIGHT HAZARD
Tires/Wheels/Lug Nuts
Tire Wear/Inflation
Suspension
MAINTENANCE TRAILER
Lug Nut Torque Requirements
1. Start all wheel lug nuts by hand
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
Figure 62. Trailer/Towing Vehicle Wiring Diagram
TRAILER WIRING DIAGRAM
PAGE 64 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
GENERATOR WIRING DIAGRAM
Figure 63. Generator Wiring Diagram
Figure 64. Engine Wiring Diagram
DCA-180SSJU - ENGINE WIRING DIAGRAM
PAGE 66 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
TABLE 17. GENERATOR TROUBLESHOOTING
TROUBLESHOOTING GENERATOR
SYMPTOM
POSSIBLE PROBLEM
PAGE 68 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
TROUBLESHOOTING ENGINE CONTROLLER
TABLE 18. ENGINE CONTROLLER TROUBLESHOOTING MPEC
SYMPTOM
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
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EXPLANATION OF CODE IN REMARKS COLUMN
SAMPLE PARTS LIST
NO. Column
DCA-180SSJU WHISPER WATTGENRATOR
SUGGESTED SPARE PARTS
W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITS
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
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GENERATOR ASSY
QTY. REMARKS
PART NAME
BALANCING WEIGHT KIT
GENERATOR ASSY
PAGE 74 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
CONTROL PANEL ASSY
CHANGE-OVER SWITCH, VOLTMETER
CHANGE- OVER SWITCH, AMMETER
CONTROL PANEL ASSY
PART NAME
PAGE 76 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
CONTROL BOX ASSY
PART NAME
CONTROL BOX ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
AUTOMATIC VOLTAGE REGULATOR, 5A
CONTROL BOX ASSY
PAGE 78 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
CONTROL BOX ASSY
REMARKS
PART NAME
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
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ENGINE AND RADIATOR ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
ENGINE AND RADIATOR ASSY
PART NAME
REMARKS
PAGE 82 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
ENGINE AND RADIATOR ASSY. CONT
PART NAME
ENGINE AND RADIATOR ASSY. CONT
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
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OUTPUT TERMINAL ASSY
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
PART NAME
OUTPUT TERMINAL ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
SUPPORTER, CABLE OUTLET COVER
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
PAGE 86 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
OUTPUT TERMINAL ASSY
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
OUTPUT TERMINAL ASSY
PART NAME
PAGE 88 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
BATTERY ASSY
PART NAME
BATTERY ASSY
REMARKS
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
PAGE 90 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
MUFFLER ASSY
PART NAME
MUFFLER ASSY
REMARKS
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
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FUEL TANK ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
FUEL TANK ASSY
PART NAME
PAGE 94 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
ENCLOSURE ASSY
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
ENCLOSURE ASSY
PART NAME
PAGE 96 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
ENCLOSURE ASSY. CONT
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
ENCLOSURE ASSY. CONT
PART NAME
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
PAGE 98 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
ENCLOSURE ASSY. CONT
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
ENCLOSURE ASSY. CONT
PART NAME
RUBBER SEALS ASSY
RUBBER SEALS ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
RUBBER SEALS ASSY
PART NAME
NAMEPLATE AND DECALS ASSY
NAMEPLATE AND DECALS ASSY
DECAL SETTING FOR OUTPUT VOLTAGE
PLATE AMMETER CHANGE-OVER SWITCH
NAMEPLATE AND DECALS ASSY
PART NAME
SPECIAL EXPEDITING SERVICE
TERMS AND CONDITIONS OF SALE - PARTS
PAYMENT TERMS
FREIGHT POLICY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
HERE’S HOW TO GET HELP
MQ Power
Contact mqpower@multiquip.com