Manuals / Multiquip / Lawn and Garden / Portable Generator

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

Models: DCA180SSJU

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Multiquip DCA180SSJU operation manual DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE

Contents

OPERATION AND PARTS MANUAL PARTS LIST NO. M3870301004MODEL DCA180SSJU 60HZ GENERATOR WHISPERWATTTM SERIESPAGE 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 DEFECTSCOMPONENT DRAWINGS TABLE OF CONTENTSMQ POWER DCA-180SSJU WHISPERWATTTMWhen ordering parts, please supply PARTS ORDERING PROCEDURESOrdering parts has never been easier Choose from three easy optionsTable 1. Generator Specifications SPECIFICATIONSEngine Specifications PAGE 6 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10TABLE 3. DIMENSIONS DIMENSIONS TOP, SIDE AND FRONTFigure 1. Dimensions Dimension ft. mmSAFETY MESSAGE ALERT SYMBOLS SAFETY MESSAGE ALERT SYMBOLSHAZARD SYMBOLS DANGERCAUTION - ACCIDENTAL STARTING WARNING - ROTATING PARTSCAUTION - RESPIRATORY HAZARDS CAUTION - SIGHT AND HEARING HAZARDSRULES FOR SAFE OPERATION General SafetyDANGER - READ THIS MANUAL PAGE 10 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Generator Grounding Electrical SafetyNEVER RULES FOR SAFE OPERATIONBattery Safety Maintenance SafetyDANGER - EXPLOSION HAZARDS PAGE 12 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Emergencies Towing & Transporting SafetyRULES FOR SAFE OPERATION towing your generatorPAGE 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 Indoor Installation Outdoor InstallationCAUTION - EXHAUST HAZARD MountingGenerator GENERAL INFORMATIONEngine Operating Panel Generator Control PanelTable 4. Generator Major Components MAJOR COMPONENTSOutput Terminal Panel Assembly Output Receptacles AssemblyFigure 6. Diagnostic Display Panel DIAGNOSTIC DISPLAYDisplay Parameters PAGE 20 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/101800 RPM First Time Start UpMain Menu Navigation 1800 RPMEngine Configuration Data Stored Fault CodesPAGE 22 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAYFirst Time Start Up DIAGNOSTIC DISPLAY1800 RPM Main Menu NavigationDIAGNOSTIC DISPLAY PAGE 24 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Stored Fault Codes Engine Configuration DataDIAGNOSTIC DISPLAY FAULTS AND WARNINGS Auxiliary Gage Fault1800 RPM 1800 RPMPAGE 26 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Active Fault CodesDIAGNOSTIC DISPLAY 1800 RPMShut Down Codes Backlight AdjustmentDIAGNOSTIC DISPLAY 1800 RPMPAGE 28 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Contrast AdjustmentDIAGNOSTIC DISPLAY 1800 RPMSelect Units Setup 1- Up DisplayDIAGNOSTIC DISPLAY 1800 RPMDIAGNOSTIC DISPLAY PAGE 30 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/103. Once the “Setup 1-up Display” menu icon has been 6. Touch the “Enter Button” to activate the “Use Defaults” function1800 RPM DIAGNOSTIC DISPLAYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE Note that the numbersPAGE 32 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Setup 4-Up DisplayDIAGNOSTIC DISPLAY 1800 RPMDIAGNOSTIC DISPLAY Utilities1800 RPM DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEDIAGNOSTIC DISPLAY PAGE 34 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIAGNOSTIC DISPLAY MODBUS SETUPSERIAL PORT SETUP MODBUS SETUPDATA ERROR GLOSSARY Troubleshooting information CANBUS FAILURETIMEOUT ECU NOT RESPONDING NO DATADCA-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 ENGINE OPERATING PANEL 13. Auto On/Off Engine Controller MPECengine by initializing the DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEOutput Terminal Familiarization OUTPUT TERMINAL PANEL FAMILIARIZATIONPAGE 40 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Output Terminal Panel120 VAC GFCI Receptacles Removing the Plastic Face Plate Hard Wire Hookup PanelOUTPUT TERMINAL PANEL FAMILIARIZATION DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEConnecting Loads PAGE 42 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10OUTPUT TERMINAL PANEL FAMILIARIZATION Three Phase Load Single Phase LoadLOAD APPLICATION DANGER - ELECTRICAL SYSTEM HAZARDSGenerator Output Voltages GENERATOR OUTPUTSVoltage Change-Over Board Maximum AmpsAC Ammeter Gauge Reading GENERATOR OUTPUTS/ GAUGE READINGAC Voltmeter Gauge Reading 3Ø 240V ConfigurationUVWO Terminal Output Voltages OUTPUT TERMINAL PANEL CONNECTIONS3Ø-240V UVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output VoltagesFigure 28. Output Terminal Lugs 3Ø-480V Connections 3Ø-480 UVWO Output Terminal Voltages1Ø-480V UVWO Terminal Output Voltages Figure 29. UWVO Output Terminal Lugs 1Ø-480V ConnectionsCircuit Breakers SETUPLubrication Oil Fuel CheckWARNING - RESPIRATORY HAZARDS Refueling ProcedureFigure 34. Fueling the Generator ONLY! useAir Cleaner Cleaning the RadiatorCoolant Antifreeze Table 10 Coolant CapacityBattery Cable Installation BatteryCAUTION - BATTERY SERVICING SAFETY WiringFigure 42. Engine Speed Switch Low GENERATOR START-UP PROCEDURE MANUALBefore Starting CAUTION - LETHAL EXHAUST HAZARDFigure 45. Engine Speed Switch High OFF/RESET positionFigure 44. Active Fault Code Message Figure 48. VoltmeterStarting Auto Mode CAUTION - BACKUP GENERATOR USEPAGE 54 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 GENERATOR START-UP PROCEDURE MANUALWARNING - AUTO MODE MAINTENANCE GENERATOR START-UP PROCEDURE AUTO MODECAUTION - ENGINE SPEED SWITCH Figure 56. Engine Speed Switch HighCAUTION - DIAGNOSTIC SWITCH GENERATOR SHUT-DOWN PROCEDURESNormal Shutdown Procedure Figure 58. Engine Speed Switch LowAir Cleaner with Dust Indicator MAINTENANCE ENGINEService Daily General InspectionAir Removal Cleaning the Fuel StrainerCheck Oil Level Replacing Oil Filtercommercial power to theand MAINTENANCE HEATER/CHARGERNOTEcapability, always have power applied to the generators To ensure adequate startingMAINTENANCE TRAILER Trailer MaintenancePAGE 60 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Brakes Brake AdjustmentHydraulic Surge Brakes ActuatorCAUTION - EYESIGHT HAZARD Tires/Wheels/Lug NutsTire Wear/Inflation SuspensionMAINTENANCE TRAILER Lug Nut Torque Requirements1. Start all wheel lug nuts by hand DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGETRAILER 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 TABLE 17. GENERATOR TROUBLESHOOTING TROUBLESHOOTING GENERATORSYMPTOM POSSIBLE PROBLEMPAGE 68 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 TROUBLESHOOTING ENGINE CONTROLLERTABLE 18. ENGINE CONTROLLER TROUBLESHOOTING MPEC SYMPTOMDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE PAGE 70 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 EXPLANATION OF CODE IN REMARKS COLUMNSAMPLE PARTS LIST NO. ColumnDCA-180SSJU WHISPER WATTGENRATOR SUGGESTED SPARE PARTSW/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITS DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 72 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 GENERATOR ASSYQTY. REMARKS PART NAMEBALANCING WEIGHT KIT GENERATOR ASSYPAGE 74 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 CONTROL PANEL ASSYCHANGE-OVER SWITCH, VOLTMETER CHANGE- OVER SWITCH, AMMETERCONTROL PANEL ASSY PART NAMEPAGE 76 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 CONTROL BOX ASSYPART NAME CONTROL BOX ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE AUTOMATIC VOLTAGE REGULATOR, 5ACONTROL BOX ASSY PAGE 78 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10CONTROL BOX ASSY REMARKSPART NAME DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 80 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ENGINE AND RADIATOR ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENGINE AND RADIATOR ASSYPART NAME REMARKSPAGE 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 PAGE 84 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 OUTPUT TERMINAL ASSYWHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERPART NAME OUTPUT TERMINAL ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE SUPPORTER, CABLE OUTLET COVERWHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT PAGE 86 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10OUTPUT TERMINAL ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBEROUTPUT 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 ASSYPART NAME BATTERY ASSYREMARKS DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 90 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 MUFFLER ASSYPART NAME MUFFLER ASSYREMARKS DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 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 PAGE 94 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ENCLOSURE ASSYWHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERENCLOSURE ASSY PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE PAGE 96 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ENCLOSURE ASSY. CONTWHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERENCLOSURE ASSY. CONT PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT PAGE 98 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10ENCLOSURE ASSY. CONT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERENCLOSURE 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 ASSYDECAL SETTING FOR OUTPUT VOLTAGE PLATE AMMETER CHANGE-OVER SWITCHNAMEPLATE AND DECALS ASSY PART NAMESPECIAL EXPEDITING SERVICE TERMS AND CONDITIONS OF SALE - PARTSPAYMENT TERMS FREIGHT POLICYDCA-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 HELPMQ Power Contact mqpower@multiquip.com