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Multiquip DCA180SSJU operation manual Control Box Assy

Models: DCA180SSJU

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CONTROL BOX ASSY.

PAGE 76 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

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Contents

PARTS LIST NO. M3870301004 OPERATION AND PARTS MANUALMODEL DCA180SSJU 60HZ GENERATOR WHISPERWATTTM SERIESPROPOSITION 65 WARNING PAGE 2 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10REPORTING SAFETY DEFECTS DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGETABLE OF CONTENTS COMPONENT DRAWINGSMQ POWER DCA-180SSJU WHISPERWATTTMPARTS ORDERING PROCEDURES When ordering parts, please supplyOrdering parts has never been easier Choose from three easy optionsSPECIFICATIONS Table 1. Generator SpecificationsEngine Specifications PAGE 6 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIMENSIONS TOP, SIDE AND FRONT TABLE 3. DIMENSIONSFigure 1. Dimensions Dimension ft. mmSAFETY MESSAGE ALERT SYMBOLS SAFETY MESSAGE ALERT SYMBOLSHAZARD SYMBOLS DANGERWARNING - ROTATING PARTS CAUTION - ACCIDENTAL STARTINGCAUTION - RESPIRATORY HAZARDS CAUTION - SIGHT AND HEARING HAZARDSGeneral Safety RULES FOR SAFE OPERATIONDANGER - READ THIS MANUAL PAGE 10 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Electrical Safety Generator GroundingNEVER RULES FOR SAFE OPERATIONMaintenance Safety Battery SafetyDANGER - EXPLOSION HAZARDS PAGE 12 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Towing & Transporting Safety EmergenciesRULES FOR SAFE OPERATION towing your generatorGENERATOR DECALS PAGE 14 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE GENERATOR DECALSFigure 3. Generator Decals Cont inued Figure 4.Typical Generator Grounding Application INSTALLATIONPAGE 16 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Outdoor Installation Indoor InstallationCAUTION - EXHAUST HAZARD MountingGENERAL INFORMATION GeneratorEngine Operating Panel Generator Control PanelMAJOR COMPONENTS Table 4. Generator Major ComponentsOutput Terminal Panel Assembly Output Receptacles AssemblyDIAGNOSTIC DISPLAY Figure 6. Diagnostic Display PanelDisplay Parameters PAGE 20 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10First Time Start Up 1800 RPMMain Menu Navigation 1800 RPMStored Fault Codes Engine Configuration DataPAGE 22 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAYDIAGNOSTIC DISPLAY First Time Start Up1800 RPM Main Menu NavigationPAGE 24 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAYStored Fault Codes Engine Configuration DataFAULTS AND WARNINGS Auxiliary Gage Fault DIAGNOSTIC DISPLAY1800 RPM 1800 RPMActive Fault Codes PAGE 26 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIAGNOSTIC DISPLAY 1800 RPMBacklight Adjustment Shut Down CodesDIAGNOSTIC DISPLAY 1800 RPMContrast Adjustment PAGE 28 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIAGNOSTIC DISPLAY 1800 RPMSetup 1- Up Display Select UnitsDIAGNOSTIC DISPLAY 1800 RPMPAGE 30 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAY3. Once the “Setup 1-up Display” menu icon has been 6. Touch the “Enter Button” to activate the “Use Defaults” functionDIAGNOSTIC DISPLAY 1800 RPMDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE Note that the numbersSetup 4-Up Display PAGE 32 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIAGNOSTIC DISPLAY 1800 RPMUtilities DIAGNOSTIC DISPLAY1800 RPM DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 34 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DIAGNOSTIC DISPLAYMODBUS SETUP DIAGNOSTIC DISPLAYSERIAL PORT SETUP MODBUS SETUPGLOSSARY Troubleshooting information CANBUS FAILURE DATA ERRORTIMEOUT ECU NOT RESPONDING NO DATAGENERATOR CONTROL PANEL DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 38 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ENGINE OPERATING PANELFigure 8. Engine Operating Panel 13. Auto On/Off Engine Controller MPEC ENGINE OPERATING PANELengine by initializing the DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEOUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal FamiliarizationPAGE 40 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Output Terminal PanelRemoving the Plastic Face Plate Hard Wire Hookup Panel 120 VAC GFCI ReceptaclesOUTPUT TERMINAL PANEL FAMILIARIZATION DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 42 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Connecting LoadsOUTPUT TERMINAL PANEL FAMILIARIZATION Single Phase Load Three Phase LoadLOAD APPLICATION DANGER - ELECTRICAL SYSTEM HAZARDSGENERATOR OUTPUTS Generator Output VoltagesVoltage Change-Over Board Maximum AmpsGENERATOR OUTPUTS/ GAUGE READING AC Ammeter Gauge ReadingAC Voltmeter Gauge Reading 3Ø 240V ConfigurationOUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages3Ø-240V UVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output Voltages3Ø-480 UVWO Output Terminal Voltages Figure 28. Output Terminal Lugs 3Ø-480V Connections1Ø-480V UVWO Terminal Output Voltages Figure 29. UWVO Output Terminal Lugs 1Ø-480V ConnectionsSETUP Circuit BreakersLubrication Oil Fuel CheckRefueling Procedure WARNING - RESPIRATORY HAZARDSFigure 34. Fueling the Generator ONLY! useCleaning the Radiator Air CleanerCoolant Antifreeze Table 10 Coolant CapacityBattery Battery Cable InstallationCAUTION - BATTERY SERVICING SAFETY WiringGENERATOR START-UP PROCEDURE MANUAL Figure 42. Engine Speed Switch LowBefore Starting CAUTION - LETHAL EXHAUST HAZARDOFF/RESET position Figure 45. Engine Speed Switch HighFigure 44. Active Fault Code Message Figure 48. VoltmeterCAUTION - BACKUP GENERATOR USE Starting Auto ModePAGE 54 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 GENERATOR START-UP PROCEDURE MANUALGENERATOR START-UP PROCEDURE AUTO MODE WARNING - AUTO MODE MAINTENANCECAUTION - ENGINE SPEED SWITCH Figure 56. Engine Speed Switch HighGENERATOR SHUT-DOWN PROCEDURES CAUTION - DIAGNOSTIC SWITCHNormal Shutdown Procedure Figure 58. Engine Speed Switch LowMAINTENANCE ENGINE Air Cleaner with Dust IndicatorService Daily General InspectionCleaning the Fuel Strainer Air RemovalCheck Oil Level Replacing Oil FilterMAINTENANCE HEATER/CHARGER commercial power to theandNOTEcapability, always have power applied to the generators To ensure adequate startingTrailer Maintenance MAINTENANCE TRAILERPAGE 60 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Brake Adjustment BrakesHydraulic Surge Brakes ActuatorTires/Wheels/Lug Nuts CAUTION - EYESIGHT HAZARDTire Wear/Inflation SuspensionLug Nut Torque Requirements MAINTENANCE TRAILER1. Start all wheel lug nuts by hand DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 64 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 TRAILER WIRING DIAGRAMFigure 62. Trailer/Towing Vehicle Wiring Diagram Figure 63. Generator Wiring Diagram GENERATOR WIRING DIAGRAMDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE PAGE 66 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DCA-180SSJU - ENGINE WIRING DIAGRAMFigure 64. Engine Wiring Diagram TROUBLESHOOTING GENERATOR TABLE 17. GENERATOR TROUBLESHOOTINGSYMPTOM POSSIBLE PROBLEMTROUBLESHOOTING ENGINE CONTROLLER PAGE 68 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10TABLE 18. ENGINE CONTROLLER TROUBLESHOOTING MPEC SYMPTOMDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE EXPLANATION OF CODE IN REMARKS COLUMN PAGE 70 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10SAMPLE PARTS LIST NO. ColumnSUGGESTED SPARE PARTS DCA-180SSJU WHISPER WATTGENRATORW/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITS DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEGENERATOR ASSY PAGE 72 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10PART NAME QTY. REMARKSBALANCING WEIGHT KIT GENERATOR ASSYCONTROL PANEL ASSY PAGE 74 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10CHANGE- OVER SWITCH, AMMETER CHANGE-OVER SWITCH, VOLTMETERCONTROL PANEL ASSY PART NAMECONTROL BOX ASSY PAGE 76 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10CONTROL BOX ASSY PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE AUTOMATIC VOLTAGE REGULATOR, 5APAGE 78 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 CONTROL BOX ASSYREMARKS CONTROL BOX ASSYPART NAME DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEENGINE AND RADIATOR ASSY PAGE 80 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10ENGINE AND RADIATOR ASSY DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPART NAME REMARKSENGINE AND RADIATOR ASSY. CONT PAGE 82 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENGINE AND RADIATOR ASSY. CONTPART NAME OUTPUT TERMINAL ASSY PAGE 84 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBEROUTPUT TERMINAL ASSY PART NAMEDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE SUPPORTER, CABLE OUTLET COVERPAGE 86 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNITOUTPUT TERMINAL ASSY ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERPART NAME OUTPUT TERMINAL ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE BATTERY ASSY PAGE 88 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10BATTERY ASSY PART NAMEREMARKS DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEMUFFLER ASSY PAGE 90 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10MUFFLER ASSY PART NAMEREMARKS DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEFUEL TANK ASSY PAGE 92 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10PART NAME FUEL TANK ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENCLOSURE ASSY PAGE 94 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERPART NAME ENCLOSURE ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENCLOSURE ASSY. CONT PAGE 96 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERPART NAME ENCLOSURE ASSY. CONTDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE PAGE 98 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNITENCLOSURE ASSY. CONT ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERPART NAME ENCLOSURE ASSY. CONTDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE RUBBER SEALS ASSY RUBBER SEALS ASSYPART NAME RUBBER SEALS ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSYPLATE AMMETER CHANGE-OVER SWITCH DECAL SETTING FOR OUTPUT VOLTAGENAMEPLATE AND DECALS ASSY PART NAMETERMS AND CONDITIONS OF SALE - PARTS SPECIAL EXPEDITING SERVICEPAYMENT TERMS FREIGHT POLICYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLINGMQ Power Contact mqpower@multiquip.com