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Multiquip DCA180SSJU operation manual Remarks, Control Box Assy, Part Name, Relay, Base, Clip

Models: DCA180SSJU

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Page 79

REMARKS

CONTROL BOX ASSY.

CONTROL BOX ASSY. ( CONT.)
NO.	PART NO.	PART NAME	QTY.	REMARKS
27	M4260500003	SET PANEL, ELECTRIC PARTS	1
28	0016908020	HEX. HEAD BOLT	4
29	0602202592	STARTER RELAY	1
29A	0030006000	HEX. NUT	2
30	0027106016	MACHINE SCREW	2
31	LY2DUS12VDC	RELAY	1	REPLACES P/N 0601827656
31A	PTF08A	BASE	1	REPLACES P/N 0601823109
31B	PYCA1	CLIP	2	REPLACES P/N 0601824400
32	0027104020	MACHINE SCREW	2
33	0601823240	RECTIFIER	2
34	0027104020	MACHINE SCREW	2
35	M4260600404	BRACKET, RESISTOR UNIT	1
36	0016906016	HEX. HEAD BOLT	2
37	M4266600004	RESISTOR UNIT	1
38	0027105016	MACHINE SCREW	1
39	0601802218	HOLDER, FUSE 3P	1
39A	0601806653	FUSE, RIGHT SIDE 20A	1
39B	0601802149	FUSE, CENTER 10A	1
40	0027103020	MACHINE SCREW	2
41	0601815154	TERMINAL SCREW	2
42	0027104016	MACHINE SCREW	2
43	M4213600104	STOPPER, CONTROL PANEL	1
44	0041206000	WASHER, FLAT	1
45	0605010502	SNAP PIN	1
46	M4213500104	COVER, CONTROL BOX	1
47	0016908020	HEX. HEAD BOLT	8
48	M4213400104	BACK PANEL, CONTROL BOX	1
49	0016908020	HEX. HEAD BOLT	8
50	0330000300	EDGING	1
51	0330000215	EDGING	1
52	0016908020	HEX. HEAD BOLT	8
53	0016908020	HEX. HEAD BOLT	6

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 79

Image 79

Multiquip DCA180SSJU operation manual Remarks, Control Box Assy, Part Name, Relay, Base, Clip

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 DECALSDCA-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 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 PANELPAGE 38 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ENGINE OPERATING PANELFigure 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 FAMILIARIZATIONPAGE 42 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Connecting LoadsOUTPUT 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 generatorsTrailer Maintenance MAINTENANCE TRAILERPAGE 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 handPAGE 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 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. CONTDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENGINE AND RADIATOR ASSY. CONTPART 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 ASSYPART NAME OUTPUT TERMINAL ASSYDCA-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 ASSYPART NAME FUEL TANK ASSYDCA-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 UNITPART NAME ENCLOSURE ASSYDCA-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 UNITPART NAME ENCLOSURE ASSY. CONTDCA-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. CONTPART 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 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