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DCA180SSJU operation manual Engine And Radiator Assy. Cont
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DCA180SSJU
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Troubleshooting
Specs
Install
Parts list
Error codes
Trailer Wiring Diagram
Warranty
Dimension
Maintenance
Engine Configuration Data
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ENGINE AND RADIATOR ASSY. (CONT)
ENGINE AND RADIATOR ASSY. (CONT.)
PAGE 82 —
DCA-180SSJU
— OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)
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Contents
MODEL DCA180SSJU 60HZ GENERATOR
PARTS LIST NO. M3870301004
OPERATION AND PARTS MANUAL
WHISPERWATTTM SERIES
PROPOSITION 65 WARNING
PAGE 2 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
REPORTING SAFETY DEFECTS
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
MQ POWER DCA-180SSJU
TABLE OF CONTENTS
COMPONENT DRAWINGS
WHISPERWATTTM
Ordering parts has never been easier
PARTS ORDERING PROCEDURES
When ordering parts, please supply
Choose from three easy options
Engine Specifications
SPECIFICATIONS
Table 1. Generator Specifications
PAGE 6 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Figure 1. Dimensions
DIMENSIONS TOP, SIDE AND FRONT
TABLE 3. DIMENSIONS
Dimension ft. mm
HAZARD SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
DANGER
CAUTION - RESPIRATORY HAZARDS
WARNING - ROTATING PARTS
CAUTION - ACCIDENTAL STARTING
CAUTION - SIGHT AND HEARING HAZARDS
DANGER - READ THIS MANUAL
General Safety
RULES FOR SAFE OPERATION
PAGE 10 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
NEVER
Electrical Safety
Generator Grounding
RULES FOR SAFE OPERATION
DANGER - EXPLOSION HAZARDS
Maintenance Safety
Battery Safety
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RULES FOR SAFE OPERATION
Towing & Transporting Safety
Emergencies
towing your generator
GENERATOR DECALS
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DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
GENERATOR DECALS
Figure 3. Generator Decals Cont inued
Figure 4.Typical Generator Grounding Application
INSTALLATION
PAGE 16 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
CAUTION - EXHAUST HAZARD
Outdoor Installation
Indoor Installation
Mounting
Engine Operating Panel
GENERAL INFORMATION
Generator
Generator Control Panel
Output Terminal Panel Assembly
MAJOR COMPONENTS
Table 4. Generator Major Components
Output Receptacles Assembly
Display Parameters
DIAGNOSTIC DISPLAY
Figure 6. Diagnostic Display Panel
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Main Menu Navigation
First Time Start Up
1800 RPM
1800 RPM
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Stored Fault Codes
Engine Configuration Data
DIAGNOSTIC DISPLAY
1800 RPM
DIAGNOSTIC DISPLAY
First Time Start Up
Main Menu Navigation
Stored Fault Codes
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DIAGNOSTIC DISPLAY
Engine Configuration Data
1800 RPM
FAULTS AND WARNINGS Auxiliary Gage Fault
DIAGNOSTIC DISPLAY
1800 RPM
DIAGNOSTIC DISPLAY
Active Fault Codes
PAGE 26 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
1800 RPM
DIAGNOSTIC DISPLAY
Backlight Adjustment
Shut Down Codes
1800 RPM
DIAGNOSTIC DISPLAY
Contrast Adjustment
PAGE 28 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
1800 RPM
DIAGNOSTIC DISPLAY
Setup 1- Up Display
Select Units
1800 RPM
3. Once the “Setup 1-up Display” menu icon has been
PAGE 30 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
DIAGNOSTIC DISPLAY
6. Touch the “Enter Button” to activate the “Use Defaults” function
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
DIAGNOSTIC DISPLAY
1800 RPM
Note that the numbers
DIAGNOSTIC DISPLAY
Setup 4-Up Display
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1800 RPM
1800 RPM
Utilities
DIAGNOSTIC DISPLAY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
PAGE 34 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
DIAGNOSTIC DISPLAY
SERIAL PORT SETUP
MODBUS SETUP
DIAGNOSTIC DISPLAY
MODBUS SETUP
TIMEOUT ECU NOT RESPONDING
GLOSSARY Troubleshooting information CANBUS FAILURE
DATA ERROR
NO DATA
GENERATOR CONTROL PANEL
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
PAGE 38 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
ENGINE OPERATING PANEL
Figure 8. Engine Operating Panel
engine by initializing the
13. Auto On/Off Engine Controller MPEC
ENGINE OPERATING PANEL
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
PAGE 40 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Familiarization
Output Terminal Panel
OUTPUT TERMINAL PANEL FAMILIARIZATION
Removing the Plastic Face Plate Hard Wire Hookup Panel
120 VAC GFCI Receptacles
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
PAGE 42 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Connecting Loads
OUTPUT TERMINAL PANEL FAMILIARIZATION
LOAD APPLICATION
Single Phase Load
Three Phase Load
DANGER - ELECTRICAL SYSTEM HAZARDS
Voltage Change-Over Board
GENERATOR OUTPUTS
Generator Output Voltages
Maximum Amps
AC Voltmeter Gauge Reading
GENERATOR OUTPUTS/ GAUGE READING
AC Ammeter Gauge Reading
3Ø 240V Configuration
3Ø-240V UVWO Terminal Output Voltages
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
1Ø-240V UVWO Terminal Output Voltages
1Ø-480V UVWO Terminal Output Voltages
3Ø-480 UVWO Output Terminal Voltages
Figure 28. Output Terminal Lugs 3Ø-480V Connections
Figure 29. UWVO Output Terminal Lugs 1Ø-480V Connections
Lubrication Oil
SETUP
Circuit Breakers
Fuel Check
Figure 34. Fueling the Generator
Refueling Procedure
WARNING - RESPIRATORY HAZARDS
ONLY! use
Coolant Antifreeze
Cleaning the Radiator
Air Cleaner
Table 10 Coolant Capacity
CAUTION - BATTERY SERVICING SAFETY
Battery
Battery Cable Installation
Wiring
Before Starting
GENERATOR START-UP PROCEDURE MANUAL
Figure 42. Engine Speed Switch Low
CAUTION - LETHAL EXHAUST HAZARD
Figure 44. Active Fault Code Message
OFF/RESET position
Figure 45. Engine Speed Switch High
Figure 48. Voltmeter
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CAUTION - BACKUP GENERATOR USE
Starting Auto Mode
GENERATOR START-UP PROCEDURE MANUAL
CAUTION - ENGINE SPEED SWITCH
GENERATOR START-UP PROCEDURE AUTO MODE
WARNING - AUTO MODE MAINTENANCE
Figure 56. Engine Speed Switch High
Normal Shutdown Procedure
GENERATOR SHUT-DOWN PROCEDURES
CAUTION - DIAGNOSTIC SWITCH
Figure 58. Engine Speed Switch Low
Service Daily
MAINTENANCE ENGINE
Air Cleaner with Dust Indicator
General Inspection
Check Oil Level
Cleaning the Fuel Strainer
Air Removal
Replacing Oil Filter
NOTEcapability, always have power applied to the generators
MAINTENANCE HEATER/CHARGER
commercial power to theand
To ensure adequate starting
Trailer Maintenance
MAINTENANCE TRAILER
PAGE 60 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
Hydraulic Surge Brakes
Brake Adjustment
Brakes
Actuator
Tire Wear/Inflation
Tires/Wheels/Lug Nuts
CAUTION - EYESIGHT HAZARD
Suspension
1. Start all wheel lug nuts by hand
Lug Nut Torque Requirements
MAINTENANCE TRAILER
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
PAGE 64 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
TRAILER WIRING DIAGRAM
Figure 62. Trailer/Towing Vehicle Wiring Diagram
Figure 63. Generator Wiring Diagram
GENERATOR WIRING DIAGRAM
DCA-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 DIAGRAM
Figure 64. Engine Wiring Diagram
SYMPTOM
TROUBLESHOOTING GENERATOR
TABLE 17. GENERATOR TROUBLESHOOTING
POSSIBLE PROBLEM
TABLE 18. ENGINE CONTROLLER TROUBLESHOOTING MPEC
TROUBLESHOOTING ENGINE CONTROLLER
PAGE 68 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
SYMPTOM
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
SAMPLE PARTS LIST
EXPLANATION OF CODE IN REMARKS COLUMN
PAGE 70 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
NO. Column
W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITS
SUGGESTED SPARE PARTS
DCA-180SSJU WHISPER WATTGENRATOR
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
GENERATOR ASSY
PAGE 72 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
BALANCING WEIGHT KIT
PART NAME
QTY. REMARKS
GENERATOR ASSY
CONTROL PANEL ASSY
PAGE 74 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
CONTROL PANEL ASSY
CHANGE- OVER SWITCH, AMMETER
CHANGE-OVER SWITCH, VOLTMETER
PART NAME
CONTROL BOX ASSY
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DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
CONTROL BOX ASSY
PART NAME
AUTOMATIC VOLTAGE REGULATOR, 5A
PAGE 78 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
CONTROL BOX ASSY
PART NAME
REMARKS
CONTROL BOX ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
ENGINE AND RADIATOR ASSY
PAGE 80 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
PART NAME
ENGINE AND RADIATOR ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
REMARKS
ENGINE AND RADIATOR ASSY. CONT
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DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
ENGINE AND RADIATOR ASSY. CONT
PART NAME
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
OUTPUT TERMINAL ASSY
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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
SUPPORTER, CABLE OUTLET COVER
OUTPUT TERMINAL ASSY
PAGE 86 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
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
BATTERY ASSY
PAGE 88 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
REMARKS
BATTERY ASSY
PART NAME
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
MUFFLER ASSY
PAGE 90 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
REMARKS
MUFFLER ASSY
PART NAME
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
FUEL TANK ASSY
PAGE 92 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
PART NAME
FUEL TANK ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
ENCLOSURE ASSY
PAGE 94 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
PART NAME
ENCLOSURE ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
ENCLOSURE ASSY. CONT
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ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
PART NAME
ENCLOSURE ASSY. CONT
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
ENCLOSURE ASSY. CONT
PAGE 98 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10
WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER
PART NAME
ENCLOSURE ASSY. CONT
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
RUBBER SEALS ASSY
RUBBER SEALS ASSY
PART NAME
RUBBER SEALS ASSY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
NAMEPLATE AND DECALS ASSY
NAMEPLATE AND DECALS ASSY
NAMEPLATE AND DECALS ASSY
PLATE AMMETER CHANGE-OVER SWITCH
DECAL SETTING FOR OUTPUT VOLTAGE
PART NAME
PAYMENT TERMS
TERMS AND CONDITIONS OF SALE - PARTS
SPECIAL EXPEDITING SERVICE
FREIGHT POLICY
DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE
MQ Power
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING
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