Manuals / Multiquip / Lawn and Garden / Portable Generator

Multiquip DCA180SSJU Output Terminal Assy, Part Name, Supporter, Cable Outlet Cover

Models: DCA180SSJU

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Page 85

OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY.
NO.	PART NO.	PART NAME	QTY.	REMARKS
1	M3230700113	TERMINAL BOARD	1
2	M9220100914	OUTPUT TERMINAL BOLT	5
3	M9220101004	TIE BOLT	5
4	0039320000	HEX. NUT	10
5	0040020000	LOCK WASHER	15
6	0041420000	WASHER, FLAT	20
7	0016908040	HEX. HEAD BOLT	5
8	M4236100403	TERMINAL COVER	1
9	M4236100504	OUTPUT WINDOW	1
10	0605010040	HINGE	2
11	0027103010	MACHINE SCREW	4
11A	0030003000	HEX. NUT	4
11B	0041203000	WASHER, FLAT	4
12	0027103015	MACHINE SCREW	4
12A	0030003000	HEX. NUT	4
13	M9220100804	SET SCREW	2
13A	0040006000	LOCK WASHER	2
13B	0041206000	WASHER, FLAT	2
13C	0080200005	RETAINING RING	2
14	0019206015	HEX. HEAD BOLT	2
15	0019206015	HEX. HEAD BOLT	2
16	M4236400004	CABLE, OUTLET COVER	1
17	M4236400104	SUPPORTER, CABLE OUTLET COVER	1
18	0019206015	HEX. HEAD BOLT	8
19	0601815194	TERMINAL BLOCK	1
20	0025304015	MACHINE SCREW	2
21	0601850275	GROMMET	1
22	0603306775	GROMMET	2
23	0601808803	CIRCUIT BREAKER, 20A	2
24	0601808804	CIRCUIT BREAKER, 50A	3

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 85

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Multiquip DCA180SSJU Output Terminal Assy, Part Name, 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 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 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 PANELPAGE 38 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ENGINE OPERATING PANELFigure 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 - PAGEPAGE 42 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Connecting LoadsOUTPUT 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 startingTrailer Maintenance MAINTENANCE TRAILERPAGE 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 - 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 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. CONTDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENGINE AND RADIATOR ASSY. CONTPART 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 NUMBERPART 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 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 ASSYPART NAME FUEL TANK ASSYDCA-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 NUMBERPART NAME ENCLOSURE ASSYDCA-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 NUMBERPART NAME ENCLOSURE ASSY. CONTDCA-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 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 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