Manuals / Multiquip / Lawn and Garden / Portable Generator

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PAGE 86 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

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MODEL DCA180SSJU 60HZ GENERATOR PARTS LIST NO. M3870301004OPERATION AND PARTS MANUAL 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 - PAGEMQ POWER DCA-180SSJU TABLE OF CONTENTSCOMPONENT DRAWINGS WHISPERWATTTMOrdering parts has never been easier PARTS ORDERING PROCEDURESWhen ordering parts, please supply Choose from three easy optionsEngine Specifications SPECIFICATIONSTable 1. Generator Specifications PAGE 6 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Figure 1. Dimensions DIMENSIONS TOP, SIDE AND FRONTTABLE 3. DIMENSIONS Dimension ft. mmHAZARD SYMBOLS SAFETY MESSAGE ALERT SYMBOLSSAFETY MESSAGE ALERT SYMBOLS DANGERCAUTION - RESPIRATORY HAZARDS WARNING - ROTATING PARTSCAUTION - ACCIDENTAL STARTING CAUTION - SIGHT AND HEARING HAZARDSDANGER - READ THIS MANUAL General SafetyRULES FOR SAFE OPERATION PAGE 10 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10NEVER Electrical SafetyGenerator Grounding RULES FOR SAFE OPERATIONDANGER - EXPLOSION HAZARDS Maintenance SafetyBattery Safety PAGE 12 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10RULES FOR SAFE OPERATION Towing & Transporting SafetyEmergencies towing your generatorGENERATOR DECALS PAGE 14 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Figure 3. Generator Decals Cont inued GENERATOR DECALSDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE PAGE 16 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 INSTALLATIONFigure 4.Typical Generator Grounding Application CAUTION - EXHAUST HAZARD Outdoor InstallationIndoor Installation MountingEngine Operating Panel GENERAL INFORMATIONGenerator Generator Control PanelOutput Terminal Panel Assembly MAJOR COMPONENTSTable 4. Generator Major Components Output Receptacles AssemblyDisplay Parameters DIAGNOSTIC DISPLAYFigure 6. Diagnostic Display Panel PAGE 20 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10Main Menu Navigation First Time Start Up1800 RPM 1800 RPMPAGE 22 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 Stored Fault CodesEngine Configuration Data DIAGNOSTIC DISPLAY1800 RPM DIAGNOSTIC DISPLAYFirst Time Start Up Main Menu NavigationStored Fault Codes PAGE 24 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIAGNOSTIC DISPLAY Engine Configuration Data1800 RPM FAULTS AND WARNINGS Auxiliary Gage FaultDIAGNOSTIC DISPLAY 1800 RPMDIAGNOSTIC DISPLAY Active Fault CodesPAGE 26 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 1800 RPMDIAGNOSTIC DISPLAY Backlight AdjustmentShut Down Codes 1800 RPMDIAGNOSTIC DISPLAY Contrast AdjustmentPAGE 28 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 1800 RPMDIAGNOSTIC DISPLAY Setup 1- Up DisplaySelect Units 1800 RPM3. Once the “Setup 1-up Display” menu icon has been PAGE 30 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DIAGNOSTIC DISPLAY 6. Touch the “Enter Button” to activate the “Use Defaults” functionDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE DIAGNOSTIC DISPLAY1800 RPM Note that the numbersDIAGNOSTIC DISPLAY Setup 4-Up DisplayPAGE 32 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 1800 RPM1800 RPM UtilitiesDIAGNOSTIC DISPLAY 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 DISPLAYSERIAL PORT SETUP MODBUS SETUPDIAGNOSTIC DISPLAY MODBUS SETUPTIMEOUT ECU NOT RESPONDING GLOSSARY Troubleshooting information CANBUS FAILUREDATA ERROR NO DATAGENERATOR CONTROL PANEL DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEFigure 8. Engine Operating Panel ENGINE OPERATING PANELPAGE 38 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 engine by initializing the 13. Auto On/Off Engine Controller MPECENGINE OPERATING PANEL DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEPAGE 40 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 OUTPUT TERMINAL PANEL FAMILIARIZATIONOutput Terminal Familiarization Output Terminal PanelOUTPUT TERMINAL PANEL FAMILIARIZATION Removing the Plastic Face Plate Hard Wire Hookup Panel120 VAC GFCI Receptacles DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEOUTPUT TERMINAL PANEL FAMILIARIZATION Connecting LoadsPAGE 42 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 LOAD APPLICATION Single Phase LoadThree Phase Load DANGER - ELECTRICAL SYSTEM HAZARDSVoltage Change-Over Board GENERATOR OUTPUTSGenerator Output Voltages Maximum AmpsAC Voltmeter Gauge Reading GENERATOR OUTPUTS/ GAUGE READINGAC Ammeter Gauge Reading 3Ø 240V Configuration3Ø-240V UVWO Terminal Output Voltages OUTPUT TERMINAL PANEL CONNECTIONSUVWO Terminal Output Voltages 1Ø-240V UVWO Terminal Output Voltages1Ø-480V UVWO Terminal Output Voltages 3Ø-480 UVWO Output Terminal VoltagesFigure 28. Output Terminal Lugs 3Ø-480V Connections Figure 29. UWVO Output Terminal Lugs 1Ø-480V ConnectionsLubrication Oil SETUPCircuit Breakers Fuel CheckFigure 34. Fueling the Generator Refueling ProcedureWARNING - RESPIRATORY HAZARDS ONLY! useCoolant Antifreeze Cleaning the RadiatorAir Cleaner Table 10 Coolant CapacityCAUTION - BATTERY SERVICING SAFETY BatteryBattery Cable Installation WiringBefore Starting GENERATOR START-UP PROCEDURE MANUALFigure 42. Engine Speed Switch Low CAUTION - LETHAL EXHAUST HAZARDFigure 44. Active Fault Code Message OFF/RESET positionFigure 45. Engine Speed Switch High Figure 48. VoltmeterPAGE 54 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 CAUTION - BACKUP GENERATOR USEStarting Auto Mode GENERATOR START-UP PROCEDURE MANUALCAUTION - ENGINE SPEED SWITCH GENERATOR START-UP PROCEDURE AUTO MODEWARNING - AUTO MODE MAINTENANCE Figure 56. Engine Speed Switch HighNormal Shutdown Procedure GENERATOR SHUT-DOWN PROCEDURESCAUTION - DIAGNOSTIC SWITCH Figure 58. Engine Speed Switch LowService Daily MAINTENANCE ENGINEAir Cleaner with Dust Indicator General InspectionCheck Oil Level Cleaning the Fuel StrainerAir Removal Replacing Oil FilterNOTEcapability, always have power applied to the generators MAINTENANCE HEATER/CHARGERcommercial power to theand To ensure adequate startingPAGE 60 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 MAINTENANCE TRAILERTrailer Maintenance Hydraulic Surge Brakes Brake AdjustmentBrakes ActuatorTire Wear/Inflation Tires/Wheels/Lug NutsCAUTION - EYESIGHT HAZARD Suspension1. Start all wheel lug nuts by hand Lug Nut Torque RequirementsMAINTENANCE TRAILER DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEFigure 62. Trailer/Towing Vehicle Wiring Diagram TRAILER WIRING DIAGRAMPAGE 64 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE GENERATOR WIRING DIAGRAMFigure 63. Generator Wiring Diagram Figure 64. Engine Wiring Diagram DCA-180SSJU - ENGINE WIRING DIAGRAMPAGE 66 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 SYMPTOM TROUBLESHOOTING GENERATORTABLE 17. GENERATOR TROUBLESHOOTING POSSIBLE PROBLEMTABLE 18. ENGINE CONTROLLER TROUBLESHOOTING MPEC TROUBLESHOOTING ENGINE CONTROLLERPAGE 68 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 SYMPTOMDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE SAMPLE PARTS LIST EXPLANATION OF CODE IN REMARKS COLUMNPAGE 70 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 NO. ColumnW/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITS SUGGESTED SPARE PARTSDCA-180SSJU WHISPER WATTGENRATOR DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEGENERATOR ASSY PAGE 72 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10BALANCING WEIGHT KIT PART NAMEQTY. REMARKS GENERATOR ASSYCONTROL PANEL ASSY PAGE 74 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10CONTROL PANEL ASSY CHANGE- OVER SWITCH, AMMETERCHANGE-OVER SWITCH, VOLTMETER PART NAMECONTROL BOX ASSY PAGE 76 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE CONTROL BOX ASSYPART NAME AUTOMATIC VOLTAGE REGULATOR, 5APAGE 78 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 CONTROL BOX ASSYPART NAME REMARKSCONTROL BOX ASSY 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 02/01/10PART NAME ENGINE AND RADIATOR ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE REMARKSENGINE AND RADIATOR ASSY. CONT PAGE 82 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10PART NAME ENGINE AND RADIATOR ASSY. CONTDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT OUTPUT TERMINAL ASSYPAGE 84 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE OUTPUT TERMINAL ASSYPART NAME SUPPORTER, CABLE OUTLET COVEROUTPUT TERMINAL ASSY PAGE 86 - 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 NUMBERDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE OUTPUT TERMINAL ASSYPART NAME BATTERY ASSY PAGE 88 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10REMARKS BATTERY ASSYPART NAME DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEMUFFLER ASSY PAGE 90 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10REMARKS MUFFLER ASSYPART NAME DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGEFUEL TANK ASSY PAGE 92 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE FUEL TANK ASSYPART NAME WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ENCLOSURE ASSYPAGE 94 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENCLOSURE ASSYPART NAME WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT ENCLOSURE ASSY. CONTPAGE 96 - DCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 ADD THE FOLLOWING DIGITS AFTER THE PART NUMBERDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENCLOSURE ASSY. CONTPART NAME ENCLOSURE ASSY. CONT PAGE 98 - 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 NUMBERDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE ENCLOSURE ASSY. CONTPART NAME RUBBER SEALS ASSY RUBBER SEALS ASSYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE RUBBER SEALS ASSYPART NAME NAMEPLATE AND DECALS ASSY NAMEPLATE AND DECALS ASSYNAMEPLATE AND DECALS ASSY PLATE AMMETER CHANGE-OVER SWITCHDECAL SETTING FOR OUTPUT VOLTAGE PART NAMEPAYMENT TERMS TERMS AND CONDITIONS OF SALE - PARTSSPECIAL EXPEDITING SERVICE FREIGHT POLICYDCA-180SSJU - OPERATION AND PARTS MANUAL - REV. #3 02/01/10 - PAGE MQ Power HERE’S HOW TO GET HELPPLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING Contact mqpower@multiquip.com