PARTS AND OPERATION MANUAL OPERATION AND PARTS MANUAL WHISPERWATTTM SERIES MODEL DCA180SSJU 60HZ GENERATOR (JOHN DEERE 6068HF485 DIESEL ENGINE) (PARTS LIST NO. M3870301004) Revision #3 (02/01/10) To find the latest revision of this publication, visit our website at: www.mqpower.
PROPOSITION 65 WARNING PAGE 2 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
TABLE OF CONTENTS MQ POWER DCA-180SSJU WHISPER WATTTM WHISPERW GENERATOR Proposition 65 Warning ........................................... 2 Reporting Safety Defects ........................................ 3 Table Of Contents.................................................... 4 Parts Ordering Procedures ..................................... 5 Specifications .......................................................... 6 Dimensions (Top, Side And Front)...........................
www.mqpower.com PARTS ORDERING PROCEDURES Ordering parts has never been easier! Choose from three easy options: Order via Internet (Dealers Only): Best Deal! Effective: January 1st, 2006 If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip. com. Order parts on-line using Multiquip’s SmartEquip website! N View Parts Diagrams N Order Parts N Print Specification Information To obtain an MQ Account, contact your District Sales Manager for more information.
SPECIFICATIONS Table 1. Generator Specifications Model DCA-180SSJU Type Revolving field, self ventilated, open protected type synchronous generator Armature Connection Star with Nutreal Phase 3 Standby Output 198 KVA (158 KW) Prime Output 180 KVA (144 KW) Voltage 240V or 480V Frequency 60 Hz Speed 1800 rpm Power Factor 0.8 Aux. AC Power Single Phase, 60 Hz Voltage 120 V Output 4.8 KW (2.4 KW x 2) Weight (No Fuel) 6,571 lbs. (2,980 kg.) Weight (With Fuel) 7,489 lbs. (3,400 kg.
DIMENSIONS (TOP, SIDE AND FRONT) Figure 1. Dimensions TABLE 3. DIMENSIONS Reference Letter Dimension ft. (mm.) Reference Letter Dimension ft. (mm.) A 37.00 in. (940 mm.) F 137.80 in. (3,500 mm.) B 37.00 in. (940 mm.) G 67.00 in. (1,700 mm.) C 41.33 in. (1,050 mm.) H 48.80 in. (1,240 mm.) D 41.33 in. (1,050 mm.) E 41.33 in. (1,050 mm.) 1 DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY AND THE SAFETY OF OTHERS! Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others.
SAFETY MESSAGE ALERT SYMBOLS WARNING - ROTATING PARTS NEVER operate equipment with covers, or guards removed. Keep , , and clothing away from all moving parts to prevent injury. CAUTION - ACCIDENTAL STARTING ALWAYS place the MPEC control switch in the OFF/RESET position when the generator is not in use. CAUTION - OVER-SPEED CONDITIONS NEVER tamper with the factory settings of the engine governor or settings.
RULES FOR SAFE OPERATION DANGER - READ THIS MANUAL! Failure to follow instructions in this manual may lead to or even ! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only. The following safety guidelines should always be used when operating the General Safety: ■ DO NOT operate or service this equipment before reading this entire manual. ■ ALWAYS check the machine for loosened threads or bolts before starting.
RULES FOR SAFE OPERATION Generator Grounding To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground. Article 250 (Grounding) of the (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical. The following safety recommendations should also be followed: ■ ALWAYS make sure generator is properly grounded.
RULES FOR SAFE OPERATION Maintenance Safety Battery Safety ■ The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn all circuit breakers OFF before performing maintenance on the generator. Use the following guidelines when handling the battery: ■ NEVER lubricate components or attempt service on a running machine. ■ ALWAYS disconnect the before performing service on the generator.
RULES FOR SAFE OPERATION ■ The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not To reduce the possibility of an accident while transporting to exceed 15 MPH or less depending on type of terrain. the generator on public roads, always make sure the trailer underneath wheel to prevent rolling, that supports the generator and the towing vehicle are in ■ Place while parked. good operating condition and both units are mechanically sound.
GENERATOR DECALS The DCA-180SSJU generator is equipped with a number of safety decals (Figures 2 & 3). These decals are provided for operator safety and maintenance information. The illustration below and on the preceding page show the decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer. Figure 2. Generator Decals PAGE 14 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
GENERATOR DECALS Figure 3. Generator Decals (Cont inued) 1 DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
INSTALLATION Figure 4. Typical Generator Grounding Application PAGE 16 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
INSTALLATION Outdoor Installation Generator Grounding Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes. To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground.
GENERAL INFORMATION DCA-180SSJU Whisperwatt™ Series Familiarization Generator The MQ Power Model DCA-180SSJU is a 180 kW (Figure 5) that is designed as a high quality portable (requires a trailer for transport) power source for telecom sites, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.
MAJOR COMPONENTS Figure 5. Major Components Table 4. Generator Major Components ITEM NO. DESCRIPTION 1 Output Terminal Panel Assembly 2 Output Receptacles Assembly 3 Air Filter Assembly 4 Muffler Assembly 5 Fuel Tank Assembly 6 Engine Assembly 7 Battery Assembly 8 Generator Assembly 9 Circuit Breaker Assembly 10 Diagnostic Display Assembly 11 Generator/Engine Control Panel Assembly 1 DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
DIAGNOSTIC DISPLAY 3. 4. 5. 6. Figure 6. Diagnostic Display Panel 7. Right Arrow Button – Press this button to scroll through the screen either moving the parameter selection toward the right or downward. Enter Key Button – Press this button to select the parameter that is highlighted on the screen. Emergency Stop LED – When lit (RED) indicates a major fault has occured. This condition will shudown the generator.
DIAGNOSTIC DISPLAY First Time Start Up 1. 2. When power is first applied to the diagnostic display, the “Logo” is displayed. The first seven items of the “Main Menu” will be displayed. Touching the “Arrow Buttons” will scroll through the menu selection. GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS 2. The “Wait to Start” message will be displayed for engines 3. with a pre-startup sequence.
DIAGNOSTIC DISPLAY 2. The language choices will be displayed. Use the “Arrow” 4. buttons to scroll through the selections and touch “Enter” to make a selection. If the word “MORE” appears above the “Arrow Buttons” there are more stored fault codes that may be viewed. Use the “Arrow Buttons” to scroll to the next Stored Diagnostic Code. ENGLISH ESPANOL FRANCAIS DEUTSCH 1 of x SPN110 FMI10 HIGH COOLANT TEMP MORE 3. Now that you have selected the language, touch the 5.
DIAGNOSTIC DISPLAY First Time Start Up 1. 2. When power is first applied to the diagnostic display, the “Logo” is displayed. The first seven items of the “Main Menu” will be displayed. Touching the “Arrow Buttons” will scroll through the menu selection. GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS 2. The “Wait to Start” message will be displayed for engines 3. with a pre-startup sequence.
DIAGNOSTIC DISPLAY 2. The language choices will be displayed. Use the “Arrow” 4. buttons to scroll through the selections and touch “Enter” to make a selection. If the word “MORE” appears above the “Arrow Buttons” there are more stored fault codes that may be viewed. Use the “Arrow Buttons” to scroll to the next Stored Diagnostic Code. ENGLISH ESPANOL FRANCAIS DEUTSCH 1 of x SPN110 FMI10 HIGH COOLANT TEMP MORE 3. Now that you have selected the language, touch the 5.
DIAGNOSTIC DISPLAY 2. The main menu will pop up on the display. Use the FAULTS AND WARNINGS “Arrow Buttons” to scroll through the menu until the “Engine Configuration” menu item has been Auxiliary Gage Fault highlighted. 1. During normal operation the single or four parameter screen will be displayed. GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 0 1500 3000 98% 1000 RPM LOAD RPM ENG RPM 14.2 57 PSI 1800 RPM ENG RPM COOL TEMP 3.
DIAGNOSTIC DISPLAY ! 4. Indicates Auxiliary Gage Fault ! Indicates Fault Warning ! Indicates Derate or Shutdown Condition Fault 5. Touching the “Enter Button” will redisplay the hidden fault. Touching the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display. NOTE: The fault can only be cleared by correcting the cause of the fault condition. 1 of x SPN110 FMI10 HIGH COOLANT TEMP MORE 5.
DIAGNOSTIC DISPLAY 5. Shut Down Codes 1. During normal operation the single or four parameter screen will be displayed. Touching the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display. 1 of x 0 3000 1500 98% 1000 RPM LOAD RPM ENG RPM 14.2 57 PSI SPN110 FMI10 HIGH COOLANT TEMP 1800 RPM MORE BATT VOLT ENG RPM COOL TEMP 2. 6. The Single or Four parameter screen will display the fault icon until the fault condition is corrected.
DIAGNOSTIC DISPLAY 3. Once the “Adjust Backlight” menu item has been highlighted touch the “Enter Button” to activate the “Adjust Backlight” function. Contrast Adjustment 1. GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 4. Starting at the single or four engine parameter display, touch the “Menu Button”. 0 1500 3000 98% 1000 RPM LOAD RPM ENG RPM 14.
DIAGNOSTIC DISPLAY Select Units 1. 5. Touch the “Enter Button” to select the highlighted units. Starting at the single or four engine parameter display touch the “Menu Button”. 0 1500 3000 98% 1000 RPM LOAD RPM ENG RPM 14.2 57 PSI ENGLISH METRIC KPA METRIC BAR 1800 RPM BATT VOLT ENG RPM COOL TEMP OIL PRES 6. 2. The main menu will pop up on the display. Use the arrow buttons to scroll through the menu until the “Select Units” is highlighted.
DIAGNOSTIC DISPLAY 3. Once the “Setup 1-up Display” menu icon has been 7. highlighted touch the “Enter Button” to access the “Setup 1-up display” function. GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT 4. A message indicating the “Single Engine” parameter display parameters are reset to the factory defaults will be displayed, then the display will return to the “Custom Setup” menu.
DIAGNOSTIC DISPLAY 11. Touch the “Enter Button” to deselect the selected 16. Touching the “Enter Button” toggles the “Automatic parameter removing it from the list of parameters being Scan” function on. displayed on the 1-up display. USE DEFAULTS CUSTOM SETUP AUTOMATIC SCAN ON 1 ENGINE SPEED PERCENT LOAD AT CURRENT RPM 3 2 ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE 12. Use the “Arrow Button” to scroll and highlight the desired parameter that has not been selected for display. 17.
DIAGNOSTIC DISPLAY Setup 4-Up Display 1. 5. The “Use Defaults” screen will be displayed during the resetting period then will automatically return to the From the single or four engine parameter display touch “Setup 4- Up Display” menu. the “Menu Button”. 0 1500 3000 98% 1000 RPM LOAD RPM ENG RPM 14.2 57 PSI 1800 RPM ENG RPM COOL TEMP 2. BATT VOLT RESTORED TO DEFAULTS OIL PRES 6. Select the “4-Up Custom Setup” from the “4-Up Setup” menu. The main menu will pop up on the display.
DIAGNOSTIC DISPLAY 9. The parameter that is highlighted is the selected 14. Touch the “Menu Button” to return to the main menu. parameter for the screen. Use the “Arrow Buttons” to highlight the new parameter to be placed in the quadrant selected in the previous screen.
DIAGNOSTIC DISPLAY 4. Touch “Select” to enter the “Gage Data” display. When 8. “Gage Data” is selected the PowerView will communicate with the analog gages at a fixed rate of 38.4k Band, 8 data bits, no parity check, 1 stop bits, half duplex. SOFTWARE VERSION MURPHY: X.XX GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP FAULT CONVERSION ADJUST BACKLIGHT DEMO MODE ON 9. 5. Use the “Arrow Buttons” to scroll through the items or touch “Menu” to return to the “Utilities” menu.
DIAGNOSTIC DISPLAY 11. Touch the “Menu” button to return to “Utilities” menu. 4. Touch the “Menu button again to return to the “Main” menu. STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES Use the “Arrows” to scroll down to and highlight either the “Slave Active or Master Active” modes. Touch the “Enter” button to toggle between master and slave. USE FACTORY DEFAULT SERIAL PORT SETUP SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE MODBUS SETUP 1.
DIAGNOSTIC DISPLAY GLOSSARY (Troubleshooting information) CANBUS FAILURE Diagnostic Display has not received any CAN messages for at least 30 seconds. NO DATA Diagnostic Display has not received the particular message being displayed for at least 5 seconds. NOT SUPPORTED Diagnostic Display has received a message from the ECU stating the displayed message is not supported DATA ERROR Diagnostic Display has received an error message from the ECU for the displayed message.
GENERATOR CONTROL PANEL 1 2 4 HZ INCREASE DECREASE 7 V A U W 5 W-U 6 OFF V-W 3 V U-V OFF Figure 7. Generator Control Panel The definitions below describe the controls and functions of Located behind the generator control panel is the . This box contains some of the necessary the DCA-180SSJU (Figure 7). 1. Frequency Meter – Indicates the output frequency in electronic components required to make the generator function. hertz (Hz). Normally 60 Hz. 2. 3. 4. 5. 6. 7.
ENGINE OPERATING PANEL The definitions below describe the controls and functions of the DCA-180SSJU (Figure 8). 9 1 3 10 2 4 11 AUTO MANUAL OFF/RESET 5 LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING 13 MOOOOO-20001Q 6 8 7 12 14 Figure 8. Engine Operating Panel 1. 2. 3. 4. Panel Light – Normally used in dark areas or at night time. When activated, panel lights will illuminate.
ENGINE OPERATING PANEL Pre-Heat Lamp – When lit, indicates engine is in the A. MPEC Control Switch – This switch controls the running of the unit. If this switch is set to the pre-heating mode (for starting during cold weather OFF/RESET position, the unit will not run. When this operating conditiions). When lamp goes off engine is switch is set to the MANUAL position, the generator ready for starting. will start immediately. 10.
OUTPUT TERMINAL PANEL FAMILIARIZATION Output Terminal Panel Output Terminal Familiarization The (Figure 9) shown below is The “ ” (Figure 9) is provided with located on the right-hand side (left from control panel) of the the following: generator. Lift up on the cover to gain access to receptacles ■ Three (3) 120/240V output receptacles @ 50 amp and terminal lugs.
OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles There are two 120 VAC, 20 amp GFCI (Duplex Nema 520R) recepacles provided on the output terminal panel. These receptacles can be accessed in any position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.
OUTPUT TERMINAL PANEL FAMILIARIZATION Over Current Relay An (Figure 15) is connected to the main Loads can be connected to the generator by the or the convienience receptacles (Figure 14). circuit breaker. In the event of an overload, both the circuit Make sure to read the operation manual before attempting breaker and the over current relay may trip. If the circuit breaker can not be reset, the on the over curto connect a load to the generator.
LOAD APPLICATION Single Phase Load Three Phase Load Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment. When calculating the power requirements for 3-phase power use the following equation: Generally, the wattage listed on the nameplate of the equipment is its rated output.
GENERATOR OUTPUTS Maximum Amps Generator Output Voltages amps the generator can proA wide range of voltages are available to supply voltage for Table 8 shows the many different applications. Voltages are selected by apply- vide. DO NOT exceed the maximum amps as listed. ing jumpers (6) to the (Figure 16). To obtain some of the voltages as listed in Table 7 (see beTable 8. Generator Maximum Amps low) will require a fine adjustment using the (VR) located on the control panel.
GENERATOR OUTPUTS/ GAUGE READING How to Read the AC Ammeter and AC Voltage Gauges. The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches. Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe the phase to phase voltage and the current flowing to the load at the UVWO output terminals lugs.
OUTPUT TERMINAL PANEL CONNECTIONS UVWO Terminal Output Voltages Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the and the adjustment of the Figure 24. Voltage Regulator Knob . Remember the voltage change-over board determines the 1Ø-240V UVWO Terminal Output Voltages of the output voltage and can be configured in two 1.
OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480 UVWO Output Terminal Voltages 1Ø-480V UVWO Terminal Output Voltages 1. Jumper the voltage change-over board for 480V 1. Make sure the voltage change-over board is jumpered operation as shown in Figure 27. This configuration uses for 480V operation as shown in Figure 27. 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate 2. Connect the load wires to the as shown in Figure 29. must be used. Figure 27.
SETUP Circuit Breakers Fuel Check To protect the generator from an overload, a 3-pole, 500 amp, circuit breaker is provided to protect the from overload. In addition two single-pole, 20 amp circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.
SETUP Refueling Procedure: 3. WARNING - RESPIRATORY HAZARDS Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and fill tank (Figure 34). Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes. 1. Level Tanks – Make sure fuel cells are level with the ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 33).
SETUP Coolant (Antifreeze) John Deere recommends Antifreeze/Summer Coolant for use in thier engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the John Deere Engine Owner's Manual for further details WARNING - BURN HAZARDS Cleaning the Radiator The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the radiator fins with compressed air.
SETUP When connecting battery do the following: Battery This unit is of negative ground DO NOT connect in reverse. 1. NEVER connect the battery cables to the battery terminals when the is in either Always maintain battery fluid level between the specified the MANUAL or AUTO position. ALWAYS make sure that marks. Battery life will be shortened, if the fluid level are not the is in the OFF/RESET position properly maintained. Add only distilled water when when connecting the battery.
GENERATOR START-UP PROCEDURE (MANUAL) Before Starting CAUTION - LETHAL EXHAUST HAZARD The engine's exhaust contains harmful emissions. . Direct exhaust away from nearby personnel. WARNING - STARTING THE GENERATOR manually start the engine with the , or circuit breakers in the ON (closed) position. 3. Make sure the the voltage change-over board has been configured for the desired output voltage. 4. Connect the load to the or the as shown in Figure 14.
GENERATOR START-UP PROCEDURE (MANUAL) When the MPEC Control switch is 8. To restart the engine due to error codes, place the in the MANUAL position (Figure 43) placed in the manual position, NOTE preheating of the glow plugs will begin 9. If the engine is running smoothly, place the engine automatically and the preheat speed switch (Figure 45) in the “ ” (up) position. lamp will stay lit until the glow plugs are warmed.
GENERATOR START-UP PROCEDURE (MANUAL) 18. Place the , , and ON position (Figure 54). . circuit breakers in the Figure 49. Voltage Adjust Control Knob 14. The ammeter (Figure 50) will indicate with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator. Figure 54. Main, Aux. and GFCI Circuit Breakers (ON) Figure 50. Ammeter (No Load) 15. The engine oil pressure gauge (Figure 51) will indicate the oil pressure of the engine.
GENERATOR START-UP PROCEDURE (AUTO MODE) WARNING - AUTO MODE MAINTENANCE When running the generator in the AUTO mode, remember the generator can start up at any time without warning. NEVER attempt to perform any maintenance when the generator is in the auto mode. When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below). 1. Perform steps 1 through 6 in the as outlined in the 2. Place the position section .
GENERATOR SHUT-DOWN PROCEDURES WARNING - SHUTTING DOWN THE GENERATOR NEVER stop the engine suddenly except in an emergency. CAUTION - DIAGNOSTIC SWITCH Emergency Shutdown Procedure To shutdown the generator in the event of an emergency use the following procedure: 1. Place the OFF/RESET position. (Figure 59) in the ALWAYS make sure the diagnostic switch is placed in the OFF position before attempting to shut down the generator.
MAINTENANCE (ENGINE) 10 Hrs DAILY TABLE 12.
MAINTENANCE (ENGINE) Air Removal Flushing Out Radiator and Replacing Coolant If air enters the fuel injection system of a diesel engine, starting becomes impossible. After running out of fuel, or after disassembling the fuel system, bleed the system according to the following procedure. See the for details. To restart after running out of fuel, turn the switch to the “ON” position for 15-30 seconds. Try again, if needed. This unit is equipped with an automatic air bleeding system.
MAINTENANCE (HEATER/CHARGER) Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL) If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) This generator can be optionally equipped with two 120 VAC, for long periods of time, apply power to the battery charger 20 amp input receptacles located on the output terminal receptacle via commercial power using an power cord of adequate size. panel.
MAINTENANCE (TRAILER) 8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters This section is intended to provide the user with generic trailer (175,185,205, etc.). The tire diameter must match the service and maintenance information. The service and diameter of the tire rim. maintenance guidelines referenced in this section refer to a wide range of trailers. 9. Tire Ply - The tire ply (layers) number is rated in letters; 2-ply,4-ply,6-ply, etc.
MAINTENANCE (TRAILER) Brakes Trailer brakes should be inspected the of operation. This will allow the brake shoes and drums to seat properly. After the first 200 mile interval, inspect the brakes . If driving over rough terrain, inspect the brakes more frequently. Figure 61 displays the major hydraulic surge brake components that will require inspection and maintenance. Please inspect these components as required using steps 1 through 8 and Table 15 as listed below: Brake Adjustment 1.
MAINTENANCE (TRAILER) Tires/Wheels/Lug Nuts Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched. CAUTION - EYESIGHT HAZARD Suspension The springs and associated components (Figure 62) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immediately.
MAINTENANCE (TRAILER) Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows: 1. Start all wheel lug nuts by hand. 2. Torque all lug nuts in sequence (see Figure 63). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 16. 3.
TRAILER WIRING DIAGRAM Figure 62. Trailer/Towing Vehicle Wiring Diagram PAGE 64 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
GENERATOR WIRING DIAGRAM Figure 63. Generator Wiring Diagram 1 DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
DCA-180SSJU — ENGINE WIRING DIAGRAM Figure 64. Engine Wiring Diagram PAGE 66 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
TROUBLESHOOTING (GENERATOR) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 17 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company's business office or service plant. TABLE 17.
TROUBLESHOOTING (ENGINE CONTROLLER) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 (Engine Controller Troubleshooting) as a basic guideline for troubleshooting the Microprocessor Engine Controller unit (MPEC). If the problem cannot be remedied, consult our company's business office or service plant. TABLE 18. ENGINE CONTROLLER TROUBLESHOOTING (MPEC) SYMPTOM Low oil pressure light is on.
NOTES 1 DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
EXPLANATION OF CODE IN REMARKS COLUMN The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions. NOTICE The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed. SAMPLE PARTS LIST NO. 1 2% 2% 3 4 PART NO. PART NAME QTY. REMARKS 12345 BOLT......................1 .....
SUGGESTED SPARE PARTS DCA-180SSJU WHISPER WATTGENRATOR W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 TO 3 UNITS Qty. P/N Description 1 ......... M4310500803 ...... HOSE, RADIATOR UPPER 1 ......... M4310500903 ...... HOSE, RADIATOR LOWER 1 ......... 0605505070 ......... FUEL CAP 1 ......... 0602015230 ......... V-BELT, FAN 1 ......... 0602122272 ......... UNIT, OIL PRESSURE 1 ......... 0602123263 ......... UNIT, WATER TEMPERATURE 6 ......... 0602042596 ......... FILTER, FUEL PRIMARY 6 ......... 0602042597 ..
GENERATOR ASSY. GENERATOR ASSY. PAGE 72 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
GENERATOR ASSY. GENERATOR ASSY. NO. 1 1-1# 1-2# 1-3# 1-4# 1-4A# 1-4B# 1-5# 1-6# 1-7# 1-8# 1-9# 1-10# 1-11# 1-12# 1-13# 2 3 4 5 6 7 7-1 7-2 8 9 10 10A 10B 11 12 13 14 14A 14B 15 16 17 18 19 20 20A 20B 21 22 22A 23 PART NO.
CONTROL PANEL ASSY. CONTROL PANEL ASSY. PAGE 74 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
CONTROL PANEL ASSY. CONTROL PANEL ASSY. NO. 1 2 2-1 2-2 3 4 5 6 7 8 9 10 11 12 13 13A 14 15 16 17 18 19 20 21 23 23A 24 24A 25 26 27 28 28A 29 30 PART NO.
CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 76 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
CONTROL BOX ASSY. CONTROL BOX ASSY. NO. 1 2 3 4 4A 4B 5 6 7 8 9 10 11 12 13 14 14A 15 16 17 18 19 20 20A 21 22 23 24 25 25A 25B 26 26A 26B PART NO.
CONTROL BOX ASSY. CONTROL BOX ASSY. PAGE 78 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
CONTROL BOX ASSY. CONTROL BOX ASSY. ( CONT.) NO. 27 28 29 29A 30 31 31A 31B 32 33 34 35 36 37 38 39 39A 39B 40 41 42 43 44 45 46 47 48 49 50 51 52 53 PART NO.
ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. PAGE 80 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
ENGINE AND RADIATOR ASSY. ENGINE AND RADIATOR ASSY. NO. 1 1A 1-1 1-2 1-3 2 3 4 5 6 7 8 9 10 11 12 12A 13 14 15 16 17 17A 18 19 20 21 23 24 25 26 27 27A 28 28A 29 29A 30 31 32 33 34 35 36 37 38 39 40 41 42 PART NO.
ENGINE AND RADIATOR ASSY. (CONT) ENGINE AND RADIATOR ASSY. (CONT.) PAGE 82 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
ENGINE AND RADIATOR ASSY. (CONT) ENGINE AND RADIATOR ASSY. (CONT.) NO. 43 44 45 46 47 48 49 50 51 52 53 54 54A 54B 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 PART NO.
OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 3-SPECTRUM GREY 4-SUNBELT GREEN 6-CATERPILLAR YELLOW 7-CATO GOLD 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 84 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 11A 11B 12 12A 13 13A 13B 13C 14 15 16 17 18 19 20 21 22 23 24 PART NO.
OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 3-SPECTRUM GREY 4-SUNBELT GREEN 6-CATERPILLAR YELLOW 7-CATO GOLD 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 86 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
OUTPUT TERMINAL ASSY. OUTPUT TERMINAL ASSY. (CONT.) NO. 25 25-1 26 27 28 29 29A 30 31 32 33 34 35 36 37 38 39 40 41 42 PART NO. M4260600104 022100150 0019206020 0601812538 0601812538 0025304015 0207004000 M4236400204 0019206015 M4236100303 0010112045 0041212000 M9310200004 0030012000 0605011505 0025305015 M4236100604 M4236400304 0019206015 0025304015 PART NAME BRACKET, CIRCUIT BREAKER RUBBER CUSHION HEX. HEAD BOLT RECEPTACLE, 20A RECEPTACLE, 50A MACHINE SCREW HEX. NUT COVER HEX.
BATTERY ASSY. BATTERY ASSY. PAGE 88 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
BATTERY ASSY. BATTERY ASSY. NO. 1 2 3 4 5 6 7 8 8A 9 PART NO. 0602220196 M9310500404 M9103000504 0602220921 M4346900304 M4346900204 0017116030 0040516000 0040520000 PART NAME QTY. REMARKS BATTERY 1 BATTERY SHEET 1 BATTERY SHEET 1 BATTERY BOLT SET 2 BATTERY CABLE 1 BATTERY CABLE 1 CABLE .................................................................... 1............ MAKE LOCALLY HEX. HEAD BOLT 1 TOOTHED WASHER 1 TOOTHED WASHER 1 1 DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
MUFFLER ASSY. MUFFLER ASSY. PAGE 90 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
MUFFLER ASSY. MUFFLER ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 PART NO. M4330100502 0016910025 M4333000303 0602325066 M4333200004 0017112055 M4330300004 0016908020 M4333300304 0016908020 0602326062 PART NAME MUFFLER HEX. HEAD BOLT EXHAUST PIPE CLAMP GASKET HEX. HEAD BOLT COVER HEX. HEAD BOLT BRACKET HEX. HEAD BOLT U BOLT SET QTY. 1 4 1 1 1 4 2 4 1 4 1 REMARKS 1 DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
FUEL TANK ASSY. FUEL TANK ASSY. PAGE 92 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
FUEL TANK ASSY. FUEL TANK ASSY. NO. 1 1-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NO. M4363000102 0605505070 0605501069 0605516090 0027104016 M4363200104 M9310500104 0016908020 0207308000 0222100120 0222100180 M9200000003 M9200200004 0150000018 0016906020 M1363400104 0605515198 0191302800 0191302200 0605515109 PART NAME FUEL TANK CAP. FUEL TANK FUEL SENDER UNIT GASKET MACHINE SCREW TANK BAND SUPPORTER SHEET HEX.
ENCLOSURE ASSY. ENCLOSURE ASSY. ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 3-SPECTRUM GREY 4-SUNBELT GREEN 6-CATERPILLAR YELLOW 7-CATO GOLD 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 94 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
ENCLOSURE ASSY. ENCLOSURE ASSY. NO. 1 2 3 4 4A 5 5A 6 7 8 9 10 11 12 12A 13 13A 14 15 15A 16 17 17A 18 18A 18B 18C 19 19A 19B 19C 20 20A 21 22 22A 23 23A 24 25 26 27 PART NO.
ENCLOSURE ASSY. (CONT.) ENCLOSURE ASSY. (CONT.) ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 3-SPECTRUM GREY 4-SUNBELT GREEN 6-CATERPILLAR YELLOW 7-CATO GOLD 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 96 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
ENCLOSURE ASSY. (CONT.) ENCLOSURE ASSY. (CONT.) NO. 28 28A 29 30 30A 31 31A 32 33 34 35 36 36A 37 38 39 39A 40 40A 41 42 43 44 45 46 47 48 49 49A 50 50A 50B PART NO.
ENCLOSURE ASSY. (CONT.) ENCLOSURE ASSY. (CONT.) ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING ANY PAINTED PANEL TO INDICATE COLOR OF UNIT: 1-ORANGE 5-BLACK 2-WHITE 3-SPECTRUM GREY 4-SUNBELT GREEN 6-CATERPILLAR YELLOW 7-CATO GOLD 8-RED THE SERIAL NUMBER MAY BE REQUIRED. PAGE 98 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
ENCLOSURE ASSY. (CONT.) ENCLOSURE ASSY. (CONT.) NO. 51 51A 52 52A 53 53A 54 54A 55 55A 56 56A 57 57A 58 58A 59 60 61 62 62A 63 64 65 66 66A 67 67A 68 69 70 71 72 72A PART NO.
RUBBER SEALS ASSY. RUBBER SEALS ASSY. PAGE 100 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
RUBBER SEALS ASSY. RUBBER SEAL ASSY. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NO. 0229201240 0228900945 0228901200 0228901260 0228901055 0228900600 0228900660 0229201060 0229200660 0228801050 0228800595 0228800635 0228100560 0228100370 0229201020 0229201200 PART NAME RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL RUBBER SEAL QTY.
NAMEPLATE AND DECALS ASSY. NAMEPLATE AND DECALS ASSY. PAGE 102 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
NAMEPLATE AND DECALS ASSY. NAME PLATE ASSY. NO. 1 1-1 1-2 1-3 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 3-1 3-2 3-3 3-4 3-5 3-6 4-1 4-2 4-3 4-4 4-5 4-6 5-1 5-2 5-3 6-1 7-1 7-2 8-1 8-2 8-2A 8-3 8-4 8-5 8-6 8-7 8-8 8-9 PART NO.
TERMS AND CONDITIONS OF SALE — PARTS PAYMENT TERMS 5. Parts must be in new and resalable condition, in the original Multiquip package (if any), and with Multiquip part numbers clearly marked. 6. The following items are not returnable: Multiquip reserves the right to quote and sell direct to Government agencies, and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products. a. SPECIAL EXPEDITING SERVICE Terms of payment for parts are net 30 days.
NOTES 1 DCA-180SSJU — OPERATION AND PARTS MANUAL — REV.
PARTS AND OPERATION MANUAL OPERATION AND PARTS MANUAL HERE’S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING MULTIQUIP CORPORATE OFFICE 18910 Wilmington Ave Tel. (800) 421-1244 Carson, CA 90746 Fax (800) 537- 3927 Contact: mq@multiquip.com Web: www.multiquip.com MQ Power 1800 Water Ridge Rd. Tel. (800) 883-2551 Suite 500/600 Fax (972) 315-1847 Lewisville, TX 75057 Contact: mqpower@multiquip.com Web: www.mqpower.
