Multiquip DCA180SSJU manual

P AR TS AND OPERA TION MANUAL OPERA TION AND P ARTS MANUAL T o find the latest re vision of this publication, visit our website at: www .mqpower .com WHISPER W A TT TM SERIES MODEL DCA180SSJU 60HZ GENERA TOR (JOHN DEERE 6068HF485 DIESEL ENGINE) Re vision #3 (02/01/10) (P ARTS LIST NO . M3870301004)[...]

P A GE 2 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) PROPOSITION 65 W ARNING[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 3 1 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 T raffic Safety Administration (NHTSA) in addition to notifying Multiquip at 1-800-421-1244[...]

P A GE 4 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) T ABLE OF CONTENTS MQ POWER DCA-180SSJU MQ POWER DCA-180SSJU MQ POWER DCA-180SSJU MQ POWER DCA-180SSJU MQ POWER DCA-180SSJU WHISPER WHISPER WHISPER WHISPER WHISPER W W W W W A A A A A TT TT TT TT TT TM TM TM TM TM GENERATOR GENERATOR GENERATOR GENERATOR GENERATOR Pro[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 5 1 P AR TS ORDERING PROCEDURES www .mqpo we r .com Or dering par ts has never been easier! Choose fr om three easy options: WE A CCEPT ALL MAJOR CREDIT CARDS! When or dering par ts, please supply: R Dealer Account Number R Dealer Name and Address R Shipping Address (if diff[...]

P A GE 6 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) SPECIFICA TIONS T able 1. Generator Specifications Model DCA-180SSJU Ty p e Rev olving field, self v entilate d, open protected type synchr onous generator Armature Connection Star with Nutreal Phase 3 Standby Output 198 KV A (158 KW) Prime Output 180 KV A (144 KW) V[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 7 1 DIMENSIONS (TOP , SIDE AND FRONT) Figure 1. Dimensions S N O I S N E M I D . 3 E L B A T e c n e r e f e R r e t t e L ) . m m ( . t f n o i s n e m i Dr e t t e L e c n e r e f e R) . m m ( . t f n o i s n e m i D A) . m m 0 4 9 ( . n i 0 0 . 7 3F ) . m m 0 0 5 , 3 ( . [...]

P A GE 8 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) This Owner's Manual has been de v eloped to pro vide complete instr uctions f or the saf e and efficient operation of the MQ P ow er Bef ore using this g enerator , ensure that the operating individual has read and under stands all instructions in this man ual. [...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 9 1 SAFETY MESSAGE ALER T SYMBOLS AL W A YS place the MPEC control s witch in the OFF/RESET position when the generator is not in use . AL W A YS wear appro v ed protection. AL W A YS wear approv ed and protection. Other impor tant messages are pro vided throughout this manu[...]

P A GE 10 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) RULES FOR SAFE OPERA TION The f ollo wing saf ety guidelines should alwa ys be used when operating the General Safety: ■ DO NO T operate or ser vice this equipment bef ore reading this entire manual. The operator MUST BE f amiliar with proper saf ety precautions a[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 11 1 RULES FOR SAFE OPERA TION POWER CORD (POWER ON) WET HANDS Dur ing operation of this gener ator , there e xists the possibility of which can cause or e v en T o av oid these hazards: NEVER use damaged or wor n cables when connecting equipment to the generator . Make sure[...]

P A GE 12 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) RULES FOR SAFE OPERA TION Battery Safety Use the f ollo wing guidelines when handling the batter y: ■ The batter y contains acids that can cause injur y to the ey es and skin. T o a v oid e y e irr itation, wear saf ety glasses. ■ Use well insulated glo v es whe[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 13 1 Emergencies ■ AL W A YS know the location of the nearest . ■ AL W A YS know the location of the nearest and . ■ AL W A YS know the location of the nearest phone or in case of emergencies . ■ AL W A YS ha v e easy access to the phone numbers of the nearest , and [...]

P A GE 14 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) The DCA-180SSJU generator is equipped with a n umber of saf ety decals (Figures 2 & 3). These decals are provided f or operator saf ety and maintenance inf or mation. The illustration belo w and on the preceding page sho w the decals as the y appear on the machi[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 15 1 GENERA TOR DECALS Figure 3. Generator Decals (Cont inued)[...]

P A GE 16 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Figure 4. T ypical Generator Gr ounding Application INST ALLA TION[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 17 1 Outdoor Installation Install the generator in a area that is free of debris, b ystanders, and o v erhead obstructions. Mak e sure the generator is on secure le v el ground so that it cannot slide or shift around. Also install the generator in a manner so that the e xhau[...]

P A GE 18 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) GENERAL INFORMA TION DCA-180SSJU Whisperwatt™ Series F amiliarization Generator The MQ P ow er Model DCA-180SSJU is a 180 kW (Figure 5) that is designed as a high quality por tab le (requires a trailer f or transpor t) po wer source f or telecom sites , lighting f[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 19 1 MAJOR COMPONENTS Figure 5. Major Components 4 e l b a T. s t n e n o p m o C r o j a M r o t a r e n e G . O N M E T IN O I T P I R C S E D 1y l b m e s s A l e n a P l a n i m r e T t u p t u O 2y l b m e s s A s e l c a t p e c e R t u p t u O 3y l b m e s s A r e t l[...]

P A GE 20 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) DIAGNOSTIC DISPLA Y The diagnostic displa y panel located inside the control bo x on the generator (Figure 6) is designed to meet the needs f or instrumentation and control of electronically controlled engine communication using the SAEJ1939 Controller Area Network [...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 21 1 First Time Star t Up 1 . When pow er is first applied to the diagnostic displa y , the “Logo” is displa y ed. 2 . The “W ait to Star t” message will be displa yed f or engines with a pre-star tup sequence . Once the “W ait to Star t” message is no longer dis[...]

P A GE 22 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) 2. The language choices will be displa y ed. Use the “Arro w” b uttons to scroll through the selections and touch “Enter” to mak e a selection. 3. No w that y ou ha v e selected the language, touch the “Menu” button to return to the main menu displa y . [...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 23 1 First Time Star t Up 1 . When pow er is first applied to the diagnostic displa y , the “Logo” is displa y ed. 2 . The “W ait to Star t” message will be displa yed f or engines with a pre-star tup sequence . Once the “W ait to Star t” message is no longer dis[...]

P A GE 24 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) 2. The language choices will be displa y ed. Use the “Arro w” b uttons to scroll through the selections and touch “Enter” to mak e a selection. 3. Now that y ou ha v e selected the language, touch the “Menu” button to return to the main menu displa y . S[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 25 1 2 . The main menu will pop up on the displa y . Use the “Arro w Buttons” to scroll through the menu until the “Engine Configuration” menu item has been highlighted. 3. Once the “Engine Configuration” menu item has been highlighted touch the “Enter Button?[...]

P A GE 26 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) ! ! ! Indicates Auxiliary Gage Fault Indicates Fault Warning Indicates Derate or Shutdown Condition Fault 5. T ouching the “Enter Button” will redispla y the hidden f ault. T ouching the “Enter Button” once again will hide the f ault and retur n the screen t[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 27 1 Shut Down Codes 1 . During nor mal operation the single or f our par ameter screen will be displa y ed. 2 . When the diagnostic displa y receiv es a se v e re f ault code from an engine control unit the single or f our parameter screen will be replaced with the “Shutd[...]

P A GE 28 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) 3 . Once the “Adjust Backlight” menu item has been highlighted touch the “Enter Button” to activate the “Adjust Bac klight” function. 4. Use the “Arro w Buttons” to select the desired backlight intensity . 5. T ouch the “Menu Button” to retur n t[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 29 1 Select Units 1. Star ting at the single or f our engine parameter displa y touch the “Menu Button”. 2. The main menu will pop up on the displa y . Use the arrow b uttons to scroll through the menu until the “Select Units” is highlighted. 3. Once the “Select Un[...]

P A GE 30 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) 3. Once the “Setup 1-up Displa y” menu icon has been highlighted touch the “Enter Button” to access the “Setup 1-up displa y” function. 4. Three options are av ailab le f or modification of the 1-Up displa y . a). Use defaults- This option contains a set[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 31 1 1 1 . T ouch the “Enter Button” to deselect the selected parameter remo ving it from the list of parameters being displa y ed on the 1-up displa y . 12 . Use the “Arrow Button” to scroll and highlight the desired parameter that has not been selected f or displa [...]

P A GE 32 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) COOL 1800 RPM 0 1500 3000 TEMP ENG RPM 98% 14.2 57 PSI 1000 RPM LOAD RPM BATT VOL T ENG RPM OIL PRES Setup 4-Up Displa y 1. F rom the single or f our engine parameter displa y touch the “Menu Button”. 2 . The main menu will pop up on the displa y . Use the “Ar[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 33 1 9 . The parameter that is highlighted is the selected parameter f or the screen. Use the “Arro w Buttons” to highlight the ne w parameter to be placed in the quadrant selected in the pre vious screen. 1 0 . T ouch the “Enter Button” to change the selected parame[...]

P A GE 34 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) 4 . T ouch “Select” to enter the “Gage Data” displa y . When “Gage Data” is selected the P ow erView will communicate with the analog gages at a fix ed rate of 38.4k Band, 8 data bits, no parity chec k, 1 stop bits, half duple x. 5 . Use the “Arro w Bu[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 35 1 1 1 . T ouch the “Menu” b utton to retur n to “Utilities” menu. T ouch the “Men u b utton again to retur n to the “Main” menu. MODBUS SETUP 1 . Star ting at the single or f our engine parameter displa y , touch the “Menu Button”. 2 . The main menu will[...]

P A GE 36 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) GLOSSAR Y (T r oub leshooting inf ormation) CANBUS F AILURE Diagnostic Displa y has not receiv ed an y CAN messages f or at least 30 seconds . NO D A T A Diagnostic Displa y has not receiv ed the par ticular message being display ed for at least 5 seconds . NO T SUP[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 37 1 GENERA TOR CONTROL P ANEL The definitions below describe the controls and functions of the DCA-180SSJU (Figure 7). 1. Frequency Meter – Indicates the output frequency in her tz (Hz). Normally 60 Hz. 2. A C Ammeter – Indicates the amount of current the load is dra wi[...]

P A GE 38 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Figure 8. Engine Operating P anel ENGINE OPERA TING P ANEL The definitions below describe the controls and functions of the DCA-180SSJU (Figure 8). 1. Panel Light – Normally used in dar k areas or at night time. When activated, panel lights will illuminate . When [...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 39 1 ENGINE OPERA TING P ANEL 9. Pre-Heat Lamp – When lit, indicates engine is in the pre-heating mode (f or star ting during cold weather operating conditiions). When lamp goes off engine is ready f or star ting. 10 . W arning Lamp – This lamp will illuminate when a cri[...]

P A GE 40 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Output T erminal Familiarization The “ ” (Figure 9) is provided with the f ollo wing: ■ ■ ■ ■ ■ Three (3) 120/240V output receptacles @ 50 amp ■ ■ ■ ■ ■ Three (3) Circuit Break ers @ 50 amps ■ ■ ■ ■ ■ T wo (2) 100V GFCI receptacles [...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 41 1 120 V A C GFCI Receptac les There are two 120 V A C , 20 amp GFCI (Duple x Nema 5- 20R) recepacles pro vided on the output ter minal panel. These receptacles can be accessed in an y position. Each receptacle is protected by a 20 amp circuit break er . These break ers ar[...]

P A GE 42 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Figure 14. Connecting Loads Connecting Loads Loads can be connected to the generator b y the or the con vienience receptacles (Figure 14). Mak e sure to read the operation manual bef ore attempting to connect a load to the generator . T o protect the output ter mina[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 43 1 LOAD APPLICA TION Single Phase Load Alwa ys be sure to check the nameplate on the gener ator and equipment to insure the w attage, amperage , frequency , and v oltage requirements are satisf actorily supplied by the generator f or operating the equipment. Generally , th[...]

P A GE 44 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Maxim um Amps T able 8 sho ws the amps the generator can pro- vide. DO NO T exceed the maxim um amps as listed. GENERA TOR OUTPUTS Generator Output V oltages A wide range of v oltages are a v ailab le to supply v oltage f or many diff erent applications. V oltages a[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 45 1 How to Read the A C Ammeter and A C V oltage Gauges. The A C ammeter and A C voltmeter gauges are controlled b y the A C ammeter and A C v oltmeter change-ov er s witches . Both of these s witches are located on the control panel and DO NO T effect the gener ator output[...]

P A GE 46 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) OUTPUT TERMINAL P ANEL CONNECTIONS Figure 22. V oltage Chang e-Over Boar d 240V Configuration UVWO T erminal Output V oltages V ar ious output v oltages can be obtained using the UVWO output ter minal lugs. The voltages at the terminals are de- pendent on the placem[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 47 1 OUTPUT TERMINAL P ANEL CONNECTIONS Figure 27. V oltage Change-Over Board 480V Configuration Figure 28. Output T erminal Lugs 3Ø-480V Connections 2. Connect the load wires to the as sho wn in Figure 28. 3. T ur n the v oltage regulator knob (Figure 24) cloc kwise to inc[...]

P A GE 48 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) SETUP Figure 31. Engine Oil Dipstic k When chec king the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by remo ving the oil drain plug, and refill with the specified amount of oil as outlined in the John Deere Engine Owner&[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 49 1 SETUP Refueling Pr ocedure: 1. Le vel T anks – Mak e sure fuel cells are le v el with the ground. F ailure to do so will cause fuel to spill from the tank bef ore reaching full capacity (Figure 33). Figure 33. Only Fill on Le vel Ground ONL Y! use when refueling. NO T[...]

P A GE 50 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Da y-to-da y addition of coolant is done from the reco v er y tank. When adding coolant to the radiator , DO NO T remov e the radiator cap until the unit has completely cooled. See T abl e 10 f or engine , radiator , and recov er y tank coolant capacities. Mak e sur[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 51 1 SETUP When connecting batter y do the follo wing: 1. NEVER connect the batter y cables to the battery ter minals when the is in either the MANU AL or AU TO position. AL W A YS make sure that the is in the OFF/RESET position when connecting the batter y . 2. Place a smal[...]

P A GE 52 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Star ting (Manual) 1. Place the engine speed switch (Figure 42) in the “ LO W ” (down) position Figure 43. MPEC Contr ol Switch (Manual P osition) GENERA TOR ST ART -UP PROCEDURE (MANUAL) The engine's e xhaust contains har mful emissions. . Direct e xhaust [...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 53 1 10. V er ify that the Engine Running status LED on the MPEC unit (Figure 46) is ON (lit) after the engine has been star ted. 3 . If any abnormalities exists , the W ar ning and Emergency Stop lamps on the Engine Operating P anel will be lit. 4. Place the (Figure 43) in [...]

P A GE 54 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) When the generator is set in the AU TO mode , the generator will in the e v ent of comercial pow er f alling below a prescr ibed le vel b y means of a contact closure that is generated automatically b y a transf er s witch. NO TE Star ting (A uto Mode) Bef ore conne[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 55 1 1. P erf orm steps 1 through 6 in the section as outlined in the . 2. Place the (Figure 56) in the HIGH position 4. Continue operating the generator as s outlined in the procedure (star t at step 5). Figure 57. MPEC Contr ol Switch (A UT O) When r unning the generator i[...]

P A GE 56 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Normal Shutdown Pr ocedure T o shutdown the generator use the f ollowing procedure: 1. Place both the MAIN , GFCI and LO AD circuit breakers as sho wn in Figure 40 to the OFF position. 2. Place the engine speed s witch (Figure 58) in the “ ” (down) position. Fig[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 57 1 MAINTENANCE (ENGINE) Service Daily If the engine is operating in v er y or conditions , a clogged air cleaner will result. This can lead to a loss of power , excessiv e carbon buildup in the comb ustion chamber and high fuel consumption. Change air cleaner more if these[...]

P A GE 58 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) MAINTENANCE (ENGINE) Generator Storage F or longe ter m storage of the gener ator the f ollowing is recommended:  Fill the fuel tank completely . T reat with a fuel stabiliz er if necessar y .  Completely drain the oil from the crankcase and refill if necessar[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 59 1 MAINTENANCE (HEA TER/CHARGER) T o ensure adequate star ting capability , alwa ys hav e power applied to the generator's . NO TE Figure 60. DCA-180SSJUBattery Charger & Jac ket W ater Heater P o wer Connections Jac ket W ater Heater and Internal Batter y Char ge[...]

P A GE 60 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) MAINTENANCE (TRAILER) 8. Tire Size - Indicates the diameter of the tire in inches (10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim. 9. Tire Ply - The tire ply (la yers) n umber is rated in [...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 61 1 MAINTENANCE (TRAILER) Hydraulic Sur ge Brakes Hydraulic surge br ak es (Figure 61) should not require any special attention with the e xception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically check ed f or crac ks , kinks, [...]

P A GE 62 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) Tires/Wheels/Lug Nuts Tires and wheels are a v er y impor tant and cr itical components of the trailer . When specifying or replacing the trailer wheels it is impor tant the wheels, tires , and axle are proper ly matched. Tire W ear/Inflation Tire inflation pressure[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 63 1 use an pneumatic air gun to tighten wheel lug nuts . Figure 63. Wheel Lug Nuts Tightening Sequence MAINTENANCE (TRAILER) NO TE Lug Nut T orque Requirements It is e xtremely impor tant to apply and maintain proper wheel mounting torque on the trailer . Be sure to use onl[...]

P A GE 64 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) TRAILER WIRING DIAGRAM Figure 62. T railer/T owing V ehic le Wiring Diagram[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 65 1 GENERA TOR WIRING DIAGRAM Figure 63. Generator Wiring Diagram[...]

P A GE 66 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) DCA-180SSJU — ENGINE WIRING DIAGRAM Figure 64. Engine Wiring Diagram[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 67 1 Practically all breakdo wns can be pre v ented b y proper handling and maintenance inspections , but in the e vent of a breakdo wn, use T ab le 17 shown below f or diagnosis of the Generator . If the prob lem cannot be remedied, consult our compan y's b usiness off[...]

P A GE 68 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) TROUBLESHOOTING (ENGINE CONTROLLER) Practically all breakdo wns can be pre v ented b y proper handling and maintenance inspections, b ut in the ev ent of a breakdown, use T ab le 18 (Engine Controller T roubleshooting) as a basic guideline f or troubleshooting the M[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 69 1 NOTES[...]

P A GE 70 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) EXPLANA TION OF CODE IN REMARKS COLUMN The f ollowing section e xplains the different symbols and remarks used in the P ar ts section of this manual. Use the help numbers f ound on the bac k page of the manual if there are any questions . SAMPLE P ARTS LIST NO . P A[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 71 1 SUGGESTED SP ARE P ARTS P ar t number on this Suggested Spare P ar ts list ma y supercede/replace the P/N sho wn in the te xt pages of this book. NO TE DCA-180SSJU WHISPER W A TTGENRA T OR W/JOHN DEERE 6068HF485 TURBO DIESEL ENGINE 1 T O 3 UNITS Qty . P/N Description 1 [...]

P A GE 72 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) GENERA TOR ASSY . GENERA T OR ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 73 1 GENERA TOR ASSY . GENERA T OR ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 C0110000602 R O T OR ASSY . ........................... 1 ........ INCLUDES ITEMS W/# 1-1# FIELD ASSY . .............................. 1 ........ NO T SOLD SEP ARETL Y 1-2# 0601842334 RESI[...]

P A GE 74 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) CONTROL P ANEL ASSY . CONTR OL P ANEL ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 75 1 CONTROL P ANEL ASSY . CONTR OL P ANEL ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4223000303 CONTROL P ANEL 1 2 M4223000404 CONTROL P ANEL 1 2-1 022100100 SEAL R UBBER 2 2-2 022100165 SEAL R UBBER 2 3 0605011211 PIN 2 4 0017108040 HEX. HEAD BOL T 4 5 0601807642[...]

P A GE 76 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) CONTR OL BO X ASSY . CONTROL BOX ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 77 1 CONTROL BOX ASSY . CONTR OL BO X ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M3213001302 CONTROL BO X 1 2 0601809666 CURRENT TRANSFORMER, 300/5A 3 3 0027106018 MA CHINE SCREW 6 4 0601870423 CIRCUIT BREAKER, 500A 1 4A 0021006045 MA VHINE SCREW 4 4B 0207006000 HEX[...]

P A GE 78 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) CONTR OL BO X ASSY . CONTROL BOX ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 79 1 CONTR OL BO X ASSY . ( CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 27 M4260500003 SET P ANEL, ELECTRIC P AR TS 1 28 0016908020 HEX. HEAD BOL T 4 29 0602202592 ST ARTER RELA Y 1 29A 0030006000 HEX. NUT 2 30 0027106016 MA CHINE SCREW 2 31 L Y2DUS12VDC RELA Y ......[...]

P A GE 80 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) ENGINE AND RADIA TOR ASSY . ENGINE AND RADIA T OR ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 81 1 ENGINE AND RADIA TOR ASSY . ENGINE AND RADIA T OR ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4923200034 ENGINE 1 1A 0602015230 F AN BEL T 1 1-1 RE504836 CARTRIDGE, OIL FIL TER .............................................. 1 .............. REPLA CES P/N 060204[...]

P A GE 82 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) ENGINE AND RADIA TOR ASSY . (CONT) ENGINE AND RADIA T OR ASSY . (CONT .)[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 83 1 ENGINE AND RADIA TOR ASSY . (CONT) ENGINE AND RADIA T OR ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 43 0605515199 HOSE BAND 3 44 M4310401004 INTER COOLER PIPE 1 45 M4310501303 INTER COOLER HOSE 1 46 M4310501003 INTER COOLER HOSE 1 47 M4310501403 INTER CO[...]

P A GE 84 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . ADD THE FOLLO WING DIGITS AFTER THE P ART NUMBER WHEN ORDERING ANY P AINTED P ANEL T O INDICA TE COLOR OF UNIT: 1-ORANGE 5-BLA CK 2-WHITE 6-CA TERPILLAR YELLO W 3-SPECTR UM GREY 7-CA [...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 85 1 OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M3230700113 TERMINAL BOARD 1 2 M9220100914 OUTPUT TERMINAL BOL T 5 3 M9220101004 TIE BOL T 5 4 0039320000 HEX. NUT 10 5 0040020000 LOCK W ASHER 15 6 0041420000 W ASHER, FLA T 20 7[...]

P A GE 86 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . ADD THE FOLLO WING DIGITS AFTER THE P ART NUMBER WHEN ORDERING ANY P AINTED P ANEL T O INDICA TE COLOR OF UNIT: 1-ORANGE 5-BLA CK 2-WHITE 6-CA TERPILLAR YELLOW 3-SPECTR UM GREY 7-CA T[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 87 1 OUTPUT TERMINAL ASSY . OUTPUT TERMINAL ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 25 M4260600104 BRA CKET , CIRCUIT BREAKER 1 25-1 022100150 R UBBER CUSHION 1 26 0019206020 HEX. HEAD BOL T 2 27 0601812538 RECEPT A CLE, 20A 2 28 0601812538 RECEPT A CLE, 5[...]

P A GE 88 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) BA TTER Y ASSY . BA TTER Y ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 89 1 BA TTER Y ASSY . BA TTER Y ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 0602220196 BA TTER Y 1 2 M9310500404 BA TTER Y SHEET 1 3 M9103000504 BA TTER Y SHEET 1 4 0602220921 BA TTER Y BOL T SET 2 5 M4346900304 BA TTER Y CABLE 1 6 M4346900204 BA TTER Y CABLE 1 7 CAB[...]

P A GE 90 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) MUFFLER ASSY . MUFFLER ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 91 1 MUFFLER ASSY . MUFFLER ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4330100502 MUFFLER 1 2 0016910025 HEX. HEAD BOL T 4 3 M4333000303 EXHA UST PIPE 1 4 0602325066 CLAMP 1 5 M4333200004 GASKET 1 6 0017112055 HEX. HEAD BOL T 4 7 M4330300004 CO VER 2 8 0016908020 H[...]

P A GE 92 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) FUEL T ANK ASSY . FUEL T ANK ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 93 1 FUEL T ANK ASSY . FUEL T ANK ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4363000102 FUEL T ANK 1 1-1 0605505070 CAP . FUEL T ANK 1 2 0605501069 FUEL SENDER UNIT 1 3 0605516090 GASKET 1 4 0027104016 MA CHINE SCREW 5 5 M4363200104 T ANK BAND 2 6 M9310500104 SUPPO[...]

P A GE 94 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) ENCLOSURE ASSY . ENCLOSURE ASSY . THE SERIAL NUMBER MA Y BE REQUIRED . ADD THE FOLLO WING DIGITS AFTER THE P ART NUMBER WHEN ORDERING ANY P AINTED P ANEL T O INDICA TE COLOR OF UNIT: 1-ORANGE 5-BLA CK 2-WHITE 6-CA TERPILLAR YELLO W 3-SPECTR UM GREY 7-CA T O GOLD 4-S[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 95 1 ENCLOSURE ASSY . ENCLOSURE ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 M4413000302 BASE 1 2 M1413400004 CO VER 1 3 0019208020 HEX. HEAD BOL T 2 4 M4423000312 FRONT FRAME 1 4A M4493102513 A COUSTIC SHEET 1 5 M4423000412 FRONT FRAME 1 5A M4493102513 A COUSTIC SHEE[...]

P A GE 96 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) ENCLOSURE ASSY . (CONT .) ENCLOSURE ASSY . (CONT .) THE SERIAL NUMBER MA Y BE REQUIRED . ADD THE FOLLO WING DIGITS AFTER THE P ART NUMBER WHEN ORDERING ANY P AINTED P ANEL T O INDICA TE COLOR OF UNIT: 1-ORANGE 5-BLA CK 2-WHITE 6-CA TERPILLAR YELLO W 3-SPECTR UM GREY[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 97 1 ENCLOSURE ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 28 0037906000 SELF-LOCKING U NUT 8 28A 0041206000 W ASHER, FLA T 8 29 M9113000002 DOOR HANDLE 1 30 0021806016 MA CHINE SCREW 4 30A 0030006000 HEX. NUT 4 31 M9110100204 HINGE 2 31A M9116100004 W ASHER 2[...]

P A GE 98 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) ENCLOSURE ASSY . (CONT .) ENCLOSURE ASSY . (CONT . ) THE SERIAL NUMBER MA Y BE REQUIRED . ADD THE FOLLO WING DIGITS AFTER THE P ART NUMBER WHEN ORDERING ANY P AINTED P ANEL T O INDICA TE COLOR OF UNIT: 1-ORANGE 5-BLA CK 2-WHITE 6-CA TERPILLAR YELLO W 3-SPECTR UM GRE[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 99 1 ENCLOSURE ASSY . (CONT .) NO . P AR T NO . P AR T NAME QTY . REMARKS 51 M4453001203 SIDE DOOR 1 51A M4493403804 ACOUSTIC SHEET 1 52 M4453001303 SIDE DOOR 1 52A M4493403904 ACOUSTIC SHEET 1 53 M4453001003 SIDE DOOR 1 53A M4493403004 ACOUSTIC SHEET 1 54 M4453001103 SIDE D[...]

P A GE 100 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) RUBBER SEALS ASSY . R UBBER SEALS ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 101 1 RUBBER SEALS ASSY . R UBBER SEAL ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 0229201240 R UBBER SEAL 4 2 0228900945 R UBBER SEAL 4 3 0228901200 R UBBER SEAL 3 4 0228901260 R UBBER SEAL 3 5 0228901055 R UBBER SEAL 4 6 0228900600 R UBBER SEAL 1 7 0228900660 R UBB[...]

P A GE 102 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) NAMEPLA TE AND DECALS ASSY . NAMEPLA TE AND DECALS ASSY .[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 103 1 NAME PLA TE ASSY . NO . P AR T NO . P AR T NAME QTY . REMARKS 1 0229201240 R UBBER SEAL 4 1-1 M4550000303 DECAL; OPERA TING PROCEDURES 1 M45000030 1-2 M9520100304 DECAL; SAFETY INSTR UCTIONS 1 M92010030 1-3 M9520100603 DECAL; CA UTION 2 M92010060 2-1 M3550002702 DECAL;[...]

P A GE 104 — DCA-180SSJU — OPERA TION AND P ARTS MANU AL — REV . #3 (02/01/10) TERMS AND CONDITIONS OF SALE — P ARTS P A YM ENT TERMS T erms of payment for par ts are net 30 days. FREIGHT P OLIC Y All parts orders will be shipped collect or prepaid with the c harges add ed to the invoice. All shipments are F . O.B. point of origin. Multiqui[...]

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 105 1 NOTES[...]

P AR TS AND OPERA TION MANUAL OPERA TION AND P ARTS MANUAL Y our Local Dealer is: HERE’S HOW TO GET HELP PLEASE HA VE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING © COPYRIGHT 2009, MUL TIQUIP INC. MQ P ow er and the MQ P ower logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permissi[...]