Multiquip DCA180SSJU User Manual

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Page 1

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWATT

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.com

Page 2

PROPOSITION 65 WARNING

PAGE 2 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 3

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. However, NHTSA cannot become involved in individual problems between you, your dealer, or Multiquip.

To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1-888327-4236 (TTY: 1-800-424-9153), go to http://www.nhtsa.dot.gov; or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

You can also obtain information about motor vehicle safety from http://www.safecar.gov.

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

Page 4

TABLE OF CONTENTS

MQ POWER DCA-180SSJUMQ POWER DCA-180SSJU

MQ POWER DCA-180SSJU

MQ POWER DCA-180SSJUMQ POWER DCA-180SSJU

TMTM

WHISPERWHISPER

WHISPER

WHISPERWHISPER GENERATORGENERATOR

GENERATOR

GENERATORGENERATOR

Proposition 65 Warning ........................................... 2

Reporting Safety Defects ........................................ 3

Table Of Contents .................................................... 4

Parts Ordering Procedures ..................................... 5

Specifications .......................................................... 6

Dimensions (Top, Side And Front)........................... 7

Safety Message Alert Symbols ............................ 8-9

Rules For Safe Operation ................................. 10-13

Generator Decals ............................................. 14-15

Installation ........................................................ 16-17

General Information .............................................. 18

Major Components ................................................ 19

Diagnostic Display............................................ 20-36

Generator Control Panel ....................................... 37

Engine Operating Panel ................................... 38-39

Output Terminal Panel Familiarization ............. 40-42

Load Application.................................................... 43

Generator Outputs ........................................... 44-45

Gauge Reading ..................................................... 45

Output Terminal Panel Connections ................ 46-47

Setup ................................................................ 48-51

Generator Start-Up Procedure (Manual) .......... 52-54

Generator Start-Up Procedure (Auto Mode) ......... 55

Generator Shut-Down Procedures ........................ 56

Maintenance (Engine) ...................................... 57-58

Maintenance (Heater/Charger) ............................. 59

Maintenance (Trailer) ....................................... 60-63

Trailer Wiring Diagram ........................................... 64

Generator Wiring Diagram .................................... 65

Engine Wiring Diagram ......................................... 66

Troubleshooting (Generator) ................................. 67

Troubleshooting (Engine Controller) ...................... 68

Explanation Of Code In Remarks Column ............ 70

Suggested Spare Parts ......................................... 71

TTTT

TMTM

COMPONENT DRACOMPONENT DRA

COMPONENT DRA

COMPONENT DRACOMPONENT DRA

Generator Assembly ........................................ 72-73

Control Panel Assembly .................................. 74-75

Control Box Assembly ..................................... 76-79

Engine And Radiator Assembly ....................... 80-83

Output Terminal Assembly ............................... 84-87

Battery Assembly ............................................. 88-89

Muffler Assembly.............................................. 90-91

Fuel Tank Assembly ......................................... 92-93

Enclosure Assembly........................................ 94-99

Rubber Seals Assembly ............................... 100-101

Nameplate And Decals Assembly ............... 102-103

Terms And Conditions Of Sale — Parts .............. 104

WINGSWINGS

WINGS

WINGSWINGS

PAGE 4 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 5

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

January 1

Effective:

, 2006

Best Deal!

Order via Internet (Dealers Only):

Order parts on-line using Multiquip’s SmartEquip website!

N View Parts Diagrams

N Order Parts N Print Speciﬁcation Information

Goto www.multiquip.com and click on

Order Par ts

Order via Fax (Dealers Only):

All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877)

Non-Dealer Customers: Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.

to log in and save!

Order via Phone:

If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip.

com.

To obtain an MQ Account, contact your District Sales Manager for more information.

Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*

Note: Discounts Are Subject To Change

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact their local Multiquip Representatives for Parts Ordering information.

R Dealer Account Number R Dealer Name and Address R Shipping Address (if different than billing address) R Return Fax Number R Applicable Model Number R Quantity, Part Number and Description of Each Part

www.mqpower.com

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 5

When ordering parts, please supply:

R Specify Preferred Method of Shipment: UPS/Fed Ex DHL

N Priority One Tr uck  N Ground N Next Day N Second/Third Day

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

Page 6

Table 1. Generator Specifications

Model DCA-180SSJU

SPECIFICATIONS

Type

Armature Connection

Phase

Standby Output

Prime Output

Vol ta ge

Frequency

Speed

Power Factor

Aux. AC Power

Vol ta ge

Output

Weight (No Fuel)

Weight (With Fuel)

Revolving field, self ventilated, open protected type synchronous

generator

Star with Nutreal

198 KVA (158 KW)

180 KVA (144 KW)

240V or 480V

60 Hz

1800 rpm

0.8

Single Phase, 60 Hz

120 V

4.8 KW (2.4 KW x 2)

6,571 lbs. (2,980 kg.)

7,489 lbs. (3,400 kg.)

Engine Specifications

Model

Type

No. of Cylinders

Bore x Stroke

Rated Output

Displacement

Starting

Fuel Tank Capacity

Coolant Capacity

Lube Oil Capacity

Fuel Consumption

Battery

Fuel

JOHN DEERE 6068HF485

4 Cycle, water-cooled, direct injection, turbo-charged,

air to air intercooled

6 cylinders

4.17 in. x 5 in. (106 mm x 127 mm)

286 HP/1800 rpm

415 cu. in. (6.8 liters)

Electric

100 gal. (380 liters)

6.34 gal. (24 liters)

8.69 gal. (32.9 liters)

11.4 gal. (43 L)/hr at full load 9.0 gal. (34.1 L)/hr at 3/4 load

6.6 gal. (25.1 L)/hr at 1/2 load 4.3 gal. (16.2 L)/hr at 1/4 load

12V 128 Ah

#2 Diesel Fuel

PAGE 6 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 7

Figure 1. Dimensions

DIMENSIONS (TOP, SIDE AND FRONT)

SNOISNEMID.3ELBAT

ecnerefeR

retteL

A).mm049(.ni00.73F ).mm005,3(.ni08.731

B).mm0

C).mm050,1(.ni33.14H ).mm042,1(.ni08.84

D).mm050,1(.ni33.14

E).mm050,1(.ni33.14

49(.ni00.73G ).mm007,1(.ni00.76

).mm(.tfnoisnemiDretteLecnerefeR).mm(.tfnoisnemiD

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 7

Page 8

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.

This Owner's Manual has been

NOTE

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words:

DANGER, WARNING, or CAUTION.

DANGER

You WILL be KILLED or SERIOUSLY injured if you do not follow directions.

developed to provide complete instructions for the safe and efficient operation of the MQ Power

HAZARD SYMBOLS

Potential hazards associated with the operation of this equipment will be referenced with " " which appear throughout this manual, and will be referenced in conjunction with Safety " ".

equipment in a confined area or enclosed structure that does not provide ample free flow air.

DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

WARNING - LETHAL EXHAUST GASES

Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause

if inhaled. NEVER operate this

WARNING - EXPLOSIVE FUEL

is extremely flammable, and its

vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.

WARNING

You COULD be KILLED or SERIOUSLY injured if you do not follow directions.

CAUTION

You CAN be injured if you do not follow directions

PAGE 8 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

WARNING - BURN HAZARDS

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.

DANGER - ELECTROCUTION HAZARDS

During operation of this generator, there exists the possibility of

which can cause

or even

Page 9

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. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

CAUTION - RESPIRATORY HAZARDS

ALWAYS wear approved

protection.

CAUTION - SIGHT AND HEARING HAZARDS

ALWAYS wear approved and

protection.

CAUTION - EQUIPMENT DAMAGE MESSAGES

Other important messages are provided throughout this manual to help prevent damage to your generator, other property, or the surrounding environment.

This generator, other property,

NOTE

or the surrounding environment could be damaged if you do not follow instructions.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 9

Page 10

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.

The operator MUST BE familiar with proper safety precautions and operations techniques before using generator.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other

■

ALWAYS check the machine for loosened threads or bolts before starting.

■

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

■

High Temperatures – Allow the engine to cool before performing service and maintenance functions. Contact with

components can cause serious

burns.

■

The engine of this generator requires an adequate free flow of cooling air. operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine gives off DEADLY carbon monoxide gas.

protective devices required by the job.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not recommended by MQ Power for this equipment. Damage to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

■

NEVER run engine without air filter. Severe engine damage may occur.

■

DO NOT leave the generator running in the unattended.

■

Refer to the for engine technical questions or information.

■

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

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

Page 11

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.

During operation of this generator, there exists the possibility of

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:

To avoid these hazards:

NEVER use damaged or worn cables when connecting equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output terminals, insufficient tightening of the terminal connections may cause damage to the generator

■

ALWAYS make sure generator is properly grounded.

■

NEVER use gas piping as an electrical ground.

■

ALWAYS make sure that electrical circuits are properly

per the (NEC) and

local codes before operating generator. Severe or

by electrocution can result from operating an

ungrounded generator.

■

ALWAYS be sure to use the ground terminal (green wire) when connecting a load to the U,V, and W output terminal lugs.

and electrical shock.

NEVER grab or touch a live power cord with wet hands.

NEVER touch output terminals during operation. This is extremely dangerous. ALWAYS stop the machine and place the circuit breaker in the OFF position when contact with the output terminals is required.

DANGER - ELECTROCUTION HAZARDS

which can cause

or even

WET

HANDS

POWER

CORD

(POWER ON)

Electrical Safety

■

ALWAYS have a qualified electrician perform the generator wiring installation.

■

ALWAYS make sure generator installation is accordance with the (NEC) and local codes before operating generator.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper extension cord has been selected for the job. See Table 6.

■

NEVER power cables or cords r.

■

NEVER while AC power from the generator is being transfer to a load.

Backfeed to a utility system can cause and or property damage. DO NOT connect to any building's electrical system except through an approved device or after building main switch is opened. ALWAYS have a licensed electrician perform the installation

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 11

Page 12

RULES FOR SAFE OPERATION

Maintenance 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.

■

NEVER lubricate components or attempt service on a running machine.

■

ALWAYS disconnect the before performing service on the generator.

■

Follow all Battery Safety Guidelines listed in this manual when handleing or servicing the generator.

■

ALWAYS allow the machine a proper amount of time to cool before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace broken parts.

■

ALWAYS service air cleaner frequently to prevent engine malfunction.

WARNING - BURN HAZARDS

To prevent burns, DO NOT touch or open any of the below mentioned components while the engine is running or immediately after operations. Always allow sufficient time for the engine and generator to cool before performing maintenance.

■

Radiator Cap - Removing the radiator cap while the

engine is hot will result in high pressurized, boiling water to gush out of the radiator, causing severe scalding to any persons in the general area of the generator.

■

Coolant Drain Plug - Removing the coolant drain plug

while the engine is hot will result in hot coolant gushing out of the coolant drain plug, therefore causing severe scalding to any persons in the general area of the generator.

Battery Safety

Use the following guidelines when handling the battery:

■

The battery contains acids that can cause injury to the eyes and skin. To avoid eye irritation, wear safety glasses.

■

Use well insulated gloves when picking up the battery.

DANGER - EXPLOSION HAZARDS

The risk of an explosion exists when performing service on the battery. To avoid or

■■

■

DO NOT drop the battery. There

■■

is the possibility of risk that the battery may explode.

■■

■

DO NOT expose the battery to

■■

open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur.

■■

■

ALWAYS keep the battery charged. If the battery is not

■■

charged a buildup of combustible gas will occur.

■■

■

ALWAYS keep battery charging and cables in good

■■

working condition. Repair or replace all worn cables.

■■

■

ALWAYS recharge the battery in an vented air

■■

environment, to avoid risk of a dangerous concentration of combustible gases.

■■

■

In case the battery liquid (dilute sulfuric acid) comes in

■■

contact with , rinse skin or clothing immediately with plenty of water.

■■

■

In case the battery liquid (dilute sulfuric acid) comes in

■■

contact with your , rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

■

Engine Oil Drain Plug - Removing the engine oil drain

plug while the engine is hot will result in hot oil gushing out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

PAGE 12 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 13

RULES FOR SAFE OPERATION

■

Towing & Transporting Safety

To reduce the possibility of an accident while transporting the generator on public roads, always make sure the trailer that supports the generator and the towing vehicle are in good operating condition and both units are mechanically sound.

The following list of safety precautions should be followed when towing your generator:

CAUTION - FOLLOW TOWING REGULATIONS

Check with your local county or state safety towing regulations, in addition to meeting

(DOT) , before

towing your generator.

■

ALWAYS shutdown engine before transporting.

■

Tighten both fuel tank caps securely.

■

If generator is mounted on a trailer, make sure trailer complies with all local and state safety transportation laws. Follow the listed guidelines for basic towing techniques.

■

Make sure the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating.”

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place underneath wheel to prevent rolling, while parked.

■

Use the trailer’s swivel jack to adjust the trailer height to a level position while parked.

■

Avoid sudden stops and starts. This can cause skidding, or jack-knifing. Smooth, gradual starts and stops will improve towing.

■

Avoid sharp turns.

■

Trailer should be adjusted to a level position at all times when towing.

■

Raise and lock trailer wheel stand in up position when transporting.

■

The maximum speed for highway towing is 55 MPH unless posted otherwise. Recommended off-road towing is not to exceed 15 MPH or less depending on type of terrain.

■

Place prevent tipping, while parked.

■

Avoid sharp turns to prevent rolling.

■

DO NOT transport generator with fuel in tank.

support blocks

underneath the trailer’s bumper to

■

ALWAYS inspect the hitch and coupling for wear. NEVER tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both towing vehicle and trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety Chain".

■

ALWAYS attach trailer’s safety chains to towing vehicle properly.

■

ALWAYS make sure the vehicle and trailer directional, backup, brake, and trailer lights are connected and working properly.

■

DOT Requirements include the following:



Connect and test electric brake operation.



Secure portable power cables in cable tray with tie wraps.

Emergencies

■

ALWAYS know the location of the nearest .

■

ALWAYS know the location of the nearest and .

■

ALWAYS know the location of the nearest phone or

in case of emergencies.

■

ALWAYS have easy access to the phone numbers of the nearest , and . This information will be invaluable in the case of an emergency.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 13

Page 14

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. #3 (02/01/10)

Page 15

GENERATOR DECALS

Figure 3. Generator Decals (Cont inued)

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 15

Page 16

INSTALLATION

Figure 4. Typical Generator Grounding Application

PAGE 16 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 17

INSTALLATION

Outdoor Installation

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.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION - EXHAUST HAZARD

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

Indoor Installation

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 National Electrical Code (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.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the

2. When grounding the generator (Figure 4) connect the

3. NEC article 250-52(c) specifies that the earth ground

generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger.

b. Aluminum - 8 AWG (8.4 mm

ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

rod should be buried a minimum of 8 ft. into the ground.

) or larger.

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Mounting

The generator must be mounted on a solid foundation (such as concrete) and set firmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the floor or grade level (in accordance to NFPA 110, Chapter 5-4.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

NOTE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 17

Page 18

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.

Engine Operating Panel

The “Engine Operating Panel” is provided with the following:

■■

Tachometer

■

■■

■

Water Temperature Gauge

■■

■

Oil Pressure Gauge

■■

Charging Ammeter Gauge

■

■■

■

Fuel Level Gauge

■■

■

Engine Speed Switch

■■

■

Auto ON/OFF Engine Controller (MPEC)

■■

■

Preheat Lamp

■■

■

Warning Lamp

■■

■

Emergency Stop Lamp

■■

■

Emergency Stop Button

■■

■

Diagnostic Gauge

■■

■

Panel Light/Panel Light Switch

■■

Generator Control Panel

The “Generator Control Panel” is provided with the following:

■■

■

Frequency Meter (Hz)

■■

■

AC Ammeter (Amps)

■■

■

AC Voltmeter (Volts)

■■

■

Ammeter Change-Over Switch

■■

■

Voltmeter Change-Over Switch

■■

■

Voltage Regulator

■■

■

3-Pole, 500 amp Main Circuit Breaker

■■

■

“Control Box” (located behind the Gen. Control Panel)

■■

■

Automatic Voltage Regulator

■■

■

Diagnostic Display

■■

■

Current Transformer

■■

■

Over-Current Relay

■■

■

Voltage Rectifer

■■

■

Starter Relay

■■

■

Engine Controller (Computer Controlled)

■■

■

Voltage Change-over Board

■■

Output Terminal Panel

The “Output Terminal Panel” is provided with the following:

■■

■

Three 120/240V output receptacles (CS-6369), 50A

■■

■

Three auxilliary circuit breakers, 50A

■■

■

Two 120V output receptacles (GFCI), 20A

■■

■

Two GFCI circuit breakers, 20A

■■

■

Five output terminal lugs (3Ø power)

■■

■

Battery Charger (Optional)

■■

■

Water Heater (Optional)

■■

Open Delta Excitation System

The DCA-180SSJU generator is equipped with the state of the art " " excitation system. The open delta system consist of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectified and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the configuration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a " " and responds according the demands of the required load.

Engine

The DCA-180SSJU is powered by a 6 cylinder, water cooled, direct injection, turbocharged

. This engine is designed to meet every performance requirement for the generator. Reference Table 1 for engine specifications.

In keeping with MQ Power's policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

Electric Governor System

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

Extension Cables

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 6) as a guide for selecting proper extension cable size.

PAGE 18 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 19

MAJOR COMPONENTS

Figure 5. Major Components

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DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 19

Page 20

3. Right Arrow Button – Press this button to scroll through

the screen either moving the parameter selection toward the right or downward.

4. Enter Key Button – Press this button to select the

parameter that is highlighted on the screen.

5. Emergency Stop LED – When lit (RED) indicates a

major fault has occured. This condition will shudown the generator.

6. Warning LED – When lit (AMBER), indicates a engine

parameter has exceeded its limits (minor fault). The generator will still run in this condition.

Figure 6. Diagnostic Display Panel

7. Display Screen – Graphical backlight LCD screen. Back

lighting is controlled via menu or external dimmer

The diagnostic display panel located inside the control box on the generator (Figure 6) is designed to meet the needs for instrumentation and control of electronically controlled engine communication using the SAEJ1939 Controller Area Network (CAN). This diagnostic display is a multifunction tool that enables equipment operators to view many different engine parameters and service codes.

The keypad on the diagnostic display panel is a capacitive touch sensing system. There are no mechanical switches to

potentiometer. The display can show either a single parameter or a quadrant display showing four parameters simultaneously.

8. Diagnostic Switch – When placed in the ON position,

will activate the diagnostic display panel.

9. CAN Diagnostic Connector – Controller Area Network

connector. This connector outputs diagnostic error codes. Connect a scanner or similar device into this

connector to read error codes. wear or stick. This keypad (display unit) will operate in extreme hot or cold weather conditions.

Other components in the system are microprocessor-based components for displaying critical engine data broadcast by an electronic engine or transmission’s Engine Control Unit (ECU): engine RPM, oil pressure, coolant temperature, system voltage, etc., and a combination audible alarm and relay unit for warning and shutdown annunciation.

The Engine Control Unit (ECU) used with this generator diagnosis engine faults that arise with the the engine control system and the engine itself. Engine faults can be determined by viewing the Diagnostic Trouble Codes (Active Fault Codes) which are displayed on the Diagnostic Display Panel. See the John Deere Engine Operator’s Manual for a complete listing of active fault codes and countermeasures.

The following definitions describe the controls and functions of the (Figure 6).

Display Parameters

The following are some of the engine and transmission parameters displayed on the diagnostic disply panel.

■■

■

Engine RPM’s

■■

■

Engine Hours

■■

■

System Voltage

■■

■

% Engine Load at current RPM

■■

■

Coolant Temperature

■■

■

Oil Pressure

■■

■

Fuel Economy

■■

■

Current Fuel Consumption

■■

■

Throttle Position

■■

■

Engine Manifold Air Temperature

■■

■

Active Service Codes

■■

■

Set Units for Display (English or Metric)

■■

■

English Configuration Parameters.

■■

DIAGNOSTIC DISPLAY

1. Menu Button – Press this button to enter or exit menu

screens.

2. Left Arrow Button– Press this button to scroll through

the screen either moving the parameter selection toward the left or upward.

PAGE 20 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 21

DIAGNOSTIC DISPLAY

First Time Start Up

1. When power is first applied to the diagnostic display, the “Logo” is displayed.

2. The “Wait to Start” message will be displayed for engines with a pre-startup sequence. Once the “Wait to Start” message is no longer displayed the operator may start the engine. Note: Displays only when SAE J1939 message is supported by engine manufacturer.

WAIT TO

START

PREHEAT

2. 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 CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

3. Touching the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down.

ADJUST BACKLIGHT

ADJUST CONTRAST UTILITIES

4. Touch the Arrows” to scroll to the desired menu item or

3. Once the engine has started the single engine

parameter is displayed.

3000

1500

1800 RPM

TEMP

ENG RPM

Main Menu Navigation

1. Starting at the single or four engine parameter display,

COOL

Selecting a Language

1. Starting at the main menu display use the “Arrows to

touch “Menu”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

touch “Menu” to exit the Main menu and return to the engine parameter display.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

scroll to the “Language” menu and once highlighted touch the “Enter” button.

GO TO 1-UP DISPLAY

LANGUAGES

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 21

Page 22

DIAGNOSTIC DISPLAY

2. The language choices will be displayed. Use the “Arrow” buttons to scroll through the selections and touch “Enter” to make a selection.

ENGLISH

ESPANOL FRANCAIS DEUTSCH

3. Now that you have selected the language, touch the “Menu” button to return to the main menu display.

Stored Fault Codes

1. Starting at the single or the four engine parameter display touch the “Menu button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

3000

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

4. 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.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

5. Touch the “Menu Button to return to the main menu.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

6. Touch the “Menu Button” to exit the Main menu and return to the engine parameter display.

2. The main menu will pop up on the display. Use the

“Arrow Buttons” to scroll through the menu until the Stored Fault Codes is highlighted.

GO TO 1-UP DISPLAY

STORED CODES

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

3. Once the “Stored Fault Codes” menu item has been highlighted touch the “Enter Button” to view the “Stored Fault Codes” (when applicable, consult engine or transmission manufacturer for SAE J1939 supported parameters).

GO TO 1-UP DISPLAY

STORED CODES

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

Engine Configuration Data

1. Starting at the single or four engine parameter display touch the “Menu Button”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

PAGE 22 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 23

DIAGNOSTIC DISPLAY

First Time Start Up

1. When power is first applied to the diagnostic display, the “Logo” is displayed.

WAIT TO

START

PREHEAT

2. 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 CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

3. Touching the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down.

ADJUST BACKLIGHT

ADJUST CONTRAST UTILITIES

4. Touch the Arrows” to scroll to the desired menu item or

3. Once the engine has started the single engine

parameter is displayed.

3000

1500

1800 RPM

TEMP

ENG RPM

Main Menu Navigation

1. Starting at the single or four engine parameter display,

COOL

Selecting a Language

1. Starting at the main menu display use the “Arrows to

touch “Menu”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

touch “Menu” to exit the Main menu and return to the engine parameter display.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

scroll to the “Language” menu and once highlighted touch the “Enter” button.

GO TO 1-UP DISPLAY

LANGUAGES

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 23

Page 24

DIAGNOSTIC DISPLAY

2. The language choices will be displayed. Use the “Arrow” buttons to scroll through the selections and touch “Enter” to make a selection.

ENGLISH

ESPANOL FRANCAIS DEUTSCH

3. Now that you have selected the language, touch the “Menu” button to return to the main menu display.

Stored Fault Codes

1. Starting at the single or the four engine parameter display touch the “Menu button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

3000

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

4. 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.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

5. Touch the “Menu Button to return to the main menu.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

6. Touch the “Menu Button” to exit the Main menu and return to the engine parameter display.

2. The main menu will pop up on the display. Use the

“Arrow Buttons” to scroll through the menu until the Stored Fault Codes is highlighted.

GO TO 1-UP DISPLAY

STORED CODES

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

GO TO 1-UP DISPLAY

STORED CODES

ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

Engine Configuration Data

1. Starting at the single or four engine parameter display touch the “Menu Button”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

PAGE 24 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 25

DIAGNOSTIC DISPLAY

2. The main menu will pop up on the display. Use the “Arrow Buttons” to scroll through the menu until the “Engine Configuration” menu item has been highlighted.

GO TO 1-UP DISPLAY STORED CODES

ENGINE CONFG

SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

3. Once the “Engine Configuration” menu item has been highlighted touch the “Enter Button” to view the engine configuration data.

GO TO 1-UP DISPLAY STORED CODES

ENGINE CONFG

SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

FAULTS AND WARNINGS

Auxiliary Gage Fault

1. During normal operation the single or four parameter screen will be displayed.

1000 RPM

1500

1800 RPM

ENG RPM

COOL

3000

TEMP

98%

LOAD RPM

14.2

BATTVOLT

ENG RPM

57 PSI

OIL PRES

2. The PVA Series of auxiliary gages can be attached to the PowerView. These auxiliary gages communicate with the Modbus master PowerView via a daisy-chained RS-485 port. If at any time during system initialization or normal operation an auxiliary gage should fail, the single or four parameter screen will be replaced with the “MLink Gage Fault” message.

4. Use the “Arrow Buttons” to scroll through the engine configuration data.

ENGINE SPEED PT 1

1800 RPM

3. To acknowledge and “Hide” the fault and return to the

5. Touch the “Menu Button” to return to the main menu.

ENGINE SPEED PT 1

1800 RPM

4. The display will return to the single or four parameter

6. Touch the “Menu Button” to exit the Main menu and return to the engine parameter display.

1ofx

ENGINE OIL PRESSURE

GAGE NOT RESPONDING

HIDE

single or four parameter display, touch the “Enter Button”.

1ofx

ENGINE OIL PRESSURE GAGE NOT RESPONDING

HIDE

screen.

1500

1800 RPM

ENG RPM

COOL

3000

TEMP!

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 25

Page 26

DIAGNOSTIC DISPLAY

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.

1ofx

ENGINE OIL PRESSURE GAGE NOT RESPONDING

HIDE

Active Fault Codes

1. During normal operation the single or four parameter screen will be displayed.

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

4. To acknowledge and “Hide” the fault and return to the single or four parameter display touch the “Enter Button”.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

5. The display will return to the single or four parameter display but the display will contain the “Active Fault” warning icon. Touching the “Enter Button” will redisplay the hidden fault.

1500

1800 RPM

ENG RPM

COOL

3000

TEMP!

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

6. Touching the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display.

2. When the PowerView receives a fault code from an engine control unit the single or four parameter screen will be replaced with the “Active Fault Codes” message.

1ofx

WARNING

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

3. If the word “MORE” appears above the “Arrow Buttons”, there are more active fault codes that may be viewed. Use the “Arrow Buttons” to scroll to the next “Active Fault Code”.

1ofx

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

1ofx

WARNING

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

7. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

PAGE 26 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 27

GO TO 1-UP DISPLAY STORED CODES

GENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

ADJUST BACKLIGHT

DIAGNOSTIC DISPLAY

Shut Down Codes

1. During normal operation the single or four parameter screen will be displayed.

1500

1800 RPM

ENG RPM

COOL

TEMP

98%

3000

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

2. When the diagnostic display receives a severe fault code from an engine control unit the single or four parameter screen will be replaced with the “Shutdown” message.

1ofx

SHUTDOWN

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

5. Touching the “Enter Button” once again will hide the fault and return the screen to the single or four parameter display.

1ofx

SHUTDOWN

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

6. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage.

1500

1800 RPM

ENG RPM

COOL

3000

TEMP!

LOAD RPM

14.2

BATTVOLT

98%

1000 RPM

ENG RPM

57 PSI

OIL PRES

3. To acknowledge and “Hide” the fault and return to the single or four parameter display touch the “Enter Button”.

1ofx

SHUTDOWN

SPN110 FMI10

HIGH COOLANT TEMP

HIDE

4. The display will return to the single or four parameter display, but the display will contain the “Shut Down” icon. Touching the “Enter Button” will redisplay the hidden fault.

1500

1800 RPM

ENG RPM

COOL

3000

TEMP!

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

Backlight Adjustment

1. Starting at the single or four engine parameter display touch the “Menu Button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

98%

3000

LOAD RPM

14.2

BATTVOLT

ENG RPM

57 PSI

OIL PRES

1000 RPM

2. The main menu will pop up on the display. Use the “Arrow Buttons” to scroll through the menu until the “Adjust Backlight” is highlighted.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 27

Page 28

DIAGNOSTIC DISPLAY

3. Once the “Adjust Backlight” menu item has been highlighted touch the “Enter Button” to activate the “Adjust Backlight” function.

GO TO 1-UP DISPLAY STORED CODES

SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS

ADJUST BACKLIGHT

GENGINE CONF

4. Use the “Arrow Buttons” to select the desired backlight intensity.

ADJUST BACKLIGHT

5. Touch the “Menu Button” to return to the main menu.

Contrast Adjustment

1. Starting at the single or four engine parameter display, touch the “Menu Button”.

1000 RPM

1500

1800 RPM

ENG RPM

COOL

3000

TEMP

98%

LOAD RPM

14.2

BATTVOLT

ENG RPM

57 PSI

OIL PRES

2. The main menu will pop up on the display. Use the “Arrow Buttons” to scroll through the menu until “Adjust Contrast” is highlighted.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

ADJUST BACKLIGHT

6. Touch the “Menu Button” to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

3. Once the “Adjust Contrast” menu item has been highlighted touch the “Enter Button” to activate the “Adjust Contrast” function.

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

ADJUST CONTRAST

4. Use the “Arrow Buttons” to select the desired contrast intensity.

ADJUST CONTRAST

5. Touching the “Menu Button” will take you back through the menus.

PAGE 28 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 29

DIAGNOSTIC DISPLAY

Select Units

5. Touch the “Enter Button” to select the highlighted units.

1. Starting at the single or four engine parameter display touch the “Menu Button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

98%

3000

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

6. Touch the “Menu Button” to return to the “Main Menu”.

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.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY

SELECT UNITS

ADJUST BACKLIGHT

7. Touch the “Menu Button” to exit the Main menu and

3. Once the “Select Units” menu item has been highlighted touch the “Enter Button” to access the “Select Units” function.

ENGLISH

METRIC KPA METRIC BAR

ENGLISH

METRIC KPA METRIC BAR

return to the engine parameter display.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

GO TO 1-UP DISPLAY STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY

SELECT UNITS

ADJUST BACKLIGHT

4. Use the arrows to highlight the desired units. “English” for imperial units i.e. PSI,”F or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, “C.

ENGLISH

ESPANOL FRANCAIS DEUTSCH

Setup 1- Up Display

1. Starting at the single engine parameter display, touch the “Menu Button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

98%

3000

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

2. The main menu will pop up on the display. Use the “Arrow Buttons” to scroll through the menu until the “Setup 1-up Display” is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONF

SETUP 1-UP DISPLAY

SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 29

Page 30

DIAGNOSTIC DISPLAY

3. Once the “Setup 1-up Display” menu icon has been

7. A message indicating the “Single Engine” parameter highlighted touch the “Enter Button” to access the “Setup 1-up display” function.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONF

SETUP 1-UP DISPLAY

SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

4. Three options are available for modification of the 1-Up display.

8. Custom Setup- To perform a custom setup of the 1-Up

a). Use defaults- This option contains a set of engine

parameters: Engine Hours, Engine RPM. System Voltage, Battery Voltage, % Engine Load at Current RPM, Coolant Temperature, Oil Pressure.

b). Custom Setup- This option allows for the

modification of what parameter, the number of parameters, and the order in which the parameters are being displayed.

display parameters are reset to the factory defaults will be displayed, then the display will return to the “Custom Setup” menu.

RESTORED TO

DEFAULTS

Display, use the arrow buttons to scroll to and highlight “Custom Setup” on the display.

USE DEFAULTS

CUSTOM SETUP

AUTOMATIC SCAN OFF

c). Automatic scan - Selecting the scan function will

cause the 1-Up Display to scroll through the selected set of parameters one at a time, momentarily pausing at each.

5. Use Defaults- To select “Use Defaults” use the arrow buttons to scroll to and highlight “Use Defaults” in the menu display.

USE DEFAULTS

CUSTOM SETUP AUTOMATIC SCAN OFF

6. Touch the “Enter Button” to activate the “Use Defaults” function.

USE DEFAULTS

CUSTOM SETUP AUTOMATIC SCAN OFF

9. Touching the “Enter Button” will display a list of engine parameters.

USE DEFAULTS

CUSTOM SETUP

AUTOMATIC SCAN OFF

10. Use the “Arrow Buttons” to scroll to and highlight a selected parameter (parameter with a # symbol to right of it).

ENGINE SPEED

PERCENT LOAD ATCURRENT RPM ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE

3 2

This number indicates the order of display for the parameters and that the parameter is selected for display.

PAGE 30 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 31

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 displayed on the 1-up display.

ENGINE SPEED

PERCENT LOAD ATCURRENT RPM ENGINE OIL PRESSURE ENGINE COOLANT TEMPERATURE

3 2

17. Touching the “Enter Button” again toggles the “Automatic

12. Use the “Arrow Button” to scroll and highlight the desired parameter that has not been selected for display.

ENGINE SPEED PERCENT LOAD ATCURRENT RPM ENGINE OIL PRESSURE

ENGINE COOLANT TEMPERATURE

2 1

Note that the numbers now indicate the new order of display for the parameters.

18. Once the “Use Defaults”, “Custom Setup” and

13. Touch the “Enter Button” to select the highlighted parameter for inclusion in the Single Engine Parameter Display.

Scan” function on.

USE DEFAULTS CUSTOM SETUP

AUTOMATIC SCAN ON

Scan” function off.

USE DEFAULTS CUSTOM SETUP

AUTOMATIC SCAN OFF

“Automatic Scan” functions have been set touch the “Menu Button” to return to the main menu.

ENGINE SPEED PERCENT LOAD ATCURRENT RPM ENGINE OIL PRESSURE

ENGINE COOLANT TEMPERATURE

2 1

19. Touch the “Menu Button” to exit the Main menu and

14. Continue to scroll and select additional parameters for

return to the engine parameter display. the custom 1-up Display. Touch the “Menu Button” at any time to return to the “Custom Setup” menu.

15. Automatic Scan- Selecting the scan function will cause the 1-Up Display to scroll through the selected set of

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

parameters one at a time. Use the “Arrow Buttons” to scroll to the “Automatic Scan” function.

USE DEFAULTS CUSTOM SETUP

AUTOMATIC SCAN OFF

USE DEFAULTS CUSTOM SETUP

AUTOMATIC SCAN ON

1800 RPM

ENG RPM

1500

COOL

3000

TEMP

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 31

Page 32

DIAGNOSTIC DISPLAY

Setup 4-Up Display

1. From the single or four engine parameter display touch the “Menu Button”.

1500

1800 RPM

ENG RPM

COOL

TEMP

3000

98%

LOAD RPM

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

2. The main menu will pop up on the display. Use the “Arrow Buttons” to scroll through the menu until the “Setup 4-Up Display” is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY

SETUP-4-UP DISPLAY

SELECT UNITS ADJUST BACKLIGHT

3. Once the “Setup 4-Up Display” menu item has been highlighted touch the “Enter Button” to activate the “Setup 4- Up Display” menu.

5. The “Use Defaults” screen will be displayed during the resetting period then will automatically return to the “Setup 4- Up Display” menu.

RESTORED TO

DEFAULTS

6. Select the “4-Up Custom Setup” from the “4-Up Setup” menu.

USE DEFAULTS

CUSTOM SETUP

7. The quadrant with the backlit parameter value is the current selected parameter. Use the “Arrow Buttons” to highlight the parameter value in the quadrant you wish to place a new parameter.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY

SETUP-4-UP DISPLAY

SELECT UNITS ADJUST BACKLIGHT

4. Touch the “Enter Button” to activate the “Use Defaults” function. This action will reset the unit to the factory default.

USE DEFAULTS

CUSTOM SETUP

USE DEFAULTS

CUSTOM SETUP

8. Touch the “Enter Button” and a list of parameters will

appear.

125°F

COOL TEMP

14.2

BATTVOLT

1000 RPM

ENG RPM

57 PSI

OIL PRES

PAGE 32 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 33

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.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERYPOTENTIAL

ENGINE OIL TEMPERATURE

ENGINE OIL PRESSURE

The number to the right

of the parameter indicates the quadrant in which it

is displayed. 1= Upper Left Quadrant

2 = Lower Left Quadrant 3 = Upper Right Quadrant 4 = Lower Right Quadrant

15. Touch the “Menu Button” to exit the Main menu and

return to the engine parameter display.

10. Touch the “Enter Button” to change the selected parameter in the quadrant to the new parameter.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERYPOTENTIAL

ENGINE OIL TEMPERATURE

ENGINE OIL PRESSURE

1 2

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY

SETUP-4-UP DISPLAY

SELECT UNITS ADJUST BACKLIGHT

Utilities

1. Starting at the single or four engine parameter display,

11. Use the “Menu Button” to return to the “4-Up Custom

touch the “Menu Button”.

Setup” screen.

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERYPOTENTIAL

ENGINE OIL TEMPERATURE

ENGINE OIL PRESSURE

Note the number to the right of the selected parameter indicating that the parameter is now assigned to that display location

2. The main menu will be displayed. Use the “Arrow Buttons”

12. The parameter in the selected quadrant has changed to the parameter selected in the previous screen.

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

3. Once the “Utilities” menu item has been highlighted, touch

13. Repeat the parameter selection process until all spaces are filled.

1500

1800 RPM

ENG RPM

COOL

TEMP

3000

125°F

COOL TEMP

143°F

OIL TEMP

1000 RPM

ENG RPM

57 PSI

OIL PRES

to scroll through the menu until the “Utilities” is highlighted.

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

UTILITIES

the “Enter Button” to activate the “Utilities” functions.

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

UTILITIES

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 33

Page 34

DIAGNOSTIC DISPLAY

4. Touch “Select” to enter the “Gage Data” display. When

8. When the gage data has cleared, the display “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.

GAGE DATA

REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP FAULTCONVERSION ADJUST BACKLIGHT DEMO MODE ON

9. Touch “Menu” to return to “Utilities”. Highlight Fault

5. Use the “Arrow Buttons” to scroll through the items or touch “Menu” to return to the “Utilities” menu.

1ofx

ENGINE OIL PRESSURE

ADDRESS:20 SOFTWARE REVISION #: ERRORS: NONE

automatically returns to the “Utilities” menu. Scroll to “Software Version”. Touch “Select” to view the software version currently in the diagnostic display.

SOFTWARE

VERSION

MURPHY: X.XX

Conversion” using the “Arrows”. Touch “Select” to enter the Fault conversion menu.

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION

FAULT CONVERSION

6. Touch “Menu Button” to return to the “Utilities” menu.

1ofx

ENGINE OIL PRESSURE

ADDRESS:20 SOFTWARE REVISION #: ERRORS: NONE

7. Use the “Arrows” to highlight Remove All Gages”. Touch “Select” to clear gage data from memory. It takes a moment to clear all gages.

CLEARING GAGES

PLEASE WAIT

10. Use the “Arrows” to scroll to and highlight the desired version then touch “Select”. An asterisk denotes which version is currently selected.

NOTE: There are four (4) different methods for converting fault codes. The diagnostic display always looks for J1939 Version 4 and can be set to read the code as one of three (3) other J1939 versions if Version 4 is not being used. Most engine ECU’s use Version 4, therefore in most cases adjustment of this menu option will not be required.

Upon receiving an unrecognizable fault, change to a different J1939 Version. If the fault SPN does not change when the version is changed, the ECU generating the fault is using Fault Conversion method 4. If the SPN number does not change but is still unrecognizable, try changing to another J1939 Version not yet used and continue to check the SPN number.

J1939 VERSION 1

J1939 VERSION 2 J1939 VERSION 3

PAGE 34 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 35

DIAGNOSTIC DISPLAY

11. Touch the “Menu” button to return to “Utilities” menu. Touch the “Menu button again to return to the “Main” menu.

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

UTILITIES

MODBUS SETUP

1. Starting at the single or four engine parameter display, touch the “Menu Button”.

3000

1500

98%

LOAD RPM

1000 RPM

ENG RPM

1800 RPM

ENG RPM

COOL

TEMP

14.2

BATTVOLT

57 PSI

OIL PRES

2. The main menu will be displayed. Use the “Arrow Buttons” to scroll through the menu until the “Utilities” is highlighted, then touch “Enter”.

4. 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

5. Use the “Arrows” to scroll to the “Serial Port” menu to highlight it, then touch “Enter”.

USE FACTORY DEFAULT

SERIAL PORT SETUP

SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE

6. Use the “Arrow” button to scroll to each selection to configure the MODBUS values for your application.

STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP-4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

UTILITIES

3. Once in the “Utilities” menu use the “Arrows” to scroll through the menu until the “Modbus Setup” menu is highlighted, then touch “Enter”.

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION

MODBUS SETUP

FAULTCONVERSION

BAUD RATE

PARITY

DATA BITS STOP BITS

7. When finished, touch “Menu” to return to the previous screen.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 35

Page 36

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.

EMPTY

No parameter selected for this 4- UP quadrant.

WAIT TO START PREHEATING

This is a message from the engine indicating it is in a preheating cycle.

Wait until this message clears before starting the engine.

TIMEOUT ECU NOT RESPONDING

The ECU did not respond to the PowerView request.

NO GAGE DATA

The Diagnostic Display has no record of connected gages to the RS485 bus.

DISPLAY NOT VISIBLE

Press and hold the “Menu” button for approximately 3 seconds.

PAGE 36 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 37

GENERATOR CONTROL PANEL

OFF

V-W

OFF

DECREASE

W-U

Located behind the generator control panel is the

INCREASE

U-V

Figure 7. Generator Control Panel

The definitions below describe the controls and functions of the DCA-180SSJU (Figure 7).

1. Frequency Meter – Indicates the output frequency in

hertz (Hz). Normally 60 Hz.

2. AC Ammeter – Indicates the amount of current the load

is drawing from the generator per leg selected by the ammeter phase-selector switch.

3. Ammeter Change-Over Switch – This switch allows

the AC ammeter to indicate the current flowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the

electronic components required to make the generator function.

The Control Box is equipped with the following major components:

■■

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

generator output in any fashion, it is for current reading only.

4. Voltage Regulator Control – Allows ±15% manual

adjustment of the generator’s output voltage.

5. AC Voltmeter – Indicates the output voltage present at

the .

In the event of a short circuit or over current condition, it will

6. Voltmeter Change-Over Switch – This switch allows

automatically trip the 500 amp main breaker.

the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to

To restore power to the , press the

be switched off.

circuit breaker in the position (ON).

7. Main Circuit Breaker – This three-pole, 500A main

breaker is provided to protect the the

from overload.

. This box contains some of the necessary

Over-Current Relay Voltage Rectifer (AVR) Starter Relay Current Transformer Voltage Selector Switch Three Phase Circuit Breaker

Remember the

NOTE

button on the overcurrent relay and place the

monitors the current

flowing from the

load.

to the

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 37

Page 38

The definitions below describe the controls and functions of the DCA-180SSJU (Figure 8).

ENGINE OPERATING PANEL

AUTO

MANUAL

OFF/RESET

LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK

OVERSPEED ENGINE RUNNING

MOOOOO-20001Q

Figure 8. Engine Operating Panel

1. Panel Light – Normally used in dark areas or at night

time. When activated, panel lights will illuminate. When the generator is not in use be sure to turn the panel light switch to the OFF position.

2. Panel Light Switch – When activated will turn on control

panel light.

3. Oil Pressure Gauge – During normal operation this

gauge be should read between 35 to 65 psi. (241~448 kPa). When starting the generator the oil pressure may read a little higher, but after the engine warms up the oil pressure should return to the correct pressure range.

4. Water Temperature Gauge – During normal operation

this gauge be should read between 180° and 230°F. (82° C and 110° C

PAGE 38 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

5. Charging Ammeter Gauge – Indicates the current

being supplied by the engine’s alternator which provides current for generator’s control circuits and battery charging system.

6. Fuel Gauge - Indicates amount of diesel fuel available.

7. Tachometer – Indicates engine speed in RPM’s for 60

Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied. In addition a built in hour meter will record the number of operational hours that the generator has been in use.

8. Engine Speed Switch – This switch controls the speed

of the engine (low/high).

Page 39

ENGINE OPERATING PANEL

9. Pre-Heat Lamp – When lit, indicates engine is in the

pre-heating mode (for starting during cold weather operating conditiions). When lamp goes off engine is ready for starting.

10. Warning Lamp – This lamp will illuminate when a critical

engine fault has occured.

11. Emergency Stop Lamp – This lamp will illuminate when

the emergency stop button has been pressed or a critical engine fault has occured.

12. Diagnostic Display – This display monitors crtical

engine functions. If any abnormal conditions occur, an Active Fault Code will be displayed. This diagnostic display can be located inside the control box.

13. Auto On/Off Engine Controller (MPEC) –

This controller has a vertical row of status LED's (inset), that when lit, indicate that an engine malfunction (fault) has been detected. When a fault has been detected the engine controller will evaluate the fault and all major faults will shutdown the generator. During , The MPEC will attempt to crank the engine for 10 seconds before disengaging.

A. MPEC Control Switch – This switch controls the

B. Low Oil Pressure – Indicates the engine pressure has

C. High Coolant Temperature – Indicates the engine

running of the unit. If this switch is set to the OFF/RESET position, the unit will not run. When this switch is set to the MANUAL position, the generator will start immediately.

If the generator is to be connected to a building’s AC power source via an automatic transfer switch (isolation), place the switch in the AUTO position. In this position, should an outage occur, the automatic transfer switch (ATS) will start the generator automatically via the generator’s auto-start contacts connected to the ATS’s start contacts. Please refer to your ATS installation manual for further instructions for the correct installation of the auto-start contacts of the generator to the ATS.

fallen below 15 psi. The oil pressure is detected using variable resistive values from the oil pressure sending unit. This is considered a fault.

temperature has exceeded 239 temperature is detected using variable resistive values from the temperature sending unit. This is considered a fault.

F. The engine

14. Emergency Stop Button – In the event of an

emergency, press this button to shutdown the generator.

If the engine does not engage (start) by the third attempt, the engine will be shutdown by the engine controller’s

mode. If the engine engages at a speed (RPM's) that is not safe, the controller will shutdown the engine by initializing the mode.

Also the engine controller will shut down the engine in the event of low oil pressure, high coolant temperature, low coolant level, and loss of magnetic pickup. These conditions can be observed by monitoring the LED status indicators on the front of the controller module.

D. Overcrank Shutdown – Indicates the unit has

attempted to start a pre- programmed number of times, and has failed to start. The number of cycles and duration are programmable. It is pre-set at 3 cycles with a 10 second duration. This is considered a fault.

E. Overspeed Shutdown – Indicates the engine is

running at an unsafe speed. This is considered a fault.

F. Engine Running – Indicates that engine is running at

a safe operating speed.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 39

Page 40

OUTPUT TERMINAL PANEL FAMILIARIZATION

Output Terminal Panel

The (Figure 9) shown below is located on the right-hand side (left from control panel) of the generator. Lift up on the cover to gain access to receptacles

Output Terminal Familiarization

The “ ” (Figure 9) is provided with the following:

■■

■

Three (3) 120/240V output receptacles @ 50 amp

■■

and terminal lugs.

■■

■

Three (3) Circuit Breakers @ 50 amps

■■

Two (2) 100V GFCI receptacles @ 20 amp

■

■■

Two (2) GFCI Circuit Breakers @ 20 amps

■

■■

■

Five (5) Output Terminal Lugs ( U, V, W, O, Ground)

■■

NOTE

Terminal legs “O” and “Ground” are considered

Figure 9. Output Terminal Panel

PAGE 40 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 41

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

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.

Pressing the button resets the GFCI receptacle after being tripped. Pressing the (See Figure 10) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

any

Each auxilliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the

Turn the (Figure 12) on the control panel to obtain the desired voltage. Turning the knob clockwise will the voltage, turning the knob counter-clockwise will the voltage.

Figure 12. Voltage Regulator Control Knob

Removing the Plastic Face Plate (Hard Wire Hookup Panel)

The are protected by a plastic face plate cover (Figure 13). Un-screw the securing bolts and lift the plastic terminal cover to gain access to the terminal enclosure.

Figure 10. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 240/139V, 50 amp auxilliary twist-lock (CS-6369) recepacles (Figure 11) provided on the output terminal panel.These receptacles can be accessed when the voltage change-over board is configured for

Figure 11. 240/139V Twist-Lock

Auxiliary Receptacles

After the load wires have been securely attached to the terminal lugs, reinstall the plastic face plate.

Figure 13. Plastic Face Plate (Output Terminal

Lugs)

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 41

Page 42

OUTPUT TERMINAL PANEL FAMILIARIZATION

Connecting Loads

Loads can be connected to the generator by the

or the convienience receptacles (Figure 14). Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 500A circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Over Current Relay

An (Figure 15) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the on the over current relay must be pressed. The over current relay is located in the control box.

Figure 15. Over Current Relay

Figure 14. Connecting Loads

PAGE 42 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 43

LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage,

frequency

Three Phase Load

When calculating the power requirements for 3-phase power use the following equation:

, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130— 150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and starting system of the equipment.

If wattage is not given on the equipment's name plate,

NOTE

approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 5 below when connecting loads.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out

daoLyBrotcaFrewoP.5elbaT

the appliance or tool and overheat the cable. See Table 6.

NOTE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load output maybe determined by multiplying voltage by amperage by 1.732.

Motors and motor-driven equipment draw much greater current for starting than during operation.

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■■

■

When connecting a resistance load such as an

■■

incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

■■

■

When connecting a fluorescent or mercury lamp, a

■■

capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

■■

■

When connecting an electric drill or other power tools,

■■

pay close attention to the required starting current capacity.

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When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a must install an

. Serious damage to the building’s

electrical system may occur without this transfer switch.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 43

Page 44

GENERATOR OUTPUTS

Generator Output Voltages

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by apply-

Maximum Amps

Table 8 shows the amps the generator can provide. 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 below) will require a fine adjustment using the

(VR) located on the control panel.

Voltage Change-Over Board

The (Figure 16) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection.

Table 8. Generator Maximum Amps

Rated Voltage Maximum Amps

Single Phase

120 Volt

Single Phase

240 Volt

Three Phase

240 Volt

Three Phase

480 Volt

400 amps (4 wire)

200 amps (4 wire)

433 amps

216 amps

Figure 16. Voltage Change-Over Board

CAUTION - CHANGING VOLTAGES

NEVER attempt to place jumper plates on the

while the generator is in operation.

There exist the possibility of

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PAGE 44 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 45

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

AC Ammeter Gauge Reading

Place the (Figure 20) to the U position and observe the current reading (load drain) on the U terminal as indicated on the (Figure 21). This process can be repeated for terminals V and W.

flowing to the load at the UVWO output terminals lugs.

Observe that the voltage change-over board (Figure 17) has been configured for 3Ø, 240V operation.

Figure 20. AC

Change-Over Switch

Ammeter

Figure 21. AC Ammeter

(Amp reading on U lug)

Figure 17. Change-Over Board

(3Ø 240V Configuration)

AC Voltmeter Gauge Reading

Place the (Figure 18) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the

(Figure 19).

Figure 18. AC

Voltmeter

Change-Over Switch

Figure 19. AC Voltmeter

Gauge

(Volt reading on W-U Lug)

NOTE

The gauge will only show a reading when the

are

connected to a load and in use.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 45

Page 46

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

of the output voltage and can be configured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V configuration. The voltage regulator (VR) allows the user to increase or decrease the selected

1Ø-240V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 22.

2. Connect the load wires to the UVWO terminals as shown in Figure 25.

voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 22.

Figure 22. Voltage Change-Over Board

240V Configuration

1Ø-120V UVWO Terminal Output Voltages

2. Connect the load wires to the UVWO terminals as shown in Figure 23.

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 22.

Figure 25. UVWO Terminal Lugs

1Ø-240V Connections

Figure 23. UVWO Terminal Lugs

3Ø-240V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever fine tuning of the output voltage is required

PAGE 46 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

2. Connect the load wires to the UVWO terminals as shown in Figure 26.

Figure 26. UVWO Terminal Lugs

1Ø-120V Connections

Page 47

OUTPUT TERMINAL PANEL CONNECTIONS

3Ø-480 UVWO Output Terminal Voltages

1. Jumper the voltage change-over board for 480V operation as shown in Figure 27. This configuration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used.

Figure 27. Voltage Change-Over Board

480V Configuration

2. Connect the load wires to the as shown in Figure 28.

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 27.

2. Connect the load wires to the as shown in Figure 29.

Figure 29. UWVO Output Terminal Lugs

1Ø-480V Connections

1Ø-277V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 27.

Figure 28. Output Terminal Lugs

3Ø-480V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

ALWAYS make sure that the connections to the UWVO terminals are secure and tight. The possibility of arcing exists, which could cause a fire

2. Connect the load wires to the as shown in Figure 30.

Figure 30. UWVO Output Terminal Lugs

1Ø-277V Connections

3. Turn the voltage regulator knob (Figure 24) clockwise to increase voltage output, turn counterclockwise to decrease voltage output.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 47

Page 48

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

DANGER - EXPLOSION/FIRE HAZARDS

Fuel spillage on a engine can cause a or

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

completely to prevent fire hazards. NEVER smoke around or near the generator.

auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

Lubrication Oil

Fill the engine crankcase with lubricating oil through the filler hole, but DO NOT overfill. Make sure the generator is level. and verify that the oil level is maintained between the two notches (Figure 31) on the dipstick. See Table 9 for proper selection of engine oil.

Refilling the Fuel System

CAUTION - REFUELING THE GENERATOR

ONLY properly trained personel who have read and

understand this section should refill the fuel tank system.

Figure 31. Engine Oil Dipstick

This generator has an internal fuel tank located inside the

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and refill with the specified amount of oil as outlined in the John Deere Engine Owner's Manual. Oil should be warm before draining.

Other types of motor oils may be substituted if they meet the following requirements:

■■

■

API Service Classification CC/SC

■■

■

API Service Classification CC/SD

■■

■

API Service Classification CC/SE

■■

■

API Service Classification CC/SF

■■

trailer frame and may also be equipped with an environmental fuel tank (Figure 32). fill the fuel tanks with clean fresh DO NOT fill the fuel tanks beyond their capacities.

Pay attention to the fuel tank capacity when replenishing fuel.The fuel tank cap must be closed tightly after filling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

. If fuel spillage occurs, wipe up the spilled fuel

Table 9. Recommended Motor Oil

122

104

-14

-22

-40

10W40

032

-10

-20

-4

-30

-40

OIL: SAE

ARCTIC OIL

PAGE 48 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

5W30

10W/40

15W30

20W40

10W

10W30

Figure 32. Internal Fuel Tank System

Page 49

SETUP

Refueling Procedure:

WARNING - RESPIRATORY HAZARDS

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).

CAUTION - REFUELING THE GENERATOR

place trailer on firm level ground before refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

3. Open cabinet doors on the “right side” of the generator (from generator control panel position). Remove fuel cap and fill tank (Figure 34).

Figure 34. Fueling the Generator

Figure 33. Only Fill on Level Ground

NOTE

ONLY! use when

refueling.

3. NEVER overfill fuel tank – It is important to read the fuel gauge when filling trailer fuel tank. DO NOT wait for fuel to rise in filler neck (Figure 35).

Figure 35. Full Fuel Tank

CAUTION - REFUELING THE GENERATOR

DO NOT OVER-FILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 36).

Figure 36. Fuel Expansion

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 49

Page 50

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

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 10 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the "H" and the "L" markings.

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. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the

battery terminal disconnected.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the John Deere Engine Owner's Manual.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to insufficient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the John

Deere Engine Owner's Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 37) when depressed with the thumb as shown below.

Table 10 Coolant Capacity

Engine and Radiator 6.3 Gal. (24 liters)

Reserve Tank 2 Quarts (1.9 liters)

Operation Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 11) has been added.

Table 11. Anti-Freeze Operating Temperatures

Freezing Point Boiling Point

Vol %

Anti-Freeze

°C °F °C °F

40 -24 -12 106 222

50 -37 -34 108 226

Figure 37. Fan Belt Tension

CAUTION - ROTATING PARTS

NEVER place hands near

the belts or fan while the generator set is running.

NOTE

When the antifreeze is mixed with water, the antifreeze mixing ratio

less than 50%.

PAGE 50 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 51

SETUP

Battery

This unit is of negative ground DO NOT connect in reverse. Always maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. keep the terminals firmly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation

ALWAYS be sure the battery cables (Figure 38) are properly connected to the battery terminals as shown below. The Red Cable is connected to the positive terminal of the battery,

and the Black Cable is connected to the negative terminal of the battery.

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the is in either the MANUAL or AUTO position. ALWAYS make sure that the is in the OFF/RESET position when connecting the battery.

2. Place a small amount of battery terminal treatment

compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

If the battery cable is connected

NOTE

CAUTION - BATTERY SERVICING SAFETY

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

Alternator

incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION - BATTERY SERVICING SAFETY

disconnect the negative terminal FIRST and

reconnect negative terminal LAST.

Figure 38. Battery Connections

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrision and damage the alternator.

Wiring

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

Piping and Hose Connection

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose ( or ) lines are defective replace them immediately.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 51

Page 52

GENERATOR START-UP PROCEDURE (MANUAL)

Before Starting

3. Make sure the the

CAUTION - LETHAL EXHAUST HAZARD

4. Connect the load to the or the

The engine's exhaust contains harmful emissions.

Direct exhaust away from nearby personnel.

WARNING - STARTING THE GENERATOR

5. The output terminal lugs are protected by a plastic cover.

manually start the engine with the , or

circuit breakers in the ON (closed) position.

6. Close all engine enclosure doors (Figure 41). The Engine Control Unit (ECU) used with this generator diagnosis engine faults that arise with the the engine control system and the engine itself. Engine faults can be determined by viewing the Diagnostic Trouble Codes (Active Fault Codes) which are displayed on the Diagnostic Display Panel located inside the Control Box.

1. Before starting the engine, make sure the diagnostic

switch (Figure 39) on the Diagnostic Display Panel Assembly is in the “OFF” position.

voltage change-over board

has been configured for the desired output voltage.

as shown in Figure 14. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

Remove this cover to gain access to the terminals. Tighten terminal nuts securely to prevent load wires from slipping out.

INCORRECTCORRECT

Figure 41. Engine Enclosure Doors

Figure 39. Diagnostic Switch (OFF poistion)

2. Place the and circuit breakers

(Figure 40) in the OFF position prior to starting the engine.

Figure 40. Main, Aux. and GFCI

Circuit Breakers (OFF)

Starting (Manual)

1. Place the engine speed switch (Figure 42) in the

LOW

“

” (down) position

Figure 42. Engine Speed Switch (Low)

2. Place the in the MANUAL

position to start the engine (Figure 43). Observe that the Warning and Emergency Stop lamps on the Engine Operating Panel are lit during the initial starting of the engine. If no abnormal conditions exists, both lamps will turn off.

Figure 43. MPEC Control Switch

(Manual Position)

PAGE 52 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 53

GENERATOR START-UP PROCEDURE (MANUAL)

When the MPEC Control switch is

NOTE

the glow plugs are warmed. When the preheat lamp goes off this signals the completion of the preheating cycle and the starting of the engine.

3. If any abnormalities exists, the Warning and Emergency Stop lamps on the Engine Operating Panel will be lit.

4. Place the (Figure 43) in the

OFF/RESET position.

5. Place the Diagnostic ON/OFF switch in the ON position. Verify that an Active Fault Code message is being displayed (Diagnostic Display Panel). The fault code message will continued to be displayed until the fault has been corrected. Figure 44 shown below is a typical example of an active fault code message (Low Radiator Coolant).

placed in the manual position,

preheating of the glow plugs will begin automatically and the preheat lamp will stay lit until

Preheat Lamp

8. To restart the engine due to error codes, place the

in the MANUAL position (Figure 43)

9. If the engine is running smoothly, place the engine

speed switch (Figure 45) in the “” (up) position.

Figure 45. Engine Speed Switch (High)

10.Verify that the Engine Running

status LED on the MPEC unit (Figure 46) is ON (lit) after the engine has been started.

Figure 46. Engine Running LED (ON)

11. Observe that the Warning and Emergency Stop

lamps on the Engine Operating Panel are OFF.

Figure 44. Active Fault Code Message

6. In a situation where several engine problems occur

simultaneously, the word “MORE” appears above the arrow buttons indicating that there are more fault codes that need to be viewed. Use the arrow buttons to scroll to the next active fault code.

If desired, the type of fault code, cause of error and the countermeasures of the error can be referenced in a separate engine operator’s manual.

7. Before the engine can be started, the engine fault must be corrected. Also observe that there are no active fault codes displayed on the diagnostic panel. If no fault codes are displayed, place the diagnostic switch in the OFF position.

12. The generator's frequency meter (Figure 47) should be

displaying the 60 cycle output frequency in HERTZ.

Figure 47. Frequency Meter (Hz)

13. The generator's AC-voltmeter (Figure 48) will display the

generator’s output in VOLTS. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 49) to increase or decrease the desired voltage.

Figure 48. Voltmeter

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 53

Page 54

GENERATOR START-UP PROCEDURE (MANUAL)

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 50.

Ammeter (No

15. The engine oil pressure gauge (Figure 51) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 35 to 65 psi. (241~448 kPa). When starting the generator

Figure 51. Oil

Pressure Gauge

16. The (Figure 52) will indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 180~230°F (82~110 °C)

Figure 52. Coolant

Temperature Gauge

17. The (Figure

53) will indicate the speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 53. Engine

Tachometer

Load)

Gauge

18. Place the , , and . circuit breakers in the

ON position (Figure 54).

Figure 54. Main, Aux. and GFCI

Circuit Breakers (ON)

19. Observe the generator's ammeter (Figure 55) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 55.

Ammeter (Load)

20. The generator will run until manually stopped or an

abnormal condition occurs.

Starting (Auto Mode)

DANGER - ELECTRICAL SYSTEM HAZARDS

Before connecting this generator to any building’s electrical system, a

must install an

. Serious damage to the building’s electrical system may occur without this transfer switch.

CAUTION - BACKUP GENERATOR USE

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator's internal battery charger. This will ensure that the engine will not fail due to a dead battery.

When the generator is set in the

AUTO mode, the generator will

NOTE

comercial power falling below a

in the event of

prescribed level by means of a contact closure that is generated automatically by a transfer switch.

PAGE 54 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 55

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.

CAUTION - ENGINE SPEED SWITCH

The must be set to the “High” position when running in the mode. Failing to set the switch in the proper position can result in damage to your generator when it turns on.

When the MPEC

NOTE

is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically.

When starting generator in AUTO mode use the " Start-up" procedure except where noted (see below).

1. Perform steps 1 through 6 in the section

2. Place the (Figure 56) in the HIGH

3. Place the (Figure 57) in the

4. Continue operating the generator as s outlined in the

as outlined in the .

position

Figure 56. Engine Speed Switch (High)

AUTO position

Figure 57. MPEC Control Switch (AUTO)

procedure (start at step 5).

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 55

Page 56

GENERATOR SHUT-DOWN PROCEDURES

WARNING GENERATOR

NEVER stop the engine suddenly except in an emergency.

CAUTION -

ALWAYS make sure the diagnostic switch is placed in the OFF position before attempting to shut down the generator.

The OFF/RESET switch on the MEC controller will not shut down the generator if the diagnostic switch is left in the ON position.

Normal Shutdown Procedure

To shutdown the generator use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 40 to the OFF position.

2. Place the engine speed switch (Figure 58) in the “ ” (down) position.

SHUTTING DOWN THE

DIAGNOSTIC SWITCH

Emergency Shutdown Procedure

To shutdown the generator in the event of an emergency use the following procedure:

1. Place the (Figure 59) in the

OFF/RESET position.

Figure 58. Engine Speed Switch (Low)

3. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

4. Place the (Figure 59) to the

OFF/RESET position.

Figure 59. MPEC Control Switch (Off/Reset)

5. Verify that the status LED on the MPEC display are OFF (not lit).

6. Remove all loads from the generator.

7. Inspect entire generator for any damage or loosening of components that may have occured during operation.

PAGE 56 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 57

MAINTENANCE (ENGINE)

TABLE 12. INSPECTION/MAINTENANCE

Check Engine Fluid Levels X

Check Air Cleaner X

Check Battery Acid Level X

Check Fan Belt Condition X

Check for Leaks X

Check for Loosening of Parts X

ENGINE

GENERATOR

Replace Engine Oil and Filter *

Clean Air Filter X

Check Fuel Filter/Water Seperator Bowl X

Clean Unit, Inside and Outside X

Change Fuel Filter X

Clean Radiator and Check Coolant Protection Level*

Replace Air Filter Element *

Check all Hoses and Clamps *

Clean Inside of Fuel Tank X

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

*1 Replace engine oil anf filter at 100 hours, first time only.

*2 Add "Supplemental Coolant Addatives (SCA'S)" to recharge the engine coolant.

*3 Replace primary air filter element when restriction indicator shows a vaccum of 625 mm (25 in. H20).

*4 If blowby hose needs to be replaced, ensure that the slope of the bloby hose is at least a 1/2 inch per foot, with no sags or dips that could collect moisture and/or oil.

10 Hrs

DAILY

250 Hrs 500 Hrs 1000 Hrs

General Inspection

Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

Air Cleaner

Every 250 hours: Remove air cleaner element and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

Air Cleaner with Dust Indicator

This indicator is attached to the air cleaner. When the air cleaner element is clogged, air intake restriction becomes greater and the dust indicator signal shows RED meaning the element needs changing or service. After changing the

Service Daily

If the engine is operating in very or conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more if these conditions exists.

Fuel Addition

Add diesel fuel (the grade may vary according to season and locations).

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

air element, press the dust indicator button to reset the indicator.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 57

Page 58

MAINTENANCE (ENGINE)

Air Removal

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.

Check Oil Level

Check the crankcase oil level prior to each use, or when the fuel tank is filled. Insufficient oil may cause severe damage to the engine. Make sure the generator is level. The oil level must be between the two notches on the dipstick as shown in Figure 31.

Replacing Oil Filter



Remove the old oil filter.



Apply a film of oil to the gasket on the new oil filter.



Install the new oil filter.



After the oil cartridge has been replaced, the engine oil will drop slightly. Run the engine for a while and check for leaks before adding more oil if needed. Clean excessive oil from engine.

Flushing Out Radiator and Replacing Coolant



Open both cocks located at the crankcase side and at the lower part of the radiator and drain coolant. Open the radiator cap while draining. Remove the overflow tank and drain.



Check hoses for softening and kinks. Check clamps for signs of leakage.



Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.



Tighten both cocks and replace the overflow tank.



Replace with coolant as recommended by the engine manufaturer.



Close radiator cap tightly.

WARNING - BURN HAZARDS

Allow engine to when flushing out radiator. Flushing the radiator while hot could cause serious burns from water or steam.

Generator Storage

Cleaning the Fuel Strainer

Clean the fuel strainer if it contains dust or water. Remove dust or water in the strainer cap and wash it in gasoline. Securely fasten the fuel strainer cap so that fuel will not leak. Check the fuel strainer every 200 hours of operation or once a month.

Replacing Fuel Filter



Replace the fuel filter cartridge with new one every 500 hours or so.



Loosen the drain plug at the lower top of the fuel filter. Drain the fuel in the fuel body together with the mixed water. DO NOT spill the fuel during disassembly.



Vent any air.

For longe term storage of the generator the following is recommended:



Fill the fuel tank completely. Treat with a fuel stabilizer if necessary.

Completely drain the oil from the crankcase and refill if necessary with fresh oil.

Clean the entire generator, internal and external.

Cover the generating set and store in a clean, dry place.

Disconnect the battery.

Make sure engine coolant is at proper level.

If generator is mounted on a trailer, jack trailer up and place on blocks so tires do not touch the ground or block and completely remove the tires.

PAGE 58 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 59

MAINTENANCE (HEATER/CHARGER)

Jacket Water Heater and Internal Battery Charger 120 VAC Input Receptacles (OPTIONAL)

This generator can be optionally equipped with two 120 VAC, 20 amp input receptacles located on the output terminal panel.

The purpose of these receptacles is to provide power via commercial power to the and

These receptacles will ONLY function when commercial power has been supplied to them (Figure 60). To apply commercial power to these receptacles, a power cord of adequate size will be required (See Table 6).

When using the generator in climates there is no reason to apply power to jacket water heater. However, if the generator will be used in climates it is always a good idea to apply power to the jacket water heater at all times. To apply power to the jacket water heater simply apply power to the jacket water heater receptacle via commercial power using an power cord of adequate size.

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using an power cord of adequate size.

NOTE

To ensure adequate starting capability, always have power applied to the generator's

Figure 60. DCA-180SSJUBattery Charger &

Jacket Water Heater Power Connections

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 59

Page 60

MAINTENANCE (TRAILER)

Trailer Maintenance

This section is intended to provide the user with generic trailer service and maintenance information. The service and maintenance guidelines referenced in this section refer to a wide range of trailers.

Remember periodic inspection of the trailer will ensure safe towing of the generator and will prevent personal injury and damage to the equipment.

The definitions below describe some of the major components of a typical trailer that would be used with the DCA-180SSJU

1. Fuel Cell - Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transporting equipment.

2. Braking System - System employed in stopping the trailer. Typical braking systems are electric, surge, hydraulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR) is the maximum number of pounds the trailer can carry, including the fuel cell (empty).

4. Frame Length - Measurement is from the ball hitch to the rear bumper (reflector).

Whisperwatt

™

Generator.

8. Tire Size - Indicates the diameter of the tire in inches

9. Tire Ply - The tire ply (layers) number is rated in letters;

10. Wheel Hub - The wheel hub is connected to the trailer’s

11. Tire Rim - Tires mounted on a tire rim. The tire rim

12. Lug Nuts - Used to secure the wheel to the wheel hub.

13. Axle - Indicates the maximum weight the axle can sup-

14. Suspension - Protects the trailer chassis from shocks

(10,12,14, etc.), and the width in millimeters (175,185,205, etc.). The tire diameter must match the diameter of the tire rim.

2-ply,4-ply,6-ply, etc.

axle.

must match the size of the tire.

Always use a torque wrench to tighten down the lug nuts. See Table 18 and Figure 63 for lug nut tightening and sequence.

port in pounds, and the diameter of the axle expressed in inches. Please note that some trailers have a double axle. This will be shown as 2-6000 lbs., meaning two axles with a total weight capacity of 6000 pounds.

transmitted through the wheels. Types of suspension used are leaf, Q-flex, and air ride.

5. Frame Width - Measurement is from fender to fender

6. Jack Stand - Trailer support device with maximum pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

15. Electrical - Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can be connected to the towing vehicle.

16. Application - Indicates which units can be employed

on a particular trailer.

PAGE 60 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 61

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

Hydraulic Surge Brakes

Hydraulic surge brakes (Figure 61) should not require any special attention with the exception of routine maintenance such as shoe and lining replacement. Brake lines should be periodically checked for cracks, kinks, or blockage.

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. Place the trailer on jack stands. Make sure the jack stands

are placed on secure level ground.

2. Check the wheel and drum for free rotation.

3. Remove the adjusting hole cover from the adjusting slot

at the bottom brake backing plate.

4. With a screwdriver or standard adjusting tool, rotate the

Figure 61. Hydraulic Brake Components

star wheel of the adjuster assembly to expand the brake shoes.

Actuator

5. Adjust the brake shoes outward until the pressure of the

lining against the wheel drum makes the wheel difficult to turn.

6. Adjust, rotate the star wheel in the opposite direction

until the wheel rotates freely with slight lining drag.

Hydraulic surge braking requires the installation of an actuator at the tongue of the trailer. Remember the or

of the trailer toward the tow vehicle automatically synchronizes the trailer brakes with the tow vehicle brakes. As the trailer pushes against the tow vehicle the actuator telescopes together and applies force to the master cylinder,

7. Replace the adjusting hole cover and lower the trailer to supplying hydraulic pressure to the trailer brakes.

the ground.

Periodically check and test the surge “ ” to make

8. Repeat steps 1 through 7 on the remaining brakes. sure that it is functioning correctly. Never use an undersize

actuator.

Table 13. Hydraulic Brake Troubleshooting

Symptom Possible Cause Solution

No Brakes Brake line broken or kinked? Repair or replace.

Brake lining glazed? Reburnish or replace.

Weak Brakes or Brakes Pull to

One Side

Locking Brakes

Noisy Brakes

Dragging Brakes

Brake components loose, bent or broken? Replace components.

Trailer overloaded? Correct weight.

Brake drums scored or grooved? Machine or replace.

Tire pressure correct? Inflate all tires equally.

Tires unmatched on the same axle? Match tires.

Brake drums out-of-round? Replace.

System lubricated? Lubricate.

Brake components correct? Replace and correct.

Brake lining thickness incorrect or not

adjusted correctly?

Enough brake fluid or correct fluid?

Install new shoes and

linings.

Replace rubber parts

fill with dot 4 fluid.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 61

Page 62

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.

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. Torqued suspension components

CAUTION - EYESIGHT HAZARD

as detailed in Table 15.

wear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious injury.

CAUTION - REPAIRING TRAILER WHEELS

DO NOT attempt to repair or modify a wheel. DO NOT

install in inner tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inner tube may cause pieces of the rim to explode (break off) with great force and cause serious eye or bodily injury.

Figure 62. Major Suspension Components

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT bleed air from tires when they are . Check inflation pressure weekly during use to insure the maximum tire life and tread wear.

Table 14 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.

Table 15. Suspension Torque Requirements

Item Torque (Ft.-Lbs.)

3/8" U-BOLT MIN-30 MAX-35

7/16" U-BOLT MIN-45 MAX-60

1/2" U-BOLT MIN-45 MAX-60

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY

LOCKING NUTS OR COTTER PINS ARE PROVIDED

PARTS MUST ROTATE FREELY.

TO RETAIN NUT

BOLT ASSEMBLY

MIN-30 MAX-50

PAGE 62 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 63

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. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

Table 16. Tire Torque Requirements

MAINTENANCE (TRAILER)

Wheel Size First Pass

FT-LBS

12" 20-25 35-40 50-65

13" 20-25 35-40 50-65

14" 20-25 50-60 90-120

15" 20-25 50-60 90-120

16" 20-25 50-60 90-120

Second Pass

FT-LBS

Third Pass

FT-LBS

Figure 63. Wheel Lug Nuts

Tightening Sequence

NOTE

use an pneumatic air

gun to tighten wheel lug nuts.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 63

Page 64

TRAILER WIRING DIAGRAM

Figure 62. Trailer/Towing Vehicle Wiring Diagram

PAGE 64 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 65

GENERATOR WIRING DIAGRAM

Figure 63. Generator Wiring Diagram

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 65

Page 66

DCA-180SSJU — ENGINE WIRING DIAGRAM

Figure 64. Engine Wiring Diagram

PAGE 66 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 67

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. GENERATOR TROUBLESHOOTING

SYMPTOM POSSIBLE PROBLEM SOLUTION

No Voltage Output AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

Is AVR defective? Replace if necessary.

Defective Rotating Rectifier? Check and replace.

Defective Exciter Field? Check for 17.3 ohms across J & K on CN1

Low Voltage Output Is engine speed correct? Turn engine throttle lever to "High".

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

High Voltage Output Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Circuit Breaker Tripped Short Circuit in load? Check load and repair.

Over current? Confirm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Confirm load requirement and replace.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 67

Page 68

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 POSSIBLE PROBLEM SOLUTION

Low oil level? Fill oil level.

Low oil pressure light is

on.

Low coolant level light is

on. (Optionally Installed)

High coolant temperture light is on.

Oil pressure sending unit failure? Replace oil pressure sending unit.

Time delay malfuntion in Controller? Refer to dealer.

Wire shorted? Inspect/repair wire.

Low coolant level? Fill coolant level.

Sending unit failure? Replace sending unit.

Low battery voltage? Replace/charge battery.

Fan belt tension incorrect? Tighten/replace fan belt.

Air flow is not circulation through radiator? Clean/repair radiator grill.

Doors open? Close doors.

Exhaust leaking? Replace/repair gaskets or faulty part.

Generator being overloaded? Check/reduce load.

Thermostat failure? Replace thermostat.

Air intake blocked? Clear all air intakes.

Temperature switch failure? Replace temperature switch.

Overcrank light is on.

Overspeed light is on.

Loss of MPU light(s) or

on.

PAGE 68 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

No or low Fuel? Fill fuel level.

Controller needs to be calibrated? Refer to dealer.

RPM engine speed too high? Adjust RPM.

Governor actuator needs to be adjusted? Adjust governor actuator.

Governor controller needs to be adjusted? Adjust governor controller.

Engine Controller needs to be calibrated? Refer to dealer.

Magnetic pick up out of adjustment? Adjust magnetic pick up.

Magnetic pick up dirty? Clean magnetic pick up.

Page 69

NOTES

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

Page 70

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. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

QTY. Column

Numbers Used — Item quantity can be indicated by a

number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁed in the “Remarks” Column.

REMARKS Column

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the same unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTICE

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clariﬁed in the “Remarks” Column.

Serial Number Break — Used to list an effective serial number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Speciﬁc Model Number Use — Indicates that the part is used only with the speciﬁc model number or model number variant listed. It can also be used to show a part is NOT used on a speciﬁc model or model number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can be purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately” — Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.

PAGE 70 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 71

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 ......... FILTER, FUEL FINAL

6 ......... 0602041292 ......... FILTER, OIL CARTRIDGE

3 ......... 0602046683 ......... ELEMENT AIR INNER

1 ......... 0601808803 ......... CIRCUIT BREAKER 1P 20A

1 ......... 0601808804 ......... CIRCUIT BREAKER 2P 50A

2 ......... LY2DUS12VDC .... RELAY

1 ......... 0602123290 ......... SWITCH, COOLANT LEVEL

3 ......... 0602046682 ......... ELEMENT, AIR OUTER

1 ......... 0601820625 ......... AUTOMATIC VOLTAGE REGULATOR

1 ......... 0601840121 ......... KNOB, AUTOMATIC VOLTAGE REGULATOR

3 ......... 0601810245 ......... BULB, ALARM LAMP

1 ......... 0602122272 ......... UNIT, OIL PRESSURE

1 ......... 0602123263 ......... UNIT, WATER TEMPERATURE

1 ......... 0601806653 ......... FUSE, 20A

1 ......... 0601802149 ......... FUSE, 10A

SUGGESTED SPARE PARTS

Part number on this Suggested Spare Parts list

NOTE

may supercede/replace the P/N shown in the text pages of this book.

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 71

Page 72

GENERATOR ASSY.

PAGE 72 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 73

GENERATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 C0110000602 ROTOR ASSY. ........................... 1 ........ INCLUDES ITEMS W/#

1-1# FIELD ASSY. .............................. 1 ........ NOT SOLD SEPARETLY

1-2# 0601842334 RESISTOR, 100K OHM 1 1-3# 0601823282 RECTIFIER 1 1-4# 0018205020 HEX. SHCS 2 1-4A# 0040005000 WASHER, LOCK 2 1-4B# 0041205000 WASHER, FLAT 2 1-5# 8171070002 FAN 1 1-6# 8171611003 COUPLING DISK 9 1-7# C1164200004 WASHER, COUPLING HUB 1

1-8# 8171015003 BALANCING PLATE .................. 1 ........ PURCHASE ITEMS 1-1 THRU 1-11 AS A SET

1-9# 0012116045 HEX. HEAD BOLT 8 1-10# 0042616000 WASHER, LOCK 8 1-11# 0601000209 BALANCING WEIGHT KIT 1 1-12# C1112500004 BEARING FLANGE 1 1-13# 0071906314 BEARING 1 2 M4163400003 COUPLING RING 1 3 0343206120 HEX. HEAD BOLT 8 4 0043606000 WASHER, LOCK 8 5 0012112040 HEX. HEAD BOLT 8 6 0042512000 WASHER, LOCK 8 7 C0130000703 STATOR ASSY. 1 7-1 0845041804 GROMMET 2 7-2 0601850144 GROMMET 1 8 C1154000002 END BRACKET 1 9 C1138000003 FIELD ASSY. EXCITER 1 10 0012110065 HEX. HEAD BOLT 4 10A 0042610000 WASHER, LOCK 4 10B 0041210000 WASHER, FLAT 4 11 0017112045 HEX. HEAD BOLT 6 12 C1154400004 COVER, BEARING 1 13 C1154300004 GASKET, BEARING 1 14 0010106060 HEX. HEAD BOLT 4 14A 0040006000 WASHER, LOCK 4 14B 0041206000 WASHER, FLAT 4 15 C1154400103 SUCTION COVER 1 16 0017106016 HEX. HEAD BOLT 8 17 0343205150 HEX. HEAD BOLT 12 18 0043605000 WASHER, LOCK 12 19 C1132300114 COVER, FAN 1 20 0010106030 HEX. HEAD BOLT 1 20A 0041206000 WASHER, FLAT 1 20B 0600815000 NUT 1 21 0605000012 RUBBER SUSPENSION 2 22 0030020000 HEX. NUT 4 22A 0040020000 WASHER, LOCK 4 23 0070506307 BEARING 1

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 73

Page 74

CONTROL PANEL ASSY.

PAGE 74 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 75

CONTROL PANEL ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4223000303 CONTROL PANEL 1 2 M4223000404 CONTROL PANEL 1 2-1 022100100 SEAL RUBBER 2 2-2 022100165 SEAL RUBBER 2 3 0605011211 PIN 2 4 0017108040 HEX. HEAD BOLT 4 5 0601807642 FREQUENCY METER, 240V 1 6 0601817000 AC AMMETER, 0~300A/600A:5A 1 7 0601800275 CHANGE- OVER SWITCH, AMMETER 1 8 0601800275 AC VOLTMETER, 0~600V 1 9 0601801041 CHANGE-OVER SWITCH, VOLTMETER 1 10 0601840073 RHEOSTAT, VOLTAGE REGULATOR 1 11 0601840121 KNOB 1 12 0602202593 CONTROLLER 1 13 0027104040 MACHINE SCREW 2 13A 0207004000 HEX. NUT 2 14 0601831340 SWITCH 1 15 0601831340 SWITCH 1 16 0602120096 TACHOMETER 1 17 0602122093 OIL PRESSURE GAUGE 1 18 0602122272 UNIT, OIL PRESSURE 1 19 0602123092 WATER TEMPERATURE GAUGE 1 20 0602123263 UNIT, WATER TEMPERATURE 1 21 0602125090 FUEL GAUGE 1 23 0602103092 ALARM LAMP 3 23A 0601810245 BULB 1 24 0601810160 PANEL LIGHT 1 24A 0601810213 HEX. NUT 2 25 0207904000 HEX. NUT 2 26 0601831330 SWITCH, PANEL LIGHT 1 27 0601831557 EMERGENCY STOP BUTTON 2 28 M9220100004 SET SCREW 2 28A 0080200007 SNAP RING 2 29 M3246702604 WIRE HARNESS, GENERATOR 1 30 M4357200102 WIRE HARNESS, ENGINE 1

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 75

Page 76

CONTROL BOX ASSY.

PAGE 76 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 77

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M3213001302 CONTROL BOX 1 2 0601809666 CURRENT TRANSFORMER, 300/5A 3 3 0027106018 MACHINE SCREW 6 4 0601870423 CIRCUIT BREAKER, 500A 1 4A 0021006045 MAVHINE SCREW 4 4B 0207006000 HEX. NUT 4 5 0601815168 REAR CONNECTOR KIT 1 6 M3273000003 TERMINAL BOARD, VOLTAGE CHANGE-OVER 1 7 M3276400004 CHANGE TERMINAL 10 8 0017106025 HEX. HEAD BOLT 20 9 M4276200004 TERMINAL PLATE 3 10 M3276300004 CHANGE-OVER PALTE 6 11 M4276100004 TIE BOLT 20 12 0040001000 LOCK WASHER 20 13 0041410000 WASHER, FLAT 20 14 0017110040 HEX. HEAD BOLT 3 14A 0207010000 HEX. NUT 4 15 0016908030 HEX. HEAD BOLT 4 16 0601820625 AUTOMATIC VOLTAGE REGULATOR, 5A 1 17 0027105016 MACHINE SCREW 4 18 0601820847 OVER CURRENT RELAY 1 19 0601820848 OVER CURRENT RELAY, 25A 1 20 0027104016 MACHINE SCREW 2 20A 0207004000 HEX. NUT 2 21 M4260600304 BRACKET, DIAGNOSTIC GAUGE 1 22 0016908020 HEX. HEAD BOLT 2 23 0602120690 POWER VIEW 1 24 0601831330 DIAGNOSTIC SWITCH 1 25 0601813977 RECEPTACLE 1 25A 0601812891 DUST CAP 1 25B 0601812890 STRAIN RELIEF 1 26 0027103015 MACHINE SCREW 2 26A 0030003000 HEX. NUT 2 26B 0041203000 DRAIN WASHER 2

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 77

Page 78

CONTROL BOX ASSY.

PAGE 78 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 79

CONTROL BOX ASSY.

CONTROL BOX ASSY. ( CONT.)

NO. PART NO. PART NAME QTY. REMARKS

27 M4260500003 SET PANEL, ELECTRIC PARTS 1 28 0016908020 HEX. HEAD BOLT 4 29 0602202592 STARTER RELAY 1 29A 0030006000 HEX. NUT 2 30 0027106016 MACHINE SCREW 2

31 LY2DUS12VDC RELAY .................................................................... 1............ REPLACES P/N 0601827656

31A PTF08A BASE ...................................................................... 1............ REPLACES P/N 0601823109

31B PYCA1 CLIP........................................................................ 2............ REPLACES P/N 0601824400

32 0027104020 MACHINE SCREW 2 33 0601823240 RECTIFIER 2 34 0027104020 MACHINE SCREW 2 35 M4260600404 BRACKET, RESISTOR UNIT 1 36 0016906016 HEX. HEAD BOLT 2 37 M4266600004 RESISTOR UNIT 1 38 0027105016 MACHINE SCREW 1 39 0601802218 HOLDER, FUSE 3P 1 39A 0601806653 FUSE, RIGHT SIDE 20A 1 39B 0601802149 FUSE, CENTER 10A 1 40 0027103020 MACHINE SCREW 2 41 0601815154 TERMINAL SCREW 2 42 0027104016 MACHINE SCREW 2 43 M4213600104 STOPPER, CONTROL PANEL 1 44 0041206000 WASHER, FLAT 1 45 0605010502 SNAP PIN 1 46 M4213500104 COVER, CONTROL BOX 1 47 0016908020 HEX. HEAD BOLT 8 48 M4213400104 BACK PANEL, CONTROL BOX 1 49 0016908020 HEX. HEAD BOLT 8 50 0330000300 EDGING 1 51 0330000215 EDGING 1 52 0016908020 HEX. HEAD BOLT 8 53 0016908020 HEX. HEAD BOLT 6

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 79

Page 80

ENGINE AND RADIATOR ASSY.

PAGE 80 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 81

ENGINE AND RADIATOR ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4923200034 ENGINE 1 1A 0602015230 FAN BELT 1

1-1 RE504836 CARTRIDGE, OIL FILTER ..............................................1 .............. REPLACES P/N 0602041292

1-2 RE529643 CARTRIDGE, PRIMARY FUEL FILTER .........................1 .............. REPLACES P/N 0602042596

1-3 RE522878 CARTRIDGE, FINAL FUEL FILTER ...............................1 .............. REPLACES P/N 0602042597

2 0602060015 BLOWER FAN 1

3 R81876 FAN SPACER .................................................................. 1 .............. REPLACES P/N 0602061003

4 0012110110 HEX HEAD BOLT 4 5 0042510000 LOCK WASHER 4 6 M3303200404 ENGINE FOOT 2 7 0010312030 HEX. HEAD BOLT 6 8 0040012000 LOCK WASHER 6 9 0605000011 RUBBER SUSPENSION 2 10 0030016000 HEX. NUT 4 11 0040016000 LOCK WASHER 4 12 M4923200014 RADIATOR 1 12A M4493601304 ACOUSTIC SHEET 2 13 0602011062 CAP 1 14 M9200101004 ADAPTOR 1 15 0150000016 O-RING 1 16 M4310201103 SUPPORTER, RADIATOR 1 17 M4310201203 SUPPORTER, RADIATOR 1 17A M4493601504 ACOUSTIC SHEET 1 18 0016918020 HEX. HEAD BOLT 15 19 M4310600304 RUBBER SHEET 2 20 0017112055 HEX. HEAD BOLT 4 21 0030012000 HEX. NUT 8 23 0041212000 WASHER, FLAT 4 24 0016910025 HEX. HEAD BOLT 4 25 0016910025 HEX. HEAD BOLT 2 26 M4923200044 INTER COOLER 1 27 M4310201304 BRACKET, INTER COOLER 1 27A M4493601604 ACOUSTIC SHEET 1 28 M4310201404 BRACKET, INTER COOLER 1 28A M4493601604 ACOUSTIC SHEET 1 29 0017110050 HEX. HEAD BOLT 4 29A 0207010000 HEX. NUT 4 30 0016908020 HEX. HEAD BOLT 4 31 M4310301103 FAN SHROUD 1 32 M4310301203 FAN SHROUD 1 33 0016908020 HEX. HEAD BOLT 6 34 0016908020 HEX. HEAD BOLT 4 35 M4310300903 FAN GUARD 1 36 M4310301003 FAN GUARD 1 37 0016908020 HEX. HEAD BOLT 11 38 M4310300803 FAN GUARD 1 39 0016908020 HEX. HEAD BOLT 8 40 M4310500803 RADIATOR HOSE 1 41 M4310500903 RADIATOR HOSE 1 42 0605515178 HOSE BAND 1

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 81

Page 82

ENGINE AND RADIATOR ASSY. (CONT.)

ENGINE AND RADIATOR ASSY. (CONT)

PAGE 82 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 83

ENGINE AND RADIATOR ASSY. (CONT)

ENGINE AND RADIATOR ASSY. (CONT.)

NO. PART NO. PART 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 COOLER HOSE 1 48 0605515207 HOSE BAND 1 49 0605515208 HOSE BAND 3 50 0605515209 HOSE BAND 3 51 M4310600404 BRACKET, INTER COOLER PIPE 1 52 0016908020 HEX. HEAD BOLT 2 53 0602326063 U-BOLT 1 54 0602046586 AIR CLEANER 1 54A 0602046682 ELEMENT, AIR CLEANER OUTER 1 54B 0602046683 ELEMENT, AIR CLEANER INNER 1 55 0602040650 INDICATOR, AIR CLEANER 1 56 0602040558 BAND, AIR CLEANER 2 57 0016908020 HEX. HEAD BOLT 4 58 0207008000 HEX. NUT 4 59 M4373200304 BRACKET, AIR CLEANER 1 60 0016908020 HEX. HEAD BOLT 4 61 M4373000104 AIR CLEANER PIPE 1 62 0602040365 90° ELBOW 1 63 0605515202 HOSE BAND 3 64 0602022580 ADAPTER 1 65 0602022561 90° ELBOW 1 66 0603306590 CONNECTOR 1 67 0603300285 ROCKNUT 1 68 0605511395 VALVE 1 69 0603306395 HOSE JOINT 1 70 0602021070 CAP 1 71 0269200660 DRAIN HOSE 1 72 M9300000203 RESERVE TANK 1 73 0602010900 CAP, RESERVE TANK 1 74 M4316100103 BRACKET, RESERVE TANK 1 75 0016910025 HEX HEAD BOLT 2 76 0199901850 HOSE 1 77 0193601250 HOSE 1 78 0193600700 HOSE 1 79 0605515106 HOSE BAND 3 80 0191601700 BLOWBY HOSE 1 81 0605515149 HOSE BAND 2 82 M448360003 HOSE GUIDE 1 83 0016908020 HOSE GUIDE 1 84 0602017090 DRAIN VALVE 1 85 0602042601 LEAK OFF LINE 1 86 0017110020 HEX HEAD BOLT 1 87 0602123290 COOLANT LEVEL SWITCH 1 88 0602220910 CLAMP 1 89 0602220911 CLAMP 1

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 83

Page 84

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 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 84 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 85

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

Page 86

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 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

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

Page 87

OUTPUT TERMINAL ASSY.

OUTPUT TERMINAL ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

25 M4260600104 BRACKET, CIRCUIT BREAKER 1 25-1 022100150 RUBBER CUSHION 1 26 0019206020 HEX. HEAD BOLT 2 27 0601812538 RECEPTACLE, 20A 2 28 0601812538 RECEPTACLE, 50A 3 29 0025304015 MACHINE SCREW 10 29A 0207004000 HEX. NUT 10 30 M4236400204 COVER 1 31 0019206015 HEX. HEAD BOLT 8 32 M4236100303 TERMINAL COVER 1 33 0010112045 HEX. HEAD BOLT 2 34 0041212000 FLAT WASSHER 4 35 M9310200004 STAY RUBBER 2 36 0030012000 HEX. NUT 2 37 0605011505 STAY 1 38 0025305015 HEX. HEAD BOLT 4 39 M4236100604 COVER 1 40 M4236400304 BRACKET 1 41 0019206015 HEX. HEAD BOLT 2 42 0025304015 MACHINE SCREW 4

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 87

Page 88

BATTERY ASSY.

PAGE 88 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 89

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 0602220196 BATTERY 1 2 M9310500404 BATTERY SHEET 1 3 M9103000504 BATTERY SHEET 1 4 0602220921 BATTERY BOLT SET 2 5 M4346900304 BATTERY CABLE 1 6 M4346900204 BATTERY CABLE 1

7 CABLE .................................................................... 1............ MAKE LOCALLY

8 0017116030 HEX. HEAD BOLT 1 8A 0040516000 TOOTHED WASHER 1 9 0040520000 TOOTHED WASHER 1

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 89

Page 90

MUFFLER ASSY.

PAGE 90 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 91

MUFFLER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4330100502 MUFFLER 1 2 0016910025 HEX. HEAD BOLT 4 3 M4333000303 EXHAUST PIPE 1 4 0602325066 CLAMP 1 5 M4333200004 GASKET 1 6 0017112055 HEX. HEAD BOLT 4 7 M4330300004 COVER 2 8 0016908020 HEX. HEAD BOLT 4 9 M4333300304 BRACKET 1 10 0016908020 HEX. HEAD BOLT 4 11 0602326062 U BOLT SET 1

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 91

Page 92

FUEL TANK ASSY.

PAGE 92 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 93

FUEL TANK ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4363000102 FUEL TANK 1 1-1 0605505070 CAP. FUEL TANK 1 2 0605501069 FUEL SENDER UNIT 1 3 0605516090 GASKET 1 4 0027104016 MACHINE SCREW 5 5 M4363200104 TANK BAND 2 6 M9310500104 SUPPORTER SHEET 4 7 0016908020 HEX. HEAD BOLT 2 8 0207308000 SUPER LOCK NUT 2 9 0222100120 RUBBER SHEET 2 10 0222100180 RUBBER SHEET 2 11 M9200000003 DRAIN JOINT 1 12 M9200200004 DRAIN BOLT 1 13 0150000018 O RING 1 14 0016906020 HEX. HEAD BOLT 2 15 M1363400104 DRAIN HOSE 2 16 0605515198 HOSE BAND 1 17 0191302800 SUCTION HOSE 1 18 0191302200 RETURN HOSE 1 19 0605515109 HOSE BAND 4

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 93

Page 94

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 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 94 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 95

ENCLOSURE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 M4413000302 BASE 1 2 M1413400004 COVER 1 3 0019208020 HEX. HEAD BOLT 2 4 M4423000312 FRONT FRAME 1 4A M4493102513 ACOUSTIC SHEET 1 5 M4423000412 FRONT FRAME 1 5A M4493102513 ACOUSTIC SHEET 1 6 0016908020 HEX. HEAD BOLT 13 7 0019210030 HEX. HEAD BOLT 8 8 M4493102704 ACOUSTIC SHEET 1 9 0019208020 HEX. HEAD BOLT 6 10 M4423200403 OVER COVER, FRONT FRAME 1 11 0019208020 HEX. HEAD BOLT 14 12 M4423300014 DISCHARGE GUIDE 1 12A M4493601414 ACOUSTIC SHEET 1 13 M4423300114 DISCHARGE GUIDE 1 13A M4493601414 ACOUSTIC SHEET 1 14 0019206020 HEX. HEAD BOLT 12 15 M4423200204 COVER, FRONT FRAME 1 15A M4493102604 ACOUSTIC SHEET 1 16 0019208020 HEX. HEAD BOLT 10 17 M4433000102 CENTER FRAME 1 17A M4493200104 ACOUSTIC SHEET 1 18 0010114050 HEX. HEAD BOLT 4 18A 0030014000 HEX. NUT 4 18B 0040014000 LOCK WASHER 4 18C 0041214000 WASHER, FLAT 8 19 0010120045 HEX. HEAD BOLT 4 19A 0030020000 HEX. NUT 4 19B 0040020000 LOCK WASHER 4 19C 0041220000 WASHER, FLAT 8 20 M4443000102 REAR FRAME 1 20A M4493301904 ACOUSTIC SHEET 1 21 0019210030 HEX. HEAD BOLT 4 22 M4443300204 COVER, REAR FRAME 1 22A M4443302004 ACOUSTIC SHEET 1 23 M4443300303 DUCT 1 23A M4493302104 ACOUSTIC SHEET 1 24 0207008000 HEX. NUT 11 25 0019208020 HEX. HEAD BOLT 10 26 M4443200403 DOOR, REAR FRAME 1 27 M4443600004 WINDOW PLATE 1

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 95

Page 96

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 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 96 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 97

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART NAME QTY. REMARKS

28 0037906000 SELF-LOCKING U NUT 8 28A 0041206000 WASHER, FLAT 8 29 M9113000002 DOOR HANDLE 1 30 0021806016 MACHINE SCREW 4 30A 0030006000 HEX. NUT 4 31 M9110100204 HINGE 2 31A M9116100004 WASHER 2 32 0019208020 HEX. HEAD BOLT 3 33 M9310000004 BLIND PLUG 2 34 0600800320 MANUAL PAK 1 35 0021806016 MACHINE SCREW 4 36 M4463100202 ROOF PANEL 1 36A M4493501003 ACOUSTIC SHEET 1 37 M3310600004 COVER 1 38 0019208020 HEX. HEAD BOLT 4 39 M4463200202 ROOF PANEL 1 39A M4493501903 ACOUSTIC SHEET 1 40 M4463200403 DUCT, REAR ROOF 1 40A M4493502004 ACOUSTIC SHEET 1 41 0016908020 HEX. HEAD BOLT 10 42 M4463400003 DUCT COVER 1 43 0016908020 HEX. HEAD BOLT 7 44 M4463200304 COVER 2 45 0016906020 HEX. HEAD BOLT 12 46 M4463500204 GUTTER 2 47 0019206016 HEX. HEAD BOLT 8 48 0019208020 HEX. HEAD BOLT 32 49 M3453201302 SPLASHER PANEL 1 49A M4493403604 ACOUSTIC SHEET 1 50 0019108065 HEX. HEAD BOLT 6 50A 0042308000 LOCK WASHER 6 50B 0042408000 WASHER, FLAT 6

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 97

Page 98

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 6-CATERPILLAR YELLOW 3-SPECTRUM GREY 7-CATO GOLD 4-SUNBELT GREEN 8-RED

THE SERIAL NUMBER MAY BE REQUIRED.

PAGE 98 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Page 99

ENCLOSURE ASSY. (CONT.)

NO. PART NO. PART 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 DOOR 1 54A M4493403104 ACOUSTIC SHEET 1 55 M4453301004 DUCT 2 55A M4493404004 ACOUSTIC SHEET 2 56 M4453300504 DUCT 1 56A M4493403204 ACOUSTIC SHEET 1 57 M4453300704 DUCT 1 57A M4493403404 ACOUSTIC SHEET 1 58 M4453300804 DUCT 1 58A M4493403504 ACOUSTIC SHEET 1 59 0207008000 HEX. NUT 3 60 M9113000002 DOOR HANDLE 4 61 M9113000102 DOOR HANDLE 3 62 0021806016 MACHINE SCREW 28 62A 0030006000 HEX. NUT 28 63 M4453600004 GUTTER 3 64 M4453600104 GUTTER 3 65 0019206016 HEX. HEAD BOLT 15 66 M9110100804 HINGE 6 66A M9116100004 WASHER 6 67 M9110100904 HINGE 5 67A M9116100004 WASHER 5 68 0019208020 HEX. HEAD NUT 25 69 0601850097 STOPPER 9 70 0025408025 MACHINE SCREW 9 71 M9310000004 BLIND PLUG 11 72 0016908020 HEX. HEAD BOLT 1 72A 0040508000 TOOTHED WASHER 1

DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10) — PAGE 99

Page 100

RUBBER SEALS ASSY.

PAGE 100 — DCA-180SSJU — OPERATION AND PARTS MANUAL — REV. #3 (02/01/10)

Multiquip DCA180SSJU User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual