MQ Power DCA-400SSV Leitfaden

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

WHISPERWATTTM SERIES

MODEL DCA180SSJU

60HZ GENERATOR

(JOHN DEERE 6068HF485 DIESEL ENGINE)

Revision #3 (02/01/10)

(PARTS LIST NO. M3870301004)

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

PROPOSITION 65 WARNING

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 1-888-

327-4236 (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.

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

TABLE OF CONTENTS

MQ POWER DCA-180SSJUMQ POWER DCA-180SSJU

MQ POWER DCA-180SSJU

WHISPERWHISPER

WHISPERWW

WAA

ATTTT

TTTT

TTTMTM

TMTM

GENERATORGENERATOR

GENERATOR

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

COMPONENT DRACOMPONENT DRA

COMPONENT DRAWINGSWINGS

WINGSWINGS

WINGS

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

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

PARTS ORDERING PROCEDURES

www.mqpower.com

Ordering parts has never been easier!

Choose from three easy options:

WE ACCEPT ALL MAJOR CREDIT CARDS!

When ordering parts, please supply:

RDealer Account Number

RDealer Name and Address

RShipping Address (if different than billing address)

RReturn Fax Number

RApplicable Model Number

RQuantity, Part Number and Description of Each Part

RSpecify Preferred Method of Shipment:

UPS/Fed ExDHL

NPriority OneTr u c k 

NGround

NNext Day

NSecond/Third Day

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 you

District Sales Manager for more information.

Order via Internet (Dealers Only):

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

NView Parts Diagrams

NOrder Parts

NPrint Speciﬁcation Information

Note: Discounts Are Subject To Change

Goto www.multiquip.com and click on

Order Parts to log in and save!

Use the internet and qualify for a 5% Discount

on Standard orders for all orders which include

complete part numbers.*

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)

Fax your order in and qualify for a 2% Discount

on Standard orders for all orders which include

complete part numbers.*

Order via Phone: Domestic (US) Dealers Call:

1-800-427-1244

Best Deal!

International Customers should contact

their local Multiquip Representatives for

Parts Ordering information.

Non-Dealer Customers:

Contact your local Multiquip Dealer for

parts or call 800-427-1244 for help in

locating a dealer near you.

Note: Discounts Are Subject To Change

Effective:

January 1st, 2006

NOTICE

All orders are treated as Standard Orders and will

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

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

SPECIFICATIONS

Table 1. Generator Specifications

Model DCA-180SSJU

Type Revolving field, self ventilated, open protected type synchronous

generator

Armature Connection Star with Nutreal

Phase 3

Standby Output 198 KVA (158 KW)

Prime Output 180 KVA (144 KW)

Voltage 240V or 480V

Frequency 60 Hz

Speed 1800 rpm

Power Factor 0.8

Aux. AC Power Single Phase, 60 Hz

Voltage 120 V

Output 4.8 KW (2.4 KW x 2)

Weight (No Fuel) 6,571 lbs. (2,980 kg.)

Weight (With Fuel) 7,489 lbs. (3,400 kg.)

Engine Specifications

Model JOHN DEERE 6068HF485

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

air to air intercooled

No. of Cylinders 6 cylinders

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

Rated Output 286 HP/1800 rpm

Displacement 415 cu. in. (6.8 liters)

Starting Electric

Fuel Tank Capacity 100 gal. (380 liters)

Coolant Capacity 6.34 gal. (24 liters)

Lube Oil Capacity 8.69 gal. (32.9 liters)

Fuel Consumption

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

Battery 12V 128 Ah

Fuel #2 Diesel Fuel

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

DIMENSIONS (TOP, SIDE AND FRONT)

Figure 1. Dimensions

SNOISNEMID.3ELBAT

ecnerefeR

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

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

B).mm0

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

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

D).mm050,1(.ni33.14

E).mm050,1(.ni33.14

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

This Owner's Manual has been

developed to provide complete

instructions for the safe and

efficient operation of the

MQ Power

Before using this generator,ensure that the operating

individual has read and understands all instructions in

this manual.

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.

FOR YOUR SAFETY AND THE SAFETY OF OTHERS! 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 " ".

NOTE

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.

You WILL be KILLED or SERIOUSLY injured if you

do not follow directions.

You COULD be KILLED or SERIOUSLY injured if

you do not follow directions.

You CAN be injured if you do not follow directions

Gasoline engine exhaust gases contain

poisonous carbon monoxide. This gas is

colorless and odorless, and can cause

if inhaled. NEVER operate this

equipment in a confined area or enclosed structure that

does not provide ample free flow air.

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.

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.

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.

WARNING

DANGER

CAUTION

WARNING - LETHAL EXHAUST GASES

WARNING - BURN HAZARDS

WARNING - EXPLOSIVE FUEL

During operation of this generator, there

exists the possibility of

which can cause

or even

DANGER - ELECTROCUTION HAZARDS

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

SAFETY MESSAGE ALERT SYMBOLS

ALWAYS place the MPEC control switch

in the OFF/RESET position when the

generator is not in use.

ALWAYS wear approved

protection.

ALWAYS wear approved and

protection.

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,

or the surrounding environment

could be damaged if you do not

follow instructions.

NOTE

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 - OVER-SPEED CONDITIONS

CAUTION - ACCIDENTAL STARTING

CAUTION - RESPIRATORY HAZARDS

CAUTION - SIGHT AND HEARING HAZARDS

CAUTION - EQUIPMENT DAMAGE MESSAGES

NEVER operate equipment with covers,

or guards removed. Keep ,

, and clothing away from all

moving parts to prevent injury.

WARNING - ROTATING PARTS

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

RULES FOR SAFE OPERATION

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

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.

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.

DANGER - READ THIS MANUAL!

■

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.

■

HighTemperatures – 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.

■

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.

■

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.

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