MQ Power WHISPERWATT Series Operation Manual
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MQ Power WHISPERWATT Series Operation Manual

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OPERATION MANUAL
WHISPERWATT™ SERIES
MODEL
DCA180SSJU4F3PD
60 Hz GENERATOR
(JOHN DEERE 6068HFG05 DIESEL ENGINE)
INSTRUCTION MANUAL NO. M3844301404
Revision #0 (11/01/22)
To find the latest revision of this publication or
associated parts manual, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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  • Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA180SSJU4F3PD 60 Hz GENERATOR (JOHN DEERE 6068HFG05 DIESEL ENGINE) INSTRUCTION MANUAL NO. M3844301404 Revision #0 (11/01/22) To find the latest revision of this publication or associated parts manual, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING PAGE 2 — DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA180SSJU4F3PD NOTICE 60 Hz Generator Specifications are subject to change without notice. Proposition 65 Warning ........... 2 Table of Contents ............. 3 Safety Decals ............4 Safety Information ..........5–10 Specifications ............11 Dimensions ............12 Installation ............14–15 General Information ..........

  • Page 4: Safety Decals

    SAFETY DECALS SAFETY DECALS NOTICE Safety decals are attached to the generator as shown in For safety decal part numbers, refer to the associated Figure 1. Keep these safety decals clean at all times. When parts manual. the safety decals become worn or damaged, contact your nearest dealer or the Multiquip Parts Department.

  • Page 5: Safety Information

    SAFETY INFORMATION Do not operate or service the generator before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all generator will be referenced with hazard symbols which times when operating this generator. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
  • Page 6 „ NEVER use accessories or attachments that are not being used. The generator should be stored in a clean, dry location out of the reach of children and unauthorized recommended by MQ Power for this generator. Damage to the generator and/or injury to the user may result. personnel.
  • Page 7 SAFETY INFORMATION ENGINE SAFETY „ Operation of the generator may create sparks that can start fi res around dry vegetation. A spark arrestor DANGER may be required. The operator should contact local fi re agencies for laws or regulations relating to fi re prevention „...
  • Page 8 „ The trailer should be adjusted to a level position at all times when towing. „ Refer to the MQ Power trailer manual for additional safety information. „ Raise and lock the trailer wheel stand in the upright position when towing.
  • Page 9 SAFETY INFORMATION ELECTRICAL SAFETY „ Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections DANGER may cause electrical shock and damage to the generator. „ NEVER touch the output terminals NOTICE during operation. Contact with the „...
  • Page 10 SAFETY INFORMATION EMISSIONS INFORMATION „ If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty NOTICE of water and contact the nearest doctor or hospital to seek medical attention. The diesel engine used in this equipment has been designed to reduce harmful levels of carbon monoxide CAUTION (CO), hydrocarbons (HC), and nitrogen oxides (NOx)

  • Page 11: Specifications

    SPECIFICATIONS Table 1. Generator Specifications Model DCA180SSJU4F3PD Type Revolving field, self-ventilated, open protected type synchronous generator Armature Connection Star with Neutral Phase Standby Output 158 kW (198 kVA) Prime Output 144 kW (180 kVA) 3Ø Voltage (L–L/L–N) 208Y/120, 220Y/127, 240Y/139 Voltage Change-Over Board at 3Ø...

  • Page 12: Dimensions

    DIMENSIONS Figure 2. Dimensions Table 3. Dimensions Reference Dimension Reference Dimension Letter in. (mm) Letter in. (mm) 44.29 (1,125) 41.34 (1,050) 35.24 (895) 88.19 (2,240) 11.81 (300) 141.73 (3,600) 35.24 (895) 51.18 (1,300) 44.29 (1,125) PAGE 12 — DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22)
  • Page 13 NOTES DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22) — PAGE 13...

  • Page 14: Installation

    GENERATOR GROUND LUG GROUND ROD GROUND CABLE REFERENCE NEC 250 Figure 3. Typical Generator Grounding Application NOTICE Trailer-mounted generators are the sole responsibility of MQ Power. PAGE 14 — DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22)
  • Page 15 INSTALLATION OUTDOOR INSTALLATION MOUNTING Install the generator in an area that is free of debris, The generator must be mounted on a solid foundation bystanders, and overhead obstructions. Make sure the (such as concrete) and set firmly on the foundation to generator is on secure, level ground so that it cannot slide isolate vibration of the generator when it is running.

  • Page 16: General Information

    • Voltage Selector Switch Table 2 for engine specifications. • Voltage Change-Over Board In keeping with MQ Power’s policy of constantly improving OUTPUT TERMINAL PANEL its products, the specifications quoted herein are subject The output terminal panel is provided with the following: to change without prior notice.

  • Page 17: General Paralleling Information

    GENERAL PARALLELING INFORMATION PARALLELING REACTIVE POWER (KVAR) LOAD SHARING Paralleling is the sharing of a load between two or more When generator sets operate in parallel, the alternator generator sets. field excitation system of each generator set controls the proportional sharing of the total reactive power LOAD SHARING requirements (kVAR) of the system.

  • Page 18: Major Components

    MAJOR COMPONENTS Table 4. Major Components ITEM NO. DESCRIPTION Muffler Assembly 11 12 Generator Assembly Battery Assembly Engine Assembly Aftertreatment Control Module Assembly Output Terminal Panel Assembly DEF Tank Assembly Fuel Tank Assembly Parallel Communication Receptacles Emergency Stop Switch Assembly Control and Operation Panel Assembly Voltage Change-Over Board Assembly Main Circuit Breaker Assembly...

  • Page 19: Control And Operation Panel

    CONTROL AND OPERATION PANEL Figure 5. Control And Operation Panel The definitions below describe the controls and functions 8. Main Circuit Breaker — 3-pole, 500-amp, of the control and operation panel (Figure 5). motor-controlled circuit breaker. Connects or disconnects the generator output from the output 1.

  • Page 20: Output Terminal Panel Familiarization

    OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The output terminal panel (Figure 6) shown below is The output terminal panel (Figure 6) is provided with the provided for the connection of electrical loads. Lift up on following: the cover to gain access to receptacles and terminal lugs.
  • Page 21 OUTPUT TERMINAL PANEL FAMILIARIZATION 120-Volt AC GFCI Receptacles NOTICE It is recommended that the GFCI receptacles be tested when the generator is initially uncrated. The receptacles should then be tested daily at startup. SINGLE-PHASE CS-6369 240/139 VAC TWIST-LOCK 50-AMP OUTPUT RECEPTACLES There are two 120-volt, 20-amp, GFCI (duplex NEMA 5-20R) receptacles provided on the output terminal panel.
  • Page 22 OUTPUT TERMINAL PANEL FAMILIARIZATION CONNECTING LOADS OVERCURRENT RELAY An overcurrent relay (Figure 11) is connected to the Loads can be connected to the generator via the output terminal panel, convenience receptacles, or cam-loks main circuit breaker. In the event of an overload, both the (Figure 10).

  • Page 23: Load Application

    LOAD APPLICATION SINGLE-PHASE LOAD THREE-PHASE LOAD Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase and equipment to ensure the wattage, amperage, frequency, power, use the following equation: and voltage requirements are satisfactorily supplied by the VOLTAGE ×...

  • Page 24: Powerbalance

    POWERBALANCE™ PowerBalance™ (Figure 12) is an optional load „ PowerBalance™ continuously monitors engine load by management solution that helps protect the engine generator sensing the engine exhaust temperature. from problems resulting from sustained low-load operations (defined as less than 30% of the generator full-load rating). POWERBALANCE™...

  • Page 25: Generator Outputs

    GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES Maximum Amps Table 8 shows the maximum amps the generator can A wide range of voltages (Table 7) is available for many different applications. provide. DO NOT exceed the maximum amps as listed. Table 7. Voltages Available Table 8.

  • Page 26: Output Terminal Panel Connections

    OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES Single-Phase 240-Volt UVWO Terminal Output Voltages Various output voltages can be obtained using the UVWO 1. Make sure the voltage change-over board is jumpered output terminal lugs. The voltages at the terminals are for 240-volt operation as shown in Figure 14.
  • Page 27 OUTPUT TERMINAL PANEL CONNECTIONS Single-Phase 480-Volt NOTICE UVWO Terminal Output Voltages ALWAYS make sure the connections to the UVWO 1. Make sure the voltage change-over board is jumpered terminals are tight and secure. The possibility exists for 480-volt operation as shown in Figure 18. of arcing that could cause a fire.

  • Page 28: Inspection/Setup

    INSPECTION/SETUP ENGINE OIL CHECK NOTICE 1. To check the engine oil level, place the generator on When adding engine oil, DO NOT overfill (Figure 23B). secure, level ground with the engine stopped. 2. Remove the dipstick from its holder (Figure 22) and wipe it clean.
  • Page 29 INSPECTION/SETUP FUEL CHECK Refueling Procedure WARNING DANGER Diesel fuel and its vapors are dangerous Fuel spillage on a hot engine can cause a to your health and the surrounding fire or explosion. If fuel spillage occurs, environment. Avoid inhalation of fumes wipe up the spilled fuel completely to prevent and contact with skin.
  • Page 30 INSPECTION/SETUP DEF Refueling (Continuous Operation) 3. NEVER overfill the fuel tank. When refueling, DO NOT wait for fuel to rise inside the filler neck (Figure 28). It is recommended to shut down the engine prior to Leave room for fuel expansion. Fuel expands when refilling the DEF tank.
  • Page 31 INSPECTION/SETUP Verify that the coolant level in the coolant reserve tank is between the MIN and MAX markings as shown in Figure 31. COOLING FINS MAX COLD MIN COLD Figure 32. Radiator (Cooling Fins) Figure 31. Coolant Reserve Tank FAN BELT TENSION Operation In Freezing Weather The engine fan belt is automatically tensioned and does When operating in freezing weather, be certain the proper...
  • Page 32 INSPECTION/SETUP Battery Cable Installation Battery Switch (Option) ALWAYS make sure the battery cables are properly Located in the engine compartment, the Battery switch connected to the battery terminals as shown in Figure 33. (Figure 34) connects and disconnects the battery (if The red cable is connected to the positive terminal of the equipped).

  • Page 33: Generator Start-Up Procedure (Single Unit)

    GENERATOR START-UP PROCEDURE (SINGLE UNIT) BEFORE STARTING 3. Make sure the GFCI and auxiliary circuit breakers are placed in the OFF position (Figure 37). CAUTION The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. WARNING NEVER manually start the engine with the main, GFCI, or auxiliary circuit breakers in the ON (closed) position.
  • Page 34 GENERATOR START-UP PROCEDURE (SINGLE UNIT) 6. Verify that the Main Circuit Breaker OFF lamp 9. On the touch display, press the Page Down button (Figure 40) is illuminated (RED). This indicates that (Figure 43) to scroll back to the Home screen (1 of 7). the circuit breaker contacts are open.
  • Page 35 GENERATOR START-UP PROCEDURE (SINGLE UNIT) APPLICATION SELECTION 5. Verify that the A1 - Single DG/Analog LS status indicator is ON (GREEN). See Figure 49. 1. On the touch display, press the AOP button (Figure 45). Figure 45. AOP Button 2. Verify that the Main AOP screen (Figure 46) is displayed.
  • Page 36 GENERATOR START-UP PROCEDURE (SINGLE UNIT) STARTING (SEMI-AUTO MODE) NOTICE 1. On the touch display, press the Mode Change The Mode Change button will display one of the four button (Figure 52). Operational Mode icons, depending on which mode is selected. For example, if the Auto Mode button is selected, then the Mode Change button will display the Auto Mode icon.
  • Page 37 GENERATOR START-UP PROCEDURE (SINGLE UNIT) 10. Place the GFCI and auxiliary circuit breakers NOTICE (Figure 60) in the ON position to send power to the GFCI (120V) and auxiliary (dual-voltage) receptacles. When the Idle Speed Inhibit button (located on the AOP1 screen) has been pressed and the Low Idle Speed Inhibited status indicator is ON (GREEN), the engine will not undergo the standard idling warmup...
  • Page 38 GENERATOR START-UP PROCEDURE (SINGLE UNIT) 13. Press the Page Up button (Figure 63) to scroll to 9/30/2020 - 5:45:32 PM screen 5 of 7. Active Power (P) GEN ISLAND SEMI 2500 2000 Apparent Power (S) GEN 1500 6 / 7 1000 Reactive Power (Q) GEN Figure 63.
  • Page 39 GENERATOR START-UP PROCEDURE (SINGLE UNIT) STARTING (AUTO MODE) STARTING (MANUAL MODE) Manual mode enables the use of the Voltage Up/Down WARNING buttons (Figure 70) on the AOP1 screen for manual voltage When running the generator in Auto mode, remember adjustment. that the generator can start up at any time without warning.

  • Page 40: Generator Shutdown Procedure (Single Unit)

    GENERATOR SHUTDOWN PROCEDURE (SINGLE UNIT) NORMAL SHUTDOWN PROCEDURE 5. Press the STOP button (Figure 76) on the touch display. The engine will stop after a 30-second WARNING cool-down period. NEVER stop the engine suddenly except in an emergency. 1. Place the load’s ON/OFF switch in the OFF position. 2.
  • Page 41 NEVER be used for routine stopping of protection devices and fault codes. If necessary, contact the engine. MQ Power for additional technical support. To stop the engine in the event of an emergency: NOTICE 1. Press the Emergency Stop switch, located on the...

  • Page 42: Generator Start-Up Procedure (Parallel Operation)

    GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) PARALLEL SIGNAL SWITCH GENERATOR #1 OUTPUT TERMINAL PANEL GENERATOR #2 Figure 80. Communication Cable Connections (Two Generators) PARALLEL SIGNAL SWITCH GENERATOR GENERATOR GENERATOR OUTPUT TERMINAL PANEL Figure 81. Communication Cable Connections (Three Or More Generators) PAGE 42 —...
  • Page 43 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) COMMUNICATION AND POWER CONNECTIONS NOTICE (THREE OR MORE GENERATORS) To ensure stable operation of multiple generator units NOTICE connected in parallel and working as one unit, it is necessary to maintain equal voltage, frequency, and A maximum of 32 generators can be operated in engine governor characteristics between them.
  • Page 44 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) PARALLEL OPERATION Application Selection (50/50 Loadshare) (TWO OR MORE GENERATORS) Perform the following procedure on each generator: There are two available applications for parallel operation of 1. On the touch display, press the AOP button (Figure 82). multiple generators —...
  • Page 45 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 5. Verify that the A2 - 50/50 Loadshare CAN status 8. Verify that the Home screen (1 of 7) is displayed. See indicator is ON (GREEN). See Figure 86. Figure 89. 9/30/2020 - 5:45:07 PM Active Power (P)GEN DG BLOCKED FOR START Apparent Power (S)GEN...
  • Page 46 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 12. Verify that the Main AOP screen (Figure 93) is 4. Press the Controller Settings Shortcut button displayed. If the Main AOP screen is not displayed, (Figure 95) on the touch display. press the Main AOP button (Figure 84). Figure 95.
  • Page 47 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 7. Verify that the Text Keyboard screen (Figure 98) is displayed. 7531 Figure 100. Password Required Screen 12. Verify that the Passcode Keypad screen (Figure 101) Figure 98. Text Keyboard Screen is displayed. 8. Using the keyboard, enter the parameter value 7531, then press the Enter key as shown in Figure 98.
  • Page 48 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 17. Press the Save button (Figure 104). The touch display NOTICE will return to the Search Results screen (Figure 105). The Internal Communication ID value is unique for each generator (Figure 102). A different numerical value must be entered for each generator.
  • Page 49 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) Starting (50/50 Loadshare) 3. Press the Semi Mode button (Figure 109). SEMI MODE NOTICE When multiple generators are connected in parallel to act as a single unit, it is important that the voltage and phasing of each generator be synchronized. NOTICE DO NOT try to run parallel units in Manual mode.
  • Page 50 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 9. Verify that the Main Circuit Breaker ON lamp NOTICE (Figure 114) is illuminated (GREEN). This indicates that If the engine fails to start on the first crank attempt, the circuit breaker contacts are closed and power two additional crank cycles will occur automatically.
  • Page 51 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) EZ CONNECT APPLICATION 2. Verify that the Main AOP screen (Figure 117) is displayed. Perform the following procedures to operate two or more units in parallel using the EZ Connect application. Before Starting WARNING ALWAYS connect the output terminals to the load before starting up the generators.
  • Page 52 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 6. Press the EZ Connect Setup ON/OFF button 9. Next, the Receiving Application screen will be (Figure 121). displayed (Figure 124). 9/30/2020 - 5:45:45 PM EZ Connect Setup ON/OFF Receiving Application A1 - Single DG/ 480V-3PH-60Hz Auto Mode Island...
  • Page 53 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 13. Press the Main Menu button (Figure 127). 17. Verify that screen 2 of 7 is displayed (Figure 131), then press the Power Management button. 9/30/2020 - 5:45:16 PM EIC Engine Speed (SPN) ISLAND SEMI Auto.
  • Page 54 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 21. Verify that the Main AOP screen (Figure 134) is 28. Verify that the Main Menu screen is displayed (Figure 137), then press the Supervision button. displayed. If the Main AOP screen is not displayed, press the Main AOP button (Figure 118).
  • Page 55 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) Starting (EZ Connect, Semi-Auto Mode) 3. Press the Semi Mode button (Figure 141). SEMI MODE NOTICE DO NOT try to run parallel units in Manual mode. 1. On generator #1, press the Mode Change button (Figure 139) on the touch display. Figure 141.
  • Page 56 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 6. Listen for any abnormal noises. If any abnormalities 9/30/2020 - 5:46:31 PM exist, shut down the engine and correct the problem. 7. On the touch display (Figure 143), verify that the Easy connect appl. voltage (V) and frequency (Hz) match the expected output.
  • Page 57 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 19. Before proceeding, confirm that there are no active 3. The paralleled system will now start up or shut down alarms on any of the generators in the layout. The connected generators as needed, utilizing a 90/30 presence of the Alarm icon (Figure 148) on the status threshold scheme: Once the load has reached 90% of bar indicates that there are active alarms.
  • Page 58 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 3. Verify that the EZ Connect Setup Enabled status WARNING indicator (Figure 151) is OFF. Incorrect electrical connections could cause severe EZ Connect Setup damage to equipment and serious injury or death to personnel. Enable Before Starting Perform steps 1–9 under Before Starting in the Generator Start-Up Procedure (Single Unit) section of this manual.
  • Page 59 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 4. Press the Select Application 4 button (Figure 155). 9/30/2020 - 5:45:07 PM SELECT Active Power (P)GEN DG BLOCKED FOR START APPLICATION 4 Apparent Power (S)GEN 1 / 7 GEN Voltage L3-L1 Figure 155. Select Application 4 Button GEN Frequency L1 0.00 5.
  • Page 60 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 11. Repeat steps 1–3 to return to the Main AOP screen NOTICE (Figure 162). Verify that the Fixed Power status While operating in Auto mode, should a power outage indicator is ON (GREEN). occur while connected to an automatic transfer switch (ATS), the ATS will start the generator automatically via the generator’s auto-start contacts connected to the ATS’s start contacts.
  • Page 61 GENERATOR START-UP PROCEDURE (PARALLEL OPERATION) 2. Verify that the four Operational Mode buttons 5. When the generator is connected to a building’s AC (Figure 164) are displayed just above the Mode power source via an automatic transfer switch (ATS), Change button. and the building’s power has been interrupted (power outage), the ATS will start the generator automatically AUTO MODE MANUAL MODE...

  • Page 62: Generator Shutdown Procedure (Parallel Operation)

    GENERATOR SHUTDOWN PROCEDURE (PARALLEL OPERATION) SHUTDOWN PROCEDURE 6. On generator #1, press the STOP button (Figure 170) on the touch display. The engine will shut down after a (PARALLEL OPERATION) 30-second cool-down period. WARNING NEVER stop the engine suddenly except in an emergency.
  • Page 63 GENERATOR SHUTDOWN PROCEDURE (PARALLEL OPERATION) 10. The Receiving Application screen will be displayed next (Figure 173). After this message has cleared, repeat steps 8–10 on the remaining units. 9/30/2020 - 5:45:45 PM Receiving Application A1 - Single DG/ 480V-3PH-60Hz Auto Mode Island Analog LS Series Wye...

  • Page 64: Maintenance

    If John Deere COOL-GARD II is used, flushing intervals may be extended. (See Testing Diesel Coolant in engine manual.) Actual service should take place when indicated by diagnostic gauge. Contact MQ Power for DOC replacement. Replace the air cleaner element when the restriction indicator shows a vacuum of 635 mm (25 in.) H Make sure SW1 and SW2 are OFF before performing the measurement.
  • Page 65 MAINTENANCE GENERAL INSPECTION Primary And Secondary Air Cleaner Elements Every 250 hours: Remove the air cleaner elements and Prior to each use, the generator should be cleaned and inspected for deficiencies. Check for loose, missing, or clean them with a light spray of compressed air. damaged nuts, bolts, or other fasteners.
  • Page 66 MAINTENANCE Air Cleaner Restriction Indicator ENGINE FUEL FILTER The air cleaner is equipped with a restriction indicator Inspect the engine fuel filter daily. If the fuel filter has (Figure 176). As the air cleaner element becomes clogged, collected a significant amount of water and sediment at air intake restriction increases and the indicator signal the bottom of the cup, it should be drained off immediately.
  • Page 67 MAINTENANCE Fuel Filter Element Replacement Fuel Water Separator Sediment Bowl 1. Using a filter wrench, remove the fuel filter cartridge 1. Remove the sediment bowl (Figure 180) from the fuel from the filter head (Figure 179). water separator cartridge. FILTER HEAD RETAINING RING...
  • Page 68 MAINTENANCE Fuel Water Separator Replacement CLEANING INSIDE THE FUEL TANK 1. Using a filter wrench, remove the fuel water If necessary, drain the fuel inside the fuel tank completely. separator cartridge (Figure 181) from the cartridge Using a spray washer (Figure 182), wash out any deposits head.
  • Page 69 MAINTENANCE DRAINING THE ENGINE OIL ENGINE OIL FILTER REPLACEMENT NOTICE 1. Run the engine until the engine coolant reaches a temperature of 140°F (60°C). Filter head appearance may vary. 2. Turn the engine OFF. 1. Clean the area around the oil filter head (Figure 184). 3.
  • Page 70 MAINTENANCE DRAINING THE ENGINE COOLANT FLUSHING OUT THE RADIATOR AND REPLACING COOLANT WARNING WARNING DO NOT remove the pressure cap from the radiator while the engine is hot! Wait until the coolant Allow the engine to cool before flushing temperature is below 120°F (50°C) before removing out the radiator.
  • Page 71 MAINTENANCE DRIVE BELT TESTING THE GFCI RECEPTACLE Drive Belt Tension NOTICE The GFCI receptacle is designed to interrupt power A slack drive belt may contribute to overheating or when a ground fault exists to prevent injuries and shock insufficient charging of the battery. Adjust the drive belt in hazards.
  • Page 72 MAINTENANCE GENERATOR STORAGE 4. Press the TEST button (Figure 191) on the GFCI receptacle and verify that the status LED turns OFF. For long-term storage of the generator the following is recommended: „ Drain the fuel tank completely. Treat with a fuel stabilizer if necessary.
  • Page 73 MAINTENANCE ENGINE BLOCK HEATER AND When using the generator in hot climates there is no reason to apply power to the engine block heater. However, if the OPTIONAL INTERNAL BATTERY CHARGER generator will be used in cold climates it is always a good 120 VAC INPUT RECEPTACLES idea to apply power to the engine block heater at all times.
  • Page 74 MAINTENANCE EMISSION CONTROL PREVENTIVE MAINTENANCE PROGRAMS The emission control system employed with this diesel Most challenging to a rental organization is the fact that a engine consists of a diesel oxidation catalyst (DOC) customer’s power assumptions may not meet the minimum and a selective catalytic reduction (SCR) catalyst load requirements of the power equipment selected.
  • Page 75 MAINTENANCE SELECTIVE CATALYTIC REDUCTION (SCR) 2. Check Engine Indicator (Red) — This symbol is displayed when an engine fault occurs. The engine will Diesel engines can be run with a lean burn air-to-fuel ratio, undergo an emergency stop. Check active diagnostic to ensure the full combustion of soot and to prevent the trouble codes (DTC).
  • Page 76 MAINTENANCE Regeneration Guidelines For the safe operation of equipment, protection of the surrounding area, and prevention of bodily harm, use the guidelines below when regeneration is required: „ DO NOT perform regeneration in conditions where it may be unsafe due to high exhaust temperatures. „...
  • Page 77 MAINTENANCE The Regen Needed indicator (Figure 198) will appear 4. Verify that the AOP 1 screen is displayed (Figure 202). on the touch display, indicating that forced DOC/SCR 8/25/2021 - 4:32:05 PM 102% regeneration is required. When this occurs, perform the following procedure: Diagnostic Mode DPF Regen Not...
  • Page 78 MAINTENANCE Inhibit Regeneration DIESEL EXHAUST FLUID (DEF) MAINTENANCE It may be necessary to inhibit regeneration in conditions The amount of fluid in the DEF tank will be indicated on where it may be unsafe for elevating exhaust temperatures. the Exhaust After-Treatment Dashboard screen during operation (Figure 206).
  • Page 79 MAINTENANCE The Check DEF indicator (Figure 207) displayed on the Exhaust After-Treatment Dashboard screen indicates one of the following: „ The level of diesel exhaust fluid in the DEF tank is below 10% capacity. Refer to Table 13, DEF Level System Action.

  • Page 80: Troubleshooting (Faults)

    TROUBLESHOOTING (FAULTS) FAULTS/ALARMS 4. To reset an alarm, stop operation, shut down the engine, allow a sufficient cooling period, then inspect This unit is equipped with engine protection devices that the unit and repair the problem before restarting automatically shut down the engine when a fault occurs. operation.
  • Page 81 TROUBLESHOOTING (FAULTS) DIAGNOSTIC MODE Diagnostic mode allows the digital controller to communicate with the engine control module (ECM) to view active fault messages and codes as well as previous fault occurrences which have been recorded in the ECM. Whenever the generator cannot be started due to a fault, place the generator in Diagnostic mode to identify the problem.
  • Page 82 TROUBLESHOOTING (FAULTS) Table 14. Automatic Engine Shutdown System Fault Code Condition Display Message Setpoint Timer Fail Class 1000 Reverse Power -P> 1 –10% 10 s Warning 1010 Reverse Power -P> 2 –15% 10 s Controlled Stop 1030 Over Current I> 1 110% 30 s Warning...
  • Page 83 TROUBLESHOOTING (FAULTS) Table 14. Automatic Engine Shutdown System Fault Code Condition Display Message Setpoint Timer Fail Class 4570 Start Failure Start failure Trip GB 4580 Stop Failure Stop failure 30 s Shutdown 4610 Low DEF Level DEF Low 15% WA –16% Warning 4620...
  • Page 84 TROUBLESHOOTING (FAULTS) Table 15. Fail Class Actions (Engine Running) Alarm Cool Down Fail Class Alarm Horn De-Load Trip of GB Trip of MB Stop Genset Display Generator Block – – – – – ✓ ✓ – – – – – Warning ✓...

  • Page 85: Troubleshooting (Generator)

    TROUBLESHOOTING (GENERATOR) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 17 below for diagnosis of the generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 17.

  • Page 86: Troubleshooting (Engine)

    TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) Symptom Possible Problem Solution No fuel reaching injection pump? Add fuel. Check entire fuel system. Defective fuel pump? Replace fuel pump. Fuel fi lter clogged? Replace fuel fi lter and clean tank. Faulty fuel supply line? Replace or repair fuel line.
  • Page 87 TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) - continued Symptom Possible Problem Solution Air fi lter blocked? Clean or replace air fi lter. Low engine power output and low speed, Incorrect valve clearances? Adjust valves per engine specifi cation. black exhaust smoke. Malfunction at injector? See engine manual.

  • Page 88: Generator Wiring Diagram (M3814001803)

    GENERATOR WIRING DIAGRAM (M3814001803) PAGE 88 — DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22)

  • Page 89: Engine Wiring Diagram (M3814102103)

    ENGINE WIRING DIAGRAM (M3814102103) DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22) — PAGE 89...

  • Page 90: John Deere Wiring Diagram (M3814102203)

    JOHN DEERE WIRING DIAGRAM (M3814102203) PAGE 90 — DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22)

  • Page 91: Parallel Circuit Diagram (M3814300003)

    PARALLEL CIRCUIT DIAGRAM (M3814300003) DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22) — PAGE 91...

  • Page 92: Mcb Sequence Diagram (M3814200203)

    MCB SEQUENCE DIAGRAM (M3814200203) PAGE 92 — DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22)

  • Page 93: Battery Charger Wiring Diagram

    BATTERY CHARGER WIRING DIAGRAM BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) TO CHASSIS GROUND GREEN 16 AWG. TO STARTER “B” TERMINAL RED 16 AWG. 120 VAC INPUT, INSERT EXTERNAL POWER CORD HERE. NOTES: NEMA 5-15, 15A, 120 VAC, P/N EE6176 (HBL5278C/HUBBLE RECEPTACLE).

  • Page 94: Appendix

    APPENDIX TOUCH DISPLAY UNIT DIGITAL ICONS 9/30/2020 - 5:45:07 PM Figure 213. Status Bar Table 18. Status Bar Icons Item Description Fuel Level Indicates the current fuel level. Running Hours Indicates the total running hours. Date and Time Indicates the controller date and time. Language Press to open Language (shortcut).
  • Page 95 APPENDIX 9/05/2019 - 12:46:16 255 h ISLAND SEMI Active Power (P) GEN Apparent Power (S) GEN 1 / 7 GEN Voltage L3-L1 GEN Frequency L1 0.00 CAN ID: 1 Priority: 1 Figure 214. Home Screen (1 of 7) Table 19. Home Screen Icons Item Description Settings...
  • Page 96 APPENDIX 9/30/2020 - 5:45:16 PM EIC Engine Speed (SPN) DG BLOCKED FOR START Auto. Mains Island operation Peak shaving Failure EIC Engine Oil Pressure 0.00 Mains Power Fixed Power Load take over Export 2 / 7 EIC Engine Coolant Power Remote Dry alternator management...
  • Page 97 APPENDIX 9/30/2020 - 5:45:20 PM GEN Voltage L1-L2 DG BLOCKED FOR START BB Voltage L1-L2 480 V 480 V 60.0 Hz 60.0 Hz 3 / 7 GEN Frequency L1 0.00 240 V 208 V 60.0 Hz 60.0 Hz Busbar Frequency L1 0.00 Figure 216.
  • Page 98 APPENDIX 9/30/2020 - 5:45:24 PM GEN Voltage L1-L2 ISLAND SEMI 1000 1000 1000 GEN Voltage L2-L3 4 / 7 GEN Voltage L3-L1 Phi BB L1-DGL1 -180.0 G V L1-L2 G V L2-L3 G V L3-L1 deg. Figure 217. Output Voltage Status Screen (4 of 7) Table 22.
  • Page 99 APPENDIX 9/30/2020 - 5:45:28 PM Current L1 ISLAND SEMI 1200 1200 1200 Current L2 5 / 7 Current L3 Active Power (P) GEN Current L1 Current L2 Current L3 Figure 218. Generator Amperage Screen (5 of 7) Table 23. Generator Amperage Screen Icons Item Description Menu...
  • Page 100 APPENDIX 9/30/2020 - 5:45:32 PM Active Power (P) GEN ISLAND SEMI 2500 2000 Apparent Power (S) GEN 1500 6 / 7 1000 Reactive Power (Q) GEN 180.0 90.00 1800 kVAR 0.80 EIC Coolant EIC Engine Oil EIC speed temperature Pressure Figure 219.
  • Page 101 APPENDIX 9/30/2020 - 5:45:36 PM GEN Voltage L1-L2 SYNCHRONIZING BB Voltage L1-L2 7 / 7 GEN Frequency L1 60.10 -0.5 -1.0 Busbar Frequency L1 60.10 df [Hz] dV [%] Figure 220. Synchronization Status Screen (7 of 7) Table 25. Synchronization Status Screen Icons Item Description Menu...
  • Page 102 APPENDIX 9/30/2020 - 5:45:23 PM Figure 221. Main Menu Screen Table 26. Main Menu Screen Icons Item Description Home Press to return to the Home screen. Alarm Press to view Alarm(s). Logs Press to view logs. Service Press to view the Service Menu. Setup Press to view the Setup screen.
  • Page 103 APPENDIX 9/30/2020 - 5:47:22 PM Figure 222. Controller Settings Groups Screen Table 27. Controller Settings Groups Screen Icons Item Description Back Press to return to the previous display. Protection Press to view a list (group) of controller Protection settings. Synchronization Press to view a list (group) of controller Synchronization settings.
  • Page 104 APPENDIX 9/30/2020 - 5:46:31 PM Easy connect appl. Figure 223. Supervision Screen Table 28. Supervision Screen Icons Item Description Menu Press to view the Menu screen. Displays the system state. Live System Overview NOTE: Actual system shown depends on your plant configuration. Figure 224.
  • Page 105 APPENDIX Figure 225. Value Keyboard Table 30. Value Keyboard Icons Item Description Value Displays the value you are entering. Cancel Press to cancel the changes. Backspace Press to delete the last character. Forward Delete Press to delete the next character. Enter Press to confirm the value entered.
  • Page 106 APPENDIX Figure 226. Passcode Keypad Table 31. Passcode Keypad Icons Item Description Value Displays the value you are entering. Cancel Press to cancel the changes. Backspace Press to delete the last character. Forward Delete Press to delete the next character. Enter Press to confirm the value entered.
  • Page 107 APPENDIX 9/30/2020 - 5:45:45 PM A1 - Single DG/ 480V-3PH-60Hz Auto Mode Island Analog LS Series Wye A2 - 50/50 Power 460V-3PH-60Hz Semi-Auto Mode Loadshare CAN Management Series Wye 208V-3PH-60Hz A3 - EZ Connect Fixed Power Parallel Wye A4 - Fixed Power EZ Connect Setup 240V-3PH-60Hz to Mains...
  • Page 108 APPENDIX 8/25/2021 - 4:32:05 PM 102% Diagnostic Mode DPF Regen Not DPF Active Regen Manual Mode Active Active Needed Needed Low Idle Speed Regen Needed - DPF Active Regen Inhibited Lowest Level Activated Force Purge Regen Needed - High Exhaust Temperature Activated Moderate Level...
  • Page 109 APPENDIX 9/30/2020 - 5:46:44 PM 7531 Internal COM ID 1 / 1 Search Results Figure 229. Controller Settings List Screen Table 34. Controller Settings List Screen Icons Item Description Edit Press to edit the setting. Scroll Page Right Press to scroll the page to the right. Scroll Page Left Press to scroll the page to the left.
  • Page 110 APPENDIX 9/30/2020 - 5:47:22 PM 7351 Int. comm. ID Setpoint Enable High Alarm Inverse Proportional Auto-Acknowledge Figure 230. Edit Internal Communication ID Screen Table 35. Edit Internal Communication ID Screen Icons Item Description Setting Displays the name of the current setting. Cancel Press to cancel the changes.
  • Page 111 APPENDIX 9/05/2019 - 12:46:16 255 h Figure 232. Alarm Screen Table 37. Alarm Screen Icons Item Description Indicates the current state of the alarm: Alarm State Acknowledged alarm. Unacknowledged alarm. Acknowledge Press to acknowledge alarm. Alarm Settings Press to view the alarm configuration. Alarm List Swipe to scroll the alarm list up or down.
  • Page 112 APPENDIX 9/30/2020 - 5:45:45 PM Figure 233. Exhaust After-Treatment Dashboard Screen Table 38. Exhaust After-Treatment Dashboard Screen Icons Item Description Minimum DEF Level (%) Displays the minimum level for the diesel exhaust fluid. Diesel Exhaust Fluid Level (%) Indicates the current level of the diesel exhaust fluid. Diesel Particle Filter (DPF) Inhibit When lit (yellow), indicates that regeneration is inhibited.
  • Page 113 NOTES DCA180SSJU4F3PD 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (11/01/22) — PAGE 113...
  • Page 114 © COPYRIGHT 2022, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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