MQ Power WHISPERWATT DCA-180SSV Guide

PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
Revision #1 (04/14/10)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
WHISPERWATTTM SERIES
MODEL DCA-180SSV
60 Hz GENERATOR
PARTS LIST NO. C0870301204
Serial Number 3770213~

PAGE 2 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)
Diesel engine exhaust and some of

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 3
1

PAGE 4 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)
TABLE OF CONTENTS
Specification and part
number are subject to
change without notice.
NOTE
MQ POWER DCA-180SSVMQ POWER DCA-180SSV
MQ POWER DCA-180SSVMQ POWER DCA-180SSV
MQ POWER DCA-180SSV
WHISPERWHISPER
WHISPERWHISPER
WHISPERWW
WW
WAA
AA
ATTTT
TTTT
TTTMTM
TMTM
TM
GENERATORGENERATOR
GENERATORGENERATOR
GENERATOR
California Proposition 65 Warning ..................................... 2
Here's How To Get Help .................................................... 3
Table Of Contents ............................................................. 4
Parts Ordering Procedures ............................................... 5
Specifications ................................................................... 6
Dimensions (Top, Side, 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
Generator Control Panel ............................................ 20-21
Engine Operating Panel .................................................. 22
Output Terminal Panel Familiarization ........................ 24-26
Load Application ............................................................. 27
Generator Outputs .......................................................... 28
Gauge Reading ............................................................... 29
Output Terminal Panel Connections ........................... 30-31
Setup ......................................................................... 32-35
Generator Start-up Procedure (Manual) ..................... 36-37
Generator Start-up Procedure (Auto Mode) .................... 38
Generator Shut-Down Procedure .................................... 39
Maintenance (Engine) ................................................ 40-42
Jacket Water Heater/battery Charger (Option) ................ 43
Maintenance (Trailer) ................................................. 44-47
Trailer Wiring Diagram ..................................................... 48
Generator Wiring Diagram ............................................... 49
Engine Wiring Diagram ................................................... 50
Generator Troubleshooting .............................................. 51
Engine Controller Troubleshooting ................................... 52
Troubleshooting Diagnostic Lamp ................................... 53
Explanation of Code in Remarks Column ....................... 54
Suggested Spare Parts .................................................. 55
Generator Assembly .................................................. 56-57
Control Panel Assembly ............................................ 58-59
Control Box Assembly ............................................... 60-63
Engine and Radiator Assembly ................................. 64-65
Output Terminal Assembly ......................................... 66-67
Battery Assembly ...................................................... 68-69
Muffler Assembly ...................................................... 70-71
Fuel Tank Assembly .................................................. 72-73
Enclosure Assembly ................................................. 74-77
Rubber Seals Assembly ............................................ 78-79
Nameplate and Decals .............................................. 80-81
Terms and Condition of Sale — Parts ............................ 82
COMPONENT DRACOMPONENT DRA
COMPONENT DRACOMPONENT DRA
COMPONENT DRAWINGSWINGS
WINGSWINGS
WINGS

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 5
1
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Truck 
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
r
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-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)
DCA-180SSV— SPECIFICATIONS
Table 1. Generator Specifications
Model DCA-180SSV
Type Revolving field, self ventilated,
open protected type synchronous generator
Armature Connection Star with Neutral
Phase 3
Standby Output 198 KVA (158 KW)
Prime Output 180 KVA (144 KW)
Voltag e — 1Ø 120, 127, 139, 240, 254, and 277V
Voltag e — 3Ø 208, 220, 240, 416, 440, and 480V
Frequency 60 Hz
Speed 1800 rpm
Power Factor 0.8
Aux. AC Power Single Phase, 60 Hz
Aux. Voltage/Output 120 VAC/ 4.8 Kw (2.4 kW x 2)
Dry Weight 11,136 lbs. (5,050 kg.)
Wet Weight 12,260 lbs. (5,560 kg.)
Table 2. Engine Specifications
Model VOLVO TAD722GE
Type 4 cycle, water-cooled, direct injection, turbo-charged
No. of Cylinders 6 cylinders
Bore x Stroke 5.15 in. x 5.90 in. (131 mm x 150 mm)
Displacement 740.2 cu. in. (12,130 cc)
Starting Electric 24 VDC
Coolant Capacity 11.6 gal. (44 liters)
Lube Oil Capacity 9.2 gal. (35 liters)
Fuel Type #2 Diesel Fuel
Fuel Tank Capacity 129 gal. (490 liters)
Fuel Consumption
11.2 gal. (42.2 L)/hr at full load 8.5 gal. (32.0 L)/hr at 3/4 load
5.9 gal. (22.4 L) at 1/2 load 3.7 gal (14.0 L) at 1/4 load
Battery 12V-150 Ah x 2

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 7
1
DCA-180SSV— DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
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E).mm050,1(.ni33.14

PAGE 8 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)
This Owner's Manual has been
developed to provide complete
instructions for the safe and
efficient operation of the
MQ Power Model DCA-180SSV
Whisperwatt™ Generator.
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 " Hazard Symbols " which
appear throughout this manual, and will be referenced in
conjunction with Safety " Message Alert Symbols ".
NOTE
DCA-180SSV— SAFETY MESSAGE ALERT SYMBOLS
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
DEATH if inhaled. NEVER operate this
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
Gasoline 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 electrocution,
electrical shock or burn, which can cause
severe bodily harm or even DEATH!
DANGER - ELECTROCUTION HAZARDS

DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10) — PAGE 9
1
DCA-180SSV— SAFETY MESSAGE ALERT SYMBOLS
ALWAYS place the Engine ON/OFF
switch in the OFF position and remove
the ignition key when the pump is not in
use.
ALWAYS wear approved respiratory
protection.
ALWAYS wear approved eye and
hearing 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 fingers , hands ,
hair and clothing away from all moving
parts to prevent injury.
WARNING - ROTATING PARTS

PAGE 10 — DCA-180SSV— OPERATION AND PARTS MANUAL — REV. #1 (04/14/10)
DCA-180SSV— RULES FOR SAFE OPERATION
The following safety guidelines should always be used when
operating the DCA-180SSVWhisperwatt™ AC Generator.
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
serious injury or even DEATH ! 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 bodily harm or even death.
■ 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
hot! components can cause serious
burns.
■ The engine of this generator requires an adequate free
flow of cooling air. NEVER 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 manual mode
unattended.
■ Refer to the VOLVO Engine Owner's Manual 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.