MQ Power WHISPERWATT DCA180SSK Guide

OPERATION AND PARTS MANUAL
PARTS LIST NO. C0874300704A
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES.
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
WHISPERWATT™ SERIES
MODEL DCA180SSK (STD.)
60 HZ GENERATOR
(KOMATSU SA6D108E-2 DIESEL ENGINE)
Revision #3 (06/11/09)

PAGE 2 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
PROPOSITION 65 WARNING

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 3
NOTE PAGE

PAGE 4 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
TABLE OF CONTENTS
NOTE
Specification and part
number are subject to
change without notice.
MQ Power DCA-180SSK
AC Generator
Proposition 65 Warning ..............................................2
Table Of Contents ......................................................4
Parts Ordering Procedures ........................................5
Rules For Safe Operation ...................................... 6-9
Towing ......................................................................10
Trailer Safety Guidelines .................................... 11-17
Trailer Wiring Diagram..............................................18
Electrical Brake Troubleshooting ..............................19
Hydraulic Brake Troubleshooting .............................20
Operation And Safety Decals ............................. 21-24
Specifications ...........................................................25
General Information ........................................... 26-27
Major Components ..................................................28
Dimensions (Top, Side And Rear)............................29
Control Panel ...................................................... 30-31
Engine Operating Panel ..................................... 32-33
Output Terminal Panel Overview ........................ 34-39
Installation .......................................................... 40-41
Pre-Setup ........................................................... 42-45
Load Application ......................................................46
Generator Start-Up Procedure (Manual) ........... 47-51
Generator Start-up Procedure (Auto) ................ 52-53
Generator Shut-Down Procedure ............................54
Maintenance ...................................................... 55-57
Generator Wiring Diagram .......................................58
Engine Wiring Diagram ............................................59
Troubleshooting (Engine) ................................... 60-61
Troubleshooting (Engine/Generator) .......................62
Troubleshooting (MPEC) .......................................... 63
Explanation Of Codes In Remarks Column .............64
Suggested Spare Parts ............................................65
COMPONENT DRAWINGS
Generator Assembly .......................................... 66-67
Control Panel Assembly ..................................... 68-69
Control Box Assembly ........................................ 70-71
Engine Radiator Assembly ................................. 72-73
Engine Operating Panel Assembly .................... 74-75
Output Terminal Assembly ................................. 76-77
Battery Assembly ............................................... 78-79
Muffler Assembly ............................................... 80-81
Fuel Tank Assembly ........................................... 82-83
Enclosure Assembly ........................................... 84-87
Enclosure Lining Assembly ................................ 88-89
Enclosure (Rubber Seals) .................................. 90-91
Name Plate and Decals ..................................... 92-95
Terms and Conditions Of Sale — Parts ...................96

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 5
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:
❒❒
❒❒
❒ Dealer Account Number
❒❒
❒❒
❒ Dealer Name and Address
❒❒
❒❒
❒ Shipping Address (if different than billing address)
❒❒
❒❒
❒ Return Fax Number
❒❒
❒❒
❒ Applicable Model Number
❒❒
❒❒
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex ✓DHL
■ Priority One ✓ Tr u ck
■ Ground
■Next Day
Allorders are treated as StandardOrders
andwillshipthe same day if receivedprior
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
[email protected].
To obtain an MQ Account, contact your
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
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
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
Order via Phone: Domestic (US) Dealers Call:
International Customers should con-
tact their local Multiquip Representatives
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
Note: Discounts Are Subject To Change
Effective:
PARTS ORDERING PROCEDURES

PAGE 6 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
RULES FOR SAFE OPERATION
RULES FOR SAFE OPERATION
■ NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■ 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.
■ High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with hot components can cause serious
burns.
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION:
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.
The following safety guidelines should always be used when
operating the DCA-180SSK portable generator:
GENERAL SAFETY
■ DO NOT operate or service this equipment before
reading this entire manual.
■ 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.
■ 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.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■ Always check the machine for loosened threads or bolts
before starting.
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
■ Always use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it to
cool. DO NOT smoke around or near the
machine. Fire or explosion could result
from fuel vapors, or if fuel is spilled on a
hot engine.
■ 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.
■ Topping-off to filler port is dangerous, as it tends to spill
fuel.
■ Always refuel in a well-ventilated area,
away from sparks and open flames.

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 7
RULES FOR SAFE OPERATION
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
■ Backfeed to a utility system can cause electrocution
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.
Never use damaged or worn cables when
connecting power tools or 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 and
electrical shock.
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
■ DO NOT touch or open any of the below
mentioned components while the
generator is running. Always allow
sufficient time for the engine and generator
to cool before performing maintenance.
Radiator
1. 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.
2. Coolant Drain Plug - Removing the coolant drain plug
while the engine is hot will result in hot coolant to gush
out of the coolant drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
3. Engine Oil Drain Plug - Removing the engine oil drain
plug while the engine is hot will result in hot oil to gush
out of the oil drain plug, therefore causing severe
scalding to any persons in the general area of the
generator.
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
■ NEVER touch output terminals during operation. This is
extremely dangerous.
Always stop the machine when
contact with the output terminals.

PAGE 8 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
RULES FOR SAFE OPERATION
■ NEVER Run engine without air filter. Severe engine
damage may occur.
■ Always service air cleaner frequently to prevent carburetor
malfunction.
■ Always disconnect the battery before performing service
on the generator.
■ Always be sure the operator is familiar with proper safety
precautions and operations techniques before using
generator.
■ Always store equipment properly when not in use.
Equipment should be stored in a clean, dry location out of
the reach of children.
■ DO NOT leave the generator running in the manual mode
unattended.
■ DO NOT allow unauthorized people to operate this
equipment.
■ Always read, understand, and follow procedures in
Operator’s Manual before attempting to operate equipment.
■ Refer to the Komatsu Engine Owner's Manual for engine
technical questions or information.
Loading and Unloading (Crane)
■ Before lifting, make sure the generator's lifting hook is
secure and that there is no apparent damage to the
generator itself (loose screws, nuts and bolts). If any
part is loose or damaged, please take corrective action
before lifting.
■ Always drain fuel prior to lifting.
■ Always make sure crane or lifting device has been
properly secured to the hook of guard frame on generator.
■ NEVER lift the machine while the engine is running.
■ Use adequate lifting cable (wire or rope) of sufficient
strength.
■ When lifting the generator, always use the balanced
center-point suspension hook and lift straight upwards.
■ NEVER allow any person or animal to stand underneath
the machine while lifting.
■ When loading the generator on a truck, be sure to use
the front and back frame bars as a means to secure the
generator during transport.
Battery
Never over fill the battery with water above
the upper limit.
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION :
The battery contains acids that can cause injury to the eyes
and skin.To avoid eye irritation, always wear safety glasses.
Use well insulated gloves when picking up the battery. Use
the following guidelines when handling the battery:
1. DO NOT drop the battery. There is the possibility of risk
that the battery may explode.
2. 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.
3. Always keep the battery charged. If the battery is not
charged a buildup of combustible gas will occur.
4. Always keep battery charging and booster cables in good
working condition. Repair or replace all worn cables.
5. Always recharge the battery in an open air environment,
to avoid risk of a dangerous concentration of combustible
gases.
6. In case the battery liquid (dilute sulfuric acid) comes in
contact with clothing or skin , rinse skin or clothing
immediately with plenty of water.
7. In case the battery liquid (dilute sulfuric acid) comes in
contact with your eyes, rinse eyes immediately with
plenty of water, then contact the nearest doctor or hospital,
and seek medical attention.

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 9
RULES FOR SAFE OPERATION
Transporting
■ Always shutdown engine before transporting.
■ Tighten fuel tank cap securely.
■ Drain fuel when transporting generator over long distances
or bad roads.
■ Always tie-down the generator during transportation by
securing the generator.
■ If generator is mounted on a trailer, make sure trailer
complies with all local and state safety transportation
laws. See page 10 for basic towing procedures.
Emergencies
■ Always know the location of the nearest fire extinguisher
and first aid kit . Know the location of the nearest telephone.
Also know the phone numbers of the nearest ambulance ,
doctor and fire department .
Maintenance Safety
■ NEVER lubricate components or attempt service on a
running machine.
■ 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.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, coolant,
fuel, and fuel filters.
■ DO NOT use plastic containers to dispose of hazardous
waste.
■ DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source

PAGE 10 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 1) that supports the generator and the towing vehicle
are in good operating condition and both units are
mechanically sound.
The following list of suggestions should be used when towing
your generator:
Towing Safety Precautions
■ ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
■ ALWAYS make sure the vehicle and trailer directional,
backup, brake, and trailer lights are connected and working
properly.
■ Remember the maximum speed unless otherwise posted for
highway towing is 45 MPH. Recommended off-road towing
is not to exceed 10 MPH or less depending on type of terrain.
■ Place chocked blocks underneath wheel to prevent rolling,
while parked.
■ Place support blocks underneath the trailer's bumper to
prevent
tipping , while parked.
■ Use the trailer's hand winch to adjust the height of the trailer,
then insert locking pin to lock wheel stand in place, while
parked.
■ Avoid sudden stops and starts.This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gas milage.
■ Avoid sharp turns to prevent rolling.
■ Remove wheel stand when transporting.
■ DO NOT transport generator with fuel in tank.
Check with your county or state safety
towing regulations department before
towing your generator.
■ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer "gross vehicle
weight rating" (GVWR).
■ 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".
DCA-180SSK — TOWING
Figure 1. Generator with Trailer
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION:

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 11
DCA-180SSK — TRAILER-SAFETY GUIDELINES
Explanation of Chart:
This section is intended to provide the user with trailer ser-
vice and maintenance information. The service and main-
tenance guidelines referenced in this section apply a wide
range of trailers. Remember periodic inspection of the trailer
will ensure safe towing of the equipment and will prevent
damage to the equipment and personal injury.
It is the purpose of this section to cover the major mainte-
nance components of the trailer. The following trailer com-
ponents will be discussed in this section:
 Brakes
 Tires
 Lug Nut Torquing
 Suspension
 Electrical
 Brake Troubleshooting Tables
Use the following definitions while reading Table 1.
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, hy-
draulic, hydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, in-
cluding the fuel cell (empty).
4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This measurement is from fender to
fender.
6. Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer.
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (layers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires are mounted on a tire rim. The tire rim
must match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 4 and Figure 5 for lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can sup-
port in pounds, and the diameter of the axle expressed
in inches (see Table 3 on page 17). Please not that
some trailers have a double axle. This will be shown as
2-6000 lbs., meaning two axles with a total weight ca-
pacity of 6000 pounds.
14. Suspension - Protects the trailer chassis from shock
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle. See page 16 for
proper wiring connections.
16. Application - Indicates which units can be employed
on a particular trailer.

PAGE 12 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
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DCA-180SSK —TRAILER-SPECIFICATIONS

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 13
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DCA-180SSK —TRAILER-SPECIFICATIONS

PAGE 14 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — TRAILER SAFETY GUIDELINES
Brakes
If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow the
brake shoes and drums to seat properly. After the first 200
mile interval, inspect the brakes every 3,000 miles. If driving
over rough terrain, inspect the brakes more frequently.
Electric Brakes
Electrically actuated brakes (Figure 2) are similar to hydraulic
brakes. The basic difference is that hydraulic brakes are
actuated by an electromagnet.
Listed below are some of the advantages that electric brakes
have over hydraulic brakes:
 Brake system can be manually adjusted to provide the
corrected braking capability for varying road and load
conditions
 Brake system can be modulated to provide more or less
braking force, thus easing the brake load on the towing
vehicle
 Brake system has very little lag time between the time
the vehicle’s brakes are actuated and the trailer’s brakes
are actuated
 Brake system can provide an independent emergency
brake system
Remember in order to properly synchronize the tow vehicle’s
braking to the trailer’s braking, can only be accomplished by
road testing. Brake lockup, grabbiness or harshness is due
to lack of synchronization between the tow vehicle and the
trailer being towed or under-adjusted brakes.
Before any brake synchronizations adjustments can be made,
the trailer brakes should be burnished-in by applying the
brakes 20-30 times with approximately a 20 m.p.h. decrease
in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample time for
brakes to cool between application. This allows the brake
shoes to slightly be seated into the brake drum surface.
Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect these
components as required.
Electric 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
star wheel of the adjuster assembly to expand the brake
shoes.
5. Adjust the brake shoes outward until the pressure of the
lining against the wheel drum makes the wheel difficult
to turn.
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer to
the ground.
8. Repeat steps 1 through 6 on the remaining brakes.

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 15
DCA-180SSK — TRAILER SAFETY GUIDELINES
Hydraulic/Air/Surge Brakes
Hydraulic brakes (Figure 3) should not require any special
attention with the exception of routine maintenance such as
shoe and lining replacement. These brakes can be adjusted
in the same manner as electric brakes. Brake lines should
be periodically checked for cracks, kinks, or blockage.
Figure 3 below displays the major hydraulic/air/surge brake
components that will require inspection and maintenance.
Please inspect these components as required using steps 1
through 6 as referenced in the electric brake adjustments
section.
Figure 2. Electrical Brake Components
Figure 3. Hydraulic Brake Components

PAGE 16 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
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.
CAUTION:
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.
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 hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear.
Table 2 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.
DCA-180SSK — TRAILER SAFETY GUIDELINES
Figure 4. Major Suspension Components
Suspension
The leaf suspension springs and associated components
(Figure 4) 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
as detailed in Table 3.

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 17
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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 5. DO NOT
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Table 4.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-180SSK — TRAILER SAFETY GUIDELINES
Figure 5. Wheel Lug Nuts Tightening Sequence

PAGE 18 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
DCA-180SSK —TRAILER-WIRING DIAGRAM

DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 19
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DCA-180SSK —TRAILER-BRAKETROUBLESHOOTING

PAGE 20 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
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DCA-180SSK —TRAILER-BRAKETROUBLESHOOTING