Multiquip DCA180SSK User Manual
OPERATION AND PARTS MANUAL
WHISPERWATT™ SERIES
MODEL DCA180SSK (STD.)
60 HZ GENERATOR
(KOMATSU SA6D108E-2 DIESEL ENGINE)
Revision #3 (06/11/09)
PARTS LIST NO. C0874300704A
To find the latest revision of this
publication, visit our website at:
www.mqpower.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
PAGE 2 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
NOTE PAGE
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 3
TABLE OF CONTENTS
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
NOTE
Specification and part
number are subject to
change without notice.
PAGE 4 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
■
View Parts Diagrams
■
Order Parts
Goto www.multiquip.com and click on
Order Parts
to log in and save!
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
Order via Phone:
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
If you have an MQ Account, to obtain a
Username and Password, E-mail us at:
parts@multiquip.com.
To obtain an MQ Account, contact your
internet
Use the
on
Standard orders
Fax
your order in and qualify for a 2% Discount
on
Standard orders
Domestic (US) Dealers Call:
and qualify for a 5% Discount
for all orders which include
for all orders which include
International Customers
tact their local Multiquip Representatives
Note: Discounts Are Subject To Change
Note: Discounts Are Subject To Change
should con-
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www.mqpower.com
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 5
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
All orders are treated as
and will ship the same day if received prior
WE ACCEPT ALL MAJOR CREDIT CARDS!
❒❒
Standard Orders
Specify Preferred Method of Shipment:
✓
UPS/Fed Ex
■
Priority One
■
Ground
■ Next Day
✓ DHL
✓
Tru c k
RULES FOR SAFE OPERATION
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.
RULES FOR SAFE OPERATION
■
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.
■
High Temperatures – Allow the engine to cool before
adding fuel or performing service and maintenance
functions. Contact with
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.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
hot
components can cause serious
:
■
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.
■
NEVER operate the generator in an explosive atmosphere
or near combustible materials. An explosion or fire could
result causing severe
■
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.
■
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.
bodily harm or even death.
PAGE 6 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
RULES FOR SAFE OPERATION
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
■
NEVER touch output terminals during operation. This is
extremely dangerous.
contact with the output terminals.
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
■
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.
:
Always stop the machine when
:
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
Radiator
1. Radiator Cap - Removing the radiator cap while the
2. Coolant Drain Plug - Removing the coolant drain plug
3. Engine Oil Drain Plug - Removing the engine oil drain
:
■
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.
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.
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.
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
CAUTION
CAUTIONCAUTION
:
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.
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 7
RULES FOR SAFE OPERATION
■
Battery
CAUTIONCAUTION
CAUTION
CAUTIONCAUTION
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:
:
Never over fill the battery with water above
the upper limit.
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.
■
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
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.
clothing or skin
, rinse skin or clothing
Refer to the
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.
Komatsu Engine Owner's Manual
for engine
PAGE 8 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
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
and
first aid kit
Also know the phone numbers of the nearest
doctor
Maintenance Safety
■
and
NEVER lubricate components or attempt service on a
running machine.
. Know the location of the nearest telephone.
fire department
.
fire extinguisher
ambulance
,
RULES FOR SAFE OPERATION
■
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
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 9
■
Towing Safety Precautions
CAUTION:CAUTION:
CAUTION:
CAUTION:CAUTION:
Check with your county or state safety
towing regulations department before
towing your generator.
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:
■
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 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
while parked.
■
Place
prevent
■
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.
DCA-180SSK — TOWING
chocked blocks
support blocks
tipping
underneath wheel to prevent
underneath the trailer's bumper to
, while parked.
rolling,
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
Figure 1. Generator with Trailer
PAGE 10 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — TRAILER-SAFETY GUIDELINES
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.
Explanation of Chart:
This section is intended to provide the user with trailer service and maintenance information. The service and maintenance 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 maintenance components of the trailer. The following trailer components 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, hydraulic, hydraulic-surge and air.
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 support 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 capacity 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.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
4. Frame Length - 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.
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 11
DCA-180SSK — TRAILER-SPECIFICATIONS
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PAGE 12 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — TRAILER-SPECIFICATIONS
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DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 13
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.
PAGE 14 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — TRAILER SAFETY GUIDELINES
Figure 2. Electrical Brake Components
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 3. Hydraulic Brake Components
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 15
DCA-180SSK — TRAILER SAFETY GUIDELINES
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.
Suspension
The leaf suspension springs and associated components
(Figure 4) should be visually inspected every 6,000 miles for
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.
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.
CAUTION:
NOTE
ALWAYS wear safety glasses when removing
or installing force fitted parts. Failure to comply
may result in serious injury.
PAGE 16 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
Figure 4. Major Suspension Components
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DCA-180SSK — TRAILER SAFETY GUIDELINES
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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.
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DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 17
Figure 5. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
DCA-180SSK — TRAILER-WIRING DIAGRAM
NOTE:
LIGHTS ARE ORIENTED FROM THE DRIVER’S SEAT
PAGE 18 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — TRAILER-BRAKE TROUBLESHOOTING
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DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 19
DCA-180SSK — TRAILER-BRAKE TROUBLESHOOTING
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PAGE 20 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — OPERATION AND SAFETY DECALS
Machine Safety Decals
The DCA-180SSK generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information. The illustration below and on the preceding pages shows the decals as they appear on the machine.
Should any of these decals become unreadable, replacements can be obtained from your dealer.
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 21
DCA-180SSK — OPERATION AND SAFETY DECALS
PAGE 22 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — OPERATION AND SAFETY DECALS
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 23
DCA-180SSK — OPERATION AND SAFETY DECALS
PAGE 24 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — SPECIFICATIONS
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DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 25
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DCA-180SSK — GENERAL INFORMATION
DCA-180SSK FAMILIARIZATION
Generator
The MQ Power Model DCA-180SSK is a 144 kW
that has been designed as a high quality portable (requires
a trailer for transport) power source for telecom sites, lighting
facilities, power tools, submersible pumps and other
industrial and construction machinery.
Engine Control Panel
The “Engine Control Panel” is provided with the following:
Tachometer
Water Temperature Gauge
Oil Pressure Gauge
Charging Ammeter Gauge
Engine Speed Switch
Pre-Heat Button
Pre-Heat Lamp
Emergency Stop Button
Battery Switch
Ignition Key Switch
MPEC Module (on some models)
generator
Control Box
The “Control Box” is provided with the following:
Main Circuit Breaker 500 amps
Over-Current Relay
High Idle Adjust Trimmer
Microprocessor Controlled Alarm System
The DCA-180SSK generator is equipped with various alarms
and LED status indicators. These alarms and status indicators
are provided to add safety to the generator when operating
under normal conditions. The DCA-180SSK generator is
designed to shutdown in the event of low oil, high coolant
temperature, low battery and other operation conditions that
may cause severe damage to the generator.
Open Delta Excitation System
The DCA-180SSK generator is equipped with the state of
the art "
system consist of an electrically independent winding wound
among stationary windings of the AC output section.
Open-Delta
" excitation system. The open delta
Generator Control Panel
The “Generator Control Panel” is provided with the following:
Output Voltage Adjustment Knob
Frequency Meter (Hz)
AC Ammeter (Amps)
AC Voltmeter (Volts)
Ammeter Change-Over Switch
Voltmeter Change-Over Switch
Panel Light
Panel Light Switch
Pilot Lamp
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
Two 120V GFCI receptacles, 20 amp
Three 240/139V output receptacles, 50 amp
Two 120V input receptacles, 20 amp
3 Load Circuit Breakers 265V @65 amps
2 Load GFCI Circuit Breakers 265V@ 20amps
There are four connections: A, B, C and D. During steady
loads, the power to the
is supplied from the parallel connections of A to B, A to D,
and C to D. These three phases are rectified and are used as
the current for the exciter section.
During a heavy load, such as motor starting, the AVR
switches the configuration of the Open-Delta to the series
connection B to C. This has the effect of adding the voltages
of each phase to provide better voltage response during heavy
loads.
The connections of the AVR to the AC output windings are
for the sole purpose of sensing. No power is required from
these windings.
The open-delta design provides virtually unlimited excitation
current due to its independent power supply offering maximum
motor starting capabilities. The excitation does not have a
"
fixed ceiling
required load.
" and responds according the demands of the
Automatic Voltage Regulator
(AVR)
PAGE 26 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — GENERAL INFORMATION (OPTIONS)
Engine
The DCA-180SSK is powered by a 4 cycle, water cooled,
turbocharged KOMATSU Model SA6D108E-2
engine. This engine is designed to meet every performance
requirement for the generator. Reference Table 7, page 25
for engine specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
The basic controls and indicators for the DCA-180SSK
generator are addressed on the following pages.
Mechanical Governor System
The mechanical governor system control the RPM of the
engine. When the engine demands increase or decrease,
the mechanical governor system regulates the frequency
variation to ±1.0%. The electronic governor option
increases frequency variation to ±0.25%.
Electronic Governor System
The electronic governor system is made up of two parts, an
electronic controller that monitors frequency variation as the
load increases and decreases and an electronic actuator
that controls the engine throttle. The frequency is regulated
at ±0.25 to help protect sensitive equipment.
Jacket Water Heater (OPTIONAL)
The jacket water heater is a 1500-watt heater designed to
keep the coolant from freezing in the engine block. The
heater is thermostatically controlled and once an acceptable
engine temperature is achieved it will cycle on and off,
operating only about 1/3 of the time. This becomes a very
energy efficient option compared to a direct immersion block
heater. It is designed to keep the engine between 100 and
120 degrees Fahrenheit. This is not a throwaway heater. It
is completely serviceable.
diesel
gasoline
CAUTION :
There is a bleed screw on the valve on the engine block.
After service of either the heater or the cooling system, it is
possible to create an air bubble in this area. The air bubble
would prevent hot water created by the jacket water heater
from circulating, if the air bubble were not allowed to escape.
This bleed screw allows for the bleeding process to be
accomplished.
Battery Charger (OPTIONAL)
The battery charger will operate in a ‘BOOST’ mode until
the battery’s current acceptance falls to 70% of the
charger’s rating. The charger will then go into a ‘FLOAT’
mode, where it discharges a lower voltage until an AC
failure, or the battery is discharged.
Fuel Water Separator
The fuel water separator separates water mixed in the
fuel. It has an indicator to let the operator know to drain
the water. See maintenance section for instructions how
to drain water from separator.
ALWAYS unplug the jacket water heater
before servicing.
In normal conditions, 20 to 15 minutes is all that is required
to raise the engine temperature of a cold engine to 100
degrees Fahrenheit.
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 27
DCA-180SSK — MAJOR COMPONENTS
Figure 6. Major Components
PAGE 28 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
DCA-180SSK — DIMENSIONS (TOP, SIDE, AND REAR)
Figure 7. Dimensions
DCA-180SSK — PARTS AND OPERATION MANUAL— REV. #3 (06/11/09) — PAGE 29
DCA-180SSK — CONTROL PANEL
Figure 8. Control Panel
PAGE 30 — DCA-180SSK — PARTS AND OPERATION MANUAL — REV. #3 (06/11/09)
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