Summary of Contents for MQ Power WHISPERWATT DCA150SSJU4F
Page 1
OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA150SSJU4F 60Hz GENERATOR (JOHN DEERE 6068HFG08 DIESEL ENGINE) INSTRUCTION MANUAL NO. M3844300204 Revision #4 (03/24/22) 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.
TABLE OF CONTENTS DCA150SSJU4F 60 Hz Generator Proposition 65 Warning ........... 2 Safety Decals ............4 Safety Information ..........5–10 Specifications ............11 Dimensions ............12–13 Installation ............14–15 General Information ......... 16–17 General Paralleling Information (Option) ..18–20 Major Components ..........21 Engine Control Unit (ECU-835) ......
SAFETY DECALS Safety decals are attached to the generator as shown in NOTICE Figure 1. Keep these safety decals clean at all times. When For safety decals part numbers, refer to the parts the safety decals become worn or damaged, contact your manual.
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
SAFETY INFORMATION State Health Safety Codes and Public Resources Refer to the MQ Power trailer manual for additional safety Codes specify that in certain locations, spark arresters information. must be used on internal combustion engines that use In order to reduce the possibility of an accident hydrocarbon fuels.
Page 9
SAFETY INFORMATION Raise and lock the trailer wheel stand in the upright NEVER use damaged or worn cables or cords when position when towing. connecting equipment to the generator. Inspect the insulation for cuts. Place chock blocks underneath the wheels to prevent rolling while parked.
Page 10
SAFETY INFORMATION ALWAYS keep the battery charged. If the battery is not Metal recycling involves the collection of metal from charged, combustible gas will build up. discarded products and its transformation into raw materials to use in manufacturing a new product. ...
DIMENSIONS MAXIMUM LIFTING POINT TOP VIEW TOP VIEW 14,050 lbs. (6,373 kg) SIDE VIEW FRONT VIEW Figure 2. Dimensions Table 3. Dimensions Reference Dimension in. (mm) Reference Letter Dimension in. (mm) Letter 35.83 in. (910 mm) 43.70 in. (1,110 mm) 35.83 in.
M I N 2 . 4 T . / REFERENCE NEC 250 Figure 3. Typical Generator Grounding Application NOTICE Trailer-mounted generators are the sole responsibility of MQ Power. PAGE 14 — DCA150SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (03/24/22)
Page 15
INSTALLATION OUTDOOR INSTALLATION GENERATOR GROUNDING NOTICE Install the generator in an area that is free of debris, bystanders, and overhead obstructions. Make sure the The Occupational Safety and Health Administration generator is on secure, level ground so that it cannot slide (OSHA) and the National Electrical Code (NEC) or shift around.
GENERAL INFORMATION GENERAL INFORMATION GENERATOR CONTROL PANEL This generator (Figure 7) is designed as a high-quality, The “Control Panel” is provided with the following: portable (requires a trailer for transport) power source for Frequency Meter (Hz) telecom sites, lighting facilities, power tools, submersible pumps, and other industrial and construction machinery.
Page 17
There are four connections of the open delta—A, B, C and D. During steady state loads, the power from the voltage In keeping with MQ Power’s policy of constantly improving regulator is supplied from the parallel connections of A to B, its products, the specifications quoted herein are subject A to D, and C to D.
GENERAL PARALLELING INFORMATION (OPTION) The kVAR load sharing is achieved by increasing or NOTICE decreasing the field excitation to the systems’ alternators. When the paralleling option is employed, the Basler As the field excitation of one generator set in a group is DGC-2020HD controller must be installed.
Page 19
GENERAL PARALLELING INFORMATION (OPTION) SEQUENCING The set-point for the desired hours until maintenance can now be changed. Press edit to save. NOTICE Ethernet communication is required when the generators are configured for the sequencing mode Edit Edit of operation. Figure 4. Password Sequence 2.04 and Lower These generators are capable of sequencing for control PASSWORD ENTRY 2.04 AND HIGHER of balanced maintenance schedules.
Page 20
GENERAL PARALLELING INFORMATION (OPTION) Pressing the alarm silence button will stop the toggling NOTICE between the pre-alarm and the overview screen. When connecting load cables to the power distribution Once the overview screen is selected, the maintenance panel be sure to select the correct size of the load interval can be reset by pressing and holding the reset cables to handle full load/amperage of both generators button for 10 seconds.
ENGINE CONTROL UNIT (ECU-835) Series 800 Controller Engine Started °F °F VOLTS VOLTS INCREASE INCREASE DECREASE DECREASE OIL PRESS OIL PRESS WATER TEMP WATER TEMP BATTERY BATTERY Shutdown ½ ½ °F °F RPMX10 RPMX10 FUEL FUEL SPEED SPEED Pre-Alarm Series 800 Controller Engine Started Shutdown Pre-Alarm...
BASLER DIGITAL GENSET CONTROLLER (OPTION) Figure 11. Basler DGC-2020HD NOTICE The Basler DGC-2020HD controller is an option. It replaces the ECU 845 controller that comes standard with this generator when the paralleling option is employed. PAGE 24 — DCA150SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #4 (03/24/22)
Page 25
BASLER DIGITAL GENSET CONTROLLER (OPTION) The definitions below describe the controls and functions 9. Off Pushbutton and Mode Indicator — Pressing this button places the DGC-2020HD in Off mode.The red of the Digital Genset Controller (Figure 11). Off mode LED lights when the DGC-2020HD is in Off 1.
Page 27
PARALLELING PANEL (OPTION) The definitions below describe the controls and functions For units with manually operated breakers, the breaker of the Paralleling Panel (Figure 12). will need to be reset by toggling the handle down, then can be turned back to the “ON” position. On models 1.
OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel (Figure 13) shown below is The “Output Terminal Panel” (Figure 14) is provided with provided for the connection of electrical loads. Lift up on the following: the cover to gain access to receptacles and terminal lugs.
Page 29
OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles Twist-Lock Dual-Voltage 120/240 VAC Receptacles There are three 240/139V, 50-amp, auxiliary twist-lock NOTICE (CS-6369) receptacles (Figure 15) provided on the output It is recommended that the GFCI receptacles be tested terminal panel. These receptacles can only be accessed when the generator is initially uncrated.
Page 30
OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Overcurrent Relay Loads can be connected to the generator by the Output An overcurrent relay (Figure 18) is connected to the Terminal Lugs, convenience receptacles or the optional main circuit breaker. In the event of an overload, both the camlocks (Figure 17).
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 ×...
POWERBALANCE™ (OPTION) PowerBalance™ (Figure 19) 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). Figure 19.
GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES Maximum Amps Table 9 shows the maximum amps the generator can A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using provide. DO NOT exceed the maximum amps as listed. the voltage selector switch (Figure 20).
GENERATOR OUTPUTS/GAUGE READING HOW TO READ THE AC AMMETER AC Ammeter Gauge Reading AND AC VOLTMETER GAUGES Place the AC Ammeter Change-Over Switch (Figure 24) in the U position and observe the current reading (load The AC ammeter and AC voltmeter gauges are controlled drain) on the U terminal as indicated on the AC Ammeter by the AC ammeter and AC voltmeter change-over switches.
OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator knob (Figure 28) clockwise to increase voltage output, turn counterclockwise to Various output voltages can be obtained using the UVWO decrease voltage output. Use the voltage regulator output terminal lugs.
Page 36
OUTPUT TERMINAL PANEL CONNECTIONS 3Ø-480/277V UVWO Terminal Output Voltages 1Ø-240/120V UVWO Terminal Output Voltages 1. Place the voltage selector switch in the 3Ø 480/277 1. Place the voltage selector switch in the 1Ø 240/120 position as shown in Figure 30. position as shown in Figure 32.
INSPECTION/SETUP 1. To check the engine oil level, place the generator on 6. Fill with recommended type oil as listed in Table 12. secure, level ground with the engine stopped. Maximum oil capacity is 11.2 quarts (10.5 liters). 2. Remove the dipstick from its holder (Figure 34) and wipe it clean.
Page 38
INSPECTION/SETUP FUEL CHECK Refueling Procedure DANGER WARNING Fuel spillage on a hot engine can cause Diesel fuel and its vapors are dangerous a fire or explosion. If fuel spillage occurs, to your health and the surrounding wipe up the spilled fuel completely to environment.
Page 39
INSPECTION/SETUP DEF Refilling (Continuous Operation) 3. NEVER overfill the fuel tank — It is important to read the fuel gauge when filling the fuel tank. DO NOT wait It is recommended to shut down the engine prior to for fuel to rise in the filler neck (Figure 40). refilling the DEF tank.
Page 40
INSPECTION/SETUP COOLANT Operation in Freezing Weather (ANTIFREEZE/SUMMER COOLANT/WATER) When operating in freezing weather, be certain the proper amount of antifreeze (Table 14) has been added. John Deere recommends Cool-Gard™ II antifreeze/summer coolant for use in their engines, which can be purchased in Table 14.
Page 41
INSPECTION/SETUP Battery Cable Installation ALWAYS be sure the battery cables (Figure 45) are properly connected to the battery terminals as shown below. The red cable is connected to the positive terminal of the battery, and the black cable is connected to the negative terminal of the battery.
Page 42
INSPECTION/SETUP ALTERNATOR COLD WEATHER ENGINE STARTING FLUID (ETHER SYSTEM) The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the This unit is equipped with an automatically controlled circuit will be in short circuit instantaneously, resulting in Engine Starting Fluid System (KBi’s DIESELMATIC NVT) alternator failure.
GENERATOR START-UP PROCEDURE (MANUAL) BEFORE STARTING STARTING (MANUAL) CAUTION 1. Place the Auto-Off/Reset-Manual Switch in the MANUAL position to start the engine (Figure 48). The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel. AUTO MANUAL OFF/RESET...
Page 44
GENERATOR START-UP PROCEDURE (MANUAL) 5. If the voltage is not within the specified tolerance, use 10. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 54). the voltage adjustment control knob (Figure 51) to increase or decrease the desired voltage. DECREASE INCREASE Figure 51.
GENERATOR START-UP PROCEDURE (AUTO MODE) STARTING (AUTO MODE) When starting the generator in AUTO mode use the “Manual Start-Up” procedure except where noted (see DANGER below). Before connecting this generator to any 1. Perform steps 1 through 5 in the Before Starting section building’s electrical system, a licensed as outlined in the Manual Starting Procedure.
GENERATOR SHUTDOWN PROCEDURES EMERGENCY SHUTDOWN PROCEDURE WARNING 1. Place the Auto Off/Reset Manual Switch (Figure 59) NEVER stop the engine suddenly except in an in the OFF/RESET position. emergency. NORMAL SHUTDOWN PROCEDURE AUTO MANUAL To shut down the generator, use the following procedure: OFF/RESET 1.
MAINTENANCE 500 Hrs 3,000 Hrs 10 Hrs Table 15. Inspection/Maintenance 250 Hrs or Every or Every OTHER DAILY 12 Months 36 Months Check Engine Oil and Coolant Levels Check Fuel Filter/Water Separator Bowl Check Air Cleaner/Element Clean or Replace Air Cleaner/Element Check for Leaks/Hoses/Clamps Check for Loosening of Parts Change Engine Oil and Oil Filter *...
Page 48
MAINTENANCE GENERAL INSPECTION CAUTION Prior to each use, the generator should be cleaned and Wear protective equipment such as inspected for deficiencies. Check for loose, missing or approved safety glasses or face shields damaged nuts, bolts or other fasteners. Also check for and dust masks or respirators when fuel, oil, and coolant leaks.
Page 49
MAINTENANCE 8. Replace both elements if they are damaged or 4. At completion of draining CLOSE the drain valve (C). excessively dirty. FUEL FILTER ELEMENT REPLACEMENT 9. Clean the inside of the air cleaner body. 1. Use a filter wrench to remove the fuel filter cup 10.
Page 50
MAINTENANCE FUEL WATER SEPARATOR SEDIMENT BOWL FUEL WATER SEPARATOR REPLACEMENT 1. Remove the sediment bowl from the fuel water 1. Use a filter wrench to remove the fuel water separator separator cartridge as shown in Figure 64. cartridge (Figure 65) from the cartridge body head. CARTRIDGE BODY (HEAD) RETAINING...
Page 51
MAINTENANCE Cleaning Inside the Fuel Tank If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 66) wash out any deposits or debris that have accumulated inside the fuel tank. 0.39–0.59 IN. (10–15 MM) DEFLECTION Figure 67.
Page 52
MAINTENANCE DRAINING ENGINE OIL ENGINE OIL FILTER REPLACEMENT 1. Run the engine until the engine coolant reaches a 1. Using an oil filter wrench (Figure 70), remove the temperature of 140°F (60°C). engine oil filter. 2. Turn the engine off. 3.
Page 53
MAINTENANCE DRAINING ENGINE COOLANT FLUSHING OUT THE RADIATOR AND REPLACING COOLANT WARNING Open both cocks located at the crankcase side and at DO NOT remove the pressure cap from the the lower part of the radiator and drain the coolant. Open radiator when the engine is hot! Wait until the radiator cap while draining.
Page 54
MAINTENANCE TESTING THE GFCI RECEPTACLE 4. Press the TEST button (Figure 76) on the GFCI receptacle and verify that the status LED turns OFF. NOTICE The GFCI receptacle is designed to interrupt power when a ground fault exists to prevent injuries and shock hazards.
Page 55
MAINTENANCE GENERATOR STORAGE For long-term storage of the generator the following is recommended: Drain the fuel tank completely. Treat with a fuel stabilizer if necessary. Completely drain the oil from the crankcase and refill if necessary with fresh oil. ...
Page 56
MAINTENANCE ENGINE BLOCK HEATER AND INTERNAL When using the generator in hot climates, there is no need to apply power to the engine block heater (heating element). BATTERY CHARGER 120 VAC INPUT However, if the generator will be used in cold climates, it is RECEPTACLES (OPTIONAL) best to apply power to the engine block heater at all times.
Page 57
MAINTENANCE Forced (Stationary) Regeneration — A forced EMISSION CONTROL regeneration only occurs when the operator has initiated The emission control system employed with the John Deere this action at the ECU and the ECM recognizes a pre- 6068HFG08 diesel engine consist of a Diesel Oxidation programmed set point of soot in the PDF to allow a forced Catalyst (DOC) and a Diesel Particulate Filter (DPF).
Page 58
MAINTENANCE FORCED REGENERATION PROCEDURE Follow the steps below to initiate a forced regeneration: Series 800 Controller Engine Started 1. Verify that the AMBER pre-alarm LED is ON or DPF STAT Shutdown FLASHING and the DPF symbol is shown on the ECU display.
Page 59
MAINTENANCE If the diesel exhaust fluid (DPF) symbol (Figure 83) is If the engine emissions system malfunction (EESM) displayed during ECU controller operation, it indicates the symbol (Figure 84) is displayed during ECU controller following: operation, it indicates the following: ...
Page 60
MAINTENANCE EXHAUST SYSTEM Regeneration Regeneration is a cleaning process to remove trapped urea deposits. In normal conditions, the exhaust system will be regenerated or cleaned as the exhaust temperature is sufficient enough for urea sublimation. Figure 86. Regeneration Required Indicator This process does not have any influence on the unit operation or require any operator action.
Page 61
MAINTENANCE Press and hold the “REQUEST” button (Figure 88) until The Inhibit Regen indicatorl (Figure 89) wil be displayed the “REGEN ACTIVE” message is displayed on the when regeneration will not occur. monitor and then release button. NOTICE The inhibit regeneration indicator appears in conditions REGEN ACTIVE MODE REQUEST where it may be unsafe for elevating exhaust...
Page 62
MAINTENANCE AUTOMATIC DPF SYSTEM Reference Table 17 for the various soot level stages for the DPF system. Table 17. Automatic DPF System Soot Level 0 Soot Level 0 Soot Level 1 & 2 Soot Level 3 Soot Level 4 Soot Level 5 FILTER CLEAN SOOT LEVEL SOOT LEVEL...
TROUBLESHOOTING (GENERATOR) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 18 shown below for diagnosis of the generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 18.
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 filter clogged? Replace fuel filter and clean tank. Faulty fuel supply line? Replace or repair fuel line. Check piston, cylinder and valves.
Page 65
TROUBLESHOOTING (ENGINE) Troubleshooting (Engine) - continued Symptom Possible Problem Solution Air filter blocked? Clean or replace air filter. Low engine power output and low speed, Incorrect valve clearances? Adjust valves per engine specification. black exhaust smoke. Malfunction at injector? See engine manual. Drain off engine oil down to uppermark on Too much oil in engine crankcase? dipstick.
TROUBLESHOOTING (DIAGNOSTICS) 835 ECU SERIES CONTROLLER 4. Releasing the Hour Check Button and pushing the Program/Exit Button (Figure 92) on the ECU The engine controller of this generator diagnoses problems controller will return the controller to the main screen. that may arise from the engine control system and the engine itself.
Page 67
TROUBLESHOOTING (DIAGNOSTICS) DGC2020HD SERIES CONTROLLER 7. The diagnostic mode will remain active until the Reset button (Figure 94) is pressed or if the engine rpm At times, it may be desired to power up the Engine Control becomes greater than zero. Module (ECM), key switch ON while the engine is not running.
GENERATOR WIRING DIAGRAM (M3844300204) WIRE SIZE CODE/WIRE COLOR 38 mm² BLACK 30 mm² BLUE WHITE GENERATOR WIRING DIAGRAM NO. M3844300204 8 mm² BROWN YELLOW 5.5: 5.5 mm² GREEN LIGHT BLUE 2 mm² GRAY LIGHT GREEN VIOLET ORANGE NO MARKED WIRE SIZE: 1.25 mm² PINK –...
ENGINE BLOCK HEATER WIRING DIAGRAM (OPTION) BLACK 14 AWG. LINE (L)120VAC INPUT WHITE 14 AWG. NEUTRAL (N) GREEN 14 AWG. GROUND (G) ENGINE BLOCK HEATER TEMP. BLACK 14 AWG. SWITCH LINE (L)120VAC INPUT HEATING 120 VAC WHITE 14 AWG. ELEMENT NEUTRAL (N) GREEN 14 AWG.