MQ Power WHISPERWATT DCA300SSJU4F Operation Manual

60hz john deere 6090hfg09 diesel engine

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OPERATION MANUAL

WHISPERWATT™ SERIES

MODEL DCA300SSJU4F

60Hz GENERATOR

(JOHN DEERE 6090HFG09 DIESEL ENGINE)

Revision #2 (01/18/18)

To find the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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Page 1 OPERATION MANUAL WHISPERWATT™ SERIES MODEL DCA300SSJU4F 60Hz GENERATOR (JOHN DEERE 6090HFG09 DIESEL ENGINE) Revision #2 (01/18/18) To find the latest revision of this publication, visit our website at: www.mqpower.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
Page 2: Proposition 65 Warning
PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DCA300SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (01/18/18)
Page 3: Table Of Contents
TABLE OF CONTENTS DCA300SSJU4F 60 Hz Generator Proposition 65 Warning ........... 2 Table Of Contents ............ 3 Nameplate/Safety Information ......... 4 Safety Information ..........5-10 Specifications ............11 Dimensions ............12 Installation ............14-15 General Information ..........16 Major Components ..........17 Engine Control Unit (Ecu) ........
Page 4: Nameplate And Safety Labels
NAMEPLATE/SAFETY INFORMATION NAMEPLATE AND SAFETY LABELS NOTICE Safety labels are attached to the generator as shown in For safety label part numbers, reference parts manual.. Figure 1. Keep these safety labels clean at all times. When the safety labels become worn or damaged, contact your nearest dealer or the Multiquip Parts Dept.
Page 5: Safety Messages
SAFETY INFORMATION Do not operate or service the equipment before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all equipment will be referenced with hazard symbols which times when operating this equipment. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
Page 6: General Safety
SAFETY INFORMATION GENERAL SAFETY  NEVER use accessories or attachments that are not recommended by MQ Power for this equipment. Damage CAUTION to the equipment and/or injury to user may result.  NEVER operate this equipment without proper protective  ALWAYS know the location of the nearest clothing, shatterproof glasses, respiratory protection, ﬁ...
Page 7: Engine Safety
SAFETY INFORMATION ENGINE SAFETY NOTICE DANGER  NEVER run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter  The engine fuel exhaust gases contain poisonous carbon frequently to prevent engine malfunction.
Page 8: Fuel Safety
Safety Towing Regulations, before towing when towing. your generator.  Raise and lock trailer wheel stand in up position when  Refer to MQ Power trailer manual for additional safety towing. information.  Place chock blocks underneath wheel to prevent rolling ...
Page 9: Electrical Safety
SAFETY INFORMATION ELECTRICAL SAFETY  Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections DANGER may cause electrical shock and damage to the generator.  DO NOT touch output terminals during operation. Contact with output terminals NOTICE during operation can cause electrocution, ...
Page 10: Emissions Information
SAFETY INFORMATION EMISSIONS INFORMATION  If the battery liquid (dilute sulfuric acid) comes into contact with clothing or skin, rinse skin or clothing NOTICE immediately with plenty of water. The diesel engine used in this equipment has been  If the battery liquid (dilute sulfuric acid) comes into designed to reduce harmful levels of carbon monoxide contact with eyes, rinse eyes immediately with plenty (CO), hydrocarbons (HC) and nitrogen oxides (NOx)
Page 11: Specifications
SPECIFICATIONS Table 1. Generator Specifications Model DCA300SSJU4F Revolving field, self ventilated, Type open protected type synchronous generator Armature Connection Star with Neutral Phase 3Ø Standby Output 264 kW (330 kVA) Prime Output 240 kW (300 kVA) 3Ø Voltage (L-L/L-N) 208Y/120, 220Y/127, 240Y/139 Voltage Change-Over Bd.
Page 12: Dimensions
DIMENSIONS Figure 2. Dimensions Table 3. Dimensions Reference Dimension in. (mm) Reference Letter Dimension in. (mm) Letter 37.24 (946) 46.42 (1,179) 37.24 (946) 149.60 (3,800) 46.42 (1,179) 74.80 in. (1,900) 23.03 (585) 59.05 in. (1,500) 25.20 (640) PAGE 12 — DCA300SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (01/18/18)
Page 13 NOTES DCA300SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #2 (01/18/18) — PAGE 13...
Page 14: Installation
INSTALLATION CONNECTING THE GROUND The ground cable should be #8 size wire (aluminum) minimum. If copper wire is used, #10 size wire minimum Consult with local Electrical and Safety Codes for proper should be used. connection based on condition of use. Connect one end of the ground cable terminal to the EXAMPLE of how to ground the unit if the condition generator ground point (Figure 3).
Page 15: Outdoor Installation
INSTALLATION OUTDOOR INSTALLATION GENERATOR GROUNDING NOTICE Install the generator in a 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.
Page 16: General Information
• Automatic Voltage Regulator Reference Table 2 for engine specifications. • Current Transformer In keeping with MQ Power’s policy of constantly improving • Over-Current Relay its products, the specifications quoted herein are subject • Starter Relay to change without prior notice.
Page 17: Major Components
MAJOR COMPONENTS Table 4. Generator Major Components ITEM NO. DESCRIPTION Muffler Assembly Enclosure Assembly Generator Assembly Battery Assembly Engine Assembly Fuel Tank Assembly Output Terminal Assembly Circuit Breaker Assembly Auto Start/Stop Controller Assembly Gauge Unit Assembly Operating Panel Assembly Voltage Change-Over Board Figure 4.
Page 18: Engine Control Unit (Ecu)
ENGINE CONTROL UNIT (ECU) Figure 5. Engine Control Unit (ECU) E. Alarm Acknowledge Button — When the engine The definitions below describe the controls and functions of the Engine Control Unit (Figure 5). experiences a fault, the "Pre Alarm Lamp" or the "Shutdown Lamp"...
Page 19: Engine/Generator Control Panel
ENGINE/GENERATOR CONTROL PANEL °F VOLTS INCREASE DECREASE OIL PRESS WATER TEMP BATTERY °F VOLTS ½ °F RPMX10 FUEL SPEED OIL PRESS WATER TEMP BATTERY ½ Series 800 Controller Engine Started °F RPMX10 Shutdown Pre-Alarm FUEL SPEED Alarm Screen Program Option Acknowledge Change Exit...
Page 20: Output Terminal Panel Familiarization
OUTPUT TERMINAL PANEL FAMILIARIZATION OUTPUT TERMINAL PANEL OUTPUT TERMINAL FAMILIARIZATION The Output Terminal Panel (Figure 8) shown below is The “Output Terminal Panel” (Figure 8) 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 21 OUTPUT TERMINAL PANEL FAMILIARIZATION 120 VAC GFCI Receptacles Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the There are two 120 VAC, 20 amp GFCI (Duplex Nema GFCI receptacles. Remember the load output (current) on 5-20R) receptacles provided on the output terminal panel.
Page 22 OUTPUT TERMINAL PANEL FAMILIARIZATION Connecting Loads Over Current Relay Loads can be connected to the generator by the Output An over current relay (Figure 12) is connected to the main Terminal Lugs or the convenience receptacles (Figure 11). circuit breaker. In the event of an overload, both the circuit Make sure to read the operation manual before attempting breaker and the over current relay may trip.
Page 23: Load Application
LOAD APPLICATION SINGLE PHASE LOAD THREE PHASE LOAD Always be sure to check the nameplate on the generator When calculating the power requirements for 3-phase and equipment to insure the wattage, amperage, frequency, power use the following equation: and voltage requirements are satisfactorily supplied by the generator for operating the equipment.
Page 24: Generator Outputs
GENERATOR OUTPUTS GENERATOR OUTPUT VOLTAGES Maximum Amps Table 8 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 change-over board (Figure 13).
Page 25: Generator Outputs/Gauge Reading
GENERATOR OUTPUTS/GAUGE READING HOW TO READ THE AC AMMETER AND AC AC Ammeter Gauge Reading VOLTAGE GAUGES Place the AC Ammeter Change-Over Switch (Figure 17) 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.
Page 26: Output Terminal Panel Connections
OUTPUT TERMINAL PANEL CONNECTIONS UVWO TERMINAL OUTPUT VOLTAGES 3. Turn the voltage regulator knob (Figure 21) clockwise to increase voltage output, turn counterclockwise to Various output voltages can be obtained using the UVWO decrease voltage output. Use voltage regulator output terminal lugs. The voltages at the terminals are adjustment knob whenever fine tuning of the output dependent on the placement of the jumpers plates (6) on voltage is required.
Page 27 OUTPUT TERMINAL PANEL CONNECTIONS 1Ø-480V UVWO Terminal Output Voltages NOTICE 1. Make sure the voltage change-over board is jumpered ALWAYS make sure that the connections to the UVWO for 480V operation as shown in Figure 24. terminals are secure and tight. The possibility of arcing exist that could cause a fire.
Page 28: Circuit Breakers
INSPECTION/SETUP CIRCUIT BREAKERS FUEL CHECK To protect the generator from an overload, a 3-pole, 800 DANGER amp, main circuit breaker is provided to protect the U,V, Fuel spillage on a hot engine can cause and W Output Terminals from overload. In addition two a fire or explosion.
Page 29 INSPECTION/SETUP Refueling Procedure: WARNING Diesel fuel and its vapors are dangerous to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes. Figure 32. Full Fuel Tank 1. Level Tanks — Make sure fuel cells are level with the CAUTION ground.
Page 30: Air Cleaner
INSPECTION/SETUP COOLANT (ANTIFREEZE/SUMMER COOLANT/ Cleaning the Radiator WATER) The engine may overheat if the radiator fins become overloaded with dust or debris. Periodically clean the John Deere recommends Cool-Gard II antifreeze/summer radiator fins with compressed air. Cleaning inside the coolant for use in their engines, which can be purchased in machine is dangerous, so clean only with the engine turned concentrate (and mixed with 50% demineralized water) or off and the negative battery terminal disconnected.
Page 31 INSPECTION/SETUP BATTERY When connecting battery do the following: 1. NEVER connect the battery cables to the battery This unit is of negative ground DO NOT connect in reverse. terminals when the Auto-Off/Reset-Manual Switch Always maintain battery fluid level between the specified is in either the AUTO or MANUAL position.
Page 32: Generator Start-Up Procedure (Manual)
GENERATOR START-UP PROCEDURE (MANUAL) COLD WEATHER ENGINE STARTING FLUID BEFORE STARTING (ETHER SYSTEM) CAUTION This unit is equipped with an automatic controlled Engine The engine’s exhaust contains harmful emissions. Starting Fluid System (KBi’s DIESELMATIC NVT) that ALWAYS have adequate ventilation when operating. assists the engine starting during low ambient temperature Direct exhaust away from nearby personnel.
Page 33: Starting (Manual)
GENERATOR START-UP PROCEDURE (MANUAL) STARTING (MANUAL) 5. If the voltage is not within the specified tolerance, use the voltage adjustment control knob (Figure 42) to 1. Place the Auto-Off/Reset Manual Switch in the increase or decrease the desired voltage. MANUAL position to start the engine (Figure 39). Auto-Off/Reset Figure 39.
Page 34 GENERATOR START-UP PROCEDURE (MANUAL) 9. The tachometer gauge (Figure 46) will indicate the 11. Observe the generator’s ammeter (Figure 48) and speed of the engine when the generator is operating. verify it reads the anticipated amount of current with Under normal operating conditions this speed is respect to the load.
Page 35: Generator Start-Up Procedure (Auto Mode)
GENERATOR START-UP PROCEDURE (AUTO MODE) STARTING (AUTO MODE) NOTICE DANGER When the Auto Off/Reset Manual Switch is placed in the AUTO position, the engine glow plugs will be Before connecting this generator to any warmed and the engine will start automatically. building’s electrical system, a licensed electrician must install an isolation When starting generator in AUTO mode use the “Manual...
Page 36: Normal Shutdown Procedure
GENERATOR SHUT-DOWN PROCEDURES EMERGENCY SHUTDOWN PROCEDURE WARNING 1. Place the Auto Off/Reset Manual Switch (Figure 52) NEVER stop the engine suddenly except in an in the OFF/RESET position. emergency. NORMAL SHUTDOWN PROCEDURE AUTO MANUAL To shutdown the generator, use the following procedure: OFF/RESET 1.
Page 37: Maintenance
MAINTENANCE 500 Hrs 3000 Hrs 10 Hrs Table 12. 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 Check Air Cleaner Element Check for Leaks/Hoses/Clamps Check for Loosening of Parts Change Engine Oil and Oil Filter *...
Page 38: General Inspection
MAINTENANCE GENERAL INSPECTION FUEL ADDITION Prior to each use, the generator should be cleaned and Add diesel fuel (the grade may vary according to season inspected for deficiencies. Check for loose, missing or and locations). damaged nuts, bolts or other fasteners. Also check for Removing Water from the Fuel Tank fuel, oil, and coolant leaks.
Page 39: Oil Filter
MAINTENANCE FUEL TANK INSPECTION Replacing Oil Filter „ Remove the old oil filter. In addition to cleaning the fuel tank, the following components should be inspected for wear: „ Apply a film of oil to the gasket/rubber seal (Figure 55) on the new oil filter.
Page 40: Radiator Cleaning
MAINTENANCE JACKET WATER HEATER AND INTERNAL BATTERY WARNING CHARGER 120 VAC INPUT RECEPTACLES Allow engine to cool when flushing out (OPTIONAL) radiator. Flushing the radiator while hot This generator can be optionally equipped with two 120 could cause serious burns from water or VAC, 20 amp input receptacles located on the output steam.
Page 41: Emission Control
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- 6068HFG09 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 42 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 43 MAINTENANCE If the diesel exhaust fluid (DEF) symbol (Figure 61) is displayed during ECU controller operation, it indicates the following: „ DEF tank level is below 10%. Reference Table 13, DEF Level System Action System. „ DEF quality is poor. The urea concentration to water is Figure 62.
Page 44 MAINTENANCE AUTO REGENERATION PROCEDURE Auto regeneration process will automatically occur. No operator action is required for this process. Allow the engine to run for at least 30 minutes to complete the automatic regeneration process. Reference Table 14 for the various soot level stages for the DPF system.
Page 45: Generator Wiring Diagram
GENERATOR WIRING DIAGRAM DCA300SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #2 (01/18/18) — PAGE 45...
Page 46: Engine Wiring Diagram
ENGINE WIRING DIAGRAM PAGE 46 — DCA300SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (01/18/18)
Page 47: Battery Charger Wiring Diagram (Option)
BATTERY CHARGER WIRING DIAGRAM (OPTION) DCA300SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #2 (01/18/18) — PAGE 47...
Page 48: Water Heating Element Wiring Diagram (Option)
WATER HEATING ELEMENT WIRING DIAGRAM (OPTION) PAGE 48 — DCA300SSJU4F 60 HZ GENERATOR • OPERATION MANUAL — REV. #2 (01/18/18)
Page 49: Troubleshooting (Generator)
TROUBLESHOOTING (GENERATOR) Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 15 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business office or service plant. Table 15.
Page 50: Troubleshooting Diagnostics
TROUBLESHOOTING DIAGNOSTICS The engine controller of this generator diagnoses problems 5. Push the Program/Exit Button on the ECU controller and select the Fault Diagnostics mode. This mode that arise from the engine control system and the engine itself. enables the ability to carry out the fault diagnostics as listed below: 1.
Page 51 NOTES DCA300SSJU4F 60 HZ GENERATOR• OPERATION MANUAL — REV. #2 (01/18/18) — PAGE 51...
Page 52: Here's How To Get Help
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