MQ Power WHISPERWATT DCA300SSJU4F2 Operation Manual

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OPERATION MANUAL

WHISPERWATT™ SERIES

MODEL DCA300SSJU4F2

60Hz GENERATOR

(JOHN DEERE 6090HFG06 DIESEL ENGINE)

Revision #0 (06/26/18)

To ﬁnd the latest revision of this

publication, visit our website at:

www.mqpower.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

Diesel engine exhaust and some of

PAGE 2 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

DCA300SSJU4F2 60 Hz GENERATOR

Proposition 65 Warning ........................................... 2

Table Of Contents .................................................... 3

Nameplate/Safety Information ................................. 4

Safety Information ................................................ 5-9

Safety Information ................................................. 10

Speciﬁcations ........................................................ 11

Dimensions ............................................................ 12

Installation ........................................................ 14-15

General Information ............................................... 16

General Paralleling Information (Option) .......... 17-19

Major Components ................................................ 20

Engine Control Unit (ECU-845) ............................. 21

Gauge Unit Assembly ............................................ 22

Engine/Generator Control Panel............................ 23

Basler Digital Genset Controller (Option) ......... 24-25

Paralleling Panel (Option) ................................. 26-27

Output Terminal Panel Familiarization .............. 28-30

Load Application .................................................... 31

Generator Outputs ............................................ 32-33

Generator Outputs/Gauge Reading ....................... 33

Output Terminal Panel Connections ................. 34-35

Inspection/Setup ............................................... 36-40

Generator Start-Up Procedure (Manual) .......... 41-42

Generator Start-Up Procedure (Auto Mode) .......... 43

Generator Shut-Down Procedures ........................ 44

Maintenance ..................................................... 45-60

Generator Wiring Diagram ..................................... 61

Engine Wiring Diagram (ECU-845)........................ 62

Engine Wiring Diagram (DGC2020HD Option)...... 63

3Ø-480 VAC Parallel Wiring Diagram .................... 64

3Ø-208 VAC Parallel Wiring Diagram .................... 65

Battery Charger Wiring Diagram ........................... 66

Engine Block Heater Wiring Diagram .................... 67

Troubleshooting (Generator) .................................. 68

Troubleshooting (Engine) .................................. 69-70

Troubleshooting (Diagnostics ECU-845) ............... 71

Troubleshooting (Diagnostics DGC2020HD) ......... 72

TABLE OF CONTENTS

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 3

NAMEPLATE/SAFETY INFORMATION

NAMEPLATE AND SAFETY LABELS

Safety labels are attached to the generator as shown in 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.

WARNING

HOT COOLANT can cause

severe burns.

Do not remove cap if radiator is hot.

M90310000

TOP VIEW

150

180

120

140

180

220

PSI

RPMX10

°F

100

210

100

260

OIL PRESS

SPEED

WATER TEMP

ＥＣＵ

VOLTS

Integrated Gauge Panel

100

Check

DEF

Emissions Failure

°F

Emissions

Failure

Regen Needed

Low

FUEL

DEF

Regen

Fuel

Inhibit

ECU

Series 800 Controller

Engine Started

Shutdown

Pre-Alarm

Alarm

Screen

Program

Option

Acknowledge

Change

Exit

WARNING

MOVING PARTS can cause severe injury. DO NOT operate with doors open.

Stop engine before servicing.

WARNING

ARC FLASH AND SHOCK HAZARD Appropriate PPE Required

Appropriate Personal Protection Equipment and Tools Required when working on this equipment.

INCREASE DECREASE

OFF

V-W

W-U

U-V

OFF

M9503000004

M92010070

NOTICE

For safety label part numbers, reference parts manual.

CAUTION

Maximum capacity of lifting

bail is 19,000 lbs.

CAUTION

HOT PARTS can burn skin.

DO NOT touch until the

machine has sufficiently cooled.

M911010000

M55100080

300

No Diesel

This machine stops and starts automatically and without notice.

CAUTION

EXHAUST FLUID ONLY

Filling this tank with anything other than DIESEL EXHAUST FLUID may result in severe engine damage.

REAR VIEW

CAUTION

M94110000

M92010060

CAUTION

DO NOT disconnect the Battery Cables

after shutting down the engine for

at least 30 seconds

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is a poison gas you cannot see or smell.

NEUTRAL BONDED TO FRAME

120V

120

NEUTRAL BONDED TO FRAME

GAC-2.2H

120V

NEUTRE MIS A LA MASSE A

120

15A

GAC-2.2H

LA CARCASSE DU MOTEUR

NEUTRE MIS A LA MASSE A

15A

LA CARCASSE DU MOTEUR

Honda Engines

211052

AC CIRCUIT BREAKER

211052

INTERRUPTEUR DE

AC CIRCUIT BREAKER

OFF

GR PRISE DE

COURANT PRINCIPAL

INTERRUPTEUR DE

TERRE

OFF

GR PRISE DE

COURANT PRINCIPAL

TERRE

ONLY use OUTSIDE and

NEVER use inside a home

far away from windows,

or garage. Even if doors

doors, and vents.

and windows are open.

Avoid other generator hazards. READ MANUAL BEFORE USE.

WARNING

ENVIRONMENTAL

This unit is designed to contain operating uids only. The environmental containment is not designed to control uids from an external source. It is the operator’s responsibility to monitor uid levels at all times.

DO NOT EXCEED THE RECOMMENDED

MAXIMUM CAPACITY

Figure 1. Nameplate

and Safety Decals

CAUTION

Ensure the “Auto-Off/Reset-Manual” switch is in the “Off/Reset” position. If it is not, when the battery cables are connected, the engine will crank and attempt to start.

M90130000

WARNING

ELECTRIC SHOCK HAZARD

Do not touch internal wiring or connections while this machine is operating.

Turn power off before servicing.

M92010000

Operation of this equipment may create sparks that can start fires around dry vegetation.

A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.

NEUTRAL BONDED TO FRAME

120V

120

GAC-2.2H

NEUTRE MIS A LA MASSE A

15A

LA CARCASSE DU MOTEUR

Honda Engines

211052

AC CIRCUIT BREAKER INTERRUPTEUR DE

OFF

GR PRISE DE

COURANT PRINCIPAL

TERRE

M90320010

150

180 25 75

120

140

180

220

PSI

RPMX10

°F

100

210

100

260

OIL PRESS

SPEED

WATER TEMP

50 18 12

ＥＣＵ

VOLTS

Integrated Gauge Panel

100

Check

DEF

Emissions Failure

°F

Emissions

Failure

Regen Needed

Low

FUEL

DEF

Regen

Fuel

Inhibit

ECU

Series 800 Controller

Engine Started

Shutdown

Pre-Alarm

Screen

Program/

Alarm

Option

Change

Exit

Acknowledge

P/N M91110000

M9504200004

DECREASE

INCREASE

OFF

V-W

W-U

U-V

OFF

Denyo

CAUTION

This machine stops and starts automatically and without notice.

MODEL SERIAL NO.

．

ｙ

DANGER

HIGH VOLTAGE

FRONT VIEW

SIDE VIEW

S-2731

WARNING

ELECTRIC SHOCK HAZARD

Do not touch output terminals while this machine is operating.

Turn power off before servicing.

M92010060

300

WARNING

ELECTRIC SHOCK HAZARD Always complete the grounding path from the ground terminal on the genset to an external grounding source.

See instruction manual for details.

WARNING

ELECTRIC SHOCK HAZARD

Do not touch internal wiring or connections while this machine is operating.

Turn power off before servicing.

WARNING

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch.

Serious injury or death may result without this transfer switch.

M92010050

M92010000

SIDE VIEW

WARNING

ENGINE EXHAUST can cause severe injury or death.

Use only in open, well ventilated areas or vent exhaust outside.

M91010040

M9503200004

PAGE 4 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

SAFETY INFORMATION

DO NOT operate or service the generator before reading the entire manual. Safety precautions should be followed at all times when operating this generator. Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages speciﬁ cally address the level of exposure to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION

SAFETY SYMBOLS

Potential hazards associated with the operation of this generator will be referenced with hazard symbols which may appear throughout this manual in conjunction with

safety messages.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in DEATH or SERIOUS INJURY.

WARNING

Indicates a hazardous situation which, if not avoided, COULD result in DEATH or SERIOUS INJURY.

or NOTICE.

CAUTION

Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 5

SAFETY INFORMATION

GENERAL SAFETY



 NEVER use accessories or attachments that are not

recommended by MQ Power for this generator. Damage

Also, know the

and

This information will be invaluable in

emergency or safety devices.

These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these

lubricate components or attempt service on a

keep the generator in proper running condition.

Fix damage to generator and replace any broken parts

store generator properly when it is not being used. Generator should be stored in a clean, dry location out of the reach of children and unauthorized personnel.

CAUTION

NEVER operate this generator without proper protective

clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

NEVER operate this generator when not

feeling well due to fatigue, illness or when under medication.

NEVER operate this generator under the inﬂ uence of

drugs or alcohol.

ALWAYS check the generator for loosened threads or bolts before starting.

DO NOT use the generator for any purpose other than

its intended purposes or applications.

to the generator and/or injury to user may result.

 ALWAYS know the location of the nearest

ﬁ re extinguisher.

 ALWAYS know the location of the nearest

ﬁ rst aid kit.

 ALWAYS know the location of the nearest

phone or keep a phone on the job site. phone numbers of the nearest ambulance, doctor

ﬁ re department.

the case of an emergency.

GENERATOR SAFETY

 NEVER operate the generator in an explosive

atmosphere or near combustible materials. An explosion or ﬁ re could result causing severe

bodily harm or even death.

DANGER

WARNING

NOTICE

This generator should only be operated by trained and qualiﬁ ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and

safety decals when they become difﬁ cult read.

Manufacturer does not assume responsibility for any

accident due to generator modiﬁ cations. Unauthorized generator modiﬁ cation will void all warranties.

 NEVER disconnect any

devices will void all warranties.

CAUTION

 NEVER

running machine.

NOTICE

 ALWAYS ensure generator is on level ground before use.

 ALWAYS



immediately.

 ALWAYS

PAGE 6 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

ENGINE SAFETY



NOTICE

run engine without an air ﬁ lter or with a dirty air

ﬁ lter. Severe engine damage may occur. Service air ﬁ lter

Wet stacking is a common problem with diesel engines which are operated for extended periods with light or no load applied. When a diesel engine operates without sufﬁ cient load (less than 40% of the rated output), it will not operate at its optimum temperature. This will allow unburned fuel to accumulate in the exhaust system, which can foul the fuel injectors, engine valves and exhaust system, including turbochargers, and reduce

it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine

Wet stacking does not usually cause any permanent

damage and can be alleviated if additional load is applied to relieve the condition. It can reduce the system performance and increase maintenance. Applying an increasing load over a period of time until the excess fuel is burned off and the system capacity is reached usually can repair the condition. This can take several

State Health Safety Codes and Public Resources Codes specify that in certain locations, spark arresters must be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or ﬂ ames from the engine exhaust. Spark arresters are qualiﬁ ed and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the

SAFETY INFORMATION

DANGER

The engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine in this generator

requires an adequate free ﬂ ow of cooling air. NEVER operate this generator in any enclosed or narrow area where free ﬂ ow of the air is restricted. If the air ﬂ ow is restricted it will cause injury to people and property and serious damage to the generator or engine.

WARNING

DO NOT place hands or fingers inside engine

compartment when engine is running.

NEVER operate the engine with heat shields or

guards removed.

Keep ﬁ ngers, hands hair and clothing away

from all moving parts to prevent injury.

 NEVER

frequently to prevent engine malfunction.

 NEVER tamper with the factory settings

of the engine or engine governor. Damage to the engine or generator can result if operating in speed ranges above the maximum allowable.



the operating performance.

In order for a diesel engine to operate at peak efﬁ ciency,

to completely burn all of the fuel.

DO NOT remove the radiator cap while the

engine is hot. High pressure boiling water will gush out of the radiator and severely scald any persons in the general area of the generator.

DO NOT remove the coolant drain plug while the engine

is hot. Hot coolant will gush out of the coolant tank and severely scald any persons in the general area of the generator.

DO NOT remove the engine oil drain plug while the

engine is hot. Hot oil will gush out of the oil tank and severely scald any persons in the general area of the generator.

CAUTION

NEVER touch the hot exhaust manifold,

mufﬂ er or cylinder. Allow these parts to cool before servicing generator.

hours to burn off the accumulated unburned fuel.



local Health and Safety Administrator.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 7

FUEL SAFETY

DANGER



ELECTRICAL SAFETY



 Backfeed to a utility system can cause electrocution

codes. Failure to do so could result in electrical shock or

while AC power from the

cables or cords when

connecting generator to generator. Inspect for cuts in the

connected to the generator’s output receptacles. Incorrect connections may cause electrical shock and

make certain that proper power or extension

cord has been selected for the job. See Cable Selection

DO NOT start the engine near spilled fuel or combustible ﬂ uids. Diesel fuel is extremely ﬂ ammable and its vapors can cause an explosion if ignited.

ALWAYS refuel in a well-ventilated area, away from sparks and open ﬂ ames.

ALWAYS use extreme caution when working with

ﬂ ammable liquids.

SAFETY INFORMATION

and/or property damage. NEVER connect the generator to a building’s electrical system without a transfer switch or other approved device. All installations should be performed by a licensed electrician in accordance with all applicable laws and electrical

burn, causing serious injury or even death.

Power Cord/Cable Safety

DO NOT ﬁ ll the fuel tank while the engine is running

or hot.

DO NOT overﬁ ll tank, since spilled fuel could ignite if it

comes into contact with hot engine parts or sparks from the ignition system.

Store fuel in appropriate containers, in well-ventilated areas and away from sparks and ﬂ ames.

NEVER use fuel as a cleaning agent.

DO NOT smoke around or near the

generator. Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

DANGER

DO NOT touch output terminals during

operation. Contact with output terminals during operation can cause electrocution,

electrical shock or burn.

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. Turn generator and all circuit breakers OFF before performing maintenance on the generator or making contact with output terminals.

DANGER

 NEVER let power cords or cables lay in water.

 NEVER stand in water

generator is being transferred to a load.

 NEVER use damaged or worn

insulation.

 NEVER grab or touch a live power

cord or cable with wet hands. The possibility exists of electrical shock,

electrocution or death.

 Make sure power cables are securely

damage to the generator.

NOTICE

 ALWAYS

Chart in this manual.

NEVER insert any objects into the output

receptacles during operation. This is extremely dangerous. The possibility exists of electrical shock, electrocution

or death.

PAGE 8 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

SAFETY INFORMATION

Grounding Safety



BATTERY SAFETY

keep the battery charged. If the battery is not

recharge the battery in a well-ventilated

environment to avoid the risk of a dangerous concentration

If the battery liquid (dilute sulfuric acid) comes into

, rinse skin or clothing

If the battery liquid (dilute sulfuric acid) comes into

, rinse eyes immediately with plenty

of water and contact the nearest doctor or hospital to

NEGATIVE battery terminal

keep battery cables in good working condition.

WARNING

DANGER

This generator is equipped with a grounding terminal attached to the enclosure. Electrical grounding requirements can differ by State, Province, District,

Municipality, and unique application settings.

For portable and vehicle-mounted generators, Multiquip recognizes the guidance provided in NEC Handbook Article 250.34 Parts A and B, and 29 CFR 1926.404 (f) (3) (i). If a more deﬁ nitive earth-to-ground safeguard is required, please consult a qualiﬁ ed electrician and reference appropriate National Electrical Code (NEC) guidelines in establishing an exterior grounding point

generator.

NEVER use gas piping as an electrical ground.

NOTICE

There is a permanent conductor bond between generator (stator winding) and the frame.

DANGER

DO NOT drop the battery. There is a possibility that the

battery will explode.

DO NOT expose the battery to open ﬂ ames,

sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a ﬂ ame or spark, an explosion could occur.

 ALWAYS wear safety glasses when

handling the battery to avoid eye irritation. The battery contains acids that can cause injury to the eyes and skin.

 Use well-insulated gloves when picking up the battery.

 ALWAYS

charged, combustible gas will build up.

 ALWAYS

of combustible gasses.



contact with clothing or skin immediately with plenty of water.



contact with eyes

seek medical attention.

CAUTION

 ALWAYS disconnect the

before performing service on the generator.

 ALWAYS

Repair or replace all worn cables.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 9

SAFETY INFORMATION

ENVIRONMENTAL SAFETY/DECOMMISSIONING

Decommissioning is a controlled process used to safely retire a piece of generator that is no longer serviceable. If the generator poses an unacceptable and unrepairable safety risk due to wear or damage or is no longer cost effective to maintain (beyond life-cycle reliability) and is to be decommissioned (demolition and dismantlement),be sure to follow rules below.

EMISSIONS INFORMATION

The diesel engine used in this generator has been designed to reduce harmful levels of carbon monoxide (CO), hydrocarbons (HC) and nitrogen oxides (NOx) contained

This engine has been certiﬁ ed to meet US EPA Evaporative

Attempting to modify or make adjustments to the engine emission system by unauthorized personnel without proper training could damage the generator or create an unsafe

Additionally, modifying the fuel system may adversely affect evaporative emissions, resulting in ﬁ nes or other penalties.

The emission control label is an integral part of the emission

If a replacement emission label is needed, please contact

NOTICE

DO NOT pour waste or oil directly onto the ground, down

a drain or into any water source.

Contact your country's Department of

Public Works or recycling agency in your area and arrange for proper disposal of any electrical components, waste or oil associated with this generator.

When the life cycle of this generator is over, remove

battery(s) and bring to an appropriate facility for lead reclamation. Use safety precautions when handling batteries that contain sulfuric acid.

When the life cycle of this generator is over, it is

recommended that the generator frame and all other metal parts be sent to a recycling center.

Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product.

Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings.

NOTICE

in diesel exhaust emissions.

emissions requirements in the installed conﬁ guration.

condition.

Emission Control Label

system and is strictly controlled by regulations.

The label must remain with the engine for its entire life.

your authorized engine distributor.

PAGE 10 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

Table 1. Generator Speciﬁcations

Model

Type

Armature Connection Star with Neutral

Phase

Standby Output

Prime Output

3Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 3Ø 240/139

3Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 3Ø 480/277

1Ø Voltage (L-L/L-N)

Voltage Change-Over Bd. at 1Ø 240/120

Power Factor

Frequency

Speed

Aux. AC Power

Aux. Voltage/Output

Dry Weight

Wet Weight

Table 2. Engine Speciﬁcations

Model

Type

No. of Cylinders

Bore x Stroke

Displacement

Rated Output

Starting

Cold Weather Starting Aid

Coolant Capacity with Radiator

Lube Oil Capacity

Lubricating Type Oil

DEF Tank Capacity

Fuel Type

Fuel Tank Capacity

16.7 gal. (63.2 L)/hr at full load 12.5 gal. (47.4 L)/hr at 3/4 load

Fuel Consumption

Battery

Includes engine and radiator hoses, 2 Includes ﬁlters

SPECIFICATIONS

DCA300SSJU4F2

Revolving ﬁeld, self ventilated,

open protected type synchronous generator

3Ø

264 kW (330 kVA)

240 kW (300 kVA)

208Y/120, 220Y/127, 240Y/139

416Y/240, 440Y/254, 480Y/277

N/A

0.8

60 Hz

1800 rpm

Single Phase, 60 Hz

4.8 Kw (2.4 kW x 2)

11,220 lbs. (5,090 kg)

15,010 lbs. (6,810 kg)

John Deere 6090HFG09 EPA Tier 4 Final Certiﬁed

4 cycle, water-cooled, direct injection, turbo-charged

charged air cooled, EGR, DOC and SCR

6 cylinders

4.64 in. x 5.34 in. (118.4 mm x 136 mm)

549.2 cu. in. (9.0 liter)

437 HP (326 kW) at 1800 rpm

Electric

NVT Dieselmatic Starting Fluid System

17.7 gal. (67 liters)

API service class CJ-4, ACEA E9 or ACEA E6

#2 Diesel Fuel (Ultra low sulfur diesel fuel only)

8.9 gal. (33.8 L)/hr at 1/2 load 5.8 gal. (21.9 L)/hr at 1/4 load

8D (CCA 0°F 1400A) X 1

John Deere Cool-Gard II ™

9.3 gal. (35 liters)

29.7 gal. (112.4 liters)

430.6 gal. (1,630 liters)

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 11

DIMENSIONS

TOP VIEW

SIDE VIEW

MAXIMUM

LIFTING

POINT

19,000 lbs.

(8,618 kg)

A F

300

FRONT VIEW

150

180

120

140

180

220

PSI

RPMX10

°F

100

210

100

260

DECREASE

INCREASE

OIL PRESS

SPEED

WATER TEMP

50 18 12 24

ＥＣＵ

% VOLTS

Integrated Gauge Panel

100

Check

DEF

Emissions Failure

°F

Emissions

Failure

Regen

Needed

Low

FUEL

DEF

Regen

Fuel

Inhibit

OFF

ECU

Series 800 Controller

Engine Started

Shutdown

V-W

Pre-Alarm

W-U

U-V

OFF

Screen

Program/

Alarm

Option

Change

Exit

Acknowledge

Figure 2. Dimensions

Table 3. Dimensions

Denyo

Reference

Letter

Dimension in. (mm) Reference Letter Dimension in. (mm)

A 38.19 (970) F 46.42 (1,179)

B 38.19 (970) G 149.60 (3,800)

C 45.47 (1,155) H 96.46 in. (2,450)

D 23.03 (585) I 59.05 in. (1,500)

E 25.20 (640)

PAGE 12 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

NOTES

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 13

INSTALLATION

./2.4 M (MINIMUM)

CONNECTING THE GROUND

Consult with local Electrical and Safety Codes for proper connection based on condition of use.

EXAMPLE of how to ground the unit if the condition of use requires such a device:

The ground terminal on the generator should always be used to connect the generator to a suitable ground when required.

The ground cable should be #8 size wire (aluminum) minimum. If copper wire is used, #10 size wire minimum should be used.

Connect one end of the ground cable terminal to the generator ground point (Figure 3). Connect the other end of the ground cable to a suitable earth ground (ground rod)

GENERATOR

GROUND LUG

GROUND CABLE

IF THE GENERATOR IS PROVIDING ELECTRIC POWER TO A BUILDING VIA A TRANSFER SWITCH IT MUST BE CONNECTED TO A GROUND ROD.

REFERENCE

NEC 250

8 FT

Figure 3. Typical Generator Grounding Application

PAGE 14 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

INSTALLATION

OUTDOOR INSTALLATION

Install the generator in a area that is free of debris, bystanders, and overhead obstructions. Make sure the generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

CAUTION

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements. Engine exhaust must be routed to a ventilated area.

GENERATOR GROUNDING

NOTICE

The Occupational Safety and Health Administration (OSHA) and the National Electrical Code (NEC) recommend that if the generator is providing electrical power to a structure (home, ofﬁce shop, trailer or similar) it must be connected to a grounding electrode system, such as driven ground rod (Figure 3).

If applicable, to guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground, (Figure 3).

NOTICE

ALWAYS check with State, Province, District and Municipalities for electrical grounding requirements before using generator.

Article 250 (Grounding) of the NEC handbook provides guidelines for proper grounding and speciﬁes that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

INDOOR INSTALLATION

Exhaust gases from diesel engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

MOUNTING

The generator must be mounted on a solid foundation such as concrete) and set ﬁrmly on the foundation to isolate vibration of the generator when it is running. The generator must set at least 6 inches above the ﬂoor or grade level (in accordance to NFPA 110, Chapter 54.1). DO NOT remove the metal skids on the bottom of the generator. They are to resist damage to the bottom of the generator and to maintain alignment.

NEC article 250 specifices the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper 10 AWG (5.3 mm

b. Aluminum 8 AWG (8.4 mm

) or larger.

2. When grounding of the generator (Figure 3) is required, connect one end of the ground cable to the ground lug on the generator. Connect the other end of the ground cable to the ground rod (earth ground).

3. NEC article 250 speciﬁes that the earth ground rod should be buried a minimum of 8 ft. into the ground.

NOTICE

When connecting the generator to any buildings electrical system ALWAYS consult with a licensed electrician.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 15

GENERAL INFORMATION

GENERATOR

This generator (Figure 7) is 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.

OPERATING PANEL

The “Operating Panel” is provided with the following:

 ECU-845 Controller  Gauge Unit (ECU-670)

• Oil Pressure Gauge

• Water Temperature Gauge

• Charging Voltmeter

• Fuel Gauge/DEF Gauge

• Tachometer/Generator Load

 Panel Light/Panel Light Switch  Hour Check Button  Auto Start/Stop Switch  Emergency Stop Button  Engine Speed Switch  Fuel Leak Detected Alarm Lamp

CONTROL PANEL

The “Control Panel” is provided with the following:

 Frequency Meter (Hz)  AC Ammeter (Amps)  AC Voltmeter (Volts)  Ammeter Change-Over Switch  Voltmeter Change-Over Switch  Voltage Regulator  3-Pole, 800 amp Main Circuit Breaker  “Control Box” (located behind Control Panel)

• Automatic Voltage Regulator

• Current Transformer

• Over-Current Relay

• Starter Relay

• Voltage Change-Over Board

OUTPUT TERMINAL PANEL

The “Output Terminal Panel” is provided with the following:

 Three 120/240V output receptacles (CS-6369), 50A  Three auxiliary circuit breakers, 50A  Two 120V output receptacles (GFCI), 20A  Two GFCI circuit breakers, 20A  Eight output terminal lugs (3Ø power)  Ground lug  Battery Charger (Optional)  Jacket Water Heater (Optional)

OPEN DELTA EXCITATION SYSTEM

Each generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist

of an electrically independent winding wound among stationary windings of the AC output section.

There are four connections of the open delta A, B, C and D. During steady state loads, the power from the voltage regulator is supplied from the parallel connections of A to B, A to D, and C to D. These three phases of the voltage input to the voltage regulator are then rectiﬁed and are the excitation current for the exciter section.

When a heavy load, such as a motor starting or a short circuit occurs, the automatic voltage regulator (AVR) switches the conﬁguration of the open delta to the series connection of B to C. This has the effect of adding the voltages of each phase to provide higher excitation to the exciter section and thus better voltage response during the application of heavy loads.

The connections of the AVR to the AC output windings are for sensing only. No power is required from these windings.

The open-delta design provides virtually unlimited excitation current, offering maximum motor starting capabilities. The excitation does not have a “ﬁxed ceiling” and responds according the demands of the required load.

ENGINE

This generator is powered by a 6 cylinder, 4-cycle water cooled, direct injection, turbocharged, air cooled EGR John

Deere 6090HFG06 diesel engine. This engine is designed to meet every performance requirement for the generator. Reference Table 2 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.

ELECTRIC GOVERNOR SYSTEM

The electric governor system controls the RPMs of the engine. When the engine demand increases or decreases, the governor system regulates the frequency variation to ±.25%.

EXTENSION CABLES

When electric power is to be provided to various tools or loads at some distance from the generator, extension cords are normally used. Cables should be sized to allow for distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum. Use the cable selection chart (Table 8) as a guide for selecting proper extension cable size.

PAGE 16 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

GENERAL PARALLELING INFORMATION (OPTION)

NOTICE

When the paralleling option is employed, the Basler DGC-2020HD controller must be installed. The factory installed ECU-845 controller cannot be used for paralleling.

PARALLELING

Paralleling is the sharing of a load between two generator sets or more.

LOAD SHARING

Load sharing is deﬁned as the proportional division of the kW and kVAR total load between multiple generator sets in a paralleled system.

Load sharing is essential to avoid overloading and stability problems on the systems’ generator sets.

ACTIVE POWER (KW) LOAD SHARING

When generator sets operate in parallel, the engine speed governor of each generator set determines the proportional sharing of the total active power requirements (kW) of the systems’.

The kW load sharing is achieved by increasing or decreasing fuel to the systems’ engines. As the fuel to the engine of one generator set in a group is increased it will not lead to an increase in speed and hence frequency (as it would if it were operating alone) but it will lead to an increase in the proportion of the total kW load that it will deliver.

As the fuel to the engine of one generator set in a group is decreased it will not lead to a decrease in speed and hence frequency (as it would if it were operating alone) but it will lead to a decrease in the proportion of the total kW load that it will deliver.

The control system of the generator sets (via the engine speed control system) monitors and controls the sharing of the total kW load in proportion to the relative rating of the engines on the systems’ generator sets.

REACTIVE POWER (KVAR) LOAD SHARING

When generator sets operate in parallel the alternator ﬁeld excitation system of each generator set controls the proportional sharing of the total reactive power requirements (kVAR) of the system.

As the ﬁeld excitation of one generator set in a group is increased i.e. over excited it will not lead to an increase in voltage (as it would if it were operating alone) but It will lead to an increase in the proportion of the total kVAR load it will deliver and a decrease in its power factor.

As the ﬁeld excitation of one generator set in a group is decreased i.e. over excited it will not lead to an decrease in voltage (as it would if it were operating alone) but It will lead to an decrease in the proportion of the total kVAR load it will deliver and a increase in its power factor.

An undesirable circulating reactive current (cross current) will ﬂow in the system if the excitation of the alternators are not matched.

ETHERNET COMMUNICATION

Ethernet communication is the preferred method for paralleling. This method supports breaker negotiation to avoid simultaneous breaker closures, kW load sharing and kVAR sharing, soft load transfers on and off loading.

The Ethernet ports are located at the output bus splash panel area. There are two ports which are identical so either one can be used. Using a standard Ethernet cable, interconnect units to be paralleled and or sequenced.

LOAD MANAGEMENT

These generators are set up to automatically manage load, based on demand. Load management is only functional in auto mode. While in auto mode, if the auto start contacts are closed, load management is active by default. Load management will only run the number of units needed to support the load.

If the load demand is small, only one generator will remain running while the other generators will be in standby mode. If the load increases above 80% of its capacity, it will start the next generator. The next generator priority is based on the time remaining on the maintenance timer.

Generators with more time until scheduled maintenance will take priority over units that are almost due for maintenance. Once the second unit starts it will synchronize and parallel in then ramp up to share the load. If the load levels drop below 35% of its combined rating, the generator that is no longer needed will ramp off, shut down and wait in standby mode.

The kVAR load sharing is achieved by increasing or decreasing the ﬁeld excitation to the systems’ alternators

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 17

GENERAL PARALLELING INFORMATION (OPTION)

SEQUENCING

NOTICE

Ethernet communication is required when the generators are conﬁgured for the sequencing mode of operation.

These generators are capable of sequencing for control of balanced maintenance schedules. As described above, these generators can start and stop as demand raises or lowers. In addition, if the units get to the point of maintenance, it will ramp off and start the next generator to relieve it based on the time remaining on the maintenance timer.

After maintenance is performed, the maintenance timers should be reset to the recommended service interval. This is usually 250 hours depending on the engine oil type.

MAINTENANCE INTERVAL

Maintenance intervals are factory set for 250 hours. The maintenance interval timer will count down to zero indicating that it is time for the unit to be serviced.

Once the timer counts down to zero, a pre-alarm will appear indicating that the unit is due for maintenance. To reset the maintenance interval back to the default time of 250 hours, press and hold the “Reset” button for ten seconds.

The complete password sequence is shown in Figure 4. The set-point for the desired hours until maintenance can now be changed. Press edit to save.

Edit Edit

Figure 4. Password Sequence 2.04 and Lower

PASSWORD ENTRY 2.04 AND HIGHER

User Name and Password is A.

Once prompted, the cursor will be in the user name ﬁeld. Press the down button () twice to highlight the A character.

Once the user name of A is populated in the user name ﬁeld, press the up arrow () button four times to highlight the check box in the upper right corner of the screen. With the check box highlighted press the edit button to accept the entry.

The cursor will move to the password ﬁeld. Again, press the down arrow () button twice until the A is highlighted and then press edit. Press the up arrow () button four times to highlight the check box in the upper right corner of the screen. With the check box highlighted press the edit button to accept the entry. This completes the password entry.

The complete password sequence is as follows:

To reset the maintenance interval using the reset button, the Maintenance Due pre-Alarm must be active, and the Basler controller must display the “Overview Screen” (Main Screen).

If the maintenance timer has not yet expired and it is desired to reset the unit back to 250 hours, navigate back to the settings menu. Settings Menu->System Parameters>Engine Statistics->Hours To Maintenance.

PASSWORD ENTRY 2.04 AND LOWER

When highlighted, press the “Edit” button. Username and Password is required. User Name is A and Password is A. Use the up arrow button () and scroll to the alpha character A, then press edit to select.

Next, the cursor will move to the password ﬁeld, press the up arrow button () and scroll to the alpha character A, then press edit to select.

PAGE 18 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

Edit Edit

Figure 5. Password Sequence 2.04 and Higher

Pre-alarm Silence allows the user to suppress the toggling of the alarm screen when a new Pre-alarm becomes active. While a Pre-alarm is active, pressing the Alarm Silence button will suppress the fault display.

This happens to be very handy function when the “Maintenance Interval” Pre-Alarm occurs. Right after the Pre-Alarm occurs it will begin toggling between the pre- alarm and the overview screen.

While in this mode, pressing the reset button does not reset the maintenance interval. In order to reset the maintenance interval the overview screen must be selected.

GENERAL PARALLELING INFORMATION (OPTION)

Pressing the alarm silence button will stop the toggling between the pre-alarm and the overview screen.

Once the overview screen is selected, the maintenance interval can be reset by pressing and holding the reset button for 10 seconds.

THREE PHASE 480V/208V PARALLEL WIRING VIA CAMLOCKS

REQUIRED EQUIPMENT

 4/0 Single Conductor Cable (User Supplied)

 CAT5E Shielded Cable or Better (User Supplied)

 Power Distribution Panel (User Supplied)

The following procedure intended to assist the user with the parallel wiring conﬁguration for the DCA300SSJU4F2 generator using the camlok connector panel.

NOTICE

Only a qualified service technician or licensed electrician with proper training should perform

this installation. Follow all shop safety rules when performing this installation.

NOTICE

When connecting load cables to the power distribution panel be sure to select the correct size of the load cables to handle full load/amperage of both generators (parallel).

3Ø-208 VAC PARALLEL WIRING CONFIGURATION

1. Using 4/0 cables connect the two generators to the power distribution panel as referenced in the 3Ø-208V parallel wiring diagram.

ETHERNET CABLE CONNECTION

1. Connect a CAT5E Ethernet cable (shielded) between port 1 on both generators as shown in Figure 6.

CAT5E PORT 1 GENERATOR 1

PORT 2

CAT5E ETHERNET CABLE (SHIELDED)

PREPARATION

1. Make sure generator is turned off and engine is cool.

2. Disconnect any loads connected to the generator.

3. Place the main circuit breaker in the OFF position.

4. Place the generator in an area free of dirt and debris Make sure it is on secure level ground.

5. Disconnect negative battery cable from the battery.

3Ø-480 VAC PARALLEL WIRING CONFIGURATION

1. Using 4/0 cables connect the two generators to the power distribution panel as referenced in the 3Ø-480V parallel wiring diagram.

DANGER

To prevent arcing make sure cables are securely tighten at power distribution panel, the possibility exist of the unit catching on ﬁre thus causing equipment damage and severe bodily harm.

CAT5E PORT 1 GENERATOR 2

PORT 2

Figure 6. Ethernet Cable Connection

2. Reference Table 4 for additional Ethernet port connections.

Table 4. Ethernet Cable Connections

Generator 1 Generator 2

Port 2 Port 1

Port 1 Port 2

Port 2 Port 2

3. Reconnect battery.

4. Start generator as outlined in start up section of this manual.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 19

MAJOR COMPONENTS

300

V W

300

Table 5. Generator Major Components

ITEM NO. DESCRIPTION

150

180

120

140

180

220

PSI

RPMX10

°F

100

210

100

260

DECREASE

INCREASE

OIL PRESS

SPEED

WATER TEMP

50 18 12

ＥＣＵ

% VOLTS

Integrated Gauge Panel

100

Check

DEF

Emissions Failure

°F

Emissions

Failure

Regen

Needed

Low

FUEL

DEF

Regen

Fuel

Inhibit

ECU

Acknowledge

OFF

Series 800 Controller

Engine Started

Shutdown

V-W

Pre-Alarm

W-U

U-V

OFF

Screen

Program/

Alarm

Option

Change

Exit

1 Mufﬂer Assembly

2 Air Filter Assembly

3 Generator Assembly

4 Engine Assembly

5 Fuel Tank Assembly

6 Output Terminal Assembly

Denyo

7 ECU-670 Gauge Unit Assembly

8 Generator Control Panel Assembly

9 Voltage Change-Over Board Assembly

9 Auto Start/Stop Controller Assembly

10 Circuit Breaker Assembly

11 Battery Assembly

12 ECU-845 Controller Assembly

Figure 7. Major Components

PAGE 20 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

ECU

Acknowledge

Series 800 Controller

Alarm

Screen Change

Option

Program

Exit

Engine Started

Shutdown

Pre-Alarm

ENGINE CONTROL UNIT (ECU-845)

PSI

ECU

OIL PRESS

Check DEF

Emissions Failure

Regen Needed

Regen Inhibit

Alarm

Acknowledge

100

Series 800 Controller

Screen Change

B C D

150

180

120

140

180

220

RPMX10

°F

210

100

260

SPEED

WATER TEMP

ＥＣＵ

VOLTS

Integrated Gauge Panel

100

°F

Low Fuel

Option

FUEL

DEF

Engine Started

Shutdown

Pre-Alarm

Program

Exit

INCREASE DECREASE

OFF

V-W

W-U

U-V

OFF

E F

Figure 8. Engine Control Unit (ECU-845)

The deﬁnitions below describe the controls and functions of the Engine Control Unit (Figure 8).

1. ECU-845 Controller — This auto start/stop

controller displays the parameters and the diagnostic troubleshooting messages of the engine.

In addition, this controller also displays symbols and indications related to the exhaust gas after treatment system (DOC, SCR) including the Diesel Exhaust Fluid (DEF) level in the DEF tank.

A. ECU Display Screen — Engine fault diagnostic

messages are shown on this LCD display. screen

B. Engine Started Lamp — This lamp when lit

indicates engine is operating normally.

C. Engine Shutdown Lamp — When an engine

failure has occured this lamp will blink, indicating the engine has been shutdown. The diagnostic fault message will be displayed on the LCD screen.

The fault message will be displayed on the screen. When multiple engine faults occur, the lamp will continue blinking until all fault messages are conﬁrmed. The blinking lamp will change to a solid lamp display all current conﬁrmed fault messages will scroll across the screen.

F. Screen Change Button — When this button is

pushed during operation, the screen (Figure 9) will cycle through main and secondary parameter screens.

VOLTS AMPS

278

278 278

240 kW

60 Hz

ENGINE GENERATOR SYSTEM OK

VW WU

480 480

480

361

300 kVA

100 h

D. Pre Alarm Lamp — When an engine failure has

occured this lamp will blink. Indicating a pre-fault engine condition and the possibility of engine shutdown.The diagnostic fault message will be displayed on the LCD screen.

E. Alarm Acknowledge Button — When the engine

experiences a fault, the "Pre Alarm Lamp" or the "Shutdown Lamp" will start blinking. Pushing this button will conﬁrm the fault message and the blinking lamp will change to a solid lamp display.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 21

Figure 9. Generator Parameter Screen

NOTICE

The screen as shown in (Figure 9) represents the phase voltages for each phase to neutral (UO, VO and WO) and the line voltages between each phase (UV, VW and WU).

G. Option Button — This button is not active. Do

not use.

H. Program/Exit Button — Push this button from the

home screen to enter the main menu.

GAUGE UNIT ASSEMBLY

180

140

220

PSI

ECU

OIL PRESS

Check DEF

Emissions Failure

Regen Needed

Regen Inhibit

Series 800 Controller

Alarm

Acknowledge

°F

100

260

WATER TEMP

VOLTS

°F

Low

FUEL

Fuel

Screen

Program

Option

Change

Exit

PSI

OIL PRESS

Check DEF

Emissions Failure

Regen Needed

Regen Inhibit

100

180

140

°F

100

WATER TEMP

VOLTS

°F

Low

FUEL

Fuel

150

120

220

260

180

RPMX10

210

SPEED

ＥＣＵ

Integrated Gauge Panel

100

°F

DEF

Figure 10. Gauge Unit

The deﬁnitions below describe the readouts and functions of the Gauge Unit Assembly (Figure 10).

1. Gauge Unit Assembly — This assembly houses the

various engine monitoring gauges. These gauges indicate: oil pressure, water temperature, charging voltmeter, generator load, fuel level, DEF level and engine speed RPM (tachometer).

A. Oil Pressure Gauge — During normal operation,

this gauge should read approximately 44 psi. (300 kPa). When starting the generator, the oil pressure may read a little higher but after the engine warms up, the oil pressure should return to the correct pressure range.

B. Water Temperature Gauge — During normal

operation this gauge should read between 185° and 207°F (85°~97°C).

C. Tachometer — Indicates engine speed in RPM’s

for 60 Hz operation. This meter should indicate 1800 RPM’s when the rated load is applied.

120

100

Engine Started

Shutdown

Pre-Alarm

150

180

RPMX10

210

SPEED

ＥＣＵ

Integrated Gauge Panel

°F

DEF

INCREASE DECREASE

OFF

V-W

W-U

U-V

OFF

D. Battery Voltmeter Gauge — During normal

operation this gauge indicates a minimum 14 VDC.

E. Generator Load Gauge — Indicates the generator

load rate. It is recommended the load be above the red area (20%) for maintaining sufﬁcient exhaust temperature.

F. Fuel Gauge — Indicates amount of diesel fuel

available. The red area in the gauge indicates a low fuel level (20%).

G. DEF Gauge — Indicates amount of diesel exhaust

ﬂuid available. The red area in the gauge indicates a low DEF level (10%).

H. Exhaust System State Indicator Lamps — Lamps

illuminate when engine is at Exhaust System State or DEF state. Refer to the maintenance section of this manual for more detailed indormation.

I. Low fuel Warning LED — When ON (lit) indicates

that fuel level is low.

PAGE 22 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

ENGINE/GENERATOR CONTROL PANEL

Table 6.

OFF

V-W

W-U

U-V

OFF

ECU

PSI

OIL PRESS

Check DEF

Emissions Failure

Regen Needed

Regen Inhibit

Series 800 Controller

100

VOLTS

Low Fuel

140

WATER TEMP

120

180

220

RPMX10

°F

210

260

SPEED

ＥＣＵ

Integrated Gauge Panel

100

°F

FUEL

DEF

INCREASE DECREASE

150

180

Engine Started

Shutdown

Pre-Alarm

Alarm

Screen

Program

Option

Acknowledge

Change

Exit

Figure 11. Generator/Engine Control Panel

The deﬁnitions below describe the controls and functions of the Generator/Engine Control Panel (Figure 11).

1. Panel Light — For operation at night, panel light

illuminates control panel for ease of reading meters and gauges. Make sure oanel light switch is in the OFF position when light is not in use.

2. Panel Light Switch — When activated will turn on

control panel light.

3. Frequency Meter — Indicates the output frequency

in hertz (Hz). Normally 60 Hz

4. AC Ammeter — Indicates the amount of current the

load is drawing from the generator per leg selected by the ammeter phase-selector switch.

5. AC Voltmeter — Indicates the output voltage present at the U,V, and W Output Terminal Lugs.

6. Voltage Regulator Control — Allows ±15% manual adjustment of the generator’s output voltage.

7. Ammeter Change-Over Switch — This switch allows the AC ammeter to indicate the current ﬂowing to the load connected to any phase of the output terminals, or to be switched off. This switch does not effect the generator output in any fashion, it is for current reading only.

8. Voltmeter Change-Over Switch — This switch allows

the AC voltmeter to indicate phase to phase voltage between any two phases of the output terminals or to be switched off.

9. Emergency Stop Switch Button — In the event

of an emergency press this button to shut down the generator.

10. Hour Check Button — With the engine stopped, press

and hold ths button. The total running hours, fuel level, and battery voltage will be displayed.

11. Auto/Start Switch — This switch selects either manual or automatic operation. Center position is OFF (reset).

12. Engine Speed Switch Switch — This switch controls the speed of the engine low or high.

13. Voltage Change-Over Board — 6 jumper plates that allows the generator to be conﬁgured for either 3Ø, 240 or 480 VAC output.

14. Main Circuit Breaker — This three-pole, 800 amp main breaker is provided to protect the U,V, and W

Output Terminal Lugs from overload.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 23

BASLER DIGITAL GENSET CONTROLLER (OPTION)

Figure 12. Basler DGC-2020HD

NOTICE

The Basler DGC-2020HD is an option. It replaces the ECU 845 controller that comes standard with this generator when the paralleling option is employed.

PAGE 24 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

BASLER DIGITAL GENSET CONTROLLER (OPTION)

The deﬁnitions below describe the controls and functions of the Digital Genset Controller (Figure 12).

1. LCD Display — Display consists of a LCD color touch

screen. The backlit, 272X480 pixel color LCD serves as the local information source for metering, alarms, pre-alarms, and protective functions. Touch screen capability provides convenient navigation through metering and settings. Display operation is maintained down to –4°F (−20°C).

2. Not In Auto Indicator — This red LED lights when the DGC-2020HD is not operating in AUTO mode.

3. Alarm Indicator — This red LED lights continuously during alarm conditions and ﬂashes during pre-alarm conditions.

4. Supplying Load Indicator — This green LED lights when the generator current is greater than emergency power supply (EPS) threshold current.

5. Programmable Indicators — These three red LEDs light when the corresponding logic element is set true. Logic element PROGLED 1 controls the upper LED, PROGLED 2 controls the middle LED, and PROGLED 3 controls the lower LED. A card is provided for labeling the programmable indicators. See Programmable Indicator Conﬁguration, below.

6. Alarm Silence Pushbutton — Pressing this button tests the DGC-2020HD indicators by exercising all LCD pixels and lighting all LEDs.

7. Lamp Test Pushbutton — Pressing this button tests the DGC-2020HD indicators by exercising all LCD pixels and lighting all LEDs.

8. Auto Pushbutton and Mode Indicator — Pressing the Auto button places the DGC-2020HD in Auto mode. The green Auto mode LED lights when Auto mode is active.

9. Off Pushbutton and Mode Indicator. — Pressing this

button places the DGC-2020HD in Off mode.The red Off mode LED lights when the DGC-2020HD is in Off mode. This button also resets the Breaker Management Pre-Alarms and all MTU ECU Alarms.

10. Run Pushbutton and Mode Indicator. — Pressing

this button places the DGC-2020HD in Run mode. The green Run mode LED lights when Run mode is active.

11. Reset Pushbutton — This button is pressed to cancel

a settings editing session and discard any settings changes. When pressed momentarily, this button resets the Breaker Management Pre-Alarms and all MTU ECU Alarms. This button is also used to reset the Maintenance Interval when pressed for 10 seconds while viewing Hours Until Maintenance or Maintenance Due Pre-Alarm.

12. Arrow Pushbuttons — These four buttons are used

to navigate through the front panel display menus and modify settings.

• The left and right arrow buttons are used to navigate through the menu levels. The right arrow button is pressed to move downward through the menu levels and the left arrow button is pressed to move upward through the menu levels.

• Within a level, the up and down arrow buttons are used to move among items within the menu level. Pressing the down arrow button moves to items lower in the list. Pressing the up arrow button moves to items higher in the list.

• During a settings editing session, the up and down arrow buttons are used to raise and lower the value of the selected setting. The right and left arrow buttons move to different digits.

While in “AUTO” the controller will be in standby awaiting a signal to start via the remote start terminals. While in auto, closure of the auto start contacts will immediately start the engine. Once the generator is up to speed and voltage it will compare its voltage to the bus.

If the bus is dead it will immediately close the contactor to provide power to the load(s). If the bus is already hot from another generator it will ﬁrst synchronize then close its contactor then slowly ramp up to share load if load were present.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 25

13. Edit Pushbutton — Pressing this button starts an

editing session and enables changes to DGC-2020HD settings. At the conclusion of an editing session, the Edit pushbutton is pressed again to save the setting changes.

PARALLELING PANEL (OPTION)

PANEL

LIGHTS

VOLTAGE

ADJUST

CONTACTOR

OPEN

EMERGENCY STOP

WHISPERWATT

300 kVA AC GENERATOR

Figure 13. Paralleling Panel Components

CONTROL

POWER

PAGE 26 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

PARALLELING PANEL (OPTION)

The deﬁnitions below describe the controls and functions of the Paralleling Panel (Figure 13).

1. Panel Lights — For operation at night or in dark areas,

panel light illuminates paralleling panel for ease of reading.

2. Panel Light Switch — When activated will turn on

control panel light.

3. Voltage Adjust potentiometer — The voltage adjust

potentiometer is a way to adjust the voltage up or down for ﬁne tuning. The adjustment sends a signal to the controller to offset the system rated voltage (Trim Voltage). It is important that all machines are set to the same value when paralleling.

When ﬁrst turning on the control power, the controller will begin its boot sequence much like a computer does. After completing the boot sequence the unit will be ready to run or be placed in auto for auto start applications.

4. Control Power Toggle Switch — The control power

switch is a master power switch for the digital controller. The control power switch has a latch feature that prevents powering down control power while the engine is running.

For units with manual operated breakers, the breaker will need to be reset by toggling the handle down, then can be turned back to the “ON” position. On models with spring charged breakers resetting the breaker is not necessary.

6. Contactor Operation (Manual Mode) — The For

manual run applications, user action is required to get the generator power to the output bus. Depending on the model, some utilize contactors in series with toggle handle circuit breakers and others have spring charged automatic circuit breakers.

On the spring charged types, the buttons on the breaker itself are not intended for circuit breaker operation. For instructional purposes both will be referred to as “contactor”.

There are two pushbuttons on the control panel for controlling the contactor. There is a green “CLOSE CONTACTOR” button to close the contactor and a red “OPEN CONTACTOR” button to open the contactor. These buttons illuminate to show the contactor status. If the contactor is open, the red “OPEN CONTACTOR” button will be illuminated. If the contactor is closed the green “CLOSE CONTACTOR” button will be illuminated.

5. Emergency Stop Button Switch — The Emergency

Stop pushbutton switch is used to stop the engine in case of emergency or to lock out operation during service. The emergency stop button should not be used for routine stopping of the engine.

Actuation of the Emergency stop button while the control power is on will illuminate the light on the button as well as display “Emergency Stop” on the controller display. Actuating the Emergency stop button will deenergize all controller outputs and cause the engine to stop as well as tripping the circuit breaker. This condition is a latched condition that must be reset prior to restarting the engine.

The procedure for resetting the emergency stop requires several actions. Rotate the emergency stop button to release the spring latch. To clear the latch, the controller must be placed into the off mode by pressing the “OFF” button. While in the “OFF” mode, the “RESET” button must be pressed to clear the E-STOP fault.

These buttons can sometimes be multifunctional depending on the situation. For stand-alone operation the buttons simply close and open the contactor as expected. For paralleling the buttons can act a little different.

When the bus is already hot from another generator, pressing the green online button will initiate a synchronizing sequence before closing the contactor. There will be an image of a synchro scope on the controller display and when the voltage and phases are matched, the contactor will close.

If there was already load on the bus the unit will slowly ramp up load until it is sharing equally with the other generator(s). While sharing load with other generators, pressing the red “OPEN CONTACTOR” button once will initiate a ramp down sequence. The unit will begin to ramp down and when at a low level of load it will automatically open it contactor. Pressing the red “OPEN CONTACTOR” button twice will immediately open the contactor.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 27

OUTPUT TERMINAL PANEL FAMILIARIZATION

OUTPUT TERMINAL PANEL

The Output Terminal Panel (Figure 15) shown below is provided for the connection of electrical loads. Lift up on the cover to gain access to receptacles and terminal lugs.

NOTICE

Terminal legs “O” and “Ground” are considered bonded grounds

300

V W

OUTPUT TERMINAL FAMILIARIZATION

The “Output Terminal Panel” (Figure 15) is provided with the following:

 Three (3) 240/139V output receptacles @ 50 amp

 Three (3) Circuit Breakers @ 50 amps

 Two (2) 120V GFCI receptacles @ 20 amp

 Two (2) GFCI Circuit Breakers @ 20 amps

 Eight (8) Output Terminal Lugs ( U, V, W, O, Ground)

1Ø AND 3Ø,

480 -120 VAC

OUTPUT TERMINALS

BLACK RED BLUE WHITE GREEN

NEUTRAL

TERMINAL

CS-6369 TWIST-LOCK

Figure 14. Output Terminal Panel

GROUND

TERMINAL

RECEPTACLES (3)

240Y/139, 50 AMPS

HOOKUP PANEL

CS-6369

TWIST-LOCK

HARD WIRE

CIRCUIT BREAKERS

FOR GFCI RECEPTACLES

CIRCUIT BREAKERS FOR CS-6369 TWIST

LOCK RECEPTACLES

PAGE 28 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

OUTPUT TERMINAL PANEL FAMILIARIZATION

120 VAC GFCI Receptacles

There are two 120 VAC, 20 amp GFCI (Duplex Nema 5-20R) receptacles provided on the output terminal panel. These receptacles can be accessed in any voltage change-over board position. Each receptacle is protected by a 20 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) of both GFCI receptacles is dependent on the load requirements of the U, V, and W output terminal lugs.

Pressing the reset button resets the GFCI receptacle after being tripped. Pressing the test button (See Figure 15) in the center of the receptacle will check the GFCI function. Both receptacles should be tested at least once a month.

Each auxiliary receptacle is protected by a 50 amp circuit breaker. These breakers are located directly above the GFCI receptacles. Remember the load output (current) on all three receptacles is dependent on the load requirements of the output terminal lugs.

Turn the voltage regulator control knob (Figure 17) on the control panel to obtain the desired voltage. Turning the knob clockwise will increase the voltage, turning the knob counter-clockwise will decrease the voltage.

Figure 17. Voltage Regulator Control Knob

Figure 15. G.F.C.I. Receptacle

Twist Lock Dual Voltage 120/240 VAC Receptacles

There are three 240/139V, 50 amp auxiliary twist-lock (CS-6369) receptacles (Figure 16) provided on the output terminal panel. These receptacles can only be accessed when the voltage change-over board is conﬁgured for single-phase 240/120 application

Figure 16. 240/139V Twist-Lock Auxiliary

Receptacles

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 29

OUTPUT TERMINAL PANEL FAMILIARIZATION

CS-6369

Connecting Loads

Loads can be connected to the generator by the Output Terminal Lugs or the convenience receptacles (Figure 18).

Make sure to read the operation manual before attempting to connect a load to the generator.

To protect the output terminals from overload, a 3-pole, 800A main circuit breaker is provided. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

TWIST-LOCK

RECEPTACLES

GFCI

RECEPTACLES

BLACK

HARD WIRE

HOOKUP PANEL

BLUE

RED

LOAD

WHITE

NEUTRAL

GREEN

GROUND

CAMLOCKS

LOAD

Over Current Relay

An over current relay (Figure 19) is connected to the main circuit breaker. In the event of an overload, both the circuit breaker and the over current relay may trip. If the circuit breaker can not be reset, the reset button on the over current relay must be pressed. The over current relay is located in the control box.

Figure 19. Over Current Relay

NOTICE

Figure 18. Connecting Loads

Remember the overcurrent relay monitors the current ﬂowing from the U,V, and W Output Terminal Lugs to the load.

In the event of a short circuit or over current condition, it will automatically trip the 800 amp main breaker.

To restore power to the Output Terminal Panel, press the reset button on the overcurrent relay and place the

main circuit breaker in the closed position (ON).

PAGE 30 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

LOAD APPLICATION

SINGLE PHASE LOAD

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage, frequency, and voltage requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130—150% more wattage than the rating on the nameplate, as the wattage is inﬂuenced by the efﬁciency, power factor and starting system of the equipment.

NOTICE

If wattage is not given on the equipment’s name plate, approximate wattage may be determined by multiplying nameplate voltage by the nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 0.8. See Table 7 below when connecting loads.

Table 7. Power Factor By Load

Type of Load Power Factor

Single-phase induction motors 0.4-0.75

Electric heaters, incandescent lamps 1.0

Fluorescent lamps, mercury lamps 0.4-0.9

Electronic devices, communication equipment

Common power tools 0.8

Table 8. Cable Selection (60 Hz, Single Phase Operation)

Current

Amperes

2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft.

5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.

7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.

10 1200 2400 250 ft. 150 ft. 100 ft.

15 1800 3600 150 ft. 100 ft. 65 ft.

20 2400 4800 125 ft. 75 ft. 50 ft.

Load in Watts Maximum Allowable Cable Length

At 100

Volts

CAUTION: Equipment damage can result from low voltage

At 200

Volts

#10 Wire #12 Wire #14 Wire #16 Wire

1.0

THREE PHASE LOAD

When calculating the power requirements for 3-phase power use the following equation:

NOTICE

If 3Ø load (kVA) is not given on the equipment nameplate, approximate 3Ø load may be determined by multiplying voltage by amperage by 1.732

NOTICE

Motors and motor-driven equipment draw much greater current for starting than during operation.

An inadequate size connecting cable which cannot carry the required load can cause a voltage drop which can burn out the appliance or tool and overheat the cable. See Table 6.

 When connecting a resistance load such as an

incandescent lamp or electric heater, a capacity of up to the generating set’s rated output (kW) can be used.

 When connecting a ﬂuorescent or mercury lamp, a

capacity of up to the generating set’s rated output (kW) multiplied by 0.6 can be used.

 When connecting an electric drill or other power tools,

pay close attention to the required starting current capacity.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

DANGER

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch. Serious damage to the building’s electrical system may occur without this transfer switch.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 31

GENERATOR OUTPUTS

JUMPER

6 PLACES

GENERATOR OUTPUT VOLTAGES

A wide range of voltages are available to supply voltage for many different applications. Voltages are selected by using the voltage change-over board (Figure 20). To obtain some of the voltages as listed in Table 9 (see below) will require a ﬁne adjustment using the voltage regulator (VR)

control knob located on the control panel.

Voltage Change-Over Board

The voltage change-over board (Figure 20) is located on the control box, behind the generator control panel. This board has been provided for ease of voltage selection.

Maximum Amps

Table 10 shows the maximum amps the generator can provide. DO NOT exceed the maximum amps as listed.

Table 10. Generator Maximum Amps

Rated Voltage Maximum Amps

1Ø 120 Volt 666.7 X 2 amps (4 wire)

1Ø 240 Volt 333.3 amps (4 wire)

3Ø 240 Volt 722 amps

3Ø 480 Volt 360 amps

Main Line Circuit

Breaker Rating

800 amps

Figure 20. Voltage Change-Over Board

CAUTION

NEVER attempt to place jumper plates on the voltage change-over board while the generator is in operation. There exist the possibility of electrocution, electrical shock or burn, which can cause severe bodily harm or even death!

Table 9. Voltages Available

UVWO Output Terminal Lugs

Line-Line

3Ø

1Ø Line-Neutral 120V 127V 139V 240V 254V 277V

1Ø Line-Neutral/

Line-Line

Voltage Change-Over Board

3-Phase 240/139V Position

208V 220V 240V 416V 440V 480V

Voltage Change-Over Board Single-Phase 240/120V Position

120V

Line-Neutral

PAGE 32 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

N/A N/A

Voltage Change-Over Board

3-Phase 480/270V Position

240V

Line-Line

N/A N/A

GENERATOR OUTPUTS/GAUGE READING

JUMPER

6 PLACES

HOW TO READ THE AC AMMETER AND AC VOLTAGE GAUGES

The AC ammeter and AC voltmeter gauges are controlled by the AC ammeter and AC voltmeter change-over switches.

Both of these switches are located on the control panel and DO NOT effect the generator output. They are provided to help observe how much power is being supplied, produced at the UVWO terminals lugs.

Before taking a reading from either gauge, conﬁgure the Voltage Change-Over Board (Figure 21) for the desired output voltage.

AC Ammeter Gauge Reading

Place the AC Ammeter Change-Over Switch (Figure 24) in the U position and observe the current reading (load drain) on the U terminal as indicated on the AC Ammeter Gauge (Figure 25). This process can be repeated for terminals V and W.

Figure 24. AC Ammeter Change-Over Switch

NOTICE

The ammeter gauge will only show a reading when the Output Terminal Lugs are connected to a load and in use.

Figure 25. AC Ammeter

(Amp reading on U Lug)

Figure 21. Voltage Change-Over Board-

Ø Position

240/3

AC Voltmeter Gauge Reading

Place the AC Voltmeter Change-Over Switch (Figure 22) in the W-U position and observe the phase to phase voltage reading between the W and U terminals as indicated on the AC Voltmeter Gauge (Figure 23).

Figure 22. AC Voltmeter Change-Over Switch

Figure 23. AC Voltmeter Gauge (Volt reading on W-U Lug)

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 33

OUTPUT TERMINAL PANEL CONNECTIONS

JUMPER

6 PLACES

BE USED

UVWO TERMINAL OUTPUT VOLTAGES

Various output voltages can be obtained using the UVWO output terminal lugs. The voltages at the terminals are dependent on the placement of the jumpers plates (6) on the Voltage Change-Over Board and the adjustment of the Voltage Regulator Control Knob.

Remember the voltage change-over board determines the range of the output voltage and can be conﬁgured in two different positions that provide 6 different output voltages at the UVWO output terminals. The generator is shipped from the factory in the 240V conﬁguration. The voltage regulator (VR) allows the user to increase or decrease the selected voltage.

3Ø-240V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 240V operation as shown in Figure 26

3. Turn the voltage regulator knob (Figure 28) clockwise to increase voltage output, turn counterclockwise to decrease voltage output. Use voltage regulator adjustment knob whenever ﬁne tuning of the output voltage is required

Figure 28. Voltage Regulator Knob

1Ø-240V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 26.

2. Connect the load wires to the UVWO terminals as shown in Figure 29.

BLACK

240V

RED

BLUE

240V

WHITE

GREEN

Figure 26. Voltage Change-Over Board 240V

Conﬁguration

2. Connect the load wires to the UVWO terminals as shown in Figure 27

BLACK

Figure 27. UVWO Terminal Lugs

3Ø-240/1Ø-139 Connections

PAGE 34 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

RED

THREE-PHASE

240 VAC (LOAD CONNECTIONS)

BLUE

WHITE

GREEN

GROUND

CONNECTION

MUST

AT ALL TIMES

240V

SINGLE-PHASE

240 VAC (LOAD CONNECTIONS)

GROUND

CONNECTION

BE USED

MUST

AT ALL TIMES

Figure 29. UVWO Terminal Lugs

1Ø-240V Connections

1Ø-120V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 240V operation as shown in Figure 26.

2. Adjust voltage regulator knob (Figure 28) for an output of 208V to obtain 120V at the UVWO terminals.

3. Connect the load wires to the UVWO terminals as shown in Figure 30

BLACK

RED

SINGLE-PHASE

BLUE

120V

Figure 30. UVWO Terminal Lugs 1Ø-120V

Connections

WHITE

GREEN

GROUND

CONNECTION

MUST

AT ALL TIMES

OUTPUT TERMINAL PANEL CONNECTIONS

BE USED

480 VAC (LOAD CONNECTIONS)

BE USED

277 VAC (LOAD CONNECTIONS)

NOTICE

ALWAYS make sure that the connections to the UVWO terminals are secure and tight. The possibility of arcing exist that could cause a ﬁre.

3Ø-480V UVWO Terminal Output Voltages

1. Jumper the voltage change-over board for 480V operation as shown in Figure 31. This conﬁguration uses 6 jumper plates in 3 different positions. Remember there are 2 jumper plates at every position. Every jumper plate must be used.

1Ø-480V UVWO Terminal Output Voltages

1. Make sure the voltage change-over board is jumpered for 480V operation as shown in Figure 31.

2. Connect the load wires to the UVWO terminals as shown in Figure 33.

BLACK

RED

480V

THREE-PHASE

BLUE

480V

Figure 33. UVWO Terminal Lugs 1Ø-480V

Connections

WHITE

GREEN

GROUND

CONNECTION

MUST

AT ALL TIMES

1Ø-277V UVWO Terminal Output Voltages

Figure 31. UVWO Terminal Lugs 1Ø-120V

Connections

2. Connect the load wires to the UVWO terminals as shown in Figure 32.

BLACK

RED

THREE-PHASE

480 VAC (LOAD CONNECTIONS)

BLUE

Figure 32. UVWO Terminal Lugs

3Ø-480V Connection

WHITE

GREEN

GROUND

CONNECTION

BE USED

MUST

AT ALL TIMES

1. Make sure the voltage change-over board is jumpered for 480V operation as shown inFigure 31.

2. Connect the load wires to the UVWO terminals as shown in Figure 34.

BLACK

RED

SINGLE-PHASE

BLUE

277V

Figure 34. UVWO Terminal Lugs 1Ø-277V

Connections

WHITE

GREEN

GROUND

CONNECTION

MUST

AT ALL TIMES

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 35

INSPECTION/SETUP

CIRCUIT BREAKERS

To protect the generator from an overload, a 3-pole, 800 amp, main circuit breaker is provided to protect the U , V, and W Output Terminals from overload. In addition two single-pole, 20 amp GFCI circuit breakers are provided to protect the GFCI receptacles from overload. Three 50 amp load circuit breakers have also been provided to protect the auxiliary receptacles from overload. Make sure to switch ALL circuit breakers to the OFF position prior to starting the engine.

LUBRICATION OIL

Fill the engine crankcase with lubricating oil through the ﬁller hole, but DO NOT overﬁll. Make sure the generator is level and verify that the oil level is maintained between the two notches (Figure 35) on the dipstick. See Table 11 for proper selection of engine oil.

FUEL CHECK

DANGER

Fuel spillage on a hot engine can cause a ﬁre or explosion. If fuel spillage occurs, wipe up the spilled fuel completely to prevent fire hazards. NEVER smoke around or near the generator.

Reﬁlling the Fuel System

CAUTION

ONLY properly trained personnel who have read

and understand this section should reﬁll the fuel tank system.

This generator has an internal fuel tank located inside the enclosure (). ALWAYS ﬁll the fuel tank with clean fresh #2 diesel fuel. DO NOT ﬁll the fuel tank beyond its capacity. Some units may be equipped with a fuel cell mounted inside the trailer frame.

Figure 35. Engine Oil Dipstick

When checking the engine oil, be sure to check if the oil is clean. If the oil is not clean, drain the oil by removing the oil drain plug, and reﬁll with the speciﬁed amount of oil as outlined in the John Deere Owner’s Manual. Oil should be warm before draining.

API service class engine oil is the recommended engine oil for this generator. When replacing engine oil please reﬁll using API CJ-4, ACEA E9 or ACEA E6 engine oil.

Table 11. Recommended Motor Oil

Pay attention to the fuel tank capacity when replenishing fuel. The fuel tank cap must be closed tightly after ﬁlling. Handle fuel in a safety container. If the container does not have a spout, use a funnel. Wipe up any spilled fuel immediately.

300

FUEL CAP

Figure 36. Internal Fuel Tank System

INTERNAL

FUEL TANK

PAGE 36 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

INSPECTION/SETUP

Unlevel Ground

Refueling Procedure:

WARNING

Diesel fuel and its vapors are dangerous

to your health and the surrounding environment. Avoid skin contact and/or inhaling fumes.

1. Level Tanks — Make sure fuel cells are level with the

ground. Failure to do so will cause fuel to spill from the tank before reaching full capacity (Figure 37).

CAUTION

ALWAYS place trailer on ﬁrm level ground before

refueling to prevent spilling and maximize the amount of fuel that can be pumped into the tank.

300

DO NOT fill on unlevel ground

3. NEVER overﬁll fuel tank — It is important to read the fuel gauge when ﬁlling trailer fuel tank. DO NOT wait for fuel to rise in ﬁller neck (Figure 39).

FUEL GAUGE LOCATED

ON GAUGE UNIT ASSEMBLY

°F

FUEL

Figure 39. Full Fuel Tank

CAUTION

DO NOT OVERFILL fuel system. Leave room for fuel

expansion. Fuel expands when heated (Figure 40).

Level Ground

Figure 37. Only Fill on Level Ground

NOTICE

ONLY use #2 diesel fuel (ultra low sulfur diesel fuel) when refueling.

2. Open the enclosure door and remove fuel cap and ﬁll tank as shown in Figure 38.

FUEL TANK

FILLER PORT

DIESEL

FUEL

Figure 40. Fuel Expansion

Figure 38. Fueling the Generator

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 37

INSPECTION/SETUP

DEF Reﬁlling

NOTICE

ONLY ﬁll the DEF tank with diesel exhaust ﬂuid. Any other type of ﬂuid may cause severe engine damage.

Diesel exhaust ﬂuid is an aqueous solution made with 32.5% high puirty urea carbamide) and 67.5 deionized water. DEF is used as a consumable in selective catalytic reduction (SCR) in order to lower NOx concentration from diesel exhaust emissions.

1. Make sure engine is OFF.

2. Open the enclosure door and remove the ﬁller cap from the DEF tank (Figure 41).

3. Upon initial start up, completely ﬁll the DEF tank with DEF ﬂuid. DO NOT overﬁll.

DEF Reﬁlling (Continuous Operation)

It is recommended to shut down the engine prior to reﬁlling the DEF tank. However, in special applications where shutdown is not possible, it is recommended to ONLY reﬁll the DEF tank when the ﬂuid level has been consumed down to 50%.

COOLANT (ANTIFREEZE/SUMMER COOLANT/ WATER)

John Deere recommends Cool-Gard II coolant for use in their engines, which can be purchased in concentrate (and mixed with 50% demineralized water) or pre-diluted. See the John Deere Engine Owner’s Manual for further details.

WARNING

If adding coolant/antifreeze mix to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns.

Day-to-day addition of coolant is done from the recovery tank. When adding coolant to the radiator, DO NOT remove the radiator cap until the unit has completely cooled. See Table 12 for engine, radiator, and recovery tank coolant capacities. Make sure the coolant level in the recovery tank is always between the “H” and the “L” markings.

Table 12. Coolant Capacity

antifreeze/summer

The DEF level sending unit requires a gradual DEF level decrease during continuous operation to validate proper operation. Failure of this sensor to report the decrease could result in an engine shutdown. A engine service technician would be required to remedy the shutdown.

DEF TANK

CAUTION

EXHAUST FLUID ONLY

Filling this tank with

anything other than DIESEL EXHAUST FLUID

No Diesel

may result in severe engine damage.

M94110000

Figure 41. DEF Tank Filling

CAP

REAR VIEW

Engine and Radiator 17.7gal (67 liters)

Reserve Tank N/A

Operation in Freezing Weather

When operating in freezing weather, be certain the proper amount of antifreeze (Table 13) has been added.

Table 13. Coolant Capacity

Climate

Warm

Cold

Outside

Temperature

10°F (-12°C) or

Above

-22°F (30°C) or Above

NOTICE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

Longlife Coolant

Concentration

30%

50%

PAGE 38 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

INSPECTION/SETUP

Cleaning the Radiator

The engine may overheat if the radiator ﬁns become overloaded with dust or debris. Periodically clean the radiator ﬁns with compressed air. Cleaning inside the machine is dangerous, so clean only with the engine turned off and the negative battery terminal disconnected.

AIR CLEANER

Periodic cleaning/replacement is necessary. Inspect air cleaner in accordance with the John Deere Engine

Owner’s Manual.

FAN BELT TENSION

A slack fan belt may contribute to overheating, or to insufﬁcient charging of the battery. Inspect the fan belt for damage and wear and adjust it in accordance with the John

Engine Owner’s Manual.

The fan belt tension is proper if the fan belt bends 10 to 15 mm (Figure 42) when depressed with the thumb as shown below.

BATTERY

This unit is of negative ground DO NOT connect in reverse. Always maintain battery ﬂuid level between the speciﬁed marks. Battery life will be shortened, if the ﬂuid level are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions. Always keep the terminals firmly tightened. Coating the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this generator is BCI Group 27.

The battery is sufﬁciently charged if the speciﬁc gravity of the battery ﬂuid is 1.28 (at 68° F). If the speciﬁc gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

Battery Cable Installation

Figure 42. Fan Belt Tension

CAUTION

NEVER place hands near the belts or fan

while the generator set is running.

0.17 ~ 0.20 IN. (4.2 ~ 5.0 MM) DEFLECTION

ALWAYS be sure the battery cables (Figure 43) 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.

CAUTION

ALWAYS disconnect the negative terminal FIRST and reconnect negative terminal LAST.

NEGATIVE

POSITIVE

Figure 43. Battery Connections

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 39

INSPECTION/SETUP

When connecting battery do the following:

1. NEVER connect the battery cables to the battery

terminals when the Auto-Off/Reset-Manual Switch is in either the AUTO or MANUAL position. ALWAYS make sure that this itch is in the OFF/RESET position when connecting the battery.

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTICE

If the battery cable is connected incorrectly, electrical damage to the generator will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION

Inadequate battery connections may cause poor starting of the generator, and create other malfunctions.

ALTERNATOR

This unit is equipped with an automatic controlled Engine Starting Fluid System (KBi’s DIESELMATIC NVT) that assists the engine starting during low ambient temperature operation.

The system is designed to spray a controlled amount of starting ﬂuid into the air intake system of the engine during and immediately after the engine cranks. The ﬂuid cylinder is located on the unit’s right side center frame.

WARNING

The engine starting ﬂuid used in the system is extremely flammable and toxic. It can be harmful and fatal if swallowed. Avoid contact with skin or breathing fumes.

DO NOT smoke when installing, removing, maintaining, testing or troubleshooting the system. Make sure you are in a well-ventilated area away from heat, open ﬂames or sparks.

In low ambient temperature condition, if the engine does not start within a normal period of cranking, the starting ﬂuid cylinder may be empty and need to be replaced. For more information about the system, refer to the provided KBi DIESELMATIC NVT Instruction Manual.

The polarity of the alternator is negative grounding type. When an inverted circuit connection takes place, the circuit will be in short circuit instantaneously resulting the alternator failure.

DO NOT put water directly on the alternator. Entry of water into the alternator can cause corrosion and damage the alternator.

WIRING

Inspect the entire generator for bad or worn electrical wiring or connections. If any wiring or connections are exposed (insulation missing) replace wiring immediately.

PIPING AND HOSE CONNECTION

Inspect all piping, oil hose, and fuel hose connections for wear and tightness. Tighten all hose clamps and check hoses for leaks.

If any hose (fuel or oil) lines are defective replace them immediately. cold weather engine starting ﬂuid (ether system)

PAGE 40 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

GENERATOR START-UP PROCEDURE (MANUAL)

BEFORE STARTING

CAUTION

The engine’s exhaust contains harmful emissions. ALWAYS have adequate ventilation when operating. Direct exhaust away from nearby personnel.

WARNING

NEVER manually start the engine with the main, GFCI or auxiliary circuit breakers in the ON (closed) position.

1. Place the main, G.F.C.I., and aux. circuit breakers

(Figure 44) in the OFF position prior to starting the engine.

STARTING (MANUAL)

1. Place the Auto-Off/Reset Manual Switch in the

MANUAL position to start the engine (Figure 46).

Figure 46. Auto-Off/Reset Manual Switch

(Manual Position)

NOTICE

If engine fails to start in a speciﬁed number attempts, the shutdown lamp will illuminate and the Auto-Off/ Reset Switch must be placed in the Off/Reset position before the engine can be restarted.

NOTICE

Engine will pre-heat automatically in cold weather conditions." Glow Plug Hold " message will be displayed and the engine will start automatically after pre-heating..

Figure 44. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Make sure the voltage change-over board has been

conﬁgured for the desired output voltage.

3. Connect the load to the receptacles or the output

terminal lugs as shown in Figure 18. These load connection points can be found on the output terminal panel and the output terminal panel’s hard wire hookup panel.

4. Tighten terminal nuts securely to prevent load wires

from slipping out.

5. Close all engine enclosure doors (Figure 45).

2. Once the engine starts, let the engine run for 1-2 minutes Let engine idle longer in cold weather conditions. Listen for any abnormal noises. If any abnormalities exist, shut down the engine and correct the problem.

3. The generator’s frequency meter (Figure 47) should be displaying the 60 cycle output frequency in HERTZ.

Figure 47. Frequency Meter

4. The generator’s AC-voltmeter (Figure 48) will display the generator’s output in VOLTS.

INCORRECTCORRECT

Figure 45. Engine Enclosure Doors

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 41

Figure 48. Voltmeter

GENERATOR START-UP PROCEDURE (MANUAL)

5. If the voltage is not within the speciﬁed tolerance, use the voltage adjustment control knob (Figure 49) to increase or decrease the desired voltage.

Figure 49. Voltage Adjust Control Knob

6. The ammeter (Figure 50) will indicate zero amps with no load applied. When a load is applied, the ammeter will indicate the amount of current that the load is drawing from the generator.

Figure 50. Ammeter (No Load)

7. The engine oil pressure gauge (Figure 51A) will indicate the oil pressure of the engine. Under normal operating conditions the oil pressure is approximately 35 to 65 psi. (193~586 kPa).

10. The generator load gauge (Figure 52) Indicates the

generator load rate. It is recommended the load be above the red area (20%) for maintaining sufﬁcient exhaust temperature.

100

Figure 52. Generator Load Gauge

11. Place the main, GFCI, and aux. circuit breakers in the ON position (Figure 53).

PSI

OIL PRESS

100

140

100

WATERTEMP

180

°F

220

260

150

120

RPMX10

SPEED

180

210

Figure 51. Engine Gauges

8. The coolant temperature gauge (Figure 51B) will

indicate the coolant temperature. Under normal operating conditions the coolant temperature should be between 185°~207°F (85°~97°C).

9. The tachometer gauge (Figure 51C) will indicate the

speed of the engine when the generator is operating. Under normal operating conditions this speed is approximately 1800 RPM’s.

Figure 53. Main, Aux. and GFCI

Circuit Breakers (ON)

12. Observe the generator’s ammeter (Figure 54) and verify it reads the anticipated amount of current with respect to the load. The ammeter will only display a current reading if a load is in use.

Figure 54. Ammeter (Load)

13. The generator will run until manually stopped or an abnormal condition occurs.

PAGE 42 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

GENERATOR START-UP PROCEDURE (AUTO MODE)

STARTING (AUTO MODE)

DANGER

Before connecting this generator to any building’s electrical system, a licensed

electrician must install an isolation (transfer) switch. Serious damage to

the building’s electrical system may occur without this transfer switch.

CAUTION

When connecting the generator to a isolation (transfer) switch, ALWAYS have power applied to the generator’s internal battery charger. This will ensure that the engine will not fail due to a dead battery.

NOTICE

When the generator is set in the AUTO mode, the generator will automatically start in the event of commercial power falling below a prescribed level by means of a contact closure that is generated automatically by a transfer switch.

WARNING

When running the generator in the AUTO mode, remember the generator can start up at any time without warning. NEVER attempt to perform any maintenance when the generator is in the auto mode.

NOTICE

When the Auto Off/Reset Manual Switch is placed in the AUTO position, the engine glow plugs will be warmed and the engine will start automatically.

When starting generator in AUTO mode use the “Manual Start-up” procedure except where noted (see below).

1. Perform steps 1 through 5 in the Before Starting section

as outlined in the Manual Starting Procedure.

2. Place the Auto Off/Reset Manual Switch (Figure 55)

in the AUTO position.

Figure 55. Auto Off/Reset Manual Switch (AUTO)

3. Continue operating the generator as outlined in the

Manual Start-up procedure (start at step 2).

NOTICE

If the unit has Power Balance™ installed and once the main breaker is closed, the Power Balance™ should activate after 1 minute if the load is below 30% of rated load.

If at any time the load spikes to 90% or more, the Power Balance will immediately drop out and wait 5 minutes to re-evaluate the load.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 43

GENERATOR SHUT-DOWN PROCEDURES

MANUAL

(CENTER)

WARNING

NEVER stop the engine suddenly except in an

emergency.

NORMAL SHUTDOWN PROCEDURE

To shutdown the generator, use the following procedure:

1. Place both the MAIN, GFCI and LOAD circuit breakers as shown in Figure 56 to the OFF position.

EMERGENCY SHUTDOWN PROCEDURE

1. In the event of an emergency, push the Emergency Stop Pushbutton Switch (Figure 58) to shutdown

the generator.

Figure 58. Auto Off/Reset Manual Switch (OFF)

Figure 56. Main, Aux. and GFCI

Circuit Breakers (OFF)

2. Let the engine cool by running it at low speed for 3-5 minutes with no load applied.

3. Place the Auto Off/Reset Manual Switch (Figure 57) in the OFF/RESET position.

AUTO

OFF/RESET

Figure 57. Auto Off/Reset Manual itch

(Off/Reset)

4. Verify that all status LEDs on the ECU control panel are OFF (not lit).

5. Remove all loads from the generator.

6. Inspect entire generator for any damage or loosening of components that may have occurred during operation.

PAGE 44 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

MAINTENANCE

Table 14. Inspection/Maintenance

Check Engine Oil and Coolant Levels X

Check Fuel Filter/Water Separator Bowl X

Check Air Cleaner/Element X

Clean or Replace Air Cleaner/Element X

Check for Leaks/Hoses/Clamps X

Check for Loosening of Parts X

Change Engine Oil and Oil Filter *

Clean Unit, Inside and Outside X

Replace Fuel Filter Elements X

Check Engine Mounts X

Service Battery X

Check Air Intake Hoses X

Check Fan Belt Condition X

Check Automatic Belt Tensioner X

Engine

Generator

*1 During initial operation of a new engine, change oil and ﬁlter between a minimum of 100 hrs. and a maximum of 500 hrs. Service interval depends

on type of oil.

Perform inspection and maintenance of Urea SCR system every 4500 hours. The system does not need to replace/exchange if no problem is

found. Do not make any modiﬁcation, changes or remove the emission control system and related parts. Please contact your nearest dealer or Multiquip Service Dept. for SCR maintenance.

If John Deere COOL-GARD™ II is used, the ﬂushing intervals may be extended. See "Testing Diesel Coolant" in engine manual.

*4 Replace primary air ﬁlter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).

*5 Service should be done as indicated by Diagnostic Gauge. Contact Multiquip Service Dept. for DOC replacement.

Check Electrical Ground Connection X

Clean Radiator, Check Cooling System X

Coolant Solution Analysis, Add SCA's As Required X

Pressure Test Cooling System X

Check Engine Speed X

Test Thermostats X

Check and Adjust Engine Valve Clearance 1000 hrs.

Test Glow Plugs X

Replace DEF Filter In (Supply Module) 4500 hrs.

Replace DOC Catalyst*

Check SCR System*

Inspect Dosing Module (SRC System) 4500 hrs

Flush and Reﬁll Cooling System*

Clean Inside of Fuel Tank 1000 hrs.

Clean DEF Tank As Required

Replace Air Cleaner Elements *

Measure Insulation Resistance Over 3M ohms X

Check Rotor Rear Support Bearing X

10 Hrs

DAILY

250 Hrs

500 Hrs

or Every

12 Months

3000 Hrs or Every

36 Months

OTHER

As Required

4500 hrs.

1 yr. or 2000 hrs.

As Required

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 45

MAINTENANCE

PUSH BUTTON TO RESET

AN)

GENERAL INSPECTION

Prior to each use, the generator should be cleaned and inspected for deﬁciencies. Check for loose, missing or damaged nuts, bolts or other fasteners. Also check for fuel, oil, and coolant leaks. Use Table 14 as a general maintenance guideline Engine Side (Refer to the Engine Instruction Manual)

Air Filter Dust Indicator

NOTICE

The air ﬁlter should not be changed until the indicator reads “RED”. Dispose of old air ﬁlter. It may not be cleaned or reused.

The air ﬁlter indicator (Figure 59) is attached to the air ﬁlter. When the air ﬁlter element is clogged, air intake restriction becomes greater and the air ﬁlter indicator signal shows RED. When indicator is red, replace ﬁlter immediately. After changing the air ﬁlter, press the air ﬁlter indicator button to reset.

CAUTION

Wear protective equipment such as approved safety glasses or face shields and dust masks or respirators when cleaning air ﬁlters with compressed air.

Primary and Secondary Air Cleaner Elements

1. Release the latches (Figure 60) that secures the cover to the air cleaner body.

2. Remove the air cleaner cover and set aside.

3. Remove both the primary and secondary air cleaner elements.

4. Check the air cleaner daily or before starting the engine.

5. Check for and correct heavy buildup of dirt and debris along with loose or damaged components.

NOTICE

Operating the engine with loose or damaged air cleaner components could allow unﬁltered air into the engine causing premature wear and failure.

Figure 59. Air Filter Dust Indicator

AIR CLEANER

NOTICE

If the engine is operating in very dusty or dry grass conditions, a clogged air cleaner will result. This can lead to a loss of power, excessive carbon buildup in the combustion chamber and high fuel consumption. Change air cleaner more frequently if these conditions exist.

Every 250 hours: Remove air cleaner element (Figure 60) and clean the heavy duty paper element with light spray of compressed air. Replace the air cleaner as needed.

This John Deere diesel engine is equipped with a replaceable, high-density paper air cleaner element. This air cleaner is also equipped with an inner element (secondary) that is used as a backup ﬁlter should the primary element becomes damaged.

25 INCHES HO

6.23 kPa

6. To clean the primary element (paper air ﬁlter) as referenced in (Figure 60), tap the filter element several times on a hard surface to remove dirt, or blow

compressed air not to exceed 30 psi (207 kPa, 2.1

kgf/cm

BODY

) through the ﬁlter element from the inside out.

PRIMARY

AIR FILTER

ELEMENT

SECONDARY

AIR FILTER

ELEMENT

BLOW COMPRESSED

AIR FROM THE

INSIDE OUT

Figure 60. Air Cleaner

AIR FILTER INDICATOR

LATCH

EVACUATOR

ARROW

(DUST P

VALV E

MARK

7. Clean the secondary element (paper air ﬁlter) as referenced in step 6.

8. Replace both elements if they are damaged or excessively dirty.

PAGE 46 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

MAINTENANCE

TER BODY

FUEL

9. Clean the inside of the air cleaner body.

10. Reinstall the primary and secondary air ﬁlter elements back into air cleaner body.

11. Reinstall the air cleaner cover, and secure with latches.

DRAINING FUEL FILTER CARTRIDGE

NOTICE

Inspect the fuel ﬁlter daily. If the fuel ﬁlter (Figure 61) has collected a signiﬁcant amount of water and sediment at the bottom of the cartridge, it should be drained off immediately.

1. Loosen the air bleeder plug (Figure 61) on the fuel ﬁlter body.

2. To discharge the fuel inside the fuel ﬁlter cartridge OPEN the drain valve on the fuel ﬁlter by turning the knob counterclockwise (A) approximately 3-1/2 turns until the valve drops down 1-inch (25.4 mm) and draining occurs (B).

FUEL FILTER ELEMENT REPLACEMENT

1. Use a filter wrench to remove the fuel filter cup (Figure 62) from the fuel ﬁlter body.

FIL

(HEAD)

RETAINING

RING

GASKET

FILTER

CARTRIDGE

AIR BLEEDER

PLUG

FUEL FILTER

CARTRIDGE

DRAIN VALV E

FILTER BODY

(HEAD)

RETAINING

RING

OPEN

DRAIN

Figure 61. Fuel Filter Draining

Figure 62. Fuel Filter Cartridge Replacement

2. Wipe the inside of the ﬁlter body (head) with a clean cloth to remove any foreign matter or debris that may have accumulated.

3. Replace both gaskets. Coat each gasket with a small amount of clean 15W-40 engine oil.

4. Install new fuel ﬁlter cartridge ﬁrst by hand until it makes contact with the fuel ﬁlter body surface.

5. Tighten fuel ﬁlter cartridge securely. DO NOT over- tighten.

6. Remove the air from the fuel system. Reference John Deere Owner's Manual, "Bleeding the Fuel System.

3. Let the residue or foreign substances inside the cartridge ﬂow into a suitable container.

4. At completion of draining CLOSE drain valve (C).

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 47

MAINTENANCE

FUEL FILTER

WATER SEPARATOR

CARTRIDGE

SEDIMENT

BOWL

FUEL WATER SEPARATOR SEDIMENT BOWL

1. Remove the sediment bowl from the fuel water separator cartridge as shown in Figure 63.

Figure 63. Sediment Bowl

2. Let the residue or foreign substances inside the sediment bowl ﬂow into a suitable container.

FUEL WATER SEPARATOR REPLACEMENT

1. Use a ﬁlter wrench to remove the fuel water separator

cartridge (Figure 59) from the cartridge body head.

CARTRIDGE BODY

(HEAD)

RETAINING

RING

FUEL WATER

SEPARATOR

CARTRIDGE

Figure 64. Fuel Water Separator

2. Wipe the inside of the fuel water separator cartridge body (head) with a clean cloth to remove any foreign matter or debris that may have accumulated.

3. Wipe the inside of the sediment bowl with a clean cloth to remove any foreign matter or debris that may have accumulated.

4. Reinstall sediment bowl back onto fuel water separator cartridge

5. Tighten securely. DO NOT over-tighten.

3. Install new fuel water separator cartridge ﬁrst by hand until it makes contact with the cartridge body (head) surface.

4. Tighten fuel water cartridge securely. DO NOT over- tighten.

Removing Water from the Fuel Tank

After prolonged use, water and other impurities accumulate in the bottom of the tank. Occasionally inspect the fuel tank for water contamination and drain the contents if required.

During cold weather, the more empty volume inside the tank, the easier it is for water to condense. This can be reduced by keeping the tank full with diesel fuel.

PAGE 48 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

MAINTENANCE

H (UPPER LIMIT)

(LOWER LIMIT)

Cleaning Inside the Fuel Tank

If necessary, drain the fuel inside the fuel tank completely. Using a spray washer (Figure 65) wash out any deposits or debris that have accumulated inside the fuel tank.

FUEL TANK

Drive Belt Inspection

Inspect the drive belt for damage and wear. Horizontal cracks (across the belt) are acceptable. Vertical (direction of belt ribs) cracks that intersect with horizontal cracks are not acceptable.

Also, examine the belt and determine if it is oil soaked or "glazed " (hard shiny appearance on the sides of the belt). Either of these two conditions can cause the belt to run hot, which can weaken it and increase the danger of it breaking.

If the drive belt exhibits any of the above wear conditions, replace the drive belt immediately.

Figure 65. Fuel Tank Cleaning

FUEL TANK INSPECTION

In addition to cleaning the fuel tank, the following components should be inspected for wear:

 Rubber Suspension — Look for signs of wear or

deformity due to contact with oil. Replace the rubber suspension if necessary.

 Fuel Hoses — Inspect nylon and rubber hoses for signs

of wear, deterioration and hardening.

 Fuel Tank Lining — Inspect the fuel tank lining for signs

of excessive amounts of oil or other foreign matter.

DRIVE BELT DAILY)

Drive Belt Tension

A slack drive belt (Figure 12) may contribute to overheating, or to insufﬁcient charging of the battery, adjust drive belt in accordance with the John Deere Operator's manual.

Figure 66. Drive Belt Inspection

ENGINE OIL CHECK (DAILY)

1. When checking or adding oil, place the machine so

the engine is level.

2. Pull the engine oil dipstick from its holder.

3. Determine if engine oil is low. Oil level should be

between the upper land lower limit (Figure 67) on the dipstick.

DO NOT

OVERFILL

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 49

Figure 67. Dipstick Engine Oil Level

MAINTENANCE

104

122

4. If oil level is low, add correct amount of engine oil to bring oil level to a normal safe level. See Recommended Viscosity Grades.

5. Allow enough time for any added oil to make its way to the oil pan before rechecking.

Table 15. Oil Selection Chart

5W/40

OIL: SAE

10W/30

10W

10W/40

15W/40

20W/20

-14

-4

-22

-40

-10

-20

-30

-40

032

5W/30

DRAINING ENGINE OIL

1. Run the engine until the engine coolant reaches a temperature of 140°F (60°C) Turn the engine off.

ENGINE OIL FILTER REPLACEMENT

1. Using an oil ﬁlter wrench (Figure 69), remove engine oil ﬁlter.

OIL FILTER

HEAD

FILTER

WRENCH

REMOVE AND

DISCARD OIL FILTER

INSTALL

NEW OIL

FILTER

COAT RUBBER

SEAL WITH THIN

LAYER OF OIL

2. Remove the oil dipstick from its holder.

3. Next, remove oil drain cap (Figure 68)

4. Place the oil drain valve in the OPEN position and

allow the oil to drain into a suitable container.

OIL DRAIN

CAP

(REMOVE)

OPEN

OIL DRAIN VALV E

Figure 68. Draining Engine Oil

5. After engine oil has been completely drained, reinstall oil drain cap and tighten securely.

6. Place the oil drain valve in the CLOSED position.

Figure 69. Engine Oil Filter Removal

2. Clean the area around the lubricating oil ﬁlter head.

3. Coat the rubber seal (gasket) surface of oil ﬁlter (Figure 69) with clean 15W-40 engine oil.

4. Install new oil ﬁlter ﬁrst by hand until it makes contact with the ﬁlter head surface. Tighten it another 3/4 turn using the ﬁlter wrench.

5. Fill engine crankcase with high quality detergent oil classiﬁed "For Service CI-4". Fill to the upper limit of dipstick. DO NOT overﬁll. Reference Table 2 for engine crankcase oil capacity.

6. Run the engine for several minutes. Watch for oil leakage. Shut the engine down and allow it to sit for several minutes. Top off the oil to the upper limit on the dipstick.

PAGE 50 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

MAINTENANCE

COOLANT

DRAIN VALVE

(OPEN)

FLUSHING OUT RADIATOR AND REPLACING COOLANT

WARNING

DO NOT remove the pressure cap from the

radiator when the engine is hot! Wait until the coolant temperature is below 120°F (50°C) before removing pressure cap.

Heated coolant spray or steam can cause severe scalding and personal injury.

1. Place the coolant drain valve in the OPEN position

(Figure 70) and allow the coolant to drain into a suitable container.

RADIATOR CLEANING

The radiator (Figure 71) should be sprayed cleaned) with a high pressure washer when excessive amounts of dirt and debris have accumulated on the cooling ﬁns or tube. When using a high pressure washer, stand at least 5 feet (1.5 meters) away from the radiator to prevent damage to the ﬁns and tube.

Figure 70. Draining Engine Coolant

2. Check hoses for softening and kinks. Check clamps for signs of leakage.

3. Remove and inspect radiator cap.

4. Flush the radiator by running clean tap water through radiator until signs of rust and dirt are removed. DO NOT clean radiator core with any objects, such as a screwdriver.

5. Tighten water cock and replace the overﬂow tank.

6. Place the coolant drain valve in the CLOSED position.

Figure 71. Radiator Cleaning

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.

 Clean the entire generator, internal and external.

 Cover the generating set and store in a clean, dry place.

 Disconnect the battery.

 Make sure engine coolant is at proper level.

 If generator is mounted on a trailer, jack trailer up and

place on blocks so tires do not touch the ground or block and completely remove the tires.

7. Replace with coolant as recommended by the engine manufacturer.

8. Reinstall radiator cap. Tighten securely.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 51

MAINTENANCE

ENGINE BLOCK

WG.

ENGINE BLOCK HEATING ELEMENT AND INTERNAL BATTERY CHARGER 120 VAC INPUT RECEPTACLES (OPTIONAL)

This generator can be equipped as an option with a engine block heating element and an internal battery charger. They are provided with electric cords to connect

to a commercial power source.

The engine block heating element and internal battery charger both require 120 VAC in order to operate. A receptacle (Figure 72) has been provided on the output terminal panel to allow commercial power to be applied.

These units will ONLY function when commercial power has been supplied to them. When using extension cords, refer to Table 6 for the correct size and length.

HEATING ELEMENT

When using the generator in hot climates, there is no need to apply power to jacket water heater (heating element). However, if the generator will be used in cold climates, it is best to apply power to the jacket water heater at all times.

If the generator will be used daily, the battery should normally not require charging. If the generator will be idle (not used) for long periods of time, apply power to the battery charger receptacle via commercial power using a power cord of adequate size.

NOTICE

If the generator will be idle (not used) for long periods of time and to ensure adequate starting capability, always have power applied to the generator's internal battery charger.

BATTERY CHARGER

HEATING ELEMENT

120 VAC INPUT

RECEPTACLE

OUTPUT TERMINAL

PANELASSEMBLY

BATTERY CHARGER

120 VAC INPUT

RECEPTACLE

TO CHASSIS

GROUND

GREEN 16 A

TO STARTER “B”

TERMINAL

RED 16 AWG.

Figure 72. Heater Element and Battery Charger (Option)

PAGE 52 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

MAINTENANCE

EMISSION CONTROL

The emission control system employed with the John Deere 6090HF diesel engine consist of a Diesel Oxidation

Catalyst (DOC) and a Selective Catalytic Reduction (SCR) catalyst as an exhaust gas after-treatment system that helps reducing harmful gases and destroying the organic fraction of the particulate matter produced from the exhaust gas to meet the requirement for EPA Tier 4 Final regulations.

The DOC device (Figure 73) helps in ﬁltering out large amounts of harmful Nitrogen Oxides (NOx) and Particulate Matter (PM) which are emitted by diesel engines. These exhaust emissions pose serious environmental and health risks. It is important to maintain and service the DOC emission safety device on a periodic basis.

Diesel Oxidation Catalyst (DOC)

The DOC does not ﬁlter particles it oxidizes them. This catalyst (honeycomb like structure) uses a chemical process to break down pollutants in the exhaust stream into less harmful components. In general, this catalyst collects/burns accumulated particulates. The DOC contains palladium and platinum which serve as a catalysts to oxidize hydrocarbons and carbon monoxide.

EMISSION CARBON CHECK

Deposition of carbon (soot, unburned fuel) in the exhaust pipe line and mufﬂer could cause not only system derates but also could lead to ﬁres.

To reduce soot and unburned fuel, run the unit at rated power until the exhaust gas becomes mostly colorless every 250 hours operation time. More carbon will be generated when the unit operates at less then 30% of rated power. In this case, perform the above procedures more frequently.

NOTICE

Applying a large load suddenly to the unit when the carbon deposition is generated in the exhaust system could produce sparks and will lead to abnormal combustion. Therefore, apply load gradually and observe the exhaust gas color during the process.

Figure 73. Diesel Oxidation Catalyst DOC)

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 53

MAINTENANCE

SCR PURGE

SELECTIVE CATALYTIC REDUCTION (SCR)

Diesel engines can be run with a lean burn air-to-fuel ratio, to ensure the full combustion of soot and to prevent the exhaust of unburnt fuel. The excess of air necessarily leads to generation of nitrogen oxides (NOx), which are harmful pollutants, from the nitrogen in the air. Selective Catalytic Reduction is used to reduce the amount of NOx released into the atmosphere.

Diesel Exhaust Fluid (DEF) from a separate tank is injected into the exhaust pipeline, where the aqueous urea vaporizes and decomposes to form ammonia and carbon dioxide. Within the SCR catalyst, the NO reduced by the ammonia (NH3) into water (H2O) and nitrogen (N2), which are both harmless; and these are then released through the exhaust.

The SCR system creates a certain amount of ammonia

) that is stored in SCR catalyst. During purging

(NH

operations the increase in temperature at regular intervals eleminates the stored ammonia.

The process of keeping accurate amonia storage amounts is by counting urea injection quantities from the Dosing Control Unit (DCU)

The SCR Purge symbol (Figure 74) will be displayed on the ECU controller during operation when either an automatic or forced system purge operation is in process.

The pre-alarm lamp is only ON during SCR forced system purging and OFF during automatic system purging

ECU

Series 800 Controller

are catalytically

Engine Started

Shutdown

Pre-Alarm

NOTICE

During urea SCR system purging, white smoke may be emitted from the exhaust tailpipe temporarily this shoud not be considered a failure. In addition the smell of ammonia during the purging process should not be considered a failure.

If the purging process is underway while running a light load (0-35%) the unit may produce unusual sounds. This should not be considered a failure or malfunction.

SYSTEM PURGING GUIDELINES

NOTICE

DO NOT perform purging in conditions where it may be unsafe due to high exhaust temperatures.

For safe operation of equipment, the surrounding area and the prevention of bodily harm, use the guidelines below when system purging is required:

NOTICE

The area above and around the generator during the purging process should be free of any type of debris, ﬂammable or combustible materials, as temperatures during the purging process can reach as high 1,022 °F (550 °C).

 DO NOT operate the unit in area with poor ventilation.

 If operating the engine indoors, install exhaust/ventilation

equipment and ensure that there is sufﬁcient ventilation.

 If you begin to feel sick, stop the unit immediately and

ventilate the area.

 Exhaust emissions from the tailpipe have a smell different

from those emitted from engines without urea SCR systems due to the exhaust emission reduction functions of the exhaust system.

Alarm

Acknowledge

Screen

Change

Option

Program

Exit

Figure 74. SCR Purge Symbol

PAGE 54 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

MAINTENANCE

If the diesel exhaust ﬂuid (DEF) symbol (Figure 75) is displayed during ECU controller operation, it indicates the following:

 DEF tank level is below 10%. Reference Table 16, DEF

Level System Action System.

 DEF quality is poor. Check DEF tank level and check

active diagnostics trouble codes (DTC).

ECU

Series 800 Controller

Alarm

Acknowledge

Screen Change

DEF STAT

Program

Option

Engine Started

Shutdown

Pre-Alarm

Exit

DIESEL EXHAUST FLUID (DEF)

The amount of ﬂuid in the DEF tank will be shown on the ECU Controller main screen during operation. The symbol shown in Figure 76 will be shown on the ECU monitor indicating the level of ﬂuid in the DEF tank.

DEF

Figure 76. DEF Tank Level Guage

Figure 75. ECU DEF State Pre-Alarm

NOTICE

Models equipped with the 845 Series ECU Controller will enter emergency shutdown when the DEF level has reached 0% and emergency protective measures are necessary. When this condition exist, the unit can only be restarted after the ESCAPE MODE is activated and the unit will run for 30 minutes. Reference "Escape Mode" section in this manual.

Table 16. DEF Level System Action System

DEF Level Over 10% Below 10% 0% Empty or After 4 hrs. From 0%

Controller Message — DEF<10% Tank Level DEF<10% Tank Level DEF Tank Empty Level

DEF Symbol —

Pre-Alarm Lamp — —

Shutdown Lamp — — —

Blinking Blinking

ON ON

Engine Shutdown

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 55

INDUCEMENT

When the system senses improper usage such as no supply of DEF, use of poor quality DEF, problems with DEF jets, or disconnection of sensors, a warning will be issued before the situation becomes critical. If the warnings are ignored and the unit enters intermittent operation, the emergency shutdown will activate. The three warning levels are referenced in Table 17:

Table 17. DEF Inducement

MAINTENANCE

Stage Controller Message

Stage 1

Warning Level 1

Stage 2

Warning Level 2

SCR System

Malfunction

SCR System

Malfunction

SCR System

Pop-Up

SCR SYS ERR

DEF Symbol

Pre-Alarm

Lamp

Shutdown

Lamp

—

Slow Blinking

Stage 3

Shutdown

SCR System

Malfunction

SCR SYS ERR

ON ON

Fast Blinking

When emergency shutdown occurs, inspection and repair should generally be performed promptly. However, if

emergency protective measures are necessary, unit will enter ESCAPE MODE and may require as much as 30 minutes to restart.

PAGE 56 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

HOW TO ACTIVATE ESCAPE MODE

BUTT

[PROGRAM EXIT]

BUTTON

If the ECU displays any messages referenced in Table 18 or Figure 77, it may be necessary to restart via ESCAPE MODE.

VOLTS AMPS

UO VO

------

VW WU

KW KVA HZ 00000.9 h

ADD DEF OR USE ESCAPE MENU

Figure 77. Add DEF/Escape Menu Screen

U V

MAINTENANCE

SPEED

0000

DEF

CANBUS IS WORKING OK

HOURS

00009.7

Starting

1. Start the Diagnostic Mode as referenced in the "Troubleshooting Diagnostics" section in this manual.

2. Exit the Status Check Screen by pressing the [EXIT] button (Figure 78).

DEF

HOURS

25.1v

CANBUS IS WORKING OK EXIT

[EXIT]

00009.7

DIAGNOSTIC MODE

STATUS

CHECK

Alarm Screen

Change

Option

Program

Exit

Figure 79. Main Screen

4. Press the [DOWN] button (Figure 80) to scroll to the

Escape Mode item.

FORCE REGEN FAULT DIAGNOSTICS ABOUT UNIT USER LOGIN CUSTOMER OPTIONS ADVANCED OPTIONS ESCAPE MODE

UP DOWN SELECT

Figure 78. Status Check Screen

Diagnostic Mode)

3. Next, press the [Program/Exit] button (Figure 79) to enter the Main Menu.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 57

[DOWN]

BUTTON

Figure 80. Main Menu Down Button)

MAINTENANCE

[SELECT]

MANUAL

(CENTER)

5. Press the [SELECT] button (Figure 81) to enter the

“Escape Mode” menu.

FORCE REGEN FAULT DIAGNOSTICS ABOUT UNIT USER LOGIN CUSTOMER OPTIONS ADVANCED OPTIONS ESCAPE MODE

UP DOWN SELECT

BUTTON

Figure 81. Escape Mode (Select Button)

6. Press the [REQUEST] button (Figure 82) to send

"Escape Mode Request" signal to ECM.

ESCAPE MODE REQUEST EMERGENCY RESERVE ENGINE

RUN MAY BE POSSIBLE.

>> ESCAPE MODE ACTIVATED <<

POWER OFF. ON. TO RESTART

TO ATTEMPT ESCAPE MODE:

PRESS THE REQUEST SOFT KEY.

EXIT

REQUEST

Figure 83. Escape Mode Activated Screen

8. Place the Auto Start/Stop Switch (Figure 84), to the “Off /Reset” position.

AUTO

OFF/RESET

ESCAPE MODE REQUEST

EMERGENCY RESERVE ENGINE RUN MAY BE POSSIBLE.

TO ATTEMPT ESCAPE MODE:

PRESS THE REQUEST SOFT KEY.

EXIT

REQUEST

[REQUEST]

BUTTON

Figure 82. Escape Mode (Request Button)

7. Once the [REQUEST] button has been pressed,

the display will indicate that escape mode has been activated (Figure 83).

Figure 84. Auto Off/Reset Manual Switch

(Off/Reset Position)

9. Next, place the Auto Start/Stop Switch (Figure 85) to the “Manual” position to start the engine.

Figure 85. Auto-Off/Reset Manual Switch

(Manual Position)

PAGE 58 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

10. The Escape Mode Timer (Figure 86) will appear on

ESCAPE MODE

the main screen. This timer displays remaining time the unit can be operated.

TIMER (SEC)

DEF LOW! SHUTDOWN IN 0048

100

UV VW

173

0000

MAINTENANCE

100

------

DERATE CONDITION EXISTS

Figure 86. Escape Mode Timer

 If ESCAPE MODE is temporarily suspended, it is not

necessary to return to the ESCAPE MODE screen and press the [REQUEST] button. ESCAPE MODE operation will be available until around 30 minutes after operation has been ended.

 Once the ESCAPE MODE timer reaches zero minutes,

the engine will stop since the ESCAPE MODE time has expired. Please perform maintenance to return unit to proper operating condition.

 If the unit returns to Warning Level 1 while ESCAPE

MODE is running, ESCAPE MODE will be cancelled, the ESCAPE MODE timer display will close, and normal operation will resume.

173

40.0 HZ 00000.9 h

0000

------

KVA

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 59

MAINTENANCE

PROTECTION DEVICES

Automatic Shutdown System

This unit is equipped with engine protection devices that automatically shut down the engine if any of the faults shown in Table 18 occur. The “Shutdown” LED on the ECU Controller will turn on just before the shutdown and will stay on after the shutdown. Messages will appear on the ECU display.

After the automatic shutdown, check all Diagnostic Test Codes (DTC) displayed on the ECU Controller. Reference the Troubleshooting Diagnostic section in this manual.

Table 18. Automatic Engine Shutdown System

Operating Parameter

ECU

Shutdown LED

Place the Auto Start/Stop Switch in the “Off/Reset” position. In addition, place all circuit breakers in the OFF position. Before troubleshooting, allow sufﬁcient time for adequate cooling. Before attempting to restart the generator, perform overall inspection of the generator and correct the problem that caused the shutdown. If necessary, contact your nearest Multiquip dealer for additional technical support.

Restart the generator as reference in the Generator Startup Procedure (Manual Start).

NOTICE

Although the unit is equipped with engine protection devices, regularly scheduled preventative maintenance is strongly advised.

Operating Condition/Set Point

Low Oil Pressure

High water Temperature

Low Coolant Level

High Water Level In Fuel Water Separator

High Engine Fuel Temperature

High Charged Air-Cooler Outlet Temperature

Exhaust System Severe Malfunction

Over-Voltage

Under-Voltage

High Power (kW)

Over-Frequency (Hz)

Under-Frequency (Hz)

Over-Current Main CB Trip Load Capacity Exceeded

Set Point: 17 PSI ((117 kPa)

Set Point: 240°F (116°C)

Falls Below Specified Level

Water Level has Exceeded Filter Capacity

Fuel Temperature Too High

Reference Exhaust System,

DEF, Regeneration Sections

Set Point: 110%

Set Point: 75%

Set Point: 115%

Set Point: 110%

Set Point: 90%

PAGE 60 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

GENERATOR WIRING DIAGRAM

COT. B

Voltage Change-Over

Board-240V Set

A J C

CN1

CN3

VIEW FROM INSERTING

DKB

CN5

WIRE SIDE

CIRCUIT

BREAKER

SIDE

CB1 CONNECTOR

(VIEW FROM INSERTING

WIRE SIDE)

CN4

2 3

CN2

2 3

V W

2 1

COT. B

Voltage Change-Over

Board-480V Set

CONTROL

BOX SIDE

CONTROL

PANEL

SIDE

(VIEW FROM INSERTING

3 2

S O

1 2

U1 U2 V2

REF. DES.

NOTE: EACH CABLE IS PASSED TWICE THROUGH CURRENT TRANSFORMERS CT4~5

3 2

R T

U1 U2 V2

S O

17 18

3 2

CONNECTOR

WIRE SIDE)

WIRE SIZE

125: 125 mm 100: 100 mm 80: 80 mm

22: 22 mm 14: 14 mm 8: 8 mm

5.5: 5.5 mm

NO MARK WIRE SIZE: 1.25

CURRENT TRANSFORMERS (CT4 ~ 5)

B L BR G GR V P

MARK AT CT

NO MARK

CODE/WIRE COLOR

BLACK BLUE BROWN GREEN GRAY VIOLET PINK

R W Y LB LG O

SYMBOL

Fg ExAr ExFg

AVR

CT 1~3 CT 4~5

~ F

CB1

CB2~3 CB4~6

CON1~2 CON3~ 5

COT. B

RED WHITE YELLOW LIGHT BLUE LIGHT GREEN ORANGE

DESIGNATION

MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING EXCITER FIELD WINDING RECTIFIER AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR (RHEOSTAT) CURRENT TRANSFORMER 500:5A

CURRENT TRANSFORMER 500:5A CHANGE-OVER SWITCH,AMMETER

AC AMMETER 0~500, 1000A

AC VOLTMETER 0~600V FREQUENCY METER 45~65 Hz @220V CIRCUIT BREAKER, 3P 800A CIRCUIT BREAKER, 1P 20A

CIRCUIT BREAKER, 2P 50A

RECEPTACLE, GFCI, 125 VAC @ 20 AMPS X 2

RECEPTACLE, CS6369, 250 VAC@ 50 AMPS

OVER CURRENT RELAY VOLTAGE CHANGE-OVER BOARD

AC AMMETER CHANGE-OVER SWITCH

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 61

ENGINE WIRING DIAGRAM (ECU-845)

PAGE 62 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

ENGINE WIRING DIAGRAM (BASLER DGC2020HD OPTION)

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 63

(GND.)

THIS EXAMPLE SELECT

O HANDLE FULL

OF GENERA

PHASE

GREEN

(NEU.)

WHITE

(L3)

BLUE

GENERATOR #2

(L2)

RED

3Ø-480 VAC PARALLEL WIRING DIAGRAM

PARALLEL WIRING CONNECTIONS

VIA CAMLOKS DCA300SSJU4F2

3-PHASE 480 VAC

(L1)

BLK

(GND.)

GREEN

(NEU.)

WHITE

(L3)

BLUE

GENERATOR #1

(L2)

RED

(L1)

BLK

PHASE C (W)

(GND.)

GREEN

NOTE:

MINIMUM CABLE SIZE IS 4/0.

ALL FIVE CAMLOK PAIRS ARE CONNECTED.2POINT OF CONNECTION/COMMON OUTPUT BUS

POWER DISTRIBUTION PANEL WITH INDIVIDUAL

DISCONNECT SWITCHES.

WHITE

(NEUTRAL)

PHASE B (V)

(L3)

BLUE

PHASE A (U)

PHASE C (W)

CORRECT SIZE OF CABLES

LOAD

LOAD/AMPERAGE (722 AMPS @ 480 VAC)

(L2)

RED

TOR.

PHASE B (V)

PAGE 64 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

BLK

(L1)

A (U)

(GND.)

THIS EXAMPLE SELECT

FULL LOAD/AMPERAGE (1600

PHASE

GREEN

(NEU.)

WHITE

BLUE

GENERATOR #2

(L2)

RED

(L1)

BLK

3Ø-208 VAC PARALLEL WIRING DIAGRAM

PARALLEL WIRING CONNECTIONS

VIA CAMLOKS DCA300SSJU4F2

3-PHASE 208 VAC

(L3)

(GND.)

GREEN

(NEU.)

WHITE

BLUE

GENERATOR #1

(L2)

RED

(L1)

BLK

(L3)

NOTE:

MINIMUM CABLE SIZE IS 4/0.

PHASE C (W)

PHASE B (V)

PHASE A (U)

(GND.)

GREEN

WHITE

(NEUTRAL)

(L3)

BLUE

PHASE C (W)

LOAD

POWER DISTRIBUTION PANEL WITH INDIVIDUAL

ALL FIVE CAMLOK PAIRS ARE CONNECTED.2POINT OF CONNECTION/COMMON OUTPUT BUS

DISCONNECT SWITCHES.

AMPS @ 208 VAC) OF GENERATOR.

CORRECT SIZE OF CABLES TO HANDLE

(L2)

RED

PHASE B (V)

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 65

BLK

A (U)

(L1)

BATTERY CHARGER WIRING DIAGRAM

CORD, CAROL 3/C 14 AWG., P/N EE56557.

BLACK 14 AWG. LINE (L)120VAC INPUT

WHITE 14 AWG. NEUTRAL (N)

GREEN 14 AWG. GROUND (G)

TO CHASSIS

GROUND

GREEN 16 AWG.

TO STARTER “B”

TERMINAL

RED 16 AWG.

NOTES:

NEMA 5-15, 15A, 120 VAC, P/N HBL5278C/HUBBLE RECEPTACLE.

RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.

20 AMP, 5-20R RECEPTACLE, P/N HBL5369C/HUBBLE RECEPTACLE.

PAGE 66 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

120 VAC INPUT, INSERT EXTERNAL

POWER CORD HERE.

ENGINE BLOCK HEATER WIRING DIAGRAM

BLACK 14 AWG. LINE (L)120VAC INPUT

WHITE 14 AWG. NEUTRAL (N)

GREEN 14 AWG. GROUND (G)

ENGINE

BLOCK HEATER

BLACK 14 AWG.

LINE (L)120VAC INPUT

WHITE 14 AWG.

NEUTRAL (N)

GREEN 14 AWG.

GROUND (G)

120 VAC INPUT, INSERT EXTERNAL

POWER CORD HERE.

TEMP.

SWITCH

120 VAC

HEATING

ELEMENT

GROUND

NOTES:

NEMA 5-15, 15A, 120 VAC, P/N HBL5278C/HUBBLE RECEPTACLE.

RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.

20 AMP, 5-20R RECEPTACLE, P/N HBL5369C/HUBBLE RECEPTACLE.

CORD, CAROL 3/C 14 AWG., P/N EE56557.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 67

TROUBLESHOOTING (GENERATOR)

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, use Table 19 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our company’s business ofﬁce or service plant.

Table 19. Generator Troubleshooting

Symptom Possible Problem Solution

AC Voltmeter defective? Check output voltage using a voltmeter.

Is wiring connection loose? Check wiring and repair.

No Voltage Output

Low Voltage Output

High Voltage Output

Circuit Breaker Tripped

Is AVR defective? Replace if necessary.

Defective Rotating Rectiﬁer? Check and replace.

Defective Exciter Field? Check for approximately 19 ohms across J & K on CN1

Is engine speed correct? Place engine speed switch in “High” position.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Is wiring connections loose? Check wiring and repair.

Defective AVR? Replace if necessary.

Short Circuit in load? Check load and repair.

Over current? Conﬁrm load requirements and reduce.

Defective circuit breaker? Check and replace.

Over current Relay actuated? Conﬁrm load requirement and replace.

PAGE 68 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

Symptom Possible Problem Solution

Engine will not start or start is delayed, although engine can be turned over.

At low temperatures engine will not start.

Engine ﬁres but stops soon as starter is switched off.

Engine stops by itself during normal operation.

Low engine power, output and speed.

TROUBLESHOOTING (ENGINE)

Troubleshooting (Engine)

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.

Compression too low?

Fuel pump not working correctly? Repair or replace fuel pump.

Oil pressure too low? Check engine oil pressure.

Low starting temperature limit exceeded?

Defective battery? Charge or replace battery.

Air or water mixed in fuel system?

Engine oil too thick?

Defective battery? Replace battery.

Fuel ﬁlter blocked? Replace fuel ﬁlter.

Fuel supply blocked? Check the entire fuel system.

Defective fuel pump? Replace fuel pump.

Fuel tank empty? Add fuel.

Fuel ﬁlter blocked? Replace fuel ﬁlter.

Defective fuel pump? Replace fuel pump.

Mechanical oil pressure shutdown sensor stops the engine due to low oil?

Fuel tank empty? Replace fuel ﬁlter.

Fuel ﬁlter clogged? Replace fuel ﬁlter.

Fuel tank venting is inadequate? Ensure that tank is adequately vented.

Leaks at pipe unions?

Speed control lever does not remain in

selected position?

Engine oil level too full? Correct engine oil level.

Injection pump wear?

Check piston, cylinder and valves. Adjust or repair per engine repair manual.

Comply with cold starting instructions and proper oil viscosity.

Check carefully for loosened fuel line

coupling, loose cap nut, etc.

Reﬁll engine crankcase with correct type of oil for winter environment.

Add oil. Replace low oil shutdown sensor if necessary.

Check threaded pipe unions tape and tighten unions a required.

See engine manual for corrective action.

Use No. 2-D diesel fuel only. Check the fuel injection pump element and delivery valve assembly and replace as necessary.

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 69

Symptom Possible Problem Solution

Low engine power output and low speed, black exhaust smoke.

Engine overheats.

TROUBLESHOOTING (ENGINE)

Troubleshooting (Engine) - continued

Air ﬁlter blocked? Clean or replace air ﬁlter.

Incorrect valve clearances? Adjust valves per engine speciﬁcation.

Malfunction at injector? See engine manual.

Too much oil in engine crankcase?

Entire cooling air system contaminated/ blocked?

Fan belt broken or elongated? Change belt or adjust belt tension.

Coolant insufﬁcient? Replenish coolant.

Radiator net or radiator ﬁn clogged with dust? Clean net or ﬁn carefully.

Fan, radiator, or radiator cap defective? Replace defective part.

Thermostat defective? Check thermostat and replace if necessary.

Head gasket defective or water leakage? Replace parts.

Drain off engine oil down to uppermark on

dipstick.

Clean cooling air system and cooling ﬁn areas.

PAGE 70 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

TROUBLESHOOTING (DIAGNOSTICS)

PROGRAM EXIT

845 ECU SERIES CONTROLLER

The engine controller of this generator diagnoses problems that arise from the engine control system and the engine itself.

1. With the engine stopped (OFF). Push and hold the

Hour Check Button (Figure 87) located on the control panel.

HOUR CHECK

BUTTON

Figure 87. Hour Check Button

4. Releasing the Hour Check Button and pushing the Program/Exit Button on the ECU controller will return

the controller to the main screen.

BUTTON

Figure 89. Program Exit Button

5. Push the Program/Exit Button on the ECU controller and select the Fault Diagnostics mode. This mode enables the ability to carry out the fault diagnostics as listed below:

2. While keeping the Hour Check Button pressed, place the Auto Off/Reset Manual Switch (Figure 88) in the

MANUAL position.

Figure 88. Auto-Off/Reset

3. The Hour Check Menu Screen will be displayed on the ECU controller.

(Manual Position)

Switch

 DM1 Active Faults — Displays active fault messages

and codes.

 DM2 Messages and Codes — Displays messages and

codes which previously occurred that are recorded in the Engine Control Module (ECM).

 Last Shutdown — Displays the messages and codes

that caused the most recent shutdown.

6. After perfoming diagnostic tests, place the Auto Off/

Reset Manual Switch in the OFF position

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 71

TROUBLESHOOTING (DIAGNOSTICS)

DGC2020HD SERIES CONTROLLER

At times, it may be desired to power up the Engine Control Module (ECM), key switch ON while the engine is not running. This can be useful for diagnostic purposes and fault clearing.

To enter the diagnostic mode with the controller in the OFF mode and the engine not running do the following:

1. Press and hold the Alarm Slience and Lamp Test buttons (Figure 90) at the same time for 10 seconds.

PRESS

LAMP

TEST

BUTTON

ALARM

SILENCE

BUTTON

SIMULTANEOUS

7. The dianostic mode will remain active until the Reset button (Figure 91) is pressed or if the engine rpm becomes greater than zero.

Reset

Figure 91. Reset Button

Figure 90. Alarm Silence/Lamp Test Buttons

2. Listen for an audiable click inside the control panel which is the run relay that controls the key switch.

3. While in diagnostic mode the controller can see real time engine CAN Bus data including Diagnostic Trouble Codes (DTC).

4. To view active DTC codes navigate to Metering >J1939 ECU>DTC Active Data.

5. For previously active codes navigate to Metering>J1939 ECU>DTC Prev Data.

6. Real time ECM parameters are not supported due to lack of sensors etc. and will display NS for No Signal.

PAGE 72 — DCA300SSJU4F2 60 HZ GENERATOR • OPERATION MANUAL — REV. #0 (06/26/18)

NOTES

DCA300SSJU4F2 60 HZ GENERATOR• OPERATION MANUAL — REV. #0 (06/26/18) — PAGE 73

OPERATION MANUAL

HERE’S HOW TO GET HELP

Multiquip Inc

are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other

trademarks are the property of their respective owners and used with permission.

This manual

The information and speciﬁ cations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change speciﬁ cations, design or the information published in this publication at any time without notice and without incurring any obligations.

DENYO CO., LTD, JAPAN

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

UNITED STATES

Multiquip Corporate Ofﬁce MQ Parts Department

18910 Wilmington Ave. Carson, CA 90746 Contact: mq@multiquip.com

Service Department Warranty Department

800-421-1244 310-537-3700

Technical Assistance

800-478-1244 Fax: 310-943-2238

CANADA

Multiquip Multiquip (UK) Limited Head Ofﬁce

4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 Contact: infocanda@multiquip.com

Tel. (800) 421-1244 Fax (310) 537-3927

Tel: (450) 625-2244 Tel: (877) 963-4411 Fax: (450) 625-8664

800-427-1244 310-537-3700

800-421-1244 310-537-3700

UNITED KINGDOM

Unit 2, Northpoint Industrial Estate, Globe Lane, Dukinﬁeld, Cheshire SK16 4UJ Contact: sales@multiquip.co.uk

Fax: 800-672-7877

Fax: 310-943-2249

Tel: 0161 339 2223 Fax: 0161 339 3226

, the MQ logo and the MQ Power logo

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

Manufactured for

MQ Power Inc.

Your Local Dealer is:

MQ Power WHISPERWATT DCA300SSJU4F2 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual