MQ Power WHISPERWATT Series Guide

PARTS AND OPERATION MANUAL
OPERATION AND PARTS MANUAL
Revision #0 (05/10/06)
THIS MANUAL MUST ACCOMPANY
THE EQUIPMENT AT ALLTIMES.
WHISPERWATTTM SERIES
MODEL DCA-70SSJU2
60 Hz GENERATOR
S/N 7303870-4989 ECU/EGS
PARTS LIST NO.M2870300404
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PAGE 2 — DCA-70SSJU2 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (05/10/06)
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PAGE 4 — DCA-70SSJU2 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (05/10/06)
DCA-70SSJU2 (60 Hz) — TABLE OF CONTENTS
MQ POWER DCA-70SSJU2 (60 HZ)MQ POWER DCA-70SSJU2 (60 HZ)
MQ POWER DCA-70SSJU2 (60 HZ)MQ POWER DCA-70SSJU2 (60 HZ)
MQ POWER DCA-70SSJU2 (60 HZ)
WHISPERWHISPER
WHISPERWHISPER
WHISPERWW
WW
WAA
AA
ATT™ GENERATT™ GENERA
TT™ GENERATT™ GENERA
TT™ GENERATORTOR
TORTOR
TOR
CaliforniaProposition 65Warning .....................................2
Here's HowTo Get Help....................................................3
Table Of Contents.............................................................4
PartsOrderingProcedures ...............................................5
Specifications...................................................................6
Dimensions (Top, Side and Front) ....................................7
Safety Message Alert Symbols ....................................8-9
Rules for Safe Operation ...........................................10-13
GeneratorDecals....................................................... 14-15
Installation .................................................................16-17
GeneralInformation ........................................................18
MajorComponents .........................................................19
GeneratorControl Panel .................................................20
EngineOperating Panel ............................................. 22-23
OutputTerminal PanelFamiliarization ........................ 24-26
Load Application .............................................................27
GeneratorOutputs ..........................................................28
GaugeReading ...............................................................29
OutputTerminal PanelConnections ...........................30-31
Pre Setup ..................................................................32-35
GeneratorStart-upProcedure (Manual).....................36-37
GeneratorStart-upProcedure(Auto) ..............................38
GeneratorShut-Down Procedure ....................................39
Maintenance ..............................................................40-42
TrailerMaintenance....................................................43-46
TrailerWiringDiagram .....................................................47
GeneratorWiring Diagram...............................................48
EngineWiring Diagram ...................................................49
GeneratorTroubleshooting ..............................................50
Engine Troubleshooting.............................................51-52
EngineControllerTroubleshooting(MPEC) .....................53
Explanation of Code in Remarks Column .......................54
Suggested Spare Parts ..................................................55
COMPONENT DRAWINGS
Generator Assembly............................................ 56-57
Control Box Assembly.......................................... 58-61
Engine and Radiator Assembly........................... 62-65
Output Terminal Assy. ..........................................66-67
Battery Assembly .................................................68-69
Muffler Assembly .................................................70-71
Fuel Tank Assembly .............................................72-73
Enclosure Assembly ............................................ 74-77
Rubber Seal Assembly ........................................ 78-79
Nameplate and Decals ........................................ 80-81
Terms and Condition of Sale — Parts...................... 82
Specification and part
number are subject to
change without notice.
NOTE
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PAGE 6 — DCA-70SSJU2 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (05/10/06)
DCA-70SSJU2 (60 Hz) — SPECIFICATIONS
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DCA-70SSJU2 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (05/10/06) — PAGE 7
1
DCA-70SSJU2 (60 Hz) — DIMENSIONS (TOP, SIDE AND FRONT)
Figure 1. Dimensions
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PAGE 8 — DCA-70SSJU2 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (05/10/06)
Before using this generator,ensure that the operating
individual has read and understands all instructions in
this manual.
Safety precautions should be followed at all times when
operatingthis equipment.Failuretoreadandunderstandthe
Safety Messages and Operating Instructions could result in
injury to yourself and others.
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS! HAZARD SYMBOLS
Potential hazards associated with the operation of this
equipmentwillbe referencedwith " Hazard Symbols "which
appear throughout this manual, and will be referenced in
conjunction with Safety "
Message Alert Symbols ".
NOTE
DCA-70SSJU2 (60 Hz) — SAFETY MESSAGE ALERT SYMBOLS
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others.The
Safety Messages specifically address the level of exposure
to the operator, and are preceded by one of three words:
DANGER, WARNING,orCAUTION.
You COULD be KILLED or SERIOUSLY injured if
you do not follow directions.
You CAN be injured if you do not follow directions
Gasoline engine exhaust gases contain
poisonous carbon monoxide. This gas is
colorless and odorless, and can cause
DEATH if inhaled. NEVER operate this
equipment in a confined area or enclosed structure that
does not provide ample free flow air.
Gasoline is extremely flammable, and
its vapors can cause an explosion if
ignited. DO NOT start the engine near
spilled fuel or combustible fluids.
DO NOT fillthefuel tankwhiletheengine
is running or hot.
DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system. Store fuel in approved containers, in
well-ventilated areas and away from sparks and flames.
NEVER use fuel as a cleaning agent.
Engine components can generate extreme
heat.To preventburns,DO NOT touchthese
areas while the engine is running or
immediately after operations. NEVER
operatethe enginewithheat shieldsor heat
guardsremoved.
WARNING
CAUTION
WARNING - LETHAL EXHAUST GASES
WARNING - BURN HAZARDS
WARNING - EXPLOSIVE FUEL
During operation of this generator, there
exists the possibility of electrocution,
electricalshock orburn, whichcancause
severe bodily harm or even DEATH!
DANGER - ELECTROCUTION HAZARDS
You WILL be KILLED or SERIOUSLY injured if you
do not follow directions.
DANGER
This OperationandParts Manual
has been developed to provide
complete instructions for the safe
and efficient operation of the MQ
Power Model DCA-70SSJU2
(60Hz) UltraSilent™Generator.
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DCA-70SSJU2 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (05/10/06) — PAGE 9
1
DCA-70SSJU2 (60 Hz) — SAFETY MESSAGE ALERT SYMBOLS
ALWAYS place the engine ON/OFF
switch in the OFF position and when the
generator is not in use.
ALWAYS wear approved respiratory
protection.
ALWAYS wearapproved eye and
hearing protection.
Other important messages are provided throughout this
manual to help prevent damage to your generator, other
property, or the surrounding environment.
Thisgenerator,otherproperty,or
the surrounding environment
could be damaged if you do not
follow instructions.
NOTE
NEVER tamper with the factory settings
of the engine governor or settings.
Personal injury anddamageto theengine
or equipment can result if operating in
speedranges abovemaximum allowable.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - ACCIDENTAL STARTING
CAUTION - RESPIRATORY HAZARDS
CAUTION - SIGHT AND HEARING HAZARDS
CAUTION - EQUIPMENT DAMAGE MESSAGES
NEVER operate equipment with covers,
orguardsremoved. Keep fingers , hands ,
hair and clothing away from all moving
parts to prevent injury.
WARNING - ROTATING PARTS
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PAGE 10 — DCA-70SSJU2 (60 HZ) — OPERATION AND PARTS MANUAL — REV. #0 (05/10/06)
DCA-70SSJU2 (60 Hz) — RULES FOR SAFE OPERATION
Thefollowing safetyguidelinesshouldalwaysbe usedwhen
operating the DCA-70SSJU2 (60 Hz) Whisperwatt ™
Generator
General Safety:
■ DO NOT operate or service this
equipment before reading this entire
manual.
The operator MUST BE familiar with proper safety
precautions and operations techniques before using
generator.
■ Thisequipment shouldnot beoperated bypersons under
18 years of age.
■ NEVER operatethis equipmentwithout properprotective
clothing,shatterproof glasses,steel-toed bootsand other
protective devices required by the job.
■ NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.
■ NEVER operate this equipment under the influence or
drugs or alcohol.
■ NEVER use accessories or attachments, which are not
recommendedbyMQ Powerfor thisequipment.Damage
to the equipment and/or injury to user may result.
■ Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
■ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
Failure to follow instructions in this manual may lead to
serious injury or even DEATH ! This equipment is to be
operated by trained and qualified personnel only! This
equipment is for industrial use only.
DANGER - READTHIS MANUAL!
■ ALWAYS checkthemachineforloosenedthreads orbolts
before starting.
■ NEVERoperatethegeneratorinanexplosiveatmosphere
or near combustible materials. An explosion or fire could
result causing severe bodily harm or even death.
■ NEVER touch the hot exhaust manifold, muffler
or cylinder.Allow these parts to cool before
servicingengineor generator.
■ HighTemperatures –Allowtheengine
to cool before performing service and
maintenance functions. Contact with
hot! components can cause serious
burns.
■ The engine of this generator requires an adequate free
flow of cooling air. NEVER operate the generator in any
enclosed or narrow area where free flow of the air is
restricted. If the air flow is
restricteditwillcauseserious
damage to the generator or
engineand maycauseinjury
to people. The generator
engine gives off DEADLY
carbon monoxide gas.
■ DO NOT place hands or fingers inside generator engine
compartment when engine is running.
■ NEVER runenginewithoutairfilter.Severeenginedamage
may occur.
■ DONOT leavethegeneratorrunninginthe manualmode
unattended.
■ Refer to the John Deere Engine Owner's Manual for
engine technical questions or information.
■ ALWAYS store equipment properly when it is not being
used.Equipment shouldbe storedin aclean, drylocation
out of the reach of children.
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DCA-70SSJU2 (60 Hz) — OPERATION AND PARTS MANUAL — REV. #0 (05/10/06) — PAGE 11
1
DCA-70SSJU2 (60 Hz) — RULES FOR SAFE OPERATION
POWER
CORD
(POWER ON)
WET
HANDS
During operation of this generator, there
exists the possibility of electrocution,
electricalshock orburn,
whichcancause
severe bodily harm or even DEATH!
To avoid these hazards:
NEVER use damaged or worn cables when connecting
equipment to the generator.Make sure power connecting
cables are securely connected to the generator’s output
terminals,insufficienttighteningoftheterminal connections
maycause damagetothe generator
and electrical shock.
NEVER grab or touch a live power
cord with wet hands.
NEVER touch output terminals
during operation. This is extremely
dangerous. ALWAYS stop the
machine and place the circuit
breaker in the OFF position when
contact with the output terminals is
required.
Backfeed to a utility system can
cause electrocution andorproperty
damage. DO NOT connect to any
building's electrical system except
throughan approved deviceor after
building main switch is opened.
ALWAYS havealicensedelectrician
perform the installation
DANGER - ELECTROCUTION HAZARDS
Generator Grounding
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
Article 250 (Grounding) of the National Electrical Code
(NEC)providesguidelinesforpropergroundingandspecifies
that the cable ground shall be connected to the grounding
system of the building as close to the point of cable entry
as practical.
The following safety recommendations should also be
followed:
■ ALWAYS make sure generator is properly grounded.
■ NEVER use gas piping as an electrical ground.
■ ALWAYS make sure that electrical circuits are properly
grounded perthe National Electrical Code (NEC) and
local codes before operating generator.Severe injury or
DEATH! by electrocution can result from operating an
ungroundedgenerator.
■ ALWAYS be sureto usethe groundterminal(green wire)
when connecting a load to the U,V, and W output
terminallugs.
Electrical Safety
■ ALWAYS have a qualified electrician perform the
generator wiring installation.
■ ALWAYS makesuregeneratorinstallation isaccordance
withthe NationalElectrical Code (NEC)andlocalcodes
beforeoperatinggenerator.
■ NEVER use a defective or frayed power cable. Check
the cable for cuts in the insulation.
■ NEVER use a extension cord that is frayed or damaged
where the insulation has been cut.
■ ALWAYS make certain that proper extension cord has
been selected for the job. SeeTable 6.
■ NEVER power cables or cords lay in wate r.
■ NEVER standinwater whileACpowerfromthegenerator
is being transfer to a load.
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