MULTIQUIP DCA Series Service And Troubleshooting Manual
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MULTIQUIP DCA Series Service And Troubleshooting Manual

MULTIQUIP DCA Series Service And Troubleshooting Manual

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SERVICE AND TROUBLESHOOTING MANUAL
DCA6 – DCA600
MQ POWER GENERATORS
Revision #0 (08/29/23)
To find the latest revision of this publication or
associated operation and parts manual, visit our
website at:
www.multiquip.com

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Summary of Contents for MULTIQUIP DCA Series

  • Page 1 SERVICE AND TROUBLESHOOTING MANUAL DCA6 – DCA600 MQ POWER GENERATORS Revision #0 (08/29/23) To find the latest revision of this publication or associated operation and parts manual, visit our website at: www.multiquip.com...

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING PAGE 2 — GENERATOR SERVICE AND TROUBLESHOOTING MANUAL — REV. #0 (08/29/23)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS DCA6~DCA600 60Hz Definitions ............72-73 Alternator Resistance Chart ........74 Generators, Service and Exciter Field Current and Voltage Table ....75 Troubleshooting Manual Generator Weights and Lifting Points Table ..76 Proposition 65 Warning ........... 2 Torque Specifications Table ........77 Safety Information ..........

  • Page 4: Safety Information

    SAFETY INFORMATION Do not operate or service the generator before reading the Potential hazards associated with the operation of this entire manual. Safety precautions should be followed at all generator will be referenced with hazard symbols which times when operating this generator. Failure to read and may appear throughout this manual in conjunction with understand the safety messages and operating instructions safety messages.
  • Page 5 SAFETY INFORMATION GENERAL SAFETY „ ALWAYS know the location of the nearest phone or keep a phone on the job site. Also, know the phone numbers CAUTION of the nearest ambulance, doctor, and fi re department. This information will be invaluable in the case of an „...
  • Page 6 SAFETY INFORMATION ENGINE SAFETY „ Operation of the generator may create sparks that can start fi res around dry vegetation. A spark arrestor DANGER may be required. The operator should contact local fi re agencies for laws or regulations relating to fi re prevention „...
  • Page 7 SAFETY INFORMATION FUEL SAFETY „ Make sure the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer DANGER gross vehicle weight rating. „ NEVER start the engine near spilled fuel or combustible „ ALWAYS inspect the hitch and coupling for wear. fl uids.
  • Page 8 SAFETY INFORMATION ELECTRICAL SAFETY „ Make sure power cables are securely connected to the generator’s output receptacles. Incorrect connections DANGER may cause electrical shock and damage to the generator. „ NEVER touch the output terminals NOTICE during operation. Contact with the „...
  • Page 9 SAFETY INFORMATION EMISSIONS INFORMATION „ If the battery liquid (dilute sulfuric acid) comes into contact with eyes, rinse eyes immediately with plenty NOTICE of water and contact the nearest doctor or hospital to seek medical attention. The diesel engine used in this equipment has been designed to reduce harmful levels of carbon monoxide CAUTION (CO), hydrocarbons (HC), and nitrogen oxides (NOx)

  • Page 10: Generator Theory

    BRACKET cycle of alternating current (AC) is developed. This is called a rotating rotor. ROTOR ASSEMBLY Most current generator designs, including Multiquip's utilize a rotating field type alternator. The magnetic field rotates inside the main stator. ROTATING The frequency of the generated voltage is dependent on the...
  • Page 11 GENERATOR THEORY Stationary Exciter Field Rectifiers (Re) The stationary exciter field (Ex Fg) Figure 3 receives Rectifiers (Figure 5) are mounted on the end of the rotor DC current from the automatic voltage regulator (AVR) plate. The rectifiers vary between models, as exampl the to create an electromagnetic field that produces the DCA45-70 utilize three single-phase half wave rectifiers.
  • Page 12 GENERATOR THEORY Rotating Main Field Armature The rotating main field (Fg) Figure 6, is a 4-pole rotating The armature (Ar) houses the main armature windings field, it rotates inside of the armature windings located (Figure 8) and auxiliary open delta windings. Utilizing inside of the armature housing.
  • Page 13 GENERATOR THEORY Figure 9 represents 3Ø high/low Wye wiring applications and 1Ø applications. Reference Figure 35 for armature windings and voltage selector switch (VSS) terminal callouts. 3-Phase High Wye 3-Phase Low Wye 240 VAC phase to phase 139 VAC phase to neutral TERMINALS STATOR WINDINGS...
  • Page 14 GENERATOR THEORY Automatic Voltage Regulator The auxiliary windings are coupled to one another in a three-phase series connection or open-delta with two NOTICE open ends. Important! There is no procedure for directly testing The four terminal points (Figure 11D) of the windings the AVR.
  • Page 15 GENERATOR THEORY OUTPUT TERMINALS RHEOSTAT BUSS BAR MAIN 3-POLE BREAKER Automatic Voltage Regulator (AVR) AUX. EXCITER WINDINGS ROTOR NOTE: DCA150 GENERATOR MODELS AND BELOW USE A VOLTAGE SELECTOR SWITCH. DCA180 GENERATOR MODELS AND ABOVE USE A VOLTAGE CHANGE-OVER BOARD. Figure 11. AVR Wiring Diagram GENERATOR SERVICE AND TROUBLESHOOTING MANUAL —...

  • Page 16: Heat Rise

    HEAT RISE WHAT IS HEAT RISE? The temperature rise is the increase in winding temperature above ambient due to the flow of current in the windings The insulation classification of the alternator’s insulation and any internal losses that may occur in the machine system is based on its thermal endurance when operating during operation.
  • Page 17 HEAT RISE Material used in class F and H alternators are non-nutrient for most known fungi. Another consideration is corrosive atmospheres such as salt which will attach the outer coating of winding insulation and may cause premature failure. Abrasive dust can also impact the insulation. In dusty and sandy areas the particles can be drawn through the alternator by the cooling fan.

  • Page 18: Load Banking/Wet Stacking

    LOAD BANKING/WET STACKING LOAD BANKING WET STACKING The purpose of load banking is to simulate the actual load Wet stacking is a common problem with diesel engines that a generator (power source) will encounter during an which are operated for extended periods with light or application.

  • Page 19: Engine/Generator Inspection

    ENGINE/GENERATOR INSPECTION GENERATOR CHECK/INSPECT The following is a compiled list of duties performed by service technicians. Most of the tasks should be done „ Cable ends, wire connectors and terminals, tighten and during normal scheduled maintenance. repair as needed. ENGINE CHECK/INSPECT „...

  • Page 20: Electrical Inspection

    ELECTRICAL INSPECTION When servicing generators, having an accurate AC/DC Infestation — Insects and rodents may have created a nest multimeter is a must (Figure 13). inside the generator. These nests and associated debris can cause electrical shorts. Generators left out in remote areas provide a home for spiders, wasps other insects and mice.
  • Page 21 ELECTRICAL INSPECTION WIRE INSULATION Megohmmeters (Figure 14) provide a quick and easy way to determine the condition of the insulation on wires, All generator windings, motors, and extension cords have generators, and motor windings. A megohmmeter is an electric wire that is covered with some form of insulation. electric meter that measures very high resistance values by Electrical wire is normally copper and is a good conductor sending a high-voltage signal into the object being tested.
  • Page 22 ELECTRICAL INSPECTION When generators, welders and electric motors are new the insulation should be at its highest level of resistance. During equipment use, insulation is subject to many effects which can cause it to fail. These causes can be mechanical damage, vibrations, excessive heat or cold, dirt, oil, corrosive vapors, and even moisture from humidity.

  • Page 23: Component Identification

    COMPONENT IDENTIFICATION RHEOSTAT (VR) VOLTAGE CHANGE-OVER BOARD NOTICE The rheostat (Figure 16) is a variable resistor (VR) connected directly to the AVR and is used for fine tuning The voltage change-over board (Figure 18) is only output voltage. used on DCA 180 model generators and above. DCA 150 model generators and below use a voltage selector switch.
  • Page 24 COMPONENT IDENTIFICATION MAIN CIRCUIT BREAKER (CB1) RELAY UNIT (RY1) The main circuit breaker (Figure 20) commonly referenced The relay unit (Figure 22) disconnects the V-leg at the as CB1, protects the generator output terminals U V W from AVR and AC voltmeter when the voltage selector switch overload.
  • Page 25 COMPONENT IDENTIFICATION VOLTAGE OUTPUTS NOTICE External loads are connected to the generator via the DCA-400 model generators and below use terminal UVWO voltage outputs. Various output voltages can be lugs for the UVWO voltage output as referenced in accessed either by terminal lugs, buss bars or camloks. Figure 24.
  • Page 26 COMPONENT IDENTIFICATION CAMLOKS NOTICE Some generators are equipped with a camlok panel Contact the Multiquip sales Dept. to order the camlok (option). Use the camlok panel to connect external loads panel required for your generator. to the generator. Shown in Figure 26 are just some of the camlok panels used on MQ Power generators.
  • Page 27 COMPONENT IDENTIFICATION CONTROL PANELS There are many different types of control panels used on the DCA series generators. Figure 27 shows just a few. For a complete understanding of each control panel, please reference the associated operation manual. WHISPERWATT 6kW AC GENERATOR WATER TEMP.
  • Page 28 CONTROLLERS, GAUGE UNITS AND DISPLAYS There are many different types of controllers, gauge units and displays used on the DCA series generators. Figure 28 and Figure 29 show just a few. For a complete understanding of each assembly, please reference the associated operation manual.
  • Page 29 COMPONENT IDENTIFICATION BASLER DGC-2020 ES DIGITAL GENSET CONTROLLER NGA100SSPUL DGC-2020 ES Supplyin g Not In Alarm Load Auto Auto Back Edit DEIF AGC-4 Mk II AUTOMATIC GENSET CONTROLLER DCA180SSJU4F3PD DCA220SSJU4F3PD DCA300SSJU4F3PD DCA400SSIU4F3PD DCA600SSV4F3PD BASLER DGC-2020 DIGITAL GENSET CONTROLLER DCA70SSIU4FC8B DCA150SSJU4F3B DCA180SSJU4F3B DCA220SSJU4F3B DCA300SSJU4F3B...

  • Page 30: Current Flow Diagram

    CURRENT FLOW DIAGRAM NOTICE The current flow diagram (Figure 30) is representative of a DCA45SSIU4F type generator. MAIN STATOR 0 / 2 0 / 1 0 / 1 P S S T O L OUTPUT TERMINAL O C K PANEL REAR TO CHASSIS GROUND BLUE...

  • Page 31: Voltage Flow Diagram

    VOLTAGE FLOW DIAGRAM NOTICE The voltage flow diagram (Figure 31) is representative of a DCA45SSIU4F type generator. WHITE NORMALLY OPEN CONTACT RELAY NOT USED UNIT (RY2) ( + ) ( - ) VSS EVEN TERMIMALS GREEN YELLOW 0 /2 0 /1 0 /1 P S S T O L...

  • Page 32: Rheostat Diagram

    RHEOSTAT DIAGRAM A J C CN15 CN14 WHITE WIRE (2) RELAY UNIT (RY1) ( + ) ( - ) 1 2 3 GREEN (PLUG) U V W YELLOW VOLTAGE REGULATOR (VR) RHEOSTAT WHITE BLUE GREEN GND. 0 / 2 0 / 1 0 / 1 P S S T O L...

  • Page 33: Receptacles Diagram

    RECEPTACLES DIAGRAM VSS EVEN 0 / 1 0 / 1 TERMIMALS VSS ODD 0 / 2 TERMIMALS S S T P R E 0 / 2 0 / 1 INPUT 0 / 1 2-POLE 50A P S S AUX.CIRCUIT T O L O C K BREAKERS (2) SINGLE-POLE 20A...

  • Page 34: Main Armature Windings Resistance Test

    MAIN ARMATURE WINDINGS RESISTANCE TEST MAIN ARMATURE RESISTANCE TEST OPEN-DELTA LEAD WIRES NOTICE The main armature has four open-delta lead wires. All wires are black. These wires are designated as Before performing the main armature windings A, B, C and D (Figure 34A). The purpose of these wires is resistance test, the load lead wires (Figure 35) must to supply the supplementary voltage needed to maintain be disconnected from either the voltage selector...
  • Page 35 MAIN ARMATURE WINDINGS RESISTANCE TEST MULTIMETER MULTIMETER EXAMPLE: DCA25SSIU4F = 0.133 Ω TURN Auto SELECTION RANGE MIN MAX Hz % HOLD/LIGHT DIAL TO Ω POSITION 12 BLACK LOAD LEAD WIRES mAµA COM 10 A ARMATURE WINDINGS DISCONNECT 12 BLACK LOAD VOLTAGE SELECTOR LEAD WIRES SWITCH USED ON DCA150...

  • Page 36: Main Field/Exciter Armature Resistance Test

    MAIN FIELD/EXCITER ARMATURE RESISTANCE TEST MAIN FIELD RESISTANCE TEST EXCITER ARMATURE RESISTANCE TEST NOTICE NOTICE Before performing the resistance test, the three yellow Before performing the resistance test, the two black lead wires (Figure 37) must be disconnected from the lead wires (Figure 36) must be disconnected from rotating rectifier.

  • Page 37: Exciter Field Resistance Test

    EXCITER FIELD RESISTANCE TEST EXCITER FIELD RESISTANCE TEST Using a multimeter (Figure 38), check the resistance across the J and K wire leads on the 6-pin plug as referenced NOTICE in Table 6, column D. The reading shoud be within 2–5 ohms of nominal.

  • Page 38: Manual Excitation Field Voltage Test

    MANUAL EXCITATION FIELD VOLTAGE TEST MANUAL EXCITATION TEST (3-PHASE VOLTAGE) 6. Next, place engine speed switch in the high position and run the engine at full rpm. 1. With the engine OFF, place the voltage selector 7. Place the selection dial on the multimeter to the AC switch (Figure 39A) in the 3-Phase, 240/139V position.

  • Page 39: Manual Excitation Winding Voltage Test

    MANUAL EXCITATION WINDING VOLTAGE TEST MANUAL EXCITATION TEST (WINDING VOLTAGE) 5. Place toggle switch in the OFF (open) position, then set engine speed switch to low postion (idle). Start the 1. With the engine OFF, place the voltage selector engine and then place toggle switch in ON position switch (Figure 40A) in the 3-Phase, 240/139V position.

  • Page 40: Exciter Field Current Measurement (No Load)

    EXCITER FIELD CURRENT MEASUREMENT ( NO LOAD ) EXCITER FIELD CURRENT MEASUREMENT 3. Start the engine. (NO LOAD) 4. If equipped, place engine speed switch in the high position and run the engine at full rpm. 1. With the engine OFF, place the voltage selector switch (Figure 41A) in the 1-Phase, 240/120V position.

  • Page 41: Exciter Field Current Measurement (With Load)

    EXCITER FIELD CURRENT MEASUREMENT ( WITH LOAD ) EXCITER FIELD CURRENT MEASUREMENT 5. Start the engine. (WITH LOAD) 6. If equipped, place engine speed switch in the high position and run the engine at full rpm. 1. With the engine OFF, place the voltage selector switch (Figure 42A) in the 1-Phase, 240/120V position.

  • Page 42: Exciter Field Voltage Measurement (No Load)

    EXCITER FIELD VOLTAGE MEASUREMENT ( NO LOAD ) EXCITER FIELD VOLTAGE MEASUREMENT 3. Next, open the control panel door on the generator and (NO LOAD) locate the 6-pin plug (Figure 43A) on the AVR. 4. Set the selection dial on the multimeter to AC volts NOTICE (Figure 43B).

  • Page 43: Exciter Field Voltage Measurement (Load)

    EXCITER FIELD VOLTAGE MEASUREMENT ( LOAD ) EXCITER FIELD VOLTAGE MEASUREMENT 5. Configure load bank for the specified rated load as referenced in the data sheet. This example will use (WITH LOAD) a load rating of 20 kW/25 kVA for a DCA25SSIU4F NOTICE generator.

  • Page 44: Rotating Rectifier Test

    ROTATING RECTIFIER TEST 3-PHASE RECTIFICATION Single-phase generators are generally 120 (root mean VRMS square voltage) or 240 phase-to-neutral, also called VRMS 3-phase rectification is the process of converting a line-to-neutral (L-N), and nominally of a fixed voltage and balanced 3-phase power supply into a fixed DC supply frequency producing an alternating voltage or current in the using solid-state diodes.
  • Page 45 ROTATING RECTIFIER TEST ROTATING RECTIFIER TEST NOTICE MULTIMETER OPEN POSITICE Before performing the continuity test, all lead wires CIRCUIT LEAD Auto (Figure 48) must be disconnected from the rectifier. TURN RANGE MIN MAX Hz % SELECTION HOLD/LIGHT DIAL TO Ω POSITION ROTATING The rotating rectifier is connected to both the main field SELECT...

  • Page 46: Main Armature Avr Inputs Resistance Check

    MAIN ARMATURE AVR INPUTS RESISTANCE CHECK MAIN ARMATURE AVR INPUTS RESISTANCE Set the multimeter selection dial to the position as shown in Figure 51A. CHECK (CN1) Next, check the resistance across the A-B, C-D, D-A open NOTICE delta wire leads as referenced in Figure 51B. Compare Before performing the resistance check, the 6-pin plug measured reading to values listed in Table 6, column (Figure 51B) must be disconnected from the CN1...

  • Page 47: Automatic Voltage Regulator

    AUTOMATIC VOLTAGE REGULATOR AVR INTERNAL SENSING (CN3) As shown in Figure 52 there are three outside connectors that plug into the CN1, CN3 and CN4 receptacles on the The CN3 connector (Figure 52) is used for the internal AVR. sensing of the AVR. The CN2 receptacle has no outside plug connected to it.
  • Page 48 AUTOMATIC VOLTAGE REGULATOR RHEOSTAT CHECK (CN4) Set the multimeter selection dial to to the position as shown in Figure 53A. NOTICE Place the multimeter leads between pins 1 and 3 on the Before performing the resistance check, the CN14 CN14 connector plug (Figure 53B). Turn the voltage control connector plug (Figure 53) must be disconnected knob (Figure 53C) fully counterclockwise.

  • Page 49: Main Circuit Breaker

    MAIN CIRCUIT BREAKER MAIN CIRCUIT BREAKER With the generator OFF, place the circuit breaker (Figure 54) in the OFF position. Set the multimeter selection dial to to The main circuit breaker (Figure 54) connects and position, then select the sound icon. disconnects the generator output voltage from the U, V, Next, verify that there is no continuity (no beep!) between W output terminal lugs.
  • Page 50 MAIN CIRCUIT BREAKER Table 2. Generator Amperage Chart/CB-OC Trip Ratings CIRCUIT OVERCURRENT PRIME OUTPUT AMPS AMPS AMPS AMPS BREAKER RELAY TRIP MODEL 240 VAC 3Ø 480 VAC 3Ø 120 VAC 1Ø 240 VAC 1Ø TRIP RATING SET POINT (AMPS) (AMPS) DCA6 25.0 ×...

  • Page 51: Ecu 9988N

    ECU 9988N ENGINE CONTROL UNIT (ECU 9988N) The ECU has a 3-position switch located at the top of the unit. This switch controls the running of the unit. If this The ECU 9988N is an auto-start/stop engine controller. switch is set to the OFF/RESET position, the unit will not This controller should not be confused with the actual start.
  • Page 52 ECU 9988N If the engine ECM issues either a low oil pressure or To stop the engine or to clear a fault condition, place the high water temperature fault the engine will shut down control switch in the OFF position. immediately.
  • Page 53 ECU 9988N ENGINE CRANK DISCONNECT SMALL ENGINE CRANK FLAT-BLADE TIME SCREWDRIVER FAULT DELAY OIL PRESS./TEMP. ENGINE OVERSPEED Figure 56. Potentiometer Adjustments ADJUSTING ENGINE CRANK DISCONNECT ADJUSTING ENGINE OVERSPEED This is an adjustment for the engine starter (crank duration). This adjustment is for engine overspeed as a safety Using a small, flat-blade screwdriver (Figure 56A), turn measure.
  • Page 54 1 second to the crank time. Adjusting the crank AUTO MANUAL time automatically sets the rest time to the same value. OFF/RESET Multiquip recommends a 3 second crank cycle on average. DO NOT exceed 10 seconds. LOW OIL PRESSURE HIGH COOLANT TEMPERATURE ENGINE CRANK CYCLES...
  • Page 55 ECU 9988N SINGLE OR MULTIPLE ENGINE CRANKS (DIP SWITCH 4) Using a small, flat-blade screwdriver, set DIP switch 4 (Figure 56D) for either single or multiple engine cranks as referenced in Table 4. When DIP switch 4 is placed in the ON position (up) all the multiple engine cranks will add together to create one large engine crank.

  • Page 56: Overcurrent Relay (Ocr)

    OVERCURRENT RELAY ( OCR ) OVERCURRENT RELAY The OCR is a plug-in device that plugs into a relay base located inside the box. Figure 59 provides a brief The overcurrent relay (OCR) is a circuit/load protection explanation of the control dials and the various components device.
  • Page 57 OVERCURRENT RELAY ( OCR ) OCR TESTING 5. To trip the OCR, slide the manual trip lever on the relay as shown in Figure 60E and verify that the multimeter 1. Place the selection dial (Figure 60A) on the multimeter indicates an OPEN circuit (no beep!) across terminals 95 to the position, then select the sound icon.

  • Page 58: Voltage Selector Switch

    VOLTAGE SELECTOR SWITCH VOLTAGE SELECTOR SWITCH INTERNAL CONNECTIONS BETWEEN TERMINALS 3 PHASE 3 PHASE 3 PHASE 240/139 240/139 240/139 3 PHASE 1 PHASE 3 PHASE 1 PHASE 3 PHASE 1 PHASE 480/277 240/120 480/277 240/120 480/277 240/120 P P R R E E S S S S T T O O L L O O C C K K P P R R E E S S S S T T O O L L O O C C K K P P R R E E S S S S T T O O L L O O C C K K 3-PHASE...
  • Page 59 VOLTAGE SELECTOR SWITCH Figure 62 shows the metal and wire jumper placement onto the voltage selector switch. VSS METAL JUMPERS VSS EVEN # EVEN # TERMINALS TERMINALS 0 / 2 0 / 1 0 / 1 P S S T O L JUMPER O C K CLIP...

  • Page 60: Ground Fault Circuit Interrupter (Gfci)

    GROUND FAULT CIRCUIT INTERRUPTER ( GFCI ) GFCI Is The Ground Wire Still Required? A ground fault circuit interrupter (GFCI) is a device that The GFCI will work and perform its function with or without compares the amount of current flowing through a circuit. If the tool being grounded.
  • Page 61 GROUND FAULT CIRCUIT INTERRUPTER ( GFCI ) GREEN STATUS LED STATUS FLASHING LED ( Figure 67. GFCI Receptacle (RED Flashing LED) Figure 64. GFCI Receptacle (ON) GFCI Method 2 Testing 4. Press the TEST button (Figure 65) on the GFCI To measure the trip current of a GFCI requires a GFCI receptacle and verify that the status LED turns OFF.

  • Page 62: Fuel Pump Relay

    FUEL PUMP RELAY FUEL PUMP RELAY 7. If the DC voltage is not present at the relay coil along with a known good ground, refer to associated wiring The fuel pump relay, sometimes called an run or ignition diagram to trace relay DC signal path. relay, provides the DC voltage to the fuel pump.
  • Page 63 FUEL PUMP RELAY FUEL PUMP RELAY MULTIMETER BOTTOM VIEW MULTIMETER DCA150 ~DCA600 Auto BEEP! BEEP! BEEP! TURN SELECTION RANGE MIN MAX Hz % HOLD/LIGHT (CONTINUITY) NUMBERS DIAL TO POSITION SELECT SOUND ICON mAµA COM 10 A FUEL PUMP RELAY COIL CONTACTS (PINS) CONTACTS...

  • Page 64: Engine Starter (Crank) Relay

    ENGINE STARTER ( CRANK ) RELAY ENGINE START (CRANK) RELAY Pin 4 on the starter relay is provided a ground signal via the starter cut relay (pins 3 and 6). The starter cut relay For use on DCA20, 25 36, 45, 70 (Isuzu) and 125 is controlled by the engine control module (ECM).
  • Page 65 ENGINE STARTER ( CRANK ) RELAY CON'T ENGINE START (CRANK) RELAY The B+ battery voltage is also connected to the normally open contact on the starter relay (terminal 4). When the For use on DCA70, 150, 180, 220 and 300 generators starter relay is energized at terminal 2 (coil) by the ECU (John Deere Engines).

  • Page 66: Engine Glow Plug Relay

    ENGINE GLOW PLUG RELAY ENGINE GLOW PLUG RELAY (ISUZU ENGINES The coil of the glow plug relay (pins 3 and 4) are controlled by the ECM. Pin 3 is connected to B+ while pin 4 is waiting ONLY) to received a ground signal from the ECM. Once the ground The engine glow plug relay (Figure 72) is connected to the signal is received on pin 4, the normally open contact will be engine glow plugs and directly to the battery via a 65-amp...

  • Page 67: Magnetic Pickup Unit

    MAGNETIC PICKUP UNIT MAGNETIC PICK UP (MPU) MPU AC Voltage Test The magnetic pick-up (MPU) is an electromagnetic sensor 1. With the multimeter test leads still placed across and is mounted in the flywheel bell housing of the engine. pins 1 and 2 on the ECU auto-start module, set the When a tooth from the engine flywheel passes under the multimeter selection dial to the AC Volts position tip of the sensor, electrical impulses are induced within the...
  • Page 68 MAGNETIC PICKUP UNIT MPU Installation And Adjustment 4. Attach a ratchet to the crankshaft pulley and rotate the flywheel gear until the highest point of the flywheel 1. Loosen the jam nut that secures the MPU to the sensor gear tooth is visible as shown in Figure 77. plate.

  • Page 69: Magnetic Pickup Unit/Fuel Feed Pump Strainer

    MAGNETIC PICKUP UNIT/FUEL FEED PUMP STRAINER FUEL FEED PUMP STRAINER 6. After making contact with the flywheel gear tooth, unscrew the MPU sensor counterclockwise 1/2 turn. The fuel pump strainer is used on all DCA generators Reference Figure 79. equipped with Isuzu engines. NOTICE When replacing fuel pump strainer always replace banjo bolt and gasket.

  • Page 70: Frequently Asked Questions

    FREQUENTLY ASKED QUESTIONS Below is a list of typically asked questions received by the Answer (DCA180~DCA600 Models): MQ Power Service Department. The 50-amp CS6369 twist-lock receptacles can be used Question: anytime during operation. Voltage can be adjusted using the voltage control regulator located on the control panel. Why are the 50-amp twist-lock receptacles not working.

  • Page 71: Frequently Asked Questions

    FREQUENTLY ASKED QUESTIONS Question: Question: The main circuit breaker will not reset? I replaced the engine temperature sensor but the engine still shuts down with the high temperature indicator on (why)? Answer: Answer: The overcurrent relay (OCR) has been tripped and needs to be reset before the main breaker can be reset.

  • Page 72: Definitions

    These Heat Rise — Is in direct relation to the longevity of the brushes have a short life due to erosion. Multiquip’s unique generator. Reference the heat rise section in this manual...
  • Page 73 DEFINITIONS Permanent Magnetic Generator (PMG) — The PMG • Metal Oxide Varistor — The metal oxide varistor eliminates the excitation losses in the rotor, which otherwise (MOV) contains a material, typically granular zinc oxide typically represent 20–30% of the total generator losses. It that conducts current (shorts) when presented with a also gives a lower temperature rise in the generator.

  • Page 74: Alternator Resistance Chart

    ALTERNATOR RESISTANCE CHART Table 6. Alternator Resistance Values Generator ID Resistance Measured In Ohms Ω Main Armature Main Exciter (AVR Inputs) Gen-Set Model Generator Model Column A Column B Column C Column D Column E Column F (Armature) (Field) (Armature) (Field) (Coil) (Coil)

  • Page 75: Exciter Field Current And Voltage Table

    EXCITER FIELD CURRENT AND VOLTAGE TABLE Table 7. Exciter Field Current And Voltage Values Exciter (Ex) Exciter (Ex) Induction Voltage (V) By Generator ID Field Current (A) Field Voltage (A) Separate Excitation (12V) Column F Column E Exciting 3-Phase Gen-Set Model Column A Column B Column C...

  • Page 76: Generator Weights And Lifting Points Table

    GENERATOR WEIGHTS AND LIFTING POINTS TABLE Table 8. Generator Weights And Lifting Points Dry Weight Wet Weight Maximum lb. (kg) lb. (kg) Lifting Generator Trailer Point Model Model Capacity Generator Trailer Total Generator Trailer Total lb. (kg) DA7000SSA3 TRLRMPXF* 533 (242) 508 (230) 1,041 (472) 597 (271)

  • Page 77: Torque Specifications Table

    TORQUE SPECIFICATIONS TABLE Table 9. Bolt Torque Specs OUTPUT TERMINAL BOLTS AND TIE BOLTS PART NUMBER TIE BOLT TORQUE SPEC MODEL REMARKS OUTPUT TERMINAL BOLT TIE BOLT N∙m lbf∙in DCA10SPXU4 No output terminal bolt DCA15SPXU4 M0235100014 M9220000104A 65.0 DCA20SPXU2 M9220000204 M9220000104A 65.0 DCA36SPXU2...
  • Page 78 ECU - 845 AC FAULT CODES Table 10. ECU-845 AC Defaults (John Deere) Setpoint Defaults J4FSA : J4FSB : J4FSC : J4FSD : J4FSE : DCA70SSJU4F DCA180SSJU4F DCA300SSJU4F2 DCA150SSJU4F2 DCA220SSJU4F2 Menu Structure J4FSA 0-11-0-17 J4FSB 0-11-0-17 J4FSC 0-11-0-17 J4FSD 0-11-0-17 J4FSE 0-11-0-17 |->...
  • Page 79 ECU - 845 AC FAULT CODES Table 10. ECU-845 AC Defaults (John Deere) Setpoint Defaults J4FSA : J4FSB : J4FSC : J4FSD : J4FSE : DCA70SSJU4F DCA180SSJU4F DCA300SSJU4F2 DCA150SSJU4F2 DCA220SSJU4F2 Menu Structure J4FSA 0-11-0-17 J4FSB 0-11-0-17 J4FSC 0-11-0-17 J4FSD 0-11-0-17 J4FSE 0-11-0-17 |->...

  • Page 80: Ecu - 845 Ac Fault Codes

    ECU - 845 AC FAULT CODES Table 11. ECU-845 AC Defaults (Isuzu/Volvo) Setpoint Defaults I4JHA : DCA70 I4JHB : DCA125 IZ4F : DCA400 V4F : DCA600 Menu Structure I4JHA0-9-0-45 I4JHB0-9-0-45 IZ4F0-7-0-45 V4F0-12-0-9 |-> AC MISC SETTINGS |-> AC HIGH HZ % |->...
  • Page 81 ECU - 845 AC FAULT CODES Table 11. ECU-845 AC Defaults (Isuzu/Volvo) Setpoint Defaults I4JHA : DCA70 I4JHB : DCA125 IZ4F : DCA400 V4F : DCA600 Menu Structure I4JHA0-9-0-45 I4JHB0-9-0-45 IZ4F0-7-0-45 V4F0-12-0-9 |-> HI WYE RATED VOLTS LL |-> HI WYE RATED VOLTS LN |->...

  • Page 82: Ovrcurrent Relay Trip Point Table

    OVRCURRENT RELAY TRIP POINT TABLE Table 12. Overcurrent Relay Trip Points Generator Model Factory OCR Setting CT Ratios DCA-10SPXU4 No OCR DCA-15SPXU4F 100:5A DCA-20SPXU4F No OCR DCA-36SPXU4F No OCR DCA-25SSIU4F 100:5A DCA-25SSIU4FC8 100:5A DCA-25SSIU4FDS 100:5A DCA-40SSKU4F2 150:5A DCA-45SSIU4F 150:5A DCA-45SSIU4FC8 150:5A DCA-45SSIU4FDS 150:5A...

  • Page 83: Troubleshooting (Engine)

    TROUBLESHOOTING ( ENGINE ) Troubleshooting (Engine) Symptom Possible Problem Solution No fuel reaching injection pump? Add fuel. Check entire fuel system. Defective fuel pump? Replace fuel pump. Fuel fi lter clogged? Replace fuel fi lter and clean tank. Faulty fuel supply line? Replace or repair fuel line.
  • Page 84 TROUBLESHOOTING ( ENGINE ) Troubleshooting (Engine) - continued Symptom Possible Problem Solution Air fi lter blocked? Clean or replace air fi lter. Low engine power output and low speed, Incorrect valve clearances? Adjust valves per engine specifi cation. black exhaust smoke. Malfunction at injector? See engine manual.

  • Page 85: Troubleshooting Flowcharts

    TROUBLESHOOTING FLOWCHARTS The following flowcharts are intended to suggest a „ Was the engine operating at a constant speed at the systematic approach to locating and correcting generator time of the fault? malfunctions. The flowcharts’ steps have been arranged „ Have there been extended periods of engine under-speed in such a manner as to perform the easy checks first and operation? prevent further damage when troubleshooting of a disabled...
  • Page 86 TROUBLESHOOTING FLOWCHARTS NO VOLTAGE - RESIDUAL VOLTAGE ONLY Verify Low Voltage Output Start unit and run at Inspect and troubleshoot Set Voltage Selector PASS With unit OFF, inspect 1800 RPM. Verify output voltage voltmeter on control Switch or Bus Bars to for loose damage or at top of circuit breaker with panel/digital controller...
  • Page 87 TROUBLESHOOTING FLOWCHARTS NO VOLTAGE Verify no voltage output. Start unit and Inspect and troubleshoot Set Voltage Selector run at 1800 RPM. Verify PASS With unit OFF, inspect voltmeter on control output voltage at top of circuit Switch or Bus Bars to for loose damage or breaker with multimeter.
  • Page 88 TROUBLESHOOTING FLOWCHARTS LOW VOLTAGE - NO LOAD Verify Low Voltage Output Start unit and run at Inspect and troubleshoot PASS 1800 RPM. Verify output voltage voltmeter on control at top of circuit breaker with panel/digital controller multimeter. Phase to Phase and Phase to Neutral FAIL...
  • Page 89 TROUBLESHOOTING FLOWCHARTS LOW VOLTAGE - WITH LOAD Verify Low Voltage Output Start unit and run at Inspect and troubleshoot PASS 1800 RPM. Verify output voltage voltmeter on control at top of circuit breaker with panel/digital controller multimeter. Phase to Phase and Phase to Neutral FAIL...
  • Page 90 TROUBLESHOOTING FLOWCHARTS HIGH VOLTAGE Verify Low Voltage Output Start unit and run at Inspect and troubleshoot PASS 1800 RPM. Verify output voltage voltmeter on control at top of circuit breaker with panel/digital controller multimeter. Phase to Phase and Phase to Neutral FAIL Is engine...
  • Page 91 TROUBLESHOOTING FLOWCHARTS OUTPUT VOLTAGE UNSTABLE - NO LOAD Verify Unstable Output Voltage Start unit and run at 1800 rpm Verify Check voltage is engine speed voltmeter gauge unstable by measuring PASS hunting or fluctuating? or digital controller on voltage with a multimeter. Test or replace voltmeter Is engine speed control panel for loose,...
  • Page 92 TROUBLESHOOTING FLOWCHARTS VOLTAGE UNBALANCED Verify Unbalanced Output Voltage Start unit and run at 1800 rpm Verify voltage is unba anced by measur ng the vo tage with a multimeter. Phase to phase and phase to neutral. Test voltage at load lugs with circuit breaker closed and no load connected to the unit.
  • Page 93 NOTES GENERATOR SERVICE AND TROUBLESHOOTING MANUAL — REV. #0 (08/29/23) — PAGE 93...
  • Page 94 © COPYRIGHT 2023, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power logo 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.

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