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DCA25-150 Service Manual - Multiquip Service & Support Center

1. MODEL Old MSKva New MSKva of Lit Prime Lit Stby LGR Hp 6Pf Increase Code G Kw Kw DcasssUu 58 tt y y 2555 8 2 2 hM w L i pcasssu 78 jJ I ft 0844566 99 a 3 3 17 a ee pcavossyu 1401 5 44149 2 56 6 3 _ O _DCA85SSKM f S o S S O y o Deas5sss 26 3 66 70 4 cass 1811 10055 __ 231 2 39 DcA sssKJ 23 oo pcaizsssss 410 10 6 372 J S o T S O y y o 15055 55 3 10 132 9 35 Multiquip Inc DCA Series Generators Manual No DCA25150CD ENGINE CONTROLS The DCA 25 150 Series generators are powered by four cycle engines and are manufactured by Isuzu and John Deere The following information is to provide the service technician with a base level of knowledge on engine controls and related components For more on engine maintenance and repairs see engine manufacturer s service manual INDEX ENGINE CONTROLS TIOUDIOSDOOHLIG u uu he ann dde entame
2. _ Cotes RECEP G GREEN LB LIGHT BLUE fonar Ls GREEN v o P ___ ___ Multiquip Inc Series Generators Manual No DCA25150CD DCA 150USJ ENGINE OTT TT r 2 L TTT aas 2 e escis JOHN DEERE INTAKE HEATER i CAN TIC I CONNECTOR LEVEL 12 ECU CONNECTOR TERMINATOR CRANE SENSOR COOLANT TEMP LAMP FORM ES MALE CONNECTOR LAMP SIDE FEMALE COMMOMESS INTAKE HEATER ALTERNATOR 120 OHM TERMINATOR FUEL TEMP MANIFOLD WAIT LAMP AVRING SIDE CIL PRESSURE SENSOR COLOR CODE WARE SIZE COLOR SYM WIRE COLOR or 3 GNE At mm PE SHSMATEL Co Lo AV a5 mm LG v 77 Multiquip Inc Series Generators Manual DCA25150CD GENERATOR GLOSSARY Ammeter An instrument that measures electric current in amperes Amperage Amps The strength of a electrical current measured in amperes Armature That part of a generator or of an electric motor in which a current is induced by a magnetic field The armature usually consists of a series of coils or groups of insulated conductors surrounding a core of iron See page 8 for more infor
3. NEN NEN ww ws NEN Es s FEE NM RESISTANCE MEASURED IN OHMS Armature Armature Field 2 1 13 12 Main Armature AVR Inputs 83 O gt N N p 58 oo 083 os 09 09 05 2 22 2 22 2 22 2 15 2 22 2 15 1 25 1 83 1 11 1 11 1 85 1 11 1 85 0 97 0 84 0 84 0 84 0 84 0 82 0 82 0 82 0 82 0 82 je N NIN B C N Wires Location of Wires Measuring between AC Output leads J amp K connected to AVR Tae i ifi U2 to X2 UVW connected to rotating rectifier UD DC DC connected to rotating rectifier Mo u 12 Load Leads AC Outputs W2 to 22 4 Open Delta Leads connected to AVR A B C D Multiquip Inc Series Generators Manual No DCA25150CD VOLTAGE SELECTOR SWITCH When inspecting the selector switch visually look for burned spots discoloration smoke damage damaged cables and connectors Also rotate the switch with unit not running and ensure there is proper rotation with no sticking between positions or a locked switch without the ability to turn If any of these faults are found replace the switch BENCH TEST Remove and disconnect all cables EXCEPT wire jumpers amp metal jumpers DO NOT remove jumpers during testing Test the switch using the above contact diagrams Switch must be tested in all three 3 positions a
4. SERVICE MULTIQUIP MANUAL ku ri pouur uen a i DCA 25 150 GENERATORS SCHEMATICS o TESI PROCEDURES o TROUBLESHOOTING DCA 25150 CD CALIFORNIA Proposition 65 Warning Engine exhaust and some of its constituents and some dust created by power sanding sawing grinding driling and other construction activities contains chemicals known to the State of California to cause cancer birth defects and other reproductive harm Some examples of these chemicals are Lead and lead based paint Crystalline silica from bricks Cement and other masonry products Arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals ALWAYS work in a well ventilated area and work with approved safety equipment such as dust mask that are specially designed to filter out microscopic particles Multiquip Inc Series Generators Manual No DCA25150CD Read the operator s manual for safety instructions before you attempt to troubleshoot Use extreme caution when troubleshooting power equipment Never start or run power equipment inside a closed area breathing exhaust fumes can kill Basically a tool is an object that enables you to take advantage of the laws of physics and mechanics in such a way th
5. BATTERY CONTINUED FROM WIRE SIZE PREVIOUS PAGE No 125mm VIEW FROM INSERTING WIRE SIDE _ KEY CONNECTION DIAGRAM Br 82 COLOR CODE SYM WIRE COLOR SYM WIRE COLOR RED V VIOLET 0 ORANGE P PINK C 54 Multiquip Inc Series Generators Manual No DCA25150CD DCA 45SSI GENERATOR WIRING VIEW COLOR CODE B BLACK R RED ____ BR BROWN ___ Y YELLOW ___ V VIOLET JORANGE LP IMNK CN o LE BRUSHLESS AC GENERATOR N E uU Can A ae L 1 designation lead size 1 25 SYMBOL DESIGNATION Ar Fg ExAr ExFq RECTIFIER AVR CT 123 CB1 CB234 CONI 23 CON5 6 RY1 2 VR AS A VS V F CB5 6 OC SW 25 Multiquip Inc Series Generators Manual DCA25150CD DCA 45SSI ENGINE CN 1 CONTROLLER WIZING DIAGRAM CHI ET PANEL LIGHT TO Sw CEAMQE QTER SWITCH MAIN RELAY 5 STARTER CUT RELAY 1 18 gt TO FORD xELAY 1 AEL FS 04 TO THI C L GH TO CH C E MAIN RELAY a m TO Fi iu 38 CHI Vli M TACHO METER TO F5 CNS TOR TO Cae WIRIHG DI
6. TS ETT ETTI VEU M POPE PPPS EAT E Q9 CZ BLA 202222 1 B R SWITCH B T no t ds DIL PRESS ENGINE VITCH SPEED SIM B CIRE NORMALLY EL CTRIF YING 2 FUEL CUT RELAY an GLOW RELAY WIRE SIZE Q i VIEW FROM INSERTING WIRE SIDE KEY CONNECTION DIAGRAM ____ Rr acc R2 C or O J RUN START TO TO 25 Multiquip Inc Series Generators Manual No DCA25150CD DCA 25USI ENGINE Part 2 J FUEL LEAK I DETECTED B ALARM LAMP __ TO CONTROL BOX Ber ree 7 TOCONTROL SWITCH PREHEAT LAMP Eur DIL PRESS ALARM m VATER TEMPALARM ra I IW d 4 G VATER Z N GAUGE Ww GAUGE s 1 S T gt WATER SEPARATOR DIL E WATER E Tos PRESS TEMP UNIT UNIT VATER LEVEL ALARM TU B YiL j FILI 4 20 7r PICKUP _ D x 20 FUEL PUMP FUSE CSA FUSE CA ae e d TERMINAL BOARD 8 J AC1 2 CHARGING 11 PANEL LIGHT OR C PANEL LIGHT SWITCH STARTER 3 60 WE i
7. Zp P m d 43 Multiquip Inc Series Generators Manual No DCA25150CD ACTUATOR The following information is general and not model specific always refer to Actuator manufacture documentation for specifications The Actuator ACT is designed to utilize the principle of variable reluctance It s basically a simple proportional electric solenoid having a sliding armature whose magnetic force is proportional to input coil current Balance between the force of its return spring and magnetic force the armature glides on anti friction bearings proving a hysteresis free linear movement Linear motion is converted to an output shaft rotation by a bell crank ROTARY ACTUATOR WITH ROTARY FUEL PUMP Max Min ever Max Assembly Fuel N Fuel Lus ROTARY ACTUATOR WITH LINEAR FUEL PUMP Max Fuel Lever 44 Multiquip Inc Series Generators Manual No DCA25150CD FUEL RELAY The Fuel Relay FR sometimes called ice cube relay provides the EGC its control DC voltage Without the FH the engine governor system will be completely dead and non operational The FR is mounted to a base with terminals to allow its connections Testing the FR is simple and does not require any special tooling with the exception of a multi meter and proper battery voltage 12V DC or 24V DC depending on the system being used The layout of contacts on the is shown below View of Relay Actual O
8. 1 dk manda Ue CHII AY 9H I Likes OCR vh TO CH gt c yia x prat hin i LE VE WIRING VIEW 1 designation lead size 1 25 ACL DESIGNATION MAIN GENERATOR ARMATURE WINDING Fg MAIN GENERATOR FIELD WINDING Fg TE CN10 B s T AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR RHEOSTAT CHANGE OVER SWTCH AMMETER v5 CHANGE OVWER SWITCH VOLTMETER AEWOLMETER F FREQUENCY METER CB55 CIRCUIT BREAKER CE RECEPTACLE 1254 20A SW SEECTO RSMTCH C C Z O Z RY12 Rel RELAY RECTIFIER SYM WIRE COLOR S B BLACK GREEN LIGHT GREEN VIOLET ___________ 72 Multiquip Inc Series Generators Manual No DCA25150CD DCA 150SSI ENGINE TU GIST ECU 20 CONTROLLER DIAGRAM CAIT CNT Diag m as BE HE wi 25 ree ena NEN a la 711 CHIT CRIE T CHi Tii R 2 fil AC T 5 al Tif euin FUEL CAM TERMINATOR 120 OHM TERMINATOR sequia vae ve c n c bee lw E 2 TERMINAL BOARD 73 Multiquip Inc Series Generators Manual
9. SELECTOR SW 4 d Yace TB2 CONTROLLER WIRINO DIAGRAM 6 WIRING VIEW CAN TERMINATOR 120 OHM TERMINATOR 1 2 3 4 099 aee van CN1 C ACC ACC2 TERMINAL BOARD TB2 B V24IGND CN2 56 Multiquip Inc DCA Series Generators Manual No DCA25150CD DCA 45USI GENERATOR ET We AE i Dui 22 CNI i CUZ 08 7 vun V2 LT __ wav LT CN3 FUSE PF CNA CNIL VR A BRUSHLESS AC GENERATOR WIRING VIEW Notice 1 No designation lead size 1 25 SYMBOL DESIGNATION Re RECTIFIER SYM WHEE COLOR RED 57 Multiquip Inc Series Generators Manual DCA25150CD DCA 45USI ENGINE Part 1 D1 YR TE PREHEAT LAMP tr gt EMERGENCY RELAY ENGINE STOPPER mo 2 VATER UNIT FOR PREHEAT SENERAYHR WIRE SIZE CONNECTOR VIEW FROM INSERTING WIRE SIDE WIRE COLOR B BLACK BLUE BR BROWN GREEN GRAY VIOLET P PINK Multiquip Inc Series Generators Manual No DCA25150CD d DCA 45USI ENGINE Part 2 FUEL FILTER DETECTED WATER LEVEL ALARM LAMP ALARM LAMP TD CONTR Wy W 41 LeveL TT 06 0 SWITCH o 56 dem CONTINUED FROM PREVIOUS PAGE Multiquip Inc Series
10. The first step in generator troubleshooting is to conduct a visual inspection before doing any electrical tests Looking the generator over carefully should expose any environmental factors that might contribute to the problem As you remove the generator control box cover and begin your inspection look for the following 1 Rusted or corroded connections An oxidized connection will prevent the circuit from being completed This applies not only to the major cables externally but also to the electronic control devices internally 2 Carbon flash deposits around the 120V AC and 240V AC receptacles This will indicate whether the device that was plugged into the generator shorted out the receptacle The device may have shorted the generator to ground and caused a carbon flash when the plug prongs touched the receptacle 3 Signs of overheating Discoloration and a burnt smell should be noticeable inside the generator Look to see if the windings turned black The winding insulative coating may vary in color from shades of reddish brown to light brown to dark brown so try to compare the color to that of a new unit 4 Wire insulation that is hardened from heat exposure Fabric and plastic insulation hardens over time due to heat exposure and overheating Long term heating should be more uniform A short excessive heat cycle may have less hardening and burning on the outer perimeter and excessive heat signs toward the center or heat source 5 In
11. Wu D CHIT CNI 77 I L i E A1 H CHIT CHI S gn Y Iu a TES VR WIRING VIEW CNS 0 J 2 3 4 CN8 12 3 Herai Multiquip Inc Series Generators Manual No DCA25150CD DCA 70USI ENGINE _ pmi ds _ INITIAL POTENTIONSTER SETTINGS 10 pangani GAIN REMOTE J U lt 30 RY 7 START CONTACT gt lt D 60 Tat DROOP ZERO z v jt ECU 5 ECU 4 ACT TACHO 5 TACHO G gt 4 10 2 iW WATER OIL gt TEMP PRESS SWITCH SWITCH 4 PREHEAT BUTTON FUEL LEVEL 2 SEALD CABLE 5 SAFETY RELAY BATTERY gt TO CONTROL BO SW 41 COLOR CODE WIRECOLOR __ WIRE COLOR TO TACHO B BLACK R RED ___ PICKUP BLUE LEVEL J BR BROWN Y UNIT G GREEN LIGHTBLUE PANEL GR GRAY LG LIGHT GREEN LIGHT PANEL V VIOLET SWITCH LIGET FUEL LEAK FUEL LEAK DETECTED DETECTED SWITCH ALARM LAMP 63 Multiquip Inc Series Generators Manual No DCA25150CD DCA 85SSJ GENERATOR CN11 CHI Nn 4 7 1 4 SYMBO DESIGNATION Ar MAIN GEMERATOR AR
12. u uu E 71 72 DCA 150SSI Engine 2 22220 2 0 002 222222222022222 73 DCA 150SSJ Generator 2 2 2 2 2 2222 2222 222 2 2 2 74 DOR T9505 T iqi uuu spen 75 DCA 150USJ Generator 4 2 22222 76 Bg EB ENGNG erensia EEEren ENERE EEEE AARE ENEE RANTE E ERN AEE NN ENE E E EEN EENAA 77 GENERATOR GLOSSARY JI 78 49 Multiquip Inc Series Generators Manual No DCA25150CD DCA 25SSI GENERATOR W V 46 46 46 GN CH15 1 J JEDE 1 x Yt DESIGNATION MAIN GENERATOR ARMATURE WINDING Fg GENERATOR FIELD WINDING _____ ExAr EXCITER ARMATURE WINDING ExFg E EXCITER FIELD WINDING he E VOLTAGE REGULATOR RHEOSTAT _ CURRENT TRANSFORMER ________ RE GR GRAY LG LIGHT GREEN _ _ ACVOLTME OSANGE F FREQUENCY METER Pipu TL T M GB CIRCUIT BREAKER ________ 2823 CIRCUIT BREAKER he m CIRCUIT BREAKER C 5 1 No designation lead size 1 26 ICON 1 2 RECEPTACLE RECEPTACLE O
13. 2 v The twist lock 50 amp receptacles only work when the generator is set in the 10 position they DO NOT work when the generator is set in the 30 positions this is normal operation The main circuit breaker will not reset why T v The Over Current Relay OCR has been tripped and needs to be reset before the main breaker can be reset The trips when maximum amperage capacity has been exceeded The temperature alert indicator lamp is on and the engine temperature is normal is this bad v f your generator has a cold weather kit installed you will notice the ALERT LED comes on This is not an alarm indicator The ALERT LED is an indicator for fan operation it will illuminate when fan turns on fan turns on 180 F ahrenheit this is normal operation Does the generator end bearing require servicing v All current model generators have a NO maintenance required bearing Older models had grease packing required as part of maintenance replaced the engine temp sensor but the engine still shuts down with hi temp indicator on why v The engines have two types of triggers one is for gauges sensor and is for engine shut down switch When replacing ensure you are replacing the correct part SENSORS have a resistance reading depending on temperature SWITCHES either open or close to ground depending on temperature This rule also applies to the oil pressure sensor and switch 13 M
14. ARM AVE Veg V 37 ER 38 39 Electronic Governor System 2 2 2 2 2202020 0 002000000000000000 40 a 41 EGC GC AMG A TT 42 Magnete PICK UB UonO OO O OUO 43 ciu MP RE 44 POOR 45 Crank Relay Glow Plug Relay 222 204 1 1 2 4 2 46 eed _ 47 VV O ie 48 WIRING SCHEMATICS ij A O9O OX 49 GENERATOR GLOSSARY lj 78 36 Multiquip Inc Series Generators Manual No DCA25150CD TROUBLESHOOTING lg Ya For more on engines see engine manufactures manual or you may contact one of our Technical Support SYMPTOM Engine does not start Engine revolution is not smooth Engine cranks but does not start Engine Hunting Engine start and shuts down after a few seconds Excessive black smoke Excessive white smoke Engine overheating POSSIBLE PROBLEM No fuel o Air in the system o Water in the fuel system o ECU o defective Magnetic pick up o defective adjustm
15. DCA 150SSV POSITION Position 2 480 277 Position 4 3 240 139 Position 6 1 240 120 1 DCA 25USI DCA 45USI DCA 70USI DCA 85USI DCA 125USJ DCA 150USJ O O O O O O See page 20 for external jumper locations 19 Multiquip Inc Series Generators Manual No DCA25150CD VOLTAGE SELECTOR SWITCH Metal Jumper Connections o DCA 25SSI DCA 150SSV o DCA 25USI o DCA 70USI DCA 45SSI o DCA 150USJ DCA 45USI o DCA 85USJ o DCA 70SSI DCA 100SSV Wire Jumper Connections DCA 25SSl o DCA 70SSI DCA 100SSV DCA 150SSV DCA 70USI 15 47 28 25 DCA 85USJ DCA 25USI DCA 125USJ DCA 45USI 20 Multiquip Inc Series Generators gt Manual No DCA25150CD OPEN DELTA RHEOSTAT DATA For best results when measuring use accurate tools that are properly calibrated OPEN DELTA The Open Delta contacts can be used for troubleshooting Disconnect the CN1 connector on the AVR and you can measure the resistance of the Open Delta windings at the connector Connector Measuring Between Wires Value el A amp B 50 90 AC voltage GIN ss AS L 50 90 AC voltage elm 50 90 AC voltage co BR a ane ee 10 AC voltage RHEOSTAT Symptom AC voltage output is half the normal
16. 800 421 1244 POSSIBLE PROBLEM AVR fuse defective AC Voltmeter check output w multi meter Breaker tripped defective Exciter Field Loose Wiring check and repair Rotating Rectifier defective OCR REFERENCE PAGE Breaker Exciter Field AVR coarse adjustment Engine Speed o 1800 RPM Rheostat fine adjustment Surge Protector o defective Main Field Coil o check and repair Hheostat Surge Protector Gen Set Data AVR o defective Engine Speed o 1800 RPM Loose Wiring o check and repair AVR o Engine Speed o 1800 RPM EGC o adjustment Hheostat o Voltage Selector Switch o Voltage Selector Switch o Replace it Voltage Selector Switch o Main Armature o Voltage Selector Switch Main Armature Breaker o Load o over current OCR o Short Circuit o check and repair PREVENTION Proper equipment maintenance will prevent the occurrence of most problems As in all troubleshooting situations when a problem does occur an understanding of the problem and a logical process of elimination are required to identify the root cause 12 Multiquip Inc Series Generators Manual No DCA25150CD FREQUENTLY ASKED QUESTIONS Below is list of common questions received the technical support 4 service department Why are the twist lock 50 amp receptacles not working not putting out power voltage
17. DCA25150CD DCA 150SSJ GENERATOR CH11 CAE NNECTER ARRANGEMENT WIRING VIEW SYM DESIGNATION Main Generator Armature Winding Main Generator Field Winding SIEI Exciter Armature Winding Re RR Re Rectifier _____________ WIRE SIZE T 3 1 100 KIV or 100 Change Over Switch Voltmeter MLEC 100 Voltmeter amp KIV or F Frequency Meter CB Circuit Breaker Over Current Selector Switch Relay Unit 74 Multiquip Inc Series Generators Manual No DCA25150CD DCA 150SSJ ENGINE COLOR CODE EIL WIRE COLOR WIRE COLOR B BLACK R IRED _ ____ WTWHIE ___ GREEN LIGHT BLUE O ORANGE JOHN DEERE Boz e S 77 En 3 CAN DIAGNOSTIC JOHN DEERE CONNECTOR LEVEL 12 ECU CONNECTOR AIR HEATER CONNECTOR CH10 FUEL LEVEL FUEL LEVEL UNIT UNIT WIRING SIDE WIRING SIDE LAMP LAMP WIRING SIDE 79 Multiquip Inc Series Generators gt Manual DCA25150CD 76 DCA 150USJ GENERATOR M o nier CHI eg _ TQ nz pact TWIRING VIEW 1 degignalian lead 1 25 DESISHATIDN GENERATOR ARMATURE WINDING Bar ARMATURE Ew EXCITER FIELD ANDARE REGTFER uum
18. Degrading is the normal failure mode MOVs that fail shorted are so small as to violate the MOV s Absolute Maximum Ratings MOVs usually are thermal fused or otherwise protected to avoid short circuits and other fire hazards 33 Multiquip Inc DCA Series Generators Manual No DCA25150CD LOAD BANKING The purpose of load banking is to imitate the actual load that a power source generator will see during application Load banking is a technique used to determine maximum stand by power and system performance A load bank serves the power source and uses its energy output to test and protect that source This method of power generation is beneficial because a real load is often unpredictable and random in value the load applied from a load bank provides a controllable load with controls that allows an operator to incrementally step and vary the load Load banking is a critical requirement to ensure the equipment will perform as expected when pressed into service This applies to the name stand by emergency power or back up generator It is also recommended as part of maintenance to avoid wet stacking Wet stacking is common when diesel engines operate for extended periods of time with little or no load applications Wet stacking is best described as unburned fuel that accumulates in the exhaust system A sign of wet stacking is black seepage around the exhaust connections or black exhaust from the stack after warm up The Nationa
19. SPEED POT SPEED sAllh 2 BV AV ILS rx 2 3 4 5 el 8 e E 4 ROLE OUT 2 A gt OUTPUT ACT INPUT CONTROL INPUT MPU VOLTAGE VOLTAGE The following voltages should be present on the EGC while cranking the engine PINS 1 2 Input Control Voltage from Fuel Relay 12 volt system 8V to 12V DC 1 2 Input Control Voltage from Fuel Relay 24 volt system 21V to 24V DC 4 5 Output Actuator Voltage to Actuator 4V DC 10 11 Input MPU Voltage from Magnetic Pick Up 2 5V AC Multiquip Inc Series Generators Manual No DCA25150CD EGC CALIBRATION The following information is general and not model specific always refer to EGC manufacture documentation for calibration specifications Prior to suspecting the EGC as the fault service the engine to ensure fuel filter and air cleaner is not the cause for unstable engine speed or response As the EGC and governor system ages it is possible for the EGC to become out of calibration TOOLS NEEDED A fine tip standard screw driver 1 Observe that potentiometer settings are adjustable from zero to 100 2 Set the small dip switch S1 to the off posostion
20. actuators electronic fuel injector etc While the ECM does include safety shutdowns its main purpose is regulating fuel to meet emission standards The ECM is preprogrammed with proprietary info by the engine manufacture CONTROL SWITCH FUNCTION Control Switch AUTO position When switch is placed in this position the ECU is connected to the auto start contacts of the unit The auto start contacts are designed to connect to an automatic transfer switch ATS which will control the automatic start stop of the engine through the ECU AUTO MANUAL OFF RESET MANUAL position When switch is placed in this position the engine will start immediately LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OFF RESET position When switch is placed in this position the engine will s not start or run these functions are canceled ENGINE RUNNING MOOOOO 20D01Q LED DEFINITIONS LOW OIL PRESSURE llluminates when engine oil pressure has fallen below 15 psi 103 kPa The oil pressure is detected by the oil pressure switch and will signal ECU to shut down the engine Do not confuse this switch with the oil pressure sensor HIGH COOLANT TEMPERATURE llluminates when engine temperature has exceeded 203 F 110 C The water temperature is detected by the water temperature switch and will signal ECU to shut down the engine Do not confuse this switch with the water temperature unit OVERCRANK SHUTDOWN llluminates when engine starting ha
21. armature Most current generator designs including MQ utilize a rotating field type generator The magnetic field rotates inside the main armature The frequency of the generated voltage is dependent on the number of field poles and the speed at which the generator is operated Frequency measured in Hertz Hz is the number of complete cycles per second in alternating current direction As current flows through the armature there is some amount of resistance and inductive reactance The combination of these make up what is known as the Internal Resistance When the load current flows a voltage drop is developed When a Direct Current DC voltage is applied to the field windings of a DC generator current flows through the windings and sets up a steady magnetic field This is called Field Excitation An exciter is part of the generator package supplying direct current to the alternator field windings to magnetize the rotating poles The exciter output may be controlled by a voltage regulator Types of exciters include brush type with rotating commutator static excitation or brush less generator and exciter A regulator is an important option to consider if there is frequency or voltage sensitive equipment such as computers 2 Multiquip Inc Series Generators Manual No DCA25150CD 7 HEAT RISE What is heat rise Generator ends are rated by Heat Rise at a given ambient temperature and load When current is put through a c
22. 1 tS 3 2 1 12 3 4 LAG CNS 2 3 1 2 M SYM WIRE COLOR R RED WHITE CB1 Fa AVR VR CT 1 23 AS A VS V F JORANGE __ LIII 66 Multiquip Inc Series Generators Manual No DCA25150CD CAN DIAGNOSTIC CONNECTOR DCA 85USJ ENGINE 16 ECU LEVEL 120 OHM TERMINATOR CNS LAMP D E SO E fe E eva pn LAMP WRING rr CONNECTOR SIDE eR CHE HE E 32 1 LEIE CAN TERMINATOR CN AUX POWER LAMP LAMP SIDE AIR HEATER CONNECTOR Cog CONNECTOR c z gt e Multiquip Inc Series Generators Manual No DCA25150CD 67 DCA 125SSI GENERATOR COLOR CODE wmECOLOR WRE COLOR JELACK R RED L w wurE _ BROWN Y vELLOW G GREEN JUGHTRUE V O JORANGE LP Pink _____ CNB AE M 1 G Tk Hiele 123 12 ens UIVIW m a 2 1 113 61412 4 2 D 13 1 2 3 4 42 3 CN10 __ CONNECTOR ARRANGEMENT WIRING VIEW 3 2 1 VR BRUSHLESS AC GENERATOR SYMBOL DESIGNATION A MAN GENERATOR ARMATURE W
23. 120 240 Trip Rating 30 10 Set Point 19 DCA 25 60 Amps 30 Amps 55 6 Amps 27 8 Amps 60 Amps 30 Amps 45 108 Amps 54 Amps 100 Amps 50 Amps 110 Amps 54 Amps 22 Multiquip Inc Series Generators Manual No DCA25150CD OVER CURRENT RELAY The Over Current Relay is used on generators and is mounted snaps onto a base The base is mounted to the machine In the event of an overload both the circuit breaker and the OCR may trip If the circuit breaker can not be reset the reset button on the OCR must be pressed The OCR is located behind the main control panel RESETTING The reset button is located on top of the OCR and is blue in color To reset press the button it does not stay down when pressed it is spring loaded and will return to the up position TESTING 1 Press the reset button 2 SLIDE the manual trip lever this trips the OCR 3 When tripped the contacts 95 96 opens the contacts 97 98 closes 4 Checking continuity between contacts while tripping the OCR will verify operation NOTE Activating the test button while the unit is running will shunt trip the main circuit breaker Only perform with no load on the generator Trip Lever Multiquip Inc Series Generators Manual No DCA25150CD OVER CURRENT RELAY FACTORY SETTINGS Test Trip Lever RO Reset and Turn Off R Only Reset The reset button dial is p
24. 3 Set the small dip switch S2 This switch selects the point at which actuator coil current level causes the intergrator limit to to be actuated This level is nominally 6 3 amperes for OFF position and 7 3 amperes for ON position 4 INITIAL POTENTIOMETERS SETTINGS GAIN 20 20 D 30 Droop Zero 5 Start engine no load 6 Adjust SPEED pot as necessary to obtain specified r p m 7 Adjust GAIN pot clockwise until the engine speed begins to oscillate hunt If engine remains stable at 100 GAIN physically disrupt the actuator linkage by hand With engine hunting turn the GAIN pot counterclockwise until engine speed becomes stable 8 Repeat step 7 for the D pot setting 9 Repeat step 7 for the pot setting After setting pots it may be necessary to re adjust engine speed With the engine is operating at proper speed 1800 r p m turn the EGC off bring to idle if equipped When the engine speed slows down to approximately half of rated speed turn the EGC back on observe the overshoot If there is a small hunt at steady state slightly turn the pot counterclockwise until stable some cases 2 to 5 Hz overshoot may be acceptable 42 Multiquip Inc Series Generators Manual No DCA25150CD MAGNETIC PICK UP The Magnetic Pick Up MPU is an electro magnetic sensor When a tooth from the engine flyw
25. Belts and pulleys for cracks and wear adjust or repair as needed Governor and injection pump for leaks and proper operation Turbo charger for proper clearance and free movement as required Fuel tank for contaminants and condensation Fuel hoses piping and connections for chafing and restrictions Line trap drain as needed Hangers anchors and supports for exhaust system Exhaust for cracks and leaks Battery charging system including alternator and external charger if applicable optional Battery terminals clean and apply anti corrosion protectant as needed Cable ends wire connectors and terminals tighten and repair as needed Generator end for signs of heat discoloration Panel controls and breakers for signs of heat discoloration and that they are securely mounted All gauges for proper operation during test run Frequency and voltage adjust as necessary Complete start up and shut down sequence Multiquip Inc Series Generators Manual No DCA25150CD COMPONENT IDENTIFICATION Components of the generator are expressed in either mechanical or electrical terms Although distinctly separate these two sets of terminology are frequently used interchangeably To clarify confusion among conversation below is the correct terminology MECHANICAL Rotor The rotating part of the generator Stator The stationary part of the generator ELECTRICAL Exciter Field Produces a magnetic field tha
26. Depressing the reset button should restart the equipment This is an adequate test for most applications To measure the actual trip current of a GFCI requires a GFCI tester The tester allows you to read the actual GFCI trip current on a meter identifying the GFCI s that do not operate within the required four to six milliamp range One test that should not be performed on is a high load test The GFCI contains small electronic parts that are damaged if high voltages are applied to them DO NOT test any GFCI on a HI POT dialectic or Doyle type tester 22 Multiquip Inc Series Generators Manual No DCA25150CD CB SHORT CIRCUIT SURGE PROTECTOR A circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit Its basic function is to detect a fault condition and by interrupting continuity to immediately discontinue electrical flow Unlike a fuse which operates once and then has to be replaced a circuit breaker can be reset either manually or automatically to resume normal operation NOTE always place the main circuit breaker in the OFF position prior to starting the engine SHORT CIRCUITS A short circuit sometimes abbreviated to short or s c in an electrical circuit is one that allows a current to travel along a different path from the one originally intended The electrical opposite of a short circuit is an op
27. Generators Manual No DCA25150CD FUEL FILTER WATER LEVEL SWITCH BDX 59 60 DCA 70SSI GENERATOR WIRING VIEW 1 2 3 4 CN5 N22 1 2 3 4 CNT CNB ne TO AW L gr BRUSHLESS AC GENERATOR LJ 3 2 1 12 3 Notice 1 No designation lead size 1 25 SYMBOL DESIGNATION MAIN GENERATOR ARMATURE WINDING MAIN GENERATOR FIELD WINDING Re RECTIFIER V ACVOLTMETER O O 1 5 5 CON123 RECEPTACLE 250V 50A Re1 RELAYRECTIFIER Multiquip Inc Series Generators Manual No DCA25150CD VR DCA 70SSI ENGINE LND OL S o SINJ 3IN2 5 382 ATITA LOD E zi 2 lt rm d i g d A e MAIN RELAY 5 TO STARTER CUT RELAY 1 mo 681 TO FORD POMP RELAY 1 at T ago 5 3s wmm 61 Multiquip Inc DCA Series Generators Manual No DCA25150CD DCA 70USI GENERATOR TO Fan SE 20 TL 75 DESIGNATION Re RECTIFIER AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR RHEOSTAT CT 123 CHANGE OVER SWITCH AMMETER AC AMMETER CHANGE OVER SWITCH VOLTMETER AC VOLTMETER F FREQUENCY METER CIRCUIT BREAKER 82 34 6 CON123 RECEPTACLE 62 BRUSHLESS AC GENERATOR CN _ _ CB W
28. INDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING EXCITER FIELD WINDING Re RECTIFIER AVR AUTOMATIC VOLTAGE REGULATOR VOLTAGE REGULATOR RHEOSTAT CURRENT TRANSFORMER AS CHANGE OVER SWITCH AMMETER AC AMMETER VS CHANGE OVER SWITCH VOLTMETER M FREQUENCY METER oc OVER CURRENT RELAY 8124455 CIRCUIT BREAKER RECEPTACLE SELECTOR SWITCH RY1 2 RELAY Multiquip Inc Series Generators Manual No DCA25150CD DCA 125SSI ENGINE 08 JVNIW38L 8 14 LE TI 2 4 Se tis 5 21 mE M Lm cT mam 1 7 c ma 9 4 tk il Dee vr 3k3D eK h 19 Er tr 83 HE D S mr e um mu T BI VR Ji a cunt SLT Ema ei LL qs Ld WB ALFA is Care 13431 m 71009 HET aVTSE a als it 44 aD 1 0 189 04 N sl ne 31 imn m um cL o oen _ T az i 3 33 T boi 7 I HE T PL i k ga 5 TE y 4 3 5 3 Hi F i NN 19 H2 LAS OL 69 Multi
29. L DCA25USI DCA45USI DCA70USI DCA85USJ DCA125USI 15005 pment NR Dre p 4LE2 WISE 4JJ1T pou 4JJ1X BJ 4HK1X 6068HF285 Power 000 Power 33 3 1 79 9 126 EE 17 2179 cc 2999 cc 2999 cc 4500 cc 5193 cc Engine RPM 1800 RPM Fuel Capacity 41 7 gal 79 2 gal 103 gal 126 gal 169 gal O IISISII II 214 gal Fuel Consumption 6800 cc full load gph 3 4 load gph 1 2 load gph 1 4 load gph Coolant Capacity 1 7 gal 3 15 gal 3 57 gal 4 76 gal 5 2 gal oe 5 8 gal Eng Oil Capacity 2 25 gal 3 83 gal 3 96 gal 3 88 gal 6 1 8 19gal Eng Oil Type u Delo 400 LE 15W40 Sound Level dB Full load at 23 feet 59 dB 58 dB 60 dB 63 dB 65 dB MM 63 dB Wet Weight Ibs 2132 lbs 3499 Ibs 4553 bs 6048 Ibs 7012 lbs o M 8223 lbs 11 Multiquip Inc Series Generators Manual No DCA25150CD SYMPTOM No Voltage Output Low Voltage Output High Voltage Output Output Voltage Hunting Output Voltage is not Adjustable Voltage is Higher on One Output Leg Voltage Selector Switch Hard or Impossible to Turn Amperage Output with no Load Attached Main Circuit Breaker Trips TROUBLESHOOTING The following troubleshooting chart was made from common calls received 4 in the Technical Support department you don t see your situation below contact one of our Technical Support coordinators at
30. MATURE WINDING MAIN GENERATOR FIELD WINDING EXCITER ARMATURE CONNECTER ARRANGEMENT L WIRING VIE ExFg EXCITER MIELO VANDING M RECTIFIER AUTOMATIC 1 designation lead size 125 9 0 Al 1123 LAS AC VOLTMETER FREQUENCY METER ORCUTBREAKER __ ______ 6 GRCLIT BREAKER KANT 3 RECEPTACLE QC OVER CURRENT RELAY G O SELECTOR SWITCH 64 Multiquip Inc DCA Series Generators Manual No DCA25150CD DCA 85SSJ ENGINE REMOTE H START CONTACT DYNTIOTSA INTAKE HEATER TEMP PRESS HEATER UNIT 5 UNIT i i R n D dp Cd e ari LIGHT SWITCH SEALED C CABLE MARING VIEW 65 Multiquip Inc DCA Series Generators Manual No DCA25150CD DCA 85USJ GENERATOR dum gt 8 n CNIT CNI2 TO 055 TO THAMIBAL ge BRUSHLESS AC GENERATOR WIRING VIEW 12 3 4 CN6 Notice mm 1 No designation lead size 1 25 SYMBOL DESIGNATION MAIN GENERATOR ARMATURE WINDING Fg MAIN GENERATOR FIELD WINDING EXCITER ARMATURE WINDING _______ Re AR _ VR CT123 AS CHANGE OVER SWTCHAMMETER _____________ EE BL E a CBI 7 OBBE CN8 4
31. Temperature Hise at full load 1 0 service factor motor C 60 80 105 125 Allowable Temperature Rise 1 15 service factor motor C 70 90 115 1 Allowable temperature rises are based upon a reference ambient temperature of 40 C Operation temperature is reference temperature allowable temperature rise allowance for hot spot winding Example Temperature Tolerance Class F 40 105 C 10 C 155 In general motor should not operate with temperatures above the maximum Each 70 rise above the rating may reduce the motor lifetime by one half Temperature Tolerance Class B is the most common insulation class used on most 60 cycle US motors Temperature Tolerance Class F is the most common for international and 50 cycle motors Multiquip Inc Series Generators Manual No DCA25150CD 29 MEG OHM METER Good Insulation Every generator winding motor and extension cord have electric wire that is covered with some form of insulation Electrical wire is normally copper and it is a good conductor of the electric current that powers motors The wires insulation must be the opposite of a conductor it should resist the current and keep it in its path along the conductor The purpose of the insulation around a conductor is similar to that of pipe carrying water Pressure on water from a pump causes flow along the pipe If the pipe was to spring a leak you d waste water and lose some w
32. The feed pump strainer is located at the water separator in the banjo bolt as shown in the illustration below Inspecting and cleaning strainer is considered part of maintenance If strainer becomes clogged remove from banjo bolt and clean in diesel fuel or replace if cannot be cleaned NOTE When replacing strainer always replace banjo bolt washer gasket 4 Multiquip Inc Series Generators Manual No DCA25150CD 7 STACKING Diesel engines that are operated for extended periods with light or no load applied will typically become wet stacked Unless a diesel engine is operated with a sufficient load it will not reach its optimum running temperature When the engine is not running at its optimum temperature unburned fuel can build up in the exhaust system This can lead to fouled fuel injectors engine valves and exhaust systems including turbo chargers and reduce overall performance For a diesel engine to operate at peak efficiency it must be able to provide fuel and air in the proper ratio and at a high enough engine temperature for the engine to completely burn all of the fuel Wet stacking does not always cause permanent damage and can be alleviated if additional load is applied to relieve the condition Usually the first sign of wet stacking is wetness in the exhaust stack that looks like oil thus the term wet stacking Continued operation under wet stacking conditions can cause diminished e
33. VER CURRENT RELAY SELECTORSMATICH ______ IRYTZIREAYUMT ____________ RJ RESISTOR C G 50 Multiquip Inc DCA Series Generators Manual No DCA25150CD DCA 25SSI ENGINE i ENGINE STOPPER B SAGE GAUGE FUSE 10A a Cif a PRESS CHARGING TOCONTROLBOX UNIT L PRESS bs F 5 pee PREHEAT GLOW LAMP PLUG 02 LAN E uw 9 PELLE PRESS ee I G TCH af SMTH BATTER L era LE COLOR CODE 60 gm _ ccn mr g laac GREEN GR LC LICHT SRE viene o CE en lil 51 Multiquip Inc Series Generators Manual No DCA25150CD DCA 25USI GENERATOR DG al ee oda ILE 1 d DE al aT a r4 WIRING VIEW CN1 Notice 1 No designation lead size 1 25 SYMBOL DESIGNATION MAIN GENERATOR ARMATURE WINDING Fg MAIN GENERATOR FIELD WINDING ___ AUTOMATIC VOLTAGE REGULATOR CHANGE OVER SWITCH AMMETER A ____________ RECEPTACLE 250 50A RECEPTACLE 125V 20AX2 12 3 4 CN2 L k Pipa 12 3 1 2 CN4 52 Multiquip Inc Series Generators Manual No DCA25150CD DCA 25USI ENGINE Part 1 DIODE 2 CN7
34. anufacture engine controller Terminal 5 This is connected to water temp switch or engine manufacture engine controller 10 BATTERY FUSE START CONTACTS OPE See C MANUAL START RELAY 39 Multiquip Inc Series Generators Manual No DCA25150CD ELECTRONIC GOVERNOR SYSTEM The Electronic Governor System consist of four components Electronic Governor Controller EGC Magnetic Pick Up MPU Actuator ACT Fuel Relay FH In order for the system to operate properly it is necessary for all the above mentioned components to operate in conjunction with each other Should one fail the entire governing system is affected Electronic Governor System Operation The Electronic Governor System controls the engine governor stroke and stability during starting variable load conditions and stopping The Electronic Governor Controller EGC is able to perform this function by receiving a signal from the Magnetic Pick Up MPU located on the outer flywheel bell housing This MPU sends an AC voltage signal to the EGC which will vary depending on load conditions affecting the engine The EGC will compare the MPU input signal to preset set points and will react accordingly by sending a variable DC voltage signal to the Actuator ACT to keep the engine within manually preset engine r p m parameters The EGC receives DC voltage from the Fuel Relay FR which is connecte
35. are even as bad as 300 degrees One outstanding feature of all MQ WhisperWatt engine generator packages is the patented Denyo open delta design alternator Of all the hardware assembled to form a complete generator package the AC alternator is probably the single most important albeit misunderstood component in the assembly The MQ Power alternator is built like no other on the market This is why MQ Power WhisperWatt generators offer industry leading motor starting with minimum voltage dips and quicker recoveries The AC alternator or power generator is the device bolted to the back of the engine bell housing the rotates at engine speed to produce AC voltage and current The alternator system is basically comprised of four component systems that work together to produce AC power These components consist of the fixed mount stator or armature coils the rotating field or rotor the exciter and the automatic voltage regulator AVR What makes MQ better MQ s Open Delta Coil Excitation System is design is a separately excited generator That is the AC voltage regulator is powered by a separate excitation winding which is placed on the stator core together with the armature windings The excitation winding provides dedicated input power to the automatic voltage regulator which controls the AC voltage output The voltage regulator increases or decreases exciter current as it senses changes in output voltage and frequency based on changes in loa
36. at you can seriously injure yourself This service manual is intended to provide information and procedures to safely maintain repair and give a basic understanding of service techniques for the DCA series generators You must be familiar with the operations of the DCA series generator before attempting to troubleshoot or make repairs Basic operating and maintenance procedures are described in the operation and parts manual supplied with the generator Use the supplied manual to order replacement parts If you are missing the operation and parts manual please contact Multiquip Inc to order a replacement or you may visit our website at www multiquip com For your safety and the safety of others carefully read understand and observe all instruction described in this manual Safety precautions should be followed at all times when servicing equipment Consult operations manual for more safety information 55 D THE INFORMATION CONTAINED IN THIS MANUAL IS BASED DCA SERIES GENERATORS MANUFACTURED UP TO THE TIME OF PUBLICATION MULTIQUIP INC RESERVES THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION WITHOUT NOTICE Multiquip Inc DCA Series Generators Manual No DCA25150CD 5 Generator Inspection eme eme se senem ens 5 6 Miaintenance InSpeclornrEISL sssus ew di novae xad 7 Component u uuu _ gt 8 10 Generator Specific
37. ater pressure With electricity voltage is like the pump pressure causing current to move along the copper wire As with the flow of water in a pipe there is resistance to flow of current but it is much less along the conductor than through its insulation It should be noted that no insulation is perfect meaning has infinite resistance so some electricity does flow along the insulation or even through it to ground The current passing through the insulation may only be a millionth of an ampere one microampere but it is the basis of insulation testing A higher voltage tends to cause more current leakage through the insulation This current leakage would become a problem if the insulation has deteriorated All this leads us to determine what is good insulation Under normal conditions good means a relatively high resistance to current Or it can also be stated that a good insulation has the ability to keep a high resistance A suitable way of measuring resistance can tell us how good the insulation is Also if regular insulation measurements are made you can track trends towards its deterioration INSULATION ELECTRICAL N LEAK COPPER WIRE VOLTAGE FF pu CURRENT RESISTANCE Ib Causes of Bad Insulation 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 ca
38. ations e Rae sauce AU E und 11 ae LM EEEN doit 12 Frequently Asked Questions iii 13 GENERATOR COMPONENT OVERVIEW 15 M HH 14 Rotating Rectifier Surge Protector a EEA a 15 Automatic Vollade uncus uei tend exe cu bein io ard Ha i RD e Ra en a dci ge Rd 16 Gen Set Data 17 Voltage Selector Switch 2 9 2 18 20 Open Delta Hhieostat Dala uuu u u uuu 21 Main Circuit Breaker Amperage Rating Chart e 22 eeiam 23 24 EDUCATION jj HQ 25 ENGINE CONTROLS gt CNP SSS OT TT SS E SSS sa 36 EE e 49 GENERATOR GLOSSARY lager qe EA 78 4 Multiquip Inc Series Generators Manual No DCA25150CD GENERATOR INSPECTION Before you attempt to diagnose a generator problem check the engine to make sure that it has been serviced and is operating correctly Perform proper maintenance and tune up procedures before evaluating the generator Ensure the engine remains at a stable rpm when electrical loads are applied When servicing generators having an accurate AC DC multi meter is a must
39. ause dissimilar metals are in contact a galvanic cell is set up that may result in corrosion when moisture is present oolder joints that have cracked or broken loose This condition occurs much less frequently than crimped connections and basically results from poor quality workmanship Worn insulation allowing wires to short Insulation deteriorates from physical contact when wires rub together due to vibrations Eventually the internal wires can short to each other or to ground Crossed wires Mistakes happen particularly if the unit comes from another shop with unresolved issues or you receive it partially disassembled Fuses circuit breakers and ground fault interrupts Check for physical damage to housing buttons and levers Multiquip Inc Series Generators Manual No DCA25150CD MAINTENANCE INSPECTION LIST The following is a compiled list of duties performed by service technicians most of the tasks should be done during normal scheduled maintenance INSPECT Air cleaner for restrictions and contaminants replace if necessary Coolant concentration and level adjust to 50 50 mix or as recommended by engine manufacture Cooling system hoses for cracks and distortions tighten clamps or repair as needed Radiator for restrictions and corrosion Block heater for leaks and is functioning properly this is an accessary on most units For coolant fuel and oil leaks tighten connections or repair as needed
40. d thus increasing or decreasing the generator field strength The main benefit of having a separate exciter winding is the fact that the voltage input power supplied to the voltage regulator is un affected by the load induce fluxuations specifically non linear loads And during motor starting operations the Denyo automatic voltage regulator switches the configuration of the internal open delta connections to provide virtually unlimited excitation voltage resulting in superior motor starting ability better voltage response and voltage transient conditions The system is so unique in design and benefits it carries U S patent 4268778 Other manufacturers systems consist of a self excited generator That means the input power supplied to the regulator is tapped from the generator output The effectiveness of the voltage regulator in managing this event is somewhat decreased when the available AC voltage signal provided to the regulator is derived from the same AC voltage circuit being fed to the load IF there are load induced fluxuations precise voltage regulation is compromised Other manufacturers typically offer to provide their alternator with a PMG or permanent magnet generator This is an extra cost bolt on alternator modification that does provide the voltage regulator with separately derived voltage input power However it is not as effective as MQ And it is extra cost The combination of the open delta excitation system and automat
41. d to the ammeter and the Relay Unit RY1 This relay disconnects the V leg at the AVR and AC volt meter when generator is operated in the 120 240 single phase setting Twist Lock Receptacles 120 240V 50 amp twist lock receptacles these can only be used when the selector switch is placed in the single phase 120 240 position and the main circuit breaker closed CS 6369 10 Multiquip Inc Series Generators Manual No DCA25150CD GENERATOR SPECIFICATIONS MODEL DCA25SSI DcAasss DCA70SSI DCA85SSJ DCA125SSI DCA150SSI DCA150SSJ Engine Model Isuzu Isuzu Isuzu John Deere Isuzu Isuzu John Deere 41 2 BU 4JJ1T 4JJ1X BEC CUN Um 4HK1X 6HK1X Power 00 Power w 3 64 99 9 8 0 O a a Fuel Consumption full load gph 3 A load gph 1 2 load gph 1 4 load gph Coolant Capacity 1 74 gal 2 96 gal 3 09 3 91 gal 5 33 gal 7 1 gal 4 6 gal Eng Capacity 2 25 gal 3 83 gal 3 96 386ga 3 88 gal 6 1 gal 10 6 gal 8 19 gal Eng Oil Type CHEVRON Delo 400 LE 15W40 Interim Tier 4 Tier 4 Interim 4 Tier 4 Tiers Tiers Sound Level dB Full load at 23 feet 63 dB 65 dB 68 dB 68 dB 68 dB 69 dB 68 dB Wet Weight Ibs 1541 lbs 2464 Ibs 3035 Ibs 4107 lbs 5182 lbs 6417 lbs 5198 lbs MODE
42. d directly to the accessory circuit of the DC wiring harness typically controlled by terminal 15 on the ECU auto start controller NOTE EGC is a dual voltage controller and can operate in either a 12 V DC or 24 V DC system Units produced prior to Tier 2 EPA standards may also have an idle function controlled by the EGC which allows the operator to warm up the engine at an idle speed Units produced within the Tier 2 limits will not have this function An EGC is normally not found in Tier 3 engines as the ECM controller controls this speed and fuel rate functions 40 Multiquip Inc Series Generators Manual No DCA25150CD EGC INSPECTION IMORTANT During inspection malfunctions may lead to other components and may require technicians to perform a complete analysis of entire system Understanding the correct operation of the electronic governor system is essential when testing diagnosing and performing adjustments to the EGC TOOLS NEEDED An accurate AC DC Multi Meter Typical faults symptoms There are three test points for the EGC cranks but will not start Input Control Voltage DC Unit starts but only runs at one speed Output Voltage to ACT DC K Input Voltage from MPU AC NOTE governor controller displayed is for educational purpose only actual controller may vary depending on generator model SI OFF DIESEL SI DN GAS S2 0FF 8000 ACT 52 0 8200 8400 ACT REMOTE
43. e is GRAY 3 Wire is YELLOW DO adjust the other two pots these are factory pre set 16 Multiquip Inc Series Generators Manual No DCA25150CD GEN SET DATA The chart below can be used as a reference guide for measuring resistance on the Gen Set CROSS REFERENCE CHART Generator Model DCA2SSSA 0 155 0 16 0124 4 _ 0 124 a o 4 4 DCA 0SSAL gt 01074 Gen Set Model Main J AC Outputs Dc uvw Je K 2 047 0 148 n 0 082 0 21 I e Co je 0 143 DCA 45SSIU DB 0501 0 082 o21 15 DCA 45SSIU2 SSJU3 DB 0501 0 082 0 21 DCA 45SSIU4 DH 0480 0 099 0 137 DCA 60SSAI 0042 0 143 DCA 60SSI 5512 DB 0661 DCA 70SSJU SSJU2 DB 0831 0 032 DCA 70USI2 DH 0750 0 046 DCA 45USI DB 0501 0 082 0 21 DCA 45USI2 DH 0480 0 099 0137 188 DCA 70SSI SSIU DB 0831 0 032 12 1 14 5 15 5 18 8 2 5 0 048 0 21 1 0 08 0 137 1 79 0 137 1 79 DCA 85USJ USJ2 DB 1001 0 021 0 08 DCA 85SSK SSM DB 1001 0 021 0 08 0 015 0 08 0 015 0 08 0 015 0 08 0 015 0 08 0 01 0 08 0 01 0 08 0 01 0 08 0 011 0 08 0 011 0 08 Name of Part DCA 70SSIU2 DH 0750 0 046 DCA 85SSJU SSJU2 DB 1001 0 021 0 08 DCA 100SSJU DB 1101 0 022 0 08 2 4 4 4 8 2 2 4 e EXE NN NEN EN Gss NEN o NM NEN NEN 0 032
44. e to the many different options available on the DCA series generators optional schematics are not included in this manual For more information on DCA generator schematics contact the Service Technical Support Department DCA 25SS Generator 4 2 2 2 2 02 020222 2202 2 22 2 2 22 2 0 50 Bee MEME TETTE TTE 51 ASA ____ 52 DOASZBUSIL Engine Parti uu u amic danseuse m RS Ov anc 53 DER 25US Endine PAZ 54 DCAA4AS5SSI AIO 55 SSI ENON 56 DOCA d5US 67 7 21 57 DCA 45USI Engine 1 58 DCAAS5USI Engine gt UP wei 59 OBHBISIOI Edd aU SEM MER MA Ud MIRA S Qaya ee 60 benc MEM TM 61 DCA 70US Generator 62 Be TOUS ENNO Emm 63 DCA 85SSJ dux De mia the ide 64 6 adu MER RU 65 DOASSUSJ Generator _ uu us RI xt OO ad 66 DCA 85USJ ENGINE E 67 DCA 125SS Generator 68 8 EANO m 69 DCA 125USI Generator 70 DCA 250S ENGNG
45. ed or sent in to get rewound This DOES NOT apply to the Surge Protector 14 Multiquip Inc Series Generators Manual No DCA25150CD ROTATING RECTIFIER SURGE PROTECTOR Rotating Rectifier Connected to both the main field amp exciter armature and is mounted on the exciter armature To properly check rectifier for continuity you must disconnect un solder all leads Set multi meter for diode testing Place the positive lead from multi meter on the DC Positive terminal of the rectifier Now touch the U V and W terminals one at a time with the negative lead each contact should give a continuity reading Reverse negative multi meter lead on the DC Positive terminal and touch U V and W with positive lead This should cause the multi meter to read Infinity If the rectifier does not meet the above specifications replace it Surge Protector Mounted soldered directly on the Rotating Rectifier in conjunction with the Main Field black leads NOTE Isolate to test disconnect un solder all leads With multi meter touching the leads this should indicate open circuit if continuity or other reading is obtained replace it DC Positive DC Negative 15 Multiquip Inc DCA Series Generators Manual No DCA25150CD AUTOMATIC VOLTAGE REGULATOR There are four connectors that attach to the AVR and two wires to the AVR terminals The AVR also has three potentiometers only one is
46. en circuit which is an infinite resistance between two nodes It is common to misuse short circuit to describe any electrical malfunction regardless of the actual problem Damage from short circuits can be reduced or prevented by employing fuses circuit breakers or other overload protection which disconnect the power in reaction to excessive current SURGE PROTECTORS A surge protector attempts to regulate the voltage supplied to an electric device by either blocking or by shorting to ground voltages above a safe threshold ZENER DIODE older generators A varistor is an electronic component with a diode like voltage characteristic Varistors are used to protect circuits against excessive transient voltages by incorporating them into the circuit in such a way that when triggered they shunt the current created by the high voltage away from the sensitive components A varistor is also known as Voltage Dependent Resistor VDR A varistors function is to conduct significantly increased current when voltage is excessive METAL OXIDE VARISTOR The metal oxide varistor MOV contains a material typically granular zinc oxide that conducts current shorts when presented with a voltage above its rated voltage MOVs typically limit voltages to about 3 to 4 times the normal circuit voltage by diverting surge current elsewhere MOVs have finite life expectancy and degrade when exposed to a few large transients or many more smaller transients
47. ent Starter o defective check and repair Battery o defective check and repair Emergency Stop Button o Fuel filter clogged dirty o clean or change Air filter clogged o clean or change EGC o adjustment Surge Protector o defective Fuel Relay o defective Loose Wiring o check and repair ECU o Magnetic pick up o AVR o Engine Speed o EGC o out of adjustment ECU o check fault and repair Low Oil Pressure o check and repair Hi Engine Temp o check and repair Wet Stack o Fuel o air in the fuel system Thermostat o defective Radiator o clogged Water Pump o defective Coolant Hose o defective coordinators at 800 421 1244 INFO PAGE Replenish fuel Bleed system Inspect and clean fuel system Magnetic pick up EGC Calibration Surge Protector See engine mfr service manual See engine mfr service manual Wet Stacking See engine mfr service manual See engine mfr service manual Multiquip Inc Series Generators Manual No DCA25150CD 37 ECU The ECU is an auto start stop engine controller When referring to ECU in general it stands for Engine Control Unit this unit is manufactured by Engineering Concepts Unlimited ECUG The ECU auto start controller should not be confused with the actual engine manufacturers Engine Control Module ECM The ECM monitors engine operational inputs and directly controls outputs for fuel delivery
48. etween power lines In other words the GFCI will react to someone standing in water and comes in contact with one of the power lines It will not protect someone who is hold the neutral power line in one hand and hot wire with the other 4 A GFCI does not replace fuses or circuit breakers Fuses and circuit breakers are designed to protect equipment and power lines by reacting to excessive current flow normally in the order of 15 to 20 amps 5 5 are designed to protect people by reacting to leakage currents to ground in the order of 005 amps Except in the case of GFCI circuit breaker combinations sold to be installed in building installations they are separate devices performing separate functions Is the ground wire still needed The GFCI will work and perform its function with or without the tool being grounded but the ground system is an important safety feature and should always be maintained and retested on a regular basis Further if a ground fault should occur the leakage current will pass down the ground wire and trip the GFCI without the operator receiving a shock at all So YES please retain the ground system How can we be sure the GFCI is working There are two methods of testing All GFCI s sold in this country are provided with a test and reset button During maintenance intervals simply plug a tool in to the GFCI and press the test button The tool should turn off and the reset button should pop out
49. for course adjustment the other two should NOT be touched IMORTANT There is no procedure for directly testing the AVR use process of elimination 8 amp fuse MQ part 6978K753 s 1 2 3 Ne BRIE Open delta leads and excitation leads connect to the AVR on this connector DCA 45 to DCA 150 DCA 25 ONLY Wire is YELLOW A Wire is labeled B Wire is labeled B E FUSE 8 2 5 Wire is ORANGE C Wire is WHITE C Wire is labeled D Wire is GRAY D Wire is labeled D E J Wire is RED J Wire is labeled J K Wire is BLUE K Wire is labeled wires colors are black z C 1 2 3 4 EH This connector has no outside connection and has a couple of bridge jumper wires P1 P2 Wire is WHITE and are bridged together t K Wire is WHITE and are bridged together 1 2 3 CN3 Two WHITE wires from the V Leg Wires connected here are for AVR internal sensing Relay are connected here U Wire is RED and is connected to terminal 14 on the voltage selector switch V Wire is WHITE and is connected to V Leg Relay W Wire is BLUE and is connected to terminal 36 on the voltage selector switch Y This potentiometer pot is the 1 2 CN4 voltage course adjustment pot JL VISUAL REMINDER The pots This connects the Rheostat VR to the AVR are positioned similar to a backwards capital letter L 1 Wir
50. he wire diagrams it is identified as the Voltage Regulator VR Voltage Selector Switch SW Is used to configure the generator coils for selected voltage output by re configuring the internal contacts each time a voltage selection is made NOTE Voltage Selector Switch SW is not used on generators above DCA 150 Control Panel There are switches located on the control panel that should not confused with the voltage selector switch These switches are used to select lines to be monitored gauges and are for monitoring purpose only Gauges HZ indicates output frequency in hertz gt Indicates current drawn from load Ws stop OPERATION PRE HEAT N START lt Indicates output voltage Multiquip Inc DCA Series Generators Manual No DCA25150CD 9 COMPONENT IDENTIFICATION Over Current Relay Thermal Overload Relay In the operation and parts manual this component is identified as the Over Current Relay is connected to the main circuit breaker and it monitors current to the output terminals via the current transformers in the event of an overload or short circuit it will electronically trip the main circuit breaker Main Circuit Breaker The Main Circuit Breaker CB1 protects the generator output terminals U V W from overload Current Transformer The Current Transformers CT1 2 3 sense output current supplied by the Gen Set and are connecte
51. he valve stems where there is enough heat to dry it out but not burn it while the rest of it is pushed into the exhaust system In addition to gathering on the valve stems the unburned fuel begins to create a glaze on the cylinder wall and interferes with the seating of the rings to the liner This glaze provides excess lubrication on the rings and reduces their ability to keep the combustion above the rings and the oil below the rings The glaze actually breaks the seal created when the rings seat to the liner If the glaze is allowed to remain for too long loading the engine will not burn off the glaze and allow the rings to reseal themselves In severe cases the glaze can only be removed by disassembling the engine and re honing the cylinder or liner Correcting a wet stacking condition can be done by applying a constant load to the engine to burn out the excess fuel and oil and reseat the rings If the engine can be loaded it needs run with a sustained load until the wet stacking condition clears up Often this can take up to two hours of run time at minimum output of 8096 rated power The exhaust temperature should be closely monitored during this time However the best way to determine the load on a specific engine is to check with the engine manufacturer and use their published temperatures as a guideline For info on load banking see page 34 48 Multiquip Inc DCA Series Generators Manual No DCA25150CD WIRING SCHEMATICS Du
52. heel passes under the tip of the sensor electrical impulses are induced within the coil and sent to the EGC The electrical impulse signal Hertz Hz is directly proportional to engine speed The EGC uses this signal to determine the amount of DC voltage to be sent to the actuator for fuel regulation during start up and load requirements LOCATION Mounted in flywheel bell housing of the engine TOOLS NEEDED An accurate AC DC Multi Meter Padi tered tom pd i a as B INSPECTION Disconnect the MPU connector isolating MPU Using a multi meter test for continuity across the two pins on the connector If an infinity reading is obtained replace the MPU If continuity is found continue to next step With MPU still disconnected set multi meter to AC and place both leads on the MPU connector Crank the engine engine will not start with MPU disconnected With engine cranking multi meter should read 3 to 5 volts AC If a low reading is obtained try adjusting MPU ADJUSTMENT amp INSTALLATION Loosen lock nut and remove MPU from housing Using a screw driver rotate the flywheel slightly so that one tooth is centered in the MPU port Reinstall MPU until it bottoms out touching the centered tooth Back the MPU out of the port 1 4 to 1 2 of a turn and tighten lock nut After adjusting re test Should the magnetic pick up fail any of the above checks replace it
53. ic voltage regulation which contribute to precisely control the generator output voltage and provide a stable supply of in rush current for motor Starting makes the MQ WhisperWatt engine generator packages superior to all others in the industry 31 Multiquip Inc Series Generators Manual No DCA25150CD GFCI What is a Ground Fault Circuit Interrupter A ground fault circuit interrupter GFCI is a small device that compares the amount of current flowing through the circuit If there is a difference of more then 5 milliamps 005 amps the GFCI opens the circuit What are the limits of a GFCI There are several limitations that you should be aware of 1 A GFCI is not a tool tester The GFCI does not have the sensitivity detection circuits nor the polarity reversal features needed to perform the function of a tool tester The makes an excellent life protection device but a very poor tool tester 2 does not prevent shocks The is only operated when a ground fault occurs someone using the equipment might receive a shock but it will be a very short duration 1 30 of a second There is a chance that a shock even of this short duration might cause someone to experience a fall or similar injury but electrocution will normally be prevented 3 A GFCI does not prevent all electrocutions The GFCI reacts to electric current flowing from the power line to ground does not react to current flow b
54. l Fire Protection Association NFPA has established standards for monthly maintenance on stand by generators The current standard can be found on the website and referred as NFPA 110 which states Generators should be exercised monthly at 30 percent of the nameplate rating or loaded to the minimum engine exhaust temperature recommended by the manufacture Reference The National Fire Protection Association NFPA Standard for emergency and standby power systems www nfpa org Load banks are used after service to confirm reliability After scheduled maintenance After AVR adjustments in shop After component replacement Gen end replacements rewinds Yearly to confirm fuel and engine cooling systems are performing correctly under full loads sepe quet 34 Multiquip Inc Series Generators Manual No DCA25150CD MOTOR STARTING CURVE STARTING CURVE SkVA 0 100 200 300 400 500 600 700 800 900 1000 0 mi 15055 12555 10055 8555 5 DCA 70SS e DCA 45SS 2555 20 VOLTAGE DIP 96 35
55. lder generators may not have the diode in relay shown in diagram below 1998 and newer generators have a diode across the coil to prevent back feed Symptoms for a possible failed relay are cranking with no start INSPECTION Remove FH from base holder Using a multi meter measure between the contact pins PIN Measurements ohms resistance should be as follows Relay not Energized y Continuity between PIN 1 and PIN 5 closed contacts Continuity between PIN 2 and 6 closed contacts Continuity between PIN 7 and 8 control 12V 160 Ohms 24V 60 Ohms Infinity between PIN 3 and PIN 5 Infinity between PIN 4 and 6 open contacts open contacts To measure Relay Energized apply 12V DC to PIN 8 and Negative to 7 gt Relay Energized Should the FR test normal problem may be within the base holder FR base is not sealed type it is possible to build corrosion and dirt within This can cause lack of path or continuity Try cleaning the base With FR removed spray dielectric spray cleaner and blow out with compressed air not to exceed 110 PSI Reinstall and attempt to start engine if fails continue to next step With FR installed and while attempting to start check for DC voltage at PIN 8 and PIN 7 o If required DC voltage is NOT present check for voltage at ECU terminal 15 and any ground no voltage indicates problem at
56. mation Automatic Voltage Regulator AVR Increases or decreases exciter current for a more linear voltage and frequency See open delta page 30 for more information Brushless Design purpose of the generator brush is to absorb power from the rotating armature of a generator and supply it to the stationary part of the generator These brushes have a short life due to erosion Multiquips unique brush less design calls for lower maintenance and a longer generator life See open delta page 30 for more information Circuit Breaker CB Connects and disconnects the generator output from the output terminals It also protects the generator from short circuits or overloads Exciter Armature The exciter armature or just the exciter generates electricity which is used for excitation of the field coil The field coil makes the magnetic field required to generate electricity which is used for the generators main power output Frequency Frequency is the number of complete cycles per second in alternating current direction The standard unit of frequency is the hertz abbreviated Hz If a current completes one cycle per second then the frequency is 1 Hz 60 cycles per second equals 60 Hz Ground Fault Interrupters GFI s These devices are designed to eliminate electrical shock hazard resulting from individuals coming in contact with a hot AC line The circuit interrupter is designed to sense any change in circuit conditions It is requi
57. ngine performance excessive fuel consumption and even severe engine failure because of the following conditions Excessive unburned fuel in the exhaust system Excessive lubricating oil consumption Cylinder wall glazing Poor cylinder wall lubrication and ring seating Collection of unburned combustion particles on exhaust valves turbo charger and exhaust manifold WHAT 15 HAPPENING All engines are designed to work within a specified load range at specific temperatures During combustion the piston and liner are subject to extreme temperatures The cylinder wall fire rings and oil control rings and valve train are designed to work under these high temperature conditions The fuel systems are calibrated to deliver the amount of fuel required to produce the rated horsepower The cooling systems are designed to remove any excess heat created to keep the combustion temperatures at optimum levels When the engine is operated with insufficient load several things begin to happen the high temperature created during compression ignites diesel fuel At idle or light loads the cooling capacity of engine exceeds the amount of heat produced creating combustion temperatures that are insufficient to burn all of the fuel Some of this unburned fuel is left in the combustion chamber while the rest of it is pushed through the exhaust system This mixes with the normal exhaust soot to create an oily mixture Some of it will turn to sludge and gather on t
58. ny contacts test the opposite of diagram replace the switch and rewire according to the specified generator wire diagram REPLACEMENT SWITCH On some models the voltage selector switch has been discontinued and replaced with a new style voltage selector switch The new style will look different and comes with new installation brackets that replace the old brackets When receiving a new style replacement switch it is required to position the jumpers in the same terminal designation as old switch Also the wire connectors are different therefore customers will have to cut the terminal wire connector ends from the wirings and change them to a new style that they will need in order to fit the new switch NOTE MQ does not supply new wire connectors since this is something that most service shops have on hand Replacement Brackets Discontinued Brackets Discontinued Switch New Style Replacement Switch 18 Multiquip Inc DCA Series Generators Manual No DCA25150CD O O O O O O DCA 25SSI DCA 45SSI 6055 DCA 70SSI DCA 70SSJ DCA 100SSJ VOLTAGE SELECTOR SWITCH The internal connections between terminals on the voltage selector switch are indicated by an gt lt also used are external metal and wire jumper connectors see page 20 for jumper locations O O O O O O N D gt OQ o o DCA 100SSV DCA 125SSI DCA 125SSJ DCA 150SSI DCA 150SSJ
59. onductor the amps cause resistance and the result is heat the temperature increase due to resistance is the Heat Rise Normally all generators are rated in degrees Celsius and at an ambient temperature of 40 degrees Celsius 104 degrees Fahrenheit All DCA series generator ends are rated at an 85 degrees C Heat Rise at the Prime rating and 105 degrees at the standby rating This is really robust The next time you hear someone talk about an oversized generator end THAT S Our competitors rate their generators at a much higher Heat Rise For example Wacker and Magnum is anywhere from 105 to 125 Baldor is rated at 125 C and Generac rates theirs up to 150 C This is very hot and the generators will experience reduced life This difference may not seem like much but remember we are using degrees Celsius not Fahrenheit When you compare temperatures in degrees Fahrenheit the differences are great An MQ generator end rated 85 degrees C equates to 185 degrees F A Baldor rated at 125 degrees C is 257 degrees F That s a difference of 72 degrees F Remember that Heat Rise goes above and beyond ambient temperature If this unit runs at 40 degree C 104 degree F then the Heat Rise is added to the total temperature of the generator windings increasing the total winding temperature The Heat Rise of a generator end directly relates to the amount of copper in it An alternator with less copper mean
60. quip Inc Series Generators Manual DCA25150CD DCA 125USI GENERATOR TO CNT TOCBI W us TO Cai CHTO r 1 gt BRUSHLESS AC GENERATOR SYMBOL AT ON 4 7 d 124 i 1134 12 Ww ul ala cun 1 EXCITER ARMATURE WINDING b jvivij U23938 112 C int ig EXCITER FIELD WINDING 123 4 PELO I oo 7 DM 3 Thy i 1 5 pyp2 OMS CN IB B ene iela 3l UR AUTOMATIC VOLTAGE REGULATOR 4 1 B Li li 1 i Ti B ATOR EmA 123 CONNECTOR ARRANGEMENT 13 3 UI OO WIRING VIEW F J FEBUENCY METER COVER CURRENT RELAY PBi12345p ORONT BREAKERS SWITCH FEM 12 FAN MOTOR Noli 1 designation lead size 1 25 70 Multiquip Inc Series Generators Manual No DCA25150CD DCA 125USI ENGINE TI ez E j 192 r3 1 1 CH12 Flu E DL CH H CH1 TO CONTROLLER WIRING DIAGRAM CHI TRI ADC2 1 TERMIMAL BOARD T WIRING VIEW B2 71 Multiquip Inc Series Generators Manual No DCA25150CD DCA 150SSI GENERATOR CB 2 GHT CRI Ww il
61. rators Manual No DCA25150CD CURRENT FLOW DIAGRAM OLIT PUT TERMINAL LUGS ELE SET CURRENT AUTOMATIC eur np a 5 VOLTAGE 71 L y 7 de E I af rp ae 3 E s mm ie i 3 enc 5 YE a VOLTAGE SELECTOR SWITCH i EL NE X _ E TQ Me E ier d E T AUXILIARY CIRCUIT BREAKERS Seat ud am t Fp em Loi cra RECEPTACLES TWIST LOCK RECEPTACLES NOTE Current flow diagram represents the basic flow in the generator Some components may not be shown example Voltmeter voltmeter switch frequency meter rectifiers relays wire terminals connectors etc 26 Multiquip Inc DCA Series Generators Manual No DCA25150CD GENERATOR THEORY The generator creates electricity by a series of fine wire windings inside a magnetic field called an armature As the armature is spun inside this magnetic field by the diesel engine current and voltage gets generated in those windings of wire and electricity is transferred That current and voltage will be directly proportional to the speed that the armature spins and to the strength of the magnetic field Each complete revolution one complete cycle of alternating current AC is developed This is called a rotating
62. re set to RO If replacing be sure to set to factory settings of original OCR 1 i A 9 96 97 Signaling contacts connected to Circuit Breaker Connected to the Ammeter amp Ammeter Switch 1 3 5 Sensing contacts are connected to Current Transformers 24 Multiquip Inc Series Generators Manual No DCA25150CD EDUCATION The following information provided is for educational purpose For more in depth training on Multiquip generators University of Multiquip UMQ offers comprehensive training for salespeople or service technicians covering a complete range Contact your local MQ rep or visit the Multiquip website at www multiquip com search under service and you will find more information about UMQ INDEX EDUCATION Current Flow Diag ATI annee 26 Generator Theory 9 nene 27 PICA 28 SAR u a 29 C __ 30 Dec ID 31 T7 32 Circuit Breaker Short Circuit Surge Protector 33 Load AIG PR 34 Molor CUVE uuu 35 ENGINE CONTROLS lel q 36 25 Multiquip Inc Series Gene
63. red by the NEC that all 12 volt single phase 15 or 20 ampere receptacle outlets that are installed outdoors or in bathrooms have ground fault interrupters connected to them Heat Rise Is in direct relation to the longetivity of the generator To find out why Multiquip units exceed the competition see page 27 KVA Kilo Volt Amp which sizes three phase loads can be converted to Kilowatts by multiplying the KVA by the power factor 0 8 NEMA National Electrical Manufacturers Association For more information about NEMA and their standards visit their website at http www nema org Ohm A unit of electrical resistance equal to that of a conductor in which a current of one ampere is produced by a potential of one volt across its terminals 78 Multiquip Inc Series Generators Manual No DCA25150CD GENERATOR GLOSSARY Phase Single Phase Power typically 120V AC or 230V AC depending on the country is carried between two wires live and neutral and sometimes a third ground wire for safety frequency of AC voltage is 50 or 60 Hz depending on the country Single phase power is used in very many applications for example to power all typical home electrical appliances you use single phase power from a normal electrical outlet at home Three Phase Power is very common and is a more efficient use of conductors Voltage is carried through three conductors 120 out of phase with the other two Three phase power provide
64. s a more efficient means of supplying large electrical loads like motors and is used more in industrial areas PMG Permanent Magnetic Generator Eliminates the excitation losses in the rotor which otherwise typically represent 20 to 30 of the total generator losses It also gives a lower temperature rise in the generator Rheostat A continuously variable electrical resistor used to regulate current Voltage the rate at which energy is drawn from a source that produces a flow of electricity in a circuit Expressed in volts V Voltmeter This feature serves as a convenient diagnostic tool on the jobsite operator can quickly tell whether or not the generator is producing the correct voltage and prevent overheating of tools and equipment Watt An international system unit of power equal to one joule per second the power dissipated by a current of 1 ampere flowing across a resistance of 1 ohm A Amps 1 Single Phase W Watts 3 Three Phase kW Kilowatts v Volts Volt amps dB Decibels Kilovolt amps Hz Frequency hertz 79 Multiquip Inc Series Generators Manual No DCA25150CD 80 MULTIQUIP Corporate Headquarters Multiquip Inc 18910 Wilmington Ave Carson 90746 Multiquip Inc DCA Series Generators Manual No DCA25150CD
65. s failed after a pre programmed number of attempts DCA generators are pre set at 3 cycles with 10 second duration OVERSPEED SHUTDOWN llluminates when engine is running at an unsafe speed ENGINE RUNNING Illuminates when engine is running at safe operating speed 38 Multiquip Inc Series Generators Manual No DCA25150CD O O O O O O O O O ECU Wire terminals are located on the back of the LED panel BACK FRONT AUTO MANUAL OFF RESET LOW OIL PRESSURE HIGH COOLANT TEMPERATURE OVERCRANK OVERSPEED ENGINE RUNNING 5 0000 20001 Below is an example of the basic wiring for the ECU some generators may differ depending on model Check Points Control Switch Battery positive voltage is present constantly on center terminal of switch Terminal 13 This is manual power input to the ECU voltage is supplied from the control switch to this terminal Terminal 14 This is auto power input to the ECU voltage is supplied from the control switch via remote start contacts Terminal 6 This is power output with control switch in manual position check for DC voltage at this terminal Terminal 2 This is ground input Ensure this terminal has continuity to ground Terminal 15 This will have constant battery voltage when unit is running Terminal 1 This receives an input signal voltage from the Magnetic Pick Up Terminal 4 This is connected to oil pressure switch or engine m
66. s higher temperature Reduced copper means less cost This is an area where our competitors can cut cost and sell for less The fact is MQ uses more copper in our patented generator ends coupled with a patented excitation system results in greater motor starting capabilities increased longevity and a great reputation Many times competitors state that they have Class H insulation and MQ uses Class F The class of the insulation used directly relates to the temperature that the insulation can withstand and does not relate in any way to the quality or thickness of the insulation Class F is rated up to a 135 degrees Heat Rise and Class H is rated to a 155 degrees Heat Rise Other companies uses class because they have too their generators have less copper and operate at much higher temperatures than then the DCA series generator Understanding Heat Rise and Insulation Class really helps in comprehending the value of an MQ generator For more on Insulation Class see next page 28 Multiquip Inc Series Generators Manual No DCA25150CD INSULATION CLASS What is Insulation Class Insulation systems are rated by standard NEMA National Electrical Manufacturers Association classifications according to maximum allowable operating temperatures Maximum Operation Temperature Tolerance Class C A 105 B 130 F 155 H 180 TCC I 9 5 32 Temperature Allowed im 221 266 311 356 Allowable
67. sects that have developed a community inside the generator Their nests and debris can cause electrical shorts Generators left out in the elements such as for running water wells provide a nice home for critters such as spiders wasps and mice Multiquip Inc Series Generators Manual No DCA25150CD 6 10 11 12 GENERATOR INSPECTION continued Loose bolts screws and fasteners This condition will either prevent full time service or give intermittent service depending on the situation Problems in quick disconnect connectors These are often overlooked A quick disconnect could have one to a dozen male female connections These are often inside some plastic or rubber cover that prevents you from seeing any possible corrosion In electrical troubleshooting always unplug and plug in all connectors three times to produce a freshly scraped metallic surface for good electrical contact If the unit works after that soak the connectors first in vinegar for a few minutes then in a baking soda solution Rinse the connectors thoroughly with distilled water This acid base wash will remove corrosion but not oil or grease Blow dry thoroughly Using an ohm meter check for zero ohms on all connections Spray the contacts with an electrical insulative spray before reassembling them Crimp connections Even though they re widely used they can become loose as the machine vibrates and lose consistent quality contact Bec
68. t induces AC output from the exciter armature Exciter Armature Powers main field via rotating rectifier Main Field Produces a magnetic field that induces AC output from main armature Main Armature AC output to receptacles and terminals GENERATOR ASSEMBLY In the operation and parts manual this component is identified as the Generator Assembly Gen Set It consists of the following Main Field Exciter Armature Rotating Rectifier Converts AC to DC Surge Protector Is connected in parallel with the field coil and protects the rotating rectifier from excessive voltage surges produced in the field coil Stator Frame Housing which encloses the main armature and exciter field Main Armature Exciter Field oupplies a magnetic field to the exciter armature Multiquip Inc Series Generators Manual No DCA25150CD COMPONENT IDENTIFICATION Automatic Voltage Regulator The Automatic Voltage Regulator AVR maintains a constant voltage level during load changes AMR internal sensors regulate the configuration of the Open Delta connections and automatically adjust the amount of DC current directed to the exciter field in order to maintain stable output voltage Rheostat Voltage Regulator Is variable resistor connected directly to the AVH and is used for fine tuning output voltage NOTE In the operation and parts manual this component is identified as the Rheostat when ordering parts In t
69. the ECU o If required DC voltage is present and the FR is known to be good check for voltage at EGC terminal 1 and any ground no voltage indicates base is defective and needs to be replaced 45 Multiquip Inc DCA Series Generators Manual No DCA25150CD CRANK RELAY GLOW PLUG RELAY Used on series with ISUZU engines that are equipped with ECU auto start auto stop engine controller Same style relay is used for both crank and glow plugs This relay is not sealed and has an open body Most commonly used relay in Isuzu equipped units is a Deltrol 30 amp relay ENGINE CRANK RELAY The engine crank relay is connected to the starter motor solenoid and directly to the battery for starting This relay is fed off the ECU crank circuit located on ECU pin 6 ENGINE GLOW PUG RELAY The engine glow plug relay is connected to the engine glow plugs and directly to the battery for pre heating This relay 15 fed off the ECU crank circuit located on ECU pin 6 DELTROL 30 AMP RELAY To Starter Solenoid or Glow Plugs Coil 12V DC Coil Ground BATTERY Battery Positive 46 Multiquip Inc Series Generators Manual No DCA25150CD FEED PUMP STRAINER Used on DCA45 and DCA70 series with ISUZU engine 4861 STRAINER Part 1 13260047 0 WASHER GASKET Part 109630085 0 Symptoms of clogged strainer Hard starting Engine runs rough White smoke coming out the exhaust
70. ultiquip Inc Series Generators Manual No DCA25150CD GEN SET Main Armature Wires Qty Identification Loadleads 14 color Black U1 U2 U3 V1 V2 V3 W1 W2 X1 X2 Y1 Y2 Z1 Z2 These wires are AC outputs and they are connected to the selector switch TERI n DM Wires Qty Identification k N V ni Open delta leads 4 color Black C D These wires supply the supplementary voltage needed to maintain a steady state excitation output during the different level of loads Wires are connected to the AVR through connector CN 1 Exciter Field Wires Qty Identification Excitation leads 2 color Black J K These excitation leads are connected to the AVR on the same connector as the open delta leads 1 Main Field Wires Qty Identification Leads 2 color Black leads No Markings These leads are connected to DC positive amp DC negative terminals on the Rotating Rectifier in conjunction with Surge Protector Exciter Armature Wires Qty Identification Leads 3 color Yellow leads No Markings NS i d These leads are connected to the U V W terminals on the Rotating Rectifier IMPORTANT Inspect the components above with multi meter set on Ohms O measure resistance across the leads and compare reading to the resistance chart on page 1 if reading indicates an open circuit component may need to be replac
71. use it to fail These causes can be mechanical damage vibrations excessive heat or cold dirt oil corrosive vapors and even moisture from humidity During the life of a conductors insulation all of these causes are at work in combination with electrical stresses If a pin hole or even a crack in the insulation develops moisture and foreign matter can penetrate the surfaces of the insulation This provides for a low resistance path for leakage current Once the insulation has begun to deteriorate all elements of causes tend to combine until excessive current leakage is allowed through the insulation At times the drop in insulation resistance can be sudden such as occurs if the equipment is flooded Normally insulation resistance drops gradually and gives plenty of warning if checked as a preventative maintenance Periodic checks would allow planned reconditioning prior to operation failure and the ability to remove from service if the insulation resistance became dangerously low Equipment with no checks may not only be dangerous to touch with voltage applied but also be subject to total burn out A failed insulator becomes a partial conductor Multiquip Inc Series Generators Manual No DCA25150CD OPEN DELTA Why is the open delta design efficient As copper softens it generates less power The open delta design runs with the copper wires at 180 F while other competitors models run with their copper wires at 220 and some
72. value and there is no response when adjusting rheostat Disconnect the CN4 connector on the AVR and you can measure the resistance of the rheostat at the connector The multi meter should indicate a smooth change in resistance value while rotating the adjustment knob back and forth between min amp max Connector Measuring Between Wires Value 2 Ec CHR 0 1000 Ohms CN4 If the Rheostat indicates open or varies from the above it should be replaced 24 Multiquip Inc Series Generators Manual No DCA25150CD MAIN CIRCUIT BREAKER RATING CHART This Main Circuit Breaker CB connects and disconnects the generator to the output terminal lugs U V W and is monitored by the OCR 99 of the breaker trip faults are due to insufficient sizing of the generator to the load It is essential that the unit being used for the application be sized properly to the load in order to prevent these types of nuisance faults IMORTANT Verify load and ensure it is not causing the breaker to trip Proper sizing formulas can be found in operation and parts manuals Checking continuity between contacts while tripping the CB will verify operation o OFF position reading between input and output contacts should be OPEN o position reading between input and output contacts should be CLOSED s A Amps Amps Amps Amps Over Current Circuit Breaker MODEL 240VAC 480

DCA25-150 Service Manual - Multiquip Service & Support Center

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DCA25-150 Service Manual - Multiquip Service &amp; Support Center

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DCA25-150 Service Manual - Multiquip Service & Support Center