Multiquip Portable Generator DCA220SSJU4F3

Warning: This procedure requires trained personnel with PPE!

If fuel pump relay did not test normal, report the issue to the maintenance team and stop the procedure

Is the generator model between DCA6 and DCA125?

If the generator model is not between DCA6 and DCA125, report the issue to the maintenance team and stop the procedure

Is the fuel pump relay base holder not a ‘sealed type’?

If the fuel pump relay base holder is a ‘sealed type’, report the issue to the maintenance team and stop the procedure

Is there corrosion and dirt in the fuel pump relay base holder?

If there is no corrosion and dirt in the fuel pump relay base holder, report the issue to the maintenance team and stop the procedure

MANUAL EXCITATION TEST (3-PHASE VOLTAGE):

1. With the engine OFF, place the voltage selector switch (Figure 39A) in the 3-Phase, 240/139V position.

2. Unplug the 6-pin plug from the CN1 receptacle on the AVR (Figure 39B).

3. Connect a SPST toggle switch (Figure 39C) between the positive battery terminal and pin J on the 6-pin plug.

4. Connect a wire from the negative battery terminal to pin K on the 6-pin plug (Figure 39D).

5. Place toggle switch in the OFF (open) position, if equipped set engine speed switch to the low position (idle). Start the engine and then place toggle switch in ON position (closed).

6. Next, place engine speed switch in the high position and run the engine at full rpm.

7. Place the selection dial on the multimeter to the AC volts position (Figure 39E).

8. Using; a multimeter, measure voltage at the U, V and W terminals (Figure 39F) located on top of the main circuit breaker (line side).

Warning: This procedure requires trained personnel with PPE!

Multimeter test leads placed across pins 1 and 2 on the ECU auto-start module

Is the multimeter reading between 2.25 VAC ± 0.50?

If a low voltage reading is obtained, reference the 'MPU Installation and Adjustment' section.

Sign off on the Mpu Ac Voltage Test

NOTICE: Before performing the resistance check, the 6-pin plug (Figure 51B) must be disconnected from the CN1 receptacle on the AVR. If the reading indicates an open circuit the component may have to be replaced or repaired.

6-pin plug disconnected from the CN1 receptacle on the AVR?

Set the multimeter selection dial to the W position as shown in Figure 51A.

Check the resistance across the A-B, C-D, D-A open delta wire leads as referenced in Figure 51B. Compare measured reading to values listed in Table 6, column E.

Check the resistance across the B-C open delta wire leads as referenced in Figure 51B. Compare measured reading to values listed in Table 6, column F.

6-pin plug disconnected from the CN1 receptacle on the AVR again?

As shown in Figure 52 there are three outside connectors that plug into the CN1, CN3 and CN4 receptacles on the AVR.

The CN2 receptacle has no outside plug connected to it. Pins 1 and 2 are internally jumpered together and pins 3 and 4 are also jumpered together.

As shown in Figure 52 there are two WHITE wires that connect to the AVR 2-pin terminal block via relay unit RY1.

Loosen the jam nut that secures the MPU to the sensor plate

Visually view the flywheel teeth through the hole opening on the sensor plate

Attach a ratchet to the crankshaft pulley and rotate the flywheel gear until the highest point of the flywheel gear tooth is visible

Reinstall the MPU sensor back into the sensor plate. Continue screwing the MPU sensor clockwise until contact is made with the flywheel gear tooth

After making contact with the flywheel gear tooth, unscrew the MPU sensor counterclockwise 1/2 turn

Verify that the MPU sensor does not make contact with the flywheel by rotating the flywheel gear completely around. Flywheel should rotate freely

The MPU sensor-flywheel gear gap should be adjusted so that the minimum voltage required is attained while the engine is in crank status. The voltage setting we are looking to obtain is 2.25 VAC +/- 0.50 VAC

Once the correct gap is obtained, tighten the MPU sensor jam nut to secure it to the sensor plate