Multiquip Portable Generator DCA36SPXU2

NOTICE: The GFCI receptacle is designed to interrupt power when a ground fault exists to prevent injuries and shock hazards. DO NOT use the GFCI receptacle if the test below fails. Consult a qualified electrician for repair or replacement of the GFCI receptacle. Test the GFCI receptacle at least once a month.

Start the generator as outlined in the start-up procedure in this manual.

Place a GFCI circuit breaker (Figure 63) in the ON position.

Verify that the status LED on the corresponding GFCI receptacle (Figure 63) is ON (GREEN).

Press the TEST button (Figure 65) on the GFCI receptacle and verify that the status LED turns OFF.

Press the RESET button (Figure 66) to restore power to the GFCI receptacle and verify that the status LED is ON (GREEN).

If the status LED (Figure 67) is flashing (RED), DO NOT use the GFCI receptacle and replace it immediately.

Sign off on the GFCI Method Test

The first step in generator troubleshooting is to conduct a visual inspection before doing any electrical tests.

Looking over the generator 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:

Electrical Connections — Rusted, corroded and oxidized connections will prevent the circuit from being completed. This applies not only to the major cables externally, but also to the electronic control devices internally.

Carbon Flash — If the AC receptacles on the generator have ever been shorted, carbon flash deposits around the 120/240V AC receptacles may appear. 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.

Wire Overheating — Signs of wire 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.

Infestation — Insects and rodents may have created a nest 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. Always inspect the generator daily.

Hardware — Loose hardware will shorten the life cycle of the generator and decrease the overall performance of the generator.

Terminal Lugs/Bus Bars — Always make sure all nuts, bolts, screws, and fasteners are securely tightened. DO NOT over tighten. Reference Torque Specifications (Table 9). Look for any elongation on the bolt hole opening on the buss bar.

Electrical Connectors — Sometimes electrical connectors do not always make a good connection. Always make sure the electrical connectors are seated correctly. Some electrical connectors may have more than a dozen male-female connections.

Warning: This adjustment requires trained personnel with PPE!

Do you have a small, flat-blade screwdriver?

Turn the engine crank disconnect adjustment potentiometer 30 turns counterclockwise

Turn the engine crank disconnect adjustment potentiometer about 3 turns clockwise

Try to start the engine. Did the starter crank but disengage quickly?

If the engine starts, is the ECU engine running lamp lit?

Once verified, did you shutdown the engine?

With the engine shutdown, adjust the the engine crank disconnect adjustment potentiometer 1 turn clockwise

Try restarting the engine. Did the engine start reliably?

Air cleaner for restrictions and contaminants. Replace if necessary.

Cooling system hoses for cracks and distortions — tighten clamps or repair as needed.

Radiator for restrictions and corrosion.

Engine block heater for leaks and verify unit functioning properly. Engine block heater is an option on some units.

Coolant, fuel and oil leaks. Tighten connections or repair as needed.

Belts and pulleys for cracks and wear — adjust or repair as needed.

Governor and injection pump for leaks and proper operation.

Turbocharger for proper clearance and free movement as required. Reference engine service manual.

Fuel tank for contaminants and condensation.

NOTICE: Be sure you have adjusted the engine crank disconnect potentiometer first.

Turn the engine overspeed adjustment potentiometer (Figure 56C) 30 turns clockwise

Using a small, flat-blade screwdriver, set the DIP switch at position 5 (Figure 56D) to the ON position (up)

Start the engine. It should crank and start. Verify that the engine running LED is lit.

Now start turning the overspeed adjustment potentiometer counterclockwise until the engine control shuts down the engine (overspeed fault)

Again using a small, flat-blade screwdriver, set the DIP switch at position 5 to the OFF position (down)

If the overcrank and overspeed LEDs light at the same time on the ECU, reference troubleshooting flow charts in this service manual for additional information.

Sign off on the engine overspeed adjustment