Service Manual

43
Issue:
Possible Cause:
Solution:
Check:
Engine
Overheating
Low Oil Check the oil. Refill the oil or change the oil as needed.
Start the
engine and
let it reach
operating
temperature.
Check the
temperature.
Exhaust pipe blocked Check the exhaust pipe. If blocked, clear the blockage.
Debris in cooling fins Remove the debris.
Improper governor
setting
Check the engine speed. Adjust governor as needed.
Impellor shroud
leaking
Inspect shroud. Repair or replace as needed.
Cylinder or piston or
piston ring worn
Inspect cylinder, piston, and piston rings. Replace if
needed.
Connecting rod
deformed
Inspect connecting rod. Replace if needed.
If the engine still
overheats:
Rebuild the engine, replace the engine, or consider replacing the unit
Engine
Runs, But
Generator
Provides No
Power or
Low Power
Low engine speed
Check the engine speed. Refer to Engine Speed -
Adjust if needed.
Start the
engine and
check the
output
voltage
Circuit breaker is
open
Close the circuit breaker.
Bad connection Stop the engine and check the connections.
Defective power cord Replace the cord.
Defective device
plugged in
Unplug defective device.
Bad AVR connection
or defective AVR
Check the voltages and connections. Tighten any loose
connections. R
eplace the
AVR.
Poor carbon brush
contact
Clean the surface of the collector ring and the carbon
brush arc surface.
Improper brush
pressure
Adjust or replace the spring.
Poor stator or rotor
lead contact
Check the contacts. Tighten or replace as needed.
Poor panel, meter, or
socket contact
Engine idle control
switch on
Turn the engine idle control switch off.
Defective winding or
winding connection
Check each winding. Check connections to ground.
Check the insulation. Check the excitation loop for an
open circuit. Tighten any loose connections and replace
any defective parts.
If there is still no
power or low power:
Rebuild or replace the generator, or consider replacing the unit.
Stator Core
Overheating
High stator voltage Adjust the voltage.
Start the
engine and
let it reach
operating
temperature.
Check the
stator
temperature.
Excitation current too
high
Reduce the load on the generator.
Low engine speed
Check the engine speed. Refer to Engine Speed -
Adjust if needed.
Friction between the
stator and rotor
Look for signs of wear on the rotor core. Remove any
high spots.
Stator winding
temperature too high
Refer to the section on “Stator Winding Overheating”
If the stator core is
still overheating:
Rebuild or replace the generator, or consider replacing the unit.