Owner’s Manual 38
PROBLEM PROBABLE CAUSE SOLUTION
No output or low voltage Open or shorted armature. Replace armature.
Open or shorted field coil(s). Replace field coil(s).
Generator operating below correct rpm speed Generator must be operated at 3600 rpm +/- 90 rpm for proper
output voltage.
Generator overloaded. Reduce load to generator nameplate.
Short circuit in the load. Disconnect the load. Check voltage at receptacle. Check motors
appliances and load leads for short circuits, repair short.
Loose or broken wires or connections Remove panel cover and check all wiring and connections.
in the control box. Tighten
Defective rectifier Test rectifier. Replace if defective.
Dirty slip rigns Clean and polish. Use #00 sandpaper and crocus cloth, NEVER
emery paper.
Brushes binding in holders. Check brushes for swelling. Replace defective brushes. Clean
brush holders.
Loss of residual magnetism. Check output voltage with sensitive meter. If very low,
(e.g., 1/2 Volt), flash fields with 12 VDC battery.
Output voltage too high Engine Speed too high. See engine manual.
Generator overheating. Generator overloaded. Reduce load.
Armature rubbing pole shoes. Check bearing condition. Check field shell bearing bracket
alignment.
Poor ventilation. Clear inlet and outlet air vents of debris. If unit is housed, ensure
at least 2 ft. clearance on all sides and that inlet and outlet vents
are of adequate size.
Short circuit in fields. Repair or replace - open or shorted fields should be replaced.
Grounded fields may be repaired by insulating at the point where
the ground occurs.
Short turns in armature. Replace arm.
Sparking at the brushes Generator overload. Reduce load.
Brushes not seated properly. Contour brushes.
Slip rings rough or eccentric. Redress slip rings.
Brushes sticking in brush holder. Remove brushes and inspect and correct problem.
Brushes worn down shorter than 3/8 in. Replace brush. NOTE: Always replace brushes a full set
at a time.
120V GENERATOR TROUBLESHOOTING
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