TP-5867 11/02 19Section 3 Troubleshooting
General Troubleshooting Chart, continued
Problem Possible Cause Corrective Action Reference
Generator set
stops
suddenly,
Loss of generator output voltage
to K1 relay (LED1 not lit)
Check AC voltage at rectifier
(BR1). Check continuity of B1/B2
stator leads.
Sections 6, Component Testing
and Adjustment, and 9, Wiring
Diagrams
continued
Defective ignition module Test and/or replace. Engine S/M
Defective K3 relay (field flashing) Test/replace controller circuit
board.
Section 4, Controller
Troubleshooting
Generator set
operates
Air cleaner clogged Replace element. Section 2.4, Air Cleaner Element
and Precleaner
erratically
Faulty spark plug(s) Replace and regap plugs. Section 2.3, Spark Plugs
Fuel mixture adjustment incorrect Check and/or adjust. Section 6.11, Fuel Systems
Governor adjustment incorrect Adjust electronic governor. Section 6.9, Electronic Governor
Carbon buildup in engine Clean cylinder head. Engine S/M
Engine valves not seating
correctly
Inspect valves and valve seats. Engine S/M
Defective ignition system Test and/or replace components. Engine S/M
Defective spark plug wire(s) Replace spark plug wires. Engine S/M
Incorrect cooling (hot engine only) Inspect air inlet and outlet. Section 2.5, Cooling System
Fuel line restriction Check fuel lines. Section 6.11.1, Gas Piping
Carburetor adjustment incorrect Adjust carburetor. Section 6.9.3, Hunting/Surging
Generator set
lacks power
Air intake restriction Check air cleaner, air intake. Section 2.4, Air Cleaner Element
and Precleaner
Generator overloaded Reduce load. O/M
Faulty spark plug(s) Replace and regap plug(s). Section 2.3, Spark Plugs
Faulty spark plug wire(s) Replace spark plug wires. Engine S/M
Engine not running at rated rpm Adjust governor. Section 6.9, Electronic Governor
Governor defective or misadjusted Test/readjust governor. Section 6.9, Electronic Governor
Incorrect cooling Inspect cooling system for
obstructions.
Section 2.5, Cooling System
Defective ignition system Test and/or replace. Engine S/M
Insufficient fuel pressure Check fuel pressure at carburetor
outlet.
Section 6.11,Fuel Systems
Fuel line restriction Check fuel pipe size. Section 6.11, Fuel Systems
Defective fuel regulator Check function of fuel regulator. Section 6.11, Fuel Systemss
Generator set
overheats
Incorrect cooling Inspect cooling system for
obstructions.
Section 2.5, Cooling System
Air cleaner clogged Replace element. Section 2.4, Air Cleaner Element
and Precleaner
Fuel mixture adjustment incorrect Readjust fuel mixture. Section 6.11, Fuel Systems
Generator set
Exhaust system leaks Check and replace as necessary. Section 2.6, Exhaust System
is noisy
Engine not running smoothly See “Generator set operates
erratically,” this table
See “Generator set operates
erratically,” this table
Broken or damaged vibromount(s) Check and replace as necessary. Section 8, Disassembly/
Reassembly
Loose or vibrating sheet
metal/housing
Retighten screws, replace rivets.
—
Exhaust piping or air inlets/outlets
not securely installed
Inspect for loose parts and secure
if necessary.
Section 2.6, Exhaust System
Excessive engine/generator
vibration
Check, rotor, crankshaft, bearing,
etc. (disassembly of engine and/or
alternator may be required).
Section 8, Disassembly/
Reassembly and Engine S/M
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