PROBLEM
Engine misfires.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Engine backfires.
1.
2.
3.
4.
5.
6.
Engine overheats.
1.
2.
3.
4.
5.
6.
Black exhaust smoke
1.
discharge from the
2.
engine.
3.
High oil pressure.
1.
2.
ENGINE/GENERATOR
TROUBLESHOOTING
OPERATING
PROCEDURES
PROBABLE
CAUSE
PROBLEM
PROBABLE
CAUSE
Poor quality fuel.
No DC charge to the
1.
Faulty connections to
Incorrect timing.
starting battery. battery voltage regulator.
Dirty flame arrester.
2. Faulty battery voltage regulator.
Dirty throttle body.
3. Faulty bridge rectifier.
Throttle plate is binding.
4. Faulty generator charger
Cracked distributor cap.
windings.
Faulty high tension wires. Alternator excitation
1.
Low engine speed, check RPM'S.
Spark plugs are worn.
failure
2.
Faulty condenser, check/replace.
High exhaust back-pressure.
3. Faulty windings, check resistance
Valve clearances are incorrect.
High no-load
1.
High engine speed, adjust RPM'S.
Spark plug wires are connected
voltage
2. Faulty condenser, check/replace.
wrong.
Incorrect timing.
Engine is flooded.
Dirty flame arrester.
Low no-load
1.
Low engine speed, adjust RPM'S.
voltage
2. Faulty rotary diodes, check/replace.
3.
Breakdown in windings, check
resistance.
Cracked distributor cap.
High exhaust back-pressure.
Coolant loss (pressure test
cooling system).
4. Faulty condenser, check/replace.
Proper no-load
1.
Low loaded speed, regulate RPM.
but low loaded
2.
Load
too heavy, reduce load.
voltage.
3. Short circuit in rotary diodes,
Faulty raw water pump impeller.
check/replace.
Belts are loose or broken.
Raw water pump worn.
High exhaust back-pressure.
Proper no-load
1.
RPM too high, regulate RPM.
but high loaded
voltage.
Faulty thermostat.
Unstable
1.
Loose contacts, check connections.
Dirty flame arrester.
voltage.
2.
Uneven rotation, check for uniform
Faulty vacuum hose
..
Faulty carburetor.
Noisy generator
1.
Broken bearings, replace.
backend.
2.
Poor couplings, check/repair.
Dirty oil or wrong SAE type oil
in the engine.
Relief valve
is
stuck.
Engines & Generators
74
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