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Section 5
Troubleshooting and Maintenance
Troubleshooting and Maintenance 5-1MN2417
WARNING: Never “jump start” a generator to start the engine. If the battery charge is insufficient to start
the engine, charge or replace the battery and try to restart. Jump starting a battery can cause
the battery to explode and cause severe injury or death to anyone in the area.
Caution: If a dead battery is suspected charge battery (or replace), and then attempting starting.
Damage to engine control may result from jump starting.
Maintenance
This manual contains only very minimal engine maintenance instructions. Refer to the engine
manufacturer’s owner’s manual for specific engine maintenance instructions for your generator
set. Any maintenance instructions or recommendations in the engine owner’s manual take
precedence over any of the following general recommendations.
General:
1. Inspect the fuel system for leaks. Replace all defective components immediately.
2. Inspect and replace any fuel line that shows signs of deterioration.
3. Inspect all the fuel clamps to ensure they are tight.
4. Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank contains no
leaks.
5. Inspect and clean the battery posts and the associated battery cable terminals.
6. Inspect the external wire cables and connectors used with the generator set for cuts,
fraying, or loose connections. Repair or replace any problems prior to using the unit.
Engine:
1. Clean and/or replace any fuel, oil, and/or air filters per the engine manufacturers’
guidelines.
2. Check oil level regularly; at least every 5 to 8 operating hours. Maintain the proper oil
level.
3. Change the oil as is recommended in the engine manufacturer’s owner’s manual.
4. Clean the cooling fins on the engine to keep the engine’s heat dissipation potential at
it’s maximum.
5. Inspect and clean all governor and fuel supply linkages so they operate properly.
Alternator:
( also called Generator End)
This generator set must be run at its proper speed to obtain the correct electrical power at its
output. All engines have a tendency to slow down when a load is applied to it. The engine
governor is designed to hold the operating speed as nearly constant as possible. When the
electrical load is increased, the engine is more heavily loaded and engine speed drops slightly.
This slight decrease in engine speed results in a slight decrease in generator voltage and
frequency output. This voltage and frequency variation has no appreciable effect in the operation
of motors, lights, and most appliances and tools. However, timing devices and clocks may not
keep perfect time.
1. Clean the generator set and remove any and all dust, dirt, or other foreign material.
2. Inspect and clean the cooling air intake and exhaust louvers of the generator end.
Make sure they are clean. Remove dirt or any buildup that may restrict the cooling air
flow.
3. Clean the generator set and its components with a damp cloth or sponge.
Never use a water hose or pressure washer as this may damage electrical
components.
4. Inspect and replace any control panel components that are broken or not working
properly (receptacles, circuit breakers, switches, etc.)