Baldor Generator Service Manuals and Troubleshooting for Portable Generators

Problems and Solutions

Some of the more common problems are listed in Table 5-1. This information is intended to be a check or verification that simple causes can be located and fixed. It is not an exhaustive “how to” for all types of problems. Procedures that require in depth knowledge or skills (like flashing the field) should be referred to an authorized service department.

Table 5-1 Troubleshooting Guide

Problem	Possible Cause	Remedy
Engine will not start	No fuel.	Check that fuel valves are ON. Check fuel level in fuel tank.
	Restricted air flow.	Check/replace air filter.
	Damaged glow plug	Check/replace glow plug(s). Check that engine switch is in Start
		position.
Engine will not crank	Dead battery.	Remove battery and trickle charge or replace with new battery.
		Never Jump Start.
Engine starts but will not run smoothly	Fuel or ignition problem	Refer to engine manual.
Engine overheats	Excessive load	Remove one or more electrical loads.
	Debris or dirt buildup on engine	Remove debris. Clean engine surfaces to allow cooling.
	Low Coolant Level	Replenish coolant
Output voltage varies	Irregular speed	Check engine for malfunction or load for fluctuation
	Fluctuating speed	Stabilize load. The addition of a lamp load (resistance load) may
		compensate partially for load changes caused by intermittent motor
		operation. Do not overload.
	Loose terminal or load connections	Verify all connections are proper and check tighness torque of
		terminals.
	Defective alternator bearing (uneven air	Replace worn bearing
	gap)
Low Voltage (0−15 VAC output)	Bad Voltmeter	Measure the voltage across the voltage meter with an accurate
		voltmeter to verify.
	Bad/Open Circuit Breaker/Fuse	Check continuity across Breaker/Fuse. Replace if defective.
	Bad Connection	Check wiring including grounds, crimps and connection points.
		Repair defects.
	Loss of Residual Magnetism	The generator needs to be flashed. Contact service center to
		perform this procedure.
	Bad Voltage Selector Switch	Replace switch, contact service center to perform this procedure.
	Bad Stator Windings	Contact service center to perform this procedure.
Low Voltage (15−20 VAC output)	Bad Voltmeter	Measure the voltage across the voltage meter with an accurate
		voltmeter to verify.
	Incorrect Engine Speed	Remove electrical load, output should be 61−62 Hertz adjust engine
		speed if necessary.
	Bad/Open Circuit Breaker/Fuse	Check continuity across Breaker/Fuse. Replace if defective.
	Bad Connection	Check wiring including grounds, crimps and connection points.
		Repair defects.
	Bad Voltage Selector Switch	Replace switch, contact service center to perform this procedure.
	Bad Stator Windings	Contact service center to perform this procedure.
	Bad Voltage Adj. Rheostat	Replace rheostat, contact service center to perform this procedure.
	Bad Voltage Regulator	Replace regulator, contact service center to perform this procedure.
	Bad Rotor Diodes	Contact service center to perform this procedure.
	Bad Rotor Windings	Contact service center to perform this procedure.
Incorrect voltage output	Bad Voltmeter	Measure the voltage across the voltage meter with an accurate
		voltmeter to verify.
	Incorrect Engine Speed	Remove electrical load, output should be 61−62 Hertz adjust engine
		speed if necessary.
	Bad Voltage Adj. Rheostat	Replace rheostat, contact service center to perform this procedure.
	Bad Voltage Regulator	Replace regulator, contact service center to perform this procedure.
	Bad Connection	Check wiring including grounds, crimps and connection points.
		Repair defects.
	Bad Voltage Selector Switch	Replace switch, contact service center to perform this procedure.
High output voltage	Excessive speed	Check engine for malfunction

5-2 Troubleshooting and Maintenance MN2417