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Generac Generator Troubleshooting; 5 Issues and 25 Fixes

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Your life off the grid depends on your generator, unless you have a great set of solar panels and batteries. While that may earn you points for the planet, it is an unreliable power source that adds weight to your vehicle.

This is why most RV owners continue to rely on generators as their primary source of power, and even many people with solar panels carry generators for backup power. Generators are machines, and they’re often run long and hard. This contributes to breakdowns.

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Here are a few tips on generac generator troubleshooting and common fixes for portable generac RV generator.

A generator battery is used to provide power to the engine starter. In some cases, the generator battery can provide power to small devices, as well. What can you do if the generac generator battery keeps dying?

Here are several possible solutions.

The voltage regulator sends power from the alternator to the battery to keep it charged. If the voltage regulator is malfunctioning, the battery cannot receive enough voltage to properly charge the battery. This will cause the battery to drain quickly or simply fail to charge even though the generator is running.

The solution is typically to replace the voltage regulator.

If the alternator isn’t sending enough power to the voltage regulator, it doesn’t matter if the voltage regulator is working properly. You can determine if the alternator is the problem by checking it with a multimeter.

Test the multimeter for continuity. This is where you’re testing for a complete circuit when the switch is closed.

The continuity test means there is no or low resistance, and this is an indication that the two points are connected.

If the circuit isn’t connected, then the alternator isn’t sending enough power downstream or isn’t sending any at all.

A generator running rough is surging and then slowing. The surging may follow a pattern or be random. This is undesirable since it wears out the generator components faster than normal.

Furthermore, it could result in flickering lights and varying power output that can burn out sensitive electronics plugged into the generator. On top of that, it can be a warning that the generator is about to break down.

In contrast, a smooth running generator runs at the same, steady speed. This has the side benefit of being quieter than a “rough” generator.

The first thing to check is whether the carburetor is clogged, since this is the easiest thing to fix. The root cause of this may be that you left fuel in it for a long time.

Some of the ingredients in the fuel evaporated, leaving a thicker sludge that’s hard for the engine to run. At best, it runs rough.

At worst, it will stall. You can solve this by cleaning the carburetor with carburetor cleaner.

You can also put in fresh fuel and see how it runs. Just make sure you’re using the right type of fuel and proper fuel quality.

Note that using poor quality fuel or the wrong fuel can damage the carburetor.

If cleaning the carburetor didn’t work, you may need to repair or replace the carburetor. This is where a carburetor repair kit comes in.

Suppose the carburetor isn’t the problem. Another possibility is that the problem is the spark plug that ignites the fuel. You can check the spark plugs for damage or wear.

The simplest solution is to replace it. This is certainly necessary if you have a porcelain spark plug that’s cracked. The exposed electrode in these cases will see the electrode burn away. If you see heavy carbon buildup on the spark plug, just replace it.

What if the spark plug isn’t obviously damaged or broken?

You can test it with a spark plug tester. If you see a strong spark from the spark plug, that’s probably not the problem. If you don’t see a spark or a weak one, the spark plug needs to be replaced.

Sometimes the issue is the fuel filter. If the fuel filter is clogged, the generator can’t get a steady supply of fuel. The simplest solution is to replace the fuel filter.

Note that the fuel filter may be the root cause of the problem if cleaning the carburetor didn’t resolve the problem, especially if you had sludge-like fuel in the generator tank.

If you had enough bad fuel in the system to affect both the carburetor and fuel filter, drain the old fuel, clean the tank, and put in new fuel while you replace the fuel filter.

One possible answer is that the carburetor is clogged. That will cut off the fuel flow and cause it to stop running. Bad fuel in the float bowl will do the same thing. Drain the bad fuel, clean it with carburetor cleaner, add fresh fuel and try it.

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Remember to use the right type of fuel and good quality fuel.

Suppose cleaning it didn’t work. That gunk has probably clogged up the ports and small jets inside the carburetor. You probably need to get a carburetor repair kit and replace key components if not the entire carburetor.

This is especially true if cleaning it and running it with clean fuel and filters doesn’t solve the problem.

The fuel cap has a small vent to let air into the tank as the generator consumes fuel. If the fuel cap vent is clogged, the generator fuel tank will experience a vacuum called vapor lock. That stops the flow of fuel into the carburetor.

A simple way to determine if this is the issue is to loosen the fuel cap and run the generator. If the generator runs smoothly, then you know you need to clean the fuel cap or just replace it.

At least you can run the generator without the fuel cap on, assuming water won’t get inside of it.

When a generator surges, it may run high and then low. When the generator is dying, it starts but won’t continue running. In this section, we’ll discuss things to check when the generator won’t even start in the first place.

Assuming you have fuel in the generator, the next thing to check is the spark plug. If the spark plug can’t generate a spark, it won’t ignite and power the generator.

Take out the spark plugs and inspect them. If the spark plugs are damaged, replace them. If they’re covered in carbon build-up, you can try cleaning them and replacing them. However, that may be a sign that the spark plug is cracked and not igniting properly.

You can install it and then try to run the generator, or you can test it with spark plug tester. (If the tester shows it won’t spark, replace it.) If the generator surges or won’t start after you reinstalled the spark plug, replace the spark plug with a new, good one.

We mentioned that a generac RV generator may run rough if the carburetor is clogged. If the problem is bad enough, then the generator cannot run at all. The fuel lines may be totally blocked. And if there is no fuel flow, there may not be any fuel for the spark plug to ignite.

You can try cleaning the carburetor with carburetor cleaner. You probably need to replace the fuel filter, since the filter is probably clogged with the same residue that clogged the carburetor.

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And the fuel itself should be replaced, if you’re trying to run the generator off the fuel that was so degraded that it clogged the generator.

Ideally, you should drain the fuel, clean the carburetor, and then add clean fuel. Then test the generator.

Suppose the problem isn’t blocked fuel lines or spark plugs that won’t spark when tested. The next possible root cause is the ignition coil. The ignition coil sends voltage to the spark plug to spark it when the engine is running.

If the ignition coil is not working, the engine may not start at all. We recommended checking the spark plugs because that’s easier and cheaper to replace. Once you’ve verified it isn’t any of the spark plugs, you can move on to the ignition coil.

We’d advise you to test the ignition coil with an ignition coil tester. Unfortunately, relatively few people have one of these. It is somewhat expensive to replace the ignition coil if you don’t know for certain if that’s the source of the problem.

That’s why we’d recommend moving on to the other solutions on our list before assuming this is the right course of action.

The recoil starter connects with the crankshaft to turn over the engine. If the recoil starter isn’t working properly, it may not engage the crankshaft and turn over the engine. You can remove the starter assembly to see if it is working correctly. You do this by pulling the starter rope.

The tabs on the pulley and cam should pull on the hub of the engine and cause it to turn. When you release the starter rope, the tabs should retract. The rope should rewind along the pulley.

Of course, if the rope is broken, that explains why the thing won’t start. If the rope won’t rewind, it can’t turn the engine when you pull it because it is already extended.

There are safety switches on the generator that turn it off in unsafe conditions. Sometimes safety switches are triggered during normal operation. If the switch is defective, it will prevent the generator from starting up.

You can check this with a multimeter.

Some generators have start switches instead of forcing you to pull a pull rope to start up the generator. While this is convenient, it also introduces a new way for the generator to fail to start.

If the start switch is broken, you can’t start the generator. The switch typically has to be replaced if it isn’t stuck in the off positon due to grease and debris. You can determine if the switch is broken by testing it from continuity.

The multimeter should show an open contact when the switch is off and a closed contact in an on position.

The flywheel key is a metal piece in the crankshaft that connects with the flywheel when you’re starting the generator. This piece of metal is subject to a lot of mechanical stress, and it often shears.If the generator suddenly stops and won’t start back up, that’s probably what happened.

You can determine if this is what happened by taking the flywheel out of the engine and inspecting the flywheel key.

The only solution is to replace the broken part.

Is it on? We’re serious. The generator may not start because it is switched off, even if the safety switches aren’t in the way.

On the other hand, the on-off switch can break and keep the generator in an “off” position though you’re trying to turn it on.

You can check this with a multimeter if flicking the switch and trying to start the generator doesn’t solve the problem.

A gas leak is a serious problem with a generator. It doesn’t just waste fuel that could be used to run the generator longer. It creates a fire hazard, since fuel leaking beside sparking electronics and heat sources can ignite.

It is also an environmental hazard, since the leaking gas emits fumes and is poisonous to plants. This is why you want to identify and stop gas leaks as soon as possible.

We’ve discussed cleaning the carburetor as a solution to a variety of problems. The carburetor bowl gasket is the point where you remove that part to access it. When the gasket is dried out, it can’t form a tight seal.

This allows fuel to leak out. If the seal is cracked or damaged, it may leak. If you forgot to replace the gasket, you’ll have a fast fuel leak. If the fuel leak is coming from the bottom of the carburetor, the bowl gasket should be the first thing you check.

If you just cleaned the carburetor and now have a fuel leak, you should check the gasket as the source of the leak. And verify that it is fuel so that you don’t replace parts because you accidentally spilled carburetor cleaner used to clean the tank on the ground.

This is another gasket on the carburetor that can dry out, get damaged or be missing. If you’ve been cleaning the carburetor or replacing carburetor parts, check this gasket near the bottom of the carburetor. If you see fresh fuel around it, replace it, especially if you see the leak as the generator is running or soon after it is turned off.

The float chamber or float bowl in the carburetor controls the influx of fuel into the carburetor. As the fuel is consumed, the float drops. That opens a valve to bring in new fuel.

When fuel comes in, the float should rise and close the inlet valve. If there is a leak around the float bowl, this gasket may be the cause.

And in these cases, it needs to be replaced.

Fuel lines are hoses. Like garden hoses and hoses in your RV engine, they’re prone to dry and crack over time. They can be damaged, as well, whether cut by accident or worn down when vibrating and rubbing against other parts.

Inspect the fuel lines for cracks. If cracked, do not try to slow the leak with tape; the fuel line should be replaced. You can’t risk a major failure that spews fuel everywhere in a hot engine.

If you’ve had to clear clogs from the fuel lines because of bad fuel, make sure the fuel lines are securely connected to the appropriate points.

Sometimes things leak because we don’t screw in the connectors securely. Or it is as simple as failing to secure the wire retaining clip.

Fuel tanks can leak. This may be a small leak as the container is worn down or rusts. If the fuel tank is showing wear and tear or the material is degrading, replace it.

Minor damage to a fuel tank like a damaged corner is repairable, but it is safer to replace the fuel tank. You don’t want fumes from a leaking fuel tank building up around a generator. It is a fire hazard.

Make sure you properly connect the fuel lines to the new fuel tank or you’ll have a new source of leaking fuel. And before you replace the fuel tank, make sure the fuel on the ground isn’t there because you spilled it trying to refill the fuel tank. That’s generally the cause of fuel around the fuel tank cap.

However, the fuel tank cap itself can’t leak fuel, though the generator will shut off if the cap is so dirty that the unit can’t bring in air to equalize pressure through the hole in the fuel tank cap.

A primer bulb is a bulb you have to push to “prime” the engine in the generator before starting it. It is usually located next to the carburetor. When you push it, it creates a vacuum that pulls fresh fuel into the fuel intake line. That fuel is put in the carburetor to make it ready or “primed” for combustion.

If the primer bulb is cracked or damaged, it will leak fuel when you’re trying to start the engine. Don’t try to repair a cracked or damaged primer bulb. Just replace it.

The carburetor like the fuel tank is a large container for fuel. Unlike the fuel tank, the carburetor is exposed to high heat and vibration levels. This means it is prone to cracking, warping and breaking. It can also rust. If you find fuel leaks around the carburetor but none of the obvious candidates like seals or fuel line connections are responsible, the issue may be the carburetor itself.

Check for cracks and corrosion. If you find those, replace the main body of the carburetor. If you’ve replaced every other source of potential leaks and it still leaks, replace the main carburetor. This is especially true if the fuel tank itself has corroded or cracked, whether due to extremely cold weather or damage from being dropped.

Just as the priming switch to start up the engine can leak, so can the fuel shut-off valve. In general, the solenoid that controls the switch is where it will leak. Always replace the solenoid instead of trying to fix it. After all, you can’t afford to take the risk it won’t work perfectly in an emergency.

Note that the leak may be the fuel lines around the fuel shut off valve, so inspect those before you replace the fuel shut off valve. There may be cracks in the fuel line leading to the shut off valve.

The portable generac RV generators are essential to powering life off the grid. They are complex pieces of machinery. However, the most common problems are simple enough that most RV owners can troubleshoot and repair them themselves.

Generac Holdings Inc., commonly referred to as Generac, is a Fortune 1000 American manufacturer of backup power generation products for residential, light commercial and industrial markets.^[6] Generac's power systems range in output from 800 watts to 9 megawatts,^[7] and are available through independent dealers, retailers and wholesalers.^[6] Generac is headquartered in Waukesha, Wisconsin,^[3][4] and has manufacturing facilities in Berlin, Oshkosh, Jefferson, Eagle, and Whitewater; all in Wisconsin.^[7]

History[edit]

Founded by Robert Kern in 1959, the company soon began producing portable generators for Sears, Roebuck and Co. under the Craftsman brand. During the 1970s, Generac expanded its offerings in the portable and recreational vehicle markets, and in the 1980s the company entered the commercial and industrial markets with its backup power generation systems.^[7]

By end of the 1980s, the company was manufacturing residential, commercial and industrial generators, and in 1989, Generac introduced the first gaseous-fueled automatic home standby system.^[7]

In 1992, Generac began private labeling generator sets for Caterpillar, Inc. As the partnership grew between the two companies, they discussed a potential acquisition of Generac by Caterpillar, although a deal was never finalized. In June 1996, Caterpillar decided to terminate the private labeling agreement. Generac then sued Caterpillar under the Wisconsin Fair Dealership Law ('WFDL'), the Sherman Antitrust Act, the Wisconsin common law concerning restrictive covenants, and the Illinois Consumer Fraud and Deceptive Business Practices Act.^[8] The federal district court, in two separate orders, disposed of the action in Caterpillar's favor. Generac then challenged the lower court's rulings in the U.S. 7th Circuit Court of Appeals, which ruled that Generac's claims were properly dismissed by the lower court.^[9] Generac continued to supply some transfer switches to Caterpillar until 2002, when Caterpillar changed suppliers.

In 1998, Generac sold its portable products division to the Beacon group, a private equity firm, who later sold it to Briggs & Stratton Corporation. Upon expiration of a non-compete agreement related to the sale in 2007, Generac re-entered the portable generator market in 2008.^[7]

In late 2006, Generac was purchased by CCMP Capital of New York.^[7] In 2009 CCMP took a write-off, described as a non-cash goodwill and trade name impairment charge, of $583.5 million against their purchase of Generac.^[10]Aaron Jagdfeld was appointed president and chief executive officer in September, 2008 and is the current CEO.^[7]

Generac goes public[edit]

On February 11, 2010, Generac Holdings Inc. (NYSE: GNRC), parent company of Generac Power Systems, Inc., began trading on the New York Stock Exchange under the ticker symbol GNRC.^[7] The initial public offering provided $224 million in net proceeds, which were used to pay down debt.^[7]

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Recognition[edit]

Generac is a recipient of Milwaukee Magazine’s “Best Places to Work” award for Southeastern Wisconsin.^[11]

Generac's industrial sizing application, Power Design Pro, received silver in the 2010 Plant Engineering 'Product of the Year' award.^[12]

The company has also earned the Good Housekeeping Seal for its Guardian Series home standby generators and several portable generators.^[13]

Generac was honored with the 2014 Natural Gas Generator Company of the Year Award from Frost & Sullivan for its contribution to the North American natural gas generator set industry.^[14]

Products[edit]

Generac manufactures gasoline-fueled, diesel-fueled and bi-fuel engine-driven power generation equipment, modular paralleling systems, automatic transfer switches and small engines.^[6] The company supplies products to the industrial, commercial, and portable generator markets through many different distributors.In December 2009, Generac introduced Generac Industrial Power (a rebranding of its industrial products division) to include new engines, new enclosures, ergonomic changes and aesthetic changes. This included a partnership with Fiat Powertrain Technologies to supply Generac with industrial diesel engines for use in industrial generators.^[15]

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References[edit]

1. ^Generac Power Systems - About Us
2. ^Generac workers get a holiday surprise - JSOnline
3. ^ ^abcdTom Daykin (November 7, 2011), 'Generac to add over 400 jobs at Wisconsin plants', Milwaukee Journal Sentinel, JSOnline
4. ^ ^abHQ may now be based in Genesee, Wisconsin according to more recent publication: Jeff Engel (October 29, 2012), 'Hurricane Sandy puts Wisconsin generator makers into overdrive', Milwaukee Business Journal, bizjournals.com, retrieved October 30, 2012CS1 maint: discouraged parameter (link)
5. ^Financial Statements for Generac Holdings Inc. - Google Finance
6. ^ ^abc'Generac Holdings Inc (GNRC.N) Company Profile – Reuters.com'. Reuters.
7. ^ ^abcdefghi2010 Generac Holdings Annual report
8. ^American Bar Association. Section of Antitrust Law (1999). Annual review of ... antitrust law developments. Section of Antitrust Law, American Bar Association. Retrieved 30 December 2011.CS1 maint: discouraged parameter (link)
9. ^'United States Court of Appeals, Seventh Circuit No.97-1404'. Archived from the original on 2010-05-17. Retrieved 2010-03-19.
10. ^GENERAC HOLDINGS INC. - FORM S-1/A - January 25, 2010
11. ^Budde, Andrea (May 30, 2012). 'Generac named among top workplaces in area'. Living Lake Country. Retrieved 28 July 2013.CS1 maint: discouraged parameter (link)
12. ^Product of the Year 2010 Winners | Plant Engineering
13. ^'Generac Power Systems Earns Good Housekeeping Seal'. Rental Equipment Register magazine. May 15, 2009. Retrieved 28 July 2013.CS1 maint: discouraged parameter (link)
14. ^'GENERAC POWER SYSTEMS EARNS FROST & SULLIVAN'S COMPANY OF THE YEAR AWARD'. Generac Power Systems, Inc.
15. ^Generac Industrial Power, Fiat Powertrain Technologies Announce Strategic Partnership for Diesel Engines Supply | Business Wire

External links[edit]

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• Business data for Generac Holdings:

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