Generator Repair – Identifying and Servicing Common Problems

Repair Generac Generator involves inspecting and servicing power-generation equipment so it continues to function properly during outages. Generator mechanics often work on multiple types of machinery and may need to use critical thinking skills when diagnosing problems.

Generator Repair

A professional technician can identify small issues before they cause bigger problems. They can also help you save money by completing repairs quickly and efficiently.

The battery is the heart of a generator. It supplies power to the generator engine starter when needed, and is usually one of the first components to fail due to age or condition. Local codes and regulations require that batteries be tested and inspected during routine maintenance and emergency service. These inspections include a visual examination, a test of the electrolyte levels in each cell for maintainable batteries and voltage checks on maintenance-free or flooded lead acid batteries. Often, these tests also include the verification that the battery is properly connected to the generator engine starter and that all connections are tight.

The most common battery problems are mechanical in nature and involve the exposed parts that are easiest for a technician to inspect. For example, the terminals are delivery points for a battery’s electrical force, and must be clean to ensure maximum contact area. This helps to prevent corrosion, which is a major cause of battery failure. Likewise, the connections must be tight to avoid excessive current flowing through the battery and potentially causing damage.

A battery is comprised of multiple cells in either a series or parallel design. In a series design, each cell is charged by the previous cell and discharges to its neighboring cells. If the charge on any one cell is too high, it can overheat and cause an explosion.

A lead acid battery will self-discharge over time if not used, meaning that it will not take or hold a charge unless it is recharged. Keeping the battery maintained by checking and replenishing its water level regularly (using distilled water) will help to prevent this from occurring. Additionally, the battery should be kept clean both inside and out to reduce dirt accumulation, which can increase its stress on the internal components.


A generator’s wiring can corrode, fray or be cut over time. Whether the issue is caused by an electrical storm or simply from age and usage, damaged wiring is a critical problem that should be repaired immediately. Signs that your generator has damaged or worn wiring include low voltage warnings, malfunctioning gauges and tripped breakers.

If you’re experiencing these issues, it’s important to have them diagnosed by a professional. The experienced technicians at Scherer Electric can identify even the most subtle problems with your generator and fix them before they become larger, more expensive problems.

A well-maintained generator will operate correctly and safely for years to come. It’s important to adhere to the maintenance schedule recommended by the equipment manufacturer and perform regular testing of the unit. Testing is done to ensure all components are functioning properly, and it’s an ideal opportunity for the technician to catch any minor problems before they cause unneeded disruptions.

Keeping the right amount of fuel on hand is also important. Over-fueling the generator will damage it, and under-fueling may result in it not starting. Regularly removing the spark plugs and cleaning them is an excellent way to prevent overfilling or under-fueling.

Regular oil changes are also an important part of regular generator maintenance. This will keep the engine running smoothly and prevent damage to moving parts such as the transfer switch and motors. It’s also a good idea to change the filter when changing the oil. This will prevent the new oil from being contaminated with impurities and gunk that was left behind by the old one.

Using the proper sized cable for connecting the transfer switch to the generator is essential. Oversized or under-sized cables can lead to a high resistance and resulting in a higher voltage drop. Having the cable sized by a certified electrician is an excellent way to ensure it is correct and will be able to handle the load of your generator during a power outage.


Whether it is used for business or residential purposes, generators provide critical power to keep electrical equipment running during a power outage. However, like any piece of machinery, they require routine maintenance to ensure that they continue to function properly. During this process, experts examine various components to detect and repair any issues.

During the inspection process, experts carefully gain access to the inner workings of the generator using tools such as multimeters and voltage testers. They check the battery, wiring, fuel system, and other components for signs of damage or wear. Experts also inspect the ducting, exhaust system, DC electrical systems, accessories, and AC wiring.

The fuel system in a generator is crucial to ensuring that the machine continues to run when the power goes out. It is tasked with delivering fuel to the engine to generate mechanical energy for the alternator. However, it is common for this part of a generator to develop issues that could prevent it from generating power. For instance, a fuel line may leak or the fuel cut-off valve might become blocked.

Another issue that can arise with a generator’s fuel system is the build-up of impurities within the engine. Over time, this can clog the pistons and carburetor and reduce the generator’s ability to produce energy. In addition, poor quality fuel can cause the generator to overheat and shut down.

It is important to note that neglecting to perform maintenance on a generator can have serious consequences. Often, minor problems can worsen over time and lead to more expensive repairs, or even permanent damage. Additionally, failure to perform maintenance can void any warranty that might be included with the generator.

The best way to avoid these problems is by scheduling regular maintenance for the generator. This can help to spot issues when they are small and easier to repair, saving both time and money. While it might be tempting to postpone these routine inspections, it is essential that they are carried out to protect the investment in the generator and ensure that it is ready to operate when needed.


During operation, the generator produces high temperatures that can damage internal components. This includes circuit boards, transfer coils and other electrical parts. Regular maintenance helps to identify and repair minor problems before they cause a significant disruption.

Wiring can also corrode, fray or be cut during normal usage. Damaged wiring can affect the performance of the generator and lead to dangerous situations such as low voltage warnings, malfunctioning gauges or tripped breakers. Wiring repairs should always be done by a Certified Technician.

Belts and hoses are used to convey vital fluids such as engine coolant, lubricating oil, fuel and exhaust gases through the system. Even though these are made from resistant materials, they can still wear down and break over time. It is recommended that these components be replaced based on the equipment manufacturer’s guidelines. This can save the client from unanticipated breakdowns, costly repairs and possible unit replacement.

These are critical parts of a generator that can’t be ignored. A failure can cause the unit to stop working, resulting in lost production and additional costs. In order to prevent this, a qualified Technician will inspect the hoses and belts on a regular basis.

When a belt is found to be worn, a quick replacement can minimize the risk of an unexpected breakdown and reduce costs. This will keep the generator working efficiently and extend its lifespan.

During an inspection, the technician can also verify that the generator belt is at the correct tension. If not, the technician will adjust it.

Before the Generator can be removed, it is important to ensure that the ignition key is turned off and that no power is going to the generator. It is also necessary to remove the LPCA cover and the fuel pump cover. Once the generator is disconnected from the fuel pump and battery, the technician can lift the fan shroud out of the cylinder tin and pull the generator with backing plate towards the rear of the bus.

The LPCA bracket should be secured to the frame cross member using the 4 mm hex key bolts (2x). Remove the cable connectors from the Strain Gauge, Data COMM and Battery Interface on the LPCA panel. Once removed, the generator can be lifted off of the stand. Reconnect the Strain Gauge, Data COMM, and Battery Interface cables to their respective connectors on the LPCA board. Route the battery cable over the Mylar moisture barrier and connect to the LPCA Battery connector (J4). Replace the Mylar moisture barrier and secure to the LPCA with the 2 x 4-mm hex key bolts (2x). Replace the LPCA cover and reattach the LPCA gas cap.