I have a generator that has always had a rotational error issue if it’s shut off without allowing it to run down. To avoid this, we always press the Start/Stop button, let it run down until the generator starves itself of fuel and shuts off. Then, we turn it off using the Power button and restart it with the same button to ensure it’s ready for AutoStart when needed.
If we turn it off using the Power button directly, it gives a rotational error—possibly because there’s fuel in the pistons, preventing it from turning over fast enough. However, if we let it sit for a couple of hours, it will start up without any issues.
Recently, I encountered this rotational error again and replaced the primary and secondary fuel filters. After bleeding the fuel, the generator started right up.
Now, after just 5–6 hours of operation with the new fuel filters, the problem has returned. The generator won’t start and shows a rotational error(if I wait, maybe over night, it will start). I turned on the fuel pump, and while I can hear it running, nothing comes out of the bleeder screw. The primary fuel filter bowl is clean.
Could this be caused by a completely clogged secondary fuel filter? That seems unlikely after only 5 hours of use with a brand-new filter.
Could it instead be a fuel pump issue? I’ve read that these pumps are rated for 10,000 hours, but ours has only about 800 hours on it, which seems too early for a failure.
Would anyone have any other suggestions?