Generac Minicube Troubleshooting Guide

Overspeed Warning

  • Check the sensor near the flywheel (right side of the generator).
  • Crank Sensor Part Number: 0D2244M.
  • Check throttle actuator to make sure it moves smoothly.
  • Pinpoint test harness from crank sensor to J connector.
  • Pin 10 (R15B) on connector J1 is the Overspeed/Watchdog pin
  • If the engine RPM falls outside of factory parameters, the watchdog timer will shutdown the engine.
  • Inspect throttle actuator play manually and with engine running

Engine surges and doesn’t run great?

  • Potential Causes:
    • Poor fuel quality
    • Loose filter/fuel lines
    • Failing injectors
    • Failing throttle actuator
    • Loose throttle actuator
    • Bad governor settings
    • Weak lift pump

Overcrank Warning’

  • https://talk.newagtalk.com/forums/thread-view.asp?tid=64537 (Remember these generators use off the shelf injection pump, fuel pump and filter housing.)
  • Inspect the check valve on top of the tank (G070327) or the filter housing.
  • Use the strongest CCA battery possible to ensure faster cranking.
  • Add check valve to fuel return too. (This mod may be already present on some generators, especially larger ones.
  • Potential Causes:
    • Poor fuel quality
    • Clogged fuel filter
    • Exerciser not set
    • Block heater not working
    • Weak battery
    • Weak starter
    • Make sure fuel shutoff solenoid isn’t cracked or leaking.
  • Possible Mods:
    • Modify the fuel return tube to reach the bottom of the tank to prevent air in the return line.
    • Install an electric lift pump wired to the run relay (minimum pressure 10psi and minimum 1 GPM).
    • Increase cranking time in GenLink and start attempts

    • Increase number of excercises

Resetting Faults

  • General Faults: Unplug the blue connector from the back of the ECM.
  • Continuous Circuit Test Faults: Unplug or jump the sensor associated with the fault.

Panel Removal

  • Unbolt panels one by one with a 10mm tool until the radiator panel is accessible.
  • If the lock won’t unlock or lock: Push inwards on the latch while turning the key.

Fuel pickup tube

  • Fuel pickup tube is 48.8cm long
  • If OEM one broke, 5/16 brake line works great
  • OEM part number is 10000000986

Preventative Maintenance

  • Set the generator to exercise weekly to catch faults early.

Bypassing the Factory Charger

  • Save the OEM charger connector. It contains all the pins needed to hook up an aftermarket charger.
  • Make sure to jump the two alarm pins.

Slow Fuel Gauge

  • The fuel gauge consists of a magnetic sensor and float with a lever. It may take time to react to fuel changes.
  • When filling quickly, fill to 75% to ensure it doesn’t get overfilled.

Part Numbers with Leading Zeros

  • Remove all zeros before the part number before searching.

Coolant Low

  • Check the radiator cap, overflow hose, coolant heater and hose connections.
  • If no visible leaks are found, the generator may be slowly consuming coolant.

Primer

  • Primer won’t come up? Check for clog in line to primer

  • Primer won’t go down? Open bleeder screw on filter housing and try again. Otherwise, there is a clog after the primer.

Fuel Gauge Stuck?

  • Sometimes, you can tap on it, but that doesn’t always work.
  • Try unbolting the gauge and wedging it out halfway and try to free it up.

  • You can use oil filter pliers to rotate gauge off.

Panel Hard to put on?

  • Space out brass mounts with washers

How to fill coolant without taking panels off?

  • Use radiator drain valve (above fuel box) and strong enough pump to fill generator.
  • Some have an access hatch on roof of generator.

  • You can potentially fill it through overflow tube with pump too.

How to make block heater more servicable?

  • Add a 3 wire 6 screw terminal block or outlet to power the block heater

HUIO module location?

  • XXX

Common warning tripped but no alarm?

  • ????

Battery Chargers Keep Failing

  • Check for corrosion and ensure all hot/neutral lugs are tight on the generator and breaker box.
  • It’s possible to replace the battery charger with an aftermaket one, and keep the OEM connector.

Generator Runs Around 100 RPM When Switched Off

  • Check the fuel shutoff solenoid and throttle actuator.
  • Some fuel shutoff solenoids can stick, especially with bad fuel quality.

Windings Smoking When Running

  • Advice is currently unavailable for this issue.

Replacing the Coolant Heater

  • Remove the first 3 panels
  • Close both ball valves to simplify the repair process.
  • Prefill the coolant heater to limit the chance of low coolant alarm.

Largest battery possible?

  • The dimensions of the battery box is X-X-X and the battery box can fit a Group XX battery if you tip it in there.

Minicube manuals may be more accessible due to being under the G007XXXX series just like the Guardian?