Generac 7KW, Model 005251, 3 yrs old. Natural gas pressure measured 6" WC at generator when installed. When installed, dealer had to turn fuel regulator screw all the way left to get engine to start. Has always seemed to cycle on/off for several seconds before smoothing out. Replaced cracked bellows 6 months ago after engine became almost impossible to start. Now sometimes taking 3-4 cranking tries before starting. New bellows still looks good. Don't understand cycling before smoothing out and needing multiple cranks. Any ideas?

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Is this a natural gas fueled generator? Sounds like a fuel problem, i would go through the fuel system and find out whats wrong. If its a natural gas/propane unit its most likely a bad regulator or low pressure.

When you get the under speed alarm is the generator under load? Try manually starting the generator with no load and let it run for a while, if no alarm, then put it under your home load and measure current draw (maybe have an electrician check it) if the amp draw and in rush caused by compressors, pumps motors etc are within the generator rating, check your fuel pressure, on average 8-11 WC Nat gas. Pressure may test well under no load but drop starving the engine of fuel unde rload. Underspeed is just that engine cannot make RPM/Frequency

Install a pressure gauge at the gas inlet regualtor, conform it isn't less than specs normall 11-13" WC pressure. test this when it is surging, it sounds like fuel, or also incorrect governor gain setting

Before you adjust anything, suggest you verify gas line for proper pressure and importantly volume. Pressure for gas should be 5 to 7 inches and propane 11 to 14 inches W.C. Also make sure the line to the generator is sized properly and the gas meter is a high volume unit (if NG). 90% we find the problem with generator sunder load that otherwise are fine are fuel related. Good luck.

Overcrank means that it tried to start and couldn't. It will go through 5 crank cycles and then stop with this alarm. Switch to off, hit enter to clear fault and then try to start in manual. Check to make sure you have fuel and pressure is 11 to 14 in WC.

need to calibrate the main control board. 83089. also is it overspeed or overcrank? if the board does not see the right rpm or is blow a certain threshold it will think it has not started yet and shut down on overcrank.

If the generator is out of warranty, you can try spraying a short shot of ether into the intake of the generator as it is running rough. If the engine smoothes out for a few seconds, and returns back to original state, then it is likely running lean. Check the gas regulator (this is LP or natural gas I am assuming since it is standby), the vent may be clogged on the bottom of it.

Sounds like Generator mode switch should be "ON".

Typically caused by the fuel line (LP or Natural Gas) having a lot of air in it. Was your generator just installed, or was there any work done to the gas line of the building / generator? Consult local gas contractor / propane dealer / gas company for assistance in purging the fuel line.

A low battery can also cause this as well as the generator is not able to come up to starting speed quick enough. Try placing a stand alone battery charger on the generator and charge the battery. Also check the air filter as well.

OverCrank condition occurs when generator tries to start itself, or be manually started, and the starter spends too much time turning.

This can also indicate failure of the control board. This will need the expertise of generac technician. Call 1-888-GENERAC (1-888-436-3722)
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