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When you set the backlights to high it causes the inverter board to generate more energy, as well as consume more from the power supply, all the while both are generating more heat. If you have your set mounted (restricting the vents) and/or you regularly use the high setting, that could cause capacitors to bulge and leak due to excessive heat damage. I would open her up and have a look at the power supply and inverter boards. Check for bad caps or board surface discolorations.
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
You engine is TBI, It uses a MAP sensor check the vacuum line for crack and make sure yo have a good seal, The distributor also check and make sure the pick up does not have corrosion which causes the relutor to stick. As for the EGR it would cause a misfire, and yes the do fail. I am sticking with the IAC as a problem its a stepper motor and has a high failure rate, chack also the ECT (engine coolant temp sensor) for corrosion that gives false reading.
Your generator should be running @ 1800 rpm if its diesel . I have a 40 kw diesel generator and it starts up and runs a full 1800 rpm with no load . Thats how there designed because they have a 4 pole alternator. Hope this helps.
It is quite normal for the exhaust manifold and turbo to get very hot, especially when the engine is working hard running at high speed under load. Every time the mixture in the cylinder is ignited there is a small explosion producing a BIG flame and a lot of heat to push the piston down. A lot of this heat goes out the exhaust. During daylight it is usually not noticeable, but at night it will visibly glow up to a bright red.
In relation to the oil pressure dropping, providing the oil level is at the correct level, there may be a restriction in the gauze filter on the input of the oil pump due to sludge buildup. Once the engine warms up and the oil thins out, the oil pump can't work at maximum capacity. The drop in RPM could be caused by the turbo getting insufficient lubrication and cooling due to the low oil pressure reducing oil flow to the turbo causing it to not work at its optimum speed and efficiency and therefore through reduced air flow into the cylinders the engine would tend to loose speed especially when under high load. The drop in RPM could also be caused by a problem with fuel flow to the injector pump causing the engine to run lean which would not allow the engine to produce maximum power and also contribute to higher exhaust temperatures because the governor would have the throttle wide open to try and maintain the engine speed when the generator is required to produce maximum output.
Actually, without a load being connected, this voltage is within specifications. As you connect loads, the engine slows down, voltage will drop as well.
If your meter has the ability, the frequency of the generator with no load plugged in should be 65 or so (preferably 63, but hard to keep it there with mechanical governor).
If you do find that your voltage is too high, with a load plugged in, you are able to reduce it slightly by adjusting the governor ever so slightly towards a lower RPM. 60 RPM = 1 Hz, and a few volts difference.
The best way to adjust your generator is to plug in a load that is half the rated wattage of the generator. Then make your adjustments, keep the frequency just a hair above 60 so that additional loads won't cause it to drop too far.
More than likely a safety control circuit on startup. Either high water temp, low oil pressure, or over rev condition. If not any of the above quite possibly the integratrated generator/engine control circuit board.
You run again the generator but before running, check & mark the oil level. Then stop the generator & wait until the oil settle to the bottom of oil pan. Check the oil level again & if the oil level is higher than the marking before that's means you have an engine gasket leak.You need to replace that gasket.