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Part of the problem is pressure washing, and the other part is that the plugs are often not tight. I love pressure washing. But when done, and I always tried to do it when it was warm, if not hot. Or, leave the gen set in a warm building for a few days. I know, this is not always an option...

Only one way to find out. I do know that the nuts are sometimes really hard to take off, and you can snap off a feed through screw, just like over tightening them. Tight is good, but Man Mountain Dean tight is not good.

I have never seen THAT failure, but others like it. It can happen. Do you have a Meg Ohm meter? You could test the coils with that, and it should tell you if there is a broken wire, or crappy connection. Kurt is better at that kind of thing then I.

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Kurt has it right. This happens VERY often. I first ran in to this with a ROPU water purification unit. The gen set was a 30 KW. The CT wires were wrapped like a 60KW. Every time the big electric motor started, drawing about 26 KW startup, the gen set sounded like it would jump off the trailer...