Wacker Neuson G2.5A, Repair Manual

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G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair
wc_tx000208gb.fm
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6.27 Troubleshooting
Problem / Symptom Reason / Remedy
Engine Does Not Start • Engine switch is in “OFF” position. Move engine switch to “START”
position.
• Fuel valves under fuel tank and on engine are closed. Open fuel
valves.
• Fuel tank is empty. Fill fuel tank.
• Choke lever is in wrong position. Move choke lever to correct posi-
tion. (Close choke lever when starting a cold engine).
• Spark plug is in poor condition. Replace spark plug.
• Spark plug cap is loose. Tighten spark plug cap.
• Engine oil level is low. Refill oil.
No Output Voltage • Circuit breaker open. Reset breaker.
• GFI open. Test and reset GFI. Replace if defective. Tool or appliance
defective, leaking current.
• Loss of residual magnetism. Flash rotor fields.
• Defective receptacle or switch. Inspect wiring and components and
repair.
• Open or shorted stator windings. Test stator and replace.
• Open or shorted rotor windings. Test rotor and replace.
• Connector from generator to control panel is loose or disconnected.
Install tightly.
Low Voltage • Engine speed too low. Reset engine speed to 3600-3750 rpm.
• Automatic voltage regulator defective. Test AVR and replace.
• AVR voltage pot set low. Adjust voltage pot to correct voltage.
• Defective choke. Test choke and replace.
• Defective diode bridge rectifier. Test rectifier and replace.
• Brushes damaged or broken. Inspect for damage.
• Rotor winding partially shortened. Test rotor winding resistance.
Replace rotor.
• Slip rings damaged or broken. Inspect for damage or dirt. clean rings
or replace rotor
High Voltage • AVR voltage pot set too high. Adjust voltage pot.
• Automatic voltage regulator defective. Test AVR and replace.
• Wire to AVR broken. Repair or replace wire.
• Engine speed too high. Adjust engine speed to 3600-3750 rpm.
No-load Voltage Normal but
Falls when Load is Applied
• Idle speed too low, governor hunting. Adjust idle speed to 2650 rpm.
• 1.6 Amp fuse blown. Replace fuse.
• Auto idle switch defective. Test and replace switch.
• Wire harness disconnected. Reconnect.
• Auto idle module defective. Test and replace auto idle module.
• Defective auto idle actuator. Test and replace. (550 Ohm - G 3.7, G/
GS 5.6)
• Unit will not come up to speed (GS 9.7 / GS 8.5 only). Check battery
for proper voltage.