G 2.5A Portable Generator Repair
wc_tx000207gb.fm 44
5.17 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
position. (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 • Engine speed too slow. Increase engine speed to 3700 rpm,
no-load.
• 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.
• Rotor diodes open or shorted. Test diodes and replace.
• 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 discon-
nected. Install tightly.
Low Voltage • No-load voltage between 70 – 100 volts, engine operating at
correct speed. One diode on rotor open or shorted. Replace all
diodes.
• Engine slightly below operating speed, but not enough to col-
lapse all output. Increase engine speed to 3700 rpm, no-load.
• Capacitor is defective. Test capacitor and replace if necessary.
• Rotor winding wire broken off at diode. Resolder wire to diode.
• Rotor winding partially shorted. Test rotor winding resistance.
Replace rotor.
• Rotor slipping on engine crankshaft. Rotor winding partially
shorted.
High Voltage • Engine speed too high. Reduce engine speed to 3700 rpm, no-
load.
No-load Voltage Normal but Falls
when Load is Applied
• Engine lugging down under load. Refer to engine repair manual
to restore engine power.
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