GW4500
Troubleshooting Chart - General
Symptom
Possible Cause(s)
Corrective Action
Engine will not start | 1. | Engine switch is set to "OFF". | 1. | Set engine switch to "ON". |
| 2. | Fuel valve is turned to "CLOSE". | 2. | Turn fuel valve to "OPEN" position. |
| 3. | Choke is open. | 3. | Close the choke. |
| 4. | Engine is out of gas. | 4. | Add gas. |
| 5. | Engine is filled with contaminated or | 5. | Change the gas in the engine. |
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| old gas |
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| 6. | Spark plug is dirty. | 6. | Clean spark plug. |
| 7. | Spark plug is broken. | 7. | Replace spark plug. |
| 8. | Unit is not on level surface. | 8. | Move unit to a level surface to prevent low oil shutdown from |
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| triggering. |
| 9. | Oil is low. | 9. | Add or replace oil. |
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Engine runs but | 1. | Circuit reset button is off. | 1. | Wait for 2 minutes and push the circuit reset button to the "ON" |
there is no electrical |
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| position. |
output | 2. | Bad connecting of wires / cables. | 2. | If you are using an extension cord, try a different one. |
| 3. | Bad electrical device connected to | 3. | Try connecting a different device. |
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| generator / welder. |
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Generator / welder runs but does not support all electrical devices connected.
1. | Generator / welder is overloaded | 1. | Turn off all electrical devices. Unplug all electrical devices. Turn off |
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| generator / welder. Wait several minutes. Restart generator / welder. |
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| Try connecting fewer electrical loads to the generator / welder. |
2. | Short in one of the connected devices. | 2. | Try disconnecting any faulty or |
3. | Air cleaner is dirty. | 3. | Clean or replace air cleaner. |
Troubleshooting Chart - Generator
Symptom
Possible Cause(s)
Corrective Action
No output voltage | 1. | Engine speed is too slow | 1. | Adjust engine speed ★ |
| 2. | Open, shorted, or incorrect wiring | 2. | Referring to the wiring diagram, clean and reconnect all wiring ★ |
| 3. | Faulty capacitor | 3. | Replace capacitor ★ |
| 4. | Open or shorted field windings | 4. | Test winding resistance, replace field winding if necessary ★ |
| 5. | Open diodes | 5. | Test diodes, replace if necessary ★ |
| 6. | Front panel switch set incorrectly | 6. | Set front panel switch to generator |
| 7. | Circuit breaker tripped | 7. | Reset circuit breaker |
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Low output voltage | 1. | Engine speed is too slow | 1. | Adjust engine speed ★ |
with no load | 2. | Open diodes | 2. | Test diodes, replace if necessary ★ |
| 3. | Faulty capacitor | 3. | Replace capacitor ★ |
| 4. | Open or shorted field windings | 4. | Test winding resistance, replace field winding if necessary ★ |
| 5. | Voltage setting on front panel | 5. | Adjust setting on front panel |
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| incorrect |
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High output voltage | 1. | Faulty capacitor | 1. | Replace capacitor ★ |
with no load | 2. | Engine speed is too fast | 2. | Adjust engine speed ★ |
| 3. | Voltage setting on front panel | 3. | Adjust setting on front panel |
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| incorrect |
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Low output voltage | 1. | Open diode | 1. | Test diodes, replace if necessary ★ |
under load | 2. | Engine speed too slow at full load | 2. | Adjust engine speed ★ |
| 3. | Excessive load applied | 3. | Reduce the applied load |
| 4. | Voltage setting on front panel | 4. | Adjust setting on front panel |
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| incorrect |
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Erratic output | 1. | Unbalanced engine | 1. | Refer to engine manual |
voltage | 2. | Dirty, corroded, or loose wiring | 2. | Referring to the wiring diagram, clean and reconnect all wiring ★ |
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| connection |
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| 3. | Unstable load applied | 3. | Remove all loads, then apply each one individually to determine which |
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| one is causing erratic function |
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Noisy operation | 1. | Loose welder / generators or engine | 1. | Tighten all mountings |
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| bolt |
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| 2. | Short circuit in welder / generators | 2. | Test winding resistance, replace field winding if necessary ★ |
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| field or load |
| Test load devices for shorts. Replace defective load device. |
| 3. | Faulty bearing | 3. | Replace bearing |
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★These diagnostic and repair procedures should be performed by an authorized service center.
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