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| Troubleshooting Chart (Continued) |
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Generator |
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| Symptom | Possible Cause(s) | Corrective Action |
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| No output voltage | 1. | Engine speed is too slow | 1. | Adjust engine speed H |
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| 2. | Open, shorted, or incorrect wiring | 2. | Referring to the wiring diagram, clean and reconnect all wiring H |
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| 3. | Faulty capacitor | 3. | Replace capacitor H |
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| 4. | Open or shorted field windings | 4. | Test winding resistance, replace field winding if necessary H |
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| 5. | Open diodes | 5. | Test diodes, replace if necessary H |
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| 6. | Front panel switch set incorrectly | 6. | Set front panel switch to generator |
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| 7. | Circuit breaker tripped | 7. | Reset circuit breaker |
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| Low output | 1. | Engine speed is too slow | 1. | Adjust engine speed H |
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| voltage with no | 2. | Open diodes | 2. | Test diodes, replace if necessary H |
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| load | 3. | Faulty capacitor | 3. | Replace capacitor H |
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| 4. | Open or shorted field windings | 4. | Test winding resistance, replace field winding if necessary H |
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| 5. | Voltage setting on front panel | 5. | Adjust setting on front panel |
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| High output | 1. | Faulty capacitor | 1. | Replace capacitor H |
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| voltage with no | 2. | Engine speed is too fast | 2. | Adjust engine speed H |
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| load | 3. | Voltage setting on front panel | 3. | Adjust setting on front panel |
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| Low output | 1. | Open diode | 1. | Test diodes, replace if necessary H |
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| voltage under | 2. | Engine speed too slow at full load | 2. | Adjust engine speed H |
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| load | 3. | Excessive load applied | 3. | Reduce the applied load |
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| 4. | Voltage setting on front panel | 4. | Adjust setting on front panel |
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| Erratic output | 1. | Unbalanced engine | 1. | Refer to engine manual |
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| voltage | 2. | Dirty, corroded, or loose wiring | 2. | Referring to the wiring diagram, clean and reconnect all wiring H |
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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 unit or engine bolt(s) | 1. | Tighten all mountings |
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| 2. | Short circuit in unit field or load | 2. | Test winding resistance, replace field winding if necessary H |
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| Test load devices for shorts. Replace defective load device. |
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| 3. | Faulty bearing | 3. | Replace bearing |
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HThese diagnostic and repair procedures should be performed by an authorized service center.
Welder
Symptom | Possible Cause(s) | Corrective Action | ||
Welder runs but | 1. | Inadequate current at electrode | 1. | Check work clamp, cable and connection to work piece. Check electrode |
does not weld |
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| cable and clamp |
| 2. | Poor connections at welder | 2. | Check all welder external connections |
| 3. | Front panel switch set incorrectly | 3. | Set front panel switch to weld |
| 4. | Open, shorted, or incorrect wiring | 4. | Referring to the wiring diagram, clean and reconnect all wiring H |
| 5. | Faulty capacitor | 5. | Replace capacitor H |
| 6. | Open or shorted field windings | 6. | Test winding resistance, replace field winding if necessary H |
| 7. | Open diodes | 7. | Test diodes, replace if necessary H |
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Welder gives | 1. | Accidental contact with work piece | 1. | Avoid contact with work piece |
trickle shocks | 2. | Current leakage caused by moist | 2. | Make sure clothing and work area are dry |
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Arc difficult to | 1. | Wrong type of electrode. | 1. | Verify that electrode is for alternating current (AC) |
strike | 2. | Electrode diameter too large | 2. | Use smaller diameter electrode |
| 3. | Work piece not properly grounded | 3. | Verify proper grounding. (No paint, varnish or corrosion) |
| 4. | Engine speed is too slow | 4. | Adjust engine speed |
HThese diagnostic and repair procedures should be performed by an authorized service center.
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