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WGen 7500 will not start, it has no power.

396 views 15 replies 6 participants last post by  GenKnot  
#1 ·
Greetings!
I have a WGen7500 that will not turn on. I used it last year after Hurricane Milton. Ran it out of fuel, and stored it outside under a tarp. I figured I better get it going since it’s hurricane season. I brought it into the garage, flipped the power switch, and nothing, no battery light, no nothing. I ended up buying a new battery, and still nothing. I know the battery is good, 12.78v.
I took the front panel off and and started poking around. I have 12v to the starter, I have 12v to the blue wire at a module, I don’t know what it’s for, but I have 7.5v at the red push button (which is what?) on the side of the control panel box, and 7.5v at the power switch. Could this module be the problem?
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#5 ·
Had a pin loose in a molex connector once, and had to fiddle with it to get the pin back in tighter. Caused a similar set of symptoms on a wgen9500df ...

Check all wires coming into those multi-pin connectors ... one might have come loose during ops the last time you ran it. You should be able to just see it, as the loose one would be visibly different than the others in the same connector.

Hope this helps ...
 
#6 ·
I tried the recoil, but if there’s no power, the fuel cutout won’t energize , right?
The fuel cut solenoid does not need power for the gen to start or run.

I have 12v to the blue wire at a module
That blue wire (assuming you are describing the one from the starter solenoid to the module) gets grounded for the gen to crank. I would verify that the gen cranks by disconnecting the module harness and then momentarily touching the blue wire to ground. At least that will eliminate the starter as being the issue.

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#9 ·
“He said he ran it out of fuel last year, so bowl should be dry”

That is not correct. Running out of fuel, or closing the fuel tap and starving the engine doesn’t usually get rid of the last 3 tablespoons of gas in the bowl. So do that multiple times over several months and crud in the bowl is the result. Especially with e-gas. If you don’t believe me remove the fuel bowl after stalling any small engine and you’ll be surprised. All my Honda engines have drains on the carburetors and so it’s very simple to get every bit of gasoline out for long/short term Storage.
So a carburetor cleaning might be required here…
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#14 ·
“He said he ran it out of fuel last year, so bowl should be dry”

That is not correct. Running out of fuel, or closing the fuel tap and starving the engine doesn’t usually get rid of the last 3 tablespoons of gas in the bowl. So do that multiple times over several months and crud in the bowl is the result. Especially with e-gas. If you don’t believe me remove the fuel bowl after stalling any small engine and you’ll be surprised. All my Honda engines have drains on the carburetors and so it’s very simple to get every bit of gasoline out for long/short term Storage.
So a carburetor cleaning might be required here…
I've only found maybe a half teaspoon remaining in bowl (six generators, 2K to 5K) after fuel-cut off shutdown. Maybe more on bigger gensets? Full agreement on cleaning carb, "when in doubt, clean the jets."
 
#11 ·
I haven’t gotten that far yet. Still trying to figure out the no power issue. The module I have in the picture, what is it? And what is the red push button on the side of the control box for? I get 12v to the r/br wire and blue wire at the module, but 7.5v coming out at the b/w wire.
 
#16 ·
I have 12v to the blue wire at a module, I don’t know what it’s for
The module is the Control Module. The main functions of the module are for local and remote start, and controlling the stepper motor position. Having 12V on the blue wire would be normal when not starting the gen.

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I have 7.5v at the red push button (which is what?) on the side of the control panel box, and 7.5v at the power switch.
What wire colors have 7.5V on them, and what state is the power switch in (Run/Stop) when you are measuring this voltage? This voltage (7-10V) is normal for some of the measurements according to this document.

Do you have voltage at either the Black or White wires going to the AVR when the power switch is in the Run position?