Wacker Neuson G 2.1A, Repair Manual

Page 1: ...www wackergroup com Portable Generators G 2 1A G 3 3A G 4 6A GS 4 6A GS 5 7A REPAIR MANUAL 0116567 002 1000 en 0 1 1 6 5 6 7...

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Page 3: ...ides information and procedures to safely repair and maintain this WACKER model For your own safety and protection from injury carefully read understand and observe the safety instructions described i...

Page 4: ...8269 0008269 0008269 0008269 0008269 101 101 101 101 101 5010101 5010101 5010101 5010101 5010101 Nameplate A nameplate listing the Model Number Item Number Revision and Serial Number is attached to ea...

Page 5: ...se of Extension Cords 3A 2 4 Model G2 1A 4 1 Theory of Operation Capacitor Generators 4A 1 4 2 Rotor 4A 2 4 3 Stator 4A 2 4 4 Capacitor 4A 2 4 5 Diodes 4A 2 4 6 Circuit Breaker 4A 3 4 7 Earth Leakage...

Page 6: ...n Circuit Breaker 5A 4 5 10 Earth Leakage Circuit Breaker ELCB 5A 4 5 11 Engine Speed 5A 6 5 12 Auto Idle Switch 5A 7 5 13 Loss of Residual Magnetism in Rotor 5A 9 5 14 Diode Bridge 5A 9 5 15 Stator W...

Page 7: ...he possibility of personal injury damage to the equipment or improper service CAUTION Used without the safety alert symbol CAUTION indicates a potentially hazardous situation which if not avoided may...

Page 8: ...overload generator The total amperage of the tools and equipment attached to the generator must not exceed the load rating of the generator NEVER allow untrained personnel to operate or servicethegen...

Page 9: ...hout express written approval from WACKER Corporation ALWAYS replace all guards and safety devices immediately after servicing ALWAYS turn engine off before servicing generator If engine has electric...

Page 10: ...1A 4 1A SAFETY 50 HZ PORTABLE GENERATORS Notes...

Page 11: ...p e g a t l o v V 0 3 2 e s a h p 1 1 V 0 3 2 3 V 0 0 4 y c n e u q e r F z H 0 5 r o t c a F r e w o P 0 1 1 0 1 3 8 0 s e l c a t p e c e R C A l a n o i t p O r e k a e r B t i u c r i C n i a M p...

Page 12: ...l a V d l o c t s u a h x e e k a t n i m m 0 2 0 5 1 0 g u l P k r a p S e p y t U R P E 0 2 W S E 6 R P B p a G g u l P k r a p S m m 8 0 7 0 r e t r a t S V e p y t A N A N A N V 2 1 c i r t c e l...

Page 13: ...der to start If the wattage is not given for a particular tool or appli ance it can be calculated by multiplying its voltage and amperage requirements VOLTS x AMPS WATTS CAUTION If a tool or appliance...

Page 14: ...tool and increases the amount of current draw or reduces performance A heavier cord with a larger wire size will reduce the voltage loss Use Table 3 1 below as a guide for selecting proper cable size...

Page 15: ...inducing current in the rotor windings b which is rectified by the diodes c to produce direct current The main stator winding d is designed for parallel connection to give a voltage output with no vo...

Page 16: ...gs create the mag netic field for the main stator windings 4 3 Stator b The stator houses both the main windings and auxiliary winding Themainwindingsareconnecteddirectlytothe main circuit breaker to...

Page 17: ...The circuit breaker is current operatedandshutsoffthepowertothereceptacleswhen a ground fault of 30 milli Amps or greater occurs in the generator or to a piece of equipment attached to the generator...

Page 18: ...such as a screwdriver with an insulated handle across the capacitor terminals Be sure to touch only the insulated handle This will short out across the terminals and discharge the capacitor WARNING 1...

Page 19: ...atethe capacitor that is attached to the stator housing 2 Run generator at normal no load speed 3100 rpm auto idle off 3 Brieflytoucha12VDCbatteryacrossthetwocapacitor connections to pulse the auxilia...

Page 20: ...directions indicates an open diode The diode must be replaced in either case If one diode is defective it is recommended that both diodes be replaced since the remaining diode may have been weakened...

Page 21: ...e sure stator is completely disconnected from generator The main winding is intentionally grounded to the generator to form a neutral and will give a false reading 5 Check for continuity between auxil...

Page 22: ...ratorDisassembly 2 Unsolderwiresfromdiodes beingcarefulnottobreak wires 3 Measure rotor resistance as shown in Figure 4 9 4 Record resistance values of both windings and com pare them with values list...

Page 23: ...to the engine 1 Remove stator per instructions above 2 Release the rotor 3 from the engine shaft by supporting rotor in one hand and with a mallet striking firmly on a pole face Diode and or Varistor...

Page 24: ...o i t c e s e e S e c a l p e r d n a s e d o i d t s e T 7 s g n i d n i w r o t a t s d e t r o h s r o n e p O 7 3 1 4 n o i t c e s e e S e c a l p e r d n a r o t a t s t s e T 8 s g n i d n i w...

Page 25: ...storing generator for a long period of time 1 Close the fuel valve and remove and empty sediment cup under carburetor 2 Disconnect the fuel line from the carburetor Place openendoffuellineintoasuitab...

Page 26: ...ellow Br Brown Gr Gray Or Orange Pr Purple T Tan 1 Main stator winding 2 Main circuit breaker 3 Earth leakage circuit breaker G2 1AE only 4 Ignition switch 5 Oil level switch 6 Coil 7 16 Amp receptacl...

Page 27: ...g Assembly Rotor Winding f Main Stator Winding f Main Stator Winding e Automatic Voltage Regulator Basic Generator Theory These generator models use a brush slip ring design to generate and regulate p...

Page 28: ...he rotor a When the engine is running these two windings create the magnetic field for the main stator windings 5 3 Stator The stator b houses both the main windings and auxiliary winding The main win...

Page 29: ...rms a full wave rectifier to convert induced AC current in the auxilliary winding to DC current 5 4 Automatic Voltage Regulator AVR TheAutomaticVoltageRegulator AVR c providesthe generator with a mean...

Page 30: ...and shutsoffthepowertothereceptacleswhenagroundfault of 30 milli Amps or greater occurs in the generator or to a piece of equipment attached to the generator The circuit breaker is located on the cont...

Page 31: ...ptacle f Schuko IP44 CEE 7 style receptacle g Earth leakage circuit breaker G3 3AE G4 6AE GS4 6AE a a1 a2 g 1031SD41 c b d e f a c j3 j1 j2 b h g 1031SD42 Control Panel a Main circuit breaker 9 Amp b...

Page 32: ...oltage Enginespeediscontrolledbyagovernor which automatically adjusts to varying loads on the engine to maintain a constant speed of 3600 rpm There is no throttle control To set the engine to the prop...

Page 33: ...0 5 6 y r e v E r o s h t n o m s r u o h 0 0 1 y r e v E r o r a e y s r u o h 0 0 3 y r e v E r o r a e y s r u o h 0 0 5 l e v e l t c e r r o c o t l l i F l i o e n i g n e k c e h C r e n a e l...

Page 34: ...e residual magnetism may have been destroyed Loss of magnetism will prevent the generator from building voltage To check residual voltage run the generator at normal no load speed and measure the volt...

Page 35: ...ing the Bridge Rectifier Accessing the Bridge Rectifier 1 Remove the generator cover 2 Remove leads Z2 and Z3 from the bridge rectifier b and leads F1 and F2 that go to the brush assembly Checking Bri...

Page 36: ...Note Make sure stator is completely disconnected from generator The main windings are intentionally grounded to the generator to form a neutral and will give a false reading 4 Check for continuity be...

Page 37: ...etallic abrasive pad to clean the rings and then retry the generator Brushes Inspect the brushes for damage dirt freedom of movement or brush length Brushes less than 8 mm in length should be replaced...

Page 38: ...5A 12 5A G3 3A G4 6A GS4 6A GS5 7A 50 HZ PORTABLE GENERATORS Figure 5 16 Brush Type Generator 1 10 11 14 16 15 17 18 21 20 19 24 23 25 22 31 30 2 4 7 8 1020SD78...

Page 39: ...loth Stator 1 Remove the shaft securing nut 7 2 Remove the four nuts 11 from the four studs 2 securing the generator frame 14 to the engine adapter flange 1 3 For units with electric start A Disconnec...

Page 40: ...nuts 11 to secure frame to the adapter studs 2 5 Installthewasherandshaftsecuringnut 7 Tighten to 13 ft lbs 17 5 Nm 6 If brushes were changed reinstall the brushes springs and terminal plate Note New...

Page 41: ...5A 15 50 HZ PORTABLE GENERATORS G3 3A G4 6A GS4 6A GS5 7A 5A 1 10 11 14 16 15 17 18 21 20 19 24 23 25 22 31 30 2 4 7 8 1020SD78...

Page 42: ...l p e r d n a r o t a t s t s e T 7 s g n i d n i w r o t o r d e t r o h s r o n e p O 7 0 2 5 n o i t c e s e e S e c a l p e r d n a r o t o r t s e T e g a t l o V w o L 1 e v i t c e f e d r o t...

Page 43: ...Ignition switch OFF ON 1 2 T 2 4 3 1 2 F2 F1 4 Z1 Z1 Z2 Z2 R W LL W R B LL B R B LL B R B R Gr LL B LL Gr G Y G Y G Y L L L Br B R B B Y B R G 5 C 6 4 B A 3 2 1 11 12 10 9 8 7 1 3 L1 L2 F1 F2 Z3 Z3 R...

Page 44: ...L2 F1 F2 Z3 Z3 R W 1 R 1 2 4 R B G Y R B G Y 1 LL B LL W LL W Br G Y 1 Main stator winding 2 Main circuit breaker 3 Earth leakage circuit breaker G4 6AE GS4 6AE only 4 16 Amp receptacle 5 Choke 6 Auxi...

Page 45: ...2 5 1 6 3 W R Y B L W B Y L W R W G T 13 11 14 15 16 12 17 10 G4 6 Models GS4 6 Models Wire Colors B Black G Green L Blue P Pink R Red LL Light blue W White Y Yellow Br Brown Gr Gray Or Orange Pr Purp...

Page 46: ...1 Main stator winding 2 Main circuit breaker 3 Earth leakage circuit breaker GS5 7AE 4 400 volt 16 Amp receptacle 5 230 volt 16 Amp receptacle 6 Radio interference suppressor 7 Automatic voltage regul...

Page 47: ...4 4 5 2 5 1 6 3 W R Y B L W B Y L W R W G T 12 10 13 14 15 11 16 9 9 Engine crank switch 10 Oil level switch 11 Coil 12 Battery 13 Charging coil 14 Starter 15 Starter solenoid 16 15 Amp fuse Wire Col...

Page 48: ...imately one tablespoon 1 ounce of clean engine oil into the cylinder Crank the engine a few turns to distribute the oil to the inside of the cylinder walls 6 Pull the starter rope slowly until resista...

Page 49: ...eads 28824 5 ml Hernon 431 and for sealing weld porosity wicking 25316 10 ml Omnifit 1710 230LL Gaps up to 0 005 0 13 mm Temp range 65 to 300 degrees F 54 to 149 degrees C Loctite 609 Green Medium str...

Page 50: ...271 282 383 353 479 1 1 8 5 8 1 Ft Lb 1 357 Nm 1 Inch 25 4 mm In Lb Metric Fasteners DIN Inch Fasteners SAE Size Ft Lb Nm Ft Lb Nm Ft Lbs Nm Inch Metric Inch Metric M3 11 1 2 14 1 6 19 2 1 7 32 5 5 2...

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Page 52: ...0 Fax 49 0 89 354 02 390 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 1 1 262 255 0500 Fax 1 1 262 255 0550 Tel 800 770 0957 Wacker Asia Pacific Operations Sunley Center Unit 912...