Wacker Neuson G2.5A, Repair Manual

Page 1: ...www wackergroup com Portable Generators G 2 5A G 3 7A G 5 6A GS 5 6A GS 8 5V GS 9 7V REPAIR MANUAL 0112013 004 1002 en 0 1 1 2 0 1 3...

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Page 3: ...replacement Damage caused by misuse or neglect of the unit should be brought to the attention of the operator to prevent similar occurrences from happening in the future This manual provides informati...

Page 4: ...Foreword Portable Generator Repair wc_tx000224gb fm ii...

Page 5: ...erating Labels 13 3 Technical Data 18 3 1 Generator 18 3 2 Engine 22 4 Power Requirements 26 4 1 Determining Power Requirements 26 4 2 Outdoor Installation 27 4 3 Indoor Installation 27 4 4 Grounding...

Page 6: ...ine Auto Idle Module G 3 7A G 5 6A and GS 5 6A Models 51 6 8 Engine Auto Idle Module GS 8 5A and GS 9 7A Models 52 6 9 Voltage Selector Switch G 3 7A G 5 6A and GS 5 6A Models 52 6 10 Checking the Vol...

Page 7: ...7A G 5 6A and GS 5 6A Models 75 6 30 Periodic Maintenance Schedule GS 8 5V and GS 9 7V Models 76 6 31 Engine Service GS 8 5V and GS 9 7V Models 76 6 32 Generator Wiring Schematic G 3 7A G 5 6A and GS...

Page 8: ...Table of Contents Portable Generator Repair wc_bo0112013004gbTOC fm 4...

Page 9: ...erviced Follow operating instructions carefully If you have questions about operating or servicing this equipment please contact Wacker Corporation The information contained in this manual was based o...

Page 10: ...s injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION Used without the safety alert symbol CAUTION indicates a potentially ha...

Page 11: ...s manual and the engine manual and familiarize yourself with the location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the equipment bef...

Page 12: ...guidelines below Failure to follow warnings and safety guidelines could result in severe injury or death 2 3 1 DO NOT run machine indoors or in an enclosed area such as a deep trench unless adequate...

Page 13: ...und the base of the machine If water is present move the machine and allow it to dry before servicing 2 4 5 DO NOT service machine if clothing or skin is wet 2 4 6 DO NOT allow untrained personnel to...

Page 14: ...E N T F R O M T H E G E N E R A T O R T O B A C K F E E D I N T O U T I L I T Y L I N E S T H I S M A Y R E S U L T I N E L E C T R O C U T I O N O F U T I L I T Y W O R K E R S F I R E O R E X P L O...

Page 15: ...LLOW ELECTRICAL CURRENT FROM THE GENERATOR TO BACKFEED INTO UTILITY LINES THIS MAY RESULT IN ELECTROCUTION OF UTILITY WORKERS FIRE OR EXPLOSION CONNECTIONS TO A BUILDING S ELECTRICAL SYSTEM MUST BE MA...

Page 16: ...Safety Information Portable Generator Repair wc_si000081gb fm 12 GS 8 5V and GS 9 7V w c _ g r 0 0 0 5 5 8 GND 88897 D A N G E R G E F A H R D A N G E R P E L I G R O S T O P...

Page 17: ...increases the risk of injury to yourself or others CAUTION Lifting point D A N G E R G E F A H R D A N G E R P E L I G R O S T O P STOP DANGER GEFAHR PELIGRO DANGER I M P R O P E R C O N N E C T I O...

Page 18: ...Label Meaning GND 88897 IMPROPER CONNECTION OF GENERATOR TO A BUILDING S ELECTRICAL SYSTEM CAN ALLOW ELECTRICAL CURRENT FROM THE GENERATOR TO BACKFEED INTO UTILITY LINES THIS MAY RESULT IN ELECTROCUTI...

Page 19: ...n and Serial Number is attached to each unit Please record the infor mation found on this plate so it will be avail able should the nameplate become lost or damaged When ordering parts or requesting s...

Page 20: ...gb fm 16 This machine may be covered by one or more patents Open main circuit breaker Open fuel flow valve Open choke Turn engine key switch to ON position Pull rewind starter or turn engine key switc...

Page 21: ...Portable Generator Repair Safety Information wc_si000081gb fm 17 Close main circuit breaker Close fuel flow valve Close choke Turn engine key switch to OFF position Label Meaning...

Page 22: ...ut W 2500 Continuous Output W 2250 Type Single voltage single phase brushless system AC Voltages Available volts phase 120 1 Frequency Hz 60 Power Factor 1 0 AC receptacles 120V GFI duplex 120V duplex...

Page 23: ...tage single phase Auto voltage regulator system AC Voltages Available volts phase 120 240 1 Frequency Hz 60 Power Factor 1 0 AC receptacles 120V GFI duplex 120V GFI duplex 120V twist lock 240V twist l...

Page 24: ...l voltage single phase Auto voltage regulator system AC Voltages Available volts phase 120 240 1 Frequency Hz 60 Power Factor 1 0 AC receptacles 120V GFI duplex 120V GFI duplex 120V twist lock 240V tw...

Page 25: ...age single phase brush type system AC Voltages Available volts phase 120 240 1 Frequency Hz 60 Power Factor 1 0 AC receptacles 120V GFI duplex 120V GFI duplex 120V twist lock 120V twist lock 240V twis...

Page 26: ...4 1 5 5 Spark Plug BPR6ES W20EPR U Electrode Gap mm in 0 7 0 8 0 028 0 031 Engine Speed full load rpm 3600 100 Engine Speed no load rpm 3700 100 Air Cleaner type Dry type with oil wetted foam pre clea...

Page 27: ...S W20EPR U Electrode Gap mm in 0 7 0 8 0 028 0 031 Engine Speed full load rpm 3600 100 Engine Speed no load rpm 3700 100 Auto Idle Speed rpm 2200 50 Air Cleaner type Dry type with oil wetted foam pre...

Page 28: ...28 0 031 Engine Speed full load rpm 3600 100 Engine Speed no load rpm 3700 100 Auto Idle Speed rpm 2200 50 Air Cleaner type Dry type with oil wetted foam pre cleaner Battery type V capacity Size in N...

Page 29: ...0 29 3 570 34 75 Spark Plug Champion RC12YC Electrode Gap mm in 0 76 0 030 Starter type V Electric 12 Alternator amp 16 Engine Speed full load rpm 3600 Auto Idle Speed rpm 2200 Valve Clearance cold mm...

Page 30: ...ts for different types of equipment Check with your nearest Wacker Dealer or contact the manufacturer or dealer of the tool or appliance with questions regarding power requirements If the wattage is n...

Page 31: ...operating indoors may be necessary The surrounding area must be free from water and moisture All components must be protected from excessive moisture 4 3 Indoor Installation If the generator must be...

Page 32: ...or The generator should be grounded to a good ground source in compliance with National Electric Code standards and local regulations Use 8 wire and secure one end to the ground terminal a provided on...

Page 33: ...voltage loss Damaged extension cords can cause electrical shock resulting in serious injury or death DO NOT use worn bare or frayed cords Replace damaged cords immediately Use the chart below as a gu...

Page 34: ...t the receptacles Brushless Generator This model generator uses a brushless design to generate and regulate power It consists of a rotor stator diodes and an auxiliary winding The brushless generator...

Page 35: ...o diodes mounted on the diode bracket assembly There are two individual coils wound on the rotor When the engine is running these two windings create the magnetic field for the main stator windings 5...

Page 36: ...ed in series with the auxiliary winding Its purpose is to regulate the voltage when a load is applied 5 5 Diodes See Graphic wc_gr000934 Two diodes d are located on the rotor These diodes form a half...

Page 37: ...eaker b located on the panel When the circuit breaker opens the breaker button will pop out To reset the circuit breaker push the button in Control Panel Ref Description Ref Description a GFI Duplex r...

Page 38: ...hrough the GFI duplex outlet The GFI should be tested for proper operation each time the generator is used To test GFI Start generator Place main circuit breaker in the closed position Push test butto...

Page 39: ...ly the insulated handle This will short out across the terminals and discharge the capacitor Testing Capacitor 5 8 1 Discharge the capacitor as described above then disconnect all wire leads from the...

Page 40: ...e running at 3700 50 rpm Voltage output is directly related to engine speed A slow engine will reduce voltage Refer to the Operator s Manual for engine speed adjustment The generator is designed to pr...

Page 41: ...t across exposed connections Review safety rules at beginning of this manual To restore magnetism to the rotor flash it as follows 5 10 1 Remove the two screws and the end cover Locate the capacitor b...

Page 42: ...rator Disassembly 5 12 2 Set ohmmeter in lowest scale Test diode in forward position Meter should read low or close to zero a 5 12 3 Reverse meter leads and test diode in reverse position Meter should...

Page 43: ...nuity between winding and metal frame If continuity exists winding is grounded and stator assembly must be replaced Note Make sure stator is completely disconnected from generator The main winding is...

Page 44: ...ver locknut stator and rotor from generator See Generator Disassembly 5 14 2 Unsolder wires from diodes being careful not to break wires 5 14 3 Measure rotor resistance as shown 5 14 4 Record resistan...

Page 45: ...ge to windings in the stator or rotor Note If the rotor comes out with the stator skip step 6 5 15 6 Support the rotor weight with a sling or place a block between the rotor and base Rotor Rotor a rem...

Page 46: ...G 2 5A Portable Generator Repair wc_tx000207gb fm 42...

Page 47: ...silicon sealant 5 16 3 Make sure inner taper on rotor and outer taper on the engine crankshaft are clean and free of rust and oil 5 16 4 Install the rotor b on crankshaft 5 16 5 Slide stator k over t...

Page 48: ...itch 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...

Page 49: ...rmed by qualified personnel or by the nearest Honda dealer Daily before starting After first 20 hrs Every 50 hrs Every 100 hrs Every 300 hrs Check fuel level Check engine oil level Inspect air filter...

Page 50: ...carburetor 5 20 4 Change the engine oil 5 20 5 Remove the spark plug and pour approximately 30 ml 1 ounce of clean engine oil into the cylinder Crank the engine a few turns to distribute the oil to th...

Page 51: ...ion 1 Main Windings 5 Ignition Switch 2 Aux Winding 6 Oil Level Switch 3 Capacitor 25 F 400 V 7 Coil 4 Rotor Windings Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Bl...

Page 52: ...ecific voltage output regardless of load The voltage regulator accomplishes this by regulating DC current from the auxiliary winding When the load on the generator increases the voltage regulator allo...

Page 53: ...windings are connected directly to the main circuit breaker and voltage selector switch to supply power to the output receptacles The auxiliary winding induces the initial current in the field windin...

Page 54: ...c wc_gr000942 The bridge rectifier e is located on the stator housing and is placed in a cooling air flow of the rotor This bridge rectifier forms a full wave rectifier to convert induced AC current i...

Page 55: ...es the speed and turning it counter clockwise reduces the speed The module senses current draw When no current demand is sensed a signal is sent to the module The module then controls the throttle act...

Page 56: ...The battery must be installed and have the appropriate voltage nine volts minimum for the generator electronic control governor to perform properly If the generator starts but will not run at speed c...

Page 57: ...ut Worn dirty or damaged contacts can affect the operation of the voltage selection switch and result in no or low voltage at receptacles Test the selector switch using an ohmmeter 6 10 1 Remove all w...

Page 58: ...Interrupt See Graphic wc_gr000545 and wc_gr000559 GFI s differ from circuit breakers which only react to high current conditions GFI s sense very small current changes in the HOT and NEUTRAL lines in...

Page 59: ...E O F F A U T O 2 4 0 V A C 2 0 A M P C A U T I O N M A I N C O N T R O L S 1 2 0 V A C 2 0 A M P 3 0 A M P 2 0 A M P R E A D A N D U N D E R S T A N D O P E R A T O R S M A N U A L B E F O R E O P E...

Page 60: ...y and measure across choke tabs Ref Description Ref Description a Main Circuit Breaker d Auto Idle Switch b Hour meter e 120V 30A Twist lock Receptacle c 120V GFI Duplex Receptacle f 240V 20A Twist lo...

Page 61: ...ge Engine speed is controlled by a governor 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 pr...

Page 62: ...consumption To avoid extended engine warm up periods keep switch OFF when starting the engine and until engine reaches operating temperature Setting Engine Auto Idle Speed G 3 7A G 5 6A and GS 5 6A M...

Page 63: ...odule and attach other end to a good ground After 4 6 seconds engine speed should return to idle approximately 2200 rpm 6 16 4 Remove jumper wire from ground Engine should return to top governed speed...

Page 64: ...els turn Key Switch to start position and hold until engine starts CAUTION Do not crank engine longer than 15 seconds at a time Extended cranking can damage starter motor To start engine using manual...

Page 65: ...ator to governor control bracket a Torque screws and nuts to 3 4 Nm 30 in lbs b Note Hold the long screws with a inch wrench when torquing nuts Screws must NOT turn while torquing nuts 6 17 2 Assemble...

Page 66: ...age To check residual voltage run the generator at normal no load speed and measure the voltage at 120 VAC receptacles This voltage should be at least 1 5 volts If the voltage is less than 1 5 volts t...

Page 67: ...Portable Generator Repair G 3 7A G GS 5 6A GS 8 5V GS 9 7V wc_tx000208gb fm 63...

Page 68: ...wave rectifier follow these steps 6 20 1 Set multi meter on R x 1000 range 6 20 2 Remove all wires connected to rectifier 6 20 3 Place the meter probes on two adjacent rectifier terminals and check re...

Page 69: ...ble If very high ohm values or open then replace stator Low readings are not normal and may indicate a shortened winding Stator may have to be replaced 6 21 3 Test for grounded windings by checking fo...

Page 70: ...the ability to be zeroed out Using a poor quality meter may not provide accurate readings All figures are approximate values in ohms Generator Model Main Winding Auxiliary Winding Rotor Winding Choke...

Page 71: ...tor 6 22 1 Remove end cover and brush assembly 6 22 2 Measure resistance as shown in the illustration by measuring the winding at the slip rings 6 22 3 Record resistance values of both windings and co...

Page 72: ...and engine speed is 3600 rpm replace regulator If the generator has low voltage approximately 65 VAC measured at the 120 VAC receptacles remove F1 F2 L1 and L2 from the regula tor Start and run the g...

Page 73: ...ect the slip rings for dirt or damage If the slip rings are dirty use an eraser or non metallicmild abrasive pad to clean the rings and then retry the generator Brushes Inspect the brushes for damage...

Page 74: ...gain access to the gas line and shut off valve 6 25 2 Close the fuel valve and disconnect the fuel line Remove the fuel tank 6 25 3 Remove the screws that mount the control panel to the control box a...

Page 75: ...k of wood and a mallet tap stator frame away from the engine Withdraw stator frame assembly i over the rotor c carefully to avoid damage to windings in the stator or rotor Note On some occasions the r...

Page 76: ...G 3 7A G GS 5 6A GS 8 5V GS 9 7V Portable Generator Repair wc_tx000208gb fm 72...

Page 77: ...6 4 Attach the four nuts h to secure frame to the adapter studs b 6 26 5 Install the washer and shaft securing nut e Tighten to 17 5 Nm 13 ft lbs 6 26 6 If brushes were changed reinstall the brushes s...

Page 78: ...or disconnected Install tightly Low Voltage Engine speed too low Reset engine speed to 3600 3750 rpm Automatic voltage regulator defective Test AVR and replace AVR voltage pot set low Adjust voltage p...

Page 79: ...erformed by qualified personnel or by the nearest Honda dealer Daily before starting After first 20 hrs Every 50 hrs Every 100 hrs Every 300 hrs Check fuel level Check engine oil level Inspect air fil...

Page 80: ...formed by qualified personnel or by the nearest Briggs and Stratton Vanguard dealer Daily before starting After first 5 hrs Every 50 hrs Every 100 hrs Every 500 hrs Check fuel level Check engine oil l...

Page 81: ...age Regulator 8 1 Amp Fuse 3 Rotor Winding 9 Auto Idle Switch 4 Main Stator Winding 10 120 240V 30A Kit 5 Auxiliary Stator Winding 11 Electromagnet 6 Choke W B Extra wire included in kit Terminate at...

Page 82: ...Winding 9 Auto Idle Switch 4 Main Stator Winding 10 120 240V 30A Kit 5 Auxiliary Stator Winding 11 Electromagnet 6 Choke W B Extra wire included in kit Terminate at 120V 30A receptacle w c _ g r 0 0...

Page 83: ...Ref Description 1 Engine Crank Switch 5 Solenoid 1a OFF 6 Starter 1b RUN 7 Charging Coil 1c START 8 Battery 2 Oil Level Switch 9 Ignition Switch 3 Coil 9a ON 4 15 Amp Fuse 9b OFF Wire Colors B Black R...

Page 84: ...13 Spark plug 5 120V 30A twist lock receptacle 14 Battery 6 240V 20A receptacle 15 Starter 7 120V 240V 30A receptacle 16 Choke 8 120V 20A twist lock receptacle 17 Auxiliary stator winding 9 Hour mete...

Page 85: ...Portable Generator Repair G 3 7A G GS 5 6A GS 8 5V GS 9 7V wc_tx000208gb fm 81...

Page 86: ...twist lock receptacle 14 Battery 6 240V 20A receptacle 15 Starter 7 120V 240V 30A receptacle 16 Choke 8 120V 20A twist lock receptacle 17 Auxiliary stator winding 9 Hour meter 18 Resistor 390 Ohms 50...

Page 87: ...lator rectifier 2 Stop switch terminal 11 DC output wire 3 50 Hz loop GS 8 5 yellow GS 9 7 red 12 Key switch 4 Module 13 Solenoid 5 Idle down device 14 Battery terminal 6 Actuator 15 Solenoid tab term...

Page 88: ...itch See Graphic wc_gr000953 Note Terminal 1 grounded internally to switch case Meter must also indicate continuity between terminal 1 and switch case Ref Switch Position Continuity 1 Off 1 3 6 2 Run...

Page 89: ...rburetor 6 37 4 Change the engine oil 6 37 5 Remove the spark plug and pour approximately 30 ml 1 ounce of clean engine oil into the cylinder Crank the engine a few turns to distribute the oil to the...

Page 90: ...G 3 7A G GS 5 6A GS 8 5V GS 9 7V Portable Generator Repair wc_tx000208gb fm 86...

Page 91: ...before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 ml 73285 50 ml Loctite 290 Hernon 431 Omnifit 1710 230LL Green Medium to high strength for locking preassembled threads and f...

Page 92: ...n Primer 10 Omnifit VC Activator Aerosol Spray Fast curing primer for threadlocking retaining and sealing compounds Must be used with stainless steel hardware Recommended for use with gasket sealants...

Page 93: ...5 M4 26 2 9 36 4 1 43 4 9 9 32 7 3 M5 53 6 0 6 8 5 7 10 5 16 8 4 M6 7 10 10 14 13 17 10 5 M8 18 25 26 35 30 41 1 2 13 6 M10 36 49 51 69 61 83 11 16 17 8 M12 63 86 88 120 107 145 3 4 19 10 M14 99 135 1...

Page 94: ...3 5 42 4 7 11 32 9 9 64 No 10 32 3 6 45 5 1 60 6 8 3 8 5 32 1 4 6 8 1 9 12 12 16 7 16 3 32 5 16 13 18 19 26 24 33 1 2 13 1 4 3 8 23 31 33 45 43 58 9 16 5 16 7 16 37 50 52 71 69 94 5 8 16 3 8 1 2 57 7...

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Page 96: ...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...