Repair manual

ManualsBrandsWacker Neuson ManualsDo-It-Yourself toolsG 3.3A

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

0116567

Summary of content (52 pages)

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www.wackergroup.com 0116567 002 1000 en Portable Generators G 2.1A G 3.3A G 4.6A GS 4.6A GS 5.
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50 HZ PORTABLE GENERATORS FOREWORD This manual covers machines with Serial Number or Item Number: 0008243, 0008244, 0008245, 0008246, 0008247, 0008248, 0008249, 0008250, 0008251, 0008252, 0008253, 0008254, 0008255, 0008256, 0008257, 0008258, 0008259, 0008260, 0008261, 0008262, 0008263, 0008264, 0008265, 0008266, 0008267, 0008268, 0008269, 0008270, 0008271, 0008272, 0008273, 0008274, 0008275, 0008276, 0008277, 0008278, 0008279, 0008280, 0008281, 0008282, 0008283, 0008284, 0008285, 0008309, 0008310, 0008311
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FOREWORD 50 HZ PORTABLE GENERATORS Nameplate A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model, item number, revision number, and serial number of the unit.
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0 Hz Portable Generators Repair Manual Table of Contents 1 Safety 1.1 1.2 1.3 1.4 1.5 Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laws Pertaining to Spark Arresters . . . . . . . . . . . . . . . . . . . . . . Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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50 Hz Portable Generators Repair Manual Table of Contents, continued 5 Models G3.3A, G4.6A, GS4.6A, & GS5.7A 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24 Theory of Operation – Brush Generators . . . . . . . . . . . . . . . . . . 5A-1 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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50 HZ PORTABLE GENERATORS 1.1 SAFETY 1A Safety Information This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. ! This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
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1A SAFETY 50 HZ PORTABLE GENERATORS WARNING BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS! Improper connection of generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines. This could result in electrocution of utility workers, fire, or explosion.
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50 HZ PORTABLE GENERATORS 1.4 SAFETY 1A Engine Safety Internal combustion engines present special hazards during operation and fueling! Read and follow warning instructions in engine owner’s manual and safety guidelines below. Failure to follow the safety guidelines described below could result in severe injury or death. WARNING DO NOT run engine indoors or in an enclosed area unless adequate ventilation, through such items as exhaust fans or hoses, is provided.
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1A SAFETY Notes: 1A-4 50 HZ PORTABLE GENERATORS
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50 HZ PORTABLE GENERATORS 2.1 TECHNICAL DATA 2A Generator Specifications Table 2-1. Model Output kVA Type G2.1A G3.3A 2,1 3,3 Frequency GS4.6A Automatic Voltage Regulator 230V 1Ø 400V 3Ø 230V 1 phase Hz GS5.7A 4,1 1Ø 5,7 3Ø 4,6 Brushless AC Voltages available voltage & phase G4.6A 50 Power Factor 1,0 1Ø 0,8 3Ø 1,0 AC Receptacles Optional Main Circuit Breaker amp 10 (1 pole) 15 (1 pole) 20 (1 pole) 9 (3 pole) Continuous Current at 230V/400V amp 9,1/N.A. 14,3/N.A. 20,0/N.A.
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2A TECHNICAL DATA 2.2 50 HZ PORTABLE GENERATORS Engine Specifications Table 2-2. Model G2.1A G3.3A G4.
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50 HZ PORTABLE GENERATORS POWER REQUIREMENTS 3.1 Determining Power Requirements 3.2 These generators are designed to operate single-phase, 50 hertz appliances or tools running at 230 VAC for the G2.1A, G3.3A, G4.6A, and GS4.6A models, and a single phase voltage of 230 VAC and a three phase voltage of 400 VAC for the GS5.7A model. Check the nameplate or label provided on tools and appliances to make sure their power requirements match the power output of the generator.
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3A POWER REQUIREMENTS 3.4 50 HZ PORTABLE GENERATORS Grounding the Generator 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 the generator frame and the other end to a suitable ground source. See Figure 3-1. a 1001SD02 Figure 3-1. Grounding 3.
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50 HZ PORTABLE GENERATORS 4.1 G2.1A/G2.1AE 4A Theory of Operation – Capacitor Generators Basic Generator Theory Brushless Generator Wacker air-cooled generators work on the principle of electromagnetic induction i.e., the cutting of magnetic lines of force by a coil of wire to produce an electric voltage in the coil of wire. This model generator uses a brushless design to generate and regulate power. It consists of a rotor, stator, diodes, and an auxiliary winding.
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4A G2.1A/G2.1AE a 50 HZ PORTABLE GENERATORS b d c 1022SD88 Figure 4-2. Brushless Type Generator 4.2 Rotor (a) The inside of the rotor shaft is tapered and connected directly to the taper on the engine crankshaft. This end is supported by the engine crankshaft bearing. The opposite end of the rotor is supported by a bearing installed in the generator housing. This end also contains the two diodes mounted on the diode bracket assembly. There are two individual coils wound on the rotor.
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50 HZ PORTABLE GENERATORS 4.6 G2.1A/G2.1AE 4A Control Panel The generator is protected by a 10 amp circuit breaker (a) located on the control panel. b c d e The circuit breaker protects the generator from severe overloads or short circuits. If the circuit breaker opens, turn the engine off immediately and determine the cause before restarting. Check the appliances and tools attached to the generator for defects and make sure their power requirements do not exceed the power rating of the generator.
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4A G2.1A/G2.1AE 4.8 50 HZ PORTABLE GENERATORS Capacitors 4.9 WARNING ALWAYS handle or test capacitors with the engine stopped. Extremely high voltage is present at the capacitor terminals while the generator is in use. Although the capacitors used in this generator are designed to discharge when the engine is stopped, it is still a good idea to discharge them manually before handling.
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50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A 4.10 Loss of Residual Magnetism in Rotor If the rotor has been removed, or the generator has been stored over six months, the rotor’s magnetism may be lost. Loss of magnetism will prevent the generator from building voltage. To restore magnetism to the rotor, “flash” it as follows: 1. Remove the two screws and the end cover. Locate the capacitor that is attached to the stator housing. 2. Run generator at normal no-load speed – 3100 rpm, auto-idle off.
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4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS 4.11 Receptacle Panel Wiring 4.12 Rotor Diode Testing Remove receptacle panel from control box and inspect the wiring for worn or loose wires. Make sure all wire connections are secure and tight at the screws. DO NOT allow wires to be pinched, kinked or damaged in any way. Inspect for tight connections at circuit breakers, capacitors, switches and receptacles. Replace any broken or damaged parts. To check diode: 1. Disassemble generator and remove rotor.
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50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A 4.13 Stator Winding Testing The stator includes the main winding and the auxiliary winding. Auxiliary Windings To check stator windings: 1. Unplug stator connector at control box. Capacitor 2. Disconnect ground wire. 3. Set ohmmeter to lowest scale. Place meter leads on connector terminals as shown and record resistance values, see Figure 4-8. Check resistance values with those listed on Table 4-1.
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4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS 4.14 Rotor Winding Testing Before testing rotor, visually inspect windings for dark streaks which indicate a burned or shorted winding. Rotate ball bearing by hand. Replace it if it is rough or noisy. To check rotor: 1. Remove end cover, locknut, stator and rotor from generator. See Section 4.15 Generator Disassembly. 2. Unsolder wires from diodes, being careful not to break wires. NEG 3. Measure rotor resistance as shown in Figure 4-9. 4.
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50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A 4.15 Generator Disassembly Capacitor Diode and/or Varistor 1. Remove the two end cover screws (10) and the end cover (9). See Figure 4-10. 1. Unsolder leads from the diodes (5) and (8) and unscrew diode stud. See Figure 4-10. 2. Disconnect the leads from the capacitor (11), cut the nylon tie wrap, and remove the capacitor mounting screw. 2. Unsolder varistor lead from the solder tag on the diode stud. Stator 3.
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4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS 4.17 Troubleshooting Table 4-2. Generator Chart Symptom Engine Does Not Start Possible Cause 1. Engine switch is in “OFF” position. 1. Move engine switch to “START” position. 2. Fuel valves under fuel tank and on engine are closed. 2. Open fuel valves. 3. Fuel tank is empty. 3. Fill fuel tank. 4. Choke lever is in wrong position. 4. Move choke lever to correct position. (Close choke lever when starting a cold engine). 5. Spark plug is in poor condition.
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50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A 4.18 Periodic Maintenance Schedule Daily Before Starting Check engine oil. Fill to correct level. • Check air cleaner. • Clean air cleaner.* Every 3 months or 50 hours Every 6 months or 100 hours Every year or 300 hours Every year or 500 hours • Change engine oil. • Check sediment cup at carburetor. • Clean and adjust spark plug. • Clean spark arrester (optional accessory). • Check shockmounts. Replace when necessary.
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4A-12 1 1 8 9 L Br W R 1 2 B = Control box C = Engine LL G/Y 3 Br 4 R G/Y LL 2 G/Y 1 2 B(2) B(4) B(1) B(3) R/B 3 G/Y LL/B G/Y LL/Gr B/R C R/Gr 7 B 1 = Main stator winding 2 = Main circuit breaker 3 = Earth-leakage circuit breaker (G2.
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50 HZ PORTABLE GENERATORS 5.1 G3.3A/G4.6A/GS4.6A/GS5.7A 5A Theory of Operation – Brush Generators Basic Generator Theory These generator models use a brush/slip ring design to generate and regulate power and consist of a rotor, stator, diode bridge, and an auxiliary winding. They also incorporate a choke that is connected in series with the auxiliary winding. The choke’s purpose is to bring the current in the auxiliary winding “in phase” with the main windings.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS F1 a e Z3 b F2 Z2 d F1 F2 F2 c F1 L2 L1 Voltage Adjust Pot 1023SD48 Figure 5-2. Brush-Type Generator 5.2 Rotor The inside of the rotor shaft is tapered and connected directly to the taper on the engine crankshaft. This end is supported by the engine crankshaft bearing. The opposite end of the rotor is supported by a bearing housed in the generator housing. This end also contains the two slip rings.
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50 HZ PORTABLE GENERATORS 5.4 G3.3A/G4.6A/GS4.6A/GS5.7A 5A Automatic Voltage Regulator (AVR) The Automatic Voltage Regulator (AVR) (c) provides the generator with a means of maintaining a specific voltage regardless of load. The AVR accomplishes this by regulating DC current from the auxiliary winding. When the load on the generator increases, the AVR allows additional DC current into the rotor. The additional DC voltage allows the generator to increase output and maintain voltage. 5.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 5.7 Main Circuit Breaker 50 HZ PORTABLE GENERATORS 5.8 The circuit breaker protects the generator from severe overloads or short circuits. If the circuit breaker opens, turn the engine off immediately and determine the cause before restarting. Check the appliances and tools attached to the generator for defects and make sure their power requirements do not exceed the power rating of the generator or the current limit of the receptacles.
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G3.3A/G4.6A/GS4.6A/GS5.7A 5A 50 HZ PORTABLE GENERATORS b c d e f a a1 2 1 5 3 6 1 4 3 2 a2 230V Control Panel a b c d e f g Main circuit breaker - 15 Amp. Australian style receptacle. Danish IP44 style receptacle. Swiss IP X4 style receptacle. France/Belgium IP44 style receptacle. Schuko IP44 (CEE 7) style receptacle. Earth-leakage circuit breaker (G3.3AE, G4.6AE, GS4.6AE). T E S T g 230V 1031SD41 Figure 5-5. Control Panel (G3.3A, G4.6A, and GS4.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 5.9 50 HZ PORTABLE GENERATORS Engine Speed (G3.3A, G5.7A, and GS5.7A Models) Generators require a fixed engine speed to maintain the correct voltage. 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. k To set the engine to the proper speed: Turn the speed adjusting screw (k) in or out to obtain a no-load speed of 3100 rpm. See Figure 5-7.
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G3.3A/G4.6A/GS4.6A/GS5.7A 5A 50 HZ PORTABLE GENERATORS 5.10 Periodic Maintenance Schedule (G3.7A, G5.6A, and GS5.6A Models) Daily Before Starting Check engine oil. Fill to correct level. • Check air cleaner. • Clean air cleaner.* Every 3 months or 50 hours Every 6 months or 100 hours Every year or 300 hours • Change engine oil. • Check sediment cup at carburetor. • Clean and adjust spark plug. • Clean spark arrester (optional accessory). • Check shockmounts. Replace when necessary.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS Z1 Z3 c F2 b F1 a 1031SD62 Figure 5-11. Brush Type Generator 5.11 Loss of Residual Magnetism in Rotor General If the rotor has been removed, the generator stored for a considerable time, or the rotor (field) connections reversed during service, the residual magnetism may have been destroyed. Loss of magnetism will prevent the generator from building voltage.
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50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A Restoring Residual Magnetism to the Brush Type Generators Disconnect leads F1 and F2 from the brush holder (a). Run the generator at its normal speed and apply 12 volts from a battery to the brush holder for approximately 3 seconds. Ensure the positive lead is applied to the brush holder nearest the bearing housing. The output voltage of the generator, with the 12 volt supply connected, should be approximately normal voltage. See Figure 5-12.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS 5.14 Stator Windings The stator includes the two main power windings and the auxiliary winding. See Figure 5-14. To check stator windings: 1. Unplug stator connector at control box. 2. Set ohmmeter to lowest scale. Place meter leads on connector terminals as shown and record resistance values. Check resistance values with those listed on Table 51. A high or low reading indicates an open or shorted winding and the stator must be replaced. 3.
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50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A 5.15 Rotor Windings Before testing rotor, visually inspect windings for dark streaks which indicate a burned or shorted winding. Rotate ball bearing by hand. Replace it if it is rough, noisy or dry. Checking Rotor 1. Remove end cover and brush assembly. 2. Measure resistance as shown in the illustration, by measuring the winding at the slip rings. See Figure 5-15. 3.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS 2 4 1 8 10 7 11 16 15 14 17 30 18 31 21 22 19 23 20 25 24 Figure 5-16.
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50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A 5.18 Generator Disassembly Bridge Rectifier 2. Remove 3 mounting screws (25). 1. Remove the two end cover screws (19) and the end cover (20). See Figure 5-16. 3. If brushes (22) are to be changed, remove the brush terminal plate and withdraw springs and brushes. New brushes must be seated using a medium grade abrasive cloth. 2. Remove the four leads from the bridge rectifier (16) confirming lead markings per Figure 5-17. 1.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS 5.19 Generator Assembly When assembling the generator be sure to observe the following: 6. If brushes were changed, reinstall the brushes, springs and terminal plate. 1. Make sure inner taper on rotor and outer taper on the engine crankshaft are clean and free of rust and oil. See Figure 5-16. Note: New brushes must be seated using a medium grade abrasive cloth. 2. Install the rotor (4) on crankshaft. 7.
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G3.3A/G4.6A/GS4.6A/GS5.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS 5.20 Troubleshooting Table 5-2. Generator Chart Symptom Engine Does Not Star t Possible Cause Solution 1. Engine switch is in “OFF” position. 1. Move engine switch to “START” position. 2. Fuel valves under fuel tank and on engine are closed. 2. Open fuel valves. 3. Fuel tank is empty. 3. Fill fuel tank. 4. Choke lever is in wrong position. 4. Move choke lever to correct position. (Close choke lever when star ting a cold engine). 5.
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F1 10 R 9 W R Z3 Z1 1 2 C = Engine B = Control box G/Y LL/W 2 L/L G/Y Br 3 4 R A = Generator Z3 8 Z2 Z1 L Br 11 1 1 Z2 F2 B F2 L1 L2 F1 12 A 1 R/B 2 1 LL/B T R/B 2 4 3 G/Y R/W LL/W R/B G/Y LL/B 1 = Main stator winding 2 = Main circuit breaker 3 = Earth-leakage circuit breaker (G3.
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5A-18 L2 Z2 F2 F2 7 R B F1 F1 9 L1 6 1 1 1020SD85 Z3 Z1 L Br Z3 5 Z2 Z1 8 W R 1 2 3 4 Br R G/Y 3 R/B 1 1 G/Y 2 4 3 R/B LL/B R/W LL/W R/B G/Y LL/B 4 G/Y R/Gr LL/B 1 = Main stator winding 2 = Main circuit breaker 3 = Earth-leakage circuit breaker (G4.6AE, GS4.
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B/R G4.6 Models B GS4.6 Models ON 12 B Y 17 11 R 3 G OFF 5 2 18 W T 10 4 6 1 5 4 3 2 10 = Engine crank switch 11 = Oil level switch 12 = Coil 13 = Battery 14 = Charging coil 15 = Starter 16 = Starter solenoid 17 = 15 Amp fuse 18 = Ignition switch L/W B Y 1 16 W 15 R L/W B Y B - Black G - Green L - Blue P - Pink R - Red LL-Light blue Wire Colors 12 11 W- White Y - Yellow Br - Brown Gr - Gray Or - Orange Pr - Purple T - Tan 14 13 G 50 HZ PORTABLE GENERATORS G3.
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5A-20 F1 7 R F1 F2 F2 B L1 L2 8 6 1 U W N 6 4 R G/Y LL Br V G/Y LL/W Br/W R/W V/W 2 Br/B V/B R/B N 2 4 6 1 2 3 4 T 3 V/W Br/W R/W N 1 3 5 LL/W LL/B 1 2 3 4 1 = Main stator winding 2 = Main circuit breaker 3 = Earth-leakage circuit breaker (GS5.
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16 W T 5 2 R 9 3 4 6 1 9 = Engine crank switch 10 = Oil level switch 11 = Coil 12 = Battery 13 = Charging coil 14 = Starter 15 = Starter solenoid 16 = 15 Amp fuse L/W B Y B - Black G - Green L - Blue P - Pink R - Red LL-Light blue Wire Colors 5 4 3 2 1 15 W- White Y - Yellow Br - Brown Gr - Gray Or - Orange Pr - Purple T - Tan W 14 R L/W B Y 11 10 13 12 G 50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A Engine Wiring Schematic (GS5.
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5A G3.3A/G4.6A/GS4.6A/GS5.7A 5.22 Storing/Transporting Before 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 open end of fuel line into a suitable container and open fuel valve to drain fuel from tank. WARNING Gasoline is extremely flammable. Drain fuel tank in a well-ventilated area. DO NOT drain tank in an area with flames or sparks. 3.
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SEALANTS Use Of Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual and should be used where indicated. Threadlocking compounds normally break down at temperatures above 350° F (175° C). If a screw or bolt is hard to remove, heat it using a small propane torch to break down sealant. When applying sealants, follow instructions on container. The sealants listed below are recommended for use on WACKER equipment. TYPE ( ) = Europe COLOR USAGE PART NO.
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TORQUE VALUES Metric Fasteners (DIN) WRENCH SIZE TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 Size Ft.Lb. 8.8 10.9 10.9 12.9 Nm Ft.Lb. Nm Ft.Lbs. 12.9 Nm Inch Metric Inch Metric M3 *11 1.2 *14 1.6 *19 2.1 7/32 5.5 - 2.5 M4 *26 2.9 *36 4.1 *43 4.9 9/32 7 - 3 M5 *53 6.0 6 8.
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Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-354 02 - 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, 9/F · 9 Wing Qin Street, Kwai Chung, N.T. · Hong Kong · Tel.