1. DL manuals
  2. Wacker Neuson
  3. Portable Generator
  4. G 2.1A
  5. Repair Manual

Wacker Neuson G 2.1A Repair Manual

Summary of G 2.1A

  • 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.

  • Page 3

    50 hz portable generators foreword operating/parts information you must be familiar with the operation of this machine before you attempt to troubleshoot or make any repairs to it. Basic operating and maintenance procedures are described in the operator's/parts manual supplied with the machine. The ...

  • Page 4

    Foreword 50 hz portable generators menomonee falls, wi usa 53051 11 0635 rev. Serial no. A kw hz n/m item no. V class lbs kg model man. Yr. Made in usa insul. Class generating set iso 8528 serial number my machine’s numbers are: revision item number model number gs4.6a gs4.6a gs4.6a gs4.6a gs4.6a 00...

  • Page 5: 50 Hz Portable Generators

    50 hz portable generators repair manual table of contents 1 safety 1.1 safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1a-1 1.2 laws pertaining to spark arresters . . . . . . . . . . . . . . . . . . . . . . 1a-1 1.3 operating safety . . . . . . . . . . . . ...

  • Page 6: 50 Hz Portable Generators

    50 hz portable generators repair manual table of contents, continued 5 models g3.3a, g4.6a, gs4.6a, & gs5.7a 5.1 theory of operation – brush generators . . . . . . . . . . . . . . . . . . 5a-1 5.2 rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5a-2 5....

  • Page 7

    1a-1 50 hz portable generators safety 1a 1.2 laws pertaining to spark arresters notice: some local authorities require that in certain locations, spark arresters be used on internal combustion engines. A spark arrester is a device designed to prevent the discharge of sparks or flames from the engine...

  • Page 8

    1a-2 1a safety 50 hz portable generators 1.3 operating safety familiarity and proper training are required for the safe operation of electrical equipment! Equipment operated improperly or by untrained personnel can be dangerous! Read the operating instructions and familiarize yourself with the locat...

  • Page 9

    1a-3 50 hz portable generators safety 1a 1.4 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...

  • Page 10

    1a-4 1a safety 50 hz portable generators notes:.

  • Page 11

    2a-1 50 hz portable generators technical data 2a 2.1 generator specifications table 2-1. L e d o m a 1 . 2 g a 3 . 3 g a 6 . 4 g a 6 . 4 s g a 7 . 5 s g t u p t u o a v k 1 , 2 3 , 3 6 , 4 Ø 1 1 , 4 Ø 3 7 , 5 e p y t s s e l h s u r b r o t a l u g e r e g a t l o v c i t a m o t u a e l b a li a v ...

  • Page 12

    2a-2 technical data 50 hz portable generators 2a 2.2 engine specifications table 2-2. L e d o m a 1 . 2 g a 3 . 3 g a 6 . 4 g a 6 . 4 s g a 7 . 5 s g e k a m e n i g n e a d n o h l e d o m e n i g n e x v 1 k 0 6 1 x g 1 k 0 4 2 x g 1 k 0 4 3 x g m p r 0 0 0 3 @ r e w o p w k 1 , 4 0 , 6 2 , 8 c i ...

  • Page 13

    3a-1 50 hz portable generators power requirements 3a 3.1 determining power requirements 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 volta...

  • Page 14

    3a-2 3a power requirements 50 hz portable generators 3.4 grounding the generator the generator should be grounded to a good ground source in compliance with national electric code stand- ards and local regulations. Use #8 wire and secure one end to the ground terminal (a) provided on the generator f...

  • Page 15

    4a-1 50 hz portable generators g2.1a/g2.1ae 4a 4.1 theory of operation – capacitor generators 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 also contains a cap...

  • Page 16

    4a-2 4a g2.1a/g2.1ae 50 hz portable generators 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 oppo- site end of the rotor is supporte...

  • Page 17

    4a-3 50 hz portable generators g2.1a/g2.1ae 4a 230v 230v 4.6 control panel the generator is protected by a 10 amp circuit breaker (a) located on the control panel. The circuit breaker protects the generator from severe overloads or short circuits. If the circuit breaker opens, turn the engine off im...

  • Page 18

    4a-4 4a g2.1a/g2.1ae 50 hz portable generators figure 4-4. Testing capacitor 4.8 capacitors testing capacitor 1. Discharge capacitor as described above, then disconnect all wire leads from the terminals. 2. Check the capacitor charge and discharge readings using an ohmmeter as described below or use...

  • Page 19

    4a-5 50 hz portable generators g2.1a/g2.1ae 4a 4.10 loss of residual magnetism in rotor contact with exposed connections inside the control box or while handling battery leads can cause se- vere electrical shocks. Be extremely careful to avoid touching any exposed connections. Never wear jewelry or ...

  • Page 20

    4a-6 4a g2.1a/g2.1ae 50 hz portable generators 4.11 receptacle panel wiring 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. Insp...

  • Page 21

    4a-7 50 hz portable generators g2.1a/g2.1ae 4a 4.13 stator winding testing the stator includes the main winding and the auxiliary winding. To check stator windings: 1. Unplug stator connector at control box. 2. Disconnect ground wire. 3. Set ohmmeter to lowest scale. Place meter leads on connector t...

  • Page 22

    4a-8 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...

  • Page 23

    4a-9 50 hz portable generators g2.1a/g2.1ae 4a 4.15 generator disassembly capacitor 1. Remove the two end cover screws (10) and the end cover (9) . See figure 4-10. 2. Disconnect the leads from the capacitor (11) , cut the nylon tie wrap, and remove the capacitor mounting screw. Stator 1. Remove the...

  • Page 24

    4a-10 4a g2.1a/g2.1ae 50 hz portable generators 4.17 troubleshooting table 4-2. Generator chart m o t p m y s e s u a c e l b i s s o p n o i t u l o s t o n s e o d e n i g n e t r a t s . 1 . N o i t i s o p ” f f o “ n i s i h c t i w s e n i g n e . 1 . N o i t i s o p ” t r a t s “ o t h c t i ...

  • Page 25

    4a-11 50 hz portable generators g2.1a/g2.1ae 4a 4.18 periodic maintenance schedule * service more frequently in dusty conditions. Engine service normal servicing of the engine such as cleaning the air cleaner, sediment cup, carburetor adjustments, auto idle speed and engine speed can be located in t...

  • Page 26

    4a-12 4a g2.1a/g2.1ae 50 hz portable generators 4.20 wiring schematic (g2.5a model) 1020sd79 a = generator b = control box c = engine 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 - purple t - tan 1 = main stator windi...

  • Page 27

    5a-1 50 hz portable generators g3.3a/g4.6a/gs4.6a/gs5.7a 5a 5.1 theory of operation – brush generators these models are designed to operate with close regulation when supplying single phase loads. The principle of operation is schematically represented in figure 5-1, and a cross-sectional view in fi...

  • Page 28

    5a-2 5a g3.3a/g4.6a/gs4.6a/gs5.7a 50 hz portable generators 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 oppo- site end of the rotor is supported by a bearing housed in the...

  • Page 29

    5a-3 50 hz portable generators g3.3a/g4.6a/gs4.6a/gs5.7a 5a 5.5 choke the purpose of the choke (d) is to bring the auxiliary winding “in phase” with the main windings. 5.6 bridge rectifier the bridge rectifier (e) is located on the stator housing and is placed in a cooling air flow of the rotor. Thi...

  • Page 30

    5a-4 5a g3.3a/g4.6a/gs4.6a/gs5.7a 50 hz portable generators t e s t g a 1 a 2 1020sd80 1020sd89 a 1 a 2 g 5.7 main circuit breaker 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...

  • Page 31

    5a-5 50 hz portable generators g3.3a/g4.6a/gs4.6a/gs5.7a 5a 230v 230v 1 2 3 6 5 3 2 4 1 t e s t 1 2 3 6 5 3 2 4 1 230v 400v figure 5-5. Control panel (g3.3a, g4.6a, and gs4.6a models) control panel a main circuit breaker - 15 amp. B australian style receptacle. C danish ip44 style receptacle. D swis...

  • Page 32

    5a-6 5a g3.3a/g4.6a/gs4.6a/gs5.7a 50 hz portable generators 5.9 engine speed (g3.3a, g5.7a, and gs5.7a models) figure 5-7. Engine speed adjusting screw 1001sd15 k generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adj...

  • Page 33

    5a-7 50 hz portable generators g3.3a/g4.6a/gs4.6a/gs5.7a 5a 5.10 periodic maintenance schedule (g3.7a, g5.6a, and gs5.6a models) engine service (g3.7a, g5.6a, and gs5.6a models) normal servicing of the engine such as cleaning the air cleaner, sediment cup, carburetor adjustments, auto idle speed and...

  • Page 34

    5a-8 5a g3.3a/g4.6a/gs4.6a/gs5.7a 50 hz portable generators 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 ...

  • Page 35

    5a-9 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...

  • Page 36

    5a-10 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 con...

  • Page 37

    5a-11 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 b...

  • 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

    5a-13 50 hz portable generators g3.3a/g4.6a/gs4.6a/gs5.7a 5a 5.18 generator disassembly bridge rectifier 1. Remove the two end cover screws (19) and the end cover (20) . See figure 5-16. 2. Remove the four leads from the bridge rectifier (16) confirming lead markings per figure 5-17. Figure 5-17. Di...

  • Page 40

    5a-14 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: 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. 2. Install the rotor (4...

  • 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

    5a-16 5a g3.3a/g4.6a/gs4.6a/gs5.7a 50 hz portable generators 5.20 troubleshooting table 5-2. Generator chart m o t p m y s e s u a c e l b i s s o p n o i t u l o s t o n s e o d e n i g n e t r a t s . 1 . N o i t i s o p ” f f o “ n i s i h c t i w s e n i g n e . 1 . N o i t i s o p ” t r a t s “...

  • Page 43

    5a-17 50 hz portable generators g3.3a/g4.6a/gs4.6a/gs5.7a 5a 5.21 wiring schematics – generator/engine wiring schematic (g3.3a model) 1020sd83 a = generator b = control box c = engine 1 = main stator winding 2 = main circuit breaker 3 = earth-leakage circuit breaker (g3.3ae only) 4 = 16 amp receptac...

  • Page 44

    5a-18 5a g3.3a/g4.6a/gs4.6a/gs5.7a 50 hz portable generators generator wiring schematic (g4.6a, gs4.6a models) 1020sd85 4 3 1 2 f2 f1 4 z1 z1 z2 z2 r w ll/b r/b r/gr ll/b ll/gr g/y g/y l br b r 4 3 2 8 9 7 6 5 1 3 l1 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 stato...

  • Page 45

    5a-19 50 hz portable generators g3.3a/g4.6a/gs4.6a/gs5.7a 5a engine wiring schematic (g4.6a , gs4.6amodels) 1021sd67 off on b b y b/r g 18 11 12 1 2 3 4 4 5 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 - re...

  • Page 46

    5a-20 5a g3.3a/g4.6a/gs4.6a/gs5.7a 50 hz portable generators generator wiring schematic (gs5.7a models) 1021sd04 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 - purple t - tan 1 = main stator winding 2 = main circuit b...

  • Page 47

    5a-21 50 hz portable generators g3.3a/g4.6a/gs4.6a/gs5.7a 5a engine wiring schematic (gs5.7a models) 1021sd01 1 2 3 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 sol...

  • Page 48

    5a-22 5a g3.3a/g4.6a/gs4.6a/gs5.7a 50 hz portable generators 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 s...

  • Page 49

    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...

  • Page 50

    Size ft.Lb. Nm ft.Lb. Nm ft.Lbs. Nm inch metric inch metric no.4 *6 0.7 *14 1.0 *12 1.4 1/4 5.5 3/32 - no.6 *12 1.4 *17 1.9 *21 2.4 5/16 8 7/64 - no.8 *22 2.5 *31 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/...

  • Page 52

    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 o...