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  5. Repair Manual

Wacker Neuson G2.5A Repair Manual

Other manuals for G2.5A: Operator's Manual, Operator's Manual

Summary of G2.5A

  • 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.

  • Page 3: Portable Generator Repair

    Portable generator repair foreword wc_tx000224gb.Fm i 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...

  • Page 4: Foreword

    Foreword portable generator repair wc_tx000224gb.Fm ii.

  • Page 5: Portable Generator Repair

    Portable generator repair table of contents wc_bo0112013004gbtoc.Fm 1 1. Foreword 5 2. Safety information 6 2.1 laws pertaining to spark arresters ...................................................... 6 2.2 operating safety ..............................................................................

  • Page 6: Table Of Contents

    Table of contents portable generator repair wc_bo0112013004gbtoc.Fm 2 5.11 receptacle panel wiring .....................................................................38 5.12 rotor diode testing ............................................................................38 5.13 stator winding test ...

  • Page 7: Portable Generator Repair

    Portable generator repair table of contents wc_bo0112013004gbtoc.Fm 3 6.24 slip rings and brushes ...................................................................... 69 6.25 generator disassembly ...................................................................... 70 6.26 generator assembly ......

  • Page 8: Table Of Contents

    Table of contents portable generator repair wc_bo0112013004gbtoc.Fm 4.

  • Page 9: Foreword

    Foreword wc_si000081gb.Fm 5 california proposition 65 warning: engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the state of california to cause cancer and birth defects or other reproductive harm. 1. Foreword this manual provides informatio...

  • Page 10: Safety Information

    Safety information portable generator repair wc_si000081gb.Fm 6 2. 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. I...

  • Page 11: Portable Generator Repair

    Portable generator repair safety information wc_si000081gb.Fm 7 2.2 operating safety 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 cur...

  • Page 12: Safety Information

    Safety information portable generator repair wc_si000081gb.Fm 8 2.2.11 always transport generator in an upright position. 2.2.12 always keep machine at least one meter (three feet) away from structures, buildings and other equipment during use. 2.2.13 always keep the area immediately surrounding the...

  • Page 13: Portable Generator Repair

    Portable generator repair safety information wc_si000081gb.Fm 9 2.4 service safety poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. If the generator...

  • Page 14: Safety Information

    Safety information portable generator repair wc_si000081gb.Fm 10 2.5 label locations g 2.5a w c g r 0 0 0 5 5 2 gnd 88897 1 2 3 4 5 1 2 i m p r o p e r c o n n e c t i o n o f g e n e r a t o r t o a b u i l d i n g ' s e l e c t r i c a l s y s t e m c a n a l l o w e l e c t r i c a l c u r r e n ...

  • Page 15: Portable Generator Repair

    Portable generator repair safety information wc_si000081gb.Fm 11 g 3.7a, g 5.6a, and gs 5.6a w c _ g r 0 0 0 5 4 3 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 electrocu...

  • Page 16: Safety Information

    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: Portable Generator Repair

    Portable generator repair safety information wc_si000081gb.Fm 13 2.6 safety and operating labels wacker machines use international pictorial labels where needed. These labels are described below: label meaning danger! Engines emit carbon monoxide; operate only in well ventilated area. Read the opera...

  • Page 18: Safety Information

    Safety information portable generator repair wc_si000081gb.Fm 14 electrical ground. Open main circuit breaker. Open fuel flow valve. Open choke. Push or turn engine switch to on position. Pull rewind starter. Press engine crank switch to "crank" posi- tion. Label meaning gnd 88897 improper connectio...

  • Page 19: Portable Generator Repair

    Portable generator repair safety information wc_si000081gb.Fm 15 close main circuit breaker. Close fuel flow valve. Close choke. Push or turn engine switch to off position. Press engine crank switch to "off" position. Key switch: off on start a nameplate listing the model number, item number, revisi...

  • Page 20: Safety Information

    Safety information portable generator repair wc_si000081gb.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 switch to crank starter. Label meaning 1 2...

  • Page 21: Portable Generator Repair

    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: Technical Data

    Technical data portable generator repair wc_td000082gb.Fm 18 3. Technical data 3.1 generator item no. G 2.5a 0007188 generator maximum output w 2500 continuous output w 2250 type single voltage, single phase, brushless system ac voltages available volts phase 120 1ø frequency hz 60 power factor 1.0 ...

  • Page 23: Portable Generator Repair

    Portable generator repair technical data wc_td000082gb.Fm 19 item no. G 3.7a 0007189 generator maximum output w 3700 continuous output w 3320 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase 120 / 240 1ø frequency hz 60 power factor 1.0 ac receptacles:...

  • Page 24: Technical Data

    Technical data portable generator repair wc_td000082gb.Fm 20 item no. G 5.6a 0007190 gs 5.6a 0007191 generator maximum output w 5600 continuous output w 5350 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase 120 / 240 1ø frequency hz 60 power factor 1.0...

  • Page 25: Portable Generator Repair

    Portable generator repair technical data wc_td000082gb.Fm 21 item no. Gs 8.5v 0007661 gs 9.7v 0007662 generator maximum output kw / kva 8.5 / 8.5 9.7 / 9.7 continuous output w 8.2 9.3 type dual voltage, single phase, brush-type system ac voltages available volts phase 120 / 240 1ø frequency hz 60 po...

  • Page 26: Technical Data

    Technical data portable generator repair wc_td000082gb.Fm 22 3.2 engine item no. G 2.5a 0007188 engine engine type single cylinder, 4-cycle, air-cooled, gasoline engine engine make honda engine model gx 160 k1vx rated power kw (hp) 4.1 (5.5) spark plug bpr6es / w20epr-u electrode gap mm (in.) 0.7 - ...

  • Page 27: Portable Generator Repair

    Portable generator repair technical data wc_td000082gb.Fm 23 item no. G 3.7a 0007189 engine engine type single cylinder, 4-cycle, air-cooled, gasoline engine engine make honda engine model gx 240 k1 rated power kw (hp) 5.9 (8) spark plug bpr6es / w20epr-u electrode gap mm (in.) 0.7 - 0.8 (0.028 - 0....

  • Page 28: Technical Data

    Technical data portable generator repair wc_td000082gb.Fm 24 item no. G 5.6a 0007190 gs 5.6a 0007191 engine engine type single cylinder, 4-cycle, air-cooled, gasoline engine engine make honda engine model gx 340 k1 rated power kw (hp) 8.2 (11) spark plug bpr6es / w20epr-u electrode gap mm (in.) 0.7 ...

  • Page 29: Portable Generator Repair

    Portable generator repair technical data wc_td000082gb.Fm 25 item no. Gs 8.5v 0007661 gs 9.7v 0007662 engine engine type 2 cylinder, 4-cycle, air-cooled, gasoline engine engine make briggs and stratton engine model vanguard 303447 vanguard 350447 rated power kw (hp) 11.9 (16) 13.4 (18) displacement ...

  • Page 30: Power Requirements

    Power requirements portable generator repair wc_tx000206gb.Fm 26 4. Power requirements 4.1 determining power requirements these generators are designed to operate single-phase, 60 hertz appliances or tools running at a selectable voltage of 120 vac or 240 vac for the g 3.7a, g 5.6a, gs 5.6a, gs 8.5v...

  • Page 31: Portable Generator Repair

    Portable generator repair power requirements wc_tx000206gb.Fm 27 • loads such as submersible pumps and air compressors require a very large force to start. They need as much as 3–5 times the wattage stated on the nameplate in order to start. If the wattage is not given for a particular tool or appli...

  • Page 32: Power Requirements

    Power requirements portable generator repair wc_tx000206gb.Fm 28 4.4 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 g...

  • Page 33: Portable Generator Repair

    Portable generator repair power requirements wc_tx000206gb.Fm 29 4.5 use of extension cords when a long extension cord is used to connect an appliance or tool to the generator, a voltage loss occurs—the longer the cord, the greater the voltage loss. This results in less voltage being supplied to the...

  • Page 34: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 30 5. G 2.5a 5.1 theory of operation – capacitor generators see graphic: wc_gr000933 basic generator theory 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...

  • Page 35: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 31 5.2 rotor see graphic: wc_gr000934 the inside of the rotor shaft (a) 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 b...

  • Page 36: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 32 5.4 capacitor see graphic: wc_gr000934 a capacitor (c) is connected 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. T...

  • Page 37: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 33 5.6 circuit breaker see graphic: wc_gr000553 this generator is protected by a 20 amp thermal circuit breaker (b) located on the panel. When the circuit breaker opens, the breaker button will pop out. To reset the circuit breaker, push the button i...

  • Page 38: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 34 5.7 ground fault interruptor see graphic: wc_gr000553 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 a circuit. They react immediately to ...

  • Page 39: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 35 5.8 capacitors see graphic: wc_gr000935 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 design...

  • Page 40: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 36 5.9 engine speed see graphic: wc_gr000114 all generators require a fixed engine speed to maintain the correct voltage output. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constan...

  • Page 41: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 37 5.10 loss of residual magnetism see graphic: wc_gr000936 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. Contac...

  • Page 42: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 38 5.11 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...

  • Page 43: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 39 5.13 stator winding test see graphic:wc_gr000938 the stator includes the main winding and the auxiliary winding. To check stator windings: 5.13.1 unplug stator connector at control box. 5.13.2 disconnect ground wire. 5.13.3 set ohmmeter to lowest ...

  • Page 44: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 40 5.14 rotor winding test see graphic: wc_gr000939 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: 5.14.1 r...

  • Page 45: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 41 5.15 generator disassembly see graphic: wc_gr000940 capacitor 5.15.1 remove the two end cover screws (h) and the end cover (g). 5.15.2 disconnect the leads from the capacitor (j), cut the nylon tie wrap, and remove the capacitor mounting screw. St...

  • Page 46: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 42.

  • Page 47: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 43 5.16 generator assembly see graphic:wc_gr000940 when assembling the generator be sure to observe the following: 5.16.1 install diodes (c,f) to the diode bracket (b) assembly on the rotor, by placing the solder tags on the diode stud and tighten to...

  • Page 48: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 44 5.17 troubleshooting problem / symptom reason / remedy engine does not start • engine switch is in “off” position. Move engine switch to “start” position. • fuel valves under fuel tank and on engine are closed. Open fuel valves. • fuel tank is emp...

  • Page 49: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 45 5.18 periodic maintenance schedule 5.19 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 the operator’s manual. In depth engine...

  • Page 50: G 2.5A

    G 2.5a portable generator repair wc_tx000207gb.Fm 46 5.20 storing / transporting before storing generator for a long period of time: 5.20.1 close the fuel valve and remove and empty sediment cup under carburetor. 5.20.2 disconnect the fuel line from the carburetor. Place open end of fuel line into a...

  • Page 51: Portable Generator Repair

    Portable generator repair g 2.5a wc_tx000207gb.Fm 47 5.21 wiring schematic see graphic: wc_gr000767 ref. Description ref. Description ref. Description a generator b control box c engine ref. Description ref. Description 1. Main windings 5. Ignition switch 2. Aux winding 6. Oil level switch 3. Capaci...

  • Page 52: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 48 6. G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v 6.1 theory of operation – brush generators see graphic: wc_gr000941 basic generator theory these generator models use a brush/slip ring design to generate and regulate power and consist...

  • Page 53: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 49 6.2 rotor see graphic: wc_gr000942 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 rot...

  • Page 54: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 50 6.6 bridge rectifier see graphic: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...

  • Page 55: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 51 6.7 engine auto idle module (g 3.7a, g 5.6a and gs 5.6a models) see graphic: wc_gr000943 the plunger positioning is accomplished by loosening the clamping screws, and turning the threaded plunger. Turning the plunger cloc...

  • Page 56: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 52 6.8 engine auto idle module (gs 8.5a and gs 9.7a models) these two models are equipped with an electronic governor control module system. The advantage of this electronic governor is that it provides more responsive gover...

  • Page 57: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 53 6.10 checking the voltage selector switch functional output (g 3.7a, g 5.6a and gs 5.6a models) see graphic: wc_gr000944 functional output 6.10.1 confirm that the voltage selector switch is in the 120v position. 6.10.2 me...

  • Page 58: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 54 6.11 main circuit breaker see graphic: wc_gr000545 and wc_gr000559 the main breaker protects the generator from severe overloads or short circuits. If the circuit breaker opens, turn the engine off immediately and determi...

  • Page 59: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 55 control panel (g 3.7a, g 5.6a and gs 5.6a models) ref. Description ref. Description a engine switch (gs 5.6a only) f gfi duplex receptacle - 120v b auto idle switch g gfi test button c twist-lock receptacle - 240v h gfi r...

  • Page 60: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 56 control panel (gs 8.5v and gs 9.7v models) 6.13 choke test the resistance value of the choke is 7.5 ohms. To check the choke carefully remove wires z1 and z3 from the choke assembly and measure across choke tabs. Ref. Des...

  • Page 61: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 57 6.14 engine speed (g 3.7a, g 5.6a and gs 5.6a models) see graphic: wc_gr000114 generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts ...

  • Page 62: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 58 6.15 auto idle switch see graphic: wc_gr000548 the auto idle switch automatically reduces engine speed 5 – 7 seconds after all appliances or tools attached to the generator have been turned off. The engine automatically r...

  • Page 63: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 59 6.16 checking engine electronic governor speed (gs 8.5v and gs 9.7v models) note: the battery must be installed and have the appropriate voltage (nine volts minimum) for the generator electronic control governor to perfor...

  • Page 64: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 60 running generator follow instructions below and read starting and stopping instructions found in engine owner’s manual. 6.16.1 disconnect all loads from the generator and place the main circuit breaker in the open positio...

  • Page 65: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 61 6.17 removing and installing electronic governor (gs 8.5v and gs 9.7v models) see graphic: wc_gr000945 removing 6.17.1 disconnect red and green wires from control module to actuator. 6.17.2 remove air cleaner assembly. 6....

  • Page 66: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 62 6.18 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, ki...

  • Page 67: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 63.

  • Page 68: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 64 6.20 diode bridge see graphic: wc_gr000946, wc_gr000947, and wc_gr000948 accessing diode bridge 6.20.1 remove generator cover. 6.20.2 remove leads z2 and z3 from the diode bridge (a), and leads f1 and f2 that route to the...

  • Page 69: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 65 6.21 stator windings see graphic: wc_gr000949 the stator includes the two main power windings and the auxiliary winding. To check stator windings: 6.21.1 unplug stator connector at control box. 6.21.2 set ohmmeter to lowe...

  • Page 70: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 66 resistance values note: resistance values are very small and require a good quality meter with the ability to be zeroed out. Using a poor quality meter may not provide accurate readings. All figures are approximate values...

  • Page 71: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 67 6.22 rotor windings see graphic: wc_gr000950 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 dr...

  • Page 72: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 68 6.23 automatic voltage regulator see graphic: wc_gr000951 to check the regulator: unplug the generator from the control panel. • if the generator has low voltage, approximately 2 – 5 vac as mea- sured at the 120 vac recep...

  • Page 73: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 69 6.24 slip rings and brushes slip rings inspect 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 inspec...

  • Page 74: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 70 6.25 generator disassembly see graphic: wc_gr000947 and wc_gr000952 diode bridge rectifier 6.25.1 remove the two end cover screws (o) and the end cover (p). 6.25.2 remove the four leads f1, f2, z2, and z3 from the bridge ...

  • Page 75: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 71 stator 6.25.1 remove the shaft securing nut (e). 6.25.2 remove the four nuts (h) from the four studs (b) securing the generator frame (i) to the engine adapter flange (a). 6.25.3 for units with electric start: • disconnec...

  • Page 76: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 72.

  • Page 77: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 73 6.26 generator assembly see graphic: wc_gr000947 and wc_gr000952 when assembling the generator be sure to observe the following: 6.26.1 make sure inner taper on rotor and outer taper on the engine crankshaft are clean and...

  • Page 78: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 74 6.27 troubleshooting problem / symptom reason / remedy engine does not start • engine switch is in “off” position. Move engine switch to “start” position. • fuel valves under fuel tank and on engine are closed. Open fuel ...

  • Page 79: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 75 6.28 periodic maintenance schedule (g 3.7a, g 5.6a, and gs 5.6a models) 6.29 engine service (g 3.7a, g 5.6a, and gs 5.6a models) normal servicing of the engine such as cleaning the air cleaner, sediment cup, carburetor ad...

  • Page 80: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 76 6.30 periodic maintenance schedule (gs 8.5v and gs 9.7v models) 6.31 engine service (gs 8.5v and gs 9.7v models) normal servicing of the engine such as cleaning the air cleaner, sediment cup, carburetor adjustments, auto ...

  • Page 81: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 77 6.32 generator wiring schematic (g 3.7a, g 5.6a, and gs 5.6a models) (g 3.7a s/n 718901707 and higher) (g 5.6a s/n 719101533 and higher) (gs 5.6a s/n 719101173 and higher) ref. Description ref. Description ref. Descriptio...

  • Page 82: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 78 (g 3.7a s/n 718901706 and lower) (g 5.6a s/n 719101532 and lower) (gs 5.6a s/n 719101172 and lower) ref. Description ref. Description ref. Description a generator b control box c engine ref. Description ref. Description 1...

  • Page 83: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 79 6.33 engine wiring schematic (g 3.7a, g 5.6a, and gs 5.6a models) ref. Description ref. Description a control box c engine b electric start engines d manual start engines ref. Description ref. Description 1. Engine crank ...

  • Page 84: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 80 6.34 generator wiring schematic (gs 8.5v and gs 9.7v models) gs 8.5v and gs 9.7v, rev. 103 and above ref. Description ref. Description 1. Automatic voltage regulator 10. Engine module 2. Rotor winding 11. Oil level switch...

  • Page 85: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 81.

  • Page 86: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 82 gs 8.5v and gs 9.7v, rev. 102 and below ref. Description ref. Description 1. Automatic voltage regulator 10. Engine module 2. Rotor winding 11. Oil level switch 3. Main stator winding 12. Coil 4. 120v, 20a gfi receptacle ...

  • Page 87: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 83 6.35 vanguard engine wiring schematic (gs 8.5v and gs 9.7v models) ref. Description ref. Description 1. Carburetor solenoid 10. Regulator rectifier 2. Stop switch terminal 11. Dc output wire 3. 50 hz. Loop (gs 8.5=yellow,...

  • Page 88: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 84 6.36 vanguard key switch 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 +...

  • Page 89: Portable Generator Repair

    Portable generator repair g 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v wc_tx000208gb.Fm 85 6.37 storing before storing generator for a long period of time: 6.37.1 close the fuel valve and remove and empty sediment cup under carburetor. 6.37.2 disconnect the fuel line from the carburetor. Place open end of fuel ...

  • Page 90: Portable Generator Repair

    G 3.7a;g/gs 5.6a;gs 8.5v;gs 9.7v portable generator repair wc_tx000208gb.Fm 86.

  • Page 91: Threadlockers and Sealants

    Threadlockers and sealants threadlockers and sealants threadlocking adhesives and sealants are specified throughout this manual by a notation of “s” plus a number (s#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°c (350°f). If a screw or b...

  • Page 92: Threadlockers and Sealants

    Threadlockers and sealants loctite primer t hernon 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. 2006124 - 6 oz. Type ( ) = europe color usage p...

  • Page 93: Torque Values

    Torque values torque values metric fasteners (din) torque values (based on bolt size and hardness) wrench size size ft.Lb. Nm ft.Lb. Nm ft.Lb. 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 8.5 7 10 5/16 8 - 4 m6 7 10 10 14 13 ...

  • Page 94: Torque Values

    Torque values inch fasteners (sae) size ft.Lb. Nm ft.Lb. Nm ft.Lb. 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 ...

  • Page 96

    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...