Wacker Neuson G 2.1A Betriebsanleitung

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

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 operator's/parts manual should be kept with the machine. Use it to order replacement parts when needed. If this

manual becomes lost, please contact WACKER Corporation to order a 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 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

in this manual. THEINFORMATIONCONTAINEDINTHISMANUALWASBASEDONMACHINESINPRODUCTION

ATTHETIMEOFPUBLICATION.WACKERCORPORATION RESERVES THE RIGHT TO CHANGE ANY PORTION

OF THIS INFORMATION WITHOUT NOTICE.

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, 0008312,

0008313, 0008314, 0008315, 0008316

FOREWORD 50 HZ PORTABLE GENERATORS

MENOMONEE FALLS, WI USA 53051

110635

Rev. Serial No.

hz N/M

Item No.

Vclass

lbs

Model

Man.

Yr.

MADE

IN USA Insul.

Class

GENERATING SET ISO 8528

Serial Number

My machine’s numbers are:

RevisionItem Number

Model number

GS4.6AGS4.6A

GS4.6A

00082690008269

0008269 101101

101101

101 50101015010101

50101015010101

5010101

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.

1031SD44

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2

1.4 Engine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3

1.5 Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3

2 Technical Data

2.1 Generator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1

2.2 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2

3 Power Requirements

3.1 Determining Power Requirements . . . . . . . . . . . . . . . . . . . . . . . 3A-1

3.2 Outdoor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1

3.3 Indoor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1

3.4 Grounding the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2

3.5 Use 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 Circuit Breaker (ELCB) . . . . . . . . . . . . . . . . . . . 4A-3

4.8 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4

4.9 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4

4.10 Loss of Residual Magnetism in Rotor. . . . . . . . . . . . . . . . . . . . . 4A-5

4.11 Receptacle Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6

4.12 Rotor Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6

4.13 Stator Winding Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-7

4.14 Rotor Winding Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-8

4.15 Generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9

4.16 Generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9

4.17 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10

4.18 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 4A-11

4.19 Storing/Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-11

4.20 Wiring Schematic (G2.1A Model) . . . . . . . . . . . . . . . . . . . . . . . 4A-12

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

5.3 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2

5.4 Automatic Voltage Regulator (AVR) . . . . . . . . . . . . . . . . . . . . . . 5A-2

5.5 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3

5.6 Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3

5.7 Engine Auto Idle Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3

5.8 Choke Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3

5.9 Main 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 Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10

5.16 Rotor Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-11

5.17 Slip Rings and Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-11

5.18 Automatic Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-11

5.19 Generator Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-13

5.20 Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-14

5.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-15

5.22 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 5A-16

5.23 Wiring Schematics –Generator/Engine . . . . . . . . . . . . . . . . . 5A-17

5.24 Storing/Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22

1A-1

50 HZ PORTABLE GENERATORS SAFETY 1A

1.2 Laws Pertaining to Spark Arresters

Notice: Somelocal authorities require that in certain locations, sparkarrestersbeusedon internal combustion engines.

A spark arrester is a device designed to prevent the discharge of sparks or flames from the engine exhaust. It is often

required when operating equipment on forested land to reduce the risk of fires. Consult the engine distributor or local

authorities and make sure you comply with regulations regarding spark arresters.

1.1 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.

CAUTION: Used without the safety alert symbol,

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in property damage.

Note:

Contains additional information

important to a procedure.

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.

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in

death or serious injury.

CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in

minor or moderate injury.

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in

death or serious injury.

WARNING

CAUTION

DANGER

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 location and proper use of all instruments and controls. Inexperienced operators should receive instruction from

someone familiar with the equipment before being allowed to operate the generator.

WARNING

NEVER operate generator when open containers of

fuel, paint, or other flammable liquids are nearby.

NEVER operate generator, or tools attached to the

generator, with wet hands.

NEVER use worn electrical cords. Severe electrical

shock and equipment damage may result.

NEVERrungeneratorindoorsorinanenclosedarea

unless adequate ventilation, through such items as

exhaustfansor hoses, is provided. Exhaust gas from

the engine contains poisonous carbon monoxide

gas; exposure to carbon monoxide can cause loss of

consciousness and may lead to death.

NEVER run electrical cords under the generator, or

over vibrating or hot parts.

NEVER enclose or cover generator when in use or

when hot.

NEVER 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

servicethegenerator.Know how to operate and stop

generator before starting it.

NEVER operate generator in snow, rain, or standing

water.

ALWAYS keep generator at least three feet (one

meter) away from structures, buildings, and other

equipment during use.

ALWAYS keep generator out of reach of children

and pets.

ALWAYS keep the area immediately surrounding

the generator clean, neat and free of debris.

ALWAYS position and operate generator on a firm,

level surface.

ALWAYS remove all tools, cords, and other loose

items from generator before starting it.

ALWAYS make certain generator is well-grounded

and securely fastened to a good earthen ground.

ALWAYS transport generator in an upright position.

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. Connections to

a building’s electrical system must be made by a qualified electrician and comply with all applicable laws and

electrical codes.

WARNING

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 in severe injury or death.

1.5 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 is experiencing

problems or is being serviced, attach a “DO NOT START”sign to the control panel to notify other people of its condition.

WARNING

NEVER allow water to accumulate around the

base of the generator set. If water is present,

move the generator and allow it to dry before

servicing.

NEVER service generator if clothing or skin is

wet.

NEVER use gasoline or other low flash point

solvents to clean air filter elements.

NEVER allow untrained personnel to service

thisequipment.Onlytrainedelectricaltechnicians

should be allowed to service the electrical

components of this equipment.

NEVER modify the equipment without 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 start, disconnect negative

terminal on battery.

ALWAYS keep generator clean and labels legible.

Replace all missing and hard-to-read labels. Labels

provide important operating instructions and warn of

dangers and hazards.

ALWAYS let engine cool before transporting or

servicing.

ALWAYS remain aware of moving parts and keep

hands, feet, and loose clothing away from moving

parts on generator and engine.

ALWAYS keep fuel lines in good condition and

properly connected. Leaking fuel and fumes are

extremely explosive.

WARNING

DO NOT run engine indoors or in an enclosed area

unless adequate ventilation, through such items as

exhaust fans or hoses, is provided.

DO NOT fill or drain fuel tank near an open flame,

while smoking, or while engine is running.

DO NOT fill fuel tank indoors or in an enclosed area

unless adequate ventilation, through such items as

exhaust fans, is provided.

DO NOT touch or lean against hot exhaust pipes.

DO NOT operate with the fuel tank cap loose or

missing.

DO NOT add fuel to a hot or running engine.

DO NOT start engine if fuel has spilled or an odor of

fuel is present. Move generator away from the spill

and wipe generator dry before starting.

1A-4

1A SAFETY 50 HZ PORTABLE GENERATORS

Notes:

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere Wacker Neuson Tragbarer Generator Handbücher

Wacker Neuson

Wacker Neuson G 25 Bedienungsanleitung

Wacker Neuson

Wacker Neuson G2.5A Betriebsanleitung

Wacker Neuson

Wacker Neuson G2.5A Bedienungsanleitung

Wacker Neuson

Wacker Neuson GP 2500A Bedienungsanleitung

Wacker Neuson

Wacker Neuson G 25 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GV 2500A Betriebsanleitung

Wacker Neuson

Wacker Neuson GP 4000 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GPS 9700 Betriebsanleitung

Wacker Neuson

Wacker Neuson G50 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GP 2500A Bedienungsanleitung

Wacker Neuson

Wacker Neuson GP 3800A Bedienungsanleitung

Wacker Neuson

Wacker Neuson G50 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GV 7003A Bedienungsanleitung

Wacker Neuson

Wacker Neuson GH 3500 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GPS 9700 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GPi 1700 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GV 6600A Bedienungsanleitung

Wacker Neuson

Wacker Neuson GV 5000A Bedienungsanleitung

Wacker Neuson

Wacker Neuson G 240 Bedienungsanleitung

Wacker Neuson

Wacker Neuson G 43 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GP 3800A Betriebsanleitung

Wacker Neuson

Wacker Neuson GP 6600A Bedienungsanleitung

Wacker Neuson

Wacker Neuson GPi 4300 Bedienungsanleitung

Wacker Neuson

Wacker Neuson GP 2500A Bedienungsanleitung

Beliebte Tragbarer Generator Handbücher anderer Marken

Kohler

Kohler 20EORZ Bedienungsanleitung

Powerhorse

Powerhorse 83171 Bedienungsanleitung

HURST

HURST ML-630-SI Bedienungsanleitung

ETQ

ETQ TG4000 Bedienungsanleitung

Briggs & Stratton

Briggs & Stratton 40265 Einrichtungshandbuch

evertz

evertz 7700 Series Bedienungsanleitung

Firefly

Firefly Cygnus CYG2400/460/24 Bedienungsanleitung

Owon

Owon Waveform Generator Bedienungsanleitung

Draper

Draper PG950S Firmware-Update

SDMO

SDMO SH 4000 Bedienungsanleitung

EINHELL

EINHELL STE 5500 Bedienungsanleitung

Wanco

Wanco WI3000P Bedienungsanleitung

Full Boar

Full Boar FBT-3300 Bedienungsanleitung

Dwyer Instruments

Dwyer Instruments ASG Bedienungsanleitung

Westinghouse

Westinghouse WH1000i Series Bedienungsanleitung

Wallenstein

Wallenstein GF5000A Bedienungsanleitung

Leroy-Somer

Leroy-Somer LSA 49.1 Bedienungsanleitung

Yamakoyo

Yamakoyo SH2900DX Bedienungsanleitung