Wacker Neuson G 2.5A Repair Manual
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Wacker Neuson G 2.5A Repair Manual

Wacker Neuson G 2.5A Repair Manual

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REPAIR MANUAL
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Portable Generators
G 2.5A
G 3.7A
G 5.6A
GS 5.6A
GS 8.5V
GS 9.7V
004
en

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Summary of Contents for Wacker Neuson G 2.5A

  • Page 1 0112013 1002 Portable Generators G 2.5A G 3.7A G 5.6A GS 5.6A GS 8.5V GS 9.7V REPAIR MANUAL...
  • Page 3 Portable Generator Repair Foreword This manual covers machines with Item Number: 0007188, 0007189, 0007190, 0007191, 0007661, 0007662 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.
  • Page 4 Foreword Portable Generator Repair wc_tx000224gb.fm...

  • Page 5: Table Of Contents

    Determining Power Requirements ............. 26 Outdoor Installation ................27 Indoor Installation ................27 Grounding the Generator ..............28 Use of Extension Cords ..............29 G 2.5A Theory of Operation – Capacitor Generators ........30 Rotor ....................31 Stator ....................31 Capacitor .................... 32 Diodes ....................
  • Page 6 Table of Contents Portable Generator Repair 5.11 Receptacle Panel Wiring ..............38 5.12 Rotor Diode Testing ................38 5.13 Stator Winding Test ................39 5.14 Rotor Winding Test ................40 5.15 Generator Disassembly ...............41 5.16 Generator Assembly ................43 5.17 Troubleshooting ...................44 5.18 Periodic Maintenance Schedule ............45 5.19 Engine Service ..................45 5.20...
  • Page 7 Portable Generator Repair Table of Contents 6.24 Slip Rings and Brushes ..............69 6.25 Generator Disassembly ..............70 6.26 Generator Assembly ................73 6.27 Troubleshooting .................. 74 6.28 Periodic Maintenance Schedule (G 3.7A, G 5.6A, and GS 5.6A Models) 75 6.29 Engine Service (G 3.7A, G 5.6A, and GS 5.6A Models) ....
  • Page 8 Table of Contents Portable Generator Repair wc_bo0112013004gbTOC.fm...

  • Page 9: Foreword

    Foreword CALIFORNIA Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California WARNING to cause cancer and birth defects or other reproductive harm. Foreword This manual provides information and procedures to safely operate and maintain this Wacker model.

  • Page 10: Safety Information

    Safety Information Portable Generator Repair 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.

  • Page 11: Operating Safety

    Portable Generator Repair Safety Information Operating Safety BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS! DANGER 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 electrocution of utility workers, fire, or explosion.

  • Page 12: Operator Safety While Using Internal Combustion Engines

    Safety Information Portable Generator Repair 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 generator clean, neat and free of debris.

  • Page 13: Service Safety

    Portable Generator Repair Safety Information 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 WARNING the generator is experiencing problems or is being serviced, attach a "DO NOT START"...

  • Page 14: Label Locations

    Safety Information Portable Generator Repair Label Locations G 2.5A DANGER GEFAHR D A N G E R PELIGRO 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...
  • Page 15 Portable Generator Repair Safety Information G 3.7A, G 5.6A, and GS 5.6A D A N G E R G E F A H R S T O P P E L I G R O D A N G E R DANGER GEFAHR PELIGRO...

  • Page 16: Safety Information

    Safety Information Portable Generator Repair GS 8.5V and GS 9.7V D A N G E R G E F A H R S T O P P E L I G R O D A N G E R w c _ g r 0 0 0 5 5 8 wc_si000081gb.fm...

  • Page 17: Safety And Operating Labels

    Portable Generator Repair Safety Information Safety and Operating Labels Wacker machines use international pictorial labels where needed. These labels are described below: Label Meaning D A N G E R DANGER G E F A H R GEFAHR S T O P P E L I G R O PELIGRO D A N G E R...
  • Page 18 Safety Information Portable Generator Repair Label Meaning Electrical ground. DANGER GEFAHR PELIGRO DANGER 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 ELECTROCUTION OF UTILITY WORKERS, FIRE OR EXPLOSION.
  • Page 19 Portable Generator Repair Safety Information Label Meaning 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: start A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit.
  • Page 20 Safety Information Portable Generator Repair Label Meaning 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.
  • Page 21 Portable Generator Repair Safety Information Label Meaning Close main circuit breaker. Close fuel flow valve. Close choke. Turn engine key switch to “OFF” position. wc_si000081gb.fm...

  • Page 22: Technical Data

    Technical Data Portable Generator Repair Technical Data Generator Item No. G 2.5A 0007188 Generator Maximum Output 2500 Continuous Output 2250 Type Single voltage, single phase, brushless system AC Voltages Available volts phase 1ø Frequency Power Factor AC receptacles: 120V GFI duplex...
  • Page 23 Portable Generator Repair Technical Data Item No. G 3.7A 0007189 Generator Maximum Output 3700 Continuous Output 3320 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages Available volts 120 / 240 phase 1ø Frequency Power Factor AC receptacles: 120V GFI duplex 120V GFI duplex 120V twist lock...
  • Page 24 Technical Data Portable Generator Repair Item No. G 5.6A GS 5.6A 0007190 0007191 Generator Maximum Output 5600 Continuous Output 5350 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages Available volts 120 / 240 phase 1ø Frequency Power Factor AC receptacles: 120V GFI duplex 120V GFI duplex...
  • Page 25 Portable Generator Repair Technical Data Item No. GS 8.5V GS 9.7V 0007661 0007662 Generator Maximum Output 8.5 / 8.5 9.7 / 9.7 kW / kVA Continuous Output Type Dual voltage, single phase, brush-type system AC Voltages Available volts 120 / 240 phase 1ø...

  • Page 26: Engine

    Technical Data Portable Generator Repair 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.)
  • Page 27 Portable Generator Repair Technical Data 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 - 0.031) Engine Speed - full load...
  • Page 28 Technical Data Portable Generator Repair Item No. G 5.6A GS 5.6A 0007190 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 - 0.8 (0.028 - 0.031)
  • Page 29 Portable Generator Repair Technical Data Item No. GS 8.5V GS 9.7V 0007661 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 480 (29.3) 570 (34.75)

  • Page 30: Power Requirements

    VAC for the G 3.7A, G 5.6A, GS 5.6A, GS 8.5V and GS 9.7V models, and a single voltage of 120 VAC for the G 2.5A model. Check the nameplate or label provided on tools and appliances to make sure their power requirements match the power output of the generator.

  • Page 31: Outdoor Installation

    Portable Generator Repair Power Requirements • 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 appliance, it can be calculated by multiplying its voltage and amperage requirements: VOLTS x AMPS = WATTS •...

  • Page 32: Grounding The Generator

    Power Requirements Portable Generator Repair 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.

  • Page 33: Use Of Extension Cords

    Portable Generator Repair Power Requirements 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 appliance or tool and increases the amount of current draw or reduces performance.

  • Page 34: Theory Of Operation - Capacitor Generators

    G 2.5A Portable Generator Repair G 2.5A 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 to produce an electric voltage in the coil of wire.

  • Page 35: Rotor

    Portable Generator Repair G 2.5A 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 bearing installed in the generator housing.

  • Page 36: Capacitor

    G 2.5A Portable Generator Repair 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. Diodes See Graphic: wc_gr000934 Two diodes (d) are located on the rotor. These diodes form a half-wave rectifier to convert the induced AC voltage in the rotor windings to DC voltage.

  • Page 37: Circuit Breaker

    Portable Generator Repair G 2.5A 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 in.

  • Page 38: Ground Fault Interruptor

    G 2.5A Portable Generator Repair 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 open the circuit if a current leak is detected.

  • Page 39: Capacitors

    Portable Generator Repair G 2.5A 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. WARNING 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.

  • Page 40: Engine Speed

    G 2.5A Portable Generator Repair 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 constant speed of 3600 –...

  • Page 41: Loss Of Residual Magnetism

    Portable Generator Repair G 2.5A 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.

  • Page 42: Receptacle Panel Wiring

    G 2.5A Portable Generator Repair 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: Stator Winding Test

    Portable Generator Repair G 2.5A 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 scale. Place meter leads on connector terminals (b) and record resistance values.

  • Page 44: Rotor Winding Test

    G 2.5A Portable Generator Repair 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.

  • Page 45: Generator Disassembly

    Portable Generator Repair G 2.5A 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.
  • Page 46 G 2.5A Portable Generator Repair wc_tx000207gb.fm...

  • Page 47: Generator Assembly

    Portable Generator Repair G 2.5A 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 the diode base.

  • Page 48: Troubleshooting

    G 2.5A Portable Generator Repair 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.

  • Page 49: Periodic Maintenance Schedule

    Portable Generator Repair G 2.5A 5.18 Periodic Maintenance Schedule Daily After Every Every Every before first starting 20 hrs. hrs. hrs. hrs. Check fuel level. • Check engine oil level. • Inspect air filter. Replace as needed. • Check and tighten external hardware.

  • Page 50: Storing / Transporting

    G 2.5A Portable Generator Repair 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 suitable container and open fuel valve to drain fuel from tank.

  • Page 51: Wiring Schematic

    Portable Generator Repair G 2.5A 5.21 Wiring Schematic See Graphic: wc_gr000767 Ref. Description Ref. Description Ref. Description Generator Control Box Engine Ref. Description Ref. Description Main Windings Ignition Switch Aux Winding Oil Level Switch Capacitor 25 µF 400 V Coil...

  • Page 52: G 3.7A;G/Gs 5.6A;Gs 8.5V;Gs 9.7V

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 of a rotor, stator, diode bridge, and an auxiliary winding.

  • Page 53: Rotor

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 rotor is supported by a bearing housed in the generator housing.

  • Page 54: Bridge Rectifier

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 AC current in the auxilliary winding to DC current.

  • Page 55: Engine Auto Idle Module (G 3.7A, G 5.6A And Gs 5.6A Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 clockwise shortens the travel distance of the governor which increases the speed and turning it counter-clockwise reduces the speed.

  • Page 56: Engine Auto Idle Module (Gs 8.5A And Gs 9.7A Models)

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 governing than a mechanical governor system.

  • Page 57: Checking The Voltage Selector Switch Functional Output (G 3.7A, G 5.6A And Gs 5.6A Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 Measure the three receptacles labeled 120V and confirm that voltage.

  • Page 58: Main Circuit Breaker

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 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.
  • Page 59 Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V (G 3.7A, G 5.6A and GS 5.6A Models) Control Panel Ref. Description Ref. Description Engine Switch (GS 5.6A only) GFI Duplex receptacle - 120V Auto Idle Switch GFI test button Twist-lock receptacle - 240V GFI reset button Main Breaker Twist-lock receptacle - 120V...

  • Page 60: Choke Test

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 1 2 0 1 2 0 3 0 A 2 0 A 1 2 0 / 2 4 0 2 4 0 3 0 A 2 0 A (GS 8.5V and GS 9.7V models) Control Panel Ref.

  • Page 61: Engine Speed (G 3.7A, G 5.6A And Gs 5.6A Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 to varying loads on the engine to maintain a constant speed of 3600 rpm.

  • Page 62: Auto Idle Switch

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 returns to full speed when a tool or appliance is turned back on.

  • Page 63: Checking Engine Electronic Governor Speed (Gs 8.5V And Gs 9.7V Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 perform properly.
  • Page 64 G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 position. Place auto-idle switch to OFF position (G 3.7A, G 5.6A, GS 5.6A, GS 8.5V, and GS 9.7V models).

  • Page 65: Removing And Installing Electronic Governor (Gs 8.5V And Gs 9.7V Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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. 6.17.3 Disconnect governor link at carburetor.

  • Page 66: Receptacle Panel Wiring

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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, kinked or damaged in any way.
  • Page 67 Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V wc_tx000208gb.fm...

  • Page 68: Diode Bridge

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 brush assembly. Checking Diode Bridge To check the full wave rectifier, follow these steps: 6.20.1 Set multi-meter on R x 1000 range.

  • Page 69: Stator Windings

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 lowest scale. Place meter leads on connector terminals as shown and record resistance values.
  • Page 70 G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair Resistance Values Generator Main Auxiliary Rotor Choke Model Winding Winding Winding Winding G 2.5A 0.56 1.00 8.12 G 3.7A 0.66 3.18 12.2 7.50 G 5.6A 0.43 2.16 10.8 7.50 GS 5.6A 0.43 2.16...

  • Page 71: Rotor Windings

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 dry. Checking Rotor 6.22.1 Remove end cover and brush assembly.

  • Page 72: Automatic Voltage Regulator

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 receptacles, remove F1, F2, L1 and L2 from the regulator.

  • Page 73: Slip Rings And Brushes

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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.

  • Page 74: Generator Disassembly

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 rectifier (j) confirming lead markings.
  • Page 75 Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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: •...
  • Page 76 G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair wc_tx000208gb.fm...

  • Page 77: Generator Assembly

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 free of rust and oil. 6.26.2 Install the rotor (c) on crankshaft.

  • Page 78: Troubleshooting

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 valves.

  • Page 79: Periodic Maintenance Schedule (G 3.7A, G 5.6A, And Gs 5.6A Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 6.28 Periodic Maintenance Schedule (G 3.7A, G 5.6A, and GS 5.6A Models) Daily After Every Every Every before first starting 20 hrs. hrs. hrs. hrs. Check fuel level. • Check engine oil level. •...

  • Page 80: Periodic Maintenance Schedule (Gs 8.5V And Gs 9.7V Models)

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 6.30 Periodic Maintenance Schedule (GS 8.5V and GS 9.7V Models) Daily After Every Every Every before first starting 5 hrs. hrs. hrs. hrs. Check fuel level. • Check engine oil level. • Inspect fuel lines.

  • Page 81: Generator Wiring Schematic (G 3.7A, G 5.6A, And Gs 5.6A Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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) 2 4 0 V A C 2 0 A 1 2 0 V A C 1 2 0 V A C...
  • Page 82 G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair (G 3.7A S/N 718901706 and lower) (G 5.6A S/N 719101532 and lower) (GS 5.6A S/N 719101172 and lower) 2 4 0 V A C 2 0 A 1 2 0 V A C 1 2 0 V A C 1 2 0 V A C 2 0 A...

  • Page 83: Engine Wiring Schematic (G 3.7A, G 5.6A, And Gs 5.6A Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 6.33 Engine Wiring Schematic (G 3.7A, G 5.6A, and GS 5.6A Models) Ref. Description Ref. Description Control Box Engine Electric Start Engines Manual Start Engines Ref. Description Ref. Description Engine Crank Switch Solenoid Starter Charging Coil...

  • Page 84: Generator Wiring Schematic (Gs 8.5V And Gs 9.7V Models)

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 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 Automatic voltage regulator Engine module Rotor winding Oil level switch Main stator winding Coil 120V, 20A GFI receptacle...
  • Page 85 Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V wc_tx000208gb.fm...
  • Page 86 G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair GS 8.5V and GS 9.7V, Rev. 102 and below Ref. Description Ref. Description Automatic voltage regulator Engine module Rotor winding Oil level switch Main stator winding Coil 120V, 20A GFI receptacle Spark plug 120V, 30A twist-lock receptacle Battery 240V, 20A receptacle...

  • Page 87: Vanguard Engine Wiring Schematic (Gs 8.5V And Gs 9.7V Models)

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 6.35 Vanguard Engine Wiring Schematic (GS 8.5V and GS 9.7V Models) Ref. Description Ref. Description Carburetor solenoid Regulator rectifier Stop switch terminal DC output wire 50 Hz. loop Key switch (GS 8.5=yellow, GS 9.7=red) Module Solenoid Idle down device...

  • Page 88: Vanguard Key Switch

    G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair 6.36 Vanguard Key Switch See Graphic: wc_gr000953 Ref. Switch Position Continuity 1 + 3 + 6 2 + 5 + 6 Start 2 + 4 + 5 Key Switch Positions Terminal Positions Note: Terminal 1 grounded internally to switch case.

  • Page 89: Storing

    Portable Generator Repair G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 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 line into a suitable container and open fuel valve to drain fuel from tank.
  • Page 90 G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V Portable Generator Repair wc_tx000208gb.fm...
  • Page 91 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 bolt is hard to remove, heat it using a small propane torch to break down the sealant.
  • Page 92 Threadlockers and Sealants TYPE PART NO. - ( ) = Europe COLOR USAGE SIZE Loctite Primer T Aerosol Fast curing primer for threadlocking, retaining and 2006124 - Hernon Primer 10 Spray sealing compounds. Must be used with stainless 6 oz. Omnifit VC Activator steel hardware.
  • Page 93 Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE 10.9 12.9 Size ft.lb. ft.lb. ft.lb. Inch Metric Inch Metric 7/32 9/32 5/16 11/16 15/16 1-1/16 1-1/4 1 ft.lb. = 1.357 Nm. * = in.lb. 1 Inch = 25.4 mm...
  • Page 94 Torque Values Inch Fasteners (SAE) Size ft.lb. ft.lb. ft.lb. Inch Metric Inch Metric No.4 3/32 No.6 5/16 7/64 No.8 11/32 9/64 No.10 5/32 7/16 3/32 5/16 9/16 5/16 7/16 9/16 13/16 15/16 1-1/8 1 ft.lb. = 1.357 Nm. * = in.lb. 1 Inch = 25.4 mm...
  • 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 Operations ·...

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G 3.7aG 5.6aGs 8.5vGs 9.7v

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