Related Manuals for Wacker Neuson G 2.1A
Summary of Contents for Wacker Neuson G 2.1A
- Page 1 0116567 1000 Portable Generators G 2.1A G 3.3A G 4.6A GS 4.6A GS 5.7A REPAIR MANUAL...
- Page 3 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.
- Page 4 FOREWORD 50 HZ PORTABLE GENERATORS Nameplate A nameplate listing the Model Number, Item Number, Revision, and Serial Number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model, item number, revision number, and serial number of the unit.
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Page 5: Table Of Contents
50 Hz Portable Generators Repair Manual Table of Contents Safety Safety Notes ........1A-1 Laws Pertaining to Spark Arresters . - Page 6 50 Hz Portable Generators Repair Manual Table of Contents, continued Models G3.3A, G4.6A, GS4.6A, & GS5.7A Theory of Operation – Brush Generators ....5A-1 Rotor .
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Page 7: Safety
50 HZ PORTABLE GENERATORS SAFETY 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 8: Operating Safety
SAFETY 50 HZ PORTABLE GENERATORS WARNING BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS! Improper connection of generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines. -
Page 9: Engine Safety
NEVER modify the equipment without express ALWAYS keep fuel lines in good condition and written approval from WACKER Corporation. properly connected. Leaking fuel and fumes are extremely explosive. ALWAYS replace all guards and safety devices immediately after servicing. - Page 10 SAFETY 50 HZ PORTABLE GENERATORS Notes: 1A-4...
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Page 11: Technical Data
50 HZ PORTABLE GENERATORS TECHNICAL DATA Generator Specifications Table 2-1. Ø Ø c i t a t l t a l Ø a t l a l i a t l & Ø Ø Ø o i t c r i t i u n i t L x W x H... -
Page 12: Engine Specifications
TECHNICAL DATA 50 HZ PORTABLE GENERATORS Engine Specifications Table 2-2. – ± – ± 50 ± 0 – t i l - l i 2A-2... -
Page 13: Determining Power Requirements
Check with your nearest WACKER large enough to prevent excessive back pressure to the Dealer, or contact the manufacturer or dealer of the tool engine. -
Page 14: Grounding The Generator
POWER REQUIREMENTS 50 HZ PORTABLE GENERATORS 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 provided on the generator frame and the other end to a suitable ground source. -
Page 15: Theory Of Operation - Capacitor Generators
Theory of Operation – Capacitor Generators Basic Generator Theory Brushless Generator Wacker air-cooled generators work on the principle of This model generator uses a brushless design to generate electromagnetic induction i.e., the cutting of magnetic and regulate power. It consists of a rotor, stator, diodes, lines of force by a coil of wire to produce an electric and an auxiliary winding. -
Page 16: Rotor
G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS 1022SD88 Figure 4-2. Brushless Type Generator Rotor (a) Capacitor (c) The inside of the rotor shaft is tapered and connected A capacitor is connected in series with the auxiliary directly to the taper on the engine crankshaft. This end is winding. -
Page 17: Circuit Breaker
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE Control Panel The generator is protected by a 10 amp circuit breaker 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 immediately and determine the cause before restarting. -
Page 18: Capacitors
G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS Capacitors Engine Speed All generators require a fixed engine speed to maintain WARNING the correct voltage output. Engine speed is controlled by a governor which automatically adjusts to varying loads ALWAYS handle or test capacitors with the engine on the engine to maintain a constant speed of 3000 –... -
Page 19: Loss Of Residual Magnetism In Rotor
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4.10 Loss of Residual Magnetism in Rotor If the rotor has been removed, or the generator has been To restore magnetism to the rotor, “flash” it as follows: stored over six months, the rotor’s magnetism may be 1. -
Page 20: Receptacle Panel Wiring
G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS 4.11 Receptacle Panel Wiring 4.12 Rotor Diode Testing Remove receptacle panel from control box and inspect To check diode: the wiring for worn or loose wires. Make sure all wire 1. Disassemble generator and remove rotor. See Section connections are secure and tight at the screws. -
Page 21: Stator Winding Testing
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4.13 Stator Winding Testing The stator includes the main winding and the auxiliary winding. Auxiliary Windings To check stator windings: Capacitor 1. Unplug stator connector at control box. 2. Disconnect ground wire. 3. Set ohmmeter to lowest scale. Place meter leads on connector terminals as shown and record resistance values, see Figure 4-8. -
Page 22: Rotor Winding Testing
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. -
Page 23: Generator Disassembly
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4.15 Generator Disassembly Capacitor Diode and/or Varistor (10) 1. Remove the two end cover screws and the end 1. Unsolder leads from the diodes unscrew diode stud. See Figure 4-10. cover . See Figure 4-10. 2. -
Page 24: Troubleshooting
G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS 4.17 Troubleshooting Table 4-2. Generator Chart “ ” F o i t S “ ” T o i t . y t l l i o i t o i t n i t o i t l l i l l i f . -
Page 25: Periodic Maintenance Schedule
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4.18 Periodic Maintenance Schedule . l i l l i • • * . r • . l i • • • • • • • • • * Service more frequently in dusty conditions. Table 4-3. -
Page 26: Wiring Schematic (G2.1A Model)
G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS 4.20 Wiring Schematic (G2.5A Model) 1020SD79 4A-12... -
Page 27: Theory Of Operation - Brush Generators
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A Theory of Operation – Brush Generators Basic Generator Theory These models are designed to operate with close regulation when supplying single phase loads. The These generator models use a brush/slip ring design to principle of operation is schematically represented in generate and regulate power and consist of a rotor, Figure 5-1, and a cross-sectional view in Figure 5-2. -
Page 28: Rotor
G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS Voltage Adjust Pot 1023SD48 Figure 5-2. Brush-Type Generator Rotor Stator The inside of the rotor shaft is tapered and connected The stator houses both the main windings and directly to the taper on the engine crankshaft. This end is auxiliary winding. -
Page 29: Automatic Voltage Regulator (Avr)
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A Automatic Voltage Regulator (AVR) The Automatic Voltage Regulator (AVR) provides the generator with a means of maintaining a specific voltage regardless of load. The AVR accomplishes this by regulating DC current from the auxiliary winding. When the load on the generator increases, the AVR allows additional DC current into the rotor. -
Page 30: Main Circuit Breaker
G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS Main Circuit Breaker Earth-leakage Circuit Breaker The circuit breaker protects the generator from severe Generator models G3.3AE, G4.6AE, GS4.6AE, and overloads or short circuits. If the circuit breaker opens, GS5.7AE are equipped with an earth-leakage circuit turn the engine off immediately and determine the cause breaker. - Page 31 50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 230V Control Panel a Main circuit breaker - 15 Amp. b Australian style receptacle. c Danish IP44 style receptacle. d Swiss IP X4 style receptacle. e France/Belgium IP44 style receptacle. 230V f Schuko IP44 (CEE 7) style receptacle. g Earth-leakage circuit breaker (G3.3AE, G4.6AE, GS4.6AE).
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Page 32: Engine Speed
G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS Engine Speed (G3.3A, G5.7A, and GS5.7A Models) Generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constant speed of 3600 rpm. There is no throttle control. - Page 33 50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5.10 Periodic Maintenance Schedule (G3.7A, G5.6A, and GS5.6A Models) y l i l i o l l i . l e • . r e • r i a * . r • . l i •...
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Page 34: Loss Of Residual Magnetism In Rotor
G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS 1031SD62 Figure 5-11. Brush Type Generator 5.11 Loss of Residual Magnetism in Rotor General If the rotor has been removed, the generator stored for a considerable time, or the rotor (field) connections reversed during service, the residual magnetism may have been destroyed. Loss of magnetism will prevent the generator from building voltage. -
Page 35: Diode Bridge
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A Restoring Residual Magnetism to the Brush Type Generators Disconnect leads F1 and F2 from the brush holder . Run the generator at its normal speed and apply 12 volts from a battery to the brush holder for approximately 3 seconds. Ensure the positive lead is applied to the brush holder nearest the bearing housing. -
Page 36: Stator Windings
G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS 5.14 Stator Windings The stator includes the two main power windings and the auxiliary winding. See Figure 5-14. To check stator windings: 1. Unplug stator connector at control box. 2. Set ohmmeter to lowest scale. Place meter leads on connector terminals as shown and record resistance values. -
Page 37: Rotor Windings
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 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. - Page 38 G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS 1020SD78 Figure 5-16. Brush Type Generator 5A-12...
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Page 39: Generator Disassembly
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5.18 Generator Disassembly Bridge Rectifier (25) 2. Remove 3 mounting screws (22) 3. If brushes are to be changed, remove the brush (19) 1. Remove the two end cover screws and the end terminal plate and withdraw springs and brushes. (20) cover . -
Page 40: Generator Assembly
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 6. If brushes were changed, reinstall the brushes, following: springs and terminal plate. 1. Make sure inner taper on rotor and outer taper on the Note: New brushes must be seated using a medium engine crankshaft are clean and free of rust and oil. - Page 41 50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 1020SD78 5A-15...
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Page 42: Troubleshooting
G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS 5.20 Troubleshooting Table 5-2. Generator Chart “ ” “ ” l l i l l i . l i . r i . y l f i t i f i . t f . t l i t r . -
Page 43: Wiring Schematics - Generator/Engine
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5.21 Wiring Schematics – Generator/Engine Wiring Schematic (G3.3A Model) 1020SD83 5A-17... - Page 44 G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS Generator Wiring Schematic (G4.6A, GS4.6A Models) 1020SD85 5A-18...
- Page 45 50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A Engine Wiring Schematic (G4.6A , GS4.6AModels) 1021SD67 5A-19...
- Page 46 G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS Generator Wiring Schematic (GS5.7A Models) 1021SD04 5A-20...
- Page 47 50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A Engine Wiring Schematic (GS5.7A Models) 1021SD01 5A-21...
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Page 48: Storing/Transporting
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 suitable container and open fuel valve to drain fuel from tank. - Page 49 Threadlocking compounds normally break down at temperatures above 350° F (175° C). If a screw or bolt is hard to remove, heat it using a small propane torch to break down sealant. When applying sealants, follow instructions on container. The sealants listed below are recommended for use on WACKER equipment. TYPE...
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Page 50: Torque Values
TORQUE VALUES Metric Fasteners (DIN) WRENCH SIZE TORQUE VALUES (Based on Bolt Size and Hardness) 12.9 10.9 10.9 12.9 Size Ft.Lb. Ft.Lb. Ft.Lbs. Inch Metric Inch Metric 7/32 9/32 5/16 11/16 15/16 1-1/16 1-1/4 Inch Fasteners (SAE) SAE 5 SAE 8 Size Ft.Lb. - Page 52 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : +1-(1)(262) 255-0500 · Fax: +1-(1)(262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations · Sunley Center, Unit 912, 9/F · 9 Wing Qin Street, Kwai Chung, N.T. · Hong Kong · Tel. + 852 2406 60 32 · Fax: + 852 2406 60 21...