Wacker Neuson G2.5A Operating instructions

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
0112013

Portable Generator Repair Foreword
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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. THE INFORMATION CONTAINED IN THIS
MANUAL WAS BASED ON MACHINES IN PRODUCTION AT THE
TIME OF PUBLICATION. WACKER CORPORATION RESERVES
THE RIGHT TO CHANGE ANY PORTION OF THIS INFORMATION
WITHOUT NOTICE.
This manual covers machines with Item Number:
0007188, 0007189, 0007190, 0007191, 0007661, 0007662

Foreword Portable Generator Repair
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Portable Generator Repair Table of Contents
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1. Foreword 5
2. Safety Information 6
2.1 Laws Pertaining to Spark Arresters ...................................................... 6
2.2 Operating Safety .................................................................................. 7
2.3 Operator Safety while using Internal Combustion Engines .................. 8
2.4 Service Safety ...................................................................................... 9
2.5 Label Locations .................................................................................. 10
2.6 Safety and Operating Labels .............................................................. 13
3. Technical Data 18
3.1 Generator ........................................................................................... 18
3.2 Engine ................................................................................................ 22
4. Power Requirements 26
4.1 Determining Power Requirements ..................................................... 26
4.2 Outdoor Installation ............................................................................ 27
4.3 Indoor Installation ............................................................................... 27
4.4 Grounding the Generator ................................................................... 28
4.5 Use of Extension Cords ...................................................................... 29
5. G 2.5A 30
5.1 Theory of Operation – Capacitor Generators ..................................... 30
5.2 Rotor ................................................................................................... 31
5.3 Stator .................................................................................................. 31
5.4 Capacitor ............................................................................................ 32
5.5 Diodes ................................................................................................ 32
5.6 Circuit Breaker .................................................................................... 33
5.7 Ground Fault Interruptor ..................................................................... 34
5.8 Capacitors .......................................................................................... 35
5.9 Engine Speed ..................................................................................... 36
5.10 Loss of Residual Magnetism .............................................................. 37

Table of Contents Portable Generator Repair
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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 Storing / Transporting ..........................................................................46
5.21 Wiring Schematic ................................................................................47
6. G 3.7A;G/GS 5.6A;GS 8.5V;GS 9.7V 48
6.1 Theory of Operation – Brush Generators ............................................48
6.2 Rotor ....................................................................................................49
6.3 Stator ...................................................................................................49
6.4 Automatic Voltage Regulator ...............................................................49
6.5 Choke ..................................................................................................49
6.6 Bridge Rectifier ....................................................................................50
6.7 Engine Auto Idle Module (G 3.7A, G 5.6A and GS 5.6A Models) .......51
6.8 Engine Auto Idle Module (GS 8.5A and GS 9.7A Models) ..................52
6.9 Voltage Selector Switch (G 3.7A, G 5.6A and GS 5.6A Models) ........52
6.10 Checking the Voltage Selector Switch Functional Output
(G 3.7A, G 5.6A and GS 5.6A Models)................................................53
6.11 Main Circuit Breaker ............................................................................54
6.12 Ground Fault Interrupt .........................................................................54
6.13 Choke Test ..........................................................................................56
6.14 Engine Speed (G 3.7A, G 5.6A and GS 5.6A Models) ........................57
6.15 Auto Idle Switch ...................................................................................58
6.16 Checking Engine Electronic Governor Speed
(GS 8.5V and GS 9.7V models) .........................................................59
6.17 Removing and Installing Electronic Governor
(GS 8.5V and GS 9.7V Models) ..........................................................61
6.18 Receptacle Panel Wiring .....................................................................62
6.19 Loss of Residual Magnetism in Rotor ..................................................62
6.20 Diode Bridge ........................................................................................64
6.21 Stator Windings ...................................................................................65
6.22 Rotor Windings ....................................................................................67
6.23 Automatic Voltage Regulator ...............................................................68

Portable Generator Repair Table of Contents
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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) .................... 75
6.30 Periodic Maintenance Schedule (GS 8.5V and GS 9.7V Models) ...... 76
6.31 Engine Service (GS 8.5V and GS 9.7V Models) ................................ 76
6.32 Generator Wiring Schematic (G 3.7A, G 5.6A, and GS 5.6A Models) 77
6.33 Engine Wiring Schematic (G 3.7A, G 5.6A, and GS 5.6A Models) .... 79
6.34 Generator Wiring Schematic (GS 8.5V and GS 9.7V Models) ........... 80
6.35 Vanguard Engine Wiring Schematic (GS 8.5V and GS 9.7V Models) 83
6.36 Vanguard Key Switch ......................................................................... 84
6.37 Storing ................................................................................................ 85
6.38 Transporting ....................................................................................... 85

Table of Contents Portable Generator Repair
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Foreword
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CALIFORNIA
Proposition 65 Warning:
Engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known totheState of California
to cause cancer and birth defects or other reproductive harm.
1. Foreword
This manual provides information and procedures to safely operate
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.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2003 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.
WARNING

Safety Information Portable Generator Repair
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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. 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.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
2.1 Laws Pertaining to Spark Arresters
Notice: State Health Safety Codes and Public Resources Codes
specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.
DANGER
WARNING
CAUTION

Portable Generator Repair Safety Information
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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 current from the generator to backfeed into utility lines.
This may 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.
If connected to a building's electrical system the generator must meet
the power, voltage, and frequency requirements of the equipment in
the building. Differences in power, voltage, and frequency
requirements may exist and improper connection may lead to
equipment damage, fire, and personal injury or death.
Familiarity and proper training are required for the safe operation of
equipment! Equipment operated improperly or by untrained personnel
can be dangerous! Read the operating instructions contained in both
this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the equipment before
being allowed to operate the machine.
2.2.1 NEVER operate generator when open containers of fuel, paint, or
other flammable liquids are near.
2.2.2 NEVER operate generator, or tools attached to the generator, with wet
hands.
2.2.3 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
2.2.4 NEVER run electrical cords under the generator, or over vibrating or
hot parts.
2.2.5 NEVER enclose or cover generator when in use or when hot.
2.2.6 NEVER overload generator. The total amperage of the tools and
equipment attached to the generator must not exceed the load rating
of the generator.
2.2.7 NEVER operate machine in snow, rain, or standing water.
2.2.8 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a trained electrician.
2.2.9 ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
2.2.10 ALWAYS be sure machine is on a firm, level surface and will not tip,
roll, slide, or fall while operating.
DANGER
WARNING

Safety Information Portable Generator Repair
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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. Make sure that the area overhead is clear of
debris that could fall onto or into the generator, or exhaust
compartment.
2.2.14 ALWAYSremoveall tools, cords, andother loose items fromgenerator
before starting it.
2.2.15 ALWAYS make certain machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
2.3 Operator Safety while using Internal Combustion Engines
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 warnings and
safety guidelines could result in severe injury or death.
2.3.1 DO NOT run machine indoors or in an enclosed area such as a deep
trench unless adequate ventilation, through such items as exhaust
fans or 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.
2.3.2 DO NOT smoke while operating machine.
2.3.3 DO NOT smoke when refueling engine.
2.3.4 DO NOT refuel hot or running engine.
2.3.5 DO NOT refuel engine near open flame.
2.3.6 DO NOT spill fuel when refueling engine.
2.3.7 DO NOT run engine near open flames.
2.3.8 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.
2.3.9 ALWAYS refill fuel tank in well-ventilated area.
2.3.10 ALWAYS replace fuel tank cap after refueling.
2.3.11 ALWAYS check fuel lines and fuel tank for leaks and cracks before
starting engine. Do not run machine if fuel leaks are present or fuel
lines are loose.
DANGER

Portable Generator Repair Safety Information
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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 is experiencing problems or is being serviced, attach a
"DO NOT START" signto the control panel to notify other peopleof its
condition.
2.4.1 DO NOT use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
2.4.2 DO NOT attempt to clean or service machine while it is running.
2.4.3 DO NOT modify the equipment without express written approval of the
manufacturer.
2.4.4 DO NOT allow water to accumulate around the base of the machine.
If water is present, move the machine and allow it to dry before
servicing.
2.4.5 DO NOT service machine if clothing or skin is wet.
2.4.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical techniciansshouldbe allowed toservice the electrical
components of this equipment.
2.4.7 ALWAYS keep machine clean and labels legible. Replace all missing
and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
2.4.8 ALWAYS replace safety devices and guards after repairs and
maintenance.
2.4.9 ALWAYS let engine cool before transporting or servicing.
2.4.10 ALWAYSkeep hands,feet,andloose clothing away from moving parts
on generator and engine.
2.4.11 ALWAYS turn engine off before servicing generator. If the engine has
electric start, disconnect negative terminal on battery
2.4.12 ALWAYS keep fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.
WARNING

Safety Information Portable Generator Repair
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2.5 Label Locations
G 2.5A
w c
g
r000552
GND
88897
123
4
5
12
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 T F R O M T H E G E N E R A T O R T O
B A C K F E E D I N T O U T I L I T Y L I N E S .
T H I S M A Y R E S U L T I N E L E C T R O C U T I O N
O F U T I L I T Y W O R K E R S , F I R E O R
E X P L O S I O N . C O N N E C T I O N S 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 M U S T B E M A D E
B Y A U A L I F I E D E L E C T R I C I A N A N D C O M P L Y W I T H
A L L A P P L I C A B L E L A W S A N D E L E C T R I C A L C O D E S .
D A N G E R
STOP
DANGER
GEFAHR
PELIGRO
DANGER

Portable Generator Repair Safety Information
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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 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.
4
321
321
6
56 5
DANGER
GEFAHR
DANGER
PELIGRO
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

Safety Information Portable Generator Repair
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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

Portable Generator Repair Safety Information
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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 operator's
manual.
No sparks, flames or burning objects near machine. Shut off engine before refueling.
DANGER!
Electric shock hazard. Read operator’s manual for instructions.
WARNING!
Hot surface.
CAUTION!
Read and understand the supplied operator's
manual before operating this machine. Failure
to do so increases the risk of injury to yourself
or others.
CAUTION!
Lifting point
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
STOP
DANGER
GEFAHR
PELIGRO
DANGER
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 T F R O M T H E G E N E R A T O R T O
B A C K F E E D I N T O U T I L I T Y L I N E S .
T H I S M A Y R E S U L T I N E L E C T R O C U T I O N
O F U T I L I T Y W O R K E R S , F I R E O R
E X P L O S I O N . C O N N E C T I O N S 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 M U S T B E M A D E
B Y A Q U A L I F I E D E L E C T R I C I A N A N D C O M P L Y W I T H
A L L A P P L I C A B L E L A W S A N D E L E C T R I C A L C O D E S .
D A N G E R

Safety Information Portable Generator Repair
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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 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. CONNECTIONS
TO A BUILDING'S ELECTRICAL SYSTEM MUST
BE MADE BY A QUALIFIED ELECTRICIAN AND
COMPLY WITH ALL APPLICABLE LAWS AND
ELECTRICAL CODES.
4
321
321
6
56 5
DANGER
GEFAHR
DANGER
PELIGRO
123
4
5
12

Portable Generator Repair Safety Information
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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, Revision, and Serial Number is
attached to each unit. Please record the infor-
mation found on this plate so it will be avail-
able 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.
Label Meaning
M E N O M O N E E F A L L S , W I U S A 5 3 0 5 1
M o d e l
S e r i a l N o .
k W m a x
V
I e m N o .
k g
A
l b s
R e v .
P . F .
h z
M A D E I N U S A
110992

Safety Information Portable Generator Repair
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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 34
5B
5A
67
12
3