Académique Documents
Professionnel Documents
Culture Documents
com
0116567
002
1000
en
Portable Generators
G 2.1A
G 3.3A
G 4.6A
GS 4.6A
GS 5.7A
REPAIR MANUAL
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. 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.
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.
Model number
Item Number
Serial Number
Revision
Model
GS4.6A
Rev.
0008269
Serial No.
kg
hz
lbs
kW
class
5010101
101
N/M
1031SD44
Insul.
Class
Man.
Yr.
110635
Item No.
50 Hz Portable Generators
Repair Manual
Table of Contents
Safety
1.1
1.2
1.3
1.4
1.5
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Laws Pertaining to Spark Arresters . . . . . . . . . . . . . . . . . . . . . .
Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data
2.1
2.2
Power Requirements
3.1
3.2
3.3
3.4
3.5
Model G2.1A
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
1A-1
1A-1
1A-2
1A-3
1A-3
3A-1
3A-1
3A-1
3A-2
3A-2
50 Hz Portable Generators
Repair Manual
Table of Contents, continued
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
50 HZ PORTABLE GENERATORS
1.1
SAFETY
1A
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.
! DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
! WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
! CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
1.2
Notice: Some local authorities require that in certain locations, spark arresters be used on 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.
1A-1
Downloaded from www.Manualslib.com manuals search engine
1A 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 buildings 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 buildings electrical system must be made by a qualified electrician and comply with all applicable laws and
electrical codes.
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.
NEVER run generator indoors or in an enclosed area
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.
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.
1A-2
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
1.4
SAFETY
1A
Engine Safety
Internal combustion engines present special hazards during operation and fueling! Read and follow warning
instructions in engine owners manual and safety guidelines below. Failure to follow the safety guidelines described
below could result in severe injury or death.
WARNING
DO NOT run engine indoors or in an enclosed area
unless adequate ventilation, through such items as
exhaust fans or hoses, is provided.
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
this equipment. Only trained electrical technicians
should be allowed to service the electrical
components of this equipment.
NEVER modify the equipment without express
written approval from WACKER Corporation.
1A-3
Downloaded from www.Manualslib.com manuals search engine
1A SAFETY
Notes:
1A-4
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
50 HZ PORTABLE GENERATORS
2.1
TECHNICAL DATA
2A
Generator Specifications
Table 2-1.
Model
Output
kVA
Type
G2.1A
G3.3A
2,1
3,3
GS4.6A
230V
1 phase
Frequency
Hz
GS5.7A
4,1 1
5,7 3
4,6
Brushless
AC Voltages available
voltage & phase
G4.6A
50
Power Factor
1,0 1
0,8 3
1,0
AC Receptacles
Optional
amp
10 (1 pole)
15 (1 pole)
20 (1 pole)
9 (3 pole)
Continuous Current
at 230V/400V
amp
9,1/N.A.
14,3/N.A.
20,0/N.A.
18,0/8,2
LxWxH
mm
Kg
44
71
80
N/A
N/A
N/A
Weight (dry)
Battery
83
50-N18L-A/12/20
2A-1
Downloaded from www.Manualslib.com manuals search engine
2A TECHNICAL DATA
2.2
50 HZ PORTABLE GENERATORS
Engine Specifications
Table 2-2.
Model
G2.1A
G3.3A
G4.6A
Engine Make
Engine Model
Power @ 3000 rpm
Displacement cubic
Operating Speed
no load
Operating Speed
full load
Auto Idle Speed
Valve Clearance
(cold)
exhaust
intake
Spark Plug
GX 160 K1VX
GX 240 K1
GX 340 K1
4,1
163
6,0
242
8,2
337
kW
cm
rpm
GS5.7A
3100 50
rpm
rpm
3000 50
2200 50
N/A
mm
0,20
0,15
BPR6ES/W20EPR-U
type
mm
(type / V)
Alternator
Fuel
Fuel Consumption
Fuel Tank Capacity
Running Time
Air Cleaner
Engine Lubrication
amp
N/A
Type
liter/hr
1,7
liter
3,7
hr.
2,2
type
oil grade SAE 10W30
service SG, SF, or SE
class
600
ml
Capacity
GS4.6A
Honda
2A-2
Downloaded from www.Manualslib.com manuals search engine
N/A
N/A
0,7 0,8
N/A
Electric / 12V
N/A
N/A
Regular unleaded (Min. 77 Octane)
2,4
3,2
19,5
8,2
6,0
Dry type with oil-wetted foam pre-cleaner
SAE 10W30
SG or SF
1100
50 HZ PORTABLE GENERATORS
POWER REQUIREMENTS
3.2
3A
Outdoor Installation
3.3
Indoor Installation
WARNING
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 generator indoors or in an enclosed
area unless adequate ventilation, through such items
as exhaust fans or hoses, is provided.
When operated indoors, steps to prevent fire and explosion
such as, providing a good earthen ground, removing all
flammable materials near generator, and using only
electric cords in good condition, must be observed. See
Section 1.3 Operating Safety.
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
3A-1
Downloaded from www.Manualslib.com manuals search engine
3A POWER REQUIREMENTS
3.4
50 HZ PORTABLE GENERATORS
1001SD02
3.5
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. A heavier cord with a larger wire size will reduce the voltage loss.
Use Table 3-1 below as a guide for selecting proper cable size.
Use only extension cords rated for outdoor use and equipped with a third-wire ground.
Table 3-1.
Current
Amps
2.5
5
7.5
10
15
20
Load in Watts
120V
240V
300
600
600
1200
900
1800
1200
2400
1800
3600
2400
4800
WARNING
Keep electrical cords in good condition. DO NOT use worn,
bare, or frayed cords which can cause electrical shock.
3A-2
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
4.1
G2.1A/G2.1AE
4A
Brushless Generator
Diodes
(Rectifier)
Auxiliary Winding
Capacitor
b
d
Main Windings
Rotor Field
Windings
1023SD44
4A-1
Downloaded from www.Manualslib.com manuals search engine
4A G2.1A/G2.1AE
a
50 HZ PORTABLE GENERATORS
b
1022SD88
4.2
Rotor (a)
4.3
Stator (b)
4A-2
Downloaded from www.Manualslib.com manuals search engine
4.4
Capacitor (c)
4.5
Diodes (d)
50 HZ PORTABLE GENERATORS
4.6
G2.1A/G2.1AE
4A
Control Panel
a
Depending on model, the generator will have one of the
four styles of receptacles, the Danish IP44 type (b), the
Swiss IP X4 type (c), the France/Belgium IP44 type (d),
or the Schuko IP44 (CEE 7) type (e).
Note: Enlargements of receptacles show protective
covers removed for identification purposes only. Never
remove protective covers.
4.7
230V
230V
Control Panel
a
b
c
d
e
1031SD43
Generator model G2.1AE is equipped with an earthleakage circuit breaker. The circuit breaker is current
operated and shuts off the power to the receptacles when
a ground fault of 30 milli-Amps or greater occurs in the
generator or to a piece of equipment attached to the
generator. The circuit breaker is located on the opposite
side of the generator as the control panel.
f1
f2
T
E
S
T
g
1020SD80
4A-3
Downloaded from www.Manualslib.com manuals search engine
4A G2.1A/G2.1AE
4.8
50 HZ PORTABLE GENERATORS
Capacitors
4.9
WARNING
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
designed to discharge when the engine is stopped,
it is still a good idea to discharge them manually
before handling. To discharge a capacitor, place a
conductor, such as a screwdriver with an insulated
handle, across the capacitor terminals. Be sure to
touch only the insulated handle. This will short out
across the terminals and discharge the capacitor.
Testing Capacitor
1. Discharge capacitor as described above, then
disconnect all wire leads from the terminals.
2. Check the capacitor charge and discharge readings
using an ohmmeter as described below or use a
capacitor checker. See Figure 4-4.
Set Ohmmeter on R x 10k scale.
Set meter leads on capacitor terminals. The meter
should deflect momentarily towards zero (fully
discharged) and then slowly climb up to infinity
(charging).
Reverse meter leads and repeat procedure. Results
should be the same.
Engine Speed
1001SD15
1007SD87
4A-4
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
G2.1A/G2.1AE
4A
WARNING
Contact with exposed connections inside the control
box or while handling battery leads can cause severe electrical shocks. Be extremely careful to avoid
touching any exposed connections. Never wear
jewelry or use tools or metal items that may make
contact across exposed connections. Review safety
rules at beginning of this manual.
Stator Housing
Capacitor
12 VDC
Battery
1023SD45
4A-5
Downloaded from www.Manualslib.com manuals search engine
4A G2.1A/G2.1AE
50 HZ PORTABLE GENERATORS
To check diode:
1. Disassemble generator and remove rotor. See Section
4.15 Generator Disassembly.
2. Set ohmmeter in lowest scale. Test diode in forward
position. Meter should read low or close to zero.
3. Reverse meter leads and test diode in reverse position.
Meter should read high or close to infinity.
A zero reading in both directions indicates a shorted
diode. A reading of Infinity in both directions indicates an
open diode. The diode must be replaced in either case.
If one diode is defective it is recommended that both
diodes be replaced since the remaining diode may have
been weakened.
To remove diode, use a soldering iron to soften solder
and remove wires.
When soldering on wires do not allow soldering iron to
remain on diodes longer than 10 seconds or diode may
be damaged.
LOW VALUE
HIGH VALUE
POS
NEG
NEG
POS
1024SD03
4A-6
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
G2.1A/G2.1AE
4A
Capacitor
1023SD46
Main
Winding
Auxiliary
Winding
Rotor
Winding
0,918
1,04
8,12
4A-7
Downloaded from www.Manualslib.com manuals search engine
4A G2.1A/G2.1AE
50 HZ PORTABLE GENERATORS
NEG
POS
1024SD04
4
5
8
7
13 ft. lbs.
(17.5 Nm)
15
10
14
13
12
11
1023SD47
4A-8
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
G2.1A/G2.1AE
4A
1. Remove the two end cover screws (10) and the end
cover (9). See Figure 4-10.
Stator
Rotor
4A-9
Downloaded from www.Manualslib.com manuals search engine
4A G2.1A/G2.1AE
50 HZ PORTABLE GENERATORS
4.17 Troubleshooting
Table 4-2.
Generator Chart
Symptom
Engine Does Not
Start
Possible Cause
1. Engine switch is in OFF position.
7. Refill oil.
Low Voltage
Solution
2. Reset breaker.
3. GFI open.
9. Install tightly.
1.
3. Capacitor is defective.
High Voltage
No-load Voltage
Normal but Falls
when Load is
Applied
4A-10
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
G2.1A/G2.1AE
4A
Every 3
months or
50 hours
Every 6
months or
100 hours
Every
year or
300 hours
Every
year or
500 hours
Table 4-3.
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 Operators manual. In depth engine service should be performed by qualified
personnel or by the nearest Honda dealer.
4.19 Storing/Transporting
WARNING
Gasoline is extremely flammable. Drain fuel tank in
a well-ventilated area. DO NOT drain tank in an area
with flames or sparks.
3. Loosen the drain screw on the carburetor and drain
any remaining fuel from carburetor.
4. Change the engine oil.
WARNING
To avoid burns or fire hazards, let engine cool before
transporting generator or storing indoors.
Turn the fuel valves under the tank and on engine to
the off position and keep the engine level to prevent
fuel from spilling.
4A-11
Downloaded from www.Manualslib.com manuals search engine
4A-12
Br
B = Control box
C = Engine
LL
G/Y
3 Br
G/Y
LL
G/Y
1
2
B(2)
B(4)
B(1) B(3)
R/B
G/Y
LL/B
G/Y
LL/Gr
B/R
R/Gr
R/W
2
1
A = Generator
10 B
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
Wire Colors
4
G
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
4A G2.1A/G2.1AE
50 HZ PORTABLE GENERATORS
1020SD79
50 HZ PORTABLE GENERATORS
5.1
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
Automatic
Voltage
Regulator
e
Brush and Slip
Ring Assembly
Bridge Rectifier
Auxiliary
Winding
a
d
Rotor
Winding
f
b
Choke
Main
Stator
Winding
f
Main
Stator
Winding
1022SD73
5A-1
Downloaded from www.Manualslib.com manuals search engine
5A G3.3A/G4.6A/GS4.6A/GS5.7A
50 HZ PORTABLE GENERATORS
F1
Z3
F2
Z2
F1
F2
F2
F1
L2
L1
Voltage Adjust Pot
1023SD48
5.2
Rotor
5A-2
Downloaded from www.Manualslib.com manuals search engine
5.3
Stator
50 HZ PORTABLE GENERATORS
5.4
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
5.5
Choke
5.6
Bridge Rectifier
5A-3
Downloaded from www.Manualslib.com manuals search engine
5A G3.3A/G4.6A/GS4.6A/GS5.7A
5.7
50 HZ PORTABLE GENERATORS
5.8
a1
a1
a2
a2
T
E
S
T
1020SD80
5A-4
Downloaded from www.Manualslib.com manuals search engine
1020SD89
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
50 HZ PORTABLE GENERATORS
a
a1
2
3
2
a2
230V
Control Panel
a
b
c
d
e
f
g
T
E
S
T
230V
1031SD41
a
j1
j2
j3
a1
1
3
4
3
2
230V
a2
j
Control Panel
a
b
c
d
e
f
g
h
j
400V
1031SD42
5A-5
Downloaded from www.Manualslib.com manuals search engine
5A G3.3A/G4.6A/GS4.6A/GS5.7A
5.9
50 HZ PORTABLE GENERATORS
5A-6
Downloaded from www.Manualslib.com manuals search engine
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
50 HZ PORTABLE GENERATORS
Every 3
months or
50 hours
Every 6
months or
100 hours
Every
year or
300 hours
Every
year or
500 hours
Table 5-3
5A-7
Downloaded from www.Manualslib.com manuals search engine
5A G3.3A/G4.6A/GS4.6A/GS5.7A
50 HZ PORTABLE GENERATORS
Z1
Z3
F2
F1
a
1031SD62
5A-8
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
CAUTION: Ensure the battery leads are connected to the brush holder with the correct polarity, and leads F1 F2
are isolated from each other and earth. Loss of residual magnetism will result if leads touch ground, each other, or wrong
polarity.
F1
Z3
F2
F1
Z2
Z3
F2
Z2
1023SD52
1023SD98
5A-9
Downloaded from www.Manualslib.com manuals search engine
5A G3.3A/G4.6A/GS4.6A/GS5.7A
50 HZ PORTABLE GENERATORS
1024SD05
Table 5-1.
Resistance Values
Generator
Model
Main
Winding
(per section)
Auxiliary
Winding
Rotor
Winding
G3.3A
0.45
2.09
10.8
G4.6A
0.39
1.97
11.3
GS4.6A
0.39
1.97
11.3
GS5.7V
1.72
11.3
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.
5A-10
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
Checking Rotor
1. Remove end cover and brush assembly.
2. Measure resistance as shown in the illustration, by
measuring the winding at the slip rings. See Figure
5-15.
3. Record resistance values of both windings and
compare them with values listed in Table 5-1.
4. Check for grounded windings by holding one meter
lead to winding and other lead to metal frame on rotor.
Replace rotor if windings are open, shorted internally or
shorted to metal frame.
1024SD02
Slip Rings
Figure 5-15. Checking Rotor
Inspect the slip rings for dirt or damage. If the slip rings
are dirty, use an eraser or non-metallic abrasive pad to
clean the rings and then retry the generator.
Brushes
Inspect the brushes for damage, dirt, freedom of
movement, or brush length. Brushes less than 8 mm in
length should be replaced. Also replace damaged
brushes.
5A-11
Downloaded from www.Manualslib.com manuals search engine
5A G3.3A/G4.6A/GS4.6A/GS5.7A
50 HZ PORTABLE GENERATORS
10
7
11
16
15
14
17
30
18
31
21
22
19
23
20
25
24
5A-12
Downloaded from www.Manualslib.com manuals search engine
1020SD78
50 HZ PORTABLE GENERATORS
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
1. Remove the two end cover screws (19) and the end
cover (20). See Figure 5-16.
F1
Z3
F1
Z2
Z3
Stator
2. Remove the four nuts (11) from the four studs (2)
securing the generator frame (14) to the engine
adapter flange (1).
3. For units with electric start:
F2
F2
Z2
1023SD53
Choke
1. Remove the bottom mounting screw (17) and carefully pull choke assembly (18) away from stator (14).
See Figure 5-16.
2. Disconnect the two leads (Z1 & Z3).
1. Remove the fuel tank mounting bolts and tilt the tank
to gain access to the gas line and shut off valve.
Rotor
2. Release the rotor (3) from the engine shaft by supporting rotor in one hand and with a mallet, striking
firmly on a pole face.
5A-13
Downloaded from www.Manualslib.com manuals search engine
5A G3.3A/G4.6A/GS4.6A/GS5.7A
50 HZ PORTABLE GENERATORS
5A-14
Downloaded from www.Manualslib.com manuals search engine
10. Install the end cover (20) and two mounting screws
(19).
11. Reconnect the stator wires (26) and (27) to the
control panel and reinstall panel.
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
50 HZ PORTABLE GENERATORS
10
7
11
16
15
14
17
30
18
31
21
22
19
23
20
25
24
1020SD78
5A-15
Downloaded from www.Manualslib.com manuals search engine
5A G3.3A/G4.6A/GS4.6A/GS5.7A
50 HZ PORTABLE GENERATORS
5.20 Troubleshooting
Table 5-2. Generator Chart
Symptom
Engine Does Not
Star t
Possible Cause
Solution
1.
1.
2.
2.
3.
3.
4.
4.
5.
5.
6.
6.
7.
7.
Refill oil.
1.
1.
Reset breaker.
2.
GFI open.
2.
3.
3.
4.
4.
5.
5.
Install tightly.
6.
6.
7.
7.
1.
1.
2.
Defective choke.
2.
3.
3.
4.
4.
5.
5.
6.
6.
7.
7.
High Voltage
1.
1.
1.
1.
2.
2.
Replace fuse.
3.
3.
4.
Reconnect.
5.
5.
6.
6.
7.
7.
No Output Voltage
Low Voltage
5A-16
Downloaded from www.Manualslib.com manuals search engine
F1
10
Z3
Z1
C = Engine
B = Control box
G/Y
LL/W
L/L
G/Y
Br
A = Generator
Z3
Z2
Z1
Br
11
Z2
F2
B
F2
L1 L2
F1
12
R/B
LL/B
R/B
G/Y
R/W
LL/W
R/B
G/Y
LL/B
B/R
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
OFF
Wire Colors
ON
G/Y
R/Gr
LL/B
LL/Gr
50 HZ PORTABLE GENERATORS
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
1020SD83
5A-17
L2
Z2
F2
F2
R B
F1
F1
L1
5A-18
1020SD85
Z3
Z1
Br
Z3
Z2
Z1
Br
G/Y
3
R/B
1
G/Y
R/B
LL/B
R/W LL/W
R/B
G/Y
LL/B
G/Y
R/Gr
LL/B
G/Y
LL/W
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
Wire Colors
LL/Gr
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
5A G3.3A/G4.6A/GS4.6A/GS5.7A
50 HZ PORTABLE GENERATORS
B/R
G4.6 Models
GS4.6 Models
ON
12
17
11
OFF
18
10
L/W
16
15
L/W
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
Wire Colors
12
11
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
14 13
50 HZ PORTABLE GENERATORS
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
1021SD67
5A-19
5A-20
F1
F1
F2
F2
L1 L2
G/Y
LL
Br
G/Y
LL/W
Br/W
R/W
V/W
Br/B
V/B
R/B
N 2 4 6
1
2
3
4
V/W Br/W
R/W
N 1 3 5
LL/W
LL/B
1
2
3
4
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
Wire Colors
LL/B
Br/B
V/B
R/B
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
G/Y
LL/Gr
Br/R
R/Gr
G/Y
G/Y
LL/R
5A G3.3A/G4.6A/GS4.6A/GS5.7A
50 HZ PORTABLE GENERATORS
1021SD04
16
9
3
L/W
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
Wire Colors
15
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
14
L/W
11
10
13 12
50 HZ PORTABLE GENERATORS
G3.3A/G4.6A/GS4.6A/GS5.7A 5A
1021SD01
5A-21
5A G3.3A/G4.6A/GS4.6A/GS5.7A
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.
WARNING
Gasoline is extremely flammable. Drain fuel tank in
a well-ventilated area. DO NOT drain tank in an area
with flames or sparks.
3. Loosen the drain screw on the carburetor and drain
any remaining fuel from carburetor.
4. Change the engine oil.
5. Remove the spark plug and pour approximately one
tablespoon (1 ounce) of clean engine oil into the
cylinder. Crank the engine a few turns to distribute the
oil to the inside of the cylinder walls.
6. Pull the starter rope slowly until resistance is felt and
leave handle in this position. This ensures that the
intake and exhaust valves are closed.
7. Store generator in a clean, dry area.
WARNING
To avoid burns or fire hazards, let engine cool before
transporting generator or storing indoors.
Turn the fuel valves under the tank and on engine to
the off position and keep the engine level to prevent
fuel from spilling.
5A-22
Downloaded from www.Manualslib.com manuals search engine
50 HZ PORTABLE GENERATORS
SEALANTS
Use Of Threadlockers and Sealants
Threadlocking adhesives and sealants are specified throughout this manual and should be used where indicated.
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
( ) = Europe
COLOR
USAGE
Loctite 222
Hernon 420
Omnifit 1150 (50M)
Purple
73287 - 10 ml
Loctite 243
Hernon 423
Omnifit 1350 (100M)
Blue
29311 - .5 ml
17380 - 50 ml
Red
29312 - .5 ml
26685 - 10 ml
73285 - 50 ml
Loctite 290
Hernon 431
Omnifit 1710 (230LL)
Green
28824 - .5 ml
25316 - 10 ml
Loctite 609
Hernon 822
Omnifit 1730 (230L)
Green
29314 - .5 ml
Loctite 545
Hernon 947
Omnifit 1150 (50M)
Brown
Hydraulic sealant
Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)
79356 - 50 ml
Loctite 592
Hernon 920
Omnifit 790
White
26695 - 6 ml
73289 - 50 ml
Loctite 515
Hernon 910
Omnifit 10
Purple
70735 - 50 ml
Loctite 496
Hernon 110
Omnifit Sicomet 7000
Clear
Loctite Primer T
Hernon Primer 10
Omnifit VC Activator
Aerosol
Spray
52676 - 1 oz.
2006124 - 6 oz.
TORQUE VALUES
Metric Fasteners (DIN)
WRENCH SIZE
8.8
Size
Ft.Lb.
8.8
10.9
10.9
12.9
Nm
Ft.Lb.
Nm
Ft.Lbs.
12.9
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
M5
*53
6.0
8.5
10
5/16
M6
10
10
14
13
17
10
M8
18
25
26
35
30
41
1/2
13
M10
36
49
51
69
61
83
11/16
17
M12
63
86
88
120
107
145
3/4
19
10
M14
99
135
140
190
169
230
7/8
22
12
M16
155
210
217
295
262
355
15/16
24
14
M18
214
290
298
405
357
485
1-1/16
27
14
M20
302
410
427
580
508
690
1-1/4
30
17
Nm
Inch
Metric
Inch
Metric
SAE 5
Size
Ft.Lb.
No.4
SAE 8
Nm
Ft.Lb.
*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
7/64
No.8
*22
2.5
*31
3.5
*42
4.7
11/32
9/64
No.10
*32
3.6
*45
5.1
*60
6.8
3/8
5/32
1/4
8.1
12
12
16
7/16
3/32
5/16
13
18
19
26
24
33
1/2
13
1/4
3/8
23
31
33
45
43
58
9/16
5/16
7/16
37
50
52
71
69
94
5/8
16
3/8
1/2
57
77
80
109
105
142
3/4
19
3/8
9/16
82
111
115
156
158
214
13/16
5/8
112
152
159
216
195
265
15/16
24
1/2
3/4
200
271
282
383
353
479
1-1/8
5/8
1 Ft.Lb. = 1.357 Nm
Nm
Ft.Lbs.
* = In.Lb.
1 Inch = 25.4 mm
Preuenstrae 41
D-80809 Mnchen
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 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