Wacker Neuson G 2.1A, G 3.3A, GS 4.6A, GS 5.7A, G 4.6A Repair Manual

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www.wackergroup.com
Portable Generators
G 2.1A G 3.3A G 4.6A GS 4.6A GS 5.7A
REPAIR MANUAL
0116567 002 1000 en
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50 HZ PORTABLE GENERATORS FOREWORD
This manual covers machines with Serial Number or Item Number:
0008243, 0008244, 0008245, 0008246, 0008247, 0008248, 0008249, 0008250, 0008251, 0008252, 0008253, 0008254, 0008255, 0008256, 0008257, 0008258, 0008259, 0008260, 0008261, 0008262, 0008263, 0008264, 0008265, 0008266, 0008267, 0008268, 0008269, 0008270, 0008271, 0008272, 0008273, 0008274, 0008275, 0008276, 0008277, 0008278, 0008279, 0008280, 0008281, 0008282, 0008283, 0008284, 0008285, 0008309, 0008310, 0008311, 0008312,
0008313, 0008314, 0008315, 0008316
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.
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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.
My machines numbers are:
Model number
RevisionItem Number
Model
GS4.6AGS4.6A
GS4.6A
GS4.6AGS4.6A
Item No.
00082690008269
0008269 101101
00082690008269
kg
lbs
GENERATING SET ISO 8528
MADE IN USA
Serial Number
MENOMONEE FALLS, WI USA 53051
Rev. Serial No.
Vclass
Insul.
Class
101101
101
hz
kW
Man. Yr.
50101015010101
5010101
50101015010101
A
N/M
110635
1031SD44
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50 Hz Portable Generators Repair Manual
Table of Contents
1 Safety
1.1 Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
1.2 Laws Pertaining to Spark Arresters . . . . . . . . . . . . . . . . . . . . . . 1A-1
1.3 Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2
1.4 Engine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
1.5 Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
2 Technical Data
2.1 Generator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1
2.2 Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2
3 Power Requirements
3.1 Determining Power Requirements . . . . . . . . . . . . . . . . . . . . . . . 3A-1
3.2 Outdoor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
3.3 Indoor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
3.4 Grounding the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
3.5 Use of Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
4 Model G2.1A
4.1 Theory of Operation – Capacitor Generators . . . . . . . . . . . . . . . 4A-1
4.2 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
4.3 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
4.4 Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
4.5 Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
4.6 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3
4.7 Earth Leakage Circuit Breaker (ELCB) . . . . . . . . . . . . . . . . . . . 4A-3
4.8 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
4.9 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
4.10 Loss of Residual Magnetism in Rotor. . . . . . . . . . . . . . . . . . . . . 4A-5
4.11 Receptacle Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
4.12 Rotor Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
4.13 Stator Winding Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-7
4.14 Rotor Winding Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-8
4.15 Generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
4.16 Generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
4.17 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10
4.18 Periodic Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . 4A-11
4.19 Storing/Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-11
4.20 Wiring Schematic (G2.1A Model) . . . . . . . . . . . . . . . . . . . . . . . 4A-12
Page 6
50 Hz Portable Generators Repair Manual
Table of Contents, continued
5 Models G3.3A, G4.6A, GS4.6A, & GS5.7A
5.1 Theory of Operation – Brush Generators . . . . . . . . . . . . . . . . . . 5A-1
5.2 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
5.3 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
5.4 Automatic Voltage Regulator (AVR). . . . . . . . . . . . . . . . . . . . . . 5A-2
5.5 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3
5.6 Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3
5.7 Engine Auto Idle Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3
5.8 Choke Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3
5.9 Main Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
5.10 Earth Leakage Circuit Breaker (ELCB) . . . . . . . . . . . . . . . . . . . 5A-4
5.11 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6
5.12 Auto Idle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-7
5.13 Loss of Residual Magnetism in Rotor . . . . . . . . . . . . . . . . . . . . 5A-9
5.14 Diode Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-9
5.15 Stator Windings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10
5.16 Rotor Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-11
5.17 Slip Rings and Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-11
5.18 Automatic Voltage Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . 5A-11
5.19 Generator Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-13
5.20 Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-14
5.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-15
5.22 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 5A-16
5.23 Wiring Schematics – Generator/Engine . . . . . . . . . . . . . . . . . 5A-17
5.24 Storing/Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22
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50 HZ PORTABLE GENERATORS SAFETY 1A
1.1 Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service.
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
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.
CAUTION: Used without the safety alert symbol, CAUTION indicates a potentially hazardous situation which, if not avoided, may result in property damage.
Note:
Contains additional information
important to a procedure.
1.2 Laws Pertaining to Spark Arresters
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
Page 8
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.
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.
WARNING
NEVER allow untrained personnel to operate or
service the generator. Know how to operate and stop generator before starting it.
NEVER operate generator in snow, rain, or standing water.
ALWAYS keep generator at least three feet (one meter) away from structures, buildings, and other equipment during use.
ALWAYS keep generator out of reach of children and pets.
ALWAYS keep the area immediately surrounding the generator clean, neat and free of debris.
ALWAYS position and operate generator on a firm, level surface.
ALWAYS remove all tools, cords, and other loose items from generator before starting it.
ALWAYS make certain generator is well-grounded and securely fastened to a good earthen ground.
1A-2
ALWAYS transport generator in an upright position.
Page 9
50 HZ PORTABLE GENERATORS SAFETY 1A
1.4 Engine Safety
Internal combustion engines present special hazards during operation and fueling! Read and follow warning instructions in engine 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.
DO NOT fill or drain fuel tank near an open flame, while smoking, or while engine is running.
DO NOT fill fuel tank indoors or in an enclosed area unless adequate ventilation, through such items as exhaust fans, is provided.
DO NOT touch or lean against hot exhaust pipes.
DO NOT operate with the fuel tank cap loose or
missing.
DO NOT add fuel to a hot or running engine.
DO NOT start engine if fuel has spilled or an odor of
fuel is present. Move generator away from the spill and wipe generator dry before starting.
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.
ALWAYS replace all guards and safety devices immediately after servicing.
ALWAYS turn engine off before servicing generator. If engine has electric start, disconnect negative terminal on battery.
ALWAYS keep generator clean and labels legible. Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards.
ALWAYS let engine cool before transporting or servicing.
ALWAYS remain aware of moving parts and keep hands, feet, and loose clothing away from moving parts on generator and engine.
ALWAYS keep fuel lines in good condition and properly connected. Leaking fuel and fumes are extremely explosive.
1A-3
Page 10
1A SAFETY 50 HZ PORTABLE GENERATORS
Notes:
1A-4
Page 11
50 HZ PORTABLE GENERATORS TECHNICAL DATA 2A
2.1 Generator Specifications
Table 2-1.
ledoM A1.2G A3.3G A6.4G A6.4SG A7.5SG
tuptuOAVk1,23,36,4
epyTsselhsurBrotalugeRegatloVcitamotuA
Ø11,4 Ø37,5
elbaliavasegatloVCA
esahp&egatlov
ycneuqerFzH05
rotcaFrewoP0,1
selcatpeceRCAlanoitpO
rekaerBtiucriCniaMpma)elop1(01)elop1(51)elop1(02)elop3(9
tnerruCsuounitnoC
V004/V032tapma.A.N/1,9.A.N/3,41.A.N/0,022,8/0,81
LxWxH
)yrd(thgieWgK4417083838
yrettaBA/NA/NA/N02/21/A-L81N-05
mm
586x544x534586x585x035
V032
esahp1
Ø1V032 Ø3V004
Ø10,1 Ø38,0
2A-1
Page 12
TECHNICAL DATA 50 HZ PORTABLE GENERATORS
2A
2.2 Engine Specifications
ledoM A1.2G A3.3G A6.4G A6.4SG A7.5SG
ekaMenignE adnoH
ledoMenignEXV1K061XG1K042XG1K043XG
mpr0003@rewoPWk1,40,62,8
cibuctnemecalpsiDmc361242733
deepSgnitarepO
daolon
deepSgnitarepO
daollluf
deepSeldIotuAmprA/N0022±05
ecnaraelCevlaV
)dloc(
tsuahxe
ekatni
gulPkrapSepytU-RPE02W/SE6RPB
paGgulPkrapSmm8,07,0
retratS)V/epyt(A/NA/NA/NV21/cirtcelE
rotanretlApmaA/NA/NA/N1
leuFepyT)enatcO77.niM(dedaelnuralugeR
noitpmusnoCleuFrh/retil7,14,22,3
yticapaCknaTleuFretil7,35,91
emiTgninnuR.rh2,22,80,6
renaelCriAepytrenaelc-erpmaofdettew-liohtiwepytyrD
noitacirbuLenignE
yticapaC
mpr
mpr
mm02,0
edarglio ecivres ssalc
lm
006
Table 2-2.
03W01EAS
ESro,FS,GS
05±0013
0003±50
51,0
03W01EAS
FSroGS
0011
2A-2
Page 13
50 HZ PORTABLE GENERATORS POWER REQUIREMENTS 3A
3.1 Determining Power Requirements
These generators are designed to operate single-phase, 50 hertz appliances or tools running at 230 VAC for the G2.1A, G3.3A, G4.6A, and GS4.6A models, and a single phase voltage of 230 VAC and a three phase voltage of 400 VAC for the GS5.7A model. Check the nameplate or label provided on tools and appliances to make sure their power requirements match the power output of the generator.
Some appliances and tools require a surge of current when starting. This means that the amount of power needed to initially start the equipment is larger than the power required to keep it running. The generator must be capable of supplying this surge current. Other types of appliances require more power than is actually stated on their nameplates.
The chart below is offered only as a general guideline to help you in determining power requirements for different types of equipment. Check with your nearest WACKER Dealer, or contact the manufacturer or dealer of the tool or appliance, with questions regarding power requirements.
3.2 Outdoor Installation
Place the generator in an area where it will not be exposed to rain or snow. Make sure it is positioned on firm, level ground so it will not slide or shift. Position engine exhaust away from areas where people may be present.
If operating the generator inside a tunnel or deep trench, make sure there is adequate ventilation. Precautions similar to those required when operating indoors may be necessary.
The surrounding area must be free of water and moisture. All components must be protected from excessive moisture.
3.3 Indoor Installation
If the generator must be operated indoors, adequate ventilation or exhaust hoses must be provided. When venting exhaust fumes, make sure the exhaust piping is large enough to prevent excessive back pressure to the engine. Back pressure reduces engine efficiency and may cause the engine to overheat.
Incandescent lights and appliances such as irons and hot plates use a resistive-type heating element and require the same wattage to start and run as is stated on their nameplates.
Fluorescent and mercury lamps require 1.2 – 2 times their stated wattage to start.
Electrical motors and many types of electrical tools often require a large starting current. The amount of starting current depends on the type of motor and its use.
Most electrical tools require 1.2 – 3 times their stated wattage for running.
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 their nameplates 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
CAUTION: If a tool or appliance does not reach full
speed within a few seconds when switched on, turn it off immediately to avoid damage.
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.
CAUTION: When starting loads, DO NOT exceed two
(2) times the given Continuous Current rating for model G2.1A, or one-and-one-half (1 1/2) times for all other models, as damage to the generator may occur. See Section 2.1
Generator Specifications
.
3A-1
Page 14
3A POWER REQUIREMENTS 50 HZ PORTABLE GENERATORS
3.4 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. See Figure 3-1.
a
1001SD02
Figure 3-1. Grounding
3.5 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. 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 Load in Watts Maximum Cable Length in Ft.
Amps 120V 240V #10 #12 #14 #16
2.5 300 600 1000 ft. 600 ft. 375 ft. 250 ft. 5 600 1200 500 ft. 300 ft. 200 ft. 125 ft.
7.5 900 1800 350 ft. 200 ft. 125 ft. 100 ft.
10 1200 2400 250 ft. 150 ft. 100 ft. 15 1800 3600 150 ft. 100 ft. 65 ft. 20 2400 4800 125 ft. 75 ft. 50 ft.
CAUTION: Operating equipment at low voltage can cause overheating.
Keep electrical cords in good condition. DO NOT use worn, bare, or frayed cords which can cause electrical shock.
3A-2
WARNING
Page 15
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A
4.1 Theory of Operation – Capacitor Generators
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.
The two main components of the generator, the rotor and stator, are the key. The rotor acts as the magnet and the stator acts as the coil of wire. As the rotor rotates, its magnetic lines of force are cut by the coils of wire in the stationary stator. The voltage induced in the windings of the stator is tapped off and available at the receptacles.
Brushless Generator
This model generator uses a brushless design to generate and regulate power. It consists of a rotor, stator, diodes, and an auxiliary winding. The brushless generator also contains a capacitor that is connected to the auxiliary winding. Its purpose is to regulate the voltage in the main windings and prevent a voltage drop when a load is applied.
This generator is designed to operate with single phase loads at or near a power factor of 1.0. The principle of operation is schematically represented in Figure 4-1, and a cross-sectional view in Figure 4-2. The auxiliary winding (a), in conjunction with the capacitor, provide
excitation by inducing current in the rotor windings (b) which is rectified by the diodes (c) to produce direct current. The main stator winding (d) is designed for parallel connection to give a voltage output with no
voltage adjustment possible.
Diodes
(Rectifier)
c
b
d
Main Windings
Figure 4-1. Principle of Operation Schematic
Rotor Field
Windings
a
Auxiliary Winding
Capacitor
1023SD44
4A-1
Page 16
4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS
a
b
d
c
Figure 4-2. Brushless Type Generator
4.2 Rotor (a)
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 installed in the generator housing. This end also contains the two diodes mounted on the diode bracket assembly. There are two individual coils wound on the rotor. When the engine is running, these two windings create the mag­netic field for the main stator windings.
4.3 Stator (b)
The stator houses both the main windings and auxiliary winding. The main windings are connected directly to the main circuit breaker to supply power to the output recep­tacles. The auxiliary winding induces the initial voltage in the field windings of the rotor and regulates the voltage. It is connected directly to the main capacitor.
1022SD88
4.4 Capacitor (c)
A capacitor is connected in series with the auxiliary winding. Its purpose is to regulate the voltage when a load is applied.
4.5 Diodes (d)
Two diodes 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.
4A-2
Page 17
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A
4.6 Control Panel
The generator is protected by a 10 amp circuit breaker
(a) 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. 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.
When the circuit breaker opens, the breaker button will pop out. To reset circuit breaker, push button in.
Depending on model, the generator will have one of the four styles of receptacles, the Danish IP44 type 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.
(b), the
bc
a
de
230V 230V
Control Panel
a Main circuit breaker - 10 Amp. b Danish IP44 style receptacle. c Swiss IP X4 style receptacle. d France/Belgium IP44 style receptacle. e Schuko IP44 (CEE 7) style receptacle.
1031SD43
4.7 Earth-leakage Circuit Breaker
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.
The circuit breaker should be tested for proper operation every time the generator is used.
To test the earth-leakage circuit breaker:
Start the generator. Place main circuit breaker in closed position. Push in TEST button (g). The circuit breaker lever will lower to the open position (f at both receptacles. If the lever does not lower, the circuit breaker is not working. Do not use the generator until the problem can be corrected. To restore power to the receptacles, raise the circuit breaker lever to the closed position (f
If the circuit breaker lever lowers to the open position during operation, stop the generator and check it and equipment for defects. Repair all defects before operat­ing generator.
).
1
). Power is now off
2
f
1
f
2
T E S T
g
1020SD80
4A-3
Page 18
4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS
4.8 Capacitors
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.
4.9 Engine Speed
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 3000 – 3100 rpm.
Testing Engine Speed
Measure the engine speed using a tachometer with no load applied to the generator. The engine must be running at 3100 ± 50 rpm. Voltage output is directly related to engine speed. A slow engine will reduce voltage. Refer to the Operators Manual for engine speed adjustment.
The generator is designed to produce no output if engine rpm falls 10% or more below the required speed (approximately 2700 rpm).
Setting Engine Speed
Setting the engine speed requires the adjustment to the governor. See Figure 4-5.
To set the engine to the proper speed:
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.
3. If meter does not deflect torward zero, or deflects to zero and remains there, the capacitor is open or shorted and must be replaced.
Turn the engine speed adjusting screw (a) in or out to obtain a no-load speed of 3100 rpm.
CAUTION: Setting the engine speed too high or too low may damage tools and other appliances attached to the generator.
a
1001SD15
Figure 4-5. Engine Speed Adjusting Screw
Figure 4-4. Testing Capacitor
4A-4
1007SD87
Page 19
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A
4.10 Loss of Residual Magnetism in Rotor
If the rotor has been removed, or the generator has been stored over six months, the rotors magnetism may be lost. Loss of magnetism will prevent the generator from building voltage.
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.
To restore magnetism to the rotor, flash it as follows:
1. Remove the two screws and the end cover. Locate the capacitor that is attached to the stator housing.
2. Run generator at normal no-load speed – 3100 rpm, auto-idle off.
3. Briefly touch a 12 VDC battery across the two capacitor connections to pulse the auxiliary winding. The leads should remain attached to capacitor. The polarity of the battery leads is not important.
CAUTION: DO NOT hold battery leads on connection
longer than two seconds.
The output voltage should quickly come up to normal
levels. Repeat if necessary. See Figure 4-6.
4. Stop engine and replace end cover.
Stator Hous-
ing
Capacitor
12 VDC
Battery
1023SD45
Figure 4-6. “Flashing” the Rotor
4A-5
Page 20
4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS
POS
NEGPOS
NEG
4.11 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. Inspect for tight connections at circuit breakers, capacitors, switches and receptacles. Replace any broken or damaged parts.
4.12 Rotor Diode Testing
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.
.
HIGH VALUE
LOW VALUE
Figure 4-7. Rotor Diode Testing
4A-6
1024SD03
Page 21
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A
4.13 Stator Winding Testing
The stator includes the main winding and the auxiliary winding.
To check stator windings:
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.
Check resistance values with those listed on Table 4-1.
A high or low reading indicates an open or shorted winding and the stator must be replaced.
4. Test for grounded windings by checking for continuity between winding and metal frame.
If continuity exists, winding is grounded and stator assembly must be replaced.
Auxiliary Windings
Capacitor
Note:
Make sure stator is completely disconnected from generator. The main winding is intentionally grounded to the generator to form a neutral and will give a false reading.
5. Check for continuity between auxiliary winding and main winding. If continuity exists, the auxiliary winding has a short to the main winding and stator must be replaced.
6. Test the auxilliary windings by disconnecting themfrom the capacitor and taking a resistance reading. Reading should compare with the value in Table 4-1.
Table 4-1.
Resistance Values (Ohms)
niaM
gnidniW
yrailixuA
gnidniW
rotoR
gnidniW
819,040,121,8
Resistance values are very small and require a good quality meter with the ability to be zeroed out. A poor quality meter may not provide accurate readings.
All resistance values are approximate.
1023SD46
Figure 4-8. Stator Winding Testing
4A-7
Page 22
4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS
POS
NEG
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. Remove end cover, locknut, stator and rotor from generator. See Section 4.15
2. Unsolder wires from diodes, being careful not to break wires.
3. Measure rotor resistance as shown in Figure 4-9.
4. Record resistance values of both windings and com­pare them with values listed in Table 4-1.
Generator Disassembly
.
5. 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.
2
1024SD04
Figure 4-9. Rotor Winding Testing
3
4
5
8
7
13 ft. lbs.
(17.5 Nm)
5
1
15
14
4A-8
13
Figure 4-10. Brushless Generator
12
9
10
11
1023SD47
Page 23
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A
4.15 Generator Disassembly
Capacitor
1. Remove the two end cover screws (10) and the end cover (9). See Figure 4-10.
2. Disconnect the leads from the capacitor nylon tie wrap, and remove the capacitor mounting screw.
(11), cut the
Stator
1. Remove the control panel, unscrew the ground wire
(14) and unplug the stator wire (15) from the back of
the panel. See Figure 4-10.
2. Remove the shaft securing nut (7).
3. Remove the four nuts (13) securing the generator frame (12) to the engine adapter flange.
4. Remove the two bolts and nuts that secure the stator
(12) to the shock mount bracket.
5. With a block of wood and a mallet, tap stator frame away from the engine. Withdraw stator frame assembly (12) over the rotor (3) carefully to avoid damage to windings in the stator or rotor.
Note:
skip step 6.
6. Support the rotor weight with a sling or place a block
If the rotor comes out with the stator,
between the rotor and base.
Diode and/or Varistor
1. Unsolder leads from the diodes (5) and (8) and
unscrew diode stud. See Figure 4-10.
2. Unsolder varistor lead from the solder tag on the diode stud.
3. Remove the silicon sealant supporting the varistor from the diode bracket (4).
4.16 Generator Assembly
When assembling the generator be sure to observe the following:
1. Install diodes (5) to the diode bracket (4) assembly on the rotor, by placing the solder tags on the diode stud and tighten to the diode base. See Figure 4-10.
2. Insert varistor leads first, and push varistor well down into the diode bracket assembly recess. Solder leads to the diode pin and the solder tag on the diode stud. Reseal varistor with silicon sealant.
3. Make sure inner taper on rotor and outer taper on the engine crankshaft are clean and free of rust and oil.
Rotor
Rotor (3) removed with stator:
1. Place stator on flat surface with bearing (8) end up. Elevate the stator (12) by placing two blocks of wood on the edge of the stator frame to allow the rotor to
drop. See Figure 4-10.
2. Partially screw one of the frame mounting bolts into the bearing and tap screw with a mallet. The rotor should drop out of the stator.
Rotor (3) still attached to the engine:
1. Remove stator per instructions above.
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.
4. Install the rotor (3) on crankshaft.
5. Slide stator (12) over the rotor carefully to avoid
hitting and damaging windings. Tap the frame onto the rotor bearing.
6. Attach the four nuts (13) to secure frame to the
engine adapter flange.
7. Install the shaft securing nut (7). Tighten to 13 ft. lbs.
(17.5 Nm).
8. Install the capacitor (11) using the mounting screw
and a new nylon tie wrap. Re-attach the two leads.
9. Install the end cover (9) and two mounting screws
(10).
10. Reconnect the ground wire (14) and the stator wire
(15) to the control panel, and reinstall panel.
4A-9
Page 24
4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS
4.17 Troubleshooting
Table 4-2.
Generator Chart
motpmySesuaCelbissoPnoituloS
toNseoDenignE
tratS
.1.noitisop”FFOnisihctiwsenignE.1.noitisop”TRATSothctiwsenigneevoM
.2nodnaknatleufrednusevlavleuF
.desolceraenigne
.3.ytpmesiknatleuF.3.knatleuflliF
.2.sevlavleufnepO
.4.noitisopgnorwnisirevelekohC.4.noitisoptcerrocotrevelekohcevoM
.5.noitidnocroopnisigulpkrapS.5.gulpkrapsecalpeR
.6.esoolsipacgulpkrapS.6.pacgulpkrapsnethgiT
.7.wolsilevellioenignE.7.liollifeR
egatloVtuptuOoN.1.wolsootdeepsenignE.1,mpr0013otdeepsenigneesaercnI
.2.neporekaerbtiucriC.2.rekaerbteseR
.3.nepoIFG.3.evitcefedfiecalpeR.BCLEteserdnatseT
.4.msitengamlaudiserfossoL.4)01.4noitceseeS(.sdleifrotorhsalF
.5.hctiwsroelcatpecerevitcefeD.5.riaperdnastnenopmocdnagniriwtcepsnI
.6.detrohsroneposedoidrotoR.6)21.4noitceseeS(.ecalperdnasedoidtseT
.7.sgnidniwrotatsdetrohsronepO.7)31.4noitceseeS(.ecalperdnarotatstseT
.8.sgnidniwrotordetrohsronepO.8)41.4noitceseeS(.ecalperdnarotortseT
.9lortnocotrotarenegmorfrotcennoC
.detcennocsidroesoolsilenap
.9.ylthgitllatsnI
.)enignedloca
gnitratsnehwrevelekohcesolC(
)9.4noitceseeS(.daol-on
.tnerrucgnikael,evitcefedecnailpparolooT
)7.4noitceseeS(
)11.4noitceseeS(
egatloVwoL.1002041neewtebegatlovdaol-oN
.2,deepsgnitarepowolebylthgilsenignE
.3.evitcefedsiroticapaC.3.yrassecenfiecalperdnaroticapactseT
.4.edoidtaffonekorberiwgnidniwrotoR.4.edoidoteriwredloseR
.5.detrohsyllaitrapgnidniwrotoR.5ecalpeR.ecnatsisergnidniwrotortseT
.6.tfahsknarcenignenognippilsrotoR.6.detrohsyllaitrapgnidniwrotoR
egatloVhgiH.1.hgihootdeepsenignE.1,mpr0013otdeepsenigneecudeR
egatloVdaol-oN
sidaoLnehw
deilppA
.1.daolrednunwodgniggulenignE.1erotserotlaunamriaperenigneotrefeR
sllaFtublamroN
.deeps
4A-10
tcerroctagnitarepoenigne,stlov
.1.detrohsroneporotornoedoidenO
.2,mpr0013otdeepsenigneesaercnI
.tuptuollaespallocothguonetontub
)8.4noitceseeS(
.rotor
)41.4noitceseeS(
.rewopenigne
)9.4noitceseeS(.daol-on
)9.4noitceseeS(.daol-on
)21.4noitceseeS(.sedoidllaecalpeR
Page 25
50 HZ PORTABLE GENERATORS G2.1A/G2.1AE 4A
4.18 Periodic Maintenance Schedule
.leveltcerrocotlliF.lioenignekcehC
.renaelcriakcehC
*.renaelcrianaelC
.lioenigneegnahC
.roterubractapuctnemideskcehC
.gulpkrapstsujdadnanaelC
.)yrosseccalanoitpo(retserrakrapsnaelC
*.ecnaraelcevlavtsujdadnakcehC
*.knatleufnaelC
.enilleuffonoitidnockcehC
.yrassecennehwecalpeR
* Service more frequently in dusty conditions.
yliaD
erofeB
gnitratS
3yrevE
roshtnom
sruoh05
6yrevE
roshtnom
sruoh001
yrevE
roraey
sruoh003
yrevE
roraey
sruoh005
.yrassecennehwecalpeR.stnuomkcohskcehC
••
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
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.
4A-11
Page 26
4A G2.1A/G2.1AE 50 HZ PORTABLE GENERATORS
4.20 Wiring Schematic (G2.5A Model)
G
5
6
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
4
7
B
Y
B
Wire Colors
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
7
G/Y
R/Gr
G/Y
R/B
G/Y
B/R
LL/Gr
LL/B
3
B(3)
B(1)
2
1
B(2)
B(4)
2
1
R/W
2
LL
R
4
R
Br
3
2
W
Br
1
1
G/Y
LL
1
L
ABC
4A-12
G/Y
B
10
1 = Main stator winding
2 = Main circuit breaker
3 = Earth-leakage circuit breaker (G2.1AE only)
4 = Ignition switch
5 = Oil level switch
6 = Coil
7 = 16 Amp receptacle
8 = Rotor winding
9 = Capacitor (25µF)
10 = Auxiliary winding
9
B
8
C = Engine
B = Control box
A = Generator
1020SD79
Page 27
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
5.1 Theory of Operation – Brush Generators
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. They also incorporate a choke that is connected in series with the auxiliary winding. The chokes purpose is to bring the current in the auxiliary winding in phase with the main windings. The current from the auxiliary winding is carried to the rotor via the brushes and slip rings.
The generators also contain an Automatic Voltage Regulator (AVR) that maintains a specific voltage output regardless of load. The voltage regulator accomplishes this by regulating DC current from the auxiliary winding. When the load on the generator increases, the voltage regulator allows additional DC current into the main rotor. The additional DC current allows the generator to increase output and maintain the desired output voltage.
Brush and Slip
Bridge Rectifier
c
Ring Assembly
Auxiliary
Winding
a
These models are designed to operate with close regulation when supplying single phase loads. The principle of operation is schematically represented in Figure 5-1, and a cross-sectional view in Figure 5-2. The auxiliary winding (a) provides excitation power through
a choke (b) and bridge rectifier (c) into the rotor winding
(d) via slip rings and brushes. The AVR (e) diverts
excess excitation to maintain the stator winding (f) output voltage within close limits. The main stator winding is designed for series/parallel connection to give a dual
voltage output.
Automatic
Voltage
Regulator
e
b
Choke
d
Rotor
Winding
f
Main
Stator
Winding
Figure 5-1. Principle of Operation Schematic
f
Main
Stator
Winding
1022SD73
5A-1
Page 28
5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS
F1
a b
Z3
e
Voltage Adjust Pot
F2
F2 F1 L2
L1
Z2
d
F1 F2
c
Figure 5-2. Brush-Type Generator
5.2 Rotor
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. This end also contains the two slip rings. There are two individual coils wound on the rotor
(a). When the engine is running, these two windings
create the magnetic field for the main stator windings.
1023SD48
5.3 Stator
The stator (b) houses both the main windings and auxiliary winding. The main windings are connected directly to the main circuit breaker and voltage selector switch to supply power to the output receptacles. The auxiliary winding induces the initial current in the field windings of the rotor. It is connected directly to the choke and the AC input to the bridge rectifier.
5A-2
Page 29
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
5.4 Automatic Voltage Regulator (AVR)
The Automatic Voltage Regulator (AVR) (c) 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. The additional DC voltage allows the generator to increase output and maintain voltage.
5.5 Choke
The purpose of the choke (d) is to bring the auxiliary winding in phase with the main windings.
5.6 Bridge Rectifier
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.
5A-3
Page 30
5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS
5.7 Main Circuit Breaker
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. 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.
When the circuit breaker opens, the breaker lever will snap down. To reset the circuit breaker, lift lever up. See Figures 5-5 and 5-6.
5.8 Earth-leakage Circuit Breaker
Generator models G3.3AE, G4.6AE, GS4.6AE, and GS5.7AE are equipped with an earth-leakage 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 control panel and should be tested for proper operation every time the generator is used.
To test the earth-leakage circuit breaker: Start the generator. Place main circuit breaker in closed
position. Push the TEST button (g) on the circuit breaker. The circuit breaker lever will lower to the open position
(a2). Power is now off at both receptacles. If the lever
does not lower, the circuit breaker is not working. Do not use the generator until the problem can be corrected. To restore power to the receptacles, raise the circuit breaker lever to the closed position (a
If the circuit breaker lever lowers to the open position during operation, stop the generator and check it and equipment for defects. Repair all defects before operat­ing generator.
).
1
T E S T
Figure 5-4a. ELCB for G3.3AE, G4.6AE, and
GS4.6AE Models
5A-4
a
1
a
2
g
1020SD80
g
1020SD89
Figure 5-4b. ELCB for GS5.7AE Models
a
1
a
2
Page 31
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
cbdef
a
a
a
g
1
2
1
2
3
1
4
365
2
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. f Schuko IP44 (CEE 7) style receptacle. g Earth-leakage circuit breaker (G3.3AE, G4.6AE, GS4.6AE).
Figure 5-5. Control Panel (G3.3A, G4.6A, and GS4.6A Models)
230V
230V
T E S T
1031SD41
b
j
1
j
2
j
3
j
2
3
1
c
65
4
def
1
3
2
Control Panel
a Main circuit breaker - 9 Amp. b Australian style receptacle. c Danish IP44 style receptacle. d Swiss IP X4 style receptacle. e France/Belgium IP44 style, 230 Volt receptacle. f Schuko IP44 (CEE 7) style, 230 Volt receptacle. g Earth-leakage circuit breaker (GS5.7AE). h 3 Phase/400 volt (CEE 17, 3P+N+E, IP44)receptacle. j Engine crank switch.
h
a
a
1
230V
a
2
400V
g
1031SD42
Figure 5-6. Control Panel (GS5.7A Models)
5A-5
Page 32
5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS
5.9 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.
To set the engine to the proper speed:
k
Turn the speed adjusting screw
no-load speed of 3100 rpm. See Figure 5-7.
CAUTION: Setting the engine speed too high or too low
may damage tools and other appliances attached to the generator.
(k) in or out to obtain a
1001SD15
Figure 5-7. Engine Speed Adjusting Screw
5A-6
Page 33
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
5.10 Periodic Maintenance Schedule (G3.7A, G5.6A, and GS5.6A Models)
yliaD
erofeB
gnitratS
.leveltcerrocotlliF.lioenignekcehC
3yrevE
roshtnom
sruoh05
6yrevE
roshtnom
sruoh001
.renaelcriakcehC
*.renaelcrianaelC
.lioenigneegnahC
.roterubractapuctnemideskcehC
.gulpkrapstsujdadnanaelC
.)yrosseccalanoitpo(retserrakrapsnaelC
.yrassecennehwecalpeR.stnuomkcohskcehC
*.ecnaraelcevlavtsujdadnakcehC
*.knatleufnaelC
.enilleuffonoitidnockcehC
.yrassecennehwecalpeR
sgnirpilsdna**sehsurbfonoitidnockcehC
sledoMA6.5SGdnaA6.5G,A7.3Grof
yrevE
roraey
sruoh003
yrevE
roraey
sruoh005
* Service more frequently in dusty conditions.
** Brushes should not be less than 8mm long.
Table 5-3
Engine Service (G3.7A, G5.6A, and GS5.6A Models)
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.
5A-7
Page 34
5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS
Z1
Z3
F2
F1
a
Figure 5-11. Brush Type Generator
c
b
1031SD62
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.
To check residual voltage, run the generator at normal no-load speed and measure the voltage at 120 VAC receptacles. This voltage should be at least 1.5 volts. If the voltage is less than 1.5 volts, the residual magnetism must be restored by flashing with a 12 volt battery.
5A-8
Page 35
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
Restoring Residual Magnetism to the Brush Type Generators
Disconnect leads F1 and F2 from the brush holder (a). 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. The output voltage of the generator, with the 12 volt supply connected, should be approximately normal voltage. See Figure 5-12.
Stop the generator and reconnect leads F1 – F2.
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.
5.12 Testing the Bridge Rectifier
Accessing the Bridge Rectifier
F1
1. Remove the generator cover.
2. Remove leads Z2 and Z3 from the bridge rectifier (b),
and leads F1 and F2 that go to the brush assembly.
Z3
Z3
F1
Z2
Checking Bridge Rectifier
To check the rectifier, follow these steps:
1. Set multi-meter on R x 1000 range.
2. Remove all wires connected to the rectifier.
3. Place the meter probes on two adjacent rectifier terminals and check resistance value. See Figure 5-13.
4. Reverse the probes and recheck.
5. The meter should indicate low resistance in one direction and a high resistance in the other direction.
6. Repeat this procedure for each adjacent set of termi­nals on the rectifier until all four diodes have been checked.
F2
F2
Figure 5-12. Diode Bridge
Figure 5-13. Checking Diode Bridge
Z2
1023SD52
1023SD98
5.13 Testing the Choke
To test the choke remove wires Z1 and Z3 from the choke (c) and the choke assembly. The resistance value of the choke should be 7.5 ohms.
5A-9
Page 36
5A 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.
Check resistance values with those listed on Table 5-
1. A high or low reading indicates an open or shorted
winding and the stator must be replaced.
3. Test for grounded windings by checking for continuity between winding and metal frame.
If continuity exists, winding is grounded and stator assembly must be replaced.
Note:
Make sure stator is completely disconnected from generator. The main windings are intentionally grounded to the generator to form a neutral and will give a false reading.
4. Check for continuity between auxiliary winding and main windings. If continuity exists, the auxiliary winding has made contact with the main winding and stator must be replaced.
Figure 5-14. Checking Stator
1024SD05
Table 5-1.
Resistance Values
rotareneG
ledoM
A3.3G54.090.28.01
A6.4G93.079.13.11
A6.4SG93.079.13.11
V7.5SG27.1
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.
All figures are approximate values in ohms.
niaM
gnidniW
)noitcesrep(
yrailixuA
gnidniW
rotoR
gnidniW
3.11
5A-10
Page 37
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
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. 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.
5.16 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-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.
5.17 Automatic Voltage Regulator
To check the regulator:
If the generator has low voltage, approximately 2 – 5
VAC as measured at the 120 VAC receptacles, remove F1 and F2 from the regulator. Start and run the generator. If voltage output is approximately 150 VAC measured at the receptacles and engine speed is 3750 rpm, replace regulator.
If the generator has low voltage, approximately 65
VAC measured at the 120 VAC receptacles, remove F1 and F2 from the regulator. Start and run the generator. If voltage output is approximately 150 VAC measured at the receptacles, and engine speed is 3750 rpm, replace regulator.
If the generator has high voltage, approximately 150
VAC as measured at the 120 VAC receptacles, and the engine speed is 3750 rpm, replace regulator.
1024SD02
Figure 5-15. Checking Rotor
5A-11
Page 38
5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS
2
1
4
8
10
7
11
16
15
14
17
30
31
25
Figure 5-16. Brush Type Generator
5A-12
22
24
18
21
19
23
20
1020SD78
Page 39
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
5.18 Generator Disassembly
Bridge Rectifier
1. Remove the two end cover screws (19) and the end cover (20). See Figure 5-16.
2. Remove the four leads from the bridge rectifier confirming lead markings per Figure 5-17.
(16)
F1
Z3
F1
Z3
Z2
Z2F2
F2
Figure 5-17. Diode Bridge Rectifier
3. Remove the choke/rectifier mounting screw (15).
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).
Fuel Tank and Control Box
1. Remove the fuel tank mounting bolts and tilt the tank
to gain access to the gas line and shut off valve.
1023SD53
2. Remove 3 mounting screws
3. If brushes terminal plate and withdraw springs and brushes. New brushes must be seated using a medium grade abrasive cloth.
(22) are to be changed, remove the brush
(25).
Stator
1. Remove the shaft securing nut (7).
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:
A. Disconnect the negative lead from the battery
terminal first, and then the positive lead.
B. Loosen battery mounting bracket nuts and slide
mounting bracket off the battery.
C. Remove battery and store in cool dry place.
4. Remove the two bolts (30) and nuts (31) that mount the stator (14) to the lifting bracket (10). Remove the two bolts (30) and nuts (31) that mount the other end of the stator (14) to the shock mounted support.
5. With a block of wood and a mallet, tap stator frame away from the engine. Withdraw stator frame assembly
(14) over the rotor (4) carefully to avoid damage to
windings in the stator or rotor.
Note:
On some occasions, the rotor may come out with
the stator. If it does, skip step 6.
6. Support the rotor weight with a sling or place a block between the rotor and base.
2. Close the fuel valve and disconnect the fuel line. Remove the fuel tank.
3. Remove the screws that mount the control panel to the control box, and disconnect the harnesses and ground wire from the control panel. Set the control panel aside.
4. Remove the screws that mount the control box to the generator and set control box aside.
Automatic Voltage Regulator (AVR) and Brush Assembly
Disconnect the leads from the AVR (24) and brush holder (23).
1. Remove the mounting screw (21), AVR (24) and
brush holder (23).
Rotor
Rotor (3) removed with stator:
1. Place stator (14) on flat surface with bearing (8) end
up. Elevate the stator by placing two blocks of wood on the edge of the stator frame to allow the rotor to drop.
2. Partially screw one of the frame mounting bolts into the bearing and tap screw with a mallet. The rotor should drop out of the stator.
Rotor (3) still attached to the engine:
1. Remove stator per instructions above.
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
Page 40
5A 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 following:
1. Make sure inner taper on rotor and outer taper on the engine crankshaft are clean and free of rust and oil. See Figure 5-16.
2. Install the rotor (4) on crankshaft.
3. Slide stator (14) over the rotor carefully to avoid hitting and damaging windings. Tap the frame onto the rotor bearing.
4. Attach the four nuts (11) to secure frame to the adapter studs (2).
5. Install the washer and shaft securing nut (7). Tighten to 13 ft. lbs. (17.5 Nm).
6. If brushes were changed, reinstall the brushes, springs and terminal plate.
Note:
New brushes must be seated using a medium
grade abrasive cloth.
7. Attach AVR (24) to brush holder (23) using three mounting screws (25).
8. Reattach the two leads (Z1 and Z3) to the choke. Using the two mounting screws (15) and (17), install the diode bridge rectifier (16) and choke (18).
9. Reattach lead to bridge rectifier (16).
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.
5A-14
Page 41
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
2
1
4
8
10
7
11
16
15
14
17
30
31
25
22
24
18
21
19
23
20
1020SD78
5A-15
Page 42
5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS
5.20 Troubleshooting
Table 5-2. Generator Chart
motpmySesuaCelbissoPnoituloS
toNseoDenignE
tratS
.1.noitisop”FFO“nisihctiwsenignE.1.noitisop”TRATS“othctiwsenigneevoM
.2nodnaknatleufrednusevlavleuF
.desolceraenigne
.3.ytpmesiknatleuF.3.knatleuflliF
.2.sevlavleufnepO
.4.noitisopgnorwnisirevelekohC.4.noitisoptcerrocotrevelekohcevoM
.5.noitidnocroopnisigulpkrapS.5.gulpkrapsecalpeR
.6.esoolsipacgulpkrapS.6.pacgulpkrapsnethgiT
.7.wolsilevellioenignE.7.liollifeR
egatloVtuptuOoN.1.neporekaerbtiucriC.1.rekaerbteseR
.2.nepoIFG.2.evitcefedfiecalpeR.IFGteserdnatseT
.3.msitengamlaudiserfossoL.3)71.5noitceseeS(.sdleifrotorhsalF
.4.hctiwsroelcatpecerevitcefeD.4.riaperdnastnenopmocdnagniriwtcepsnI
.5lortnocotrotarenegmorfrotcennoC
.detcennocsidroesoolsilenap
.6sgnidniwrotatsdetrohsronepO.6)91.5noitceseeS(.ecalperdnarotatstseT
.7.sgnidniwrotordetrohsronepO.7)02.5noitceseeS(.ecalperdnarotortseT
egatloVwoL.1.evitcefedrotalugeregatlovcitamotuA.1.ecalperdnaRVAtseT
.2.ekohcevitcefeD.2)31.5noitceseeS(.ecalperdnaekohctseT
.3.reifitceregdirbedoidevitcefeD.3noitceseeS(.ecalperdnareifitcertseT
.5.ylthgitllatsnI
.)enigne
dlocagnitratsnehwrevelekohcesolC(
.tnerrucgnikael,evitcefedecnailpparolooT
)21.5noitceseeS(
)61.5noitceseeS(
)81.5
.4.nekorbrodegamadsehsurB.4.egamadroftcepsnI
.5.tfahsknarcenignenognippilsrotoR.5.tlobretnecrotornethgiT
.6.denetrohsyllaitrapgnidniwrotoR.6.rotorecalpeR.ecnatsisergnidniwrotortseT
.7.nekorbrodegamadsgnirpilS.7.tridroegamadroftcepsnI
egatloVhgiH.1.evitcefedrotalugeregatlovcitamotuA.1.ecalperdnaRVAtseT
toNeldIotuA
deepSenignE(
)gnitautculF
.1.gnitnuhronrevog,wolootdeepseldI.1.mpr0562otdeepselditsujdA
yltcerroCgnikroW
.2.nwolbesufpmAenO.2.esufecalpeR
.3.evitcefedhctiwseldiotuA.3)51.5noitceseeS(.hctiwsecalperdnatseT
-4
.
.5.evitcefedeludomeldiotuA.5.eludomeldiotuaecalperdnatseT
.6.dioneloseldiotuaevitcefeD.6.ecalperdnatseT
.7deepsotpuemoctonlliwtinU
5A-16
)02.5noitceseeS(
.detcennocsidssenraheriW.4.tcennoceR
)8.5dna7.5snoitceseeS(
.7.egatlovreporprofyrettabkcehC
.)ylno5.8SG/7.9SG(
Page 43
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
5.21 Wiring Schematics – Generator/Engine
Wiring Schematic (G3.3A Model)
C
BA
5
OFF
ON
6
B
LL/Gr
LL/B
G
Y
LL/B
B/R
4
R/B
B
4
R/Gr
G/Y
7
G/Y
W- White
Y - Yellow
Wire Colors
B - Black
G - Green
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
L - Blue
P - Pink
R - Red
LL-Light blue
T - Tan
6 = Oil level switch
7 = Coil
8 = Choke
9 = Auxiliary winding
10 = Rotor winding
11 = Radio interference suppressor
12 = Automatic voltage regulator
1
2
LL/W
2
R
4
R
R/W
1
L1
3
1
W
L2
3
T
2
3
LL/W
Br
11
12
4
F2
F1
LL/B
R/B
F2
B R
2
1
Br
2
F1
R/B
L/L
L
G/Y
1
1
10
G/Y
G/Y
Z1
9
Z2
Z1
8
Z3
Z3
Z2
(G3.3AE only)
1 = Main stator winding
2 = Main circuit breaker
3 = Earth-leakage circuit breaker
4 = 16 Amp receptacle
5 = Ignition switch
A = Generator
B = Control box
C = Engine
1020SD83
5A-17
Page 44
5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS
Generator Wiring Schematic (G4.6A, GS4.6A Models)
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
4
Wire Colors
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
LL/Gr
G/Y
LL/B
R/Gr
4
2
R
4
3
LL/W
1
R/W
LL/B
G/Y
R/B
R/B
4
LL/B
2
G/Y
1
R/B
3
1 = Main stator winding
2 = Main circuit breaker
3 = Earth-leakage circuit breaker (G4.6AE, GS4.6AE only)
4 = 16 Amp receptacle
5 = Choke
6 = Auxiliary winding
7 = Rotor winding
8 = Radio interference suppressor
9 = Automatic voltage regulator
LL/W
Br
3
2
G/Y
G/Y
1
R
W
Br
8
1
F2
F2
L2
L1
9
5A-18
B
R
F1
F1
L
Z1
1
6
Z1
Z2
5
Z3
Z3
Z2
7
1020SD85
Page 45
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
Engine Wiring Schematic (G4.6A , GS4.6AModels)
13
G
14
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
11
Wire Colors
B - Black
G - Green
L - Blue
P - Pink
R - Red
12
Y
LL-Light blue
1
10
B
L/W
2
3
16
R
4
15
W
5
Y
10 = Engine crank switch
11 = Oil level switch
12 = Coil
13 = Battery
14 = Charging coil
15 = Starter
16 = Starter solenoid
17 = 15 Amp fuse
B
18 = Ignition switch
L/W
1
3
4
6
G
R
18
OFF
ON
B
11
B
Y
12
2
T
5
W
17
GS4.6 Models
B/R
G4.6 Models
1021SD67
5A-19
Page 46
5A G3.3A/G4.6A/GS4.6A/GS5.7A 50 HZ PORTABLE GENERATORS
Generator Wiring Schematic (GS5.7A Models)
G/YG/YG/Y
55
2
R/W
143
2
R/W
V/W
R/Gr
R/B
Br/W
V/W
Br/R
LL/W
Br/W
35 1 N
3
LL/Gr LL/R
4
V/B
LL/W
Br/B
6T
Br/B
4 2 N
R/B
143
2
V/B
LL/B
LL/B
G/Y
W- White
Y - Yellow
Br - Brown
Wire Colors
B - Black
G - Green
L - Blue
Gr - Gray
Or - Orange
Pr - Purple
P - Pink
R - Red
LL-Light blue
T - Tan
V
Br
RU
1
3
4
V
N
1
7
5A-20
W
L2
L1
F1
LL
F2
G/Y
6
1 = Main stator winding
2 = Main circuit breaker
3 = Earth-leakage circuit breaker (GS5.7AE)
4 = 400 volt/16 Amp receptacle
5 = 230 volt/16 Amp receptacle
6 = Radio interference suppressor
7 = Automatic voltage regulator
8 = Rotor winding
6
8
F2
B
R
F1
1021SD04
Page 47
50 HZ PORTABLE GENERATORS G3.3A/G4.6A/GS4.6A/GS5.7A 5A
Engine Wiring Schematic (GS5.7A Models)
12
G
13
10
11
Y
B
L/W
1
2
3
15
R
4
14
W
W- White
Y - Yellow
Br - Brown
Gr - Gray
Or - Orange
Pr - Purple
T - Tan
5
9
Y
Wire Colors
B - Black
G - Green
L - Blue
P - Pink
R - Red
LL-Light blue
B
L/W
9 = Engine crank switch
10 = Oil level switch
11 = Coil
12 = Battery
13 = Charging coil
14 = Starter
15 = Starter solenoid
16 = 15 Amp fuse
1
3
4
6
R
2
T
5
W
16
1021SD01
5A-21
Page 48
5A 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.
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
Page 49
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 PART NO. - SIZE
Loctite 222 Purple Low strength, for locking threads smaller than 1/4" (6 mm). 73287 - 10 ml Hernon 420 Hand tool removable. Omnifit 1150 (50M) Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)
Loctite 243 Blue Medium strength, for locking threads larger than 1/4" (6 mm). 29311 - .5 ml Hernon 423 Hand tool removable. 17380 - 50 ml Omnifit 1350 (100M) Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)
Loctite 271 / 277 Red High strength, for all threads up to 1" (25 mm). 29312 - .5 ml Hernon 427 Heat parts before disassembly. 26685 - 10 ml Omnifit 1550 (220M) Temp. range, -65 to 300 degrees F (-54 to 149 degrees C) 73285 - 50 ml
Loctite 290 Green Medium to high strength, for locking preassembled threads 28824 - .5 ml Hernon 431 and for sealing weld porosity (wicking). 25316 - 10 ml Omnifit 1710 (230LL) Gaps up to 0.005" (0.13 mm)
Loctite 609 Green Medium strength retaining compound for slip or press fit 29314 - .5 ml Hernon 822 of shafts, bearings, gears, pulleys, etc. Omnifit 1730 (230L) Gaps up to 0.005" (0.13 mm)
Loctite 545 Brown Hydraulic sealant 79356 - 50 ml Hernon 947 Temp. range, -65 to 300 degrees F (-54 to 149 degrees C) Omnifit 1150 (50M)
Loctite 592 White Pipe sealant with Teflon for moderate pressures. 26695 - 6 ml Hernon 920 Temp. range, -65 to 300 degrees F (-54 to 149 degrees C) 73289 - 50 ml Omnifit 790
Loctite 515 Purple Form-in-place gasket for flexible joints. 70735 - 50 ml Hernon 910 Fills gaps up to 0.05" (1.3 mm) Omnifit 10 Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)
Loctite 496 Clear Instant adhesive for bonding rubber, metal and plastics; Hernon 110 general purpose. 52676 - 1 oz. Omnifit Sicomet 7000 For gaps up to 0.006" (0.15 mm)
Loctite Primer T Aerosol Fast curing primer for threadlocking, retaining and 2006124 - 6 oz. Hernon Primer 10 Spray sealing compounds. Must be used with stainless steel Omnifit VC Activator hardware. Recommended for use with gasket sealants.
Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)
Temp. range, -65 to 300 degrees F (-54 to 149 degrees C)
Read caution instructions before using. Temp. range, -65 to 180 degrees F (-54 to 82 degrees C)
Page 50
TORQUE VALUES
Metric Fasteners (DIN)
TORQUE VALUES (Based on Bolt Size and Hardness)
8.8
8.8
10.9
10.9
12.9
12.9
WRENCH SIZE
Size Ft.Lb. Nm Ft.Lb. Nm Ft.Lbs. 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 7 - 3
M5 *53 6.0 6 8.5 7 10 5/16 8 - 4
M6 7 10 10 14 13 17 - 10 - 5
M8 18 25 26 35 30 41 1/2 13 - 6
M10 36 49 51 69 61 83 11/16 17 - 8
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
Inch Fasteners (SAE)
SAE 5
Size Ft.Lb. Nm Ft.Lb. Nm Ft.Lbs. Nm Inch Metric Inch Metric
No.4 *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 8 7/64 -
No.8 *22 2.5 *31 3.5 *42 4.7 11/32 9 9/64 -
No.10 *32 3.6 *45 5.1 *60 6.8 3/8 - 5/32 -
1/4 6 8.1 9 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
SAE 8
-
1 Ft.Lb. = 1.357 Nm
1 Inch = 25.4 mm* = In.Lb.
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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 · 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
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