Wacker Neuson GV 2500A, Repair Manual

Page 1: ...Generator GV 2500A GV 3800A GV 5600A GV 6600A REPAIR MANUAL 0171887en 002 0609 0 1 7 1 8 8 7 E N...

Page 2: ......

Page 3: ...ufactured up until the time of publication Wacker Neuson Corporation reserves the right to change any portion of this information without notice Copyright notice All rights especially copying and dist...

Page 4: ...orest Service for this purpose In order to comply with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator NOTICE Trademarks All trademarks...

Page 5: ...ng the Rotor Windings 19 2 4 Checking the Brushes 21 2 5 Checking the Excitation Winding 22 2 6 Checking the AVR s Sensing Wires 24 2 7 Checking the Main Circuit Breaker 27 2 8 Checking the Voltage Se...

Page 6: ...4 4 2 Electrical Components GV 2500A 55 4 3 Electrical Schematic GV 3800A 56 4 4 Electrical Components GV 3800A 57 4 5 Electrical Schematic GV 5600A GV 6600A 58 4 6 Electrical Components GV 5600A GV 6...

Page 7: ...l safety messages that follow this symbol DANGER indicates a hazardous situation which if not avoided will result in death or serious injury f Obey all safety messages that follow this symbol to avoid...

Page 8: ...R use worn electrical cords Severe electrical shock and equipment dam age may result Guidelines for operation NEVER enclose or cover the generator when it is in use or when it is hot NEVER overload th...

Page 9: ...NOT run the engine near open flames NEVER touch the engine or muffler while the engine is on or immediately after it has been turned off These areas get hot and may cause burns Guidelines for refueli...

Page 10: ...idelines for lifting ALWAYS make sure slings chains hooks ramps jacks and other types of lifting devices are attached securely and have enough weight bearing capacity to lift or hold the machine safel...

Page 11: ...GV Generators Safety Information wc_si000245gb fm 11 1 5 Label Locations wc_gr005497...

Page 12: ...rator to backfeed into utility lines This may result in electrocution of utility workers fire or explosion Connections to a building s electrical system must be made by a qualified electrician and com...

Page 13: ...wc_si000245gb fm 13 1 7 Procedural Labels CAUTION Use only clean filtered gasoline fuel Check the fuel level Open the fuel flow valve Close the choke Turn the engine switch to the ON position Pull th...

Page 14: ...the model number item number revision number 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 d...

Page 15: ...nce below when troubleshooting wc_gr004336 V 1000 200 20 2 200m F V A V COM WARNING Electric shock hazard High voltage exists at the alternator Electric shock can cause severe injury or death f Never...

Page 16: ...the wiring to the brushes 4 Connect a 9 Volt battery to the brushes this is a polarity sensitive connection so be certain to connect battery positive to the positive brush 5 Start the engine 6 Measur...

Page 17: ...w Y red R black B and green G wires from the alter nator 3 Measure the resistance in Ohms between the red and yellow wires Also mea sure between the black and green wires See chart below Is the correc...

Page 18: ...here the yellow Y red R black B and green G wires were connected and the ground stud Is any resistance measured for any of the checks Result The procedure to check the stator windings is now complete...

Page 19: ...e generator sdfdsf 2 Remove the screw that secures the brushes b and remove the brushes 3 Measure the resistance of the rotor winding by measuring across the slip rings c Is the correct resistance mea...

Page 20: ...f the rotor shaft Is any resistance measured for either of the checks 5 Re install the brushes do not overtighten the screws 6 Re install the end cap Result The procedure to check the rotor winding is...

Page 21: ...he length of the brush protruding from the brush holder The minimum allowable length is 6 5 mm 0 25 in 4 Measure the continuity of each brush Does each brush measure at least 6 5 mm and have continuit...

Page 22: ...e end cap a from the generator 2 Disconnect the plug b which connects the excitation winding to the Automatic Voltage Regulator AVR 3 Measure the resistance of the excitation winding by measuring acro...

Page 23: ...ach yellow wire and the ground stud Is any resistance measured for either of the checks 5 Reconnect the wiring 6 Re install the end cap Result The procedure to check the excitation winding is now comp...

Page 24: ...e the end cap a from the generator 2 Disconnect the white W red R gray Gr and light green LG wires from the generator terminal strip 3 Disconnect the AVR at the wiring harness connector b 4 Check the...

Page 25: ...y 8 Check the resistance between the light green LG wire of the wiring harness 6 wire connector c and the ground stud x Is any resistance measured 9 Check for continuity between the red white R W wire...

Page 26: ...between the 6 wire connector and the VSS Does the wiring have continuity 14 Disconnect the 4 wire plug from the automatic voltage regulator AVR 15 Check the continuity of the blue L wire from the 4 w...

Page 27: ...ove the screws b that secure the front and back halves of the control panel 3 Position the front half of the control panel to access the main circuit breaker c 4 Place the auto idle switch in the OFF...

Page 28: ...from the main circuit breaker by measuring the volt age between the red wire and a common ground then at the blue wire and a common ground Is 110 130V measured in each case The procedure to check the...

Page 29: ...move screws b that secure the front and back halves of the control panel 3 Position the front half of the control panel to access the VSS c 4 Remove the two wiring connectors d from the VSS 5 Check th...

Page 30: ...to check the auto idle circuitry 1 Remove the end cap d from the generator 2 Disconnect the 6 wire connector e 3 Measure the resistance across the two gray wires of the 6 pin connector Is the correct...

Page 31: ...as a base point Measure between it and the two other terminals Reverse the leads of the meter and measure again The meter should read approximately 0 5V in one direction and OPEN or OL in the other Do...

Page 32: ...crews a that secure the control panel to the frame Once removed lower the control panel to access the screws b 7 Remove the screws b that secure the front and back halves of the control panel 8 Positi...

Page 33: ...ne This procedure continues on the next page WARNING Electric shock hazard High voltage exists at the components of the control panel when the engine is running Electric shock can cause severe injury...

Page 34: ...OK 13 Start the engine 14 Place the auto idle switch in the ON position This procedure continues on the next page Yes ____ No ____ Your reading Reconnect the auto idle switch and continue Replace the...

Page 35: ...sured 16 Measure the DC voltage between the red white R wire of the auto idle unit and the white black W B wire of the auto idle unit Is at least 9 8VDC measured This procedure continues on the next p...

Page 36: ...onnect a load to the generator 20 Once again measure the voltage between the red R wire of the auto idle unit and the white black W B wire of the auto idle unit Is at least approximately 0 zero VDC me...

Page 37: ...i Afterfire Solenoid AAS 1 Remove the screws a that secure the control panel to the frame Once removed lower the control panel to access the screws b 2 Remove the screws b that secure the front and ba...

Page 38: ...he previous page 6 Measure the capacitance of the capacitor Does the capacitor measure approximately 4700 10 micro Farads 7 Reassemble the generator The procedure to check the AAS is now complete Yes...

Page 39: ...sion level and serial number of the machine Parts Books are also available on the Wacker Neuson Corporation Web site See www wackerneuson com Enter the site as a visitor 3 3 Information Regarding Refe...

Page 40: ...e section Removing the Fuel Tank 3 Remove the screws that secure the outer muffler guard and remove the outer muffler guard a 4 Remove the screw g that secures the generator mounting leg to the shock...

Page 41: ...epair Disassembly and Assembly wc_tx000775gb fm 41 Continued from the previous page 8 Lift the muffler and the muffler guard from the engine and frame The procedure to remove the muffler is now comple...

Page 42: ...on the muffler and the muffler guard into the frame and onto the engine 2 Remove the screws b that secure the muffler to the engine 3 Install the screw i that secures the muffler to the stator 4 Insta...

Page 43: ...775gb fm 43 Continued from the previous page 6 Remove the screws that secure the outer muffler guard and remove the outer muffler guard a 7 Install the fuel tank See section Installing the Fuel Tank T...

Page 44: ...ank and brace to the fuel frame and pull the fuel tank from the frame 5 Remove the brace from the fuel tank The procedure to remove the fuel tank is now complete 3 8 Installing the Fuel Tank Prerequis...

Page 45: ...ug 2 Remove the end cover a 3 Disconnect the wiring from the terminal strip b the ground wire c and the harness connector d On GV 2500 machines disconnect the generator plug e 4 Remove the brush holde...

Page 46: ...fm 46 Continued from the previous page 7 Remove the screw i that secures the muffler to the stator 8 Remove the four long screws j that secure the stator to the machine 9 Pull the stator k from the m...

Page 47: ...stator 1 Position the stator over the rotor and onto the machine 2 Secure the stator to the machine with the four long screws j 3 Install the screw i that secures the muffler guard to the stator 4 Ins...

Page 48: ...previous page 6 Install the brush holder f 7 Connect the wiring to the terminal strip b the ground wire c and the harness connector d On GV 2500 machines connect the generator plug e 8 Re install the...

Page 49: ...that secures the rotor to the engine To prevent the rotor from spinning secure the rotor with an oil filter wrench when removing the long bolt 4 Support the rotor with one hand then strike the rotor w...

Page 50: ...Procedure Follow the procedure below to install the rotor 1 Position the rotor on the engine shaft 2 Install the long bolt a that secures the rotor to the engine To prevent the rotor from spinning se...

Page 51: ...nect the wiring between the engine and the control panel 3 Remove the fuel tank See section Removing the Fuel Tank 4 Remove the muffler See section Removing the Muffler 5 Remove the stator See section...

Page 52: ...to the frame and secure it to the shock mounts with screws a 2 Install the rotor See section Installing the Rotor 3 Install the stator See section Installing the Stator 4 Install the muffler See secti...

Page 53: ...GV Generator Repair Disassembly and Assembly wc_tx000775gb fm 53 Notes...

Page 54: ...Schematics GV Generator Repair wc_tx000813gb fm 54 4 Schematics 4 1 Electrical Schematic GV 2500A A 3 1 2 4 14 B 5 6 7 8 9 10 11 13 12 C...

Page 55: ...ine ON OFF switch 2 Secondary winding 9 Oil alert module 3 Rotor winding 10 Oil level switch 4 Automatic voltage regulator 11 Ignition coil 5 20A circuit breaker 12 Ground terminal 6 GFI duplex recept...

Page 56: ...Schematics GV Generator Repair wc_tx000813gb fm 56 4 3 Electrical Schematic GV 3800A A B 15 16 17 18 6 6 5 3 14 1 9 8 19 20 10 11 21 13 12 4 2 22 23 C...

Page 57: ...atic voltage regulator 16 Voltage selector switch 5 20A circuit breaker 17 Twist lock receptacle 125 250V 6 GFI duplex receptacle 125V 18 Auto idle switch 7 19 Idle solenoid 8 Engine ON OFF switch 20...

Page 58: ...Schematics GV Generator Repair wc_tx000813gb fm 58 4 5 Electrical Schematic GV 5600A GV 6600A A B 15 16 17 24 18 6 6 5 3 14 1 9 8 19 20 10 11 21 13 12 4 2 22 23 C...

Page 59: ...e regulator 16 Voltage selector switch 5 Main circuit breaker 17 Twist lock receptacle 125 250V 6 GFI duplex receptacle 125V 18 Auto idle switch 7 19 Idle solenoid 8 Engine ON OFF switch 20 Capacitor...

Page 60: ...mum output W 2500 Continuous output W 2250 Type Single phase self exciting 2 pole field rotating AC voltages available Volts phase 120 1 Frequency Hz 60 Power factor cos 1 0 AC receptacles 125V GFI du...

Page 61: ...da Engine model GX 160 K1 Maximum rated power at rated speed kW Hp 3 6 4 8 3600 rpm Spark plug BPR6ES NKG Electrode gap mm in 0 7 0 8 0 028 0 031 Operating speed rpm 3600 Air cleaner type Oil wetted f...

Page 62: ...output W 3400 Type Single phase self exciting 2 pole field rotating AC voltages available Volts phase 120 240 1 Frequency Hz 60 Power factor cos 1 0 AC receptacles 125V GFI duplex 2 125 250V twist loc...

Page 63: ...onda Engine model GX 240 K1 Maximum rated power at operating speed kW Hp 5 3 7 1 3600 rpm Spark plug BPR6ES NKG Electrode gap mm in 0 7 0 8 0 028 0 031 Operating speed rpm 3600 Air cleaner type Oil we...

Page 64: ...tput W 5000 Type Single phase self exciting 2 pole field rotating AC voltages available Volts phase 120 240 1 Frequency Hz 60 Power factor cos 1 0 AC receptacles 125V GFI duplex 2 125V twist lock 125...

Page 65: ...Honda Engine model GX 340 K1 Maximum rated power at rated speed kW Hp 7 1 9 5 3600 rpm Spark plug BPR6ES NKG Electrode gap mm in 0 7 0 8 0 028 0 031 Operating speed rpm 3600 Air cleaner type Oil wett...

Page 66: ...00 Type Single phase self exciting 2 pole field rotating AC voltages available Volts phase 120 240 1 Frequency Hz 60 Power factor cos 1 0 AC receptacles 125V GFI duplex 2 125 250V twist lock 125V twis...

Page 67: ...le phase self exciting 2 pole field rotating AC voltages available Volts phase 120 240 1 Frequency Hz 60 Power factor cos 1 0 AC receptacles 125V GFI duplex 2 125 250V twist lock 125V twist lock Amp A...

Page 68: ...a Engine model GX 390 K1 Max rated power rated speed kW Hp 8 2 11 0 3600 rpm Spark plug BPR6ES NKG Electrode gap mm in 0 7 0 8 0 028 0 031 Operating speed rpm 3600 Air cleaner type Oil wetted foam Eng...

Page 69: ...model GX 390 R1 Max rated power rated speed kW Hp 9 7 13 3600 rpm Spark plug BPR6ES NKG Electrode gap mm in 0 7 0 8 0 028 0 031 Operating speed rpm 3600 Air cleaner type Oil wetted foam Engine lubrica...

Page 70: ...311 5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 m...

Page 71: ...follow instructions on container The sealants listed are recommended for use on Wacker Neuson equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant a...

Page 72: ...5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 M5 6 0 53 8 5 6 10 7 8 5 16 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 1...

Page 73: ...8 2 5 22 3 5 31 4 7 42 9 11 32 9 64 No 10 3 6 32 5 1 45 6 8 60 3 8 5 32 1 4 8 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8...

Page 74: ...2 390 Wacker Neuson Corporation P O Box 9007 Menomonee Falls WI 53052 9007 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Neuson Limited Room 1701 03 1717 20 17 F Tower 1 Grand Century Plac...