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Wacker Neuson GV 2500A Repair Manual
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Wacker Neuson GV 2500A Repair Manual

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

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Summary of Contents for Wacker Neuson GV 2500A

  • Page 1 0171887en 0609 Generator GV 2500A GV 3800A GV 5600A GV 6600A REPAIR MANUAL...

  • Page 3: Foreword

    Expectations This manual provides information and procedures to safely operate and main- tain the above Wacker Neuson model(s). For your own safety and to reduce the information in risk of injury, carefully read, understand, and observe all instructions described this manual in this manual.
  • Page 4 GV Generator Repair and rated by the United States Forest Service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator. NOTICE: Trademarks All trademarks referenced in this manual are the property of their respective own- ers.

  • Page 5: Table Of Contents

    GV Generators Table of Contents Foreword Safety Information Callouts Found in this Manual .............. 7 Safety Guidelines for Operating the Machine ........8 Safety Guidelines while Using Internal Combustion Engines ....9 Safety Guidelines for Maintaining the Machine ........10 Label Locations ..................
  • Page 6 Installing the Rotor ................50 3.13 Removing the Engine ................51 3.14 Installing the Engine ................52 Schematics Electrical Schematic—GV 2500A ............54 Electrical Components—GV 2500A ............55 Electrical Schematic—GV 3800A ............56 Electrical Components—GV 3800A ............57 Electrical Schematic—GV 5600A, GV 6600A ........58 Electrical Components—GV 5600A, GV 6600A ........59 Technical Data Generator—GV 2500A ................60...

  • Page 7: Safety Information

    GV Generators Safety Information Safety Information Callouts Found in this Manual This is the safety alert symbol. It is used to alert you to potential personal hazards. Obey all safety messages that follow this symbol. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

  • Page 8: Safety Guidelines For Operating The Machine

    Familiarize yourself with the location and proper use of all controls and safety devices. Contact Wacker Neuson Corporation for additional training if necessary. When operating this machine: Do not allow improperly trained people to operate the machine. People operating the machine must be familiar with the potential risks and hazards associated with it.

  • Page 9: Safety Guidelines While Using Internal Combustion Engines

    GV Generators Safety Information Standards for NEVER operate the generator, or tools attached to the generator, when your operator hands are wet. NEVER allow untrained personnel to operate the generator. NEVER stand on the machine. Safety Guidelines while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling.

  • Page 10: Safety Guidelines For Maintaining The Machine

    Safety Information GV Generators Safety Guidelines for Maintaining the Machine WARNING CAUTION! 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. Attach a “DO NOT START”...

  • Page 11: Label Locations

    GV Generators Safety Information Label Locations wc_gr005497 wc_si000245gb.fm...

  • Page 12: Warning Labels

    Safety Information GV Generators Warning Labels Label Definition DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling. WARNING! Hot surface! Improper connection of generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines.

  • Page 13: Procedural Labels

    GV Generators Safety Information 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 the rewind starter. Open the choke. wc_si000245gb.fm...

  • Page 14: Informational Labels

    Safety Information GV Generators Turn the engine switch to “OFF”. Close the fuel flow valve. Electrical ground Informational Labels A nameplate listing 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 damaged.

  • Page 15: Troubleshooting Voltage Issues

    GV Generators Troubleshooting Voltage Issues Troubleshooting Voltage Issues Prerequisites Generator must be able to start Multimeter Procedure To determine where to begin troubleshooting voltage issues, follow the procedure below. 1. Remove the end cap (a) from the generator. 1000 200m wc_gr004336 WARNING! Electric shock hazard.

  • Page 16: Charging The Generator With 9-Volt Battery

    Troubleshooting Voltage Issues GV Generators Charging the Generator with 9-Volt Battery Prerequisites 9-Volt battery Multimeter Procedure Follow the procedure below to test charge the generator with a 9-Volt battery. 1. Remove the end cap (a) from the generator. 2. Disconnect the wiring at the connector to the automatic voltage regulator (AVR) (b).

  • Page 17: Checking The Stator Windings

    2. Disconnect the yellow (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. Machine R–Y B–G GV 2500A 0.9–1.4 0.9–1.4 GV 3800A 0.7–1.2 0.7–1.2 GV 5600A 0.4–0.9...
  • Page 18 Troubleshooting Voltage Issues GV Generators Continued from the previous page. 4. Check each winding to ground. Measure the resistance between each post where 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? Yes ____ No ____...

  • Page 19: Checking The Rotor Windings

    GV Generators Troubleshooting Voltage Issues Checking the Rotor Windings Prerequisites Generator shut down Multimeter Procedure Follow the procedure below to check the rotor winding. 1. Remove the end cap (a) from the generator. sdfdsf 2. Remove the screw that secures the brushes (b) and remove the brushes. 3.
  • Page 20 Troubleshooting Voltage Issues GV Generators Continued from the previous page. 4. Check for shorts to the rotor shaft by measuring resistance between each slip ring and the end of the rotor shaft. Is any resistance measured for either of the checks? Yes ____ No ____ The rotor winding has failed.

  • Page 21: Checking The Brushes

    GV Generators Troubleshooting Voltage Issues Checking the Brushes Prerequisites Generator shut down Multimeter Procedure Follow the procedure below to check the brushes. 1. Remove the end cap (a) from the generator. sdfdsf 2. Remove the screw that secures the brush holder (b) and remove the brush holder.

  • Page 22: Checking The Excitation Winding

    Troubleshooting Voltage Issues GV Generators Checking the Excitation Winding Prerequisites Generator shut down Multimeter Procedure Follow the procedure below to check the excitation winding. 1. Remove the end cap (a) from the generator. 2. Disconnect the plug (b) which connects the excitation winding to the Automatic Voltage Regulator (AVR).
  • Page 23 GV Generators Troubleshooting Voltage Issues Continued from the previous page. 4. Check each side of the winding to ground by Measuring the resistance between each yellow wire and the ground stud. Is any resistance measured for either of the checks? Yes ____ No ____ The excitation winding has failed.

  • Page 24: Checking The Avr's Sensing Wires

    Troubleshooting Voltage Issues GV Generators Checking the AVR’s Sensing Wires Prerequisites Generator shut down Multimeter Procedure Follow the procedure below to check the Automatic Voltage Regulator (AVR) sens- ing wires. 1. Remove 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.
  • Page 25 GV Generators Troubleshooting Voltage Issues Continued from the previous page. 5. Check the resistance between the brown (Br) wire of the wiring harness connec- tor (b) and the ground stud (x). Is any resistance measured? Yes ____ No ____ The sensing wire has failed. Replace the stator. Continue.
  • Page 26 Troubleshooting Voltage Issues GV Generators Continued from the previous page. 10.Open the control panel to access the Voltage Selector Switch (VSS) (d). 11.Check the continuity of the red-white (RW) wire from the 6-wire connector (e) to the VSS (d). Does the wiring have continuity? Yes ____ No ____ The wiring has failed.

  • Page 27: Checking The Main Circuit Breaker

    GV Generators Troubleshooting Voltage Issues Checking the Main Circuit Breaker Prerequisites Multimeter Procedure Follow the procedure below to check the main circuit breaker. 1. Remove the screws (a) that secure the control panel to the frame. Once removed, lower the control panel to access screws (b). 2.
  • Page 28 Troubleshooting Voltage Issues GV Generators Continued from the previous page. 6. Measure the voltage between the red (R) wire at the main circuit breaker and a common ground; then at the blue (L) wire and a common ground. Is 110–130V measured in each case? Yes ____ No ____ Your reading...

  • Page 29: Checking The Voltage Selector Switch (Vss)

    GV Generators Troubleshooting Voltage Issues Checking the Voltage Selector Switch (VSS) Prerequisites Multimeter Procedure Follow the procedure below to check the Voltage Selector Switch (VSS). 1. Remove the screws (a) that secure the control panel to the frame. Once removed, lower the control panel to access screws (b). 2.

  • Page 30: Checking The Auto Idle Unity And Circuity

    Troubleshooting Voltage Issues GV Generators Checking the Auto Idle Unity and Circuity Prerequisites Multimeter Procedure Follow the procedure below to check the auto idle circuitry. 1. Remove the end cap (d) from the generator. 2. Disconnect the 6-wire connector (e). 3.
  • Page 31 GV Generators Troubleshooting Voltage Issues Continued from the previous page. 4. Disconnect the DC rectifier (z). 1000 200m wc_gr004370 wc_gr004372 5. Check across the terminals of the DC rectifier using the diode scale. Use the terminal (y) where the BR-R wire connects as a base point. Measure between it and the two other terminals.
  • Page 32 Troubleshooting Voltage Issues GV Generators Continued from the previous page. 6. Remove the screws (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.
  • Page 33 GV Generators Troubleshooting Voltage Issues Continued from the previous 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 or death. Never touch any control panel component with your bare hands when the engine is run- ning.
  • Page 34 Troubleshooting Voltage Issues GV Generators Continued from the previous page. 12.Disconnect the auto idle switch (d) and check it for continuity. It should have continuity in the Auto position and no continuty in the OFF position. Is the auto idle switch OK? Yes ____ No ____ Your reading...
  • Page 35 GV Generators Troubleshooting Voltage Issues Continued from the previous page. 15.Measure the DC voltage between the black (B) wire of the auto idle unit and the white-black (W/B) wire of the auto idle unit. Is at least 9.8VDC measured? Yes ____ No ____ Your reading Continue.
  • Page 36 Troubleshooting Voltage Issues GV Generators Continued from the previous page. 17.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 9.8VDC measured? Yes ____ No ____ Your reading The auto idle unit has failed.

  • Page 37: Checking The Anti-Afterfire Solenoid

    GV Generators Troubleshooting Voltage Issues 2.10 Checking the Anti-Afterfire Solenoid Prerequisites Multimeter Functioning DC Rectifier (See section Checking Auto Idle Unit and Circuitry.) Procedure Follow the procedure below to check the Anti-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).
  • Page 38 Troubleshooting Voltage Issues GV Generators Continued from the previous page. 6. Measure the capacitance of the capacitor. ±10% Does the capacitor measure approximately 4700 micro Farads? Yes ____ No ____ Your reading The capacitor is OK. The capacitor has failed; replace it. 7.

  • Page 39: Disassembly And Assembly

    When ordering a replacement Parts Book, please list the model number, item number, revision 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.

  • Page 40: Removing The Muffler

    Disassembly and Assembly GV Generator Repair Removing the Muffler Prerequisites Engine cool Procedure Follow the procedure below to remove the muffler. 1. Disconnect the spark plug. 2. Remove the fuel tank. See section Removing the Fuel Tank. 3. Remove the screws that secure the outer muffler guard and remove the outer muffler guard (a).
  • Page 41 GV Generator Repair Disassembly and Assembly Continued from the previous page. 8. Lift the muffler and the muffler guard from the engine and frame. wc_gr004408 The procedure to remove the muffler is now complete. wc_tx000775gb.fm...

  • Page 42: Installing The Muffler

    Disassembly and Assembly GV Generator Repair Installing the Muffler Prerequisites Engine cool Procedure Follow the procedure below to install the muffler. 1. Position the muffler and the muffler guard into the frame and onto the engine. wc_gr004408 2. Remove the screws (b) that secure the muffler to the engine. 3.
  • Page 43 GV Generator Repair Disassembly and Assembly 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. The procedure to install the muffler is now complete. wc_tx000775gb.fm...

  • Page 44: Removing The Fuel Tank

    Disassembly and Assembly GV Generator Repair Removing the Fuel Tank Prerequisites Machine shut down Procedure Follow the procedure below to remove the fuel tank. 1. Disconnect the spark plug. 2. Close the fuel valve. 3. Disconnect the fuel hose (a) from fuel valve. wc_gr004397 4.

  • Page 45: Removing The Stator

    GV Generator Repair Disassembly and Assembly Removing the Stator Prerequisites Machine shut down Procedure Follow the procedure below to remove the stator. 1. Disconnect the spark plug. 2. Remove the end cover (a). wc_gr004398 3. Disconnect the wiring from the terminal strip (b), the ground wire (c), and the harness connector (d).
  • Page 46 Disassembly and Assembly GV Generator Repair 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 machine. The procedure to remove the stator is now complete.

  • Page 47: Installing The Stator

    GV Generator Repair Disassembly and Assembly 3.10 Installing the Stator Prerequisites Machine shut down Procedure Follow the procedure below to install the 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.
  • Page 48 Disassembly and Assembly GV Generator Repair Continued from the previous page. 6. Install the brush holder (f). wc_gr004398 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.

  • Page 49: Removing The Rotor

    GV Generator Repair Disassembly and Assembly 3.11 Removing the Rotor Prerequisites Oil filter wrench Procedure Follow the procedure below to remove the rotor. 1. Disconnect the spark plug. 2. Remove the stator. See section Removing the Stator. 3. Loosen the long bolt (a) 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.

  • Page 50: Installing The Rotor

    Disassembly and Assembly GV Generator Repair 3.12 Installing the Rotor Prerequisites Oil filter wrench 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, secure the rotor with an oil filter wrench when installing the long bolt.

  • Page 51: Removing The Engine

    GV Generator Repair Disassembly and Assembly 3.13 Removing the Engine Prerequisites Engine cool Procedure Follow the procedure below to remove the engine. 1. Disconnect the spark plug. 2. Label and disconnect the wiring between the engine and the control panel. 3.

  • Page 52: Installing The Engine

    Disassembly and Assembly GV Generator Repair 3.14 Installing the Engine Prerequisites Engine cool Procedure Follow the procedure below to install the engine. 1. Position the engine into the frame and secure it to the shock mounts with screws (a). 2. Install the rotor. See section Installing the Rotor. 3.
  • Page 53 GV Generator Repair Disassembly and Assembly Notes wc_tx000775gb.fm...

  • Page 54: Schematics

    Schematics GV Generator Repair Schematics Electrical Schematic—GV 2500A wc_tx000813gb.fm...

  • Page 55: Electrical Components-Gv 2500A

    GV Generator Repair Schematics Electrical Components—GV 2500A Ref. Description Ref. Description Ref. Description Generator Control Box Engine Ref. Description Ref. Description Main stator winding Engine ON-OFF switch Secondary winding Oil alert module Rotor winding Oil level switch Automatic voltage regulator...

  • Page 56: Electrical Schematic-Gv 3800A

    Schematics GV Generator Repair Electrical Schematic—GV 3800A wc_tx000813gb.fm...

  • Page 57: Electrical Components-Gv 3800A

    GV Generator Repair Schematics Electrical Components—GV 3800A Ref. Description Ref. Description Ref. Description Generator Control Box Engine Ref. Description Ref. Description Main stator winding Spark plug Secondary winding Slip ring Rotor winding Auto idle unit Automatic voltage regulator Voltage selector switch 20A circuit breaker Twist lock receptacle—125/250V GFI duplex receptacle—125V...

  • Page 58: Electrical Schematic-Gv 5600A, Gv 6600A

    Schematics GV Generator Repair Electrical Schematic—GV 5600A, GV 6600A wc_tx000813gb.fm...

  • Page 59: Electrical Components-Gv 5600A, Gv 6600A

    GV Generator Repair Schematics Electrical Components—GV 5600A, GV 6600A Ref. Description Ref. Description Ref. Description Generator Control Box Engine Ref. Description Ref. Description Main stator winding Spark plug Secondary winding Slip ring Rotor winding Auto idle unit Automatic voltage regulator Voltage selector switch Main circuit breaker Twist lock receptacle—125/250V...

  • Page 60: Technical Data

    Technical Data GV Generators Technical Data Generator—GV 2500A Item No. GV 2500A 0620286 0620542 Generator Maximum output 2500 Continuous output 2250 Type Single phase, self-exciting, 2-pole, field rotating AC voltages available Volts phase Frequency Power factor cos ø AC receptacles:...

  • Page 61: Engine-Gv 2500A

    GV Generators Technical Data Engine—GV 2500A Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GV 2500A 0620286 0620542 Engine Engine make Honda Engine model GX 160 K1 Maximum rated power 3.6 (4.8) @ 3600 rpm...

  • Page 62: Generator-Gv 3800A

    Technical Data GV Generators Generator—GV 3800A Item No. GV 3800A 0620287 Generator Maximum output 3800 Continuous output 3400 Type Single phase, self-exciting, 2-pole, field rotating AC voltages available 120/240 Volts phase Frequency Power factor cos ø AC receptacles: 125V GFI duplex (2) 125/250V twist lock Main circuit breaker 16 per pole...

  • Page 63: Engine-Gv 3800A

    GV Generators Technical Data Engine—GV 3800A Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GV 3800A 0620287 0620334 0620409 Engine Engine make Honda Engine model GX 240 K1 Maximum rated power 5.3 (7.1) @ 3600 rpm kW (Hp)

  • Page 64: Generator-Gv 5600A

    Technical Data GV Generators Generator—GV 5600A Item No. GV 5600A 0620288 0620335 0620410 Generator Maximum output 5600 Continuous output 5000 Type Single phase, self-exciting, 2-pole, field rotating AC voltages available 120/240 Volts phase Frequency Power factor cos ø AC receptacles: 125V GFI duplex (2) 125V twist lock 125/250V twist lock...

  • Page 65: Engine-Gv 5600A

    GV Generators Technical Data Engine—GV 5600A Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GV 5600A 0620288 0620335 0620410 Engine Engine make Honda Engine model GX 340 K1 Maximum rated power 7.1 (9.5) @ 3600 rpm kW (Hp)

  • Page 66: Generator-Gv 6600A

    Technical Data GV Generators Generator—GV 6600A Item No. GV 6600A 0620289 Generator Maximum output 6600 Continuous output 6000 Type Single phase, self-exciting, 2-pole, field rotating AC voltages available 120/240 Volts phase Frequency Power factor cos ø AC receptacles: 125V GFI duplex (2) 125/250V twist lock 125V twist lock Main circuit breaker...
  • Page 67 GV Generators Technical Data Item No. GV 6600A 0620336 Generator Maximum output 6600 Continuous output 6000 Type Single phase, self-exciting, 2-pole, field rotating AC voltages available 120/240 Volts phase Frequency Power factor cos ø AC receptacles: 125V GFI duplex (2) 125/250V twist lock 125V twist lock Main circuit breaker...

  • Page 68: Engine-Gv 6600A

    Technical Data GV Generators Engine—GV 6600A Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GV 6600A 0620289 Engine Engine make Honda Engine model GX 390 K1 Max.
  • Page 69 GV Generators Technical Data Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GV 6600A 0620336 Engine Engine make Honda Engine model GX 390 R1 Max. rated power @ 9.7 (13) @ 3600 rpm kW (Hp) rated speed...
  • Page 70 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson equipment. TYPE PART NO. –...
  • Page 71 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson equipment. TYPE PART NO. –...

  • Page 72: Torque Values

    Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE 10.9 12.9 Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch 7/32 – 9/32 – 5/16 – – – – 11/16 – – – 15/16 –...
  • Page 73 Torque Values Torque Values (continued) Inch Fasteners (SAE) Size ft.lb. ft.lb. ft.lb. Metric Inch Metric Inch No.4 – 3/32 No.6 5/16 – 7/64 No.8 11/32 – 9/64 No.10 – – 5/32 – 7/16 – 3/32 5/16 – – 9/16 – 5/16 7/16 –...
  • Page 74 Fax: +49 - (0)89-3 54 02-390 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 Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.

This manual is also suitable for:

Gv 5600aGv 3800aGv 6600a

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