Wacker Neuson GV 2500A Operating instructions

Generator
GV 2500A
GV 3800A
GV 5600A
GV 6600A
REPAIR MANUAL
0171887en 002
0609
0171887EN

GV Generator Repair
wc_tx000771gb.fm 3
Foreword
Machines
covered by
this manual
Machine
documentation
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
If you are missing any of these documents, please contact Wacker Neuson Cor-
poration to order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations
for
information in
this manual
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
risk of injury, carefully read, understand, and observe all instructions described
in this manual.
Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
The information contained in this manual is based on machines manufactured
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 distribution rights, are reserved.
Copyright 2009 by Wacker Neuson Corporation.
This publication may be reproduced through photocopying by the original
purchaser of the machine. Any other type of reproduction is prohibited without
express written permission from Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Cor-
poration represents an infringement of valid copyrights, and violators will be
prosecuted.
CALIFORNIA
Proposition
65 Warning:
Engine exhaust, some of its constituents, and certain vehicle components, contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Laws
pertaining to
spark
arresters
NOTICE: State Health Safety Codes and Public Resources Codes specify that in
certain locations spark arresters be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed to prevent accidental dis-
charge of sparks or flames from the engine exhaust. Spark arresters are qualified
Machine Item Number
GV 2500A 0620286, 0620542
GV 3800A 0620287, 0620409, 0620334
GV 5600A 0620288, 0620410, 0620335
GV 6600A 0620289, 0620336

GV Generator Repair
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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.

GV Generators Table of Contents
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Foreword 3
1 Safety Information 7
1.1 Callouts Found in this Manual .............................................................. 7
1.2 Safety Guidelines for Operating the Machine ....................................... 8
1.3 Safety Guidelines while Using Internal Combustion Engines ............... 9
1.4 Safety Guidelines for Maintaining the Machine .................................. 10
1.5 Label Locations .................................................................................. 11
1.6 Warning Labels .................................................................................. 12
1.7 Procedural Labels .............................................................................. 13
1.8 Informational Labels ........................................................................... 14
2 Troubleshooting Voltage Issues 15
2.1 Charging the Generator with 9-Volt Battery ....................................... 16
2.2 Checking the Stator Windings ............................................................ 17
2.3 Checking 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 Selector Switch (VSS) ..................................... 29
2.9 Checking the Auto Idle Unity and Circuity .......................................... 30
2.10 Checking the Anti-Afterfire Solenoid .................................................. 37
3 Disassembly and Assembly 39
3.1 Tools Required for Disassembly/Assembly Procedures ..................... 39
3.2 Information Regarding Replacement Parts ........................................ 39
3.3 Information Regarding Reference Numbers ( ) .................................. 39
3.4 Information Regarding Threadlocking Compounds ............................ 39
3.5 Removing the Muffler ......................................................................... 40
3.6 Installing the Muffler ........................................................................... 42
3.7 Removing the Fuel Tank .................................................................... 44
3.8 Installing the Fuel Tank ...................................................................... 44
3.9 Removing the Stator ........................................................................... 45
3.10 Installing the Stator ............................................................................. 47

Table of Contents GV Generators
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3.11 Removing the Rotor ............................................................................49
3.12 Installing the Rotor ..............................................................................50
3.13 Removing the Engine ..........................................................................51
3.14 Installing the Engine ............................................................................52
4 Schematics 54
4.1 Electrical Schematic—GV 2500A ........................................................54
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 6600A ..................................59
5 Technical Data 60
5.1 Generator—GV 2500A ........................................................................60
5.2 Engine—GV 2500A .............................................................................61
5.3 Generator—GV 3800A ........................................................................62
5.4 Engine—GV 3800A .............................................................................63
5.5 Generator—GV 5600A ........................................................................64
5.6 Engine—GV 5600A .............................................................................65
5.7 Generator—GV 6600A ........................................................................66
5.8 Engine—GV 6600A .............................................................................68

GV Generators Safety Information
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1 Safety Information
1.1 Callouts Found in this Manual
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
fObey all safety messages that follow this symbol.
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fObey all safety messages that follow this symbol to avoid injury or death.
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
fObey all safety messages that follow this symbol to avoid possible injury or
death.
CAUTION indicates a situation which, if not avoided, could result in minor or mod-
erate injury.
fObey all safety messages that follow this symbol to avoid possible minor or
moderate injury.

Safety Information GV Generators
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1.2 Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
Read and understand the operating instructions contained in all manuals
delivered with 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.
Guidelines for
machine
devices
ALWAYS operate the machine with all safety devices and guards in place and in
working order.
NEVER modify or defeat safety devices.
NEVER operate the machine if any safety devices or guards are missing or
inoperative.
ALWAYS check that all controls are functioning properly immediately after start-
up! DO NOT operate the machine unless all controls operate correctly.
NEVER use accessories or attachments that are not recommended by Wacker
Corporation. Damage to the machine and injury to the user may result.
NEVER 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 the generator. The total amperage of the tools and equipment
attached to the generator must not exceed the load rating of the generator.
NEVER attach equipment to the machine when it is suspended.
NEVER stand under the machine while it is being lifted or moved.
ALWAYS remove all tools, cords, and other loose items from the generator
before starting it.
ALWAYS make certain the machine is well-grounded and securely fastened to a
good earthen ground per national and local regulations.
Guidelines for
work space
NEVER operate the generator when open containers of fuel, paint, or other
flammable liquids are near.
NEVER run the electrical cords under the generator or over the top of the gener-
ator.
ALWAYS store the machine properly when it is not being used. The machine
should be stored in a clean, dry location out of the reach of children.
ALWAYS position and operate the generator when it is on a firm, noncombusti-
ble, level surface.
ALWAYS keep the area immediately surrounding and underneath the machine
clean, neat, and free of debris and combustible materials.
ALWAYS keep the area above the machine clear of debris that could fall on the
machine.

GV Generators Safety Information
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Standards for
operator
NEVER operate the generator, or tools attached to the generator, when your
hands are wet.
NEVER allow untrained personnel to operate the generator.
NEVER stand on the machine.
1.3 Safety Guidelines while Using Internal Combustion Engines
Guidlines for
running the
engine
NEVER use this generator inside a home or garage, EVEN IF doors and win-
dows are open. Only use OUTSIDE and far away from windows, doors, and
vents. Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or smell.
NEVER use a generator inside an enclosed area such as a tunnel or a trench.
DO NOT smoke while operating the machine.
DO 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
refueling the
engine
NEVER smoke when refueling the engine.
DO NOT refuel a hot or running engine.
DO NOT refuel the engine near an open flame.
DO NOT spill fuel when refueling the engine.
ALWAYS refill the fuel tank in a well-ventilated area.
ALWAYS replace the fuel tank cap after refueling.
ALWAYS check the fuel lines and the fuel tank for leaks and cracks before start-
ing the engine. Do not run the machine if fuel leaks are present or the fuel lines
are loose.
WARNING
Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety guidelines could result in severe injury or
death.
fRead and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.

Safety Information GV Generators
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1.4 Safety Guidelines for Maintaining the Machine
NEVER use gasoline or other types of fuels or flammable solvents to clean
parts. Fumes from fuels and solvents can become explosive.
ALWAYS keep the fuel lines in good condition and properly connected.
NEVER attempt to clean the machine while it is running.
DO NOT allow water to accumulate around the base of the machine. If water is
present, move the machine and allow the machine to dry before servicing.
DO NOT allow untrained personnel to maintain this equipment. Only trained
electrical technicians should be allowed to maintain the electrical components of
this machine.
ALWAYS allow the engine to cool before transporting or maintaining it.
ALWAYS replace the safety devices and guards after repairs and maintenance.
Guidelines 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 safely.
Always remain aware of the location of other people nearby when lifting the
machine.
Guidelines for
spare parts
ALWAYS replace worn or damaged components with spare parts designed and
recommended by Wacker Corporation.
ALWAYS keep the machine clean and labels legible. Replace all missing and
hard-to-read labels. Labels provide important operating instructions and warn of
dangers and hazards.
DO NOT modify the machine without the express written approval of the manu-
facturer.
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.
fAttach a “DO NOT START” sign to the control panel to notify other people of its condi-
tion whenever the machine is being serviced.

GV Generators Safety Information
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1.5 Label Locations
wc_gr005497

Safety Information GV Generators
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1.6 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. This may result
in electrocution of utility workers, fire, or
explosion. Connections to a building’s
electrical system must be made by a
qualified electrician and comply with all
applicable laws and electrical codes.
Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or
smell.
NEVER use inside a home or garage,
EVEN IF doors and windows are open.
Only use OUTSIDE and far away from
windows, doors, and vents.

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

Safety Information GV Generators
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1.8 Informational Labels
Turn the engine switch to “OFF”.
Close the fuel flow valve.
Electrical ground
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.
When ordering parts or requesting
service information, you will always be
asked to specify the model number, item
number, revision number, and serial
number of the unit.

GV Generators Troubleshooting Voltage Issues
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2 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.
2. Start the engine.
3. Place the auto idle switch in the OFF position.
4. Measure the voltage between the red and yellow wires; also measure between
the black and green wires.
Sequence Follow the sequence below when troubleshooting:
wc_gr004336
V
1000200
20
2
200m
FV
A
V- COM
WARNING! Electric shock hazard. High voltage exists at the alternator. Electric shock can
cause severe injury or death.
fNever touch the alternator components or the wires of the generator when the engine is
running.
If Then
Between 100–140 VAC is measured in both
locations Start with step 6.
All other cases Start with step 1.
Step Topic
1. Test charge the generator with a 9-Volt battery. 2.1
2. Check the stator windings. 2.2
3. Check the rotor windings. 2.3
4. Check the brushes. 2.4
5. Check the excitation winding. 2.5
6. Check AVR sensing wires. 2.6
7. Check main circuit breaker. 2.7
8. Check the voltage selector switch. 2.8

Troubleshooting Voltage Issues GV Generators
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2.1 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).
3. Disconnect 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. Measure the AC voltage between the red and yellow wires at the terminal strip.
Is 18–65 VAC measured?
The procedure to test charge the generator is now complete.
Disconnect the 9-Volt battery and continue troubleshooting.
Yes ____ No ____ Your reading
The AVR has failed, replace it. Continue troubleshooting by
checking the stator windings.
wc_gr004395
V
1000200
20
2
200m
FV
A
V- COM
9V
+–

GV Generators Troubleshooting Voltage Issues
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2.2 Checking the Stator Windings
Prerequisites Generator shut down
Multimeter
Procedure Follow the procedure below to check the stator windings.
1. Remove the end cap (a) from the generator.
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.
Is the correct resistance measured for your machine?
This procedure continues on the next page.
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 0.4–0.9
GV 6600A 0.3–0.8 0.3–0.8
Yes ____ No ____
Continue. The stator windings have failed. Replace the stator.

Troubleshooting Voltage Issues GV Generators
wc_tx000772gb.fm 18
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?
Result The procedure to check the stator windings is now complete.
Reassemble the generator or, if the problem has not been resolved, continue with
the next topic.
Yes ____ No ____
The stator windings have failed. Replace the stator. Continue.

GV Generators Troubleshooting Voltage Issues
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2.3 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. Measure the resistance of the rotor winding by measuring across the slip rings
(c).
Is the correct resistance measured for your model?
This procedure continues on the next page.
Yes ____ No ____
Continue. The rotor winding has failed. Replace the rotor.
wc_gr004340
1000200
20
2
200m
FV
A
V- COM
GP 2500: 51–53
GP 3800: 47–49
GP 5600: 57–59
GP 6600: 59–61
c

Troubleshooting Voltage Issues GV Generators
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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?
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 now complete.
Reassemble the generator or, if the problem has not been resolved, continue with
the next topic.
Yes ____ No ____
The rotor winding has failed. Replace the rotor. The rotor winding is
OK.