GV 2500A GV 3800A GV 5600A GV 6600A

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

GV Generator Repair Foreword Machines covered by this manual Machine Item Number GV 2500A 0620286, 0620542 GV 3800A 0620287, 0620409, 0620334 GV 5600A 0620288, 0620410, 0620335 GV 6600A 0620289, 0620336 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 Corporation 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 maintain 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 Corporation 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 discharge of sparks or flames from the engine exhaust. Spark arresters are qualified wc_tx000771gb.fm 3

GV Generator Repair Trademarks 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: All trademarks referenced in this manual are the property of their respective owners. wc_tx000771gb.fm 4

GV Generators Table of Contents 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 wc_br0171887en_002toc.fm 5

Table of Contents GV Generators 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 wc_br0171887en_002toc.fm 6

GV Generators 1 Safety Information 1.1 Callouts Found in this Manual Safety Information 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. Obey 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. Obey 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 moderate injury. Obey all safety messages that follow this symbol to avoid possible minor or moderate injury. 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. wc_si000245gb.fm 7

Safety Information 1.2 Safety Guidelines for Operating the Machine GV Generators Operator training Guidelines for machine devices Guidelines for operation Guidelines for work space 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. 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 startup! 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 damage may result. 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. 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 generator. 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, noncombustible, 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. wc_si000245gb.fm 8

GV Generators Safety Information 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 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. Read and follow the warning instructions in the engine owner s manual and the safety guidelines below. Guidlines for running the engine NEVER use this generator inside a home or garage, EVEN IF doors and windows 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 starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose. wc_si000245gb.fm 9

Safety Information GV Generators 1.4 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 sign to the control panel to notify other people of its condition whenever the machine is being serviced. 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 manufacturer. wc_si000245gb.fm 10

GV Generators 1.5 Label Locations Safety Information wc_gr005497 wc_si000245gb.fm 11

Safety Information 1.6 Warning Labels GV Generators 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. wc_si000245gb.fm 12

GV Generators 1.7 Procedural Labels Safety Information 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 13

Safety Information GV Generators Turn the engine switch to OFF. Close the fuel flow valve. Electrical ground 1.8 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. 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. wc_si000245gb.fm 14

200m GV Generators 2 Troubleshooting Voltage Issues Prerequisites Generator must be able to start Multimeter Troubleshooting Voltage Issues Procedure To determine where to begin troubleshooting voltage issues, follow the procedure below. 1. Remove the end cap (a) from the generator. V F 1000 200 20 V 2 A V- COM wc_gr004336 WARNING! Electric shock hazard. High voltage exists at the alternator. Electric shock can cause severe injury or death. Never touch the alternator components or the wires of the generator when the engine is running. 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. If Then Between 100 140 VAC is measured in both Start with step 6. locations All other cases Start with step 1. Sequence Follow the sequence below when troubleshooting: 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 wc_tx000772gb.fm 15

200m Troubleshooting Voltage Issues GV Generators 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. + F 1000 200 20 V 2 V 9V A V- COM wc_gr004395 5. Start the engine. 6. Measure the AC voltage between the red and yellow wires at the terminal strip. Is 18 65 VAC measured? Yes No Your reading The AVR has failed, replace it. Continue troubleshooting by checking the stator windings. The procedure to test charge the generator is now complete. Disconnect the 9-Volt battery and continue troubleshooting. wc_tx000772gb.fm 16

GV Generators Troubleshooting Voltage Issues 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 alternator. 3. Measure the resistance in Ohms between the red and yellow wires. Also measure 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 0.4 0.9 GV 6600A 0.3 0.8 0.3 0.8 Is the correct resistance measured for your machine? Yes Continue. No The stator windings have failed. Replace the stator. This procedure continues on the next page. wc_tx000772gb.fm 17

Troubleshooting Voltage Issues Continued from the previous page. GV Generators 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 The stator windings have failed. Replace the stator. No Continue. 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. wc_tx000772gb.fm 18

200m GV Generators Troubleshooting Voltage Issues 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). GP 2500: 51 53 GP 3800: 47 49 GP 5600: 57 59 GP 6600: 59 61 F 1000 200 20 2 V c A V- COM wc_gr004340 Is the correct resistance measured for your model? Yes Continue. No The rotor winding has failed. Replace the rotor. This procedure continues on the next page. wc_tx000772gb.fm 19

Troubleshooting Voltage Issues Continued from the previous page. GV Generators 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 The rotor winding has failed. Replace the rotor. 5. Re-install the brushes do not overtighten the screws. 6. Re-install the end cap. No The rotor winding is OK. 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. wc_tx000772gb.fm 20

GV Generators Troubleshooting Voltage Issues 2.4 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. 3. Measure the length of the brush protruding from the brush holder. The minimum allowable length is 6.5 mm (0.25 in.). 6.5 mm 4. Measure the continuity of each brush. Does each brush measure at least 6.5 mm and have continuity? wc_gr004341 Yes No Your reading The brushes are OK The brushes have failed. Replace the brushes. 5. Re-install the brush holder do not overtighten the screw. 6. Re-install the end cap. The procedure to check the brushes is now complete. If the problem has not been resolved, continue with checking the excitation winding. wc_tx000772gb.fm 21

Troubleshooting Voltage Issues GV Generators 2.5 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). 3. Measure the resistance of the excitation winding by measuring across the two yellow (Y) wires of the connector. Is the correct resistance measured for your model? Yes No Your reading Continue. The excitation winding has failed. Replace the stator. This procedure continues on the next page. wc_tx000772gb.fm 22

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 The excitation winding has failed. Replace the stator. 5. Reconnect the wiring. 6. Re-install the end cap. No Continue. Result The procedure to check the excitation winding is now complete. Reassemble the generator or, if the problem has not been resolved, continue with the next topic. wc_tx000772gb.fm 23

Troubleshooting Voltage Issues GV Generators 2.6 Checking the AVR s Sensing Wires Prerequisites Generator shut down Multimeter Procedure Follow the procedure below to check the Automatic Voltage Regulator (AVR) sensing 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. 3. Disconnect the AVR at the wiring harness connector (b). 4. Check the continuity between the brown (Br) wire of the wiring harness connector (b) and the yellow wire (Y) of the generator. Does the wiring have continuity? Yes Continue. No The wiring has failed. Replace the stator. This procedure continues on the next page. wc_tx000772gb.fm 24

GV Generators Troubleshooting Voltage Issues Continued from the previous page. 5. Check the resistance between the brown (Br) wire of the wiring harness connector (b) and the ground stud (x). Is any resistance measured? Yes The sensing wire has failed. Replace the stator. 6. Disconnect the 6-wire connector (c). No Continue. 7. Check for continuity between the light green (LG) wire of the 6-wire connector and the black (B) wire of the generator. Does the wiring have continuity? Yes Continue. No The wiring has failed. Replace the stator. 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? Yes The sensing wire has failed. Replace the stator. No Continue. 9. Check for continuity between the red-white (R/W) wire of the 6-wire connector and the red (R) wire of the generator. Does the wiring have continuity? Yes Continue. No The wiring has failed. Replace the stator. This procedure continues on the next page. wc_tx000772gb.fm 25

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 Continue. No 12.Check the continuity of the gray (GR) wire between the 6-wire connector and the VSS. Does the wiring have continuity? Yes Continue. The wiring has failed. Repair the RW wire. No 13.Check the continuity of the light green (LG) wire between the 6-wire connector and the VSS. Does the wiring have continuity? Yes Continue. The wiring has failed. Repair the GR wire. No The wiring has failed. Repair the LG wire. 14.Disconnect the 4-wire plug from the automatic voltage regulator (AVR). 15.Check the continuity of the blue (L) wire from the 4-wire connector to the 6-wire connector. Does the wiring have continuity? Yes Continue. No The wiring has failed. Repair the L wire. 16.Reconnect the wiring and reassemble the generator. Result The procedure to check the AVR sensing wires is now complete. wc_tx000772gb.fm 26

GV Generators 2.7 Checking the Main Circuit Breaker Troubleshooting Voltage Issues Prerequisites Procedure Multimeter 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. Remove 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 position. 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 running. 5. Start the engine. This procedure continues on the next page. wc_tx000772gb.fm 27

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 The main circuit breaker is receiving voltage; continue. The main circuit breaker is not receiving voltage. Shut down the engine and check the wiring. 7. Place the main circuit breaker in the ON position. 8. Check the outgoing voltage from the main circuit breaker by measuring the voltage between the red wire and a common ground; then at the blue wire and a common ground. Is 110 130V measured in each case? Yes No Your reading The main circuit breaker is OK. The main circuit breaker has failed; replace it. The procedure to check the main circuit breaker is now complete. Reassemble the generator. wc_tx000772gb.fm 28

GV Generators 2.8 Checking the Voltage Selector Switch (VSS) Troubleshooting Voltage Issues Prerequisites Procedure Multimeter 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. Remove 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 the VSS for continuity as shown below. 1 2 3 4 5 6 7 8 Does the VSS function properly? Yes No Your reading The VSS is OK. The VSS has failed; replace it. 6. Reassemble the generator. The procedure to check the VSS is now complete. wc_tx000772gb.fm 29 9 10 11 12 Position 120V 120/240V 1 5 5 9 Terminals with 2 6 6 10 continuity 3 7 7 11 4 8 8 12 wc_gr004368

Troubleshooting Voltage Issues GV Generators 2.9 Checking the Auto Idle Unity and Circuity Prerequisites Procedure Multimeter 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. Measure the resistance across the two gray wires of the 6-pin connector. Is the correct resistance measured for your machine? Yes No Your reading Continue. The auxiliary winding has failed. Call Wacker Service. This procedure continues on the next page. wc_tx000772gb.fm 30

200m GV Generators Troubleshooting Voltage Issues Continued from the previous page. 4. Disconnect the DC rectifier (z). z F 1000 200 20 V 2 y V- COM A d 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. 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. Does the DC rectifier function as stated above? Yes No Your reading The DC rectifier is OK; continue. The DC rectifier has failed; replace it. This procedure continues on the next page. wc_tx000772gb.fm 31

Troubleshooting Voltage Issues Continued from the previous page. GV Generators 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. 8. Position the front half of the control panel to access the auto idle unit (c). This procedure continues on the next page. wc_tx000772gb.fm 32

200m GV Generators Continued from the previous page. Troubleshooting Voltage Issues 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 running. 9. Start the engine. 10.Measure the DC voltage between the black/red (B/R) wire at the connector and the white/black (W/B) wire of the auto idle unit. B/R W/B F 1000 200 20 V 2 A VDC V- COM VDC wc_gr004361 Is at least 9.8VDC measured? Yes No Your reading Continue. The wiring has failed. Check the continuity of the B/R wire and the continuity of the W/B wire. 11.Shut down the engine. This procedure continues on the next page. wc_tx000772gb.fm 33

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 Reconnect the auto idle switch and Replace the auto idle switch. continue. 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 running. 13.Start the engine. 14.Place the auto idle switch in the ON position. This procedure continues on the next page. wc_tx000772gb.fm 34

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. The wiring has failed. Shutdown engine and check the continuity of the B wire and the continuity of the W/B wire. 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? Yes No Your reading Continue. The auto idle unit has failed. Call Wacker Service. This procedure continues on the next page. wc_tx000772gb.fm 35

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 Continue. The auto idle unit has failed. Call Wacker Service. 18.Place the main breaker in the ON position. 19.Connect 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 measured? Yes No Your reading The auto idle circuit is OK. The auto idle unit has failed. Call Wacker Service. 21.Reassemble the generator. The procedure to check the auto idle circuitry is now complete. wc_tx000772gb.fm 36

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). 2. Remove 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 capacitor (c). 4. Remove the wiring from the capacitor. 5. Discharge the capacitor by placing a screwdriver across the two terminals. This procedure continues on the next page. wc_tx000772gb.fm 37

Troubleshooting Voltage Issues Continued from the previous page. 6. Measure the capacitance of the capacitor. GV Generators Does the capacitor measure approximately 4700 ±10% micro Farads? Yes No Your reading The capacitor is OK. The capacitor has failed; replace it. 7. Reassemble the generator. The procedure to check the AAS is now complete. wc_tx000772gb.fm 38

GV Generator Repair Disassembly and Assembly 3 Disassembly and Assembly 3.1 Tools Required for Disassembly/Assembly Procedures It is up to the mechanic to use common sense and good judgment in tool selection to reduce the risk of injury while repairing the machine. In cases where a special tool is required, the special tool is listed in the prerequisite section of the procedure. Before substituting another tool or procedure from those recommended in this manual, the mechanic must be satisfied that neither personal injury nor damage to the machine will result due to the substitution. 3.2 Information Regarding Replacement Parts The repair procedures contained in this manual do not include part numbers. For replacement parts information, refer to the Parts Book originally supplied with the machine. If the original Parts Book has been lost, a replacement may be ordered from Wacker Neuson Corporation. 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. 3.3 Information Regarding Reference Numbers ( ) Repair procedures contain reference numbers enclosed in parentheses ( ). These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings. They are included to aid the mechanic in identifying parts and assembling components. 3.4 Information Regarding Threadlocking Compounds Background Due to the heavy vibration inherent in this type of equipment, the repair and service procedures described in this manual specify the use of threadlocking compounds. These compounds should be used where indicated to prevent the fasteners from becoming loose. Recommended threadlockers Although Loctite is referred to throughout this manual, any equivalent type of sealant such as Hernon, Prolock, or Omnifit may be used. For a complete list of recommended sealing and locking compounds, refer to the Use of Threadlockers and Sealants chart at the end of this manual. Applying threadlockers Clean the screw threads and wipe off any oil or grease before applying a threadlocking compound. wc_tx000775gb.fm 39

Disassembly and Assembly 3.5 Removing the Muffler GV Generator Repair Prerequisites Procedure Engine cool 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). a 4. Remove the screw (g) that secures the generator mounting leg to the shock mount bracket. 5. Remove the screw (h) that secures the ground wire. 6. Remove the screw (i) that secures the muffler to the stator. 7. Remove the screws (b) that secure the muffler to the engine. This procedure continues on the next page. wc_tx000775gb.fm 40

GV Generator Repair Continued from the previous page. Disassembly and Assembly 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 41

Disassembly and Assembly 3.6 Installing the Muffler GV Generator Repair Prerequisites Procedure Engine cool 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. Install the screw (i) that secures the muffler to the stator. 4. Install the screw (g) that secures the generator mounting leg to the shock mount bracket. 5. Install the screw (h) that secures the ground wire. This procedure continues on the next page. wc_tx000775gb.fm 42

GV Generator Repair Continued from the previous page. Disassembly and Assembly 6. Remove the screws that secure the outer muffler guard and remove the outer muffler guard (a). a 7. Install the fuel tank. See section Installing the Fuel Tank. The procedure to install the muffler is now complete. wc_tx000775gb.fm 43

Disassembly and Assembly 3.7 Removing the Fuel Tank GV Generator Repair Prerequisites Procedure Machine shut down 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. a b 4. Remove the screws (b) that secure the tank 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 wc_gr004397 Prerequisites Procedure Machine shut down Follow the procedure below to install the fuel tank. 1. Install the brace to the fuel tank. 2. Position the fuel tank into the frame and secure it with screws (b). a b 3. Connect the fuel hose (a) to the fuel valve. wc_gr004397 The procedure to install the fuel tank is now complete. wc_tx000775gb.fm 44

GV Generator Repair 3.9 Removing the Stator Disassembly and Assembly Prerequisites Procedure Machine shut down Follow the procedure below to remove the stator. 1. Disconnect the spark plug. 2. Remove the end cover (a). d c e b wc_gr004398 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 holder (f). 5. Remove the screw (g) that secures the generator mounting leg to the shock mount bracket. 6. Remove the screw (h) that secures the ground wire. This procedure continues on the next page. wc_tx000775gb.fm 45

Disassembly and Assembly Continued from the previous page. GV Generator Repair 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. wc_tx000775gb.fm 46

GV Generator Repair 3.10 Installing the Stator Disassembly and Assembly Prerequisites Procedure Machine shut down 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. Install the screw (i) that secures the muffler guard to the stator. 4. Install the screw (h) that secures the ground wire. 5. Install the screw (g) that secures the generator mounting leg to the shock mount bracket. This procedure continues on the next page. wc_tx000775gb.fm 47

Disassembly and Assembly Continued from the previous page. GV Generator Repair 6. Install the brush holder (f). d c e b 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. Re-install the end cover (a). The procedure to install the stator is now complete. wc_tx000775gb.fm 48

GV Generator Repair 3.11 Removing the Rotor Disassembly and Assembly Prerequisites Procedure Oil filter wrench 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. 4. Support the rotor with one hand then strike the rotor with a rubber hammer repeatedly while rotating the rotor until it comes free of the engine shaft. NOTICE: Do not strike the winding wires or the magnet (c). Damage to the rotor may occur. 5. Remove the long bolt and the rotor from the engine. The procedure to remove the rotor is now complete. wc_tx000775gb.fm 49

Disassembly and Assembly 3.12 Installing the Rotor GV Generator Repair Prerequisites Procedure Oil filter wrench 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. The procedure to install the rotor is now complete. wc_tx000775gb.fm 50

GV Generator Repair 3.13 Removing the Engine Disassembly and Assembly Prerequisites Procedure Engine cool 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. 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 Removing the Stator. 6. Remove the rotor. See section Removing the Rotor. 7. Remove the screws (a) that secure the engine to the shock mounts. 8. Pull the engine from the frame. The procedure to remove the engine is now complete. wc_tx000775gb.fm 51

Disassembly and Assembly 3.14 Installing the Engine GV Generator Repair Prerequisites Procedure Engine cool 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. Install the stator. See section Installing the Stator. 4. Install the muffler. See section Installing the Muffler. 5. Install the fuel tank. See section Installing the Fuel Tank. 6. Connect the wiring between the engine and the control panel. The procedure to install the engine is now complete. wc_tx000775gb.fm 52

GV Generator Repair Notes Disassembly and Assembly wc_tx000775gb.fm 53

Schematics 4 Schematics 4.1 Electrical Schematic GV 2500A GV Generator Repair A 3 1 14 4 2 12 B C 5 13 11 6 7 9 10 8 wc_tx000813gb.fm 54

GV Generator Repair 4.2 Electrical Components GV 2500A Schematics Ref. Description Ref. Description Ref. Description A Generator B Control Box C Engine Ref. Description Ref. Description 1 Main stator winding 8 Engine 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 receptacle 125V 13 Spark plug 7 Duplex receptacle 125V 14 Slip ring Wire Colors B Black V Violet Or Orange G Green W White Pr Purple L Blue Y Yellow Sh Shield P Pink Br Brown LL Light Blue R Red Cl Clear G/Y Green/Yellow T Tan Gr Gray wc_tx000813gb.fm 55

Schematics 4.3 Electrical Schematic GV 3800A GV Generator Repair 3 A B 1 14 2 22 23 4 12 15 16 13 C 18 11 5 10 21 17 9 20 8 6 6 19 wc_tx000813gb.fm 56

GV Generator Repair 4.4 Electrical Components GV 3800A Schematics Ref. Description Ref. Description Ref. Description A Generator B Control Box C Engine Ref. Description Ref. Description 1 Main stator winding 13 Spark plug 2 Secondary winding 14 Slip ring 3 Rotor winding 15 Auto idle unit 4 Automatic 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 Capacitor 9 Oil alert module 21 Fuel stop solenoid 10 Oil level switch 22 Auxiliary winding 11 Ignition coil 23 DC rectifier 12 Ground terminal - --- Wire Colors B Black V Violet Or Orange G Green W White Pr Purple L Blue Y Yellow Sh Shield P Pink Br Brown LL Light Blue R Red Cl Clear G/Y Green/Yellow T Tan Gr Gray wc_tx000813gb.fm 57

Schematics 4.5 Electrical Schematic GV 5600A, GV 6600A GV Generator Repair 3 A B 1 14 2 22 23 4 12 15 16 C 13 18 11 5 10 21 17 24 20 9 6 8 6 19 wc_tx000813gb.fm 58

GV Generator Repair 4.6 Electrical Components GV 5600A, GV 6600A Schematics Ref. Description Ref. Description Ref. Description A Generator B Control Box C Engine Ref. Description Ref. Description 1 Main stator winding 13 Spark plug 2 Secondary winding 14 Slip ring 3 Rotor winding 15 Auto idle unit 4 Automatic voltage 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 9 Oil alert module 21 Fuel stop solenoid 10 Oil level switch 22 Auxiliary winding 11 Ignition coil 23 DC rectifier 12 Ground terminal 24 Twist lock receptacle 125V Wire Colors B Black V Violet Or Orange G Green W White Pr Purple L Blue Y Yellow Sh Shield P Pink Br Brown LL Light Blue R Red Cl Clear G/Y Green/Yellow T Tan Gr Gray wc_tx000813gb.fm 59

Technical Data 5 Technical Data 5.1 Generator GV 2500A GV Generators Item No. Generator GV 2500A 0620286 0620542 Maximum output W 2500 Continuous output W 2250 Type AC voltages available Volts phase Single phase, self-exciting, 2-pole, field rotating Frequency Hz 60 120 1 Power factor cos ø 1.0 AC receptacles: 125V GFI duplex 125V duplex Amp Amp Main circuit breaker Amp 20 L x W x H mm (in.) 625 x 440 x 490 (24.5 x 17.2 x 19.3) Weight (dry) kg (lbs.) 45 (99.2) 20 20 wc_td000248gb.fm 60

GV Generators Technical Data 5.2 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 Engine model Maximum rated power at rated speed Spark plug kw (Hp) Honda GX 160 K1 3.6 (4.8) @ 3600 rpm BPR6ES (NKG) Electrode gap mm (in.) 0.7 0.8 (0.028 0.031) Operating speed rpm 3600 Air cleaner type Oil-wetted foam EnginelLubrication oil grade SAE 10W30 service class SF or SG Engine oil capacity l (qts.) 0.6 (0.7) Fuel type Regular unleaded gasoline Fuel tank capacity l (gal.) 14 (3.7) Fuel consumption l (qts.)/hr. 1.5 (1.6) Running time - continuous load hrs. 9.7 wc_td000248gb.fm 61

Technical Data 5.3 Generator GV 3800A GV Generators Item No. Generator GV 3800A 0620287 Maximum output W 3800 Continuous output W 3400 Type AC voltages available Volts phase Single phase, self-exciting, 2-pole, field rotating 120/240 1 Frequency Hz 60 Power factor cos ø 1.0 AC receptacles: 125V GFI duplex (2) 125/250V twist lock Amp Amp Main circuit breaker Amp 16 per pole (two pole) L x W x H mm (in.) 710 x 550 x 515 (28.0 x 21.6 x 20.3) Weight (dry) kg (lbs.) 65 (143.3) 20 20 wc_td000248gb.fm 62

GV Generators Technical Data 5.4 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 Engine model Maximum rated power at operating speed Spark plug kw (Hp) Honda GX 240 K1 5.3 (7.1) @ 3600 rpm 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 lubrication oil grade SAE 10W30 service class SF or SG Engine oil capacity l (qts.) 1.1 (1.2) Fuel type Regular unleaded gasoline Fuel tank capacity l (gal.) 21 (5.5) Fuel consumption l (qts.)/hr. 2.4 (2.5) Running time - continuous load hrs. 8.8 wc_td000248gb.fm 63

Technical Data 5.5 Generator GV 5600A GV Generators Item No. Generator GV 5600A 0620288 0620335 0620410 Maximum output W 5600 Continuous output W 5000 Type AC voltages available Volts phase Single phase, self-exciting, 2-pole, field rotating 120/240 1 Frequency Hz 60 Power factor cos ø 1.0 AC receptacles: 125V GFI duplex (2) 125V twist lock 125/250V twist lock Amp Amp Amp Main circuit breaker Amp 15 per pole (two pole) L x W x H mm (in.) 710 x 550 x 515 (28.0 x 21.6 x 20.3) Weight (dry) kg (lbs.) 78 (172) 20 30 30 wc_td000248gb.fm 64

GV Generators Technical Data 5.6 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 Engine model Maximum rated power at rated speed Spark plug kw (Hp) Honda GX 340 K1 7.1 (9.5) @ 3600 rpm 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 lubrication oil grade SAE 10W30 service class SF or SG Engine oil capacity l (qts.) 1.1 (1.2) Fuel type Regular unleaded gasoline Fuel tank capacity l (gal.) 21 (5.5) Fuel consumption l (qts.)/hr. 3.5 (3.7) Running time - continuous load hrs. 6.2 wc_td000248gb.fm 65

Technical Data 5.7 Generator GV 6600A GV Generators Item No. Generator GV 6600A 0620289 Maximum output W 6600 Continuous output W 6000 Type AC voltages available Volts phase Single phase, self-exciting, 2-pole, field rotating 120/240 1 Frequency Hz 60 Power factor cos ø 1.0 AC receptacles: 125V GFI duplex (2) 125/250V twist lock 125V twist lock Amp Amp Amp Main circuit breaker Amp 15 per pole (two pole) L x W x H mm (in.) 710 x 550 x 515 (28.0 x 21.6 x 20.3) Weight (dry) kg (lbs.) 80 (176.4) 20 30 30 wc_td000248gb.fm 66

GV Generators Technical Data Item No. Generator GV 6600A 0620336 Maximum output W 6600 Continuous output W 6000 Type AC voltages available Volts phase Single phase, self-exciting, 2-pole, field rotating 120/240 1 Frequency Hz 60 Power factor cos ø 1.0 AC receptacles: 125V GFI duplex (2) 125/250V twist lock 125V twist lock Amp Amp Amp Main circuit breaker Amp 15 per pole (two pole) L x W x H mm (in.) 710 x 550 x 515 (28.0 x 21.6 x 20.3) Weight (dry) kg (lbs.) 80 (176.4) 20 30 30 wc_td000248gb.fm 67

Technical Data GV Generators 5.8 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 Engine model Max. rated power @ rated speed Spark plug kw (Hp) Honda GX 390 K1 8.2 (11.0) @ 3600 rpm 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 lubrication oil grade SAE 10W30 service class SF or SG Engine oil capacity l (qts.) 1.1 (1.2) Fuel type Regular unleaded gasoline Fuel tank capacity l (gal.) 26 (6.8) Fuel consumption l (qts.)/hr. 3.9 (4.1) Running time - continuous load hrs. 6.7 wc_td000248gb.fm 68

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 Engine model Max. rated power @ rated speed Spark plug kw (Hp) Honda GX 390 R1 9.7 (13) @ 3600 rpm 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 lubrication oil grade SAE 10W30 service class SF or SG Engine oil capacity l (qts.) 1.1 (1.2) Fuel type Regular unleaded gasoline Fuel tank capacity l (gal.) 21 (5.5) Fuel consumption l (qts.)/hr. 3.9 (4.1) Running time - continuous load hrs. 5.4 wc_td000248gb.fm 69