Wacker Neuson GP 3800A Repair Manual
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Wacker Neuson GP 3800A Repair Manual

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REPAIR MANUAL
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0160415en
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Generator
GP 2500A
GP 3800A
GP 5600A
GPS 5600A
GP 6600A
GPS 6600A
001

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  • Page 1 0160415en 0806 Generator GP 2500A GP 3800A GP 5600A GPS 5600A GP 6600A GPS 6600A REPAIR MANUAL...
  • Page 3 GP Repair Foreword This manual covers machines with Item Number: 0620009, 0620010, 0620011, 0620012, 0620013, 0620014, 0620015, 0620016, 0620041, 0620042, 0620043, 0620044, 0620045, 0620046, 0620047 Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair it.
  • Page 4 Foreword GP Repair 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 WARNING 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.

  • Page 5: Table Of Contents

    Safety and Operating Labels .............. 10 Technical Data Generator—GP 2500A ............... 14 Engine—GP 2500A ................15 Generator—GP 3800A, GP 3800A CAN ..........16 Engine—GP 3800A, GP 3800A CAN ..........17 Generator—GP/GPS 5600A/5600A CAN .......... 18 Engine—GP/GPS 5600A/5600A CAN ..........20 Generator—GP/GPS 6600A/6600A CAN ..........
  • Page 6 Electrical Schematic—GP 3800A (0620010 rev. > 103) .....50 4.16 Components—GP 3800A (0620010 rev. > 103) .........51 4.17 Electrical Schematic—GP 3800A CAN (0620041 rev. < 104) .....52 4.18 Components—GP 3800A CAN (0620041 rev. < 104) ......53 4.19 Electrical Schematic—GP 3800A CAN (0620041 rev. > 103) .....54 4.20...
  • Page 7 GP Repair Table of Contents Troubleshooting Troubleshooting Methodology ............72 Checking Continuity ................74 Checking Resistance ................74 Checking Voltage ................74 Troubleshooting Flowcharts ............... 75 No Voltage at Receptacles—Flowchart 1A ........76 No Voltage at Receptacles—Flowchart 1B ........77 Checking Voltage at Generator Terminal Strip ........

  • Page 8: Safety Information

    Safety Information GP Repair Safety Information This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

  • Page 9: Operating Safety

    GP Repair Safety Information Operating Safety BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS! DANGER 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.
  • Page 10 Safety Information GP Repair 1.1.12 ALWAYS store the equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children. 1.1.13 ALWAYS position operate generator firm, noncombustible, level surface. 1.1.14 ALWAYS transport the generator in an upright position.

  • Page 11: Operator Safety While Using Internal Combustion Engines

    GP Repair Safety Information Operator Safety while using Internal Combustion Engines Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the warnings and safety guidelines could result in severe injury or death.

  • Page 12: Service Safety

    Safety Information GP Repair Service Safety Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. If the generator is experiencing problems or is being serviced, attach a WARNING “DO NOT START”...

  • Page 13: Label Locations

    GP Repair Safety Information Label Locations wc_si000169gb.fm...

  • Page 14: Safety And Operating Labels

    Safety Information GP Repair Safety and Operating Labels Wacker machines use international pictorial labels where needed. These labels are described below: Label Meaning WARNING! Hot surface! CAUTION! Read and understand the supplied Operator’s Manuals before operating this machine. Fail- ure to do so increases the risk of injury to your- self or others.
  • Page 15 GP Repair Safety Information Label Meaning Close main circuit breaker. Check the fuel level. Open the fuel flow valve. Press engine switch to ON position. GPS — Press ignition switch. GP — Pull the rewind starter. Open main circuit breaker. Press engine switch to OFF position.
  • Page 16 Safety Information GP Repair Label Meaning Close the fuel flow valve. DANGER! Asphyxiation hazard. Read the operator’s manual for instructions. Use in a well-ventilated area. Do not use indoors or near open windows. Fumes can cause death. WARNING! To reduce the risk of electrical shock, read the operator’s manual.
  • Page 17 GP Repair Safety Information Label Meaning This machine may be covered by one or more patents. DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling. wc_si000169gb.fm...

  • Page 18: Technical Data

    Technical Data GP Repair Technical Data Generator—GP 2500A Item No. GP 2500A 0620009 Generator Maximum Output 2500 Continuous Output 2250 Type Single voltage, single phase, Auto voltage regulator system AC Voltages Available volts phase 1ø Frequency Power Factor AC receptacles: 125V GFI duplex 125V duplex Main Circuit Breaker...

  • Page 19: Engine-Gp 2500A

    GP Repair Technical Data Engine—GP 2500A Item No. GP 2500A 0620009 Engine Engine Make Honda Engine Model GX 160 K1VX Rated Power 4.1 (5.5) kW (Hp) Spark Plug BPR6ES / W20EPR-U Electrode Gap 0.7–0.8 (0.028–0.031) mm (in.) Operating Speed (Max.) 3600 Air Cleaner type...

  • Page 20: Generator-Gp 3800A, Gp 3800A Can

    Technical Data GP Repair Generator—GP 3800A, GP 3800A CAN Item No. GP 3800A GP 3800A CAN 0620010 0620041 Generator Maximum Output 3800 Continuous Output 3400 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages Available 120 / 240...

  • Page 21: Engine-Gp 3800A, Gp 3800A Can

    GP Repair Technical Data Engine—GP 3800A, GP 3800A CAN Item No. GP 3800A GP 3800A CAN 0620010 0620041 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 240 Rated Power 6 (8) kW (Hp)

  • Page 22: Generator-Gp/Gps 5600A/5600A Can

    Technical Data GP Repair Generator—GP/GPS 5600A/5600A CAN Item No. GP 5600A GP 5600A GPS 5600A 0620011 0620012 0620013 Generator Maximum Output 5600 Continuous Output 5000 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages 120 / 240 volts phase Available 1ø...
  • Page 23 GP Repair Technical Data Item No. GP 5600A CAN GP 5600A CAN GPS 5600A CAN 0620042 0620043 0620044 Generator Maximum Output 5600 Continuous Output 5000 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages 120 / 240 volts phase Available 1ø...

  • Page 24: Engine-Gp/Gps 5600A/5600A Can

    Technical Data GP Repair Engine—GP/GPS 5600A/5600A CAN Item No. GP 5600A GP 5600A GPS 5600A GPS 5600A 0620011 0620042 0620013 0620044 0620012 0620043 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 340 K1 Rated Power 8.2 (11) kW (Hp)
  • Page 25 GP Repair Technical Data Notes wc_td000169gb.fm...

  • Page 26: Generator-Gp/Gps 6600A/6600A Can

    Technical Data GP Repair Generator—GP/GPS 6600A/6600A CAN Item No. GP 6600A GP 6600A GPS 6600A 0620014 0620015 0620016 Generator Maximum Output 6600 Continuous Output 6000 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages 120 / 240 volts phase available 1ø...
  • Page 27 GP Repair Technical Data Item No. GP 6600A CAN GP 6600A CAN GPS 6600A CAN 0620045 0620046 0620047 Generator Maximum Output 6600 Continuous Output 5500 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages 120 / 240 volts phase available 1ø...

  • Page 28: Engine-Gp/Gps 6600A/6600A Can

    Technical Data GP Repair Engine—GP/GPS 6600A/6600A CAN Item No. GP 6600A GP 6600A GPS 6600A GPS 6600A 0620014 0620045 0620016 0620047 0620015 0620046 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 390 Rated Power 9.7 (13) kW (Hp) Spark Plug...

  • Page 29: Operation

    GP Repair Operation Operation Information Regarding Operation The information regarding the operation of the machine included in this manual is condensed. Refer to the Operator’s Manual for complete operating instructions. Always read, understand, and follow the procedures in the Operator’s Manual when operating the machine. Determining Power Requirements This generator is designed to operate single-phase, 60 Hz appliances running at 120 VAC or 240 VAC.
  • Page 30 Operation GP Repair If the wattage is not given for a particular tool or appliance, it can be calculated by multiplying its voltage and amperage requirements: Single Phase: VOLTS x AMPS = WATTS Three Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS wc_tx000545gb.fm...

  • Page 31: Outdoor Installation

    GP Repair Operation Outdoor Installation Place the generator in an area where it will not be exposed to rain, snow, or direct sunlight. Make sure it is positioned on firm, level ground, so it will not slide or shift. Position the engine exhaust away from areas where people may be present.

  • Page 32: Generator Derating

    Operation GP Repair Generator Derating All generators are subject to derating for altitude and temperature. Internal combustion engines, unless modified, run less efficiently at higher altitudes due to the reduction of air pressure. This translates into a lack of power and thus reduction in generator output. Temperature affects both engine and generator performance.

  • Page 33: Grounding The Generator

    GP Repair Operation Grounding the Generator See Graphic: wc_gr000544 A ground connection (a) is located on the generator frame. For proper operating safety, this ground terminal must be connected to a good ground source. This ground connection must comply with National Electrical Code standards, and state and local regulations.

  • Page 34: Control Panel

    Operation GP Repair Control Panel See Graphic: wc_gr002324 Ref. Description Ref. Description GFI duplex receptacle—120V GFI test button Circuit breaker—20 Amp. GFI reset button Duplex receptacle—120V wc_tx000545gb.fm...

  • Page 35: Control Panel-Gp 3800

    GP Repair Operation Control Panel—GP 3800 See Graphic: wc_gr002327 Ref. Description Ref. Description Engine switch GFI test button Auto idle switch GFI reset button Twist-lock receptacle—120V Twist-lock receptacle—120/240V Main circuit breaker 20A circuit breaker (CAN only) Voltage Selector Switch (VSS) 30A circuit breaker (CAN only) GFI duplex receptacle—120V wc_tx000545gb.fm...

  • Page 36: Control Panel-Gp 5600/Gp6600

    Operation GP Repair 3.10 Control Panel—GP 5600/GP6600 See Graphic: wc_gr002498 Ref. Description Ref. Description Engine Switch GFI test button Auto Idle Switch GFI reset button Twist-lock receptacle - 120V Twist-lock receptacle - 120/240V Main Circuit Breaker Ignition Switch (GPS only) Voltage Selector Switch 20A circuit breaker (CAN only) GFI Duplex receptacle - 120V...

  • Page 37: Ground Fault Interrupt (Gfi)

    GP Repair Operation 3.11 Ground Fault Interrupt (GFI) See Graphic: wc_gr002498 The two receptacles (f) are protected by a ground fault circuit interrupt (GFI). The GFI shuts off the power to the receptacle when a ground fault occurs in the generator or to a piece of equipment attached to the generator.

  • Page 38: Engine Auto Idle

    Operation GP Repair 3.13 Engine Auto Idle See Graphic: wc_gr002498 The auto idle switch (b) automatically reduces engine speed approximately 7 seconds after all appliances or tools attached to the generator have been turned off. The engine automatically returns to full speed when a tool or appliance is turned back on.

  • Page 39: Voltage Selection

    GP Repair Operation 3.15 Voltage Selection See Graphic: wc_gr002497 The voltage selector switch (e) allows the generator to operate in either single (120V) or dual voltage (120/240V) mode. In single-voltage mode, use only the 120V twist-lock (c) and duplex receptacles (f1, f2). The full rated power of the generator is shared between the three receptacles.

  • Page 40: To Start

    Operation GP Repair 3.16 To Start See Graphic: wc_gr002500 Before starting, be sure you read and understand all the safety and operating instructions in this manual. 3.16.1 Disconnect all loads from the generator and place the main circuit breaker switch in the OFF position (a2). 3.16.2 Set the auto idle switch to “OFF”...

  • Page 41: To Stop

    GP Repair Operation 3.17 To Stop See Graphic: wc_gr002500 3.17.1 Turn off and disconnect all tools and appliances attached to the generator. 3.17.2 Place the main circuit breaker in the OFF position (a2). 3.17.3 Turn the engine switch to “OFF” (b2). 3.17.4 Close the fuel valve (d2).

  • Page 42: Maintenance

    Maintenance GP Repair Maintenance Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to engine manufacturer’s Operator’s Manual for additional information on engine maintenance. Periodic Maintenance Schedule Daily After Every Every Every before first starting 20 hrs. hrs.

  • Page 43: Engine Oil

    GP Repair Maintenance Engine Oil See Graphic: wc_gr000022 4.3.1 Drain the oil while the engine is still warm. 4.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off.

  • Page 44: Servicing Air Cleaner

    Maintenance GP Repair Servicing Air Cleaner See Graphic: wc_gr002815 Service the air cleaner frequently to prevent carburetor malfunction. CAUTION: NEVER run the engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner.

  • Page 45: Spark Plug

    GP Repair Maintenance Spark Plug See Graphic: wc_gr000028 Clean or replace the spark plug as needed to ensure proper operation. Refer to the engine owner’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. WARNING Note: Refer to the Technical Data for the recommended spark plug type and the electrode gap setting.

  • Page 46: Cleaning The Sediment Cup

    Maintenance GP Repair Cleaning the Sediment Cup See Graphic: wc_gr000029 4.6.1 Turn the fuel valve off. 4.6.2 Remove the sediment cup (a) and the O-ring (b). 4.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 4.6.4 Turn the fuel valve on and check for leaks. Carburetor Adjustment See Graphic: wc_gr000032 4.7.1...

  • Page 47: Adjusting Engine Speed

    GP Repair Maintenance Adjusting Engine Speed See Graphic: wc_gr000032 Generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constant speed. There is no throttle control.

  • Page 48: Storage

    Maintenance GP Repair Storage Before storing the generator for a long period of time: 4.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 4.9.2 Disconnect the fuel line from the carburetor. Place open end of fuel line into a suitable container and open fuel valve to drain fuel from tank.

  • Page 49: Transport

    GP Repair Maintenance 4.10 Transport Let the engine cool before transporting the generator or storing indoors, to avoid burns or fire hazards. WARNING When transporting the generator: 4.10.1 Turn the engine fuel valve to the OFF position. 4.10.2 Position the generator level to prevent fuel from spilling. 4.10.3 Secure the generator by tying it down with a suitable rope.

  • Page 50: Electrical Schematic-Gp 2500A

    Maintenance GP Repair 4.11 Electrical Schematic—GP 2500A wc_tx000546gb.fm...

  • Page 51: Components-Gp 2500A

    GP Repair Maintenance 4.12 Components—GP 2500A Ref. Description Ref. Description Ref. Description Generator Control Box Engine Ref. Description Ref. Description Main stator winding Duplex receptacle—120V Secondary winding Ignition switch Rotor winding Oil alert module Automatic voltage regulator Oil level switch 20A circuit breaker Coil GFI duplex receptacle—120V...

  • Page 52: Electrical Schematic-Gp 3800A (0620010 Rev. < 104)

    Maintenance GP Repair 4.13 Electrical Schematic—GP 3800A (0620010 rev. < 104) wc_tx000546gb.fm...

  • Page 53: Components-Gp 3800A (0620010 Rev. < 104)

    GP Repair Maintenance 4.14 Components—GP 3800A (0620010 rev. < 104) Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Main stator winding 1 Capacitor Main stator winding 2 Engine ON / OFF switch Auto idle unit...

  • Page 54: Electrical Schematic-Gp 3800A (0620010 Rev. > 103)

    Maintenance GP Repair 4.15 Electrical Schematic—GP 3800A (0620010 rev. > 103) wc_tx000546gb.fm...

  • Page 55: Components-Gp 3800A (0620010 Rev. > 103)

    GP Repair Maintenance 4.16 Components—GP 3800A (0620010 rev. > 103) Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Main stator winding 1 Engine ON / OFF switch Main stator winding 2 Rectifier Auto idle unit...

  • Page 56: Electrical Schematic-Gp 3800A Can (0620041 Rev. < 104)

    Maintenance GP Repair 4.17 Electrical Schematic—GP 3800A CAN (0620041 rev. < 104) wc_tx000546gb.fm...

  • Page 57: Components-Gp 3800A Can (0620041 Rev. < 104)

    GP Repair Maintenance 4.18 Components—GP 3800A CAN (0620041 rev. < 104) Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Main stator winding 1 Engine ON / OFF switch Main stator winding 2 Rectifier...

  • Page 58: Electrical Schematic-Gp 3800A Can (0620041 Rev. > 103)

    Maintenance GP Repair 4.19 Electrical Schematic—GP 3800A CAN (0620041 rev. > 103) wc_tx000546gb.fm...

  • Page 59: Components-Gp 3800A Can (0620041 Rev. > 103)

    GP Repair Maintenance 4.20 Components—GP 3800A CAN (0620041 rev. > 103) Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Main stator winding 1 Rectifier Main stator winding 2 Rotor winding/brushes Auto idle unit...

  • Page 60: Electrical Schematic-Gp/Gps 5600A/6600A (Rev. < 104)

    Maintenance GP Repair 4.21 Electrical Schematic—GP/GPS 5600A/6600A (rev. < 104) wc_tx000546gb.fm...

  • Page 61: Components-Gp/Gps 5600A/6600A (Rev. < 104)

    GP Repair Maintenance 4.22 Components—GP/GPS 5600A/6600A (rev. < 104) Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Main stator winding 1 Capacitor Main stator winding 2 Engine ON / OFF switch Auto idle unit Rectifier Main circuit breaker Rotor winding/brushes...

  • Page 62: Electrical Schematic-Gp/Gps 5600A/6600A (Rev. > 103)

    Maintenance GP Repair 4.23 Electrical Schematic—GP/GPS 5600A/6600A (rev. > 103) wc_tx000546gb.fm...

  • Page 63: Components-Gp/Gps 5600A/6600A (Rev. > 103)

    GP Repair Maintenance 4.24 Components—GP/GPS 5600A/6600A (rev. > 103) Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Main stator winding 1 Engine ON / OFF switch Main stator winding 2 Rectifier Auto idle unit Rotor winding/brushes Main circuit breaker Secondary (excitation) winding...

  • Page 64: Electrical Schematic (Can)-Gp/Gps 5600A/6600A (Rev. < 104)

    Maintenance GP Repair 4.25 Electrical Schematic (CAN)—GP/GPS 5600A/6600A (rev. < 104) wc_tx000546gb.fm...

  • Page 65: Components (Can)-Gp/Gps 5600A/6600A (Rev. < 104)

    GP Repair Maintenance 4.26 Components (CAN)—GP/GPS 5600A/6600A (rev. < 104) Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Main stator winding 1 Engine ON / OFF switch Main stator winding 2 Rectifier Auto idle unit Rotor winding/brushes Main circuit breaker Secondary (excitation) winding...

  • Page 66: Electrical Schematic (Can)-Gp/Gps 5600A/6600A (Rev. >103)

    Maintenance GP Repair 4.27 Electrical Schematic (CAN)—GP/GPS 5600A/6600A (rev. >103) wc_tx000546gb.fm...

  • Page 67: Components (Can)-Gp/Gps 5600A/6600A (Rev. > 103)

    GP Repair Maintenance 4.28 Components (CAN)—GP/GPS 5600A/6600A (rev. > 103) Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Main stator winding 1 Rectifier Main stator winding 2 Rotor winding/brushes Auto idle unit Secondary (excitation) winding Main circuit breaker DC winding Voltage selector switch...

  • Page 68: Engine Schematic (All)-Gp/Gps 3800A/5600A/6600A

    Maintenance GP Repair 4.29 Engine Schematic (all)—GP/GPS 3800A/5600A/6600A wc_tx000546gb.fm...

  • Page 69: Engine Components (All)-Gp/Gps 3800A/5600A/6600A

    GP Repair Maintenance 4.30 Engine Components (all)—GP/GPS 3800A/5600A/6600A Ref. Description Ref. Description Generator Engine Control box Electric start engines Ref. Description Ref. Description Idle solenoid Solenoid (GPS only) Fuel cut solenoid Starter (GPS only) Oil alert module Charging coil (GPS only) Oil level switch Battery (GPS only) Coil...
  • Page 70 Maintenance GP Repair Notes wc_tx000546gb.fm...

  • Page 71: Theory Of Operation

    GP Repair Theory of Operation Theory of Operation Introduction A generator set is a transducer, which means it converts energy from one form of (heat) into another (electrical). The two main components of a generator set are the prime mover (engine) and the generator assembly.

  • Page 72: Windings And Fields

    Theory of Operation GP Repair Windings and Fields See Graphic: wc_gr003117 In Wacker GP generators there are multiple coil (winding) and magnetic field pairs. Each combination has its own function. In all Model GP 2500 there are three pairs and in Models GP 3800, GP 5600, and GP 6600 there are four.

  • Page 73: Voltage Regulation

    GP Repair Theory of Operation wc_gr003117 Voltage Regulation See Graphic: wc_gr003117 The Automatic Voltage Regulator (AVR) (c) is an encapsulated, electronic control device that is rectangular in shape and located inside the end cover of the generator. Its function is to maintain constant generator voltage over varying load conditions.

  • Page 74: Auto Idle Circuit

    Theory of Operation GP Repair Auto Idle Circuit See Graphic: wc_gr003120 The auto idle circuit consists of the DC winding (a), the rectifier (b), the 5A fuse (c), the auto idle unit (d), main output wires (which serve as sensing wires for the auto idle circuit) (e), and the idle solenoid (f). AC voltage induced in the DC winding is sent to the rectifier where it is rectified to DC.

  • Page 75: Anti-Afterfire Circuit

    GP Repair Theory of Operation Anti-Afterfire Circuit See Graphic: wc_gr003121 The anti-afterfire circuit consists of the DC winding (a), the rectifier (b), one half of the engine ON/OFF switch (c) (shown as a simple switch for this discussion), the 5A fuse (d), the anti-afterfire solenoid (AAS) (e), and the 1000 microfarad capacitor (f).

  • Page 76: Troubleshooting

    Troubleshooting GP Repair Troubleshooting Troubleshooting Methodology See Graphic: wc_gr003415 If a generator problem is not an obvious engine or wire fault, the cause of the problem will be associated with one of two things: a malfunctioning generator or faults in the circuit supplying voltage to the receptacles.
  • Page 77 GP Repair Troubleshooting wc_tx000548gb.fm...

  • Page 78: Checking Continuity

    Troubleshooting GP Repair Checking Continuity Conduct continuity tests when the engine is shut down. When checking continuity, use the Ohm setting on your multimeter. Place a lead of the multimeter on one end of the wiring or component and the other lead on the opposite end. If your meter reads “OL” or “OPEN”, there is no continuity and the wiring or component must be repaired or replaced.

  • Page 79: Troubleshooting Flowcharts

    GP Repair Troubleshooting Troubleshooting Flowcharts The troubleshooting flowcharts are designed to take you through the process of determining the source of a problem with engine starting or machine operation. Many of the tests involve live voltages and therefore should only be attempted by qualified personnel. Detailed procedures for carrying out the tests are included in this manual.

  • Page 80: No Voltage At Receptacles-Flowchart 1A

    Troubleshooting GP Repair No Voltage at Receptacles—Flowchart 1A No Voltage at Receptacles Is circuit Close circuit breaker(s). breaker(s) in closed position? Reset GFI. receptacle GFI set correctly? (GP 2500A only) Checking voltage at generator terminal strip Checking voltage at generator plug Check voltage at back of generator Check voltage at back of generator between terminals R &...

  • Page 81: No Voltage At Receptacles-Flowchart 1B

    GP Repair Troubleshooting No Voltage at Receptacles—Flowchart 1B Checking main and rotor windings Measure the resistance values of the main windings by measuring across R & Y (main 2); B & G (main 1). For GP 2500A models, measure between R &W for (main 2);...

  • Page 82: Checking Voltage At Generator Terminal Strip

    Troubleshooting GP Repair Checking Voltage at Generator Terminal Strip See Graphic: wc_gr003122 Electric shock hazard. Only qualified personnel should conduct this test. WARNING By starting the troubleshooting procedures at the generator output terminal strip you can determine whether the problem lies within the generator or the circuit supplying the receptacles.

  • Page 83: Checking Voltage At Plug-Gp 2500A

    GP Repair Troubleshooting Checking Voltage at Plug—GP 2500A See Graphic: wc_gr003146 Electric shock hazard. Only qualified personnel should conduct this test. WARNING By starting the troubleshooting procedures at the generator output plug (d), you can determine whether the problem lies within the generator or the circuit supplying the receptacles.

  • Page 84: Checking Main And Rotor Windings

    Troubleshooting GP Repair 6.10 Checking Main and Rotor Windings See Graphic: wc_gr003123 To check the resistance of the windings, carry out the following procedures: 6.10.1 Stop the engine. 6.10.2 Remove the two screws which secure the end cover to the generator and remove the end cover.
  • Page 85 GP Repair Troubleshooting GP 2500..47.5 GP 3800..47.0 GP 5600..60.5 1000 GP 6600..64.8 200m GP 2500..0.9 GP 3800..0.7 1000 GP 5600..0.4 200m GP 6600..0.3 wc_gr003123 wc_tx000548gb.fm...

  • Page 86: No Voltage At Receptacles-Flowchart 1C

    Troubleshooting GP Repair 6.11 No Voltage at Receptacles—Flowchart 1C Checking main circuit breaker Check voltage to main circuit breaker. Check wiring to generator terminal strip. correct voltage Repair or replace measured? wiring as needed. Check outgoing voltage from main circuit breaker. Replace the main correct voltage circuit breaker.
  • Page 87 GP Repair Troubleshooting Notes wc_tx000548gb.fm...

  • Page 88: Checking Main Circuit Breaker And Receptacle Circuitry

    Troubleshooting GP Repair 6.12 Checking Main Circuit Breaker and Receptacle Circuitry See Graphic: wc_gr003140 Electric shock hazard. Only qualified personnel should conduct this test. WARNING If there is no voltage measured at the receptacles but there is voltage at the generator terminal strip, you’ll need to check the following: the wiring to the main circuit breaker, the main circuit breaker, and the wiring to the receptacles.
  • Page 89 GP Repair Troubleshooting 1000 200m 1000 200m GP 2500A wc_gr003140 wc_tx000548gb.fm...

  • Page 90: Low Voltage At Receptacles-Flowchart 2A

    Troubleshooting GP Repair 6.13 Low Voltage at Receptacles—Flowchart 2A Low Voltage at Receptacles If you have recently worked on the generator, be sure the wiring at the generator terminal strip is correct. Checking main and rotor windings Measure the resistance values of the main windings by measuring across R &...

  • Page 91: Checking Brushes

    GP Repair Troubleshooting 6.14 Checking Brushes See Graphic: wc_gr003126 As long as the brushes have continuity and are long enough to touch the slip rings, they should be functioning. To check the brushes, carry out the following procedures: 6.14.1 Stop the engine. 6.14.2 Remove the two screws that secure the end cover to the generator and remove the end cover.

  • Page 92: Checking Excitation Winding

    Troubleshooting GP Repair 6.15 Checking Excitation Winding See Graphic: wc_gr003127 The excitation winding provides AC voltage to the Automatic Voltage Regulator (AVR). The AVR then sends a DC voltage through the rotor winding “exciting” the rotor into becoming an electromagnet. To check the excitation winding, carry out the following procedures: 6.15.1 Stop the engine.
  • Page 93 GP Repair Troubleshooting GP 2500..2.3 GP 3800..1.1 1000 GP 5600..0.9 200m GP 6600..0.9 wc_gr003127 wc_tx000548gb.fm...

  • Page 94: Checking Avr's Sensing Wires-Gp 2500A

    Troubleshooting GP Repair 6.16 Checking AVR’s Sensing Wires—GP 2500A See Graphic: wc_gr003148 There are two sensing wires feeding the Automatic Voltage Regulator (AVR) both attached to main winding 2. If the sensing wires are shorted or broken, the AVR will not perform correctly. To check the continuity of the sensing wires, carry out the following procedures: 6.16.1 Stop the engine.
  • Page 95 GP Repair Troubleshooting wc_gr003148 wc_tx000548gb.fm...

  • Page 96: Checking Avr's Sensing Wires

    Troubleshooting GP Repair 6.17 Checking AVR’s Sensing Wires See Graphic: wc_gr003128 There are two sensing wires feeding the Automatic Voltage Regulator (AVR), one attached to each of the main windings. If the sensing wires are shorted or broken, the AVR will not perform correctly. To check the continuity of the sensing wires, carry out the following procedures: 6.17.1 Stop the engine.
  • Page 97 GP Repair Troubleshooting • If the second sensing wire (circuit) does not have continuity, check the wiring through the various connectors and the VSS. Repair or replace components as needed. wc_gr003128 wc_tx000548gb.fm...

  • Page 98: Confirming A Malfunctioning Avr

    Troubleshooting GP Repair 6.18 Confirming a Malfunctioning AVR See Graphic: wc_gr003152 By removing the two sensing wires of the regulator and measuring the output voltage of the generator, you can determine if the generator windings and the AVR are functioning correctly. When the sensing wires are removed from the circuit, the generator should produce high voltage (greater than 150V, usually around 180V).
  • Page 99 GP Repair Troubleshooting 1000 200m wc_gr003152 wc_tx000548gb.fm...

  • Page 100: Checking And Installing The Voltage Selector Switch (Vss)

    Troubleshooting GP Repair 6.19 Checking and Installing the Voltage Selector Switch (VSS) See Graphic: wc_gr003134 and wc_gr003135 Personal injury may occur while running the generator if the VSS is incorrectly wired. If the VSS has been worked on, be sure the VSS is correctly wired before running the generator.
  • Page 101 GP Repair Troubleshooting Terminal Wire Brown #1 Brown #2 Brown #3 Gray #104 Brown #5 Gray #103; jumper to terminal 7 Brown #7 jumper to terminal 6 Blue #8 Jumper to terminal 4 Brown #10 Brown #11 Brown #12 wc_gr003134 wc_tx000548gb.fm...

  • Page 102: High Voltage Troubleshooting-Flowchart 3A

    Troubleshooting GP Repair 6.20 High Voltage Troubleshooting—Flowchart 3A High Voltage at Receptacles Check engine speed. Be sure that it is within range limits. Checking AVR's sensing wires Checking AVR's sensing wires—GP 2500A Check the continuity of the AVR’s sensing wire Check the continuity of the AVR’s sensing wires to main winding 2 by checking the continuity from the generator plug to the DC winding plug:...

  • Page 103: Auto Idle Circuit Troubleshooting-Flowchart 4A

    GP Repair Troubleshooting 6.21 Auto Idle Circuit Troubleshooting—Flowchart 4A Auto Idle Malfunctioning Examine the mechanical linkage. Be sure all parts are functioning. Checking voltage to auto idle solenoid With the engine running, check the DC voltage Confirm the solenoid is malfunctioning by between the two white/red (W/R) wires.

  • Page 104: Checking Voltage To Auto Idle Solenoid

    Troubleshooting GP Repair 6.22 Checking Voltage to Auto Idle Solenoid See Graphic: wc_gr003130 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Problems with the auto idle system can be classified into one of two categories: electrical problems with power to the idle solenoid or problems with the mechanical linkage.
  • Page 105 GP Repair Troubleshooting 1000 200m 1000 200m 1000 200m wc_gr003130 wc_tx000548gb.fm...

  • Page 106: Checking Auto Idle Circuitry Between Generator And Fuse

    Troubleshooting GP Repair 6.23 Checking Auto Idle Circuitry Between Generator and Fuse See Graphic: wc_gr003131 Voltage may be prevented from reaching the 5A fuse by a faulty rectifier or by a faulty DC winding. The auto idle circuit may also be malfunctioning due to faulty sensing wires.
  • Page 107 GP Repair Troubleshooting GP 2500..--- GP 3800..0.6 GP 5600..0.5 GP 6600..0.5 1000 200m 1000 200m wc_gr003131 wc_tx000548gb.fm...

  • Page 108: Checking Auto Idle Circuitry Between Fuse And Auto Idle Unit

    Troubleshooting GP Repair 6.24 Checking Auto Idle Circuitry Between Fuse and Auto Idle Unit See Graphic: wc_gr003132 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Voltage may be prevented from reaching the idle solenoid by a faulty auto idle switch or by a faulty auto idle unit.

  • Page 109: Engine Backfires-Troubleshooting Flowchart 5A

    GP Repair Troubleshooting 6.25 Engine Backfires—Troubleshooting Flowchart 5A Engine Backfires Checking Anti-Afterfire Solenoid (AAS) circuit With the engine running, probe wires G & W at the connections for the AAS. Shutdown the engine and measure voltage at shutdown. There should be 18±2VDC. Confirm the solenoid is malfunctioning by measuring its coil’s resistance.

  • Page 110: Checking Anit-Afterfire Solenoid (Aas) Circuit

    Troubleshooting GP Repair 6.26 Checking Anit-Afterfire Solenoid (AAS) Circuit See Graphic: wc_gr003133 Electric shock hazard. Only qualified personnel should conduct this test. WARNING The AAS is located on the engine underneath the carburetor bowl. Voltage may be prevented from reaching the AAS by: a faulty DC winding, a blown fuse, a faulty engine ON/OFF switch, or a faulty capacitor.
  • Page 111 GP Repair Troubleshooting 1000 200m µF 1000 200m wc_gr003133 wc_tx000548gb.fm...
  • Page 112 Troubleshooting GP Repair Notes: wc_tx000548gb.fm...

  • Page 113: Disassembly/Assembly Procedures

    GP Repair Disassembly/Assembly Procedures Disassembly/Assembly Procedures Tools Because all possible problems encountered while repairing the equipment cannot be anticipated, it is up to the mechanic to use common sense and good judgement in tool selection. The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate.

  • Page 114: Replacing The Muffler

    Disassembly/Assembly Procedures GP Repair Replacing the Muffler See Graphic: wc_gr003136 Removal: 7.5.1 Disconnect the spark plug. 7.5.2 Remove the screw (a) that secures the muffler guard and the generator mounting leg (b) to the shock mount bracket. 7.5.3 Remove the screws (c) that secure the muffler guard to the frame. 7.5.4 Remove the six screws (d) that secure the muffler guard halves together and remove the outer muffler guard (e).
  • Page 115 GP Repair Disassembly/Assembly Procedures wc_gr003136 wc_tx000549gb.fm...

  • Page 116: Replacing The Fuel Tank

    Disassembly/Assembly Procedures GP Repair Replacing the Fuel Tank See Graphic: wc_gr003137 Removal: 7.6.1 Disconnect the spark plug. 7.6.2 Turn the fuel valve (a) off. Remove the fuel hose (b) at the fuel valve; plug the fuel hose as soon as it is free from the fuel valve. 7.6.3 Remove the shoulder bolts (c) and hardware that secure the lifting handle (d) to the frame and remove the lifting handle.
  • Page 117 GP Repair Disassembly/Assembly Procedures wc_gr003137 wc_tx000549gb.fm...

  • Page 118: Replacing The Stator

    Disassembly/Assembly Procedures GP Repair Replacing the Stator See Graphic: wc_gr003138 Removal: 7.7.1 Disconnect the spark plug. 7.7.2 Remove the two screws (a) that secure the end cover and remove the end cover from the generator. 7.7.3 Disconnect the wires (b) from the terminal strip, the ground wire (c), and the harness connector (d).
  • Page 119 GP Repair Disassembly/Assembly Procedures wc_gr003138 wc_tx000549gb.fm...

  • Page 120: Replacing The Rotor

    Disassembly/Assembly Procedures GP Repair Replacing the Rotor See Graphic: wc_gr003139 Removal 7.8.1 Disconnect the spark plug. 7.8.2 Remove the stator. See section Replacing Stator. 7.8.3 Prevent the engine’s flywheel from turning by wedging a wrench (a) or like object into the fins of the fan. Then, remove the M8 screw (b) from the end of the rotor.
  • Page 121 GP Repair Disassembly/Assembly Procedures wc_gr003139 wc_tx000549gb.fm...

  • Page 122: Replacing The Engine

    Disassembly/Assembly Procedures GP Repair Replacing the Engine See Graphic: wc_gr003141 Removal: 7.9.1 Disconnect the spark plug. 7.9.2 Remove the generator. See section Replacing the Rotor. 7.9.3 Turn the fuel valve (a) off. Remove the fuel hose (b) at the fuel valve; plug the fuel hose as soon as it is free from the fuel valve.
  • Page 123 GP Repair Disassembly/Assembly Procedures wc_gr003141 wc_tx000549gb.fm...
  • Page 124 Disassembly/Assembly Procedures GP Repair wc_tx000549gb.fm...
  • Page 125 Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 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.
  • Page 126 Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 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.

  • Page 127: 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 128 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 130 Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations ·...

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