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Wacker Neuson GP 6600A Repair Manual

Other manuals for GP 6600A: Operator's Manual, Operator's Manual

Summary of GP 6600A

  • Page 1

    Www.Wackergroup.Com generator gp 2500a gp 3800a gp 5600a gps 5600a gp 6600a gps 6600a repair manual 0160415en 001 0806 0 1 6 0 4 1 5 e n.

  • Page 3: Gp Repair

    Gp repair foreword wc_tx000544gb.Fm i operating / parts information you must be familiar with the operation of this machine before you attempt to troubleshoot or repair it. Basic operating and maintenance procedures are described in the operator’s manual supplied with the machine. Keep a copy of the...

  • Page 4: Foreword

    Foreword gp repair wc_tx000544gb.Fm ii 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 arrest...

  • Page 5: Gp Repair

    Gp repair table of contents wc_br0160415en_001toc.Fm 1 1. Safety information 4 1.1 operating safety .................................................................................. 5 1.2 operator safety while using internal combustion engines .................. 7 1.3 service safety ..................

  • Page 6: Table Of Contents

    Table of contents gp repair wc_br0160415en_001toc.Fm 2 4. Maintenance 38 4.1 engine maintenance ............................................................................38 4.2 periodic maintenance schedule ..........................................................38 4.3 engine oil ..................

  • Page 7: Gp Repair

    Gp repair table of contents wc_br0160415en_001toc.Fm 3 6. Troubleshooting 72 6.1 troubleshooting methodology ............................................................ 72 6.2 checking continuity ........................................................................... 74 6.3 checking resistance ...

  • Page 8: Safety Information

    Safety information gp repair wc_si000169gb.Fm 4 1. 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 ale...

  • Page 9: Gp Repair

    Gp repair safety information wc_si000169gb.Fm 5 1.1 operating safety backfeed from the generator into the public power distribution system can cause serious injury or death to utility workers! Improper connection of generator to a building's electrical system can allow electrical current from the ge...

  • Page 10: Safety Information

    Safety information gp repair wc_si000169gb.Fm 6 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 and operate the generator on a firm, noncombustible, level surface. 1.1.14 al...

  • Page 11: Gp Repair

    Gp repair safety information wc_si000169gb.Fm 7 1.2 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...

  • Page 12: Safety Information

    Safety information gp repair wc_si000169gb.Fm 8 1.3 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...

  • Page 13: Gp Repair

    Gp repair safety information wc_si000169gb.Fm 9 1.4 label locations gnd 88897.

  • Page 14: Safety Information

    Safety information gp repair wc_si000169gb.Fm 10 1.5 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 m...

  • Page 15: Gp Repair

    Gp repair safety information wc_si000169gb.Fm 11 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. Label meaning.

  • Page 16: Safety Information

    Safety information gp repair wc_si000169gb.Fm 12 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 t...

  • Page 17: Gp Repair

    Gp repair safety information wc_si000169gb.Fm 13 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. Label meaning.

  • Page 18: Technical Data

    Technical data gp repair wc_td000169gb.Fm 14 2. Technical data 2.1 generator—gp 2500a item no. Gp 2500a 0620009 generator maximum output w 2500 continuous output w 2250 type single voltage, single phase, auto voltage regulator system ac voltages available volts phase 120 1ø frequency hz 60 power fac...

  • Page 19: Gp Repair

    Gp repair technical data wc_td000169gb.Fm 15 2.2 engine—gp 2500a item no. Gp 2500a 0620009 engine engine make honda engine model gx 160 k1vx rated power kw (hp) 4.1 (5.5) spark plug bpr6es / w20epr-u electrode gap mm (in.) 0.7–0.8 (0.028–0.031) operating speed (max.) rpm 3600 air cleaner type dry ty...

  • Page 20: Technical Data

    Technical data gp repair wc_td000169gb.Fm 16 2.3 generator—gp 3800a, gp 3800a can item no. Gp 3800a 0620010 gp 3800a can 0620041 generator maximum output w 3800 continuous output w 3400 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase 120 / 240 1ø freq...

  • Page 21: Gp Repair

    Gp repair technical data wc_td000169gb.Fm 17 2.4 engine—gp 3800a, gp 3800a can item no. Gp 3800a 0620010 gp 3800a can 0620041 engine engine type single cylinder, 4-cycle, air-cooled, gasoline engine engine make honda engine model gx 240 rated power kw (hp) 6 (8) spark plug bpr6es / w20epr-u electrod...

  • Page 22: Technical Data

    Technical data gp repair wc_td000169gb.Fm 18 2.5 generator—gp/gps 5600a/5600a can item no. Gp 5600a 0620011 gp 5600a 0620012 gps 5600a 0620013 generator maximum output w 5600 continuous output w 5000 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase 120...

  • Page 23: Gp Repair

    Gp repair technical data wc_td000169gb.Fm 19 item no. Gp 5600a can 0620042 gp 5600a can 0620043 gps 5600a can 0620044 generator maximum output w 5600 continuous output w 5000 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase 120 / 240 1ø frequency hz 60...

  • Page 24: Technical Data

    Technical data gp repair wc_td000169gb.Fm 20 2.6 engine—gp/gps 5600a/5600a can item no. Gp 5600a 0620011 0620012 gp 5600a can 0620042 0620043 gps 5600a 0620013 gps 5600a can 0620044 engine engine type single cylinder, 4-cycle, air-cooled, gasoline engine engine make honda engine model gx 340 k1 rate...

  • Page 25: Gp Repair

    Gp repair technical data wc_td000169gb.Fm 21 notes.

  • Page 26: Technical Data

    Technical data gp repair wc_td000169gb.Fm 22 2.7 generator—gp/gps 6600a/6600a can item no. Gp 6600a 0620014 gp 6600a 0620015 gps 6600a 0620016 generator maximum output w 6600 continuous output w 6000 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase 120...

  • Page 27: Gp Repair

    Gp repair technical data wc_td000169gb.Fm 23 item no. Gp 6600a can 0620045 gp 6600a can 0620046 gps 6600a can 0620047 generator maximum output w 6600 continuous output w 5500 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase 120 / 240 1ø frequency hz 60...

  • Page 28: Technical Data

    Technical data gp repair wc_td000169gb.Fm 24 2.8 engine—gp/gps 6600a/6600a can item no. Gp 6600a 0620014 0620015 gp 6600a can 0620045 0620046 gps 6600a 0620016 gps 6600a can 0620047 engine engine type single cylinder, 4-cycle, air-cooled, gasoline engine engine make honda engine model gx 390 rated p...

  • Page 29: Gp Repair

    Gp repair operation wc_tx000545gb.Fm 25 3. Operation 3.1 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...

  • Page 30: Operation

    Operation gp repair wc_tx000545gb.Fm 26 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.

  • Page 31: Gp Repair

    Gp repair operation wc_tx000545gb.Fm 27 3.3 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 ma...

  • Page 32: Operation

    Operation gp repair wc_tx000545gb.Fm 28 3.6 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 th...

  • Page 33: Gp Repair

    Gp repair operation wc_tx000545gb.Fm 29 3.7 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 electr...

  • Page 34: Operation

    Operation gp repair wc_tx000545gb.Fm 30 3.8 control panel see graphic: wc_gr002324 ref. Description ref. Description a gfi duplex receptacle—120v d gfi test button b circuit breaker—20 amp. E gfi reset button c duplex receptacle—120v.

  • Page 35: Gp Repair

    Gp repair operation wc_tx000545gb.Fm 31 3.9 control panel—gp 3800 see graphic: wc_gr002327 ref. Description ref. Description a engine switch g gfi test button b auto idle switch h gfi reset button c twist-lock receptacle—120v j twist-lock receptacle—120/240v d main circuit breaker m 20a circuit brea...

  • Page 36: Operation

    Operation gp repair wc_tx000545gb.Fm 32 3.10 control panel—gp 5600/gp6600 see graphic: wc_gr002498 ref. Description ref. Description a engine switch g gfi test button b auto idle switch h gfi reset button c twist-lock receptacle - 120v j twist-lock receptacle - 120/240v d main circuit breaker k igni...

  • Page 37: Gp Repair

    Gp repair operation wc_tx000545gb.Fm 33 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 att...

  • Page 38: Operation

    Operation gp repair wc_tx000545gb.Fm 34 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...

  • Page 39: Gp Repair

    Gp repair operation wc_tx000545gb.Fm 35 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) ....

  • Page 40: Operation

    Operation gp repair wc_tx000545gb.Fm 36 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) ...

  • Page 41: Gp Repair

    Gp repair operation wc_tx000545gb.Fm 37 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 ...

  • Page 42: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 38 4. Maintenance 4.1 engine maintenance the chart below lists basic machine and engine maintenance. Refer to the engine manufacturer’s operator’s manual for additional information on engine maintenance. 4.2 periodic maintenance schedule daily before starting a...

  • Page 43: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 39 4.3 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 containe...

  • Page 44: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 40 4.4 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-po...

  • Page 45: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 41 4.5 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 touc...

  • Page 46: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 42 4.6 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 ...

  • Page 47: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 43 4.8 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. The...

  • Page 48: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 44 4.9 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 a...

  • Page 49: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 45 4.10 transport let the engine cool before transporting the generator or storing indoors, to avoid burns or fire hazards. 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 fu...

  • Page 50: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 46 4.11 electrical schematic—gp 2500a.

  • Page 51: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 47 4.12 components—gp 2500a ref. Description ref. Description ref. Description a generator b control box c engine ref. Description ref. Description 1 main stator winding 7 duplex receptacle—120v 2 secondary winding 8 ignition switch 3 rotor winding 9 oil alert ...

  • Page 52: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 48 4.13 electrical schematic—gp 3800a (0620010 rev..

  • Page 53: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 49 4.14 components—gp 3800a (0620010 rev. Ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 main stator winding 1 11 capacitor 2 main stator winding 2 12 engine on / off switch 3 au...

  • Page 54: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 50 4.15 electrical schematic—gp 3800a (0620010 rev. > 103).

  • Page 55: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 51 4.16 components—gp 3800a (0620010 rev. > 103) ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 main stator winding 1 12 engine on / off switch 2 main stator winding 2 13 rectifi...

  • Page 56: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 52 4.17 electrical schematic—gp 3800a can (0620041 rev..

  • Page 57: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 53 4.18 components—gp 3800a can (0620041 rev. Ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 main stator winding 1 12 engine on / off switch 2 main stator winding 2 13 rectifier ...

  • Page 58: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 54 4.19 electrical schematic—gp 3800a can (0620041 rev. > 103).

  • Page 59: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 55 4.20 components—gp 3800a can (0620041 rev. > 103) ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 main stator winding 1 13 rectifier 2 main stator winding 2 14 rotor winding/br...

  • Page 60: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 56 4.21 electrical schematic—gp/gps 5600a/6600a (rev..

  • Page 61: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 57 4.22 components—gp/gps 5600a/6600a (rev. Ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 main stator winding 1 11 capacitor 2 main stator winding 2 12 engine on / off switch 3 ...

  • Page 62: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 58 4.23 electrical schematic—gp/gps 5600a/6600a (rev. > 103).

  • Page 63: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 59 4.24 components—gp/gps 5600a/6600a (rev. > 103) ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 main stator winding 1 12 engine on / off switch 2 main stator winding 2 13 recti...

  • Page 64: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 60 4.25 electrical schematic (can)—gp/gps 5600a/6600a (rev..

  • Page 65: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 61 4.26 components (can)—gp/gps 5600a/6600a (rev. Ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 main stator winding 1 12 engine on / off switch 2 main stator winding 2 13 rectif...

  • Page 66: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 62 4.27 electrical schematic (can)—gp/gps 5600a/6600a (rev. >103).

  • Page 67: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 63 4.28 components (can)—gp/gps 5600a/6600a (rev. > 103) ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 main stator winding 1 13 rectifier 2 main stator winding 2 14 rotor windin...

  • Page 68: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 64 4.29 engine schematic (all)—gp/gps 3800a/5600a/6600a.

  • Page 69: Gp Repair

    Gp repair maintenance wc_tx000546gb.Fm 65 4.30 engine components (all)—gp/gps 3800a/5600a/6600a ref. Description ref. Description a generator c engine b control box d electric start engines ref. Description ref. Description 1 idle solenoid 6 solenoid (gps only) 2 fuel cut solenoid 7 starter (gps onl...

  • Page 70: Maintenance

    Maintenance gp repair wc_tx000546gb.Fm 66 notes.

  • Page 71: Gp Repair

    Gp repair theory of operation wc_tx000547gb.Fm 67 5. Theory of operation 5.1 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 assem...

  • Page 72: Theory Of Operation

    Theory of operation gp repair wc_tx000547gb.Fm 68 5.2 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...

  • Page 73: Gp Repair

    Gp repair theory of operation wc_tx000547gb.Fm 69 5.3 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 consta...

  • Page 74: Theory Of Operation

    Theory of operation gp repair wc_tx000547gb.Fm 70 5.4 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 ...

  • Page 75: Gp Repair

    Gp repair theory of operation wc_tx000547gb.Fm 71 5.5 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-af...

  • Page 76: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 72 6. Troubleshooting 6.1 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 cir...

  • Page 77: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 73 wc_gr003415 z y.

  • Page 78: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 74 6.2 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. ...

  • Page 79: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 75 6.5 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...

  • Page 80: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 76 6.6 no voltage at receptacles—flowchart 1a no voltage at receptacles is circuit breaker(s) in closed position? Close circuit breaker(s). Is receptacle gfi set correctly? Reset gfi. No yes yes no see flowchart 1b see flowchart 1c checking voltage at gener...

  • Page 81: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 77 6.7 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); br & l (main 1). Is...

  • Page 82: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 78 6.8 checking voltage at generator terminal strip see graphic: wc_gr003122 electric shock hazard. Only qualified personnel should conduct this test. By starting the troubleshooting procedures at the generator output terminal strip you can determine whethe...

  • Page 83: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 79 6.9 checking voltage at plug—gp 2500a see graphic: wc_gr003146 electric shock hazard. Only qualified personnel should conduct this test. By starting the troubleshooting procedures at the generator output plug (d) , you can determine whether the problem l...

  • Page 84: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 80 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 en...

  • Page 85: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 81 wc_gr003123 1000 200 20 2 200m f v a v- com gp 2500.... 47.5 gp 3800.... 47.0 gp 5600.... 60.5 gp 6600.... 64.8 1000 200 20 2 200m f v a v- com 1 d b c a f e 1 2 2 g 1 2 gp 2500.... 0.9 0.9 gp 3800.... 0.7 0.7 gp 5600.... 0.4 0.4 gp 6600.... 0.3 0.3 2 2 ...

  • Page 86: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 82 6.11 no voltage at receptacles—flowchart 1c wc_gr003114 checking main circuit breaker check voltage to main circuit breaker. Check wiring to generator terminal strip. Repair or replace wiring as needed. Is correct voltage measured? Yes no no check outgoi...

  • Page 87: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 83 notes.

  • Page 88: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 84 6.12 checking main circuit breaker and receptacle circuitry see graphic: wc_gr003140 electric shock hazard. Only qualified personnel should conduct this test. If there is no voltage measured at the receptacles but there is voltage at the generator termin...

  • Page 89: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 85 wc_gr003140 b a c d e v v gp 2500a f g 1000 200 20 2 200m f v a v- com 1000 200 20 2 200m f v a v- com.

  • Page 90: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 86 6.13 low voltage at receptacles—flowchart 2a wc_gr003112 checking brushes check condition of brushes and holder. Are brushes ok? Yes no replace the brushes. Checking excitation winding check resistance of excitation winding. Replace the stator. Low volta...

  • Page 91: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 87 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...

  • Page 92: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 88 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. ...

  • Page 93: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 89 wc_gr003127 b a 1000 200 20 2 200m f v a v- com gp 2500.... 2.3 gp 3800.... 1.1 gp 5600.... 0.9 gp 6600.... 0.9.

  • Page 94: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 90 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....

  • Page 95: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 91 wc_gr003148 b c d a.

  • Page 96: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 92 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 correctl...

  • Page 97: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 93 • 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 d a b e c f g h.

  • Page 98: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 94 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 th...

  • Page 99: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 95 wc_gr003152 a 1000 200 20 2 200m f v a v- com v b c.

  • Page 100: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 96 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 wir...

  • Page 101: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 97 wc_gr003134 2 1 3 12 9 6 5 4 7 8 11 10 terminal 1 2 3 4 5 6 7 8 9 10 11 12 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 wire.

  • Page 102: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 98 6.20 high voltage troubleshooting—flowchart 3a wc_gr003113 check engine speed. Be sure that it is within range limits. Replace the stator. High voltage at receptacles checking avr's sensing wires check the continuity of the avr’s sensing wire to main win...

  • Page 103: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 99 6.21 auto idle circuit troubleshooting—flowchart 4a wc_gr003115 examine the mechanical linkage. Be sure all parts are functioning. Replace auto idle switch. Auto idle malfunctioning checking voltage to auto idle solenoid with the engine running, check th...

  • Page 104: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 100 6.22 checking voltage to auto idle solenoid see graphic: wc_gr003130 electric shock hazard. Only qualified personnel should conduct this test. Problems with the auto idle system can be classified into one of two categories: electrical problems with powe...

  • Page 105: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 101 wc_gr003130 b a c 1000 200 20 2 200m f v a v- com 1000 200 20 2 200m f v a v- com v 1000 200 20 2 200m f v a v- com v.

  • Page 106: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 102 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 sens...

  • Page 107: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 103 wc_gr003131 1000 200 20 2 200m f v a v- com a b 1000 200 20 2 200m f v a v- com gp 2500.... --- gp 3800.... 0.6 gp 5600.... 0.5 gp 6600.... 0.5 c d e.

  • Page 108: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 104 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. Voltage may be prevented from reaching the idle solenoid by a faulty auto idle switch or...

  • Page 109: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 105 6.25 engine backfires—troubleshooting flowchart 5a wc_gr003116 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...

  • Page 110: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 106 6.26 checking anit-afterfire solenoid (aas) circuit see graphic: wc_gr003133 electric shock hazard. Only qualified personnel should conduct this test. The aas is located on the engine underneath the carburetor bowl. Voltage may be prevented from reachin...

  • Page 111: Gp Repair

    Gp repair troubleshooting wc_tx000548gb.Fm 107 wc_gr003133 b c 1000 200 20 2 200m f v a v- com v a 1000 200 20 2 200m f v a v- com d d µf.

  • Page 112: Troubleshooting

    Troubleshooting gp repair wc_tx000548gb.Fm 108 notes:.

  • Page 113: Gp Repair

    Gp repair disassembly/assembly procedures wc_tx000549gb.Fm 109 7. Disassembly/assembly procedures 7.1 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...

  • Page 114: Gp Repair

    Disassembly/assembly procedures gp repair wc_tx000549gb.Fm 110 7.5 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...

  • Page 115: Gp Repair

    Gp repair disassembly/assembly procedures wc_tx000549gb.Fm 111 wc_gr003136 c e f f h f g a b d.

  • Page 116: Gp Repair

    Disassembly/assembly procedures gp repair wc_tx000549gb.Fm 112 7.6 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...

  • Page 117: Gp Repair

    Gp repair disassembly/assembly procedures wc_tx000549gb.Fm 113 wc_gr003137 a c gg c d c b d e f f h g.

  • Page 118: Gp Repair

    Disassembly/assembly procedures gp repair wc_tx000549gb.Fm 114 7.7 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 te...

  • Page 119: Gp Repair

    Gp repair disassembly/assembly procedures wc_tx000549gb.Fm 115 wc_gr003138 a d e c b f g i h.

  • Page 120: Gp Repair

    Disassembly/assembly procedures gp repair wc_tx000549gb.Fm 116 7.8 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...

  • Page 121: Gp Repair

    Gp repair disassembly/assembly procedures wc_tx000549gb.Fm 117 wc_gr003139 d d c c e f a b.

  • Page 122: Gp Repair

    Disassembly/assembly procedures gp repair wc_tx000549gb.Fm 118 7.9 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...

  • Page 123: Gp Repair

    Gp repair disassembly/assembly procedures wc_tx000549gb.Fm 119 wc_gr003141 c a b d e f.

  • Page 124: Gp Repair

    Disassembly/assembly procedures gp repair wc_tx000549gb.Fm 120

  • Page 125: Threadlockers and Sealants

    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 b...

  • Page 126: Threadlockers and Sealants

    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 ...

  • Page 127: Torque Values

    Torque values torque values metric fasteners (din) torque values (based on bolt size and hardness) wrench size size nm ft.Lb. Nm ft.Lb. Nm ft.Lb. Metric inch metric inch m3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 – m4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 – m5 6.0 *53 8.5 6 10 7 8 5/16 4 – m6 10 7 14 10 17 ...

  • Page 128: Torque Values

    Torque values torque values (continued) inch fasteners (sae) size nm ft.Lb. Nm ft.Lb. Nm ft.Lb. Metric inch metric inch no.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32 no.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64 no.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64 no.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32 1/4 8.1...

  • 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...