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- Wacker Neuson
- Portable Generator
- GPS 5600A
- Repair Manual
Wacker Neuson GPS 5600A Repair Manual
Summary of GPS 5600A
Page 1
Generator gv 2500a gv 3800a gv 5600a gv 6600a repair manual 0171887en 002 0609 0 1 7 1 8 8 7 e n.
Page 3: Gv Generator Repair
Gv generator repair wc_tx000771gb.Fm 3 foreword machines covered by this manual machine documentation keep a copy of the operator’s manual with the machine at all times. Use the separate parts book supplied with the machine to order replacement parts. Refer to the separate repair manual for detailed...
Page 4: Gv Generator Repair
Gv generator repair wc_tx000771gb.Fm 4 and rated by the united states forest service for this purpose. In order to comply with local laws regarding spark arresters, consult the engine distributor or the local health and safety administrator. Notice: trademarks all trademarks referenced in this manua...
Page 5: Gv Generators
Gv generators table of contents wc_br0171887en_002toc.Fm 5 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 guideli...
Page 6: Table of Contents
Table of contents gv generators wc_br0171887en_002toc.Fm 6 3.11 removing the rotor ............................................................................49 3.12 installing the rotor ..............................................................................50 3.13 removing the engine .........
Page 7: Gv Generators
Gv generators safety information wc_si000245gb.Fm 7 1 safety information 1.1 callouts found in this manual notice: used without the safety alert symbol, notice indicates a situation which, if not avoided, could result in property damage. Note: contains additional information important to a procedure...
Page 8: Safety Information
Safety information gv generators wc_si000245gb.Fm 8 1.2 safety guidelines for operating the machine operator training before operating the machine: read and understand the operating instructions contained in all manuals delivered with the machine. Familiarize yourself with the location and proper us...
Page 9: Gv Generators
Gv generators safety information wc_si000245gb.Fm 9 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 combus...
Page 10: Safety Information
Safety information gv generators wc_si000245gb.Fm 10 1.4 safety guidelines for maintaining the machine never use gasoline or other types of fuels or flammable solvents to clean parts. Fumes from fuels and solvents can become explosive. Always keep the fuel lines in good condition and properly connec...
Page 11: Gv Generators
Gv generators safety information wc_si000245gb.Fm 11 1.5 label locations wc_gr005497.
Page 12: Safety Information
Safety information gv generators wc_si000245gb.Fm 12 1.6 warning labels label definition danger! No sparks, flames or burning objects near machine. Shut off the engine before refueling. Warning! Hot surface! Improper connection of generator to a building’s electrical system can allow electrical curr...
Page 13: Gv Generators
Gv generators safety information wc_si000245gb.Fm 13 1.7 procedural labels caution! Use only clean, filtered gasoline fuel. Check the fuel level. Open the fuel flow valve. Close the choke. Turn the engine switch to the on position. Pull the rewind starter. Open the choke..
Page 14: Safety Information
Safety information gv generators wc_si000245gb.Fm 14 1.8 informational labels turn the engine switch to “off”. Close the fuel flow valve. Electrical ground a nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the information fo...
Page 15: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 15 2 troubleshooting voltage issues prerequisites generator must be able to start multimeter procedure to determine where to begin troubleshooting voltage issues, follow the procedure below. 1. Remove the end cap (a) from the generator. 2...
Page 16: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 16 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...
Page 17: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 17 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...
Page 18: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 18 continued from the previous page. 4. Check each winding to ground. Measure the resistance between each post where the yellow (y), red (r), black (b), and green (g) wires were connected and the ground stud. Is any resistance measured fo...
Page 19: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 19 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 bru...
Page 20: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 20 continued from the previous page. 4. Check for shorts to the rotor shaft by measuring resistance between each slip ring and the end of the rotor shaft. Is any resistance measured for either of the checks? 5. Re-install the brushes—do n...
Page 21: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 21 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)...
Page 22: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 22 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 conne...
Page 23: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 23 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? 5. Reconnect the wiring. 6. Re...
Page 24: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 24 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) sens- ing wires. 1. Remove the end cap (a) from the generator. 2. Dis...
Page 25: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 25 continued from the previous page. 5. Check the resistance between the brown (br) wire of the wiring harness connec- tor (b) and the ground stud (x). Is any resistance measured? 6. Disconnect the 6-wire connector (c). 7. Check for conti...
Page 26: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 26 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 continui...
Page 27: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 27 2.7 checking the main circuit breaker prerequisites multimeter procedure follow the procedure below to check the main circuit breaker. 1. Remove the screws (a) that secure the control panel to the frame. Once removed, lower the control...
Page 28: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 28 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? 7. Place the main circ...
Page 29: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 29 2.8 checking the voltage selector switch (vss) prerequisites multimeter procedure follow the procedure below to check the voltage selector switch (vss). 1. Remove the screws (a) that secure the control panel to the frame. Once removed,...
Page 30: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 30 2.9 checking the auto idle unity and circuity prerequisites multimeter procedure follow the procedure below to check the auto idle circuitry. 1. Remove the end cap (d) from the generator. 2. Disconnect the 6-wire connector (e). 3. Meas...
Page 31: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 31 continued from the previous page. 4. Disconnect the dc rectifier (z). 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 th...
Page 32: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 32 continued from the previous page. 6. Remove the screws (a) that secure the control panel to the frame. Once removed, lower the control panel to access the screws (b). 7. Remove the screws (b) that secure the front and back halves of th...
Page 33: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 33 continued from the previous page. 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. Is at least 9.8vdc measured? 11.Shut down the engi...
Page 34: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 34 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? 13.Start the engine....
Page 35: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 35 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? 16.Measure the dc voltage between the red/w...
Page 36: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 36 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? 18.Place the main breaker in the on position. 19...
Page 37: Gv Generators
Gv generators troubleshooting voltage issues wc_tx000772gb.Fm 37 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...
Page 38: Gv Generators
Troubleshooting voltage issues gv generators wc_tx000772gb.Fm 38 continued from the previous page. 6. Measure the capacitance of the capacitor. Does the capacitor measure approximately 4700 ±10% micro farads? 7. Reassemble the generator. The procedure to check the aas is now complete. Yes ____ no __...
Page 39: Gv Generator Repair
Gv generator repair disassembly and assembly wc_tx000775gb.Fm 39 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...
Page 40: Disassembly and Assembly
Disassembly and assembly gv generator repair wc_tx000775gb.Fm 40 3.5 removing the muffler prerequisites engine cool procedure follow the procedure below to remove the muffler. 1. Disconnect the spark plug. 2. Remove the fuel tank. See section removing the fuel tank. 3. Remove the screws that secure ...
Page 41: Gv Generator Repair
Gv generator repair disassembly and assembly wc_tx000775gb.Fm 41 continued from the previous page. 8. Lift the muffler and the muffler guard from the engine and frame. The procedure to remove the muffler is now complete. Wc_gr004408.
Page 42: Disassembly and Assembly
Disassembly and assembly gv generator repair wc_tx000775gb.Fm 42 3.6 installing the muffler prerequisites engine cool procedure follow the procedure below to install the muffler. 1. Position the muffler and the muffler guard into the frame and onto the engine. 2. Remove the screws (b) that secure th...
Page 43: Gv Generator Repair
Gv generator repair disassembly and assembly wc_tx000775gb.Fm 43 continued from the previous page. 6. Remove the screws that secure the outer muffler guard and remove the outer muffler guard (a). 7. Install the fuel tank. See section installing the fuel tank. The procedure to install the muffler is ...
Page 44: Disassembly and Assembly
Disassembly and assembly gv generator repair wc_tx000775gb.Fm 44 3.7 removing the fuel tank prerequisites machine shut down procedure follow the procedure below to remove the fuel tank. 1. Disconnect the spark plug. 2. Close the fuel valve. 3. Disconnect the fuel hose (a) from fuel valve. 4. Remove ...
Page 45: Gv Generator Repair
Gv generator repair disassembly and assembly wc_tx000775gb.Fm 45 3.9 removing the stator prerequisites machine shut down procedure follow the procedure below to remove the stator. 1. Disconnect the spark plug. 2. Remove the end cover (a). 3. Disconnect the wiring from the terminal strip (b), the gro...
Page 46: Disassembly and Assembly
Disassembly and assembly gv generator repair wc_tx000775gb.Fm 46 continued from the previous page. 7. Remove the screw (i) that secures the muffler to the stator. 8. Remove the four long screws (j) that secure the stator to the machine. 9. Pull the stator (k) from the machine. The procedure to remov...
Page 47: Gv Generator Repair
Gv generator repair disassembly and assembly wc_tx000775gb.Fm 47 3.10 installing the stator prerequisites machine shut down procedure follow the procedure below to install the stator. 1. Position the stator over the rotor and onto the machine. 2. Secure the stator to the machine with the four long s...
Page 48: Disassembly and Assembly
Disassembly and assembly gv generator repair wc_tx000775gb.Fm 48 continued from the previous page. 6. Install the brush holder (f). 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 ...
Page 49: Gv Generator Repair
Gv generator repair disassembly and assembly wc_tx000775gb.Fm 49 3.11 removing the rotor prerequisites oil filter wrench procedure follow the procedure below to remove the rotor. 1. Disconnect the spark plug. 2. Remove the stator. See section removing the stator. 3. Loosen the long bolt (a) that sec...
Page 50: Disassembly and Assembly
Disassembly and assembly gv generator repair wc_tx000775gb.Fm 50 3.12 installing the rotor prerequisites oil filter wrench procedure follow the procedure below to install the rotor. 1. Position the rotor on the engine shaft. 2. Install the long bolt (a) that secures the rotor to the engine. To preve...
Page 51: Gv Generator Repair
Gv generator repair disassembly and assembly wc_tx000775gb.Fm 51 3.13 removing the engine prerequisites engine cool procedure follow the procedure below to remove the engine. 1. Disconnect the spark plug. 2. Label and disconnect the wiring between the engine and the control panel. 3. Remove the fuel...
Page 52: Disassembly and Assembly
Disassembly and assembly gv generator repair wc_tx000775gb.Fm 52 3.14 installing the engine prerequisites engine cool procedure follow the procedure below to install the engine. 1. Position the engine into the frame and secure it to the shock mounts with screws (a). 2. Install the rotor. See section...
Page 53: Gv Generator Repair
Gv generator repair disassembly and assembly wc_tx000775gb.Fm 53 notes.
Page 54: Schematics
Schematics gv generator repair wc_tx000813gb.Fm 54 4 schematics 4.1 electrical schematic—gv 2500a a 31 2 4 14 b 5 6 7 8 9 10 11 13 12 c.
Page 55: Gv Generator Repair
Gv generator repair schematics wc_tx000813gb.Fm 55 4.2 electrical components—gv 2500a 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 wi...
Page 56: Schematics
Schematics gv generator repair wc_tx000813gb.Fm 56 4.3 electrical schematic—gv 3800a ab 15 16 17 18 6 6 5 3 14 1 9 8 19 20 10 11 21 13 12 4 2 22 23 c.
Page 57: Gv Generator Repair
Gv generator repair schematics wc_tx000813gb.Fm 57 4.4 electrical components—gv 3800a 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 i...
Page 58: Schematics
Schematics gv generator repair wc_tx000813gb.Fm 58 4.5 electrical schematic—gv 5600a, gv 6600a ab 15 16 17 24 18 6 6 5 3 14 1 9 8 19 20 10 11 21 13 12 4 2 22 23 c.
Page 59: Gv Generator Repair
Gv generator repair schematics wc_tx000813gb.Fm 59 4.6 electrical components—gv 5600a, gv 6600a 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...
Page 60: Technical Data
Technical data gv generators wc_td000248gb.Fm 60 5 technical data 5.1 generator—gv 2500a item no. Gv 2500a 0620286 0620542 generator maximum output w 2500 continuous output w 2250 type single phase, self-exciting, 2-pole, field rotating ac voltages available volts phase 120 1 frequency hz 60 power f...
Page 61: Gv Generators
Gv generators technical data wc_td000248gb.Fm 61 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 honda engine model gx 160 k1 maximum rated power at rated spee...
Page 62: Technical Data
Technical data gv generators wc_td000248gb.Fm 62 5.3 generator—gv 3800a item no. Gv 3800a 0620287 generator maximum output w 3800 continuous output w 3400 type single phase, self-exciting, 2-pole, field rotating ac voltages available volts phase 120/240 1 frequency hz 60 power factor cos ø 1.0 ac re...
Page 63: Gv Generators
Gv generators technical data wc_td000248gb.Fm 63 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 honda engine model gx 240 k1 maximum rated power at op...
Page 64: Technical Data
Technical data gv generators wc_td000248gb.Fm 64 5.5 generator—gv 5600a item no. Gv 5600a 0620288 0620335 0620410 generator maximum output w 5600 continuous output w 5000 type single phase, self-exciting, 2-pole, field rotating ac voltages available volts phase 120/240 1 frequency hz 60 power factor...
Page 65: Gv Generators
Gv generators technical data wc_td000248gb.Fm 65 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 honda engine model gx 340 k1 maximum rated power at ra...
Page 66: Technical Data
Technical data gv generators wc_td000248gb.Fm 66 5.7 generator—gv 6600a item no. Gv 6600a 0620289 generator maximum output w 6600 continuous output w 6000 type single phase, self-exciting, 2-pole, field rotating ac voltages available volts phase 120/240 1 frequency hz 60 power factor cos ø 1.0 ac re...
Page 67: Gv Generators
Gv generators technical data wc_td000248gb.Fm 67 item no. Gv 6600a 0620336 generator maximum output w 6600 continuous output w 6000 type single phase, self-exciting, 2-pole, field rotating ac voltages available volts phase 120/240 1 frequency hz 60 power factor cos ø 1.0 ac receptacles: 125v gfi dup...
Page 68: Technical Data
Technical data gv generators wc_td000248gb.Fm 68 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 honda engine model gx 390 k1 max. Rated power @ rated speed kw (hp) 8....
Page 69: Gv Generators
Gv generators technical data wc_td000248gb.Fm 69 engine power rating net power rating per sae j1349. Actual power output may vary due to conditions of specific use. Item no. Gv 6600a 0620336 engine engine make honda engine model gx 390 r1 max. Rated power @ rated speed kw (hp) 9.7 (13) @ 3600 rpm sp...
Page 70: 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 71: 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 72: 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 73: 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 74
Wacker neuson se · preußenstraße 41 · d-80809 münchen · tel.: +49-(0)89-3 54 02-0 · fax: +49 - (0)89-3 54 02-390 wacker neuson corporation · p.O. Box 9007 · menomonee falls, wi 53052-9007 · tel. : (262) 255-0500 · fax: (262) 255-0550 · tel. : (800) 770-0957 wacker neuson limited - room 1701–03 & 171...