GV 2500A GV 3800A GV 5600A GV 6600A: Generator

0171887en 002

0609

Generator

GV 2500A
GV 3800A
GV 5600A
GV 6600A
REPAIR MANUAL
0 1 7 1 8 8 7 E N
GV Generator Repair
Foreword
Machines
covered by Machine Item Number
this manual
GV 2500A 0620286, 0620542
GV 3800A 0620287, 0620409, 0620334
GV 5600A 0620288, 0620410, 0620335
GV 6600A 0620289, 0620336
Machine Keep a copy of the Operator’s Manual with the machine at all times.
documentation Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
If you are missing any of these documents, please contact Wacker Neuson Cor-
poration to order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations This manual provides information and procedures to safely operate and main-
for tain the above Wacker Neuson model(s). For your own safety and to reduce the
information in risk of injury, carefully read, understand, and observe all instructions described
this manual
in this manual.
Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson Corporation reserves the right
to change any portion of this information without notice.
Copyright All rights, especially copying and distribution rights, are reserved.
notice Copyright 2009 by Wacker Neuson Corporation.
This publication may be reproduced through photocopying by the original
purchaser of the machine. Any other type of reproduction is prohibited without
express written permission from Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Cor-
poration represents an infringement of valid copyrights, and violators will be
prosecuted.
CALIFORNIA Engine exhaust, some of its constituents, and certain vehicle components, contain
Proposition or emit chemicals known to the State of California to cause cancer and birth
65 Warning: defects or other reproductive harm.
Laws NOTICE: State Health Safety Codes and Public Resources Codes specify that in
pertaining to certain locations spark arresters be used on internal combustion engines that use
spark hydrocarbon fuels. A spark arrester is a device designed to prevent accidental dis-
arresters charge of sparks or flames from the engine exhaust. Spark arresters are qualified
wc_tx000771gb.fm 3
GV Generator Repair
and rated by the United States Forest Service for this purpose. In order to comply
with local laws regarding spark arresters, consult the engine distributor or the local
Health and Safety Administrator.
NOTICE:
Trademarks All trademarks referenced in this manual are the property of their respective own-
ers.
wc_tx000771gb.fm 4
GV Generators Table of Contents
Foreword 3
1 Safety Information 7
1.1 Callouts Found in this Manual .............................................................. 7

1.2 Safety Guidelines for Operating the Machine ....................................... 8
1.3 Safety Guidelines while Using Internal Combustion Engines ............... 9
1.4 Safety Guidelines for Maintaining the Machine .................................. 10
1.5 Label Locations .................................................................................. 11
1.6 Warning Labels .................................................................................. 12
1.7 Procedural Labels .............................................................................. 13
1.8 Informational Labels ........................................................................... 14
2 Troubleshooting Voltage Issues 15
2.1 Charging the Generator with 9-Volt Battery ....................................... 16

2.2 Checking the Stator Windings ............................................................ 17
2.3 Checking the Rotor Windings ............................................................. 19
2.4 Checking the Brushes ........................................................................ 21
2.5 Checking the Excitation Winding ........................................................ 22
2.6 Checking the AVR’s Sensing Wires ................................................... 24
2.7 Checking the Main Circuit Breaker ..................................................... 27
2.8 Checking the Voltage Selector Switch (VSS) ..................................... 29
2.9 Checking the Auto Idle Unity and Circuity .......................................... 30
2.10 Checking the Anti-Afterfire Solenoid .................................................. 37
3 Disassembly and Assembly 39
3.1 Tools Required for Disassembly/Assembly Procedures ..................... 39

3.2 Information Regarding Replacement Parts ........................................ 39
3.3 Information Regarding Reference Numbers ( ) .................................. 39
3.4 Information Regarding Threadlocking Compounds ............................ 39
3.5 Removing the Muffler ......................................................................... 40
3.6 Installing the Muffler ........................................................................... 42
3.7 Removing the Fuel Tank .................................................................... 44
3.8 Installing the Fuel Tank ...................................................................... 44
3.9 Removing the Stator ........................................................................... 45
3.10 Installing the Stator ............................................................................. 47
wc_br0171887en_002TOC.fm 5
Table of Contents GV Generators
3.11 Removing the Rotor ............................................................................49
3.12 Installing the Rotor ..............................................................................50
3.13 Removing the Engine ..........................................................................51
3.14 Installing the Engine ............................................................................52
4 Schematics 54
4.1 Electrical Schematic—GV 2500A ........................................................54

4.2 Electrical Components—GV 2500A ....................................................55
4.3 Electrical Schematic—GV 3800A ........................................................56
4.4 Electrical Components—GV 3800A ....................................................57
4.5 Electrical Schematic—GV 5600A, GV 6600A .....................................58
4.6 Electrical Components—GV 5600A, GV 6600A ..................................59
5 Technical Data 60
5.1 Generator—GV 2500A ........................................................................60

5.2 Engine—GV 2500A .............................................................................61
5.3 Generator—GV 3800A ........................................................................62
5.4 Engine—GV 3800A .............................................................................63
5.5 Generator—GV 5600A ........................................................................64
5.6 Engine—GV 5600A .............................................................................65
5.7 Generator—GV 6600A ........................................................................66
5.8 Engine—GV 6600A .............................................................................68
wc_br0171887en_002TOC.fm 6
GV Generators Safety Information
1 Safety Information
1.1 Callouts Found in this Manual
This is the safety alert symbol. It is used to alert you to potential personal hazards.
f Obey all safety messages that follow this symbol.
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
f Obey all safety messages that follow this symbol to avoid injury or death.
WARNING indicates a hazardous situation which, if not avoided, could result in

death or serious injury.
f Obey all safety messages that follow this symbol to avoid possible injury or
death.
CAUTION indicates a situation which, if not avoided, could result in minor or mod-
erate injury.
f Obey all safety messages that follow this symbol to avoid possible minor or
moderate injury.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
wc_si000245gb.fm 7
Safety Information GV Generators
1.2 Safety Guidelines for Operating the Machine
Operator Before operating the machine:
training Read and understand the operating instructions contained in all manuals
delivered with the machine.
Familiarize yourself with the location and proper use of all controls and safety
devices.
Contact Wacker Neuson Corporation for additional training if necessary.
When operating this machine:

Do not allow improperly trained people to operate the machine. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Guidelines for ALWAYS operate the machine with all safety devices and guards in place and in
machine working order.
devices
NEVER modify or defeat safety devices.
NEVER operate the machine if any safety devices or guards are missing or
inoperative.
ALWAYS check that all controls are functioning properly immediately after start-
up! DO NOT operate the machine unless all controls operate correctly.
NEVER use accessories or attachments that are not recommended by Wacker
Corporation. Damage to the machine and injury to the user may result.
NEVER use worn electrical cords. Severe electrical shock and equipment dam-
age may result.
Guidelines for NEVER enclose or cover the generator when it is in use or when it is hot.
operation NEVER overload the generator. The total amperage of the tools and equipment
attached to the generator must not exceed the load rating of the generator.
NEVER attach equipment to the machine when it is suspended.
NEVER stand under the machine while it is being lifted or moved.
ALWAYS remove all tools, cords, and other loose items from the generator
before starting it.
ALWAYS make certain the machine is well-grounded and securely fastened to a
good earthen ground per national and local regulations.
Guidelines for NEVER operate the generator when open containers of fuel, paint, or other
work space flammable liquids are near.
NEVER run the electrical cords under the generator or over the top of the gener-
ator.
ALWAYS store the machine properly when it is not being used. The machine
should be stored in a clean, dry location out of the reach of children.
ALWAYS position and operate the generator when it is on a firm, noncombusti-
ble, level surface.
ALWAYS keep the area immediately surrounding and underneath the machine
clean, neat, and free of debris and combustible materials.
ALWAYS keep the area above the machine clear of debris that could fall on the
machine.
wc_si000245gb.fm 8
Standards for NEVER operate the generator, or tools attached to the generator, when your
operator hands are wet.
NEVER allow untrained personnel to operate the generator.
NEVER stand on the machine.
1.3 Safety Guidelines while Using Internal Combustion Engines
WARNING
Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety guidelines could result in severe injury or
death.
f Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
Guidlines for NEVER use this generator inside a home or garage, EVEN IF doors and win-
running the dows are open. Only use OUTSIDE and far away from windows, doors, and
engine vents. Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or smell.
NEVER use a generator inside an enclosed area such as a tunnel or a trench.
DO NOT smoke while operating the machine.
DO NOT run the engine near open flames.
NEVER touch the engine or muffler while the engine is on or immediately after it
has been turned off. These areas get hot and may cause burns.
Guidelines for NEVER smoke when refueling the engine.

refueling the DO NOT refuel a hot or running engine.
engine
DO NOT refuel the engine near an open flame.
DO NOT spill fuel when refueling the engine.
ALWAYS refill the fuel tank in a well-ventilated area.
ALWAYS replace the fuel tank cap after refueling.
ALWAYS check the fuel lines and the fuel tank for leaks and cracks before start-
ing the engine. Do not run the machine if fuel leaks are present or the fuel lines
are loose.
wc_si000245gb.fm 9
1.4 Safety Guidelines for Maintaining the Machine
WARNING
CAUTION! Poorly maintained equipment can become a safety hazard! In order for the
equipment to operate safely and properly over a long period of time, periodic maintenance
and occasional repairs are necessary.
f Attach a “DO NOT START” sign to the control panel to notify other people of its condi-
tion whenever the machine is being serviced.
NEVER use gasoline or other types of fuels or flammable solvents to clean

parts. Fumes from fuels and solvents can become explosive.
ALWAYS keep the fuel lines in good condition and properly connected.
NEVER attempt to clean the machine while it is running.
DO NOT allow water to accumulate around the base of the machine. If water is
present, move the machine and allow the machine to dry before servicing.
DO NOT allow untrained personnel to maintain this equipment. Only trained
electrical technicians should be allowed to maintain the electrical components of
this machine.
ALWAYS allow the engine to cool before transporting or maintaining it.
ALWAYS replace the safety devices and guards after repairs and maintenance.
Guidelines for ALWAYS make sure slings, chains, hooks, ramps, jacks and other types of lifting
lifting devices are attached securely and have enough weight-bearing capacity to lift
or hold the machine safely.
Always remain aware of the location of other people nearby when lifting the
machine.
Guidelines for ALWAYS replace worn or damaged components with spare parts designed and
spare parts recommended by Wacker Corporation.
ALWAYS keep the machine clean and labels legible. Replace all missing and
hard-to-read labels. Labels provide important operating instructions and warn of
dangers and hazards.
DO NOT modify the machine without the express written approval of the manu-
facturer.
wc_si000245gb.fm 10
1.5 Label Locations
wc_gr005497
wc_si000245gb.fm 11
1.6 Warning Labels
Label Definition
DANGER!
No sparks, flames or burning objects near
machine.
Shut off the engine before refueling.
WARNING!
Hot surface!
Improper connection of generator to a

building’s electrical system can allow
electrical current from the generator to
backfeed into utility lines. This may result
in electrocution of utility workers, fire, or
explosion. Connections to a building’s
electrical system must be made by a
qualified electrician and comply with all
applicable laws and electrical codes.
Using a generator indoors CAN KILL YOU IN MINUTES. Generator

exhaust contains carbon monoxide. This is a poison you cannot see or
smell.
NEVER use inside a home or garage,

EVEN IF doors and windows are open.
Only use OUTSIDE and far away from

windows, doors, and vents.
wc_si000245gb.fm 12
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.
wc_si000245gb.fm 13
Turn the engine switch to “OFF”.
Close the fuel flow valve.
Electrical ground
1.8 Informational Labels
A nameplate listing the model number,

item number, revision number, and serial
number is attached to each unit. Please
record the information found on this plate
so it will be available should the
nameplate become lost or damaged.
When ordering parts or requesting
service information, you will always be
asked to specify the model number, item
number, revision number, and serial
number of the unit.
wc_si000245gb.fm 14
GV Generators Troubleshooting Voltage Issues
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.
V
F 1000
200
20
V
2
200m
V- COM
wc_gr004336
WARNING! Electric shock hazard. High voltage exists at the alternator. Electric shock can
cause severe injury or death.
f Never touch the alternator components or the wires of the generator when the engine is
running.
2. Start the engine.

3. Place the auto idle switch in the OFF position.
4. Measure the voltage between the red and yellow wires; also measure between
the black and green wires.
If Then
Between 100–140 VAC is measured in both Start with step 6.
locations
All other cases Start with step 1.
Sequence Follow the sequence below when troubleshooting:

Step Topic
1. Test charge the generator with a 9-Volt battery. 2.1
2. Check the stator windings. 2.2
3. Check the rotor windings. 2.3
4. Check the brushes. 2.4
5. Check the excitation winding. 2.5
6. Check AVR sensing wires. 2.6
7. Check main circuit breaker. 2.7
8. Check the voltage selector switch. 2.8
wc_tx000772gb.fm 15
Troubleshooting Voltage Issues GV Generators
2.1 Charging the Generator with 9-Volt Battery
Prerequisites 9-Volt battery
Multimeter
Procedure Follow the procedure below to test charge the generator with a 9-Volt battery.
2. Disconnect the wiring at the connector to the automatic voltage regulator (AVR)
(b).
3. Disconnect the wiring to the brushes.
4. Connect a 9-Volt battery to the brushes—this is a polarity-sensitive connection
so be certain to connect battery positive to the positive brush.
V
+ – F 1000
200
20
2
V
200m
9V A
V- COM
wc_gr004395

6. Measure the AC voltage between the red and yellow wires at the terminal strip.
Is 18–65 VAC measured?
Yes ____ No ____ Your reading
The AVR has failed, replace it. Continue troubleshooting by
checking the stator windings.
The procedure to test charge the generator is now complete.
Disconnect the 9-Volt battery and continue troubleshooting.
wc_tx000772gb.fm 16
2.2 Checking the Stator Windings
Prerequisites Generator shut down
Multimeter
Procedure Follow the procedure below to check the stator windings.

2. Disconnect the yellow (Y), red (R), black (B), and green (G) wires from the alter-
nator.
3. Measure the resistance in Ohms between the red and yellow wires. Also mea-
sure between the black and green wires. See chart below.
Machine R–Y B–G
GV 2500A 0.9–1.4 0.9–1.4
GV 3800A 0.7–1.2 0.7–1.2
GV 5600A 0.4–0.9 0.4–0.9
GV 6600A 0.3–0.8 0.3–0.8
Is the correct resistance measured for your machine?

Yes ____ No ____
Continue. The stator windings have failed. Replace the stator.
This procedure continues on the next page.
wc_tx000772gb.fm 17
Continued from the previous page.
4. Check each winding to ground. Measure the resistance between each post
where the yellow (Y), red (R), black (B), and green (G) wires were connected
and the ground stud.
Is any resistance measured for any of the checks?

Yes ____ No ____
The stator windings have failed. Replace the stator. Continue.
Result The procedure to check the stator windings is now complete.
Reassemble the generator or, if the problem has not been resolved, continue with
the next topic.
wc_tx000772gb.fm 18
2.3 Checking the Rotor Windings
Multimeter
Procedure Follow the procedure below to check the rotor winding.

sdfdsf
2. Remove the screw that secures the brushes (b) and remove the brushes.
3. Measure the resistance of the rotor winding by measuring across the slip rings
(c).
GP 2500: 51–53 c
GP 3800: 47–49
GP 5600: 57–59
F 1000
V
GP 6600: 59–61
200
20
2
200m
V- COM
wc_gr004340
Is the correct resistance measured for your model?

Yes ____ No ____
Continue. The rotor winding has failed. Replace the rotor.
wc_tx000772gb.fm 19
4. Check for shorts to the rotor shaft by measuring resistance between each slip
ring and the end of the rotor shaft.
Is any resistance measured for either of the checks?

Yes ____ No ____
The rotor winding has failed. Replace the rotor. The rotor winding is
OK.
5. Re-install the brushes—do not overtighten the screws.
6. Re-install the end cap.
Result The procedure to check the rotor winding is now complete.
the next topic.
wc_tx000772gb.fm 20
2.4 Checking the Brushes
Multimeter
Procedure Follow the procedure below to check the brushes.

sdfdsf
2. Remove the screw that secures the brush holder (b) and remove the brush
holder.
3. Measure the length of the brush protruding from the brush holder. The minimum
allowable length is 6.5 mm (0.25 in.).
6.5
mm
wc_gr004341
4. Measure the continuity of each brush.
Does each brush measure at least 6.5 mm and have continuity?

The brushes are OK The brushes have failed. Replace
the brushes.
5. Re-install the brush holder—do not overtighten the screw.
The procedure to check the brushes is now complete.

If the problem has not been resolved, continue with checking the excitation wind-
ing.
wc_tx000772gb.fm 21
2.5 Checking the Excitation Winding
Multimeter
Procedure Follow the procedure below to check the excitation winding.

2. Disconnect the plug (b) which connects the excitation winding to the Automatic
Voltage Regulator (AVR).
3. Measure the resistance of the excitation winding by measuring across the two
yellow (Y) wires of the connector.
Is the correct resistance measured for your model?

Continue. The excitation winding has failed.
Replace the stator.
wc_tx000772gb.fm 22
4. Check each side of the winding to ground by Measuring the resistance between
each yellow wire and the ground stud.
Is any resistance measured for either of the checks?

Yes ____ No ____
The excitation winding has failed. Replace the stator. Continue.
5. Reconnect the wiring.
Result The procedure to check the excitation winding is now complete.

the next topic.
wc_tx000772gb.fm 23
2.6 Checking the AVR’s Sensing Wires
Multimeter
Procedure Follow the procedure below to check the Automatic Voltage Regulator (AVR) sens-
ing wires.
2. Disconnect the white (W), red (R), gray (Gr), and light green (LG) wires from the
generator terminal strip.
3. Disconnect the AVR at the wiring harness connector (b).
4. Check the continuity between the brown (Br) wire of the wiring harness connec-
tor (b) and the yellow wire (Y) of the generator.
Does the wiring have continuity?

Yes ____ No ____
Continue. The wiring has failed. Replace the stator.
wc_tx000772gb.fm 24
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?
Yes ____ No ____
The sensing wire has failed. Replace the stator. Continue.
6. Disconnect the 6-wire connector (c).
7. Check for continuity between the light green (LG) wire of the 6-wire connector
and the black (B) wire of the generator.
Yes ____ No ____
8. Check the resistance between the light green (LG) wire of the wiring harness 6-
wire connector (c) and the ground stud (x).
Is any resistance measured?
Yes ____ No ____
The sensing wire has failed. Replace the stator. Continue.
9. Check for continuity between the red-white (R/W) wire of the 6-wire connector
and the red (R) wire of the generator.
Yes ____ No ____
wc_tx000772gb.fm 25
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).
Yes ____ No ____
Continue. The wiring has failed. Repair the RW wire.
12.Check the continuity of the gray (GR) wire between the 6-wire connector and
the VSS.
Yes ____ No ____
Continue. The wiring has failed. Repair the GR wire.
13.Check the continuity of the light green (LG) wire between the 6-wire connector
and the VSS.
Yes ____ No ____
Continue. The wiring has failed. Repair the LG wire.
14.Disconnect the 4-wire plug from the automatic voltage regulator (AVR).
15.Check the continuity of the blue (L) wire from the 4-wire connector to the 6-wire
connector.
Yes ____ No ____
Continue. The wiring has failed. Repair the L wire.
16.Reconnect the wiring and reassemble the generator.
Result The procedure to check the AVR sensing wires is now complete.
wc_tx000772gb.fm 26
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 panel to access screws (b).
2. Remove the screws (b) that secure the front and back halves of the control
panel.
3. Position the front half of the control panel to access the main circuit breaker (c).
4. Place the auto idle switch in the OFF position.
WARNING! Electric shock hazard. High voltage exists at the components of the control
panel when the engine is running. Electric shock can cause severe injury or death.
f Never touch any control panel component with your bare hands when the engine is run-
ning.

wc_tx000772gb.fm 27
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?
The main circuit breaker is recei- The main circuit breaker is not
ving voltage; continue. receiving voltage. Shut down the
engine and check the wiring.
7. Place the main circuit breaker in the ON position.
8. Check the outgoing voltage from the main circuit breaker by measuring the volt-
age between the red wire and a common ground; then at the blue wire and a
common ground.
Is 110–130V measured in each case?

The main circuit breaker is OK. The main circuit breaker has failed;
replace it.
The procedure to check the main circuit breaker is now complete.

Reassemble the generator.
wc_tx000772gb.fm 28
2.8 Checking the Voltage Selector Switch (VSS)
Procedure Follow the procedure below to check the Voltage Selector Switch (VSS).
removed, lower the control panel to access screws (b).
2. Remove screws (b) that secure the front and back halves of the control panel.
3. Position the front half of the control panel to access the VSS (c).
4. Remove the two wiring connectors (d) from the VSS.

5. Check the VSS for continuity as shown below.
1 5 9
Position 120V 120/240V
1–5 5–9
2 6 10 Terminals
with 2–6 6–10
3 11 continuity 3–7 7–11
7
4–8 8–12
4 12
8
wc_gr004368
Does the VSS function properly?
The VSS is OK. The VSS has failed; replace it.
6. Reassemble the generator.
The procedure to check the VSS is now complete.
wc_tx000772gb.fm 29
2.9 Checking the Auto Idle Unity and Circuity
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. Measure the resistance across the two gray wires of the 6-pin connector.
Is the correct resistance measured for your machine?

Continue. The auxiliary winding has failed.
Call Wacker Service.
wc_tx000772gb.fm 30
4. Disconnect the DC rectifier (z).
F 1000
200
20
V
y
2
200m
V- COM
A
wc_gr004370 wc_gr004372
5. Check across the terminals of the DC rectifier using the diode scale. Use the
terminal (y) where the BR-R wire connects as a base point. Measure between it
and the two other terminals. Reverse the leads of the meter and measure
again. The meter should read approximately 0.5V in one direction and OPEN or
“OL” in the other.
Does the DC rectifier function as stated above?

The DC rectifier is OK; continue. The DC rectifier has failed;
replace it.
wc_tx000772gb.fm 31
removed, lower the control panel to access the screws (b).
panel.
8. Position the front half of the control panel to access the auto idle unit (c).
wc_tx000772gb.fm 32
ning.

10.Measure the DC voltage between the black/red (B/R) wire at the connector and
the white/black (W/B) wire of the auto idle unit.
B/R W/B
F 1000
200
20
V
2
200m
VDC
VDC V- COM
wc_gr004361
Is at least 9.8VDC measured?

Continue. The wiring has failed. Check the continuity of the
B/R wire and the continuity of the W/B wire.
11.Shut down the engine.
wc_tx000772gb.fm 33
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?

Reconnect the auto idle switch and Replace the auto idle switch.
continue.
ning.
13.Start the engine.

14.Place the auto idle switch in the ON position.
wc_tx000772gb.fm 34
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.

Continue. The wiring has failed. Shutdown engine and
check the continuity of the B wire and the conti-
nuity of the W/B wire.
16.Measure the DC voltage between the red/white (R) wire of the auto idle unit and
the white/black (W/B) wire of the auto idle unit.

Continue. The auto idle unit has failed. Call
Wacker Service.
wc_tx000772gb.fm 35
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.

Continue. The auto idle unit has failed. Call
Wacker Service.
18.Place the main breaker in the ON position.

19.Connect a load to the generator.
20.Once again, measure the voltage between the red (R) wire of the auto idle unit
and the white-black (W/B) wire of the auto idle unit.
Is at least approximately 0 (zero) VDC measured?
The auto idle circuit is OK. The auto idle unit has failed. Call
Wacker Service.
21.Reassemble the generator.
The procedure to check the auto idle circuitry is now complete.
wc_tx000772gb.fm 36
2.10 Checking the Anti-Afterfire Solenoid
Functioning DC Rectifier (See section Checking Auto Idle Unit and Circuitry.)
Procedure Follow the procedure below to check the Anti-Afterfire Solenoid (AAS).
removed, lower the control panel to access the screws (b).
panel.
3. Position the front half of the control panel to access the capacitor (c).
4. Remove the wiring from the capacitor.

5. Discharge the capacitor by placing a screwdriver across the two terminals.
wc_tx000772gb.fm 37
6. Measure the capacitance of the capacitor.
Does the capacitor measure approximately 4700 ±10% micro Farads?

The capacitor is OK. The capacitor has failed; replace it.
7. Reassemble the generator.
The procedure to check the AAS is now complete.
wc_tx000772gb.fm 38
GV Generator Repair Disassembly and Assembly
3 Disassembly and Assembly
3.1 Tools Required for Disassembly/Assembly Procedures
It is up to the mechanic to use common sense and good judgment in tool
selection to reduce the risk of injury while repairing the machine.
In cases where a special tool is required, the special tool is listed in the
prerequisite section of the procedure.
Before substituting another tool or procedure from those recommended in this
manual, the mechanic must be satisfied that neither personal injury nor damage
to the machine will result due to the substitution.
3.2 Information Regarding Replacement Parts

The repair procedures contained in this manual do not include part numbers.
For replacement parts information, refer to the Parts Book originally supplied
with the machine.
If the original Parts Book has been lost, a replacement may be ordered from
Wacker Neuson Corporation.
When ordering a replacement Parts Book, please list the model number, item
number, revision level, and serial number of the machine.
Parts Books are also available on the Wacker Neuson Corporation Web site.
See www.wackerneuson.com. Enter the site as a visitor.
3.3 Information Regarding Reference Numbers ( )

Repair procedures contain reference numbers enclosed in parentheses ( ). These
numbers refer to the item numbers shown on the assembly drawings and other
detailed drawings. They are included to aid the mechanic in identifying parts and
assembling components.
3.4 Information Regarding Threadlocking Compounds

Background Due to the heavy vibration inherent in this type of equipment, the repair and service
procedures described in this manual specify the use of threadlocking compounds.
These compounds should be used where indicated to prevent the fasteners from
becoming loose.
Recommended Although Loctite® is referred to throughout this manual, any equivalent type of
threadlockers sealant such as Hernon®, Prolock, or Omnifit may be used. For a complete list of
recommended sealing and locking compounds, refer to the Use of Threadlockers
and Sealants chart at the end of this manual.
Applying Clean the screw threads and wipe off any oil or grease before applying a thread-
threadlockers locking compound.
wc_tx000775gb.fm 39
Disassembly and Assembly GV Generator Repair
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 the outer muffler guard and remove the outer
muffler guard (a).
4. Remove the screw (g) that secures the generator mounting leg to the shock
mount bracket.
5. Remove the screw (h) that secures the ground wire.
6. Remove the screw (i) that secures the muffler to the stator.
7. Remove the screws (b) that secure the muffler to the engine.
wc_tx000775gb.fm 40
8. Lift the muffler and the muffler guard from the engine and frame.
wc_gr004408
The procedure to remove the muffler is now complete.
wc_tx000775gb.fm 41
3.6 Installing the Muffler
Procedure Follow the procedure below to install the muffler.

1. Position the muffler and the muffler guard into the frame and onto the engine.
wc_gr004408
2. Remove the screws (b) that secure the muffler to the engine.
3. Install the screw (i) that secures the muffler to the stator.
4. Install the screw (g) that secures the generator mounting leg to the shock mount
bracket.
5. Install the screw (h) that secures the ground wire.
wc_tx000775gb.fm 42
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 now complete.
wc_tx000775gb.fm 43
3.7 Removing the Fuel Tank
Prerequisites Machine shut down
Procedure Follow the procedure below to remove the fuel tank.

2. Close the fuel valve.
3. Disconnect the fuel hose (a) from fuel valve.
a
b
wc_gr004397
4. Remove the screws (b) that secure the tank and brace to the fuel frame and pull
the fuel tank from the frame.
5. Remove the brace from the fuel tank.
The procedure to remove the fuel tank is now complete.
3.8 Installing the Fuel Tank

Procedure Follow the procedure below to install the fuel tank.

1. Install the brace to the fuel tank.
2. Position the fuel tank into the frame and secure it with screws (b).
a
b
wc_gr004397
3. Connect the fuel hose (a) to the fuel valve.
The procedure to install the fuel tank is now complete.
wc_tx000775gb.fm 44
3.9 Removing the Stator
Procedure Follow the procedure below to remove the stator.

2. Remove the end cover (a).
d c
e
b
wc_gr004398
3. Disconnect the wiring from the terminal strip (b), the ground wire (c), and the
harness connector (d). On GV 2500 machines, disconnect the generator plug
(e).
4. Remove the brush holder (f).
5. Remove the screw (g) that secures the generator mounting leg to the shock
mount bracket.
6. Remove the screw (h) that secures the ground wire.
wc_tx000775gb.fm 45
7. Remove the screw (i) that secures the muffler to the stator.
8. Remove the four long screws (j) that secure the stator to the machine.
9. Pull the stator (k) from the machine.
The procedure to remove the stator is now complete.
wc_tx000775gb.fm 46
3.10 Installing the Stator
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 screws (j).
3. Install the screw (i) that secures the muffler guard to the stator.
4. Install the screw (h) that secures the ground wire.
5. Install the screw (g) that secures the generator mounting leg to the shock mount
bracket.
wc_tx000775gb.fm 47
6. Install the brush holder (f).
d c
e
b
wc_gr004398
7. Connect the wiring to the terminal strip (b), the ground wire (c), and the harness
connector (d). On GV 2500 machines, connect the generator plug (e).
8. Re-install the end cover (a).
The procedure to install the stator is now complete.
wc_tx000775gb.fm 48
3.11 Removing the Rotor
Prerequisites Oil filter wrench
Procedure Follow the procedure below to remove the rotor.

2. Remove the stator. See section Removing the Stator.
3. Loosen the long bolt (a) that secures the rotor to the engine. To prevent the
rotor from spinning, secure the rotor with an oil filter wrench when removing the
long bolt.
4. Support the rotor with one hand then strike the rotor with a rubber hammer
repeatedly while rotating the rotor until it comes free of the engine shaft.
NOTICE: Do not strike the winding wires or the magnet (c). Damage to the rotor
may occur.
5. Remove the long bolt and the rotor from the engine.
The procedure to remove the rotor is now complete.
wc_tx000775gb.fm 49
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 prevent the rotor
from spinning, secure the rotor with an oil filter wrench when installing the long
bolt.
The procedure to install the rotor is now complete.
wc_tx000775gb.fm 50
3.13 Removing the Engine
Procedure Follow the procedure below to remove the engine.

2. Label and disconnect the wiring between the engine and the control panel.
3. Remove the fuel tank. See section Removing the Fuel Tank.
4. Remove the muffler. See section Removing the Muffler.
5. Remove the stator. See section Removing the Stator.
6. Remove the rotor. See section Removing the Rotor.
7. Remove the screws (a) that secure the engine to the shock mounts.
8. Pull the engine from the frame.
The procedure to remove the engine is now complete.
wc_tx000775gb.fm 51
3.14 Installing the Engine
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 Installing the Rotor.

3. Install the stator. See section Installing the Stator.
4. Install the muffler. See section Installing the Muffler.
5. Install the fuel tank. See section Installing the Fuel Tank.
6. Connect the wiring between the engine and the control panel.
The procedure to install the engine is now complete.
wc_tx000775gb.fm 52
Notes
wc_tx000775gb.fm 53
Schematics GV Generator Repair
4 Schematics
4.1 Electrical Schematic—GV 2500A
8
7
10
6
11
13
5
C
B
12
2
1
4
14
A
3
wc_tx000813gb.fm 54
GV Generator Repair Schematics
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 winding 10 Oil level switch
4 Automatic voltage regulator 11 Ignition coil
5 20A circuit breaker 12 Ground terminal
6 GFI duplex receptacle—125V 13 Spark plug
7 Duplex receptacle—125V 14 Slip ring
Wire Colors
B Black V Violet Or Orange
G Green W White Pr Purple
L Blue Y Yellow Sh Shield
P Pink Br Brown LL Light Blue
R Red Cl Clear G/Y Green/Yellow
T Tan Gr Gray
wc_tx000813gb.fm 55
4.3 Electrical Schematic—GV 3800A
19
6
8
20
9
17
10
21
5
11
18
13
16
C
15
B
23
12
22
2
1
4
14
A
3
wc_tx000813gb.fm 56
4.4 Electrical Components—GV 3800A


1 Main stator winding 13 Spark plug
2 Secondary winding 14 Slip ring
3 Rotor winding 15 Auto idle unit
4 Automatic voltage regulator 16 Voltage selector switch
5 20A circuit breaker 17 Twist lock receptacle—125/250V
6 GFI duplex receptacle—125V 18 Auto idle switch
7 --- 19 Idle solenoid
8 Engine ON-OFF switch 20 Capacitor
9 Oil alert module 21 Fuel stop solenoid
10 Oil level switch 22 Auxiliary winding
11 Ignition coil 23 DC rectifier
12 Ground terminal - ---
Wire Colors
T Tan Gr Gray
wc_tx000813gb.fm 57
4.5 Electrical Schematic—GV 5600A, GV 6600A
19
6
8
24
20
9
17
10
21
5
11
18
13
16
C
15
B
12
23
22
2
1
4
14
A
3
wc_tx000813gb.fm 58
4.6 Electrical Components—GV 5600A, GV 6600A


1 Main stator winding 13 Spark plug
2 Secondary winding 14 Slip ring
3 Rotor winding 15 Auto idle unit
4 Automatic voltage regulator 16 Voltage selector switch
5 Main circuit breaker 17 Twist lock receptacle—125/250V
6 GFI duplex receptacle—125V 18 Auto idle switch
7 --- 19 Idle solenoid
8 Engine ON-OFF switch 20 Capacitor
9 Oil alert module 21 Fuel stop solenoid
10 Oil level switch 22 Auxiliary winding
11 Ignition coil 23 DC rectifier
12 Ground terminal 24 Twist lock receptacle—125V
Wire Colors
T Tan Gr Gray
wc_tx000813gb.fm 59
Technical Data GV Generators
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 120
phase 1
Frequency Hz 60
Power factor cos ø 1.0
AC receptacles:
125V GFI duplex Amp 20
125V duplex Amp 20
Main circuit breaker Amp 20
LxWxH mm (in.) 625 x 440 x 490 (24.5 x 17.2 x 19.3)
Weight (dry) kg (lbs.) 45 (99.2)
wc_td000248gb.fm 60
GV Generators Technical Data
5.2 Engine—GV 2500A
Engine Power Rating
Net power rating per SAE J1349. Actual power output may vary due to conditions
of specific use.
Item No. GV 2500A

0620286 0620542
Engine
Engine make Honda
Engine model GX 160 K1
Maximum rated power kW (Hp) 3.6 (4.8) @ 3600 rpm
at rated speed
Spark plug BPR6ES (NKG)
Electrode gap mm (in.) 0.7–0.8 (0.028–0.031)
Operating speed rpm 3600
Air cleaner type Oil-wetted foam
EnginelLubrication oil grade SAE 10W30 service class SF or SG
Engine oil capacity l (qts.) 0.6 (0.7)
Fuel type Regular unleaded gasoline
Fuel tank capacity l (gal.) 14 (3.7)
Fuel consumption l (qts.)/hr. 1.5 (1.6)
Running time - hrs. 9.7
continuous load
wc_td000248gb.fm 61
Item No. GV 3800A

0620287
Generator
Type Single phase,
AC voltages available Volts 120/240
phase 1
Frequency Hz 60
AC receptacles:
125V GFI duplex (2) Amp 20
125/250V twist lock Amp 20
Main circuit breaker Amp 16 per pole
(two pole)
LxWxH mm (in.) 710 x 550 x 515 (28.0 x 21.6 x 20.3)
wc_td000248gb.fm 62
Engine Power Rating
of specific use.
Item No. GV 3800A

0620287
0620334
0620409
Engine
Engine make Honda
at operating speed
Engine lubrication oil grade SAE 10W30 service class SF or SG
continuous load
wc_td000248gb.fm 63
Item No. GV 5600A

0620288
0620335
0620410
Generator
Type Single phase,
phase 1
Frequency Hz 60
AC receptacles:
125V twist lock Amp 30
(two pole)
LxWxH mm (in.) 710 x 550 x 515 (28.0 x 21.6 x 20.3)
Weight (dry) kg (lbs.) 78 (172)
wc_td000248gb.fm 64
Engine Power Rating
of specific use.
Item No. GV 5600A

0620288
0620335
0620410
Engine
Engine make Honda
at rated speed
continuous load
wc_td000248gb.fm 65
Item No. GV 6600A

0620289
Generator
Type Single phase,
phase 1
Frequency Hz 60
AC receptacles:
(two pole)
LxWxH mm (in.) 710 x 550 x 515 (28.0 x 21.6 x 20.3)
wc_td000248gb.fm 66
Item No. GV 6600A

0620336
Generator
Type Single phase,
phase 1
Frequency Hz 60
AC receptacles:
(two pole)
LxWxH mm (in.) 710 x 550 x 515 (28.0 x 21.6 x 20.3)
wc_td000248gb.fm 67
Engine Power Rating
of specific use.
Item No. GV 6600A

0620289
Engine
Engine make Honda
Max. rated power @ kW (Hp) 8.2 (11.0) @ 3600 rpm
rated speed
continuous load
wc_td000248gb.fm 68
Engine Power Rating
of specific use.
Item No. GV 6600A

0620336
Engine
Engine make Honda
Engine model GX 390 R1
Max. rated power @ kW (Hp) 9.7 (13) @ 3600 rpm
rated speed
continuous load
wc_td000248gb.fm 69
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.
When applying sealants, follow instructions on container. The sealants
listed are recommended for use on Wacker Neuson equipment.
TYPE PART NO. –

( ) = Europe COLOR USAGE SIZE
Loctite 222 Purple Low strength, for locking threads smaller 73287 - 10 ml
Hernon 420 than 6 mm (1/4”).
Omnifit 1150 (50M) Hand tool removable.
Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 243 Blue Medium strength, for locking threads 29311 - .5 ml
Hernon 423 larger than 6 mm (1/4”). 17380 - 50 ml
Omnifit 1350 (100M) Hand tool removable.
Loctite 271/277 Red High strength, for all threads up to 25 mm 29312 - .5 ml
Hernon 427 (1”). 26685 - 10 ml
Omnifit 1550 (220M) Heat parts before disassembly. 73285 - 50 ml
Loctite 290 Green Medium to high strength, for locking 28824 - .5 ml
Hernon 431 preassembled threads and for sealing 25316 - 10 ml
Omnifit 1710 (230LL) weld porosity (wicking).
Gaps up to 0.13 mm (0.005”)
Loctite 609 Green Medium strength retaining compound for 29314 - .5 ml
Hernon 822 slip or press fit of shafts, bearings, gears,
Omnifit 1730 (230L) pulleys, etc.
Gaps up to 0.13 mm (0.005”)
Loctite 545 Brown Hydraulic sealant 79356 - 50 ml
Hernon 947 Temp. range: -54 to 149°C (-65 to 300°F)
Omnifit 1150 (50M)
Loctite 592 White Pipe sealant with Teflon for moderate 26695 - 6 ml
Hernon 920 pressures. 73289 - 50 ml
Omnifit 790 Temp. range: -54 to 149°C (-65 to 300°F)
Loctite 515 Purple Form-in-place gasket for flexible joints. 70735 - 50 ml
Hernon 910 Fills gaps up to 1.3 mm (0.05”)
Omnifit 10 Temp. range: -54 to 149°C (-65 to 300°F)
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.
When applying sealants, follow instructions on container. The sealants
listed are recommended for use on Wacker Neuson equipment.
TYPE PART NO. –

( ) = Europe COLOR USAGE SIZE
Loctite 496 Clear Instant adhesive for bonding rubber, 52676 - 1oz.
Hernon 110 metal and plastics; general purpose.
Omnifit Sicomet 7000 For gaps up to 0.15 mm (0.006”)
Read caution instructions before using.
Loctite Primer T Aerosol Fast curing primer for threadlocking, 2006124-6 oz.
Hernon Primer 10 Spray retaining and sealing compounds. Must
Omnifit VC Activator be used with stainless steel hardware.
Recommended for use with gasket
sealants.
Torque Values
Torque Values
Metric Fasteners (DIN)
TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE
8.8 10.9 12.9
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 13 10 – 5 –
M8 25 18 35 26 41 30 13 1/2 6 –
M10 49 36 69 51 83 61 17 11/16 8 –
M12 86 63 120 88 145 107 19 3/4 10 –
M14 135 99 190 140 230 169 22 7/8 12 –
M16 210 155 295 217 355 262 24 15/16 14 –
M18 290 214 405 298 485 357 27 1-1/16 14 –
M20 410 302 580 427 690 508 30 1-1/4 17 –
1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

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 6 12 9 16 12 – 7/16 – 3/32
5/16 18 13 26 19 33 24 13 1/2 – 1/4
3/8 31 23 45 33 58 43 – 9/16 – 5/16
7/16 50 37 71 52 94 69 16 5/8 – 3/8
1/2 77 57 109 80 142 105 19 3/4 – 3/8
9/16 111 82 156 115 214 158 – 13/16 – –
5/8 152 112 216 159 265 195 24 15/16 – 1/2
3/4 271 200 383 282 479 353 – 1-1/8 – 5/8
1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

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 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
Tel: (852) 3605 5360, Fax: (852) 2758 0032

GV 2500A GV 3800A GV 5600A GV 6600A: Generator

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0171887en 002

1.1 Callouts Found in this Manual .............................................................. 7

2 Troubleshooting Voltage Issues 15

2.1 Charging the Generator with 9-Volt Battery ....................................... 16

3 Disassembly and Assembly 39

3.1 Tools Required for Disassembly/Assembly Procedures ..................... 39

4.1 Electrical Schematic—GV 2500A ........................................................54

5.1 Generator—GV 2500A ........................................................................60

WARNING indicates a hazardous situation which, if not avoided, could result in

When operating this machine:

1.3 Safety Guidelines while Using Internal Combustion Engines

Guidelines for  NEVER smoke when refueling the engine.

 NEVER use gasoline or other types of fuels or flammable solvents to clean

Improper connection of generator to a

Using a generator indoors CAN KILL YOU IN MINUTES. Generator

NEVER use inside a home or garage,

Only use OUTSIDE and far away from

Open the fuel flow valve.

Close the choke.

Turn the engine switch to the ON position.

Pull the rewind starter.

Open the choke.

Close the fuel flow valve.

1.8 Informational Labels

A nameplate listing the model number,

2. Start the engine.

Sequence Follow the sequence below when troubleshooting:

5. Start the engine.

The procedure to test charge the generator is now complete.

Disconnect the 9-Volt battery and continue troubleshooting.

Procedure Follow the procedure below to check the stator windings.

Is the correct resistance measured for your machine?

This procedure continues on the next page.

Is any resistance measured for any of the checks?

Result The procedure to check the stator windings is now complete.

Procedure Follow the procedure below to check the rotor winding.

Is the correct resistance measured for your model?

This procedure continues on the next page.

Is any resistance measured for either of the checks?

Result The procedure to check the rotor winding is now complete.

Procedure Follow the procedure below to check the brushes.

Yes ____ No ____ Your reading

The procedure to check the brushes is now complete.

Procedure Follow the procedure below to check the excitation winding.

Is the correct resistance measured for your model?

This procedure continues on the next page.

Is any resistance measured for either of the checks?

Result The procedure to check the excitation winding is now complete.

Does the wiring have continuity?

This procedure continues on the next page.

This procedure continues on the next page.

4. Place the auto idle switch in the OFF position.

5. Start the engine.

Is 110–130V measured in each case?

The procedure to check the main circuit breaker is now complete.

4. Remove the two wiring connectors (d) from the VSS.

6. Reassemble the generator.

The procedure to check the VSS is now complete.

2. Disconnect the 6-wire connector (e).

Guidelines for NEVER smoke when refueling the engine.

NEVER use gasoline or other types of fuels or flammable solvents to clean

Yes No Your reading

Yes No Your reading

Yes No Your reading

Yes No Your reading

Yes No Your reading