0163131en 005 0609 Generator GP 2600 GP 3800A GP 4000 GP 5600A / GPS 5600A GP 6600A / GPS 6600A REPAIR MANUAL 0 1 6 3 1 3 1 E N
GP Repair Foreword This manual covers machines with Item Number: 0620088, 0620089, 0620090, 0620091, 0620092, 0620093, 0620094, 0620095, 0620096, 0620097, 0620098, 0620099, 0620100, 0620101, 0620102, 0620103, 0620104, 0620116, 0620326, 0620327, 0620328, 0620329, 0620330, 0620331, 0620342, 0620379, 0620380, 0620381, 0620382, 0620383, 0620384, 0620385, 0620386, 0620484, 0620485 Operating / Parts Information You must be familiar with the operation of this machine before you attempt to troubleshoot or repair
Foreword WARNING GP Repair CALIFORNIA Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Laws Pertaining to Spark Arresters Notice: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels.
GP 1 Table of Contents Safety Information 1.1 1.2 1.3 1.4 2 Operating Safety ..............................................................................................9 Operator Safety while using Internal Combustion Engines ...........................11 Service Safety ...............................................................................................12 Safety and Operating Labels .........................................................................13 Operation 2.1 2.2 2.3 2.4 2.5 2.
Table of Contents 3.17 3.18 3.19 3.20 4 GP Engine Electrical Schematic—GP 3800, GP/GPS 5600, GP/GPS 6600 .....46 Engine Components ......................................................................................47 Electrical Schematic—GP 4000 ....................................................................48 Electrical Schematic—GP 4000 CAN ............................................................50 Troubleshooting 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.
GP 5 Table of Contents Disassembly/Assembly Procedures 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6 Tools ..............................................................................................................91 Ordering Parts ...............................................................................................91 Reference Numbers ( ) ..................................................................................91 Replacing the Muffler ...........................................................
Safety Information 1 GP Gens Safety Information This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
GP Gens 1.1 Safety Information Operating Safety DANGER DANGER WARNING 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 this generator inside a home or garage, EVEN IF doors and windows are open. Only use this generator OUTSIDE and far away from windows, doors, and vents.
Safety Information GP Gens 1.1.8 NEVER allow untrained personnel to operate or service the generator. The generator set should be set up by a certified electrician. 1.1.9 NEVER stand on the machine. 1.1.10 DO NOT stand under the machine while it is being hoisted or moved. 1.1.11 DO NOT attach equipment to the machine when it is suspended. 1.1.12 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. 1.1.
GP Gens 1.2 Safety Information Operator Safety while using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the warnings and safety standards could result in severe injury or death. 1.2.1 NEVER use this generator inside a home or garage, EVEN IF doors and windows are open.
Safety Information 1.3 GP Gens Service Safety WARNING Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. If the generator is experiencing problems or is being serviced, attach a “DO NOT START” sign to the control panel to notify other people of its condition. 1.3.
GP Gens 1.4 Safety Information Safety and Operating Labels Wacker Neuson machines use international pictorial labels where needed. These labels are described below: Label Meaning DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling. DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling. Read the Operator’s Manual for machine information. WARNING! Hot surface! Using a generator indoors CAN KILL YOU IN MINUTES.
Safety Information Label GP Gens Meaning 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. 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 and arc flash, read the Operator’s Manual.
GP Gens Safety Information Label Meaning GND 88897 Electrical ground 1 2 3 4 5 6 1 2 CAUTION! Use only clean, filtered gasoline fuel. Check the fuel level. Open the fuel flow valve. Close the choke.
Safety Information Label GP Gens Meaning Turn the engine switch to the ON position. Pull the rewind starter. Open the choke. Turn the engine switch to “OFF”. Close the fuel flow valve. Press circuit breaker switch to OFF position. Press engine switch to ON position. GPS - Press ignition switch. GP - Pull the rewind starter.
GP Gens Label Safety Information Meaning Press circuit breaker switch to ON position. Press engine switch to OFF position. This equipment does not meet California EVP emission regulations for small off-road engines. Important Emissions Information This equipment meets California EVP emission regulations for small off-road engines. WARNING Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrestor may be required.
Safety Information Label GP Gens Meaning This machine may be covered by one or more patents.
GP Gens Safety Information Notes 19
Operation 2 GP Repair Operation 2.1 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 in the Operator’s Manual when operating the machine. 2.2 Determining Power Requirements This generator is designed to operate single-phase, 60 Hz appliances running at 120 VAC or 240 VAC.
GP Repair Operation • Loads such as submersible pumps and air compressors require a very large force to start. They need as much as 3–5 times the wattage stated on the nameplate in order to start. 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 2.3 Recommended Battery (GPS only) This generator is shipped without a battery.
Operation 2.4 GP Repair Installation Place the generator in an area where it will not be exposed to rain, snow, or direct sunlight. Make sure it is positioned on firm, level ground, so it will not slide or shift. Position the engine exhaust away from areas where people may be present. The surrounding area must be free from water and moisture. All components must be protected from excessive moisture. DANGER DANGER wc_tx000586gb.fm Using a generator indoors CAN KILL YOU IN MINUTES.
GP Repair 2.5 Operation Generator Derating All generators are subject to derating for altitude and temperature. Internal combustion engines, unless modified, run less efficiently at higher altitudes due to the reduction of air pressure. This translates into a lack of power and thus reduction in generator output. Temperature affects both engine and generator performance. As temperature increases, an engine will run less efficiently and more resistance will be found in electrical components.
Operation 2.6 GP Repair Grounding the Generator See Graphic: wc_gr000544 A ground connection (a) is located on the generator frame. For proper operating safety, this ground terminal must be connected to a good ground source. This ground connection must comply with National Electrical Code standards, and state and local regulations. wc_gr000544 wc_tx000586gb.
GP Repair 2.7 Ref. Operation Control Panel–GP 2600 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 f Engine ON-OFF switch wc_tx000586gb.
Operation 2.8 GP Repair Control Panel—GP 3800, GP 5600/GP 6600, GPS 5600/GP 6600 wc_gr003143 See Graphic: wc_gr003143 Ref. Description Ref. Description a Engine Switch g GFCI test button b Auto Idle Switch h GFCI reset button c Twist-lock receptacle - 120V j Twist-lock receptacle - 120/240V d Main Circuit Breaker k Ignition Switch (GPS only) e Voltage Selector Switch m 20A circuit breaker (CAN only) f Duplex receptacle - 120V n 30A circuit breaker (CAN only) wc_tx000586gb.
GP Repair 2.9 Operation Ground Fault Circuit Interrupter (GFCI) See Graphic: wc_gr003143 The GFCI should be tested for proper operations every time the generator is used. Normal operating state - sensing device green LED is “ON” and circuit breaker is at “ON” position. 2.9.1 Press “TEST” button (g). Green LED should go “OUT” and red LED should come “ON” and circuit breaker should trigger to “OFF” position (d). 2.9.2 If sensing device LED or breaker does not trip or change state, “DO NOT USE”.
Operation GP Repair 2.11 Engine Auto Idle See Graphic: wc_gr003143 The auto idle switch (b) automatically reduces engine speed approximately 7 seconds after all appliances or tools attached to the generator have been turned off. The engine automatically returns to full speed when a tool or appliance is turned back on. To turn the auto idle feature on, push the auto idle switch to “AUTO”. The AUTO setting is recommended while the generator is running to minimize fuel consumption.
GP Repair Operation 2.13 Voltage Selection See Graphic: wc_gr003144 The voltage selector switch (e) allows the generator to operate in either single (120V) or dual voltage (120/240V) mode. In single-voltage mode, use only the 120V twist-lock (c) and duplex receptacles (f1, f2). The full rated power of the generator is shared between the three receptacles. In dual voltage mode both the 120V and 120/240V receptacles are powered; lower watts are available on receptacles (f1, f2, c).
Operation GP Repair 2.14 To Start See Graphic: wc_gr002500 Before starting, be sure you read and understand all the safety and operating instructions in this manual. 2.14.1 Ensure that the generator is properly installed in an outdoor location. See Sections Installation and Operator Safety while using Internal Combustion Engines for installation warnings and safety guidelines. 2.14.2 Disconnect all loads from the generator and place the main circuit breaker switch in the OFF position (a2). 2.14.
GP Repair Operation wc_gr002500 2.15 To Stop See Graphic: wc_gr002500 2.15.1 Turn off and disconnect all tools and appliances attached to the generator. 2.15.2 Place the main circuit breaker in the OFF position (a2). 2.15.3 Turn the engine switch to “OFF” (b2). 2.15.4 Close the fuel valve (d2). Note: To stop the engine quickly in an emergency, turn or press the engine switch to “OFF” (b2). wc_tx000586gb.
Maintenance 3 GP Repair Maintenance 3.1 Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to your engine operator’s manual for additional information on engine maintenance. 3.2 Periodic Maintenance Schedule Daily before starting Check the fuel level. Check the engine oil level. Inspect the air filter. Replace as needed. Check external hardware. After first 20 hrs. Clean the air cleaner element.* Every 50 hrs. Every 100 hrs. Every 300 hrs.
GP Repair 3.3 Maintenance Engine Oil See Graphic: wc_gr000022 3.3.1 Drain the oil while the engine is still warm. 3.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation. 3.3.3 Install the drain plug. 3.3.
Maintenance 3.4 GP Repair Servicing Air Cleaner See Graphic: wc_gr002815 Service the air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run the engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING To service: 3.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 3.4.
GP Repair 3.5 Maintenance Spark Plug See Graphic: wc_gr000028 Clean or replace the spark plug as needed to ensure proper operation. Refer to your engine operator’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. WARNING Note: Refer to section “Technical Data” for the recommended spark plug type and the electrode gap setting. 3.5.1 Remove the spark plug and inspect it. 3.5.
Maintenance 3.6 GP Repair Cleaning the Sediment Cup See Graphic: wc_gr000029 3.6.1 Turn the fuel valve off. 3.6.2 Remove the sediment cup (a) and the O-ring (b). 3.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 3.6.4 Turn the fuel valve on and check for leaks. b a wc_gr000029 wc_tx000587gb.
GP Repair 3.7 Maintenance Carburetor Adjustment See Graphic: wc_gr000032 3.7.1 Start the engine and allow it to warm up to operating temperature. 3.7.2 Set the pilot screw (a) two turns out. See Note. 3.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 3.7.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
Maintenance 3.9 GP Repair Storage Before storing the generator for a long period of time: 3.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 3.9.2 Disconnect the fuel line from the carburetor. Place the open end of the fuel line into a suitable container and open the fuel valve to drain the fuel from the tank. WARNING wc_tx000587gb.fm Gasoline is extremely flammable. Drain the fuel tank in a wellventilated area.
GP Repair Maintenance 3.10 Transport Let the engine cool before transporting the generator or storing indoors, to avoid burns or fire hazards. WARNING When transporting the generator: 3.10.1 Turn the engine fuel valve to the OFF position. 3.10.2 Position the generator level to prevent fuel from spilling. 3.10.3 Secure the generator by tying it down with a suitable rope. WARNING wc_tx000587gb.
Maintenance GP Repair 3.11 Electrical Schematic—GP 2600 wc_tx000587gb.
GP Repair Maintenance 3.12 Components—GP 2600 Ref. Description A Generator Ref. Description Ref. Description Ref. B Control Box C Ref.
Maintenance GP Repair 3.13 Electrical Schematic—GP 3800, GP/GPS 5600, GP/GPS 6600 wc_tx000587gb.
GP Repair Maintenance 3.14 Components—GP 3800, GP/GPS 5600, GP/GPS 6600 Ref. Description Ref. Description A Generator D Honda Engine B Control box E Wacker Neuson Engine C Electric start engines (GPS) Ref. Description Ref.
Maintenance GP Repair 3.15 Electrical Schematic—GP 3800, GP/GPS 5600, GP/GPS 6600 CAN Models wc_tx000587gb.
GP Repair Maintenance 3.16 Components—GP 3800, GP/GPS 5600, GP/GPS 6600 CAN models Ref. Description Ref. Description A Generator D Wacker Engine B Control box E Honda Engine C Electric start engines (GPS) Ref. Description Ref.
Maintenance GP Repair 3.17 Engine Electrical Schematic—GP 3800, GP/GPS 5600, GP/GPS 6600 wc_tx000587gb.
GP Repair Maintenance 3.18 Engine Components Ref. Description A Generator B Control box C Electric start engines (GPS) Ref. E Description Honda Engine Ref. Description Ref. 1 Idle solenoid 6 Solenoid (GPS only) 2 Fuel cut solenoid 7 Starter (GPS only) 3 Oil alert module 8 Charging coil (GPS only) 4 Oil level switch 9 Battery (GPS only) 5 Coil wc_tx000587gb.
Maintenance GP Repair 3.19 Electrical Schematic—GP 4000 wc_tx000587gb.
GP Repair Maintenance Wire Colors BLK Black BRN Brown GRY Gray WHT White BLU Blue GRN Green RED RED YEL Yellow wc_tx000587gb.
Maintenance GP Repair 3.20 Electrical Schematic—GP 4000 CAN wc_tx000587gb.
GP Repair Maintenance Wire Colors BLK Black BRN Brown GRY Gray WHT White BLU Blue GRN Green RED RED YEL Yellow wc_tx000587gb.
Troubleshooting 4 GP Repair Troubleshooting 4.1 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 circuit supplying voltage to the receptacles.
Troubleshooting y z wc_gr003415 GP Repair wc_tx000548gb.
Troubleshooting 4.2 GP Repair Checking Continuity Conduct continuity tests when the engine is shut down. When checking continuity, use the Ohm setting on your multimeter. Place a lead of the multimeter on one end of the wiring or component and the other lead on the opposite end. If your meter reads “OL” or “OPEN”, there is no continuity and the wiring or component must be repaired or replaced. Note: Some multimeters also have an audio signal setting for determining continuity.
GP Repair 4.5 Troubleshooting Troubleshooting Flowcharts The troubleshooting flowcharts are designed to take you through the process of determining the source of a problem with engine starting or machine operation. Many of the tests involve live voltages and therefore should only be attempted by qualified personnel. Detailed procedures for carrying out the tests are included in this manual. All highlighted text within the flowcharts have matching sections in this manual. wc_tx000548gb.
Troubleshooting 4.6 GP Repair No Voltage at Receptacles—Flowchart 1A No Voltage at Receptacles Is circuit breaker(s) in closed position? No Close circuit breaker(s). Yes Is receptacle GFI set correctly? No Reset GFI. Yes (GP 2500A/GP 2600 only) Checking voltage at generator terminal strip Checking voltage at generator plug Check voltage at back of generator between terminals R & Y; B & G. Check voltage at back of generator between wires R & W; Br & L.
GP Repair 4.7 Troubleshooting No Voltage at Receptacles—Flowchart 1B Checking main and rotor windings Measure the resistance values of the main windings by measuring across R & Y (main 2); B & G (main 1). For GP 2500A models, measure between R &W for (main 2); Br & L (main 1). Is the correct value measured for main winding 2? No Replace the stator. No Replace the stator. Yes Is the correct value measured for main winding 1? Yes Check resistance of rotor winding.
Troubleshooting 4.8 GP Repair Checking Voltage at Generator Terminal Strip See Graphic: wc_gr003122 Electric shock hazard. Only qualified personnel should conduct this test. WARNING By starting the troubleshooting procedures at the generator output terminal strip you can determine whether the problem lies within the generator or the circuit supplying the receptacles. To check the voltage at the terminal strip, carry out the following procedures: 4.8.
GP Repair 4.9 Troubleshooting Checking Voltage at Plug—GP 2500A, GP 2600 See Graphic: wc_gr003146 Electric shock hazard. Only qualified personnel should conduct this test. WARNING By starting the troubleshooting procedures at the generator output plug (d), you can determine whether the problem lies within the generator or the circuit supplying the receptacles. To check the voltage at the output plug, carry out the following procedures: 4.9.
Troubleshooting GP Repair 4.10 Checking Main and Rotor Windings To check the resistance of the windings, carry out the following procedures: 4.10.1 Stop the engine. 4.10.2 Remove the two screws which secure the end cover to the generator and remove the end cover. 4.10.3 Disconnect the Automatic Voltage Regulator (AVR) (a). 4.10.4 Remove the screw (b) that secures the brushes and remove the brushes. 4.10.5 Disconnect the yellow-, red-, black-, and green-marked wires (f) from the terminal strip.
GP Repair 4.10.6 4.10.7 Troubleshooting Using the Ohms setting on the multimeter, measure the resistance of main winding 2 by measuring across the upper two terminals (c) (yellow and red). On GP 2500A/GP 2600 models, measure across the red and white wires. Also check the resistance of main winding 1 by measuring across the two lower terminals (d) (black and green). On GP 2500A/GP 2600 models, measure across the brown and blue wires. Each generator size will have a different value.
Troubleshooting GP Repair 4.10.8 Using the Ohms setting on the multimeter, measure the resistance of the rotor winding by measuring across the slip rings (e). Each generator size will have a different value. Check the chart in the graphic for the correct values; use a tolerance of +1.0/-0.0 Ohm. • If the correct resistance is not measured, the rotor winding is bad; replace the rotor. • If the correct resistance is measured, the rotor winding is OK. 4.10.
GP Repair Troubleshooting 4.11 No Voltage at Receptacles—Flowchart 1C Checking main circuit breaker Check voltage to main circuit breaker. Is correct voltage measured? No Check wiring to generator terminal strip. Repair or replace wiring as needed. Yes Check outgoing voltage from main circuit breaker. Is correct voltage measured? No Replace the main circuit breaker. Yes Check continuity of wiring to receptacles. Does wiring have continuity? No Repair/replace the wiring.
Troubleshooting GP Repair 4.12 Checking Main Circuit Breaker and Receptacle Circuitry See Graphic: wc_gr004566 Electric shock hazard. Only qualified personnel should conduct this test. WARNING If there is no voltage measured at the receptacles but there is voltage at the generator terminal strip, you’ll need to check the following: the wiring to the main circuit breaker, the main circuit breaker, and the wiring to the receptacles. To check the circuit, carry out the following procedures: 4.12.
GP Repair Troubleshooting b 1000 F a V 200 20 V 2 200m A V- COM g f V 1000 F 200 20 V 2 200m A V- COM GP 2500A, GP 2600 d e c wc_gr004566 wc_tx000548gb.
Troubleshooting GP Repair 4.13 Low Voltage at Receptacles—Flowchart 2A Low Voltage at Receptacles If you have recently worked on the generator, be sure the wiring at the generator terminal strip is correct. Checking main and rotor windings Measure the resistance values of the main windings by measuring across R & Y (main 2); B & G (main 1). Is the correct value measured for main winding 1? No Replace the stator. No Replace the stator.
GP Repair Troubleshooting 4.14 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: 4.14.1 Stop the engine. 4.14.2 Remove the two screws that secure the end cover to the generator and remove the end cover. 4.14.3 Remove the screw (a) that secures the brush holder and remove the brush holder/brushes. 4.14.
Troubleshooting GP Repair 4.15 Checking Excitation Winding The excitation winding provides AC voltage to the Automatic Voltage Regulator (AVR). The AVR then sends a DC voltage through the rotor winding “exciting” the rotor into becoming an electromagnet. To check the excitation winding, carry out the following procedures: 4.15.1 Stop the engine. 4.15.2 Remove the two screws which secure the end cover to the generator and remove the end cover. 4.15.
GP Repair 4.15.4 4.15.5 wc_tx000548gb.fm Troubleshooting Using the Ohms scale on your multimeter, check the resistance of the excitation winding. Access the excitation winding via the connector where the two yellow wires of the plug connect to it. Each generator size will have a different value for the winding resistance. Check the chart in the graphic for the correct values—use a tolerance of +0.5/-0.0 Ohm. • If the correct amount of resistance was not measured, replace the stator.
Troubleshooting GP Repair 4.16 Checking AVR’s Sensing Wires—GP 2500A, GP 2600 There are two sensing wires feeding the Automatic Voltage Regulator (AVR) both attached to main winding 2. If the sensing wires are shorted or broken, the AVR will not perform correctly. To check the continuity of the sensing wires, carry out the following procedures: 4.16.1 Stop the engine. 4.16.2 Remove the two screws which secure the end cover to the generator and remove the end cover. 4.16.
GP Repair Troubleshooting 4.17 Checking AVR’s Sensing Wires There are two sensing wires feeding the Automatic Voltage Regulator (AVR), one attached to each of the main windings. If the sensing wires are shorted or broken, the AVR will not perform correctly. To check the continuity of the sensing wires, carry out the following procedures: wc_tx000548gb.fm 4.17.1 Stop the engine. 4.17.2 Remove the two screws which secure the end cover to the generator and remove the end cover. 4.17.
Troubleshooting GP Repair • If the first sensing wire does not have continuity, replace the stator. • If the first sensing wire has continuity, continue. 4.17.6 Check the first sensing wire for a short to ground. (Measure resistance between the wire and the ground stud of the stator.) • If the first sensing wire has resistance to ground, replace the stator. • If the first sensing wire has no resistance to ground, continue. 4.17.7 The second sensing wire is really a circuit.
GP Repair wc_tx000548gb.fm Troubleshooting • If the second sensing wire (circuit) has resistance to ground, check the wiring through the various connectors and the VSS. Repair or replace components as needed. • If the second sensing wire (circuit) has no resistance to ground, the second sensing wire (circuit) is OK.
Troubleshooting GP Repair 4.18 Confirming a Malfunctioning AVR See Graphic: wc_gr003152 By removing the two sensing wires of the regulator and measuring the output voltage of the generator, you can determine if the generator windings and the AVR are functioning correctly. When the sensing wires are removed from the circuit, the generator should produce high voltage (greater than 150V, usually around 180V).
GP Repair wc_tx000548gb.
Troubleshooting GP Repair 4.19 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 WARNING correctly wired before running the generator. NOTICE: Damage to the generator will occur if the VSS is incorrectly wired. The VSS (a) selects the voltage mode setting of the generator.
GP Repair Terminal Troubleshooting Wire 1 Brown #1 2 Brown #2 3 Brown #3 4 Gray #104 5 Brown #5 6 Gray #103; jumper to terminal 7 7 Brown #7 jumper to terminal 6 8 Blue #8 9 Jumper to terminal 4 10 Brown #10 11 Brown #11 12 Brown #12 1 4 7 10 2 5 8 11 3 6 9 12 wc_gr003134 wc_tx000548gb.
Troubleshooting GP Repair 4.20 High Voltage Troubleshooting—Flowchart 3A High Voltage at Receptacles Check engine speed. Be sure that it is within range limits. Checking AVR's sensing wires Checking AVR's sensing wires—GP 2500A/GP 2600 Check the continuity of the AVR’s sensing wire to main winding 2 by checking the continuity between sensing wire at connection point on stator where brown wire from AVR would connect and terminal R or Y.
GP Repair Troubleshooting 4.21 Auto Idle Circuit Troubleshooting—Flowchart 4A Auto Idle Malfunctioning Examine the mechanical linkage. Be sure all parts are functioning. Checking voltage to auto idle solenoid With the engine running, check the DC voltage between the two white/red (W/R) wires. There should be 28±2VDC. Is correct voltage measured? Confirm the solenoid is malfunctioning by measuring its coil’s resistance and by checking action of plunger. Replace the idle solenoid.
Troubleshooting GP Repair 4.22 Checking Voltage to Auto Idle Solenoid See Graphic: wc_gr004569 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Problems with the auto idle system can be classified into one of two categories: electrical problems with power to the idle solenoid or problems with the mechanical linkage. Before checking the electrical system, check the governor mechanical linkage (a) to make sure it’s functioning properly.
GP Repair Troubleshooting a 1000 F 20 1000 F V 200 V 200 20 2 200m 2 200m A V- b Honda Honda Wacker Wacker A COM V- COM V 1000 F 20 1000 F V 200 a V 200 20 2 200m 2 200m A V- A COM V- COM b V c V 1000 F 200 20 V 2 200m A V- COM wc_gr004569 wc_tx000548gb.
Troubleshooting GP Repair 4.23 Checking Auto Idle Circuitry Between Generator and Fuse See Graphic: wc_gr004568 Voltage may be prevented from reaching the 5A fuse by a faulty rectifier or by a faulty DC winding. The auto idle circuit may also be malfunctioning due to faulty sensing wires. To check the circuit, carry out the following procedures: 4.23.1 Stop the generator. 4.23.2 Remove the two screws which secure the end cover to the generator and remove the end cover. 4.23.
GP Repair Troubleshooting GP 2500.... --GP 2600.... --GP 3800.... 0.6 GP 4000.... 0.6 a GP 5600.... 0.5 1000 F GP 6600.... 0.5 200 20 V 2 200m b A V- 1000 F 200 20 COM V 2 200m A V- COM c e d wc_gr004568 wc_tx000548gb.
Troubleshooting GP Repair 4.24 Checking Auto Idle Circuitry Between Fuse and Auto Idle Unit See Graphic: wc_gr004570 Electric shock hazard. Only qualified personnel should conduct this test. WARNING Voltage may be prevented from reaching the idle solenoid by a faulty auto idle switch or by a faulty auto idle unit. To check the circuit, carry out the following procedure: 4.24.1 Stop the generator. 4.24.2 Remove the screws which secure the control panel to the generator. Locate the auto idle switch (a). 4.
GP Repair Troubleshooting b a b V 1000 F 200 20 V V 1000 F V 2 200m A V- 200 20 2 200m A COM V- Honda COM Wacker wc_gr004570 wc_tx000548gb.
Troubleshooting GP Repair 4.25 Engine Backfires—Troubleshooting Flowchart 5A Engine Backfires Checking Anti-Afterfire Solenoid (AAS) circuit With the engine running, probe wires G & W at the connections for the AAS. Shutdown the engine and measure voltage at shutdown. There should be 18±2VDC. Is correct voltage measured? Confirm the solenoid is malfunctioning by measuring its coil’s resistance. Yes Replace the AAS if needed. No Check the function of the main ON/OFF switch.
GP Repair Troubleshooting Notes wc_tx000548gb.
Troubleshooting GP Repair 4.26 Checking Anti-Afterfire Solenoid (AAS) Circuit—Honda Engine See Graphic: wc_gr003133 Electric shock hazard. Only qualified personnel should conduct this test. WARNING The AAS is located on the engine underneath the carburetor bowl. Voltage may be prevented from reaching the AAS by: a faulty DC winding, a blown fuse, a faulty engine ON/OFF switch, or a faulty capacitor. To check the circuit, carry out the following procedure: 4.26.1 Check the 5A fuse.
GP Repair Troubleshooting V 1000 F 200 20 V 2 200m A V- COM b a c d d µF 1000 F 200 20 V 2 200m A V- COM wc_gr003133 wc_tx000548gb.
Troubleshooting GP Repair 4.27 Diagnosing GFI Tripping See Graphic: wc_gr003570 A common cause for nuisance tripping of the GFI is incorrect wiring. If you experience tripping of the GFI when changing from the 120V mode to the 240V mode, check the wiring running through the GFI. There should be four brown wires and two blue wires running through the ammeter portion (a) of the GFI. If you have any other combination, refer to the wiring schematic and correct the situation.
GP Repair 5 Disassembly/Assembly Procedures Disassembly/Assembly Procedures 5.1 Tools Because all possible problems encountered while repairing the machine cannot be anticipated, it is up to the mechanic to use common sense and good judgement in tool selection. The use of any special tools is recommended only for those operations where the use of conventional tools proves inadequate.
Disassembly/Assembly Procedures 5.4 GP Repair Replacing the Muffler See Graphic: wc_gr003136 Removal: 5.4.1 Disconnect the spark plug. 5.4.2 Remove the screw (a) that secures the muffler guard and the generator mounting leg (b) to the shock mount bracket. 5.4.3 Remove the screws (c) that secure the muffler guard to the frame. 5.4.4 Remove the six screws (d) that secure the muffler guard halves together and remove the outer muffler guard (e).
GP Repair Disassembly/Assembly Procedures f a b f d g e c h f wc_gr003136 wc_tx000549gb.
Disassembly/Assembly Procedures 5.5 GP Repair Replacing the Fuel Tank See Graphic: wc_gr003137 Removal: 5.5.1 Disconnect the spark plug. 5.5.2 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. 5.5.3 Remove the shoulder bolts (c) and hardware that secure the lifting handle (d) to the frame and remove the lifting handle. 5.5.
GP Repair Disassembly/Assembly Procedures f c c e d gg d b a c f h g wc_gr003137 wc_tx000549gb.
Disassembly/Assembly Procedures 5.6 GP Repair Replacing the Stator See Graphic: wc_gr003138 Removal: 5.6.1 Disconnect the spark plug. 5.6.2 Remove the two screws (a) that secure the end cover and remove the end cover from the generator. 5.6.3 Disconnect the wires (b) from the terminal strip, the ground wire (c), and the harness connector (d). On GP 2500A/GP 2600 models, disconnect the generator plug. 5.6.4 Remove the screw (e) that secures the brush holder and remove the brush holder. 5.6.
GP Repair Disassembly/Assembly Procedures d a e c b f g h i wc_gr003138 wc_tx000549gb.
Disassembly/Assembly Procedures 5.7 GP Repair Replacing the Rotor See Graphic: wc_gr003139 Removal 5.7.1 Disconnect the spark plug. 5.7.2 Remove the stator. See section Replacing Stator. 5.7.3 Prevent the engine’s flywheel from turning by wedging a wrench (a) or like object into the fins of the fan. Then, remove the M8 screw (b) from the end of the rotor. 5.7.4 Place a few shop towels or similar padding underneath the rotor.
GP Repair Disassembly/Assembly Procedures a b c d e f c d wc_gr003139 wc_tx000549gb.
Disassembly/Assembly Procedures 5.8 GP Repair Replacing the Engine See Graphic: wc_gr003141 Removal: 5.8.1 Disconnect the spark plug. 5.8.2 Remove the generator. See section Replacing the Rotor. 5.8.3 Turn the fuel valve (a) off. Remove the fuel hose (b) at the fuel valve; plug the fuel hose as soon as it is free from the fuel valve. 5.8.4 Label and disconnect the wiring (c) running between the engine and the control panel. 5.8.
GP Repair Disassembly/Assembly Procedures a b c e d f wc_gr003141 wc_tx000549gb.
Technical Data 6 GP Repair Technical Data 6.1 Generator—GP 2600 Item No. GP 2600 0620116 GP 2600 0620088 Generator Maximum Output W 2600 Continuous Output W 2250 Type AC Voltages Available Frequency Single voltage, single phase, auto voltage regulator system 120 1 Volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V GFI duplex 125V duplex Amp Amp 20 20 Main Circuit Breaker Amp 20 LxWxH mm (in.) 615 x 435 x 545 (24.2 x 17 x 21.5) Weight (dry) kg (lbs.) 47.
GP Repair 6.2 Technical Data Engine—GP 2600 Item No. GP 2600 0620116 GP 2600 0620088 Engine Engine Type 4-stroke, overhead valve, single cylinder Engine Make Wacker Engine Model WM 170 Rated Power Spark Plug Electrode Gap 4.2 (5.7) kW (Hp) NGK BR6HS (Champion RL86C) 0.6–0.7 (0.024–0.028) mm (in.) Operating Speed (Max.) rpm 3600 Air Cleaner type Dual Element Engine Lubrication Engine Oil Capacity Fuel Fuel Tank Capacity Fuel Consumption Running Time continuous load wc_td000177gb.
Technical Data 6.3 GP Repair Generator—GP 3800 Item No. GP 3800A 0620103 GP 3800A CAN 0620104 Generator Maximum Output W 3800 Continuous Output W 3400 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 20 Main Circuit Breaker amp 2-pole, 16 amp each pole LxWxH mm (in.
GP Repair Technical Data Item No. GP 3800A 0620342 GP 3800A 0620484 Generator Maximum Output W 3800 Continuous Output W 3400 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 20 Main Circuit Breaker amp 2-pole, 16 amp each pole LxWxH mm (in.) 685 x 530 x 537 (27 x 21 x 21.
Technical Data 6.4 GP Repair Engine—GP 3800 Item No. GP 3800A 0620103 GP 3800A CAN 0620104 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 240 Max. Rated Power @ Rated Speed 5.3 (7.1) @ 3600 rpm kW (Hp) Spark Plug Electrode Gap BPR6ES / W20EPR-U 0.7 - 0.8 (0.028 - 0.031) mm (in.
GP Repair Technical Data Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 3800A 0620342 0620484 Engine Engine type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine make Honda Engine model GX 240 K1 Max. rated power @ rated speed 5.3 (7.1) @ 3600 rpm kW (Hp) Spark plug Electrode gap BPR6ES / W20EPR-U 0.7 - 0.8 (0.028 - 0.031) mm (in.
Technical Data GP Repair Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 3800A 0620485 0620379 0620104 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 240 Max. Rated Power @ Rated Speed 5.3 (7.1) @ 3600 rpm kW (Hp) Spark Plug Electrode Gap BPR6ES / W20EPR-U 0.7 - 0.8 (0.028 - 0.031) mm (in.
GP Repair 6.5 Technical Data Generator—GP 4000 Item No. GP 4000 0620089 0620325 Generator Maximum Output W 4000 Continuous Output W 3600 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 20 Main Circuit Breaker amp 2-pole, 17 amp each pole LxWxH mm (in.
Technical Data GP Repair Item No. GP 4000 0620380 0620090 Generator Maximum Output W 4000 Continuous Output W 3600 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 20 Main Circuit Breaker amp 2-pole, 17 amp each pole LxWxH mm (in.) 685 x 530 x 535 (27 x 21 x 21.2) Weight (dry) Kg (lbs.
GP Repair 6.6 Technical Data Engine—GP 4000 Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 4000 0620089 0320325 Engine Engine Type 4-stroke, overhead valve, single cylinder Engine Make Wacker Neuson Engine Model WM 270 Max. Rated Power @ Rated Speed kW (Hp) 6.6 (9) @ 4000 rpm Spark Plug Electrode Gap (NGK) BR 6HS Champion RL86C 0.6–0.7 (0.024–0.028) mm (in.
Technical Data GP Repair Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 4000 0620380 0620090 Engine Engine Type 4-stroke, overhead valve, single cylinder Engine Make Wacker Neuson Engine Model WM 270 Max. Rated Power @ Rated Speed kW (Hp) 6.6 (9) @ 4000 rpm Spark Plug Electrode Gap (NGK) BR 6HS Champion RL86C 0.6–0.7 (0.024–0.028) mm (in.
GP Repair 6.7 Technical Data Generator—GP/GPS 5600 Item No. GP 5600A 0620091 GP 5600A 0620092 GPS 5600A 0620093 Generator Maximum Output W 5600 Continuous Output W 5000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 23 amp each pole LxWxH mm (in.
Technical Data GP Repair Item No. GP 5600A CAN 0620094 GP 5600A CAN 0620095 GPS 5600A CAN 0620096 Generator Maximum Output W 5600 Continuous Output W 5000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 23 amp each pole LxWxH mm (in.
GP Repair Technical Data Item No. GP 5600A 0620327 GP 5600A 0620326 GPS 5600A 0620328 Generator Maximum Output W 5600 Continuous Output W 5000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 23 amp each pole LxWxH mm (in.) Weight (dry) wc_td000177gb.
Technical Data GP Repair Item No. GP 5600A 0620382 GP 5600A 0620381 GPS 5600A 0620383 Generator Maximum Output W 5600 Continuous Output W 5000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 23 amp each pole LxWxH mm (in.) Weight (dry) wc_td000177gb.
GP Repair Technical Data Item No. GP 5600A CAN 0620094 GP 5600A CAN 0620095 GPS 5600A CAN 0620096 Generator Maximum Output W 5600 Continuous Output W 5000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 23 amp each pole LxWxH mm (in.
Technical Data 6.8 GP Repair Engine—GP/GPS 5600 Item No. GP 5600A GP 5600A CAN 0620094 0620095 0620091 0620092 GPS 5600A 0620093 GPS 5600A CAN 0620096 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 340 K1 Rated Power 8.2 (11) kW (Hp) Spark Plug Electrode Gap Operating Speed (Max.) Auto Idle VAC Air Cleaner Battery Engine Lubrication Engine Oil Capacity Fuel BPR6ES / W20EPR-U 0.7 - 0.8 (0.028 - 0.031) mm (in.
GP Repair Technical Data Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 5600A 0620327 0620326 GPS 5600A 0620328 Engine Engine type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine make Honda Engine model GX 340 K1 Max. rated power @ rated speed 7.1 (9.
Technical Data GP Repair Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 5600A GP 5600A CAN 0620094 0620095 0620381 0620382 GPS 5600A 0620383 GPS 5600A CAN 0620096 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 340 K1 Max. Rated Power @ Rated Speed 7.1 (9.
GP Repair 6.9 Technical Data Generator—GP/GPS 6600 Item No. GP 6600A 0620097 GP 6600A 0620098 GPS 6600A 0620099 Generator Maximum Output W 6600 Continuous Output W 6000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 27 amp each pole LxWxH mm (in.
Technical Data GP Repair Item No. GP 6600A CAN 0620100 GP 6600A CAN 0620101 GPS 6600A CAN 0620102 Generator Maximum Output W 6600 Continuous Output W 5500 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 27 amp each pole LxWxH mm (in.
GP Repair Technical Data Item No. GP 6600A 0620330 GP 6600A 0620329 GPS 6600A 0620331 Generator Maximum Output W 6600 Continuous Output W 6000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 27 amp each pole LxWxH mm (in.) Weight (dry) wc_td000177gb.
Technical Data GP Repair Item No. GP 6600A 0620385 GP 6600A 0620384 GPS 6600A 0620386 Generator Maximum Output W 6600 Continuous Output W 6000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 27 amp each pole LxWxH mm (in.) Weight (dry) wc_td000177gb.
GP Repair Technical Data Item No. GP 6600A CAN 0620100 GP 6600A CAN 0620101 GPS 6600A CAN 0620102 Generator Maximum Output W 6600 Continuous Output W 5500 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 27 amp each pole LxWxH mm (in.
Technical Data GP Repair 6.10 Engine—GP/GPS 6600 Item No. GP 6600A GP 6600A CAN 0620100 0620101 0620097 0620098 GPS 6600A 0620099 GPS 6600A CAN 0620102 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 390 Rated Power 9.7 (13) kW (Hp) Spark Plug Electrode Gap Operating Speed (Max.) Auto Idle VAC Air Cleaner Battery Engine Lubrication Engine Oil Capacity Fuel Fuel Tank Capacity Fuel Consumption Running Time wc_td000177gb.
GP Repair Technical Data Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 6600A 0620330 0620329 GPS 6600A 0620331 Engine Engine type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine make Honda Engine model GX 390 K1 Maximum rated power @ rated speed kW (Hp) 8.
Technical Data GP Repair Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 6600A GP 6600A CAN 0620100 0620101 0620385 0620384 GPS 6600A 0620386 GPS 6600A CAN 0620102 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 390 Max. Rated Power @ Rated Speed kW (Hp) 8.
Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 10.9 WRENCH SIZE 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.
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.
Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container.
Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container.
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.
