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Wacker Neuson GPS 9700, Repair Manual, Page: 1 / 60

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Wacker Neuson GPS 9700 Repair Manual Download Page 1

Generator

GS 8.5V
GPS 8500
GS 9.7V
GPS 9700

REPAIR MANUAL

0174423en

002

0809

0

1

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4

4

2

3

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Summary of Contents for GPS 9700

Page 1: ...Generator GS 8 5V GPS 8500 GS 9 7V GPS 9700 REPAIR MANUAL 0174423en 002 0809 0 1 7 4 4 2 3 E N...

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Page 3: ...until the time of publication Wacker Neuson Corporation reserves the right to change any portion of this information without notice Copyright notice All rights especially copying and distribution righ...

Page 4: ...tx000827gb fm 4 with local laws regarding spark arresters consult the engine distributor or the local Health and Safety Administrator Trademarks All trademarks referenced in this manual are the proper...

Page 5: ...hooting Voltage Issues 16 3 1 Determining Where to Begin 16 3 2 Flashing the Generator 18 3 3 Checking the Automatic Voltage Regulator AVR 20 3 4 Checking the Stator Windings 21 3 5 Checking the Rotor...

Page 6: ...moving Installing the Automatic Voltage Regulator AVR 37 4 9 Removing the Stator and Rotor 38 4 10 Installing the Stator and Rotor 41 4 11 Removing and Installing the Electronic Governor 44 5 Schemati...

Page 7: ...hazardous situation which if not avoided could result in minor or moderate injury NOTICE Used without the safety alert symbol NOTICE indicates a situation which if not avoided could result in propert...

Page 8: ...engine manual and familiarize yourself with the location and proper use of all controls Inexperienced operators should receive instruction from someone familiar with the machine before being allowed...

Page 9: ...to follow the warnings and safety standards could result in severe injury or death 1 3 1 NEVER use this generator inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far a...

Page 10: ...t move the machine and allow the machine to dry before servicing 1 4 5 DO NOT service the machine if your clothing or skin is wet 1 4 6 DO NOT allow untrained personnel to service this equipment Only...

Page 11: ...GPS 8500 GPS 9700 Safety Information wc_si000252gb fm 11 Notes...

Page 12: ...g f Ref Description Ref Description a Auto Idle Switch g Thermal Overload b Main Circuit Breaker h Voltage Selector Switch c 240V 20A Overcurrent Circuit Breaker j 120V 30A Twist lock Receptacle d 12...

Page 13: ...acle NOTICE NEVER switch the voltage selector switch with the main breaker on This can cause arcing and can damage the generator Turn all tools and appliances off and place main breaker in the OFF ope...

Page 14: ...can damage starter motor To start engine using manual start Turn key switch to the run position d2 Pull starter rope c rapidly to start engine Leave key in run position d2 while engine is running Not...

Page 15: ...9700 Operation wc_tx001265gb fm 15 2 5 To Stop the Generator 1 Disconnect all loads from generator and place main circuit breaker in open position 2 Turn engine switch to the stop position d1 3 Close...

Page 16: ...tion 5 Measure the voltage between the red and white wires also measure the voltage between the blue and brown wires 6 Turn off the engine This procedure continues on the next page 1000 200 20 2 200m...

Page 17: ...3 Check the stator windings See section Checking Stator Winding 4 Check the rotor winding See section Checking the Rotor Winding 5 Check the brushes See section Checking the Brushes 6 Check the diode...

Page 18: ...engine 7 Check the engine rpm It should be approximately 3750 rpm 8 Connect the 12V battery to the F1 and F2 wires battery positive to F 1 battery negative to F2 9 Measure the voltage between the L1...

Page 19: ...Continued from the previous page 11 Measure the voltage at the receptacles Is the correct voltage measured The flashing procedure is now complete Yes ____ No ____ The generator is ready for use Conti...

Page 20: ...ator 5 Disconnect the F1 and F2 wires and the L1 and L2 wires from the Automatic Voltage Regulator AVR b 6 Start the engine 7 Check the engine rpm It should be approximately 3750 rpm 8 Measure the vol...

Page 21: ...d brown wires Is 0 2 0 3 Ohms measured in each case 5 Check if the stator winding is shorted to ground by checking the continuity between each wire red white blue and brown and ground Is there continu...

Page 22: ...rted to the rotor winding by checking the continuity between each wire red white blue and brown and the rotor winding at the slip rings c Is there continuity between any of the wires and the rotor win...

Page 23: ...lder and the Automatic Voltage Regulator AVR b 4 Measure the resistance of the rotor winding by measuring across the slip rings Is 12 3 12 8 Ohms measured 5 Check for continuity between the rotor slip...

Page 24: ...VR and remove the AVR b and brush holder from the machine 4 Measure the length of the brush protruding from the brush holder The minimum length is 8 mm 0 32 in 5 Check the continuity of each brush Doe...

Page 25: ...scale on the multimeter check the continuity of the diode rectifier Check F1 to Z2 F1 to F2 F1 to Z3 F2 to Z3 F2 to F1 F2 to Z2 Z2 to F2 Z2 to Z3 Z2 to F1 Z3 to F1 Z3 to Z2 Z3 to F2 5 Reverse the lea...

Page 26: ...down the generator 2 Remove the rear panel from the generator 3 Remove the wires from terminals Z2 and Z3 of the diode rectifier a 4 Measure the resistance between the wire connected to Z2 and Z1 on...

Page 27: ...ctifier a 4 Measure the resistance between the wire connected to Z3 and Z1 on the choke b Is 7 6 8 1 Ohms measured 5 Check if the choke is shorted to ground by the checking continuity O 1 1 0 Ohms bet...

Page 28: ...ce between the brown wire and the blue wire Is 810 890 Ohms measured 5 Trace the red wire and the white wire coming out of the transformer The red wire runs to the main circuit breaker The white wire...

Page 29: ...to the control panel 4 Label the wires connected to the VSS 5 Remove the wires connected to the VSS 6 Reconnect the switch handle to the switch 7 Check the resistance between the terminals Your meter...

Page 30: ...Shut down the generator 2 Disconnect all loads from the generator 3 Locate the control module a 4 Remove the loom harness to expose the wires 5 Disconnect the blue wire at the connector 6 Start the en...

Page 31: ...5 Touch the green wire to the battery negative The actuator b should move to the full speed position 6 Remove the green wire from the battery negative The actuator should move to the low speed positio...

Page 32: ...idle switch e Does the current transformer measure 70 73 Ohms Checking the switch Follow the procedure below to check the switch 1 Check for 12VDC incoming to the switch 2 Check for 12VDC outgoing fro...

Page 33: ...ion 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 4 3 Information Regarding Refer...

Page 34: ...Disassembly and Assembly GPS 8500 GPS 9700 wc_tx000829gb fm 34 4 5 Generator Exploded View...

Page 35: ...Description Ref Description a Mounting plate n Choke b Stud o Screw c Rotor p Cover d Bearing q Screw e Nut r Brush holder f s Automatic Voltage Regulator AVR g Lifting plate t Screw h Nut u Brush i...

Page 36: ...e hose a 2 Cut the wire ties that secure the fuel hose to the wiring harness 3 Remove the screws b that secure the fuel tank to the frame 4 Pull the fuel tank from the frame Installation procedure Fol...

Page 37: ...R to the brush holder 2 Connect the wires to the AVR 3 Secure the mounting bracket to the stator Adjusting procedure Follow the procedure below to adjust the AVR 1 Start the engine and verify rpm it m...

Page 38: ...otor 1 Remove the fuel tank See section Removing and Installing the Fuel Tank 2 Remove the AVR See section Removing and Installing the AVR 3 Remove the choke See section Removing and Installing the Ch...

Page 39: ...0 Remove the ground wire g from the frame 11 Disconnect the main stator winding connector h and slide the connector out of the control box 12 Slide the AVR wires out of the generator and into the cont...

Page 40: ...stator 17 Support the rotor l with one hand and strike it with a rubber mallet on a pole face until it releases Separatingthe rotor from the stator Follow the procedure below to separate the rotor fr...

Page 41: ...ocedure Follow the procedure below to install the stator and rotor 1 Slide the rotor l onto the engine shaft 2 Install the threaded rod k into the rotor 3 Install the screws and nuts i that secure the...

Page 42: ...re at the auto idle switch d 6 Install the screw c that secures the battery cable 7 Connect the ground wire g to the frame 8 Slide the connector h into the control box 9 Install the engine exhaust gua...

Page 43: ...ous page 11 Install the ground wire b to the stator 12 Install the control panel a 13 Install the choke See section Removing and Installing the Choke 14 Install the AVR See section Removing and Instal...

Page 44: ...ble the actuator to the governor control bracket a Torque the screws b to 3 4 Nm 30 in lbs Note Hold the long screws with a 1 4 inch wrench when torquing the nuts The screws must not turn while torqui...

Page 45: ...GPS 8500 GPS 9700 Disassembly and Assembly wc_tx000829gb fm 45 Notes...

Page 46: ...120V 9 12 10 6 8 7 3 4 2 1 2 3 4 F2 F1 Z1 Z3 Z1 Z2 Z3 Z2 F1 F2 L1 L2 Y B B Y Br G wc_gr004671 L W R W L G R Gr G Y R G B W B G B L B Y B Or Y B Y R W G W L W Y W Or W R B L B Y B G R L B Or 20A 120VAC...

Page 47: ...ription Ref Description A Generator B Control box C Engine Ref Description Ref Description 1 Main stator winding 10 Choke 2 Transformer 11 Hour meter 3 Auto Voltage Regulator AVR 12 Engine module 4 Re...

Page 48: ...3 4 2 1 2 3 4 F2 F1 Z1 Z3 Z1 Z2 Z3 Z2 L1 L2 Y B B Y Br G L W R W L G R Gr G Y R G B W B G B L B Y B Or Y B Y R W G W L W Y W Or W R B L B Y B G R L B Or 20A 120VAC 15A 120VAC 15A 120VAC 30A 120 240VAC...

Page 49: ...x C Engine Ref Description Ref Description 1 Main stator winding 10 Choke 2 Transformer 11 Hour meter 3 Auto Voltage Regulator AVR 12 Engine module 4 Resistor GPS 9700 only 13 Oil level switch 5 Rotor...

Page 50: ...solenoid 10 Regulator rectifier 2 Stop switch terminal 11 DC output wire 3 50 Hz loop GPS 8500 yellow GPS 9700 red 12 Key switch 4 Module 13 Solenoid 5 Idle down device 14 Battery terminal 6 Actuator...

Page 51: ...pe system AC Voltages Available volts phase 120 240 1 Frequency Hz 60 Power Factor 1 0 AC receptacles 120V GFI duplex 120V GFI duplex 120V twist lock 120V twist lock 240V twist lock 120 240V twist loc...

Page 52: ...rd 356447 Rated Power kW Hp 11 9 16 13 4 18 Displacement cm3 in3 480 29 3 570 34 75 Spark Plug Champion RC12YC Electrode Gap mm in 0 76 0 030 Starter type V Electric 12 Alternator amp 16 Engine Speed...

Page 53: ...447 Max rated power rated speed kW Hp 11 9 16 3600 rpm 13 4 18 3600 rpm Displacement cm3 in3 480 29 3 570 34 75 Spark plug Champion RC12YC Electrode gap mm in 0 76 0 030 Starter type V Electric 12 Alt...

Page 54: ...x rated power rated speed kW Hp 13 4 18 3600 rpm Displacement cm3 in3 570 34 75 Spark Plug Champion RC12YC Electrode Gap mm in 0 76 0 030 Starter type V Electric 12 Alternator amp 16 Operating speed r...

Page 55: ......

Page 56: ...311 5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 m...

Page 57: ...follow instructions on container The sealants listed are recommended for use on Wacker Neuson equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant a...

Page 58: ...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 1...

Page 59: ...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...

Page 60: ...2 390 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 Plac...

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