Wacker Neuson GPS 9700 Instrucciones de funcionamiento

Generator

GS 8.5V

GPS 8500

GS 9.7V

GPS 9700

REPAIR MANUAL

0174423en 002

0809

0174423EN

GPS 8500/GPS 9700 Foreword

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Foreword

Machines

covered by

this manual

Machine

documentation

Keep a copy of the Operator’s Manual with the machine at all times.

Use the separate Parts Book supplied with the machine to order replacement

parts.

Refer to the separate Repair Manual for detailed 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

for

information in

this manual

This manual provides information and procedures to safely operate and main-

tain the above Wacker Neuson model(s). For your own safety and to reduce the

risk of injury, carefully read, understand, and observe all instructions described

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.

notice

All rights, especially copying and distribution rights, are reserved.

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

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. A spark arrester is a device designed to prevent accidental dis-

charge of sparks or flames from the engine exhaust. Spark arresters are qualified

and rated by the United States Forest Service for this purpose. In order to comply

Machine Item Number

GPS 8500 (GS 8.5V) 0008286

GPS 9700 (GS 9.7V) 0008287

GPS 9700 0620264

Foreword GPS 8500/GPS 9700

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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 property of their respective own-

ers.

GPS 8500/GPS 9700 Table of Contents

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Foreword 3

1 Safety Information 7

1.1 Laws Pertaining to Spark Arresters ...................................................... 7

1.2 Operating Safety .................................................................................. 8

1.3 Operator Safety While Using Internal Combustion Engines ................. 9

1.4 Service Safety .................................................................................... 10

2 Operation 12

2.1 Control Panel ...................................................................................... 12

2.2 Voltage Selection ............................................................................... 13

2.3 Engine Auto Idle ................................................................................. 13

2.4 To Run the Generator ........................................................................ 14

2.5 To Stop the Generator ........................................................................ 15

3 Troubleshooting 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 Windings ............................................................. 23

3.6 Checking the Brushes ........................................................................ 24

3.7 Checking the Diode Rectifier .............................................................. 25

3.8 Checking the Auxiliary Winding .......................................................... 26

3.9 Checking the Choke ........................................................................... 27

3.10 Checking the Transformer .................................................................. 28

3.11 Checking the Voltage Selector Switch (VSS) ..................................... 29

3.12 Checking the Auto Idle Circuit ............................................................ 30

4 Disassembly and Assembly 33

4.1 Tools Required for Disassembly/Assembly Procedures ..................... 33

4.2 Information Regarding Replacement Parts ........................................ 33

Table of Contents GPS 8500/GPS 970

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4.3 Information Regarding Reference Numbers ( ) ...................................33

4.4 Information Regarding Threadlocking Compounds .............................33

4.5 Generator Exploded View ...................................................................34

4.6 Exploded View Components ...............................................................35

4.7 Removing & Installing the Fuel Tank ...................................................36

4.8 Removing & 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 Schematics 46

5.1 Generator Wiring Schematic ...............................................................46

5.2 Schematic Components ......................................................................47

5.3 Generator Wiring Schematic (Revision 104 and below) ......................48

5.4 Schematic Components (Revision 104 and below) .............................49

5.5 Engine Wiring Diagram .......................................................................50

6 Technical Data 51

6.1 Generator ............................................................................................51

6.2 Windings ..............................................................................................51

6.3 Engine .................................................................................................52

GPS 8500/GPS 9700 Safety Information

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1 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.

DANGER indicates a hazardous situation which, if not avoided, will

result in death or serious injury.

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

result in death or serious injury.

CAUTION indicates a 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 property damage.

Note: Contains additional information important to a procedure.

1.1 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. A spark arrester is a

device designed to prevent accidental discharge of sparks or flames

from the engine exhaust. Spark arresters are qualified 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.

DANGER

WARNING

CAUTION

Safety Information GPS 8500/GPS 9700

wc_si000252gb.fm 8

1.2 Operating Safety

BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER

DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR

DEATH TO UTILITY WORKERS!

Improper connection of generator to a building’s electrical system can

allow electrical current from the 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.

If connected to a building’s electrical system the generator must meet

the power, voltage, and frequency requirements of the equipment in

the building. Differences in power, voltage, and frequency

requirements may exist and improper connection may lead to

equipment damage, fire, and personal injury or death.

Familiarity and proper training are required for the safe operation of the

machine. Machines operated improperly or by untrained personnel

can be hazardous. Read the operating instructions contained in this

manual and the 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 to operate it.

1.2.1 NEVER operate the generator when open containers of fuel, paint, or

other flammable liquids are near.

1.2.2 NEVER operate the generator, or tools attached to the generator, with

wet hands.

1.2.3 NEVER use worn electrical cords. Severe electrical shock and

equipment damage may result.

1.2.4 NEVER run the electrical cords under the generator, or over vibrating

or hot parts.

1.2.5 NEVER enclose or cover the generator when it is in use or when it is

hot.

1.2.6 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.

1.2.7 NEVER operate the machine in snow, rain, or standing water.

1.2.8 NEVER allow untrained personnel to operate or service the generator.

The generator set should be set up by a certified electrician.

1.2.9 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.

1.2.10 Be sure the machine is on a firm, level surface and will not tip, roll,

slide, or fall while operating.

DANGER

WARNING

GPS 8500/GPS 9700 Safety Information

wc_si000252gb.fm 9

1.2.11 ALWAYS transport the generator in an upright position.

1.2.12 ALWAYS keep the machine at least one meter (three feet) away from

structures, buildings, and other equipment during use.

1.2.13 ALWAYS keep the area immediately surrounding and underneath the

machine clean, neat, and free of debris and combustible materials.

Make sure that the area overhead is clear of debris that could fall onto

or into the machine or exhaust compartment.

1.2.14 ALWAYS remove all tools, cords, and other loose items from the

generator before starting it.

1.2.15 ALWAYS make certain the machine is well-grounded and securely

fastened to a good earthen ground per national and local regulations.

1.3 Operator Safety While Using Internal Combustion Engines

Internal combustion engines present special hazards during operation

and fueling. Read and follow the warning instructions in the engine

owner’s manual and the safety guidelines below. Failure 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 away from

windows, doors, and vents. Using a generator indoors CAN KILL YOU

IN MINUTES. Generator exhaust contains carbon monoxide. This is a

poison you cannot see or smell.

1.3.2 NEVER use a generator inside an enclosed area such as a tunnel or a

trench.

1.3.3 Do not smoke while operating the machine.

1.3.4 Do not smoke when refueling the engine.

1.3.5 Do not refuel a hot or running engine.

1.3.6 Do not refuel the engine near an open flame.

1.3.7 Do not spill fuel when refueling the engine.

1.3.8 Do not run the engine near open flames.

1.3.9 Do not start the engine if fuel has spilled or a fuel odor is present. Move

the generator away from the spill and wipe the generator dry before

starting.

1.3.10 Refill the fuel tank in a well-ventilated area.

1.3.11 Replace the fuel tank cap after refueling.

1.3.12 ALWAYS check the fuel lines and the fuel tank for leaks and cracks

before starting the engine. Do not run the machine if fuel leaks are

present or the fuel lines are loose.

WARNING

Safety Information GPS 8500/GPS 9700

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1.4 Service Safety

Poorly maintained equipment can become a safety hazard! In order

for the equipment to operate safely and properly over a long period of

time, periodic maintenance and occasional repairs are necessary. If

the generator is experiencing problems or is being serviced, attach a

“DO NOT START” sign to the control panel to notify other people of its

condition.

1.4.1 Do not use gasoline or other types of fuels or flammable solvents to

clean parts, especially in enclosed areas. Fumes from fuels and

solvents can become explosive.

1.4.2 DO NOT attempt to clean or service the machine while it is running.

1.4.3 Do not modify the machine without the express written approval of the

manufacturer.

1.4.4 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.

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

trained electrical technicians should be allowed to service the electrical

components of this equipment.

1.4.7 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.

1.4.8 ALWAYS replace the safety devices and guards after repairs and

maintenance.

1.4.9 ALWAYS let the engine cool before transporting or servicing the

machine.

1.4.10 ALWAYS keep hands, feet, and loose clothing away from the moving

parts on the generator and engine.

1.4.11 ALWAYS turn the engine off before servicing the machine. If the

engine has electric start, disconnect the negative terminal on the

battery before servicing the machine.

1.4.12 ALWAYS keep the fuel lines in good condition and properly connected.

Leaking fuel and fumes are extremely explosive.

WARNING

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