0174423en 0809 Generator GS 8.5V GPS 8500 GS 9.
GPS 8500/GPS 9700 Foreword Foreword Machines covered by this manual Machine documentation Expectations for information in this manual Copyright notice Machine Item Number GPS 8500 (GS 8.5V) 0008286 GPS 9700 (GS 9.7V) 0008287 GPS 9700 0620264 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.
Foreword GPS 8500/GPS 9700 with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator. Trademarks wc_tx000827gb.fm All trademarks referenced in this manual are the property of their respective owners.
GPS 8500/GPS 9700 1 Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 2 12 Control Panel ...................................................................................... 12 Voltage Selection ............................................................................... 13 Engine Auto Idle ................................................................................. 13 To Run the Generator ........................................................................ 14 To Stop the Generator ....
Table of Contents 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5 Information Regarding Reference Numbers ( ) ...................................33 Information Regarding Threadlocking Compounds .............................33 Generator Exploded View ...................................................................34 Exploded View Components ...............................................................35 Removing & Installing the Fuel Tank ...................................................
GPS 8500/GPS 9700 1 Safety Information 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.
Safety Information 1.2 GPS 8500/GPS 9700 Operating Safety DANGER WARNING 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.
GPS 8500/GPS 9700 1.3 Safety Information 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.
Safety Information 1.4 GPS 8500/GPS 9700 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. 1.4.
GPS 8500/GPS 9700 Safety Information Notes wc_si000252gb.
Operation 2 GPS 8500/GPS 9700 Operation 2.1 Control Panel a c b d e 000000 20 A 30 A IDLE f f 120 120 f1 g f2 120/ 240 120 h j 20 A 30 A 120/240 240 n m 30 A 20 A Ref. k Description Ref.
GPS 8500/GPS 9700 2.2 Operation Voltage Selection The voltage selector switch (h) allows the generator to operate in either single (120V) or dual voltage (120/240V) mode. In single voltage mode only the 120V twist lock and 120V duplex receptacles are powered. The full rated power of the generator is shared between the four receptacles.
Operation 2.4 GPS 8500/GPS 9700 To Run the Generator Follow instructions below and read starting and stopping instuctions found in Engine Owner’s Manual. 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. Disconnect all loads from the generator and place the main circuit breaker in the open (O) position.
GPS 8500/GPS 9700 2.5 Operation 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 fuel valve (b2). wc_tx001265gb.
Troubleshooting Voltage Issues 3 3.1 GPS 8500/GPS 9700 Troubleshooting Voltage Issues Determining Where to Begin Prerequisites Procedure Generator must be able to begin Multimeter To determine where to start troubleshooting, follow the procedure below. 1. Remove the control panel (a) from the generator. F 1000 200 20 V 2 200m A V- COM 2. Disconnect the main wiring connector. WARNING Electric shock hazard. High voltage exists at the connector.
GPS 8500/GPS 9700 Troubleshooting Voltage Issues Continued from the previous page. Sequence Follow the sequence below when troubleshooting: Step wc_tx000828gb.fm Task 1 Flash the generator. See section Flashing the Generator. 2 Check the Automatic Voltage Regulator (AVR). See section Checking the Automatic Voltage Regulator (AVR). 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.
Troubleshooting Voltage Issues 3.2 GPS 8500/GPS 9700 Flashing the Generator Prerequisites Procedure 12V battery Multimeter Follow the procedure below to flash the generator. 1. Shut down the generator. 2. Disconnect all loads from the generator. 3. Place the auto idle switch in the OFF position. 4. Remove the rear panel (a) from the generator. 5. Disconnect the F1 (+) and F2 (-) wires and the L1 and L2 wires from the Automatic Voltage Regulator (AVR) (b). WARNING Electric shock hazard.
GPS 8500/GPS 9700 Troubleshooting Voltage Issues Continued from the previous page. 11.Measure the voltage at the receptacles. Is the correct voltage measured? Yes ____ No ____ The generator is ready for use. Continue troubleshooting by checking the automatic voltage regulator (AVR). The flashing procedure is now complete. wc_tx000828gb.
Troubleshooting Voltage Issues 3.3 GPS 8500/GPS 9700 Checking the Automatic Voltage Regulator (AVR) Prerequisites Procedure Generator shut down Multimeter Follow the procedure below to check the Automatic Voltage Regulator (AVR). 1. Shut down the generator. 2. Disconnect all loads from the generator. 3. Place the auto idle switch in the OFF position. 4. Remove the rear panel (a) from the generator. 5.
GPS 8500/GPS 9700 3.4 Troubleshooting Voltage Issues Checking the Stator Windings Prerequisites Procedure Generator shut down Multimeter Follow the procedure below to check the stator windings. 1. Shut down the generator. 2. Remove the front panel (a) from the generator. F 1000 200 20 V 2 200m A V- COM wc_gr004673 3. Disconnect the main wiring connector. WARNING Electric shock hazard. High voltage exists at the connector. High voltage can cause severe injury or death.
Troubleshooting Voltage Issues GPS 8500/GPS 9700 Continued from the previous page. 6. Remove the end cap (b) from the generator. b c d wc_gr004870 7. Check if the stator windings are shorted 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 winding? Yes ____ No ____ The stator windings have failed; replace the stator. Continue.
GPS 8500/GPS 9700 3.5 Troubleshooting Voltage Issues Checking the Rotor Windings Prerequisites Generator shut down Multimeter Procedure Follow the procedure below to check the rotor windings. 1. Shut down the generator. 2. Remove the rear panel (a) from the generator. 3. Remove the brush holder and the Automatic Voltage Regulator (AVR) (b). 4. Measure the resistance of the rotor winding by measuring across the slip rings. F 1000 200 20 V 2 200m A V- COM Is 12.3–12.
Troubleshooting Voltage Issues 3.6 GPS 8500/GPS 9700 Checking the Brushes Prerequisites Procedure Generator shut down Multimeter Follow the procedure below to check the brushes. 1. Shut down the generator. 2. Remove the rear panel (a) from the generator. 3. Disconnect the F1 (+) and F2 (-) wires from the Automatic Voltage Regulator (AVR) 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.
GPS 8500/GPS 9700 3.7 Troubleshooting Voltage Issues Checking the Diode Rectifier Prerequisites Procedure Generator shut down Multimeter Follow the procedure below to check the diode rectifier. 1. Shut down the generator. 2. Remove the rear panel from the generator. 3. Mark, then disconnect the wires from the diode rectifier (a). 4. Using the diode scale on the multimeter, check the continuity of the diode rectifier.
Troubleshooting Voltage Issues 3.8 GPS 8500/GPS 9700 Checking the Auxiliary Winding Prerequisites Procedure Generator shut down Multimeter Follow the procedure below to check the auxiliary winding. 1. Shut 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 the choke (b). Is 1.8–2.
GPS 8500/GPS 9700 3.9 Troubleshooting Voltage Issues Checking the Choke Prerequisites Procedure Generator shut down Multimeter Follow the procedure below to check the choke. 1. Shut 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 Z3 and Z1 on the choke (b). Is 7.6–8.1 Ohms measured? Yes ____ No ____ Continue. The choke has failed. Replace the choke.
Troubleshooting Voltage Issues 3.10 GPS 8500/GPS 9700 Checking the Transformer Prerequisites Generator shut down Multimeter Background The transformer consists of three windings. Each needs to be checked when checking the condition of the transformer. Procedure Follow the procedure below to check the transformer. 1. Remove the front panel (a) from the generator. 2. Locate the transformer (b) within the control box. 3. Trace the brown wire and the blue wire coming out of the transformer.
GPS 8500/GPS 9700 3.11 Troubleshooting Voltage Issues Checking the Voltage Selector Switch (VSS) Prerequisites Procedure Machine shutdown Multimeter Follow the procedure below to check the Voltage Selector Switch (VSS) 1. Place the VSS in the 120V position. 2. Remove the switch handle (a). 3. Remove the screws that secure the VSS (b) 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.
Troubleshooting Voltage Issues 3.12 GPS 8500/GPS 9700 Checking the Auto Idle Circuit Prerequisites Machine’s battery must measure 12V Multimeter 14-gauge jumper wire Background The idle is controlled by the engine electronic governor system (control module and motorized actuator) and the switch and current transformer. Each component must be checked. Checking the control module Follow the procedure below to check the control module. 1. Shut down the generator. 2.
GPS 8500/GPS 9700 Troubleshooting Voltage Issues Continued from the previous page. 2. Disconnect the red and green wires from the control module (a). 3. Connect a jumper wire from the battery positive terminal to the red wire. 4. Connect a jumper wire to the green wire. 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 position.
Troubleshooting Voltage Issues GPS 8500/GPS 9700 Continued from the previous page. 2. Remove the control panel. 3. Measure the resistance of the current transformer by measuring across the two wires of the current transformer (c). One of the wires is connected to a ground stud (d). The other is connected to the auto idle switch (e). Does the current transformer measure 70–73 Ohms? Checking the switch Yes ____ No ____ The current transformer is OK; continue.
GPS 8500/GPS 9700 4 4.1 Disassembly and Assembly Tools Required for Disassembly/Assembly Procedures 4.2 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.
Disassembly and Assembly 4.5 GPS 8500/GPS 9700 Generator Exploded View wc_tx000829gb.
GPS 8500/GPS 9700 4.6 Disassembly and Assembly Exploded View Components Ref. 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 Stator v Nut j Diode rectifier w Screw k Screw x Stator winding connector l --- y Ground Screw z --- m wc_tx000829gb.
Disassembly and Assembly 4.7 GPS 8500/GPS 9700 Removing & Installing the Fuel Tank Prerequisites Removal procedure Engine shut down Engine cool Plug for fuel hose Wire ties Follow the procedure below to remove the fuel tank. 1. Disconnect the fuel hose from the engine and plug the 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.
GPS 8500/GPS 9700 4.8 Disassembly and Assembly Removing & Installing the Automatic Voltage Regulator (AVR) Prerequisites Removal procedure Engine shut down New brushes Follow the procedure below to remove the Automatic Voltage Regulator (AVR). 1. Remove the cover (a) from the generator. 2. Remove the screws that secure the mounting bracket to the stator. 3. Label, then remove the wires connected to the AVR (b). 4. Remove the screw that secures the AVR to the brush holder.
Disassembly and Assembly 4.9 GPS 8500/GPS 9700 Removing the Stator and Rotor Prerequisites Procedure Engine shut down Engine cool Two blocks of wood Follow the procedure below to remove the stator and rotor. 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 Choke. 4. Remove the control panel (a). 5. Remove the ground wire (b) from the stator. 6.
GPS 8500/GPS 9700 Disassembly and Assembly Continued from the previous page. 8. Remove the engine exhaust guard (e). 9. Remove the hardware (f) that secures the lifting eye. 10.Remove the ground wire (g) from the frame. g h wc_gr004718 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 control box. 13.Remove the screws and nuts (i) that secure the shock mount bracket to the stator. 14.
Disassembly and Assembly GPS 8500/GPS 9700 Continued from the previous page. 15.Remove the threaded rod (k) from the rotor. 16.Using a hammer and a block of wood, tap the stator to release it from the engine. Then, pull the stator off the engine. Note: On some occasions, the rotor may come out with the stator. If this happens, skip to “Separating the rotor from the stator”. 17.Support the rotor (l) with one hand and strike it with a rubber mallet on a pole face until it releases.
GPS 8500/GPS 9700 4.10 Disassembly and Assembly Installing the Stator and Rotor Prerequisites Procedure Engine shut down Engine cool 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 shock mount bracket to the stator. 4. Slide the AVR wires out of the generator and into the control box. This procedure continues on the next page.
Disassembly and Assembly GPS 8500/GPS 9700 Continued from the previous page. 5. Connect the blue wire 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. g h wc_gr004718 8. Slide the connector (h) into the control box. 9. Install the engine exhaust guard (e). 10.Install the hardware (f) that secures the lifting eye. This procedure continues on the next page. wc_tx000829gb.
GPS 8500/GPS 9700 Disassembly and Assembly Continued from the previous 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 Installing the AVR. 15.Install the fuel tank. See section Removing and Installing the Fuel Tank. wc_tx000829gb.
Disassembly and Assembly 4.11 GPS 8500/GPS 9700 Removing and Installing the Electronic Governor Prerequisites Removal procedure Engine shut down Engine cool Follow the procedure below to remove the electronic governor. 1. Disconnect the red and green wires from the control module. 2. Remove the air cleaner assembly. 3. Disconnect the governor link at the carburetor. 4. Remove the governor control bracket with the actuator. 5.
GPS 8500/GPS 9700 Disassembly and Assembly Notes wc_tx000829gb.
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GPS 8500/GPS 9700 5.2 Schematics Schematic Components (0008286 Revision 105 to 118; 0008287 Revision 105 to 117 0008287 Revision 200 and above; 0620264 Revision 200 and above) Ref. Description A Generator Ref. Description Ref. Description Ref. B Control box C Ref.
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GPS 8500/GPS 9700 5.4 Schematics Schematic Components (Revision 104 and below) Ref. Description A Generator Ref. Description Ref. Description Ref. B Control box C Ref.
Schematics 5.5 Ref. GPS 8500/GPS 9700 Engine Wiring Diagram Description Ref. Description 1 Carburetor 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 15 Solenoid tab terminal 7 Ignition coils 16 Starter terminal 8 Alternator 17 Battery 9 AC output wires 18 Starter motor wc_tx000831gb.
GPS 8500/GPS 9700 6 Technical Data Technical Data 6.1 Generator Item No. GS 8.5V 0008286 GS 9.7V 0008287, 0620624 Generator Maximum Output kW / kVA Continuous Output 8.5 / 8.5 9.7 / 9.7 8.2 9.3 W Type Dual voltage, single phase, brush-type system AC Voltages Available 120 / 240 1ø volts phase Frequency 60 Hz Power Factor 1.
Technical Data 6.3 GPS 8500/GPS 9700 Engine Item No. GS 8.5V GS 8.5V GS 9.7V GS 9.7V 0008286 Rev 108 and lower 0008286 Rev 109 to 118 0008287 Rev 108 and lower 0008287 Rev 109 to 117 Engine Engine Type 2 cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Briggs and Stratton Engine Model Vanguard Vanguard Vanguard Vanguard 303447 350447 350447 356447 Rated Power kW (Hp) 11.9 (16) 13.4 (18) Displacement cm3 (in3) 480 (29.3) 570 (34.
GPS 8500/GPS 9700 Technical Data Non CARB compliant Machines Engine power rating Gross power rating per SAE J1995. Actual power output may vary due to conditions of specific use. 0008286 0620264 Rev 200 and above Item No. GPS 8500 GPS 9700 Engine Engine type 2 cylinder, 4-cycle, air-cooled, gasoline engine Engine make Briggs and Stratton Engine model Vanguard Vanguard 305447 356447 Max. rated power @ rated speed kW (Hp) 11.9 (16) @ 3600 rpm 13.
Technical Data GPS 8500/GPS 9700 CARB Compliant Machines Engine power rating Gross power rating per SAE J1995. Actual power output may vary due to conditions of specific use. 0008287 Item No. GPS 9700 Engine Engine Type 2 cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Briggs and Stratton Engine Model Vanguard 356447 Max. 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.
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.
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.
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.
