1. DL manuals
  2. Wacker Neuson
  3. Portable Generator
  4. GPS 8500
  5. Repair Manual

Wacker Neuson GPS 8500 Repair Manual

Other manuals for GPS 8500: Operator's Manual

Summary of GPS 8500

  • 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.

  • Page 3: Gps 8500/gps 9700

    Gps 8500/gps 9700 foreword wc_tx000827gb.Fm 3 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 d...

  • Page 4: Foreword

    Foreword gps 8500/gps 9700 wc_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 property of their respective own- ers..

  • Page 5: Gps 8500/gps 9700

    Gps 8500/gps 9700 table of contents wc_br0174423en_002toc.Fm 5 foreword 3 1 safety information 7 1.1 laws pertaining to spark arresters ...................................................... 7 1.2 operating safety .................................................................................. 8 1...

  • Page 6: Table of Contents

    Table of contents gps 8500/gps 970 wc_br0174423en_002toc.Fm 6 4.3 information regarding reference numbers ( ) ...................................33 4.4 information regarding threadlocking compounds .............................33 4.5 generator exploded view .............................................

  • Page 7: Gps 8500/gps 9700

    Gps 8500/gps 9700 safety information wc_si000252gb.Fm 7 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...

  • Page 8: Safety Information

    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 fro...

  • Page 9: Gps 8500/gps 9700

    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 an...

  • Page 10: Safety Information

    Safety information gps 8500/gps 9700 wc_si000252gb.Fm 10 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 exp...

  • Page 11: Gps 8500/gps 9700

    Gps 8500/gps 9700 safety information wc_si000252gb.Fm 11 notes.

  • Page 12: Operation

    Operation gps 8500/gps 9700 wc_tx001265gb.Fm 12 2 operation 2.1 control panel 000000 idle 120 120 30 a 20 a 20 a 240 120/240 30 a 20 a 30 a 120 120/ 240 a b e d c f f1 f2 j m k n h g f ref. Description ref. Description a auto idle switch g thermal overload b main circuit breaker h voltage selector s...

  • Page 13: Gps 8500/gps 9700

    Gps 8500/gps 9700 operation wc_tx001265gb.Fm 13 2.2 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...

  • Page 14: Operation

    Operation gps 8500/gps 9700 wc_tx001265gb.Fm 14 2.4 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...

  • Page 15: Gps 8500/gps 9700

    Gps 8500/gps 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 fuel valve (b2)..

  • Page 16: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 16 3 troubleshooting voltage issues 3.1 determining where to begin prerequisites generator must be able to begin multimeter procedure to determine where to start troubleshooting, follow the procedure below. 1. Remove the control panel...

  • Page 17: Gps 8500/gps 9700

    Gps 8500/gps 9700 troubleshooting voltage issues wc_tx000828gb.Fm 17 continued from the previous page. Sequence follow the sequence below when troubleshooting: step task 1 flash the generator. See section flashing the generator. 2 check the automatic voltage regulator (avr). See section checking the...

  • Page 18: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 18 3.2 flashing the generator prerequisites 12v battery multimeter procedure 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 t...

  • Page 19: Gps 8500/gps 9700

    Gps 8500/gps 9700 troubleshooting voltage issues wc_tx000828gb.Fm 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. Continue troubleshooting by chec...

  • Page 20: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 20 3.3 checking the automatic voltage regulator (avr) prerequisites generator shut down multimeter procedure follow the procedure below to check the automatic voltage regulator (avr). 1. Shut down the generator. 2. Disconnect all load...

  • Page 21: Gps 8500/gps 9700

    Gps 8500/gps 9700 troubleshooting voltage issues wc_tx000828gb.Fm 21 3.4 checking the stator windings prerequisites generator shut down multimeter procedure follow the procedure below to check the stator windings. 1. Shut down the generator. 2. Remove the front panel (a) from the generator. 3. Disco...

  • Page 22: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 22 continued from the previous page. 6. Remove the end cap (b) from the generator. 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 rot...

  • Page 23: Gps 8500/gps 9700

    Gps 8500/gps 9700 troubleshooting voltage issues wc_tx000828gb.Fm 23 3.5 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 t...

  • Page 24: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 24 3.6 checking the brushes prerequisites generator shut down multimeter procedure 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 (+) ...

  • Page 25: Gps 8500/gps 9700

    Gps 8500/gps 9700 troubleshooting voltage issues wc_tx000828gb.Fm 25 3.7 checking the diode rectifier prerequisites generator shut down multimeter procedure 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...

  • Page 26: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 26 3.8 checking the auxiliary winding prerequisites generator shut down multimeter procedure follow the procedure below to check the auxiliary winding. 1. Shut down the generator. 2. Remove the rear panel from the generator. 3. Remove...

  • Page 27: Gps 8500/gps 9700

    Gps 8500/gps 9700 troubleshooting voltage issues wc_tx000828gb.Fm 27 3.9 checking the choke prerequisites generator shut down multimeter procedure 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 terminal...

  • Page 28: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 28 3.10 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 procedu...

  • Page 29: Gps 8500/gps 9700

    Gps 8500/gps 9700 troubleshooting voltage issues wc_tx000828gb.Fm 29 3.11 checking the voltage selector switch (vss) prerequisites machine shutdown multimeter procedure follow the procedure below to check the voltage selector switch (vss) 1. Place the vss in the 120v position. 2. Remove the switch h...

  • Page 30: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 30 3.12 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)...

  • Page 31: Gps 8500/gps 9700

    Gps 8500/gps 9700 troubleshooting voltage issues wc_tx000828gb.Fm 31 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 ...

  • Page 32: Gps 8500/gps 9700

    Troubleshooting voltage issues gps 8500/gps 9700 wc_tx000828gb.Fm 32 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...

  • Page 33: Gps 8500/gps 9700

    Gps 8500/gps 9700 disassembly and assembly wc_tx000829gb.Fm 33 4 disassembly and assembly 4.1 tools required for disassembly/assembly procedures it is up to the mechanic to use common sense and good judgment in tool selection to reduce the risk of injury while repairing the machine. In cases where a...

  • Page 34: Disassembly and Assembly

    Disassembly and assembly gps 8500/gps 9700 wc_tx000829gb.Fm 34 4.5 generator exploded view.

  • Page 35: Gps 8500/gps 9700

    Gps 8500/gps 9700 disassembly and assembly wc_tx000829gb.Fm 35 4.6 exploded view components ref. 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...

  • Page 36: Disassembly and Assembly

    Disassembly and assembly gps 8500/gps 9700 wc_tx000829gb.Fm 36 4.7 removing & installing the fuel tank prerequisites engine shut down engine cool plug for fuel hose wire ties removal procedure follow the procedure below to remove the fuel tank. 1. Disconnect the fuel hose from the engine and plug th...

  • Page 37: Gps 8500/gps 9700

    Gps 8500/gps 9700 disassembly and assembly wc_tx000829gb.Fm 37 4.8 removing & installing the automatic voltage regulator (avr) prerequisites engine shut down new brushes removal procedure follow the procedure below to remove the automatic voltage regulator (avr). 1. Remove the cover (a) from the gen...

  • Page 38: Disassembly and Assembly

    Disassembly and assembly gps 8500/gps 9700 wc_tx000829gb.Fm 38 4.9 removing the stator and rotor prerequisites engine shut down engine cool two blocks of wood procedure follow the procedure below to remove the stator and rotor. 1. Remove the fuel tank. See section removing and installing the fuel ta...

  • Page 39: Gps 8500/gps 9700

    Gps 8500/gps 9700 disassembly and assembly wc_tx000829gb.Fm 39 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. 11.Disconnect the main stator winding connector (h) and slid...

  • Page 40: Disassembly and Assembly

    Disassembly and assembly gps 8500/gps 9700 wc_tx000829gb.Fm 40 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 roto...

  • Page 41: Gps 8500/gps 9700

    Gps 8500/gps 9700 disassembly and assembly wc_tx000829gb.Fm 41 4.10 installing the stator and rotor prerequisites engine shut down engine cool procedure 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 ...

  • Page 42: Disassembly and Assembly

    Disassembly and assembly gps 8500/gps 9700 wc_tx000829gb.Fm 42 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. 8. Slide the connector (h) into the control box...

  • Page 43: Gps 8500/gps 9700

    Gps 8500/gps 9700 disassembly and assembly wc_tx000829gb.Fm 43 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 installin...

  • Page 44: Disassembly and Assembly

    Disassembly and assembly gps 8500/gps 9700 wc_tx000829gb.Fm 44 4.11 removing and installing the electronic governor prerequisites engine shut down engine cool removal procedure follow the procedure below to remove the electronic governor. 1. Disconnect the red and green wires from the control module...

  • Page 45: Gps 8500/gps 9700

    Gps 8500/gps 9700 disassembly and assembly wc_tx000829gb.Fm 45 notes.

  • Page 46: Schematics

    Schematics gps 8500/gps 9700 wc_tx000831gb.Fm 46 5 schematics 5.1 generator wiring schematic (0008286 revision 105 to 118; 0008287 revision 105 to 117 0008287 revision 200 and above; 0620264 revision 200 and above) 30a 120 v a c 7 8 12 0/ 24 0v 12 0v 9 12 10 6 8 7 3 4 2 1 2 3 4 f 2 f 1 z1 z3 z1 z 2 ...

  • Page 47: Gps 8500/gps 9700

    Gps 8500/gps 9700 schematics wc_tx000831gb.Fm 47 5.2 schematic components (0008286 revision 105 to 118; 0008287 revision 105 to 117 0008287 revision 200 and above; 0620264 revision 200 and above) ref. Description ref. Description ref. Description a generator b control box c engine ref. Description r...

  • Page 48: Schematics

    Schematics gps 8500/gps 9700 wc_tx000831gb.Fm 48 5.3 generator wiring schematic (revision 104 and below) 30a 120 vac 2 3 3 1 4 1 4 2 7 8 5 7 5 6 8 6 12 0/ 24 0v 120v 9 12 10 6 8 7 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/...

  • Page 49: Gps 8500/gps 9700

    Gps 8500/gps 9700 schematics wc_tx000831gb.Fm 49 5.4 schematic components (revision 104 and below) ref. Description ref. Description 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 regulat...

  • Page 50: Schematics

    Schematics gps 8500/gps 9700 wc_tx000831gb.Fm 50 5.5 engine wiring diagram ref. 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 ba...

  • Page 51: Gps 8500/gps 9700

    Gps 8500/gps 9700 technical data wc_td000255gb.Fm 51 6 technical data 6.1 generator 6.2 windings item no. Gs 8.5v 0008286 gs 9.7v 0008287, 0620624 generator maximum output kw / kva 8.5 / 8.5 9.7 / 9.7 continuous output w 8.2 9.3 type dual voltage, single phase, brush-type system ac voltages availabl...

  • Page 52: Technical Data

    Technical data gps 8500/gps 9700 wc_td000255gb.Fm 52 6.3 engine item no. Gs 8.5v 0008286 rev 108 and lower gs 8.5v 0008286 rev 109 to 118 gs 9.7v 0008287 rev 108 and lower gs 9.7v 0008287 rev 109 to 117 engine engine type 2 cylinder, 4-cycle, air-cooled, gasoline engine engine make briggs and stratt...

  • Page 53: Gps 8500/gps 9700

    Gps 8500/gps 9700 technical data wc_td000255gb.Fm 53 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, ...

  • Page 54: Technical Data

    Technical data gps 8500/gps 9700 wc_td000255gb.Fm 54 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...

  • Page 56: Threadlockers and Sealants

    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 b...

  • Page 57: Threadlockers and Sealants

    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 ...

  • Page 58: Torque Values

    Torque values torque values metric fasteners (din) torque values (based on bolt size and hardness) wrench size size nm ft.Lb. Nm ft.Lb. Nm ft.Lb. Metric inch metric inch m3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 – m4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 – m5 6.0 *53 8.5 6 10 7 8 5/16 4 – m6 10 7 14 10 17 ...

  • Page 59: Torque Values

    Torque values torque values (continued) inch fasteners (sae) size nm ft.Lb. Nm ft.Lb. Nm ft.Lb. Metric inch metric inch no.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32 no.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64 no.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64 no.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32 1/4 8.1...

  • Page 60

    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 & 171...