Wacker Neuson GPS 8500 Page 58 Repair Manual Download | Manualshive

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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

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

190

140

230

169

22

7/8

12

–

M16

210

155

295

217

355

262

24

15/16

14

–

M18

290

214

405

298

485

357

27

1-1/16

14

–

M20

410

302

580

427

690

508

30

1-1/4

17

–

1 ft.lb. = 1.357 Nm

* = in.lb.

1 inch = 25.4 mm

8.8

10.9

12.9

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Summary of Contents for 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 2: ......

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 rights are reserved Copyright 2009 by Wacker Neuson Corporation This publication may be reproduced through photocopying by the original purchaser of the machine Any other type of reproduction is prohibit...

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 property of their respective own ers ...

Page 5: ...shooting 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...

Page 6: ...emoving 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 Diagr...

Page 7: ...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 locat...

Page 8: ...e 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 ha...

Page 9: ...e 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 insi...

Page 10: ...nt 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 Lab...

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

Page 12: ...h 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 120 240V 30A Overcurrent Circuit Breaker k 120V 20A Twist lock Receptacle e Hour meter m 240V 20A Twist lock Receptacle f 120V GFI Duplex Receptacle n 120 240V Twist lock Receptacle ...

Page 13: ...tacle 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 open position O before changing the voltage switch position 2 3 Engine Auto Idle The auto idle switch a automatically reduces engine speed 5 seconds after all appliances or tools attached to the generat...

Page 14: ...g 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 Note Turn the keyswitch to the OFF position when the engine is not running Leaving the key in the RUN position with the engine off will drain the battery Note Although the engine will start manually and...

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 fuel valve b2 ...

Page 16: ...ition 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 F V A V COM WARNING Electric shock hazard High voltage exists at the connector High voltage can cause severe injury or death f Never touch the internal terminals of the connector while the engine is ...

Page 17: ...R 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 rectifier See section Checking the Diode Rectifier 7 Check the auxiliary winding See section Checking the Auxiliary Winding 8 Check the choke See section Checking the Choke 9 Check the transformer S...

Page 18: ...e 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 wire and the L2 wire Is 120 160 VAC measured 10 Reassemble the generator This procedure continues on the next page WARNING Electric shock hazard High voltage exists at the L1 and L2 wires Electric sh...

Page 19: ...9 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 checking the automatic voltage regulator AVR ...

Page 20: ...rator 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 voltage between the L1 wire and the L2 wire Is 120 160 VAC measured The AVR has now been checked Continue with checking the stator windings WARNING Electric shock hazard High voltage exists at the L1 an...

Page 21: ...nd 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 continuity This procedure continues on the next page wc_gr004673 1000 200 20 2 200m F V A V COM WARNING Electric shock hazard High voltage exists at the connector High voltage can cause severe injury or dea...

Page 22: ...orted 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 The stator windings have now been checked Continue with checking the rotor winding Yes ____ No ____ The stator windings have failed replace the stator Continue wc_gr004870 c b d ...

Page 23: ...older 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 rings and ground Is there continuity The rotor winding has now been checked Continue troubleshooting by checking the brushes Yes ____ No ____ Continue The rotor winding has failed replace the rotor ...

Page 24: ...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 32 in 5 Check the continuity of each brush Does each brush measure at least 8 mm 0 32 in and have continuity Note When reconnecting the wires to the brushes the F1 wire runs to the slip ring closest to the bearing The brushes have now been check...

Page 25: ...e 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 leads and check again Note For each check the multimeter should read approximately 0 5V in one direc tion and OPEN in the other Does the diode rectifier perform as stated above The diode rectifier has n...

Page 26: ...t 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 0 Ohms measured The auxiliary winding has now been checked Continue troubleshooting by checking the choke Yes ____ No ____ The auxiliary winding is OK The auxiliary winding has f...

Page 27: ...ectifier 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 between terminal Z3 and ground Also check continuity between terminal Z1 and ground Is there continuity The choke has now been checked Continue troubleshooting by checking the transformer Yes ____ No __...

Page 28: ...nce 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 runs to the neutral side of the 125V GFCI receptacle 6 Measure the resistance between the red wire and the white wire Is 630 690 Ohms measured 7 Trace the orange wire and the yellow wire coming out o...

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 should read less than 1 Ohm for closed terminals and OL or OPEN for open terminals Does the switch perform as stated above 8 Reassemble the generator The VSS has now been checked Position Closed term...

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 engine 7 Connect the jumper wire to the module s blue wire and connect it to ground After a 10 second delay the engine should idle down to 1750 rpm 8 Remove the ground wire The engine should return to ...

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 position Does the actuator perform as stated above Checking the current transformer Follow the procedure below to check the current transformer 1 Shut down the engine This procedure continues on the next pa...

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 from the switch when the switch is in the ON position Does the switch perform as stated above The auto idle circuit has now been checked Reassemble the generator Yes ____ No ____ The current transformer...

Page 33: ...sion 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 Reference Numbers Repair procedures contain reference numbers enclosed in parentheses These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings They are included t...

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

Page 35: ...f 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 Stator v Nut j Diode rectifier w Screw k Screw x Stator winding connector l y Ground m Screw z ...

Page 36: ...he 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 Follow the procedure below to install the fuel tank 1 Position the fuel tank onto the frame 2 Secure the fuel tank to the frame with screws b 3 Connect the fuel hose to the engine 4 Secure the fuel hose...

Page 37: ...VR 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 must be 3600 no load 2 Place the auto idle switch in OFF position 3 Check the voltage at the receptacles 4 Turn the adjusting pot c on the AVR so that 115 125VAC is measured at the 120V recpta cles Tu...

Page 38: ...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 Remove the screw c that secures the battery cable 7 Disconnect the blue wire at the auto idle switch d This procedure con...

Page 39: ...10 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 control box 13 Remove the screws and nuts i that secure the shock mount bracket to the sta tor 14 Support j the engine to the frame This procedure continues on the next page wc_gr004718 g h ...

Page 40: ...e 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 from the stator 1 Place the stator m on two blocks of wood with the bearing end up Place the blocks of wood near the edge to allow the rotor space to drop out 2 Partially insert one of the frame mounti...

Page 41: ...rocedure 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 ...

Page 42: ...ire 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 guard e 10 Install the hardware f that secures the lifting eye This procedure continues on the next page wc_gr004718 g h ...

Page 43: ...ious 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 ...

Page 44: ...mble 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 torquing the nuts 2 Connect the governor link to the actuator Make sure the link snaps into the hole in the actuator grommet 3 Connect the throttle return spring through the slot in the governor control br...

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 15A 120VAC 15A 120VAC 30A 120 240VAC 20A 240VAC G Y B R G Y G Y G Y G Y G Y L Y R R W L R B L L B B R Gr R Y Br R B L B G Gr B Y 1 A B C 1 5 4 3 2 8 7 9 13 14 15 12 16 G W G W G Y B G Y L Br R W W W...

Page 47: ...cription 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 Resistor GPS 9700 only 13 Oil level switch 5 Rotor winding 14 Coil 6 Circuit breaker 15 Starter 7 Auto idle unit 16 Battery 8 Auto idle switch 17 Voltage selector switch VSS 9 Auxiliary stator winding ...

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 20A 240VAC G Y B R G Y G Y G Y G Y G Y L Y R W L Br R B L L B B R Gr R Y Br R B L B G Y 1 A B C 1 5 4 3 2 8 7 9 13 14 15 12 16 G W G Y B G Y W O L Br R W O 6 10 11 18 18 17 ...

Page 49: ...ox 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 winding 14 Coil 6 Circuit breaker 15 Starter 7 Auto idle unit 16 Battery 8 Auto idle switch 17 Voltage selector switch VSS 9 Auxiliary stator winding 18 Terminal block ...

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 15 Solenoid tab terminal 7 Ignition coils 16 Starter terminal 8 Alternator 17 Battery 9 AC output wires 18 Starter motor ...

Page 51: ...ype system AC Voltages Available volts phase 120 240 1ø 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 lock amp 20 20 20 30 20 30 Continuous Current at 120V amp 68 77 5 L x W x H mm in 800 x 635 x 603 31 5 x 25 x 23 75 Weight dry Kg lbs 97 214 99 218 Machine Main stator Auxilliary Rotor Choke GPS 8500 G...

Page 52: ...ard 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 full load rpm 3600 Auto Idle Speed rpm 2200 Valve Clearance cold mm in 0 10 0 16 0 004 0 006 Air Cleaner type Dual element Battery V size CCA 12 22NF 230 Engine Lubrication oil grade service class SA...

Page 53: ...6447 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 Alternator amp 16 Engine speed operating rpm 3600 Auto idle speed rpm 2200 Valve clearance cold mm in 0 10 0 16 0 004 0 006 Air cleaner type Dual element Battery V size CCA 12 22NF 230 Engine lubricatio...

Page 54: ...ax 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 rpm 3600 Auto Idle Speed rpm 2200 Valve Clearance cold mm in 0 10 0 16 0 004 0 006 Air Cleaner type Dual element Battery V size CCA 12 22NF 230 Engine Lubrication oil grade service class SAE 10W30 SG ...

Page 55: ......

Page 56: ...9311 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 ml 73285 50 ml Loctite 290 Hernon 431 Omnifit 1710 230LL Green Medium to high strength for locking preassembled threads and for sealing weld porosity wicking Gaps up to 0 13 mm 0 005 Temp range 54 to ...

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 adhesive for bonding rubber metal and plastics general purpose For gaps up to 0 15 mm 0 006 Read caution instructions before using Temp range 54 to 82 C 65 to 180 F 52676 1oz Loctite Primer T Hernon P...

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 99 190 140 230 169 22 7 8 12 M16 210 155 295 217 355 262 24 15 16 14 M18 290 214 405 298 485 357 27 1 1 16 14 M20 410 302 580 427 690 508 30 1 1 4 17 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm 8 8 10 9 12 9 ...

Page 59: ...o 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 3 8 1 2 77 57 109 80 142 105 19 3 4 3 8 9 16 111 82 156 115 214 158 13 16 5 8 152 112 216 159 265 195 24 15 16 1 2 3 4 271 200 383 282 479 353 1 1 8 5 8 1 ft lb 1 357 Nm in lb 1 inch 25 4 mm ...

Page 60: ...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 Tel 852 3605 5360 Fax 852 2758 0032 ...

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