Wacker Neuson GPS 9700 User manual

Generator, Non-CARB
GPS 8500
GPS 9700
OPERATOR’S MANUAL
0176674en 002
0809
0176674EN

DANGER
CARBON MONOXIDE
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or
smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot
smell the exhaust, you could be breathing CO.
• NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed
areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh air.
• ONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the home. ALWAYS use a
battery-powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh
air RIGHT AWAY. See a doctor. You could have carbon monoxide poison.

wc_tx001035gb.fm 3
Machines covered in this manual
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.
Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker Neuson model. For your own safety and
protection from injury, carefully read, understand and observe the
safety instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker Neuson
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Neuson
Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Neuson Corporation
reserves the right to change any portion of this information without
notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2008 by Wacker Neuson Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker
Neuson Corporation represents an infringement of valid copyrights
and will be prosecuted. We expressly reserve the right to make
technical modifications, even without due notice, which aim at
improving our machines or their safety standards.
Machine Item Number
GPS 8500 0008286 Rev 118 and higher
GPS 9700 0620264
WARNING

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GPS 8500 / GPS 9700 Table of Contents
5
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
1.5 Label Locations .................................................................................. 11
1.6 Safety and Operating Labels .............................................................. 12
2. Operation 16
2.1 Application and Power Requirements ................................................ 16
2.2 Installation .......................................................................................... 17
2.3 Generator Derating ............................................................................. 18
2.4 Grounding the Generator ................................................................... 19
2.5 Use of Extension Cords ...................................................................... 20
2.6 Recommended Battery ....................................................................... 20
2.7 Control Panel ...................................................................................... 21
2.8 Main Circuit Breaker ........................................................................... 22
2.9 Ground Fault Circuit Interrupt (GFI) ................................................... 22
2.10 Voltage Selection ............................................................................... 23
2.11 240V Receptacles .............................................................................. 23
2.12 Engine Auto Idle ................................................................................. 24
2.13 Engine Speed ..................................................................................... 24
2.14 Before Starting ................................................................................... 25
2.15 To Run Generator .............................................................................. 25
2.16 To Stop ............................................................................................... 26

Table of Contents GPS 8500 / GPS 9700
wc_bo0176674en_002TOC.fm 6
3. Maintenance 28
3.1 Engine Maintenance ............................................................................28
3.2 Periodic Maintenance Schedule ..........................................................28
3.3 Engine Lubrication ...............................................................................29
3.4 Oil Filter ...............................................................................................30
3.5 Air Cleaner ..........................................................................................31
3.6 Spark Plug ...........................................................................................32
3.7 Fuel Filter ............................................................................................33
3.8 Carburetor Adjustment ........................................................................34
3.9 Storage ................................................................................................35
3.10 Transporting ........................................................................................36
3.11 Troubleshooting ...................................................................................37
3.12 Wire Colors ..........................................................................................37
3.13 Generator Wiring Schematic ...............................................................38
3.14 Engine Wiring Diagram .......................................................................40
4. Technical Data 41
4.1 Generator ............................................................................................41
4.2 Engine .................................................................................................42

GPS 8500 / GPS 9700 Safety Information
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 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
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 dangerous. Read the operating instructions contained in both
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
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.
DANGER

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 it.
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

GPS 8500 / GPS 9700 Safety Information
11
1.5 Label Locations
G
K
F
E
H
L
J
IA
D
B,C

Safety Information GPS 8500 / GPS 9700
12
1.6 Safety and Operating Labels
Wacker Neuson machines use international pictorial labels where
needed. These labels are described below:
Label Meaning
A
DANGER!
Engines emit carbon monoxide; operate only in well-ventilated area. Read the
Operator’s Manual.
No sparks, flames, or burning objects near the machine. Shut off the engine before
refueling.
BWARNING!
Hot surface!
CCAUTION!
Read and understand the supplied
Operator’s Manual before operating this
machine. Failure to do so increases the
risk of injury to yourself or others.
DCAUTION!
Lifting point.
EElectrical ground
DANGER
GEFAHR
DANGER
PELIGRO
STOP
GND
88897

GPS 8500 / GPS 9700 Safety Information
13
FNeutral bonded to frame.
GKey switch:
off
on
start
H
Open main circuit breaker.
Open the fuel flow valve.
Open the choke.
Turn engine key switch to “ON” position.
Label Meaning
1 2 34
5B
5A
67
12
3

Safety Information GPS 8500 / GPS 9700
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Pull rewind starter or turn engine key
switch to crank starter.
Close main circuit breaker.
Close the fuel flow valve.
Close the choke.
Turn engine key switch to “OFF”
position.
I, J
Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust
contains carbon monoxide. This is a poison you cannot see or smell.
NEVER use inside a home or garage,
EVEN IF doors and windows are open.
Label Meaning

GPS 8500 / GPS 9700 Safety Information
15
Only use OUTSIDE and far away from
windows, doors, and vents.
KThis equipment does not meet Califor-
nia EVP emission regulations for small
off-road engines.
LImproper 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.
Do not run the engine near open flames.
A nameplate listing the model number,
item number, revision number, and serial
number is attached to each unit. Please
record the information found on this
plate so it will be available should the
nameplate become lost or damaged.
When ordering parts or requesting
service information, you will always be
asked to specify the model number, item
number, revision number, and serial
number of the unit.
This machine may be covered by one or
more patents.
Label Meaning

Operation GPS 8500 / GPS 9700
16
2. Operation
2.1 Application and Power Requirements
This generator is designed to operate single-phase, 60 Hz appliances
running at 120 and 240 VAC.
NOTICE:Do not exceed the continuous rated output of the generator.
Damage to tools or generator will occur. See Technical Data.
Check the nameplate or label provided on tools and appliances to
make sure their power requirements are met by the power output of the
generator. If the wattage is not given for a particular tool or appliance,
contact the tool manufacturer for wattage requirements.
Some appliances and tools require a surge of current when starting.
This means that the amount of power needed to initially start the
equipment is larger than the power required to keep it running. The
generator must be capable of supplying this "surge" current. Other
types of appliances require more power than is actually stated on their
nameplate.
The information in “Approximate Starting Power Requirements” is
offered only as a general guideline to help you determine power
requirements for different types of equipment. Check with your nearest
Wacker dealer, or contact the manufacturer or dealer of the tool or
appliance, if you have questions regarding power requirements.
Approximate Starting Power Requirements
• Incandescent lights and appliances such as irons and hot plates,
which use a resistive-type heating element, require the same wattage
to start and run as is stated on their nameplates.
• Fluorescent and mercury lamps require 1.2–2 times their stated watt-
age to start.
• Electrical motors and many types of electrical tools often require a
large starting current. The amount of starting current depends on the
type of motor and its use.
• Most electrical tools require 1.2–3 times their stated wattage for start-
ing.
• Loads such as submersible pumps and air compressors require a
very large force to start. They need as much as 3–5 times the wattage
stated on the nameplate in order to start.
If the wattage is not given for a particular tool or appliance, it can be
calculated by multiplying its voltage and amperage requirements:
Single Phase: VOLTS x AMPS = WATTS
Three Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS

GPS 8500 / GPS 9700 Operation
17
2.2 Installation
Place the generator in an area where it will not be exposed to rain,
snow, or direct sunlight. Make sure it is positioned on firm, level
ground, so it will not slide or shift. Position the engine exhaust away
from areas where people may be present.
The surrounding area must be free from water and moisture. All
components must be protected from excessive moisture.
Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or
smell. NEVER use this generator inside a home or garage, EVEN IF
doors and windows are open. Only use this generator OUTSIDE and
far away from windows, doors, and vents.
NEVER install a generator in an enclosed area such as a tunnel or a
trench. Using a generator in a tunnel or a trench CAN KILL YOU IN
MINUTES. Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell. NEVER use this generator inside a
tunnel or a trench.
DANGER
DANGERDANGER

Operation GPS 8500 / GPS 9700
18
2.3 Generator Derating
All generators are subject to derating for altitude and temperature.
Internal combustion engines, unless modified, run less efficiently at
higher altitudes due to the reduction of air pressure. This translates
into a lack of power and thus reduction in generator output.
Temperature affects both engine and generator performance. As
temperature increases, an engine will run less efficiently and more
resistance will be found in electrical components. Therefore, as the
temperature increases, the output of the generator decreases. Altitude
also affects the cooling capacity of air—the higher the altitude the less
dense the air is and thus the lower its ability to transfer heat.
For every increase in altitude of 500 m (1650 ft.) above 1000 m (3300
ft.), the output of the generator will be reduced by 3%. For every
increase of 5° C (9° F) in ambient temperature above 40° C (104° F),
the output of the generator will be reduced by 3%. Use the tables
shown for altitude and temperature deration factors. It may be
necessary to consider both altitude and ambient temperature deration
factors to determine true generator output.
Ambient Temp.
°C (°F) Derate Factor
45 (113) 3 % 0.97
50 (122) 6 % 0.94
55 (131) 9 % 0.91
60 (140) 12 % 0.88
Altitude
m (ft.) Derate Factor
1500 (4900) 3 % 0.97
2000 (6600) 6 % 0.94
2500 (8200) 9 % 0.91
3000 (9900) 12 % 0.88
3500 (11500) 15 % 0.85
4000 (13100) 18 % 0.82

GPS 8500 / GPS 9700 Operation
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2.4 Grounding the Generator
A ground connection (a) is located on the generator frame. For proper
operating safety, this ground terminal must be connected to a good
ground source. This ground connection must comply with National
Electrical Code standards, and state and local regulations.
wc_gr000544

Operation GPS 8500 / GPS 9700
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2.5 Use of Extension Cords
When a long extension cord is used to connect an appliance or tool to
the generator, a voltage loss occurs—the longer the cord, the greater
the voltage loss. This results in less voltage being supplied to the
appliance or tool and increases the amount of current draw or reduces
performance. A heavier cord with a larger wire size will reduce the
voltage loss.
Damaged extension cords can cause electrical shock, resulting in
serious injury or death. DO NOT use worn, bare, or frayed cords.
Replace damaged cords immediately.
Use the chart below as a guide for selecting proper cable size.
Use only extension cords rated for outdoor use and equipped with a
third-wire ground.
NOTICE: Operating equipment at low voltage can cause it to overheat.
2.6 Recommended Battery
This generator is shipped without a battery. The recommended battery
to be used is:
Current Load in Watts Maximum Cable Length in Feet
(Amps) 120V 240V #10 #12 #14 #16
2.5 300 600 1000. 600 375 250
5 600 1200 500 300 200 125
7.5 900 1800 350 200 125 100
10 1200 2400 250 150 100 -
15 1800 3600 150 100 65 -
20 2400 4800 125 75 50 -
Battery Type 22NF
Voltage 12V
Capacity 230 Cold Cranking Amps
WARNING