0171950en 0609 Generator GP 6600A GPS 6600A CARB OPERATOR’S MANUAL 0 1 7 1 9 5 0 E N 002
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.
WARNING 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.
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GP/GPS 6600A Table of Contents Foreword 3 1. California Evaporative Emission Control Warranty Statement 7 2. Safety Information 2.1 2.2 2.3 2.4 2.5 2.6 3. 9 Laws Pertaining to Spark Arresters ...................................................... 9 Operating Safety ................................................................................ 10 Operator Safety while using Internal Combustion Engines ................ 12 Service Safety .............................................................
Table of Contents 4. Maintenance 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 5. GP/GPS 6600A 34 Engine Maintenance ............................................................................34 Periodic Maintenance Schedule ..........................................................34 Engine Oil ............................................................................................35 Servicing Air Cleaner ...........................................................................
California Evaporative Emission Control Warranty Statement 1. California Evaporative Emission Control Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Wacker Neuson Corporation, Inc., are pleased to explain the evaporative emission control system (EECS) warranty on your model year 2008 and later portable generator. In California, new portable generators must be designed, built and equipped to meet the State’s stringent anti-smog standards.
California Evaporative Emission Control Warranty Statement OWNER’S WARRANTY RESPONSIBILITIES: As the portable generator owner, you are responsible for performance of the required maintenance listed in your Operator’s Manual. Wacker Neuson Corporation recommends that you retain all receipts covering maintenance on your portable generator, but Wacker Neuson Corporation cannot deny warranty solely for the lack of receipts.
GP/GPS 6600A 2. 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 2.2 Operating Safety DANGER DANGER WARNING wc_si000239gb.fm GP/GPS 6600A 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.
GP/GPS 6600A Safety Information 2.2.8 NEVER allow untrained personnel to operate or service the generator. The generator set should be set up by a certified electrician. 2.2.9 NEVER stand on the machine. 2.2.10 DO NOT stand under the machine while it is being hoisted or moved. 2.2.11 DO NOT attach equipment to the machine when it is suspended. 2.2.12 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. 2.2.
Safety Information 2.3 GP/GPS 6600A Operator Safety while using Internal Combustion Engines WARNING DANGER 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. NEVER install a generator in an enclosed area such as a tunnel or a trench.
GP/GPS 6600A 2.4 Safety Information 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. 2.4.
Safety Information Label Locations GND wc_si000239gb.fm 14 88897 2.
GP/GPS 6600A 2.6 Safety Information Safety and Operating Labels Wacker Neuson machines use international pictorial labels where needed. These labels are described below: Label Meaning WARNING! Hot surface! CAUTION Lifting point. GND 88897 Electrical ground Press circuit breaker switch to OFF position. Check the fuel level.
Safety Information Label GP/GPS 6600A Meaning Open the fuel flow valve. Press engine switch to ON position. GPS - Press ignition switch. GP - Pull the rewind starter. Press circuit breaker switch to ON position. Press engine switch to OFF position. Close the fuel flow valve. 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. wc_si000239gb.
GP/GPS 6600A Label Safety Information Meaning Only use OUTSIDE and far away from windows, doors, and vents. WARNING! To reduce the risk of electrical shock and arc flash, read the Operator’s Manual. Improper connection of the 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.
Safety Information Label GP/GPS 6600A Meaning DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling. Read the Operator’s Manual for machine information. WARNING Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrestor may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.
GP/GPS 6600A 3. Operation Operation 3.1 Determining Power Requirements This generator is designed to operate single-phase, 60 Hz appliances running at 120 VAC or 240 VAC. Check the nameplate or label provided on tools and appliances to make sure their power requirements match the power output of the generator. 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.
Operation 3.2 GP/GPS 6600A 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. DANGER DANGER 3.3 Using a generator indoors CAN KILL YOU IN MINUTES.
GP/GPS 6600A 3.4 wc_tx000791gb.fm Operation Battery Installation (GPS only) 3.4.1 Align the holes found in the battery tray (a) to the holes on the frame cross-member 3.4.2 Insert M8 x 14 screws (b) through the tray then through the holes of the cross-member. 3.4.3 Insert the nuts (c) onto the screws and tighten. Torque nuts to 18.75 Nm. (13.5 ft.lbs). 3.4.4 Align the holes in the battery tube (d) to the holes in front of the battery tray. 3.4.
Operation 3.5 GP/GPS 6600A Wheel Kit The wheel kit (Part No. 0161308) is a standard item on Item Number 0620012, 0620015, 0620043 and 0620046 only. It is available as an option on all other models. 3.5.1 Hoist the generator, and align the axle (c) with the lower cross-member of frame. 3.5.2 Insert the axle brackets (k) over the axle and align the holes found in the axle bracket to the holes of the cross-member. Ensure that the brackets extend under the tube of the frame. 3.5.
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Operation 3.6 GP/GPS 6600A 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.
GP/GPS 6600A 3.7 Operation 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 3.8 Operating Heavy Loads Limit operations requiring the maximum rated output of 6600 W to 20– 30 minutes.
Operation 3.9 GP/GPS 6600A Use of Extension Cords WARNING Current 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.
GP/GPS 6600A Operation 3.10 Control Panel Ref. Description Ref. Description a Engine Switch g GFCI test button b Auto Idle Switch h GFCI reset button c Twist-lock receptacle - 120V j Twist-lock receptacle - 120/240V d Main Circuit Breaker k Ignition Switch (GPS only) e Voltage Selector Switch m 20A circuit breaker (CAN only) f Duplex receptacle - 120V n 30A circuit breaker (CAN only) wc_gr003143 wc_tx000791gb.
Operation GP/GPS 6600A 3.11 Ground Fault Circuit Interrupter (GFCI) The GFCI should be tested for proper operations every time the generator is used. Normal operating state - sensing device green LED is “ON” and circuit breaker is at “ON” position. 3.11.1 Press “TEST” button (g). Green LED should go “OUT” and red LED should come “ON” and circuit breaker should trigger to “OFF” position (d). 3.11.2 If sensing device LED or breaker does not trip or change state, “DO NOT USE”.
GP/GPS 6600A Operation 3.12 Twist-Lock Receptacles Twist-lock receptacles (c, j) are used at the 120V Amp and 120/240V outlets. These receptacles are protected by the GFCI. To attach a power cord to a twist-lock receptacle, insert plug into receptacle and turn it clockwise to lock it in place. 3.13 Engine Auto Idle The auto idle switch (b) automatically reduces engine speed approximately 7 seconds after all appliances or tools attached to the generator have been turned off.
Operation GP/GPS 6600A 3.15 Voltage Selection The voltage selector switch (e) allows the generator to operate in either single (120V) or dual voltage (120/240V) mode. In single-voltage mode, use only the 120V twist-lock (c) and duplex receptacles (f1, f2). The full rated power of the generator is shared between the three receptacles. In dual voltage mode both the 120V and 120/240V receptacles are powered; lower watts are available on receptacles (f1, f2, c).
GP/GPS 6600A Operation 3.16 Before Starting 3.16.1 Read and understand the safety and operating labels and instructions at the beginning of this manual. 3.16.2 Inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 3.16.3 Check: • oil level in engine • fuel level • condition of air cleaner • tightness of external fasteners • condition of fuel lines. Note: The engine is equipped with an oil alert system.
Operation GP/GPS 6600A 3.17 To Start Before starting, be sure you read and understand all the safety and operating instructions in this manual. 3.17.1 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. 3.17.2 Disconnect all loads from the generator and place the main circuit breaker switch in the OFF position (a2). 3.17.
GP/GPS 6600A Operation wc_gr002500 3.18 To Stop 3.18.1 Turn off and disconnect all tools and appliances attached to the generator. 3.18.2 Place the main circuit breaker in the OFF position (a2). 3.18.3 Turn the engine switch to “OFF” (b2). 3.18.4 Close the fuel valve (d2). Note: To stop the engine quickly in an emergency, turn or press the engine switch to “OFF” (b2). wc_tx000791gb.
Maintenance 4. GP/GPS 6600A Maintenance 4.1 Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to your engine operator’s manual for additional information on engine maintenance. 4.2 Periodic Maintenance Schedule Daily before starting Check the fuel level. Check the engine oil level. Inspect the air filter. Replace as needed. Check external hardware. After first 20 hrs. Clean the air cleaner element.* Every 50 hrs. Every 100 hrs. Every 300 hrs.
GP/GPS 6600A 4.3 Maintenance Engine Oil 4.3.1 Drain the oil while the engine is still warm. 4.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation. 4.3.3 Install the drain plug. 4.3.
Maintenance 4.4 GP/GPS 6600A Servicing Air Cleaner Service the air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run the engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING To service: 4.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 4.4.
GP/GPS 6600A 4.5 Maintenance Spark Plug Clean or replace the spark plug as needed to ensure proper operation. Refer to your engine operator’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. WARNING Note: Refer to section “Technical Data” for the recommended spark plug type and the electrode gap setting. 4.5.1 Remove the spark plug and inspect it. 4.5.
Maintenance 4.6 GP/GPS 6600A Cleaning the Sediment Cup 4.6.1 Turn the fuel valve off. 4.6.2 Remove the sediment cup (a) and the O-ring (b). 4.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 4.6.4 Turn the fuel valve on and check for leaks. b a wc_gr000029 wc_tx000799gb.
GP/GPS 6600A 4.7 Maintenance Carburetor Adjustment 4.7.1 Start the engine and allow it to warm up to operating temperature. 4.7.2 Set the pilot screw (a) two turns out. See Note. 4.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 4.7.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
Maintenance 4.9 GP/GPS 6600A Storage Before storing the generator for a long period of time: 4.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 4.9.2 Disconnect the fuel line from the carburetor. Place the open end of the fuel line into a suitable container and open the fuel valve to drain the fuel from the tank. WARNING Gasoline is extremely flammable. Drain the fuel tank in a wellventilated area. DO NOT drain the fuel tank in an area with flames or sparks. 4.9.
GP/GPS 6600A Maintenance 4.11 Troubleshooting Problem / Symptom Reason / Remedy If engine doesn't start, check that: • Engine switch is on “Start”. • Fuel valves under fuel tank and on engine are open. • Fuel tank has fuel. • Choke lever is in correct position. Choke should be closed when starting a cold engine. • All loads are disconnected from generator. • Spark plug is in good condition. • Spark plug cap is tight. • Engine oil level is adequate.
Maintenance GP/GPS 6600A 4.12 Wire Colors Wire Colors B Black R Red Y Yellow Or Orange G Green T Tan Br Brown Pr Purple L Blue V Violet Cl Clear Sh Shield P Pink W White Gr Gray LL Light blue 4.13 Electrical Schematic Ref. Description A Generator B Control box C Electric start engines (GPS) Ref. Description Ref. E Ref.
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Maintenance GP/GPS 6600A 4.14 Engine Schematic Ref. Description A Generator B Control box C Electric start engines (GPS) Ref. E Description Honda Engine Ref. Description Ref. 1 Idle solenoid 6 Solenoid (GPS only) 2 Fuel cut solenoid 7 Starter (GPS only) 3 Oil alert module 8 Charging coil (GPS only) 4 Oil level switch 9 Battery (GPS only) 5 Coil wc_tx000799gb.
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Technical Data 5. GP/GPS 6600A Technical Data 5.1 Generator Item No. GP 6600A 0620330 GP 6600A 0620329 GPS 6600A 0620331 Generator Maximum Output W 6600 Continuous Output W 6000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.
GP/GPS 6600A 5.2 Technical Data Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 6600A 0620330 0620329 GPS 6600A 0620331 Engine Engine type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine make Honda Engine model GX 390 K1 Maximum rated power @ rated speed kW (Hp) 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.
