0171949en 0609 Generator GP 5600A GPS 5600A Non-CARB OPERATOR’S MANUAL 0 1 7 1 9 4 9 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.
1. 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.
wc_tx000240gb.
GP/GPS 5600A 1. Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 1.5 1.6 2. Table of Contents Laws Pertaining to Spark Arresters ...................................................... 7 Operating Safety .................................................................................. 8 Operator Safety while using Internal Combustion Engines .................. 9 Service Safety .................................................................................... 11 Label Locations ....................
Table of Contents 3. Maintenance 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 4. GP/GPS 5600A 32 Engine Maintenance ............................................................................32 Periodic Maintenance Schedule ..........................................................32 Engine Oil ............................................................................................33 Servicing Air Cleaner .........................................................................
GP/GPS 5600A 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.
GP/GPS 5600A 1.2 Safety Information Operating Safety DANGER DANGER WARNING 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 5600A 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 NEVER stand on the machine. 1.2.10 DO NOT stand under the machine while it is being hoisted or moved. 1.2.11 DO NOT attach equipment to the machine when it is suspended. 1.2.12 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. 1.2.
GP/GPS 5600A Safety Information 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.
GP/GPS 5600A 1.4 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. 1.4.
GP/GPS 5600A Label Locations GND 12 88897 1.
GP/GPS 5600A 1.6 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.
GP/GPS 5600A Label Safety Information 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.
GP/GPS 5600A 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.
GP/GPS 5600A Label Safety Information Meaning DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling. Read the Operator’s Manual for machine information. GFCI TEST INSTRUCTIONS - TEST BEFORE EACH USE Normal operating state - sensing device green LED is "ON" and circuit breaker is at "ON" position. Step 1: Press "TEST" button. Green LED should go "OUT" and red LED should come "ON" and circuit breaker should trigger to "OFF" position.
GP/GPS 5600A 2. Operation Operation 2.1 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.
GP/GPS 5600A 2.2 Operation 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 2.3 Using a generator indoors CAN KILL YOU IN MINUTES.
GP/GPS 5600A 2.4 Operation Battery Tray Installation (GPS only) 2.4.1 Align the holes found in the battery tray (a) to the holes on the frame cross-member 2.4.2 Insert M8 x 14 screws (b) through the tray then through the holes of the cross-member. 2.4.3 Insert the nuts (c) onto the screws and tighten. Torque nuts to 18.75 Nm. (13.5 ft.lbs). 2.4.4 Align the holes in the battery tube (d) to the holes in front of the battery tray. 2.4.
GP/GPS 5600A 2.5 Operation 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. 2.5.1 Hoist the generator, and align the axle (c) with the lower cross-member of frame. 2.5.2 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. 2.5.
GP/GPS 5600A Operation 21
GP/GPS 5600A 2.6 Operation 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 5600A 2.7 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 2.8 Operating Heavy Loads Limit operations requiring the maximum rated output of 5600 W to 20– 30 minutes.
GP/GPS 5600A 2.9 Use of Extension Cords WARNING Current Operation 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 5600A Operation 2.10 Control Panel Ref. Description Ref.
GP/GPS 5600A Operation 2.11 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. 2.11.1 Press “TEST” button (g). Green LED should go “OUT” and red LED should come “ON” and circuit breaker should trigger to “OFF” position (d). 2.11.2 If sensing device LED or breaker does not trip or change state, “DO NOT USE”.
GP/GPS 5600A Operation 2.12 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. 2.13 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.
GP/GPS 5600A Operation 2.15 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 5600A Operation 2.16 Before Starting 2.16.1 Read and understand the safety and operating labels and instructions at the beginning of this manual. 2.16.2 Inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 2.16.3 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.
GP/GPS 5600A Operation 2.17 To Start Before starting, be sure you read and understand all the safety and operating instructions in this manual. 2.17.1 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. 2.17.2 Disconnect all loads from the generator and place the main circuit breaker switch in the OFF position (a2). 2.17.
GP/GPS 5600A Operation wc_gr002500 2.18 To Stop 2.18.1 Turn off and disconnect all tools and appliances attached to the generator. 2.18.2 Place the main circuit breaker in the OFF position (a2). 2.18.3 Turn the engine switch to “OFF” (b2). 2.18.4 Close the fuel valve (d2). Note: To stop the engine quickly in an emergency, turn or press the engine switch to “OFF” (b2).
GP/GPS 5600A 3. Maintenance Maintenance 3.1 Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to your engine operator’s manual for additional information on engine maintenance. 3.2 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 5600A 3.3 Maintenance Engine Oil 3.3.1 Drain the oil while the engine is still warm. 3.3.2 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. 3.3.3 Install the drain plug. 3.3.
GP/GPS 5600A 3.4 Maintenance 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: 3.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 3.4.
GP/GPS 5600A 3.5 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. 3.5.1 Remove the spark plug and inspect it. 3.5.
GP/GPS 5600A 3.6 Maintenance Cleaning the Sediment Cup 3.6.1 Turn the fuel valve off. 3.6.2 Remove the sediment cup (a) and the O-ring (b). 3.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 3.6.4 Turn the fuel valve on and check for leaks.
GP/GPS 5600A 3.7 Maintenance Carburetor Adjustment 3.7.1 Start the engine and allow it to warm up to operating temperature. 3.7.2 Set the pilot screw (a) two turns out. See Note. 3.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 3.7.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
GP/GPS 5600A 3.9 Maintenance Storage Before storing the generator for a long period of time: 3.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 3.9.2 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. 3.9.
GP/GPS 5600A Maintenance 3.11 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.
GP/GPS 5600A Maintenance 3.13 Electrical Schematic Ref. Description Ref. Description A Generator D Honda Engine B Control box E Wacker Neuson Engine C Electric start engines (GPS) Ref. Description Ref.
GP/GPS 5600A Maintenance 41
GP/GPS 5600A Maintenance 3.14 Electrical Schematic (CAN models only) Ref. Description Ref. Description A Generator D Wacker Engine B Control box E Honda Engine C Electric start engines (GPS) Ref. Description Ref.
GP/GPS 5600A Maintenance 43
GP/GPS 5600A Maintenance 3.15 Engine Schematic Ref. Description A Generator B Control box C Electric start engines (GPS) Ref. E Description Honda Engine Ref. Description Ref.
GP/GPS 5600A Maintenance wc_gr004900 45
GP/GPS 5600A Maintenance Notes 46
GP/GPS 5600A 4. Technical Data Technical Data 4.1 Generator Item No. GP 5600A 0620382 GP 5600A 0620381 GPS 5600A 0620383 Generator Maximum Output W 5600 Continuous Output W 5000 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 5600A Technical Data Item No. GP 5600A CAN 0620094 GP 5600A CAN 0620095 GPS 5600A CAN 0620096 Generator Maximum Output W 5600 Continuous Output W 5000 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 30 Main Circuit Breaker amp 2-pole, 23 amp each pole LxWxH mm (in.
GP/GPS 5600A 4.2 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 5600A GP 5600A CAN 0620094 0620095 0620381 0620382 GPS 5600A 0620383 GPS 5600A CAN 0620096 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 340 K1 Max. Rated Power @ Rated Speed 7.1 (9.
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.
