Operator’s Manual Portable Generator GP 5600A GPS 5600A EN 5000192945 5 0 0 0 01 1 9 0511 2 9 4 5
Copyright notice © Copyright 2011 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC. Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights.
Foreword Foreword SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models listed below. These instructions must be followed during installation and maintenance of the generator (and battery, if equipped).
Foreword Approved parts or attachments are those either manufactured or provided by Wacker Neuson. Approved modifications are those performed by an authorized Wacker Neuson service center according to written instructions published by Wacker Neuson. Unapproved parts, attachments, and modifications are those that do not meet the approved criteria.
GP / GPS 5600A 1 Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 1.5 2 Signal Words Used in this Manual ....................................................... 7 Machine Description and Intended Use ............................................... 8 Operating Safety .................................................................................. 9 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 5 Maintaining the Emission Control System .......................................... 38 Periodic Maintenance Schedule ......................................................... 38 Engine Oil ........................................................................................... 39 Servicing the Air Cleaner .................................................................... 40 Spark Plug ..........................................
GP/GPS 5600A 1 1.1 Safety Information Safety Information Signal Words Used in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words 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 hazards. f Obey all safety messages that follow this symbol.
Safety Information 1.2 GP/GPS 5600A Machine Description and Intended Use This machine is a portable electric power source. The Wacker Neuson Portable Generator consists of a tubular steel frame surrounding a fuel tank, a gasoline engine, a control panel, and an electric alternator. The control panel includes controls and receptacles. As the engine runs, the generator converts mechanical energy into electric power. The operator connects loads to the electric power receptacles.
GP/GPS 5600A Safety Information Personal injury from improper lifting techniques To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine. 1.3 Operating Safety 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.
Safety Information WARNING GP/GPS 5600A 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.
GP/GPS 5600A Safety Information 1.3.15 ALWAYS keep the machine at least one meter (three feet) away from structures, buildings, and other equipment during use. 1.3.16 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. 1.3.
Safety Information 1.4 GP/GPS 5600A Operator Safety while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. f Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. DANGER f Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO).
GP/GPS 5600A Safety Information Generator vibration Generators vibrate in normal use. During and after the use of the generator, inspect the generator as well as extension cords and power supply cords connected to it for damage from vibration. 1.5 • Have damaged items repaired or replaced as necessary. • Do not use plugs or or cords that show signs of damage such as broken or cracked insulation or damaged blades.
Safety Information GP/GPS 5600A 1.5.7 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. 1.5.8 ALWAYS replace the safety devices and guards after repairs and maintenance. 1.5.9 ALWAYS let the engine cool before transporting or servicing the machine. 1.5.10 ALWAYS keep hands, feet, and loose clothing away from the moving parts on the generator and engine. 1.5.
GP/GPS 5600A 2 2.1 Labels Labels Label Locations B G C B A E N M F L J K D wc_si000558gb.
Labels 2.2 GP/GPS 5600A Label Meanings Wacker Neuson machines use international pictorial labels where needed. These labels are described below. A Engine Choke Control B WARNING! Hot surface! C — DANGER! Read the Operator’s Manual. No sparks, flames, or burning objects near the machine. Stop the engine before refueling. — GFCI TEST INSTRUCTIONS - TEST BEFORE EACH USE Normal operating state - sensing device green LED is "ON" and circuit breaker is at "ON" position.
GP/GPS 5600A Labels — — CAUTION! Use only clean, filtered gasoline fuel. Check the fuel level. — Open the fuel flow valve. — Close the choke. — Turn the engine switch to the ON position. — Pull the rewind starter. — Open the choke. — Turn the engine switch to “OFF”. wc_si000558gb.
Labels GP/GPS 5600A — — Close the fuel flow valve. DANGER 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. — 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.
GP/GPS 5600A Labels G WARNING Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrester may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements. J 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 nameplate so it will be available should the nameplate become lost or damaged.
Labels GP/GPS 5600A Notes: 20 wc_si000558gb.
GP/GPS 5600A 3 Operation Operation 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. f NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Operation 3.2 GP/GPS 5600A Recommended Fuel Type This engine/equipment requires regular unleaded gasoline. • Use only fresh (no older than three months old), clean gasoline. • Use a fuel stabilizer per the fuel stabilizer manufacturer’s instructions. Use of oxygenated fuels Some conventional gasolines are blended with alcohol. These gasolines are collectively referred to as oxygenated fuels. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
GP/GPS 5600A 3.3 Operation 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 3.4 GP/GPS 5600A 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. 3.5 Recommended Battery (GPS only) This generator is shipped without a battery.
GP/GPS 5600A 3.6 Operation Battery Tray Installation (GPS only) wc_tx000789gb.fm 3.6.1 Align the holes found in the battery tray (a) to the holes on the frame cross-member 3.6.2 Insert M8 x 14 screws (b) through the tray then through the holes of the cross-member. 3.6.3 Insert the nuts (c) onto the screws and tighten. Torque nuts to 18.75 Nm. (13.5 ft.lbs). 3.6.4 Align the holes in the battery tube (d) to the holes in front of the battery tray. 3.6.
Operation 3.7 GP/GPS 5600A 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. 3.7.1 Hoist the generator, and align the axle (c) with the lower cross-member of frame. 3.7.2 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. 3.7.
GP/GPS 5600A wc_tx000789gb.
Operation 3.8 GP/GPS 5600A 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 3.9 Operation Grounding the Generator Location A ground connection (a) is located on the generator frame. wc_gr000544 Function This ground connection is used for electrically grounding the generator when necessary to comply with the National Electrical Code and other federal, state, and local regulations. For grounding requirements in your area, consult with a qualified electrician, electrical inspector, or local agency having jurisdiction over electrical compliance. 3.
Operation 3.11 GP/GPS 5600A 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 5600A 3.12 Ref. Operation Control Panel 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_tx000789gb.
Operation 3.13 GP/GPS 5600A Ground Fault Interrupt (GFI / 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. 3.13.1 Press “TEST” button (g). Green LED should go “OUT” and red LED should come “ON” and circuit breaker should trigger to “OFF” position (d). 3.13.2 If sensing device LED or breaker does not trip or change state, “DO NOT USE”.
GP/GPS 5600A 3.14 Operation 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. 3.15 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 3.17 GP/GPS 5600A Voltage Selector Switch 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 3.18 Operation Before Starting DANGER f 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. 3.18.1 Read and understand the safety and operating labels and instructions at the beginning of this manual. 3.18.
Operation 3.19 GP/GPS 5600A Starting Before starting, be sure you read and understand all the safety and operating instructions in this manual. 3.19.1 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. 3.19.2 Disconnect all loads from the generator and place the main circuit breaker switch in the OFF position (a2). 3.19.
GP/GPS 5600A 3.20 Operation Stopping 3.20.1 Turn off and disconnect all tools and appliances attached to the generator. 3.20.2 Place the main circuit breaker in the OFF position (a2). 3.20.3 Turn the engine switch to “OFF” (b2). 3.20.4 Close the fuel valve (d2). Note: To stop the engine quickly in an emergency, turn or press the engine switch to “OFF” (b2). 3.21 Emergency Shutdown Procedure Procedure If a breakdown or accident occurs while the machine is operating, follow the procedure below: 3.
Maintenance 4 4.1 GP/GPS 5600A Maintenance Maintaining the Emission Control System Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a dealer/service center authorized by WACKER NEUSON.
GP/GPS 5600A 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 5600A Servicing the 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 5600A 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 4.7 GP/GPS 5600A 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. Engine Speed Generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constant speed.
GP/GPS 5600A 4.8 Maintenance Long-Term Storage Before storing the generator for a long period of time: 4.8.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 4.8.2 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 4.9 Gasoline is extremely flammable. Drain the fuel tank in a wellventilated area.
Maintenance 4.10 GP/GPS 5600A 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 5 Technical Data Technical Data 5.1 Generator Item No. GP 5600A GP 5600A with wheel kit GPS 5600A 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.
Technical Data 5.2 GP/GPS 5600A 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 GPS 5600A Engine Engine type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine make Honda Engine model GX 340 RT2 Max. rated power @ rated speed 8 (10.7) @ 3600 rpm kW (Hp) Spark plug Electrode gap BPR6ES / W20EPR-U 0.7 - 0.8 (0.028 - 0.031) mm (in.
GP/GPS 5600A Technical Data Notes: wc_td000240gb.
Technical Data GP/GPS 5600A 48 wc_td000240gb.
Emission Control Systems Information and Warranty 6 Emission Control Systems Information and Warranty The Emission Control Warranty and associated information is valid only for the U.S.A., its territories, and Canada. 6.1 Emission Control System Background Information Introduction Wacker Neuson spark-ignited engines/equipment must conform with applicable Environmental Protection Agency (EPA) and the State of California emissions regulations.
Emission Control Systems Information and Warranty Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny a warranty claim. Among those acts that constitute tampering are: Removing or altering of any part of the air intake, fuel, or exhaust systems. Altering or defeating the speed-adjusting mechanism causing the engine to operate outside its design parameters. 6.
Emission Control Systems Information and Warranty 6.3 Limited Defect Warranty for Wacker Neuson Evaporative Emission Control Systems The Emission Control Warranty is valid only for the U.S.A., its territories, and Canada.
Emission Control Systems Information and Warranty System Covered Components Evaporative emissions Fuel tank (if applicable) Fuel tank cap (if applicable) Fuel line (if applicable) Fuel line fittings (if applicable) Clamps (if applicable) Carbon canister (if applicable) Purge port connector (if applicable) Miscellaneous parts associated with the evaporative emission control system Clamps Gaskets Mounting brackets What is not covered Failures other than those resulting from defects in m
Emission Control Systems Information and Warranty Support Department (1-800-770-0957) or visit wackerneuson.com to find a dealer/ service center in your area, or to answer questions regarding warranty rights and responsibilities.
Emission Control Systems Information and Warranty 6.4 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 antismog standards.
Emission Control Systems Information and Warranty What is not Covered All failures caused by abuse, neglect, or improper maintenance are not covered. In addition, the use of add-on or modified parts will be grounds for disallowing a warranty claim.
Schematics 7 GP / GPS 5600A Schematics 7.1 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 7.2 Ref. US Machines—Electrical Schematic Description A Generator B Control box C Electric start engines (GPS) Ref. Description Ref. E Ref.
14 57 - + WHT BRN BRN BLK ORG ORG/GRN 16 15 5 BLU YEL BRN YEL BLU 4 1 BLK 16 AWG 5 AMP 17 10 RED 16 AWG 3 BLU BLK 16 AWG RED 16 AWG 11 BRN 16 AWG BLK RED/WHT WHT/BLK 10 BRN 16 AWG 51 GRN/YEL 12 BRN 16 AWG 104 GRY 103 GRY 101 BLU 102 BRN GRN 4 3 1 2 BLU GRN BLK YEL RED RED/WHT 21 1 2 43 BLU 16 AWG RED 16 AWG AWG 71 BRN 12 AWG 5 BRN 102 BRN BLK 16 AWG RED 16 AWG 4 BLK 18 AWG 71 BRN 12 AWG 3 BRN 70 BRN 12 AWG YEL 18 AWG 7 71 BRN 12 AWG LOAD WHT 18
Schematics 7.3 Ref. CSA Machines—Electrical Schematic Description A Generator B Control box C Electric start engines (GPS) Ref. GP / GPS 5600A Description Ref. E Ref.
13 A 14 + WHT 59 BRN BRN BLK BLU 15 BLU ORG ORG/GRN BLK 16 AWG RED 16 AWG 11 BRN 16 AWG BLU BLK RED/WHT WHT/BLK 10 BRN 16 AWG 51 GRN/YEL 104 GRY 103 GRY 101 BLU 12 BRN 16 AWG 4 3 1 GRN GRN BLK YEL 2 102 BRN RED/WHT 21 1 2 RED 16 4 43 BLU 16 AWG RED 16 AWG 10 3 BRN YEL YEL BLU RED 16 AWG 3 1 BLK 16 AWG AMP 17 4 LOAD (BREAKER NOT USED FOR GP3800) RED 16 AWG 5 BRN BLK 16 A 102 BRN 30A BLK 18 AWG 20A 7 30 BRN 11 101 BLU 28 BRN 12 AWG 29 BRN 28 B
Schematics 7.4 Ref. GP / GPS 5600A Engine Wiring Description Ref. A Generator B Control box C Electric start engines (GPS) Description D Honda Engine Ref. Description Ref.
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 Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI 53051 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.
