Operator’s Manual
Portable Generator
GP 5600A
GPS 5600A
EN
5000192945
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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. Violators will be prosecuted.
Trademarks
All trademarks referenced in this manual are the property of their
respective owners.
Manufacturer
Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original instructions
This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.
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).
Machines
covered in
this manual
Machine
documentation
„
„
„
„
„
„
Expectations
for
information in
this manual
„
„
„
Machine
Item Number
GP 5600A
GPS 5600A
0620979, 0620980, 0620983, 0620984
0620981, 0620982
From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
If you are missing any of these documents, please contact Wacker Neuson to
order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change
any portion of this information without notice.
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.
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.
Manufacturer’s This manual contains references to approved parts, attachments, and modificaapproval
tions. The following definitions apply:
wc_tx001707gb.fm
3
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.
Unapproved parts, attachments, or modifications may have the following consequences:
„
Serious injury hazards to the operator and persons in the work area
„
Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.
„
4
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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 .................................................................................... 13
Labels
2.1
2.2
3
Table of Contents
15
Label Locations .................................................................................. 15
Label Meanings .................................................................................. 16
Operation
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
3.16
3.17
3.18
3.19
3.20
3.21
21
Preparing for first use ......................................................................... 21
Recommended Fuel ........................................................................... 22
Determining Power Requirements ..................................................... 23
Installation .......................................................................................... 24
Recommended Battery (GPS only) .................................................... 24
Battery Tray Installation (GPS only) ................................................... 25
Wheel Kit ............................................................................................ 26
Generator Derating ............................................................................. 28
Grounding the Generator ................................................................... 29
Operating Heavy Loads ...................................................................... 29
Use of Extension Cords ...................................................................... 30
Control Panel ...................................................................................... 31
Ground Fault Interrupt (GFI / GFCI) ................................................... 32
Twist-Lock Receptacles ..................................................................... 33
Engine Auto Idle ................................................................................ 33
Engine Speed ..................................................................................... 33
Voltage Selector Switch ..................................................................... 34
Before Starting ................................................................................... 35
Starting ............................................................................................... 36
Stopping ............................................................................................. 37
Emergency Shutdown Procedure ....................................................... 37
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5
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 .......................................................................................... 41
Cleaning the Sediment Cup ................................................................ 42
Engine Speed ..................................................................................... 42
Long-Term Storage ............................................................................. 43
Transporting the Machine ................................................................... 43
Troubleshooting .................................................................................. 44
45
Generator ............................................................................................ 45
Engine ................................................................................................. 46
Emission Control Systems Information and Warranty
6.1
6.2
6.3
6.4
6.5
7
38
Technical Data
5.1
5.2
6
GP / GPS 5600A
Emission Control System Background Information ............................ 49
Limited Defect Warranty for Exhaust Emission Control System ......... 50
Limited Defect Warranty for Wacker Neuson Evaporative
Emission Control Systems .................................................................. 51
California Evaporative Emission Control Warranty Statement ........... 54
Limited Defect Warranty for Exhaust Emission Control System ......... 55
Schematics
7.1
7.2
7.3
7.4
49
56
Wire Colors ......................................................................................... 56
US Machines—Electrical Schematic .................................................. 56
CSA Machines—Electrical Schematic ................................................ 58
Engine Wiring ..................................................................................... 60
6
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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.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
f To avoid death or serious injury from this type of hazard, obey all safety messages that
follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
f To avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
f To avoid possible minor or moderate injury from this type of hazard, obey all safety
messages that follow this signal word.
NOTICE: Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
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7
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.
This machine is intended for the purpose of supplying electrical power
to connected loads. Refer to the product specifications for the output
voltage and frequency of this generator, and the maximum output
power limit of this generator.
This machine has been designed and built strictly for the intended use
described above. Using the machine for any other purpose could
permanently damage the machine or seriously injure the operator or
other persons in the area. Machine damage caused by misuse is not
covered under warranty.
The following are some examples of misuse:
Connecting a load that has voltage and frequency requirements that
are incompatible with the generator output
Overloading the generator with a load that draws excessive power
during either continuous running or start-up
Operating the generator in a manner that is inconsistent with all
federal, state and local codes and regulations
Using the machine as a ladder, support, or work surface
Using the machine to carry or transport passengers or equipment
Operating the machine outside of factory specifications
Operating the machine in a manner inconsistent with all warnings
found on the machine and in the Operator’s Manual
This machine has been designed and built in accordance with the
latest global safety standards. It has been carefully engineered to
eliminate hazards as far as practicable and to increase operator
safety through protective guards and labeling. However, some risks
may remain even after protective measures have been taken. They
are called residual risks. On this machine, they may include exposure
to:
Heat, noise, exhaust, and carbon monoxide from the engine
Fire hazards from improper refueling techniques
Fuel and its fumes
Electric shock and arc flash
8
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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. 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.
Using a fan or opening windows and doors does NOT supply enough fresh air.
f ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
f 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.
f 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.
Operator qualifications
Only trained personnel are permitted to start, operate, and shut down
the machine. They also must meet the following qualifications:
•
have received instruction on how to properly use the machine
•
are familiar with required safety devices
The machine must not be accessed or operated by:
•
children
•
people impaired by alcohol or drugs
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
operating this machine:
DANGER
wc_si000237gb.fm
•
Close-fitting work clothes that do not hinder movement
•
Safety glasses with side shields
•
Hearing protection
•
Safety-toed footwear
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER
DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR
DEATH TO UTILITY WORKERS!
9
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.
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 hazardous. Read the operating instructions contained in 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.
1.3.1
NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
1.3.2
NEVER operate the generator, or tools attached to the generator, with
wet hands.
1.3.3
NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
1.3.4
NEVER run the electrical cords under the generator, or over vibrating
or hot parts.
1.3.5
NEVER enclose or cover the generator when it is in use or when it is
hot.
1.3.6
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.
1.3.7
NEVER operate the machine in snow, rain, or standing water.
1.3.8
NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a certified electrician.
1.3.9
NEVER stand on the machine.
1.3.10 DO NOT stand under the machine while it is being hoisted or moved.
1.3.11
DO NOT attach equipment to the machine when it is suspended.
1.3.12 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.
1.3.13 ALWAYS position and operate the generator on a firm,
noncombustible, level surface.
1.3.14 ALWAYS transport the generator in an upright position.
10
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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.
1.3.17 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
1.3.18 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
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11
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). 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.
Refueling safety
When refueling the engine:
•
Do not smoke.
•
Do not refuel if the generator is sitting in a truck fitted with a
plastic bed liner. Static electricity can ignite the fuel or fuel vapors.
•
Do not refuel a hot or running engine.
•
Do not refuel the engine near an open flame.
When refueling the engine, always:
•
Refill the fuel tank in a well-ventilated area.
•
Replace the fuel tank cap after refueling.
Operating safety
When operating the generator:
•
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.
•
Do not run the engine near open flames.
•
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.
•
Do not smoke while operating the machine.
12
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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.
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.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
servicing or maintaining this machine:
•
Close-fitting work clothes that do not hinder movement
•
Safety glasses with side shields
•
Hearing protection
•
Safety-toed footwear
In addition, before servicing or maintaining the machine:
wc_si000237gb.fm
•
Tie back long hair.
•
Remove all jewelry (including rings).
1.5.1
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.
1.5.2
DO NOT attempt to clean or service the machine while it is running.
1.5.3
Do not modify the machine without the express written approval of the
manufacturer.
1.5.4
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.
1.5.5
DO NOT service the machine if your clothing or skin is wet.
1.5.6
DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
13
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.
1.5.11 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.
1.5.12 ALWAYS keep the fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.
1.5.13 When replacement parts are required for this machine, use only
Wacker Neuson replacement parts or those parts equivalent to the
original in all types of specifications, such as physical dimensions,
type, strength, and material.
14
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GP/GPS 5600A
2
2.1
Labels
Labels
Label Locations
B
G
C
B
A
E
N
M
F
L
J K
D
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wc_gr003142
15
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.
Step 1: Press "TEST" button. Green LED should go "OUT" and red LED should come "ON" and
circuit breaker should trigger to "OFF" position.
Step 2: If sensing device LED or breaker does not trip or change state, "DO NOT USE". Consult
an electrician for assistance.
Step 3: Press "RESET" button. Red LED should turn "OFF" and green LED should turn "ON".
Step 4: Manually reset (switch) circuit breaker to "ON" position to restore circuit power.
D
16
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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.fm
17
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. 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. Connections to a
building’s electrical system must be made by a
qualified electrician and comply with all
applicable laws and electrical codes.
E
NOTICE
Lifting point.
F
Electrical ground
GND
88897
—
18
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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. 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.
K
This machine may be covered by one or more
patents.
L
WARNING!
Test GFCI before each use.
See label above.
M
Important Emissions Information
This equipment meets California EVP
emission regulations for small off-road
engines.
N
Emission Control Information
This equipment meets U.S. EPA EVAP
standards.
Evaporative Family: BWIXNHEQCL2
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19
Labels
GP/GPS 5600A
Notes:
20
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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.
Using a fan or opening windows and doors does NOT supply enough fresh air.
f ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
f 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.
f 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.
3.1
Preparing for first use
To prepare your machine for first use:
wc_tx000789gb.fm
3.1.1
Make sure all loose packaging materials have been removed from the
machine.
3.1.2
Check the machine and its components for damage. If there is visible
damage, do not operate the machine! Contact your Wacker Neuson
dealer immediately for assistance.
3.1.3
Take inventory of all items included with the machine and verify that
all loose components and fasteners are accounted for.
3.1.4
Attach component parts not already attached.
3.1.5
Add fluids as needed and applicable, including fuel, engine oil, and
battery acid.
3.1.6
Move the machine to its operating location.
21
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.
Before using an oxygenated fuel, confirm the fuel's contents. Some
states / Provinces require this information to be posted on the fuel
pump.
The following are Wacker Neuson approved percentages of
oxygenates:
ETHANOL - (ethyl or grain alcohol) 10% by volume. You may use
gasoline containing up to 10% ethanol by volume (commonly referred
to as E10). Gasoline containing more than 10% ethanol (such as E15,
E20, or E85) may not be used because it could damage the engine.
If you notice any undesirable operating symptoms, try another service
station, or switch to another brand of gasoline.
Fuel system damage or performance problems resulting from the use
of an oxygenated fuel containing more than the percentages of
oxygenates mentioned above are not covered under warranty.
22
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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. 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 in determining power
requirements for different types of equipment. Check with your nearest
Wacker Neuson dealer, or contact the manufacturer or dealer of the
tool or appliance, with questions regarding its power requirements.
NOTICE: If a tool or appliance does not reach full speed within a few
seconds when switched on, turn it off immediately to avoid damage.
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
wattage 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
starting.
•
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
wc_tx000789gb.fm
23
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. The recommended
battery to be used is:
Battery Type
50-N18L-A
Voltage
12 V
Capacity
20 A/h
LxWxH
206 x 90 x 164 mm
(8-1/8 x 3-9/16 x 6-7/16 in.)
24
wc_tx000789gb.fm
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.
3.6.5
Insert M8 x 35 screws (e) through the battery tray then through the
tube.
3.6.6
Insert the nuts (f) onto the screws and tighten. Torque nuts to 18.75
Nm. (13.5 ft.lbs).
3.6.7
Insert the tube clamps (g) onto the upper frame tube and align the
holes to the holes of the battery tube.
3.6.8
Insert M8 x 35 screws (h) through the battery tube then through the
tube clamps.
3.6.9
Insert the nuts (j) onto the bolts and tighten. Torque nuts to 18.75 Nm.
(13.5 ft.lbs).
3.6.10
Slide the J-bolt (k) through the holes found in the battery holder (l).
3.6.11
Insert the rounded end of the J-bolt (k) into the slot of the battery tray
and insert the tip of the J-bolt through the hole.
25
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.
3.7.3
Insert M6 x 16 screws (l) through the outer holes on the cross-member,
then through the holes of the axle bracket.
3.7.4
Insert M6 nuts (m) onto the screws and tighten. Torque to 7.5 Nm (5.25
ft.lbs.).
3.7.5
Assemble the washers (g) next to the rings (h), then add the wheels
(d).
3.7.6
Add the washers (g) next to the wheels, then insert the pins (f) into the
holes of the axle and separate the legs of the pins.
3.7.7
Align the holes found in the leg bracket (b) to the holes of the lower
cross-member.
3.7.8
Insert M6 x 16 screws (l) through the outer holes on the cross-member,
then through the holes of the leg bracket.
3.7.9
Insert M6 nuts (n) onto the screws and tighten. Torque to 7.5 Nm (5.25
ft.lbs.).
3.7.10 Insert M8 x 30 screw (o) through the hole in the leg bracket and
through the hole in cross-member.
3.7.11 Insert M8 nut (p) onto the screw and tighten. Torque to 18.75 Nm (13.5
ft.lbs.).
3.7.12 Align the holes in the rubber foot mounts (e) to the holes of the leg
bracket.
3.7.13 Insert M6 x 20 screws (m) through the leg bracket, then through the
holes of the rubber foot mounts.
3.7.14 Insert the nuts (n) onto the screws and tighten. Torque to 7.5 Nm (5.25
ft.lbs.).
3.7.15 Align the holes found in the handles (a, j) to the holes of the brackets
(1) on the frame.
3.7.16 Insert M6 x 16 screws (l) through the handles, then through the
brackets on the frame.
3.7.17 Insert nuts (m) onto the screws and tighten. Torque to 7.5 Nm (5.25
ft.lbs.).
26
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GP/GPS 5600A
wc_tx000789gb.fm
Operation
27
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. 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
28
wc_tx000789gb.fm
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.
3.10
•
If the generator is used at a construction site, there may be
additional regulations which must be observed.
•
In some areas, generators are required to be registered with local
utility companies.
•
There is a conductor between the generator (stator neutral
winding) and the frame.
Operating Heavy Loads
Limit operations requiring the maximum rated output of 5600 W to 20–
30 minutes. For continuous operation do not exceed the continuous
rated output of 5000 W.
NOTICE: DO NOT exceed the current limit specified on the control
panel for any receptacle.
wc_tx000789gb.fm
29
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.
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.
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
-
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.
30
wc_tx000789gb.fm
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.fm
31
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”. Consult an electrician for assistance.
3.13.3 Press “RESET” button (h). Red LED should turn “OFF” and green LED
should turn “ON”.
3.13.4 Manually reset (switch) circuit breaker to “ON” position to restore
circuit power (d).
wc_gr003143
32
wc_tx000789gb.fm
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. The engine automatically returns to
full speed when a tool or appliance is turned back on.
To turn the auto idle feature on, push the auto idle switch to “AUTO”.
The AUTO setting is recommended while the generator is running to
minimize fuel consumption. To avoid extended engine warm-up
periods, keep switch set to “OFF” when starting the engine and until
the engine reaches operating temperature.
3.16
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.
See Technical Data. There is no throttle control. Use the Auto Idle
switch on the generator to control engine speed.
wc_tx000789gb.fm
33
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). The 120/
240V twist-lock receptacle (j) should be used in dual mode only. To
achieve full power in this receptacle it should be used alone.
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 (d) in the OFF
position before changing voltage switch position.
wc_gr003144
34
wc_tx000789gb.fm
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.
3.18.2
Inspect the generator for any signs of damage which may affect
operation or pose a safety hazard.
3.18.3
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. If the oil level in
the engine drops too low, the engine will not start.
3.18.4
Fill the fuel tank with fresh, regular, unleaded grade gasoline. Do not
exceed the fuel tank capacity (see Technical Data).
NOTICE: Fill the tank after placing the machine on level ground.
3.18.5
wc_tx000789gb.fm
DO NOT use an oil/gas mixture to fill the tank. The use of gasohol or
any fuel containing more than 10% ethanol is not recommended.
Consult the engine owner's manual for complete fuel specifications.
35
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).
3.19.3 Set the auto idle switch to “OFF” (c).
3.19.4 Open the fuel valve (d1).
Note: If the engine is cold, move the choke lever to the closed position
(e2). If the engine is warm, set the choke lever to the open position
(e1).
3.19.5 On recoil start engines, turn the engine switch to “ON” (b1) and pull the
starter rope (f).
3.19.6 On electric start engines, press the ignition switch (k) and hold until the
engine starts. Release the switch after the engine starts.
NOTICE: DO NOT run the starter motor more than 5 seconds at a time
or damage to the starter motor may occur. If the engine fails to start,
release the switch and wait 10 seconds to let the starter motor cool
before trying again.
Note: If the oil level in the engine is low, the engine will not start. If this
happens, check the oil level and add oil as needed.
3.19.7 As the engine warms up, move the choke lever to the OPEN position
(e1).
3.19.8 Allow the engine to warm up for a few minutes before placing the main
breaker in the "ON" position (a1) and attaching loads.
wc_gr002500
36
wc_tx000789gb.fm
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:
3.21.1
Stop the engine.
3.21.2 Turn off the fuel supply.
3.21.3 Disconnect tools from the machine.
3.21.4 Allow the machine to cool.
3.21.5 Contact the rental yard or machine owner for further instructions.
wc_tx000789gb.fm
37
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. The use of
service parts that are not equivalent in performance and durability to
authorized parts may impair the effectiveness of the emission control
system and may have a bearing on the outcome of a warranty claim.
4.2
Periodic Maintenance Schedule
The table below lists basic machine and engine maintenance. Tasks
designated with check marks may be performed by the operator.
Tasks designated with square bullet points require special training
and equipment.
Refer to the engine owner’s manual for additional information.
Daily
before
starting
Check the fuel level.
3
Check the engine oil level.
3
Inspect the air filter. Replace as
needed.
3
Check external hardware.
3
After
first
20 hrs.
Clean the air cleaner element.*
Every
50
hrs.
Every
100
hrs.
Every
300
hrs.
„
Inspect the shockmounts for damage.
3
Change the engine oil.*
„
„
Clean the sediment cup or fuel
strainer.
„
Check and clean the spark plug.
„
Check and adjust the valve clearance.
„
Clean the fuel tank.*
„
Check condition of the fuel lines.
Replace when necessary.
„
*Service more frequently in dusty conditions.
38
wc_tx000797gb.fm
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.
4.3.4
Fill the engine crankcase with the recommended oil up to the level of
the plug opening (c). See section Technical Data for oil quantity and
type.
4.3.5
Install the oil filler plug.
wc_gr000022
WARNING
Most used oil contains small amounts of materials that can cause cancer and other
health problems if inhaled, ingested, or left in contact with skin for prolonged
periods of time.
f Take steps to avoid inhaling or ingesting used engine oil.
f Wash skin thoroughly after exposure to used engine oil.
wc_tx000797gb.fm
39
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.
4.4.2
Wash the foam element (b) in a solution of mild detergent and warm
water. Rinse it thoroughly in clean water. Allow the element to dry
thoroughly. Soak the element in clean engine oil and squeeze out
excess oil.
wc_gr002815
40
wc_tx000797gb.fm
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.
4.5.2
Replace the spark plug if the insulator is cracked or chipped.
4.5.3
Clean the spark plug electrodes with a wire brush.
4.5.4
Set the electrode gap (a).
4.5.5
Tighten the spark plug securely.
NOTICE: A loose spark plug can become very hot and may cause
engine damage.
wc_tx000797gb.fm
41
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.
There is no throttle control.
To set the engine to the proper speed:
Turn the speed adjusting screw (b) in or out to obtain a no-load speed.
See Technical Data.
NOTICE: Setting the engine speed too high or too low may damage
tools and other appliances attached to the generator.
42
wc_tx000797gb.fm
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. DO NOT drain the fuel tank in an area with flames or
sparks.
4.8.3
Loosen the drain screw on the carburetor and drain any remaining fuel
from the carburetor.
4.8.4
Change the engine oil.
4.8.5
Remove the spark plug and pour approximately 30 ml (1 ounce) of
clean engine oil into the cylinder. Crank the engine a few turns to
distribute the oil to the inside of the cylinder walls.
4.8.6
Pull the starter rope slowly until resistance is felt and leave the handle
in this position. This ensures that the intake and exhaust valves are
closed.
4.8.7
Store the generator in a clean, dry area.
Transporting the Machine
Let the engine cool before transporting the generator or storing it
indoors, to avoid burns or fire hazards.
WARNING
4.9.1
Turn the engine fuel valve to the OFF position.
4.9.2
Position the generator level to prevent fuel from spilling.
4.9.3
Secure the generator by tying it down with a suitable rope.
WARNING
wc_tx000797gb.fm
When transporting the generator:
When transporting the machine by hand, be sure to employ manpower
commensurate with the weight of the machine. To avoid back injury
when lifting the machine, bend the knees to pick it up rather than
bending your back only.
43
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.
If engine starts but there is no
power at receptacles, check
that:
• Circuit breaker is closed.
If engine starts but runs erratically, check that:
• Hose routing from the fuel tank to the engine is correct. For proper operation, the hose must run
through the bushing in the lifting bracket. Refer to
the Parts Book for illustration.
If the GFCI trips when a load
is connected, check that:
• The connected equipment may be wired incorrectly
or faulty. Contact equipment supplier.
• Connector from generator to control panel is tight.
• See section Determining Power Requirements.
44
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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.)
Weight (dry)
wc_td000240gb.fm
Kg (lbs.)
685 x 530 x 537
(27 x 21 x 21.2)
1003 x 686 x 677
(39.5 x 27 x 26.7)
870 x 530 x 537
(34.3 x 21 x 21.2)
89 (194)
98 (216)
97.1 (214)
45
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.)
Operating speed
rpm
3600
Air cleaner
type
Dry type with oil-wetted foam pre-cleaner
Battery
Engine lubrication
Engine oil capacity
Fuel
type
V/
capacity
Size
(in.)
oil grade
N/A
SAE 10W30 service class SJ or higher
1.1 (1.2)
l (qts.)
type
Y50-N18L-A
12V - 20 Amp-hour
8-1/8 x 3-9/16 x 6-7/16
Regular unleaded gasoline
Fuel tank capacity
l (gal.)
18.7 (4.94)
Fuel consumption
l (qts.)/
hr.
3.2 (3.4)
Running time
5.8
hrs.
46
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GP/GPS 5600A
Technical Data
Notes:
wc_td000240gb.fm
47
Technical Data
GP/GPS 5600A
48
wc_td000240gb.fm
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. There are two types of emissions that fall under these regulations: 1)
exhaust, and 2) evaporative. These regulations require that manufacturers warrant
the emission control systems for defects in materials and workmanship.
Furthermore, EPA and California regulations require all manufacturers to furnish
written instructions describing how to operate and maintain the engines/equipment
including the emission control systems. This information is provided with all
Wacker Neuson engines/equipment at the time of purchase.
Exhaust Emissions
The combustion process produces carbon monoxide, oxides of nitrogen, and
hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important
because, under certain conditions, they react to form photochemical smog when
subjected to sunlight. Carbon monoxide does not react in the same way, but it is
toxic.
Wacker Neuson utilizes lean carburetor settings and other systems to reduce the
emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons.
Evaporative Emissions
Evaporative emissions are fuel emissions and generally include emissions that
result from permeation of fuel through the fuel-system materials or from ventilation
of the fuel system.
Wacker Neuson utilizes low-permeation fuel lines and fuel tanks where applicable
to reduce evaporative emissions.
Problems that may affect Emissions
If any of the following symptoms arise, have the engine/equipment inspected and
repaired by a Wacker Neuson dealer/service center.
„ Hard starting or stalling after starting
„ Rough idling
„ Misfiring or backfiring under load
„ Afterburning (backfiring)
„ Presence of black exhaust smoke during operation
„ High fuel consumption
wc_tx001772gb.fm
49
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.
6.2
Limited Defect Warranty for Exhaust Emission Control System
See the supplied engine owner’s manual for the applicable emission warranty
statement.
50
wc_tx001772gb.fm
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.
Wacker Neuson Sales Americas, LLC, N92 W15000 Anthony Avenue,
Menomonee Falls, WI 53051, (hereinafter “Wacker Neuson”) warrants to the initial
retail purchaser and each subsequent owner, that this engine/equipment, including
all parts of its evaporative emission control system, have been designed, built, and
equipped to conform at the time of initial sale to all applicable evaporative emission
regulations of the U.S. Environmental Protection Agency (EPA), and that the
engine/equipment is free of defects in materials and workmanship which would
cause this engine/equipment to fail to conform to EPA regulations during its
warranty period.
Wacker Neuson is also liable for damages to other engine/equipment components
caused by a failure of any warranted parts during the warranty period.
Limited Defect Warranty Period for Wacker Neuson Evaporative
Emission Control Systems
The warranty period for this engine/equipment begins on the date of sale to the
initial purchaser and continues for a minimum of two (2) years. For the warranty
terms for your specific engine/equipment, visit wackerneuson.com.
Any implied warranties are limited to the duration of this written warranty.
What is covered
Wacker Neuson recommends the use of genuine Wacker Neuson parts, or the
equivalent, whenever maintenance is performed. The use of replacement parts not
equivalent to the original parts may impair the effectiveness of the engine/
equipment emission controls systems. If such a replacement part is used in the
repair or maintenance of the engine/equipment, assure yourself that such part is
warranted by its manufacturer to be equivalent to the parts offered by Wacker
Neuson in performance and durability. Furthermore, if such a replacement part is
used in the repair or maintenance of the engine/equipment, and an authorized
Wacker Neuson dealer/service center determines it is defective or causes a failure
of a warranted part, the claim for repair of the engine/equipment may be denied. If
the part in question is not related to the reason the engine/equipment requires
repair, the claim will not be denied.
For the components listed in the following table, an authorized Wacker Neuson
dealer/service center will, at no cost to you, make the necessary diagnosis, repair,
or replacement necessary to ensure that the engine/equipment complies with the
applicable EPA regulations. All defective parts replaced under this warranty
become property of Wacker Neuson.
wc_tx001772gb.fm
51
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 material or workmanship.
Any systems or parts which are affected or damaged by owner abuse,
tampering, neglect, improper maintenance, misuse, improper fueling,
improper storage, accident and/or collision; the incorporation of, or any use
of, add-on or modified parts, or unsuitable attachments, or the alteration of
any part.
Replacement of expendable maintenance items made in connection with
required maintenance services after the item’s first scheduled replacement
as listed in the maintenance section of the engine/equipment operator’s
manual, such as spark plugs and filters.
Incidental or consequential damages such as loss of time or the use of the
engine/equipment, or any commercial loss due to the failure of the engine/
equipment.
Diagnosis and inspection charges that do not result in warranty-eligible
service being performed.
Any non-authorized replacement part, or malfunction of authorized parts due
to use of-non authorized parts.
Owner’s Warranty Responsibility
The engine/equipment owner, is responsible for the performance of the required
maintenance listed in the Wacker Neuson engine/equipment operator’s manual.
Wacker Neuson recommends that all receipts covering maintenance on the
engine/equipment be retained, but Wacker Neuson cannot deny warranty
coverage solely for the lack of receipts or for the failure to ensure the performance
of all scheduled maintenance.
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 an authorized Wacker Neuson dealer/
service center.
The engine/equipment must be presented to an authorized Wacker Neuson dealer/
service center as soon as a problem exists. Contact Wacker Neuson Product
52
wc_tx001772gb.fm
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.
How to Make a Claim
In the event that any emission-related part is found to be defective during the
warranty period, you shall notify Wacker Neuson Product Support Department (1800-770-0957), and you will be advised of the appropriate dealer/service center
where warranty repair can be performed. All repairs qualifying under this limited
warranty must be performed by an authorized Wacker Neuson dealer/service
center.
You must take your Wacker Neuson engine/equipment along with proof of original
purchase date, at your expense, to the authorized Wacker Neuson dealer/service
center during their normal business hours.
For owners located more than 100 miles from an authorized dealer/service center
(excluding the states with high-altitude areas as identified in 40 CFR Part 1068,
Appendix III), Wacker Neuson will pay for pre-approved shipping costs to and from
an authorized Wacker Neuson dealer/service center.
Claims for repair or adjustment found to be caused solely by defects in material or
workmanship will not be denied because the engine/equipment was not properly
maintained and used.
The warranty repairs should be completed in a reasonable amount of time, not to
exceed 30 days.
wc_tx001772gb.fm
53
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. Wacker Neuson Corporation must warrant the EECS on your
portable generator for the period of time listed below, provided there has been no
abuse, neglect or improper maintenance of your portable generator.
Your EECS on your model year 2008 and later portable generator includes the fuel
and vent line, fuel and vent line clamps, fuel and vent line fittings, carbon canister,
fuel tank and fuel tank cap, purge port connector, gaskets, and mounting brackets.
Where a warrantable condition exists, Wacker Neuson Corporation will repair your
portable generator at no cost to you including diagnosis, parts and labor.
Manufacturer’s Warranty Coverage
This EECS is warranted for two years from the initial date of purchase. If any
evaporative emission-related part on your equipment is defective, the part will be
repaired or replaced by Wacker Neuson Corporation at no charge to you. The
owner shall not be charged for diagnostic labor that leads to determination that a
warranted part is in fact defective, provided that such diagnostic work is performed
at a Wacker Neuson Corporation authorized service center.
Warranty Period
Any warranted part that is not scheduled for replacement as required maintenance,
or which is scheduled only for regular inspection to the effect of “repair or replace
as necessary”, shall be warranted for two years. Any warranted part that is
scheduled for replacement as required maintenance shall be warranted for a time
not less than the remaining warranty period.
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.
As the portable generator owner, you should however be aware that Wacker
Neuson Corporation may deny you warranty coverage if your portable generator or
a part has failed due to abuse, neglect, or improper maintenance or unapproved
modifications.
You are responsible for presenting your portable generator to Wacker Neuson
Corporation’s authorized service center as soon as the problem exists. The
warranty repairs should be completed in a reasonable amount of time, not to
exceed 30 days. If you have a question regarding your warranty coverage, you
should contact your nearest authorized Wacker Neuson service center or call 1800-770-0957.
54
wc_tx001772gb.fm
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.
What is covered
The repair or replacement of any warranted part otherwise eligible for warranty
coverage may be excluded from such warranty coverage if Wacker Neuson
Corporation demonstrates that the portable generator has been abused, neglected,
or improperly maintained, and that such abuse, neglect, or improper maintenance
was the direct cause of the need for repair or replacement of the part. That
notwithstanding, any adjustment of a component that has a factory installed, and
properly operating, adjustment limiting device is still eligible for warranty coverage.
The following emission warranty parts are covered:
Systems Covered
Components
Evaporative control system
Fuel and vent line
Fuel and vent line clamps
Fuel and vent line fittings
Carbon canister
Fuel tank
Fuel tank cap
Purge port connector
Miscellaneous parts associated with the
evaporative emission control system
6.5
Gaskets
Mounting brackets
Limited Defect Warranty for Exhaust Emission Control System
See the supplied engine owner’s manual for the applicable emission warranty
statement.
wc_tx001772gb.fm
55
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.
Description
Honda Engine
Description
1
Main stator winding 1
12
Engine ON / OFF switch
2
Main stator winding 2
13
Rectifier
3
Auto idle unit
14
Rotor winding/brushes
4
Main circuit breaker
15
Secondary (excitation) winding
5
Voltage selector switch
(120/240V position shown)
16
DC winding
6
Duplex receptacle—120V
17
Automatic voltage regulator (AVR)
7
Twist-lock receptacle—120V
18
15A fuse (GPS only)
8
Twist-lock receptacle—120/240V
19
Ignition switch (GPS only)
9
Auto idle switch
20
GFCI
10
5A fuse
21
Neutral bond wire
11
Capacitor
56
wc_tx001774gb.fm
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 AWG
101 BLU
73 BRN
ORG
42 BLU
B
GRN/YEL
70 BRN 12 AWG
40 BLU
GRN/YEL
20
101 BLU
5 BRN
104 GRY
103 GRY
3
3
RED 16 AWG
WHT/RED 16 AWG
72 BRN
wc_tx001774gb.fm
13
A
41 BLU
WHT 16 AWG
RED 16 AWG
12 BRN
10 BRN
11 BRN
WHT/RED 16 AWG
GRN/YEL
GRN/YEL
1 BRN
3 BRN
8 BLU
2 BRN
2
OFF
5
2
OFF
ON
6
4
3
START
ON
9
OFF
19
C
10 BRN 16 AWG
12 BRN 16 AWG
1 BRN
3 BRN
1
5
8
11 BRN
16 AWG
2 BRN
5 BRN
8 BLU
WHT 16 AWG
RED 16 AWG
RED 16 AWG
RED 16 AWG
BLK 16 AWG
WHT 16 AWG
GRN 16AWG
WHT/RED 16 AWG
WHT/RED 16 AWG
2
5
wc_gr008235
10
12
3
7
7 BRN
6
9
9 BRN
I
G
H
E
F
C
D
A
B
GP / GPS 5600A
Schematics
GRN
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.
Description
Honda Engine
Description
1
Main stator winding 1
12
Engine ON / OFF switch
2
Main stator winding 2
13
Rectifier
3
Auto idle unit
14
Rotor winding/brushes
4
Main circuit breaker
15
Secondary (excitation) winding
5
Voltage selector switch
(120/240V position shown)
16
DC winding
6
Duplex receptacle—120V
17
Automatic voltage regulator (AVR)
7
Twist-lock receptacle—120V
18
15A fuse (GPS only)
8
Twist-lock receptacle—120/240V
19
Ignition switch (GPS only)
9
Auto idle switch
20
GFCI
10
5A fuse
21
Neutral bond wire
11
Capacitor
58
wc_tx001774gb.fm
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 BRN 12 AWG
29 BRN
2 BRN
22 BRN
21 BRN 12AWG
YEL 18 AWG
8 BLU
3 BRN
WHT 18 AWG
GRN/YEL
ORG
26 BRN
12 AWG
30A
21 BRN
12 AWG
20A
8
23
BRN
WHT/RED 16 AWG
40 BLU
GRN/YEL
22 BRN
GFCI
20
2
0
RED 16 AWG
(20A FOR
GP3800)
GRN/YEL
24 BRN
12 AWG
wc_tx001774gb.fm
42 BLU
B
101 BLU
5 BRN
15 AMP
WHT 16 AWG
GRN/YEL
104 GRY
103 GRY
41 BLU
RED 16 AWG
12 BRN
10 BRN
11 BRN
2
OFF
5
12
2
OFF
WHT/RED 16 AWG
1 BRN
3 BRN
8 BLU
2 BRN
4
1
3
6
3
START
ON
19
ON
9
12
1
3
4
7
5
C
2
11 BRN
16 AWG
2 BRN
5 BRN
8 BLU
WHT 16 AWG
RED 16 AWG
I
G
H
E
F
C
D
A
B
wc_gr008236
BLK 16 AWG
WHT 16 AWG
GRN 16AWG
WHT/RED 16 AWG
WHT/RED 16 AWG
1
5
8
RED 16 AWG
RED 16 AWG
OFF
12 BRN 16 AWG
1 BRN
3 BRN
103 GRY
7 BRN
9 BRN
GP / GPS 5600A
Schematics
GRN
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.
Description
1
Idle solenoid
6
Solenoid (GPS only)
2
Fuel cut solenoid
7
Starter (GPS only)
3
Oil level sender
8
Charging coil (GPS only)
4
Spark plug
9
Battery (GPS only)
5
Coil
D
WHT/RED
A
B
1
WHT/RED
C
D
GRN
2
GRN/WHT
3
BLK
E
F
YEL
RED
COIL
4
G
H
9
6
8
7
I
WHT 16 AWG
wc_gr008237
60
wc_tx001774gb.fm
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.
Tel: (852) 3605 5360, Fax: (852) 2758 0032