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Wacker Neuson GP 5600A Operator's Manual

Other manuals for GP 5600A: Repair Manual, Operator's Manual

Summary of GP 5600A

  • Page 1

    5000192945 01 0511 5 0 0 0 1 9 2 9 4 5 operator’s manual portable generator gp 5600a gps 5600a en.

  • Page 2

    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 permissio...

  • Page 3: Foreword

    Foreword wc_tx001707gb.Fm 3 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 d...

  • Page 4: Foreword

    Foreword 4 wc_tx001707gb.Fm 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, ...

  • Page 5: Table of Contents

    Wc_bo5000192945_01toc.Fm 5 table of contents gp / gps 5600a foreword 3 1 safety information 7 1.1 signal words used in this manual ....................................................... 7 1.2 machine description and intended use ............................................... 8 1.3 operating safety...

  • Page 6: Table of Contents

    6 wc_bo5000192945_01toc.Fm table of contents gp / gps 5600a 4 maintenance 38 4.1 maintaining the emission control system .......................................... 38 4.2 periodic maintenance schedule ......................................................... 38 4.3 engine oil ..........................

  • Page 7: Gp/gps 5600A

    Gp/gps 5600a safety information wc_si000237gb.Fm 7 1 safety information 1.1 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....

  • Page 8: Safety Information

    Safety information gp/gps 5600a 8 wc_si000237gb.Fm 1.2 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...

  • Page 9: Gp/gps 5600A

    Gp/gps 5600a safety information wc_si000237gb.Fm 9 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 operator qualifications ...

  • Page 10: Safety Information

    Safety information gp/gps 5600a 10 wc_si000237gb.Fm 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 ...

  • Page 11: Gp/gps 5600A

    Gp/gps 5600a safety information wc_si000237gb.Fm 11 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 combu...

  • Page 12: Safety Information

    Safety information gp/gps 5600a 12 wc_si000237gb.Fm 1.4 operator safety while using internal combustion engines 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 o...

  • Page 13: Gp/gps 5600A

    Gp/gps 5600a safety information wc_si000237gb.Fm 13 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. • have damaged items repaired or rep...

  • Page 14: Safety Information

    Safety information gp/gps 5600a 14 wc_si000237gb.Fm 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 main...

  • Page 15: Gp/gps 5600A

    Gp/gps 5600a labels wc_si000558gb.Fm 15 2 labels 2.1 label locations wc_gr003142 c l g b e f n k j d a m b.

  • Page 16: Labels

    Labels gp/gps 5600a 16 wc_si000558gb.Fm 2.2 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 m...

  • Page 17: Gp/gps 5600A

    Gp/gps 5600a labels wc_si000558gb.Fm 17 — — 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”..

  • Page 18: Labels

    Labels gp/gps 5600a 18 wc_si000558gb.Fm — 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 o...

  • Page 19: Gp/gps 5600A

    Gp/gps 5600a labels wc_si000558gb.Fm 19 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 nameplat...

  • Page 20: Labels

    Labels gp/gps 5600a 20 wc_si000558gb.Fm notes:.

  • Page 21: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 21 3 operation 3.1 preparing for first use to prepare your machine for first use: 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 operat...

  • Page 22: Operation

    Operation gp/gps 5600a 22 wc_tx000789gb.Fm 3.2 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 ...

  • Page 23: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 23 3.3 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...

  • Page 24: Operation

    Operation gp/gps 5600a 24 wc_tx000789gb.Fm 3.4 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 ...

  • Page 25: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 25 3.6 battery tray installation (gps only) 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 t...

  • Page 26: Operation

    Operation gp/gps 5600a 26 wc_tx000789gb.Fm 3.7 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 f...

  • Page 27: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 27.

  • Page 28: Operation

    Operation gp/gps 5600a 28 wc_tx000789gb.Fm 3.8 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...

  • Page 29: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 29 3.9 grounding the generator location a ground connection (a) is located on the generator frame. Function this ground connection is used for electrically grounding the generator when necessary to comply with the national electrical code and other federal, st...

  • Page 30: Operation

    Operation gp/gps 5600a 30 wc_tx000789gb.Fm 3.11 use of extension cords when a long extension cord is used to connect an appliance or tool to the generator, a voltage loss occurs—the longer the cord, the greater the voltage loss. This results in less voltage being supplied to the appliance or tool an...

  • Page 31: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 31 3.12 control panel ref. Description ref. Description a engine switch g gfci test button b auto idle switch h gfci reset button c twist-lock receptacle - 120v j twist-lock receptacle - 120/240v d main circuit breaker k ignition switch (gps only) e voltage se...

  • Page 32: Operation

    Operation gp/gps 5600a 32 wc_tx000789gb.Fm 3.13 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). Gre...

  • Page 33: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 33 3.14 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 loc...

  • Page 34: Operation

    Operation gp/gps 5600a 34 wc_tx000789gb.Fm 3.17 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 po...

  • Page 35: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 35 3.18 before starting 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 le...

  • Page 36: Operation

    Operation gp/gps 5600a 36 wc_tx000789gb.Fm 3.19 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...

  • Page 37: Gp/gps 5600A

    Gp/gps 5600a operation wc_tx000789gb.Fm 37 3.20 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...

  • Page 38: Maintenance

    Maintenance gp/gps 5600a 38 wc_tx000797gb.Fm 4 maintenance 4.1 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...

  • Page 39: Gp/gps 5600A

    Gp/gps 5600a maintenance wc_tx000797gb.Fm 39 4.3 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...

  • Page 40: Maintenance

    Maintenance gp/gps 5600a 40 wc_tx000797gb.Fm 4.4 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 cl...

  • Page 41: Gp/gps 5600A

    Gp/gps 5600a maintenance wc_tx000797gb.Fm 41 4.5 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 whil...

  • Page 42: Maintenance

    Maintenance gp/gps 5600a 42 wc_tx000797gb.Fm 4.6 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. 4.7 engine s...

  • Page 43: Gp/gps 5600A

    Gp/gps 5600a maintenance wc_tx000797gb.Fm 43 4.8 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...

  • Page 44: Maintenance

    Maintenance gp/gps 5600a 44 wc_tx000797gb.Fm 4.10 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 cl...

  • Page 45: Gp/gps 5600A

    Gp/gps 5600a technical data wc_td000240gb.Fm 45 5 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 dual voltage, single phase, auto voltage regulator system ac voltages avail- able volts phase 120 / 240 1ø ...

  • Page 46: Technical Data

    Technical data gp/gps 5600a 46 wc_td000240gb.Fm 5.2 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...

  • Page 47: Gp/gps 5600A

    Gp/gps 5600a technical data wc_td000240gb.Fm 47 notes:.

  • Page 48: Technical Data

    Technical data gp/gps 5600a 48 wc_td000240gb.Fm.

  • Page 49

    Emission control systems information and warranty wc_tx001772gb.Fm 49 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 introductio...

  • Page 50

    Emission control systems information and warranty 50 wc_tx001772gb.Fm 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 constit...

  • Page 51

    Emission control systems information and warranty wc_tx001772gb.Fm 51 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 aven...

  • Page 52

    Emission control systems information and warranty 52 wc_tx001772gb.Fm 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...

  • Page 53

    Emission control systems information and warranty wc_tx001772gb.Fm 53 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...

  • Page 54

    Emission control systems information and warranty 54 wc_tx001772gb.Fm 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 sy...

  • Page 55

    Emission control systems information and warranty wc_tx001772gb.Fm 55 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 r...

  • Page 56: Schematics

    Schematics gp / gps 5600a 56 wc_tx001774gb.Fm 7 schematics 7.1 wire colors 7.2 us machines—electrical schematic 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 ref. Description ref. Description a ge...

  • Page 57: Gp / Gps 5600A

    Gp / gps 5600a schematics wc_tx001774gb.Fm 57 2 brn 3 8 blu 3 brn 3 5 brn 5 2 brn 2 6 7 7 brn 12 3 1 brn 3 brn 11 brn 16 awg 10 10 brn 16 awg 1 12 brn 16 awg 41 blu 1 brn grn/yel 9 8 blu 8 9 brn wht/red 16 awg wht/red 16 awg grn 16awg wht 16 awg blk 16 awg red 16 awg 6 4 on off 12 brn 11 brn 10 brn ...

  • Page 58: Schematics

    Schematics gp / gps 5600a 58 wc_tx001774gb.Fm 7.3 csa machines—electrical schematic ref. Description ref. Description a generator e honda engine b control box c electric start engines (gps) ref. Description ref. Description 1 main stator winding 1 12 engine on / off switch 2 main stator winding 2 13...

  • Page 59: Gp / Gps 5600A

    Gp / gps 5600a schematics wc_tx001774gb.Fm 59 2 brn 8 blu 3 brn 101 blu 5 brn 8 5 8 blu 5 brn 2 2 brn 9 brn 7 brn 103 gry 7 3 brn 1 brn 3 1 4 1 11 brn 16 awg 12 brn 16 awg 12 20a 104 gry 23 brn 1 brn 41 blu 103 gry wht/red 16 awg wht/red 16 awg wht 16 awg grn 16awg off on blk 16 awg 4 6 3 1 12 brn w...

  • Page 60: Schematics

    Schematics gp / gps 5600a 60 wc_tx001774gb.Fm 7.4 engine wiring ref. Description ref. Description a generator d honda engine b control box c electric start engines (gps) ref. Description ref. Description 1 idle solenoid 6 solenoid (gps only) 2 fuel cut solenoid 7 starter (gps only) 3 oil level sende...

  • Page 62

    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 & 1...