Wacker Neuson GP 5600A User manual

5000192945 01 0511
5000192945
Operator’s Manual
Portable Generator
GP 5600A
GPS 5600A
EN

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: [phone] · Fax: [phone] · Tel: [phone]
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
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
documentation
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.
Expectations
for
information in
this manual
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 dis-
charge 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
approval
This manual contains references to approved parts, attachments, and modifica-
tions. The following definitions apply:
Machine Item Number
GP 5600A
GPS 5600A
0620979, 0620980, 0620983, 0620984
0620981, 0620982

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, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following conse-
quences:
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.

wc_bo5000192945_01TOC.fm 5
Table of ContentsGP / 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 .................................................................................. 9
1.4 Operator Safety while Using Internal Combustion Engines ............... 12
1.5 Service Safety .................................................................................... 13
2 Labels 15
2.1 Label Locations .................................................................................. 15
2.2 Label Meanings .................................................................................. 16
3 Operation 21
3.1 Preparing for first use ......................................................................... 21
3.2 Recommended Fuel ........................................................................... 22
3.3 Determining Power Requirements ..................................................... 23
3.4 Installation .......................................................................................... 24
3.5 Recommended Battery (GPS only) .................................................... 24
3.6 Battery Tray Installation (GPS only) ................................................... 25
3.7 Wheel Kit ............................................................................................ 26
3.8 Generator Derating ............................................................................. 28
3.9 Grounding the Generator ................................................................... 29
3.10 Operating Heavy Loads ...................................................................... 29
3.11 Use of Extension Cords ...................................................................... 30
3.12 Control Panel ...................................................................................... 31
3.13 Ground Fault Interrupt (GFI / GFCI) ................................................... 32
3.14 Twist-Lock Receptacles ..................................................................... 33
3.15 Engine Auto Idle ................................................................................ 33
3.16 Engine Speed ..................................................................................... 33
3.17 Voltage Selector Switch ..................................................................... 34
3.18 Before Starting ................................................................................... 35
3.19 Starting ............................................................................................... 36
3.20 Stopping ............................................................................................. 37
3.21 Emergency Shutdown Procedure ....................................................... 37

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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 ........................................................................................... 39
4.4 Servicing the Air Cleaner .................................................................... 40
4.5 Spark Plug .......................................................................................... 41
4.6 Cleaning the Sediment Cup ................................................................ 42
4.7 Engine Speed ..................................................................................... 42
4.8 Long-Term Storage ............................................................................. 43
4.9 Transporting the Machine ................................................................... 43
4.10 Troubleshooting .................................................................................. 44
5 Technical Data 45
5.1 Generator ............................................................................................ 45
5.2 Engine ................................................................................................. 46
6 Emission Control Systems Information and Warranty 49
6.1 Emission Control System Background Information ............................ 49
6.2 Limited Defect Warranty for Exhaust Emission Control System ......... 50
6.3 Limited Defect Warranty for Wacker Neuson Evaporative
Emission Control Systems .................................................................. 51
6.4 California Evaporative Emission Control Warranty Statement ........... 54
6.5 Limited Defect Warranty for Exhaust Emission Control System ......... 55
7 Schematics 56
7.1 Wire Colors ......................................................................................... 56
7.2 US Machines—Electrical Schematic .................................................. 56
7.3 CSA Machines—Electrical Schematic ................................................ 58
7.4 Engine Wiring ..................................................................................... 60

GP/GPS 5600A Safety Information
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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.
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.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo 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.
fTo 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.
fTo avoid possible minor or moderate injury from this type of hazard, obey all safety
messages that follow this signal word.

Safety Information GP/GPS 5600A
8wc_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. 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

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
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:
• 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!
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.
fNEVER 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.
fONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
fEven 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.
fIf 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.
DANGER

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 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.
WARNING

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 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.

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 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.
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.
fRead and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
fCarbon 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.

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 replaced as necessary.
• Do not use plugs or or cords that show signs of damage such as
broken or cracked insulation or damaged blades.
1.5 Service Safety
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:
• 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.
WARNING

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
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.

GP/GPS 5600A Labels
wc_si000558gb.fm 15
2 Labels
2.1 Label Locations
wc_gr003142
C
L
G
B
E
F
N
KJ
D
A
M
B

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.
AEngine Choke Control
BWARNING!
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

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”.

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 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.
ENOTICE
Lifting point.
FElectrical ground
GND
88897

GP/GPS 5600A Labels
wc_si000558gb.fm 19
GWARNING
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.
JA 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.
KThis machine may be covered by one or more
patents.
LWARNING!
Test GFCI before each use.
See label above.
MImportant Emissions Information
This equipment meets California EVP
emission regulations for small off-road
engines.
NEmission Control Information
This equipment meets U.S. EPA EVAP
standards.
Evaporative Family: BWIXNHEQCL2

Labels GP/GPS 5600A
20 wc_si000558gb.fm
Notes: