Page 1
www.wackergroup.com
Generator
G 5.6A
GS 5.6A
OPERATOR’S MANUAL
0154587en 004
0706
0154587EN
Page 2
DANGER
CARBON MONOXIDE
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or
smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot
smell the exhaust, you could be breathing CO.
• NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed
areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh air.
• ONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
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.
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.
Page 3
G/GS 5.6A Table of Contents
wc_bo0154587004enTOC.fm 1
1. Foreword 3
2. Safety Information 4
2.1 Laws Pertaining to Spark Arresters ...................................................... 4
2.2 Operating Safety .................................................................................. 5
2.3 Operator Safety while using Internal Combustion Engines .................. 6
2.4 Service Safety ...................................................................................... 7
2.5 Label Locations .................................................................................... 8
2.6 Safety and Operating Labels ................................................................ 9
3. Technical Data 12
3.1 Generator ........................................................................................... 12
3.2 Engine ................................................................................................ 13
4. Operation 14
4.1 Determining Power Requirements ..................................................... 14
4.2 Outdoor Installation ............................................................................ 15
4.3 Indoor Installation ............................................................................... 15
4.4 Recommended Battery (GS 5.6A only) .............................................. 15
4.5 Wheel Kit ............................................................................................ 16
4.6 Generator Derating ............................................................................. 17
4.7 Grounding the Generator ................................................................... 18
4.8 Use of Extension Cords ...................................................................... 19
4.9 Control Panel ...................................................................................... 20
4.10 Ground Fault Interrupt (GFI) ............................................................... 21
4.11 Twist Lock Receptacles ...................................................................... 21
4.12 Engine Switch ..................................................................................... 21
4.13 Engine Auto Idle ................................................................................. 22
4.14 Engine Speed ..................................................................................... 22
4.15 Voltage Selection ............................................................................... 23
4.16 Before Starting ................................................................................... 24
4.17 To Start ............................................................................................... 25
4.18 To Stop ............................................................................................... 26
4.19 Operating Heavy Loads ...................................................................... 26
Page 4
Table of Contents G/GS 5.6A
wc_bo0154587004enTOC.fm 2
5. Maintenance 27
5.1 Engine Maintenance ............................................................................27
5.2 Periodic Maintenance Schedule ..........................................................27
5.3 Engine Oil ............................................................................................28
5.4 Air Cleaner ..........................................................................................29
5.5 Spark Plug ...........................................................................................30
5.6 Cleaning the Sediment Cup ................................................................31
5.7 Carburetor Adjustment ........................................................................31
5.8 Auto Idle Speed ...................................................................................32
5.9 Engine Speed ......................................................................................33
5.10 Storage ................................................................................................34
5.11 Transport .............................................................................................34
5.12 Troubleshooting ...................................................................................35
5.13 Wire Colors ..........................................................................................35
5.14 Electrical Schematic ............................................................................36
5.15 Engine Schematic ...............................................................................37
Page 5
Foreword
wc_si000058gb.fm 3
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.
1. Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker model. For your own safety and protection
from injury, carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2006 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.
WARNING
Page 6
Safety Information G/GS 5.6A
wc_si000058gb.fm 4
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note: Contains additional information important to a procedure.
2.1 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.
DANGER
WARNING
CAUTION
Page 7
G/GS 5.6A Safety Information
wc_si000058gb.fm 5
2.2 Operating Safety
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER
DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR
DEATH TO UTILITY WORKERS!
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
equipment. Equipment operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
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 equipment before
being allowed to operate the machine.
2.2.1 NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
2.2.2 NEVER operate the generator, or tools attached to the generator, with
wet hands.
2.2.3 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
2.2.4 NEVER run the electrical cords under the generator, or over vibrating
or hot parts.
2.2.5 NEVER enclose or cover the generator when it is in use or when it is
hot.
2.2.6 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.
2.2.7 NEVER operate the machine in snow, rain, or standing water.
2.2.8 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a trained electrician.
2.2.9 ALWAYS store the equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
DANGER
WARNING
Page 8
Safety Information G/GS 5.6A
wc_si000058gb.fm 6
2.2.10 ALWAYS be sure the machine is on a firm, level surface and will not
tip, roll, slide, or fall while operating.
2.2.11 ALWAYS transport the generator in an upright position.
2.2.12 ALWAYS keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
2.2.13 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.
2.2.14 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
2.2.15 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
2.3 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
warnings and safety guidelines could result in severe injury or death.
2.3.1 DO NOT run the machine indoors or in an enclosed area such as a
deep trench unless adequate ventilation, through such items as
exhaust fans or hoses, is provided. Exhaust gas from the engine
contains poisonous carbon monoxide gas; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
2.3.2 DO NOT smoke while operating the machine.
2.3.3 DO NOT smoke when refueling the engine.
2.3.4 DO NOT refuel a hot or running engine.
2.3.5 DO NOT refuel the engine near an open flame.
2.3.6 DO NOT spill fuel when refueling the engine.
2.3.7 DO NOT run the engine near open flames.
2.3.8 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.
2.3.9 ALWAYS refill the fuel tank in a well-ventilated area.
2.3.10 ALWAYS replace the fuel tank cap after refueling.
2.3.11 ALWAYS check the fuel lines and the fuel tank for leaks and cracks
before starting the engine. Do not run the machine if fuel leaks are
present or the fuel lines are loose.
DANGER
Page 9
G/GS 5.6A Safety Information
wc_si000058gb.fm 7
2.4 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.
2.4.1 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.
2.4.2 DO NOT attempt to clean or service the machine while it is running.
2.4.3 DO NOT modify the equipment without the express written approval of
the manufacturer.
2.4.4 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.
2.4.5 DO NOT service the machine if your clothing or skin is wet.
2.4.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
2.4.7 ALWAYS 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.
2.4.8 ALWAYS replace the safety devices and guards after repairs and
maintenance.
2.4.9 ALWAYS let the engine cool before transporting or servicing it.
2.4.10 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
2.4.11 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.
2.4.12 ALWAYS keep the fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.
WARNING
Page 10
Safety Information G/GS 5.6A
wc_si000058gb.fm 8
2.5 Label Locations
wc_gr00054
3
GND
88897
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, FI
RE 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.
4
321
321
656
5
DANGER
GEFAHR
DANGER
PELIGRO
DANGER
GEFAHR
DANGER
PELIGRO
STOP
Page 11
G/GS 5.6A Safety Information
wc_si000058gb.fm 9
2.6 Safety and Operating Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label Meaning
DANGER!
Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator’s
Manual.
No sparks, flames, or burning objects near the machine. Shut off the engine before refueling.
WARNING!
Hot surface!
CAUTION!
Read and understand the supplied Operator’s
Manuals before operating this machine. Failure to do so increases the risk of injury to yourself or others.
CAUTION!
Lifting point
Electrical ground
DANGER
GEFAHR
DANGER
PELIGRO
STOP
GND
88897
Page 12
Safety Information G/GS 5.6A
wc_si000058gb.fm 10
Neutral bonded to frame.
Open main circuit breaker.
Open the fuel flow valve.
Open the choke.
Push or turn engine switch to ON position.
Pull the rewind starter.
Press engine crank switch to "CRANK" position.
Label Meaning
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, FI
RE 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.
4
321
321
656
5
DANGER
GEFAHR
DANGER
PELIGRO
Page 13
G/GS 5.6A Safety Information
wc_si000058gb.fm 11
Close main circuit breaker.
Close the fuel flow valve.
Close the choke.
Push or turn engine switch to OFF position.
Press engine crank switch to "OFF" position.
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 plate 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.
This machine may be covered by one or more
patents.
Label Meaning
M E N O M O N E E F A L L S , W I U S A 5 3 0 5 1
M o d e l
S e r i a l N o .
k W m a x
V
I t e m N o .
k g
A
l b s
R e v .
P . F .
h z
M A D E I N U S A
1 1 0 9 9 2
Page 14
Technical Data G/GS 5.6A
wc_td000058gb.fm 12
3. Technical Data
3.1 Generator
Item No.
G 5.6A
0007190, 0009431
GS 5.6A
0007191
Generator
Maximum Output
W
5600
Continuous Output
W
5350
Type Dual voltage, single phase,
Auto voltage regulator system
AC Voltages Available
volts
phase
120 / 240
1ø
Frequency
Hz
60
Power Factor 1.0
AC receptacles:
120V GFI duplex
120V GFI duplex
120V twist lock
240V twist lock
amp
amp
amp
amp
20
20
30
20
Main Circuit Breaker
amp
48 (2-pole, 24 amp each pole)
L x W x H
mm (in.)
685 x 585 x 530 (27 x 23 x 21)
Weight (dry)
Kg (lbs.)
76 (168) 79 (175)
Page 15
G/GS 5.6A Technical Data
wc_td000058gb.fm 13
3.2 Engine
Item No.
G 5.6A
0007190, 0009431
GS 5.6A
0007191
Engine
Engine Type Single cylinder, 4-cycle,
air-cooled, gasoline engine
Engine Make Honda
Engine Model GX 340 K1
Rated Power
kW (Hp)
8.2 (11)
Spark Plug BPR6ES / W20EPR-U
Electrode Gap
mm (in.)
0.7 - 0.8 (0.028 - 0.031)
Engine Speed - full load
rpm
3600 ± 100
Engine Speed - no load
rpm
3700 ± 100
Auto Idle Speed
rpm
2200 ± 50
Air Cleaner
type
Dry type with oil-wetted foam pre-cleaner
Battery
type
V/capacity
Size (in.)
N/A Y50-N18L-A or
C50-N18L-A
12V - 20 Amp-hour
8-1/8 x 3-9/16 x 6-7/
16
Engine Lubrication
oil grade
SAE 10W30 service class SF, SE, SD or SC
Engine Oil Capacity
l (qts.)
1.1 (1.2)
Fuel
type
Regular unleaded gasoline
Fuel Tank Capacity
l (gal.)
19.5 (5.2)
Fuel Consumption
l (qts.)/hr.
3.6 (3.8)
Running Time - full load
hrs.
5.4
Page 16
Operation G/GS 5.6A
wc_tx000152gb.fm 14
4. Operation
4.1 Determining Power Requirements
This generator is designed to operate single-phase, 60 Hz appliances
running at 120 VAC or 240 VAC. Check the nameplate or label
provided on tools and appliances to make sure their power
requirements match the power output of the generator.
Some appliances and tools require a surge of current when starting.
This means that the amount of power needed to initially start the
equipment is larger than the power required to keep it running. 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 Dealer, or contact the manufacturer or dealer of the tool or
appliance, with questions regarding its power requirements.
CAUTION: 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
Three Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS
Page 17
G/GS 5.6A Operation
wc_tx000152gb.fm 15
4.2 Outdoor 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.
If operating the generator inside a tunnel or deep trench, make sure
there is adequate ventilation. Precautions similar to those required
when operating indoors may be necessary.
The surrounding area must be free from water and moisture. All
components must be protected from excessive moisture.
4.3 Indoor Installation
If the generator must be installed indoors, adequate ventilation or
exhaust hoses must be provided. When venting exhaust fumes, make
sure the exhaust piping is large enough to prevent excessive back
pressure to the engine. Back pressure reduces engine efficiency and
may cause the engine to overheat.
Exhaust gas from the engine contains poisonous carbon monoxide
gas; exposure to carbon monoxide can cause loss of consciousness
and may lead to death. Never run the generator indoors or in an
enclosed area unless adequate ventilation, through such items as
exhaust hoses or fans, is provided.
When installed indoors, steps to prevent fire and explosion such as
providing a good, earthen ground, removing all flammable materials
near the generator, and using only electrical cables in good condition,
must be observed. See Operating Safety.
4.4 Recommended Battery (GS 5.6A 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
L x W x H 206 x 90 x 164 mm
(8-1/8 x 3-9/16 x 6-7/16 in.)
DANGER
Page 18
Operation G/GS 5.6A
wc_tx000152gb.fm 16
4.5 Wheel Kit
See Graphic: wc_gr001577
Wheel kit (Part No. 0157176) is a standard item on Item Number
0009431 and 0620008 only. Available as an option on all other models.
4.5.1 Align grooves (a) on axle (b) with U-bolts (c) and secure to cross-
member of generator.
4.5.2 Assemble lock washer (d) and nuts to U-bolts. Torque nuts to 8.1 Nm
(6 ft.lbs.).
4.5.3 Insert caps (e) on U-bolts.
4.5.4 Assemble washers (f) next to retaining clips (g).
4.5.5 Attach tires (h) with washers (i) next to wheels, insert cotter pins (j) into
holes and separate legs of pins.
4.5.6 Align holes found in handles (k) to holes of brackets (l) on frame.
4.5.7 Insert screws (m) through washers (n) then through holes of handles
and brackets on frame.
4.5.8 Attach washers (o) and nuts (p) onto screws and tighten. Torque nuts
to 25 Nm (18 ft.lbs.).
Page 19
G/GS 5.6A Operation
wc_tx000152gb.fm 17
4.6 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
Page 20
Operation G/GS 5.6A
wc_tx000152gb.fm 18
4.7 Grounding the Generator
See Graphic: wc_gr000544
A ground connection (a) is located on the generator frame. For proper
operating safety, this ground terminal must be connected to a good
ground source. This ground connection must comply with National
Electrical Code standards, and state and local regulations.
w c _ g r 0 0 0 5 4 4
a
Page 21
G/GS 5.6A Operation
wc_tx000152gb.fm 19
4.8 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 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.
Use only extension cords rated for outdoor use and equipped with a
third-wire ground.
CAUTION: Operating equipment at low voltage can cause it to
overheat.
Current 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 -
WARNING
Page 22
Operation G/GS 5.6A
wc_tx000152gb.fm 20
4.9 Control Panel
See Graphic: wc_gr000545
Control Panel
Ref. Description Ref. Description
a Engine Switch (GS 5.6A only) f GFI Duplex receptacle - 120V
b Auto Idle Switch g GFI test button
c Twist-lock receptacle - 240V h GFI reset button
d Main Breaker - 48 amps j Twist-lock receptacle - 120V
e Voltage Selector Switch
w c _ g r 0 0 0 5 4
5
E N G I N E
S T A R T
O N
O F F
E N G I N E I D L E
O F F
A U T O
2 4 0 V A C
2 0 A M P
C A U T I O N
M A I N
C O N T R O L S 1 2 0 V A C
2 0 A M P 3 0 A M P
2 0 A M P
R E A D A N D U N D E R S T A N D
O P E R A T O R ' S M A N U A L B E F O R E
O P E R A T I N G O R S E R V IC I N G
G E N E R A T O R .
S E V E R E E L E C T R I C A L S H O C K
C O
U L D O C C U R I F T H E
G E N E R A T O R I S O P E R A T E D
W I T H O U T C O V E R S O R P A N E L S ,
O R I F T H E G E N E R A T O R I S
O P E R A T E D I N W E T
C O N D IT I O N S .
M A I N B R E A K E R
S E T M A I N B R E A K E R
" O F F " B E F O R E
S W IT C H I N G V O L T A G E
1 2 0 V
1 2 0 / 2 4 0 v
V O L T A G E
f
a
b
c d
e
a
f
j
h
g
Page 23
G/GS 5.6A Operation
wc_tx000152gb.fm 21
4.10 Ground Fault Interrupt (GFI)
See Graphic: wc_gr000545
The two 120V, 20 Amp receptacles (f) are protected by a ground fault
circuit interrupt (GFI). The GFI shuts off the power to the receptacle
when a ground fault occurs in the generator or to a piece of equipment
attached to the generator.
The GFI should be tested for proper operation every time the generator
is used.
To test GFI:
Start generator. Turn auto idle "OFF". Push TEST button (h) on
receptacle in. The RESET button (g) will pop out. Power is now off at
the receptacles. If the RESET button does not pop out, the GFI is not
working. Do not run generator until the problem can be corrected. To
restore power to receptacles, push the RESET button in.
If the RESET button pops out during operation, stop the generator and
check generator and equipment for defects.
4.11 Twist Lock Receptacles
See Graphic: wc_gr000545
Twist-lock receptacles (c, j) are used at the 120V 30A and 120/240V
30A outlets. These receptacles are not protected by the GFI.
To attach a power cord to a twist-lock receptacle, insert the plug into
the receptacle and turn it clockwise to lock it in place.
4.12 Engine Switch
See Graphic: wc_gr000545
GS 5.6A only:
The engine switch (a) completes the circuit to the engine's ignition
system. The switch must be set to "START" and then held down to
crank the starter motor and start the engine. When the switch is
released it returns back to the "ON" position and must be kept in this
position while the engine is running.
To stop engine, set switch to "OFF".
Page 24
Operation G/GS 5.6A
wc_tx000152gb.fm 22
4.13 Engine Auto Idle
See Graphic: wc_gr000545
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.
4.14 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.
Page 25
G/GS 5.6A Operation
wc_tx000152gb.fm 23
4.15 Voltage Selection
See Graphic: wc_gr000546
The voltage selector switch (a) allows the generator to operate in either
single (120V) or dual voltage (120/240V) mode.
In single voltage mode only the 120V twist-lock and duplex receptacles
are powered. The full rated power of the generator is shared between
the three receptacles.
In dual voltage mode both the 120V and 240V receptacles are
powered; however, only half the rated power (23 amps) is available at
the 120V duplex receptacles and the other half at the 120V twist-lock
receptacle. Full power is available at the 240V twist-lock receptacle.
CAUTION: 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 in the “OFF”
position (open) (O) before changing voltage switch position.
w c _ g r 0 0 0 5 4 6
M A I N
C O N T R O L S
M A I N B R E A K E R
S E T M A I N B R E A K E R
" O F F " B E F O R E
S W I T C H I N G V O L T A G E
1 2 0 V
1 2 0 / 2 4 0 V
V O L T A G E
O
I
a
Page 26
Operation G/GS 5.6A
wc_tx000152gb.fm 24
4.16 Before Starting
4.16.1 Read and understand the safety and operating labels and instructions
at the beginning of this manual
4.16.2 Inspect the generator for any signs of damage which may affect
operation or pose a safety hazard.
4.16.3 Check:
• oil level in engine
• fuel level
• condition of air cleaner
• tightness of external fasteners
• condition of fuel lines.
Note: The engine is equipped with an oil alert system. If the oil level in
the engine drops too low, the engine will not start.
4.16.4 Fill the fuel tank with fresh, regular, unleaded grade gasoline. DO NOT
use an oil/gas mixture. 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.
Page 27
G/GS 5.6A Operation
wc_tx000152gb.fm 25
4.17 To Start
See Graphic: wc_gr000547
Before starting, be sure you read and understand all the safety and
operating instructions in this manual.
4.17.1 Disconnect all loads from the generator and place the main circuit
breaker switch in the "OFF" (open) position. (a1).
4.17.2 Set the Auto Idle Switch to "OFF" (c).
4.17.3 Open the fuel valve (d1).
Note: If the engine is cold, move the choke lever to the closed position
(e1). If the engine is warm, set the choke to the open position (e2).
4.17.4 On recoil start engines, turn the engine switch to “ON” (f1) and pull the
starter rope (g).
4.17.5 On electric start engines, press the engine switch to "START" (b1) and
hold it there until the engine starts. Release the switch after the engine
starts.
CAUTION: DO NOT run the starter motor more than 5 seconds at a
time or starter motor damage 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.
4.17.6 As the engine warms up, move the choke lever to the OPEN position
(e2).
4.17.7 Allow the engine to warm up for a few minutes before placing the main
breaker in the "ON" (closed) position (a2) and attaching loads.
w c _ g r 0 0 0 5 4 7
M A I N
C O N T R O L S
M A I N B R E A K E R
S E T M A I N B R E A K E R
" O F F " B E F O R E
S W I T C H I N G V O L T A G E
1 2 0 V
1 2 0 / 2 4 0 V
V O L T A G E
E N G I N E
S T A R T
O N
O F F
E N G I N E
I D L E
O F F
A U T O
a 1
a 2
b 1
b 2
c
d 1
d 2
e 1
e 2
f 1
f 2
g
Page 28
Operation G/GS 5.6A
wc_tx000152gb.fm 26
4.18 To Stop
See Graphic: wc_gr000547
4.18.1 Turn off and disconnect all tools and appliances attached to the
generator.
4.18.2 Place the main circuit breaker in the OFF position (a2).
4.18.3 Turn the engine switch to “OFF” (b2).
4.18.4 Close the fuel valve (d2).
Note: To stop the engine quickly in an emergency, turn or press the
engine switch to “OFF” (b2).
4.19 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.
CAUTION: DO NOT exceed the current limit specified on the control
panel for any receptacle.
Page 29
G/GS 5.6A Maintenance
wc_tx000164gb.fm 27
5. Maintenance
5.1 Engine Maintenance
The chart below lists basic machine and engine maintenance. Refer to
the engine manufacturer’s Operator’s Manual for additional
information on engine maintenance.
5.2 Periodic Maintenance Schedule
Daily
before
starting
After
first
20 hrs.
Every
50
hrs.
Every
100
hrs.
Every
300
hrs.
Check the fuel level.
Check the engine oil level.
Inspect the air filter. Replace as
needed.
Check external hardware.
Clean the air cleaner element.*
Inspect the shockmounts for damage.
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 line.
Replace when necessary.
*Service more frequently in dusty conditions.
Page 30
Maintenance G/GS 5.6A
wc_tx000164gb.fm 28
5.3 Engine Oil
See Graphic: wc_gr000022
5.3.1 Drain the oil while the engine is still warm.
5.3.2 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.
5.3.3 Install the drain plug.
5.3.4 Fill the engine crankcase with the recommended oil up to the level of
the plug opening (c). See Technical Data for oil quantity and type.
5.3.5 Install the oil filler plug.
Page 31
G/GS 5.6A Maintenance
wc_tx000164gb.fm 29
5.4 Air Cleaner
See Graphic: wc_gr000025
The engine is equipped with a dual element air cleaner. Service air
cleaner frequently to prevent carburetor malfunction.
CAUTION: NEVER run engine without 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.
To service:
5.4.1 Remove air cleaner cover (a). Remove both elements and inspect
them for holes or tears. Replace damaged elements.
5.4.2 Wash foam element (b) in solution of mild detergent and warm water.
Rinse thoroughly in clean water. Allow element to dry thoroughly. Soak
element in clean engine oil and squeeze out excess oil.
5.4.3 Tap paper element (c) lightly to remove excess dirt. Replace paper
element if it appears heavily soiled.
WARNING
Page 32
Maintenance G/GS 5.6A
wc_tx000164gb.fm 30
5.5 Spark Plug
See Graphic: wc_gr000028
Clean or replace the spark plug as needed to ensure proper operation.
Refer to the engine owner’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.
Note: Refer to the Technical Data for the recommended spark plug
type and the electrode gap setting.
5.5.1 Remove the spark plug and inspect it.
5.5.2 Replace the spark plug if the insulator is cracked or chipped.
5.5.3 Clean the spark plug electrodes with a wire brush.
5.5.4 Set the electrode gap (a).
5.5.5 Tighten the spark plug securely.
CAUTION: A loose spark plug can become very hot and may cause
engine damage.
WARNING
Page 33
G/GS 5.6A Maintenance
wc_tx000164gb.fm 31
5.6 Cleaning the Sediment Cup
See Graphic: wc_gr000029
5.6.1 Turn the fuel valve off.
5.6.2 Remove the sediment cup (a) and the O-ring (b).
5.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall
them.
5.6.4 Turn the fuel valve on and check for leaks.
5.7 Carburetor Adjustment
See Graphic: wc_gr000032
5.7.1 Start the engine and allow it to warm up to operating temperature.
5.7.2 Set the pilot screw (a) two turns out. See Note.
5.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting
that produces the highest rpm.
5.7.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to
obtain the standard idle speed. See Technical Data.
Note: On some engines the pilot screw is fitted with a limiter cap (c)
to prevent excessive enrichment of the air-fuel mixture in order to
comply with emission regulations. The mixture is set at the factory and
no adjustment should be necessary. Do not attempt to remove the
limiter cap. The limiter cap cannot be removed without breaking the
pilot screw.
Page 34
Maintenance G/GS 5.6A
wc_tx000164gb.fm 32
5.8 Auto Idle Speed
See Graphic: wc_gr000548
5.8.1 Adjust pilot screw on carburetor as described above.
5.8.2 Loosen clamping screw (b) on auto idle magnet bracket.
5.8.3 Start engine and set auto idle switch to "Auto".
5.8.4 Turn magnet pin (a) in or out to adjust idle speed to 2200 ± 50 rpm.
Note: To avoid excessive vibration and to maintain adequate cooling
ability, do not set engine auto idle speed lower than 2200 rpm.
5.8.5 Re-tighten clamping screw.
Page 35
G/GS 5.6A Maintenance
wc_tx000164gb.fm 33
5.9 Engine Speed
See Graphic: wc_gr000114
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 of
3000 rpm. There is no throttle control.
To set the engine to the proper speed:
Turn the speed adjusting screw (a) in or out to obtain a no-load speed
of 3000 rpm.
CAUTION: Setting the engine speed too high or too low may damage
tools and other appliances attached to the generator.
wc_gr000114
a
Page 36
Maintenance G/GS 5.6A
wc_tx000164gb.fm 34
5.10 Storage
Before storing the generator for a long period of time:
5.10.1 Close the fuel valve and remove and empty the sediment cup or fuel
strainer.
5.10.2 Disconnect the fuel line from the carburetor. Place open end of fuel line
into a suitable container and open fuel valve to drain fuel from tank.
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.
5.10.3 Loosen the drain screw on the carburetor and drain any remaining fuel
from the carburetor.
5.10.4 Change the engine oil.
5.10.5 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.
5.10.6 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.
5.10.7 Store the generator in a clean, dry area.
5.11 Transport
Let the engine cool before transporting the generator or storing
indoors, to avoid burns or fire hazards.
When transporting the generator:
5.11.1 Turn the engine fuel valve to the OFF position.
5.11.2 Position the generator level to prevent fuel from spilling.
5.11.3 Secure the generator by tying it down with a suitable rope.
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.
WARNING
WARNING
WARNING
Page 37
G/GS 5.6A Maintenance
wc_tx000164gb.fm 35
5.12 Troubleshooting
5.13 Wire Colors
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.
• Connector from generator to control panel is tight.
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.
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
Page 38
Maintenance G/GS 5.6A
wc_tx000164gb.fm 36
5.14 Electrical Schematic
See Graphic: wc_gr000556
Ref. Description Ref. Description Ref. Description
A Generator B Control Box C Engine
Ref. Description Ref. Description
1. Main Stator Winding 7. Auto Idle
2. Automatic Voltage Regulator 8. 1 Amp Fuse
3. Rotor Winding 9. Auto Idle Switch
4. Main Stator Winding 10. 120/240V 30A Kit*
5. Auxiliary Stator Winding 11. Electromagnet
6. Choke
*W/B (Extra wire included in kit. Terminate at 120V 30A receptacle.)
w c _ g r 0 0 0 5 5 6
G / W
R / W
B / W
B / W
G / W
2
G / R
G / Y
R / W
L / Y
W / O r
1
L / G
B / R
G / L
W / R
R / Y
1
3
2
1 2 0 / 2 4 0 V
W / G
R / L
5
4
7
8
9
R / G
B / G
G / Y
R / B
B / O r
6
B / L
RWR
W
1
2
4
3
2
L 2
B
F 2
S T A B .
R
F 1
V O L TA G E
L 1
L
L
3
4
F 1
Z 1
B r
Z 1
Z 3
Z 3
Z 2
Z 2
L / B
l
B / Y
1 2 0 V A C
2 0 A
1 2 0 V A C
2 0 A
1 2 0 V A C
3 0 A
2 4 0 V A C
2 0 A
F 2
W / Y
W / L
B r
A
1
2
3 4
5
6
7
8
9
O
B
1 0
C
1 1
Page 39
G/GS 5.6A Maintenance
wc_tx000164gb.fm 37
5.15 Engine Schematic
See Graphic: wc_gr000557
Ref. Description Ref. Description
A Control Box C Engine
B Electric Start Engines D Manual Start Engines
Ref. Description Ref. Description
1. Engine Crank Switch 5. Solenoid
1a. OFF 6. Starter
1b. RUN 7. Charging Coil
1c. START 8. Battery
2. Oil Level Switch 9. Ignition Switch
3. Coil 9a. ON
4. 15 Amp Fuse 9b. OFF
w c _ g r 0 0 0 5 5
7
B
Y
G
B / R
B
G
1
Y
2
3
B
3
4
6
1
L / W
R
4
5
R
W
Y
B
W
2
T
5
R
A
C
B
D
1
1 a
1 b
1 c
4
3
2
5
6
7
8
9
2
3
9 a 9 b
Page 40
Maintenance G/GS 5.6A
wc_tx000164gb.fm 38
Notes:
Page 41
Page 42
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker Asia Pacific Operations · Skyline Tower , Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21
Loading...