Wacker Neuson GV 5600A Operator's Manual

0174920en 003
0908

Generator

GV 5600A
CARB

OPERATOR’S MANUAL

0174920EN

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.

Table of Contents GV 5600A

1. Foreword 5

2. California Evaporative Emission Control Warranty Statement 6

3. Safety Information 8

3.1 Laws Pertaining to Spark Arresters .......................................................8

3.2 Operating Safety ...................................................................................9

3.3 Operator Safety while using Internal Combustion Engines .................11

3.4 Service Safety .....................................................................................12

3.5 Label Locations ...................................................................................13

3.6 Safety and Operating Labels ...............................................................14

4. Operation 17

4.1 Determining Power Requirements ......................................................17

4.2 Installation ...........................................................................................18

4.3 Installing Spark Arrester ......................................................................18

4.4 Generator Derating ..............................................................................19

4.5 Grounding the Generator ....................................................................20

4.6 Operating Heavy Loads .......................................................................20

4.7 Use of Extension Cords .......................................................................21

4.8 Control Panel .......................................................................................22

4.9 Ground Fault Interrupt (GFI) ................................................................23

4.10 Main Circuit Breaker ............................................................................23

4.11 Voltage Selection ................................................................................24

4.12 Engine Auto Idle ..................................................................................24

4.13 Before Starting ....................................................................................25

4.14 To Start ................................................................................................26

4.15 To Stop ................................................................................................27

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GV 5600A Table of Contents

5. Maintenance 28

5.1 Engine Maintenance ........................................................................... 28

5.2 Periodic Maintenance Schedule ......................................................... 28

5.3 Engine Oil ........................................................................................... 29

5.4 Servicing Air Cleaner .......................................................................... 30

5.5 Spark Plug .......................................................................................... 31

5.6 Cleaning the Sediment Cup ............................................................... 32

5.7 Storage ............................................................................................... 33

5.8 Transport ............................................................................................ 34

5.9 Troubleshooting .................................................................................. 35

6. Technical Data 36

6.1 Generator ........................................................................................... 36

6.2 Engine ................................................................................................ 37

6.3 Electrical Schematic ........................................................................... 38

6.4 Schematic Components ..................................................................... 39

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WARNING

1 Foreword

Foreword

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.

This manual provides information and procedures to safely operate
and maintain this Wacker Neuson 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 Neuson
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 Neuson
Corporation.

The information contained in this manual was based on machines in
production at the time of publication. Wacker Neuson Corporation
reserves the right to change any portion of this information without
notice.

All rights, especially copying and distribution rights, are reserved.

Copyright 2008 by Wacker Neuson 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 Neuson Corporation.

Any type of reproduction or distribution not authorized by Wacker
Neuson 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.

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California Evaporative Emission Control Warranty Statement

2. 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 anti-smog 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.

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.

6

California Evaporative Emission Control Warranty Statement

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 1-800-770-

0957.

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.

WARRANTED PARTS:

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:

(1) Fuel and Vent Lines
(2) Fuel and Vent Line Clamps
(3) Fuel and Vent Line Fittings
(4) Carbon Canister
(5) Fuel Tank
(6) Fuel Tank Cap

7

GV 5600A Safety Information

3. Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE 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.

DANGER

WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.

WARNING

CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.

CAUTION

NOTICE: Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.

Note: Contains additional information important to a procedure.

3.1 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.

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Safety Information GV 5600A

3.2 Operating Safety

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 this generator inside a home or garage, EVEN IF

DANGER

DANGER

doors and windows are open. Only use this generator OUTSIDE and
far away from windows, doors, and vents.

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 the
machine. Machines operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both

WARNING

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.

3.2.1 NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.

3.2.2 NEVER operate the generator, or tools attached to the generator, with
wet hands.

3.2.3 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.

3.2.4 NEVER run the electrical cords under the generator, or over vibrating
or hot parts.

3.2.5 NEVER enclose or cover the generator when it is in use or when it is
hot.

3.2.6 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.

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GV 5600A Safety Information

3.2.7 NEVER operate the machine in snow, rain, or standing water.

3.2.8 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a certified electrician.

3.2.9 NEVER stand on the machine.

3.2.10 DO NOT stand under the machine while it is being hoisted or moved.

3.2.11 DO NOT attach equipment to the machine when it is suspended.

3.2.12 ALWAYS 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.

3.2.13 ALWAYS position and operate the generator on a firm,
noncombustible, level surface.

3.2.14 ALWAYS transport the generator in an upright position.

3.2.15 ALWAYS keep the machine far away from structures, buildings, and
other equipment during use.

3.2.16 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.

3.2.17 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.

3.2.18 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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Safety Information GV 5600A

3.3 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

DANGER

3.3.1 NEVER use this generator inside a home or garage, EVEN IF doors

3.3.2 NEVER use a generator inside an enclosed area such as a tunnel or a

3.3.3 DO NOT smoke while operating the machine.

3.3.4 DO NOT smoke when refueling the engine.

3.3.5 DO NOT refuel a hot or running engine.

3.3.6 DO NOT refuel the engine near an open flame.

warnings and safety standards could result in severe injury or death.

and windows are open. Only use OUTSIDE and far away from
windows, doors, and vents. Using a generator indoors CAN KILL YOU
IN MINUTES. Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell.

trench.

3.3.7 DO NOT spill fuel when refueling the engine.

3.3.8 DO NOT run the engine near open flames.

3.3.9 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.

3.3.10 ALWAYS refill the fuel tank in a well-ventilated area.

3.3.11 ALWAYS replace the fuel tank cap after refueling.

3.3.12 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.

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GV 5600A Safety Information

3.4 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

WARNING

3.4.1 DO NOT use gasoline or other types of fuels or flammable solvents to

3.4.2 DO NOT attempt to clean or service the machine while it is running.

3.4.3 DO NOT modify the machine without the express written approval of

3.4.4 DO NOT allow water to accumulate around the base of the machine.

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.

clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.

the manufacturer.

If water is present, move the machine and allow the machine to dry
before servicing.

3.4.5 DO NOT service the machine if your clothing or skin is wet.

3.4.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.

3.4.7 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.

3.4.8 ALWAYS replace the safety devices and guards after repairs and
maintenance.

3.4.9 ALWAYS let the engine cool before transporting or servicing it.

3.4.10 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.

3.4.11 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.

3.4.12 ALWAYS keep the fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.

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Safety Information GV 5600A

3.5 Label Locations

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GV 5600A Safety Information

3.6 Safety and Operating Labels

Wacker Neuson machines use international pictorial labels where
needed. These labels are described below:

Label Meaning

DANGER!
No sparks, flames or burning objects near
machine.
Shut off the engine before refueling.

WARNING!
Hot surface!

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.

Close main circuit breaker.

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CAUTION!
Use only clean, filtered gasoline fuel.
Check the fuel level.

Safety Information GV 5600A

Label Meaning

Open the fuel flow valve.

Close the choke.

Turn the engine switch to the ON position.

Pull the rewind starter.

Open the choke.

Open main circuit breaker.

Turn the engine switch to “OFF”.

Close the fuel flow valve.

Electrical ground

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GV 5600A Safety Information

Label Meaning

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.

Important Emissions Information
This equipment meets California EVP
emission regulations for small off-road
engines.

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.

wc_si000269gb.fm 16

Operation GV 5600A

4. Operation

4.1 Determining Power Requirements

This generator is designed to operate single-phase, 60 Hz appliances
running at 120 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
Three Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS

17

GV 5600A Operation

4.2 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.

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 this generator inside a home or garage, EVEN IF

DANGER

DANGERDANGER

doors and windows are open. Only use this generator OUTSIDE and
far away from windows, doors, and vents.

NEVER install a generator in an enclosed area such as a tunnel or a
trench. Using a generator in a tunnel or a trench CAN KILL YOU IN
MINUTES. Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell. NEVER use this generator inside a
tunnel or a trench.

4.3 Installing Spark Arrester

A spark arrester is available as an accessory for this machine. Install
the spark arrester prior to using the machine in areas where spark
arresters are required.

To install the spark arrester:

4.3.1 Position the spark arrester (a) on the engine exhaust pipe (b).

4.3.2 Secure the spark arrester with the screw (c) included with the spark

arrester.

18

Operation GV 5600A

4.4 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)

45 (113) 3 % 0.97
50 (122) 6 % 0.94
55 (131) 9 % 0.91
60 (140) 12 % 0.88

Altitude

m (ft.)

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

Derate Factor

Derate Factor

4000 (13100) 18 % 0.82

19

GV 5600A Operation

4.5 Grounding the Generator

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.

a

4.6 Operating Heavy Loads

Limit operations requiring the maximum rated output of 5600 Watts to
20–30 minutes. For continuous operation, do not exceed the
continuous rated output of 5000 Watts.

NOTICE: DO NOT exceed the current limit specified on the control
panel for any receptacle.

20

Operation GV 5600A

4.7 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.

WARNING

Current Load in Watts Maximum Cable Length in Feet

(Amps) 120V 240V #10 #12 #14 #16

2.5 300 600 1000. 600 375 250

Replace damaged cords immediately.
Use the chart below as a guide for selecting proper cable size.

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.

21

GV 5600A Operation

4.8 Control Panel

Ref. Description Ref. Description

a Engine switch f GFI duplex receptacle—125V
b Auto idle switch g GFI test button

c Twist-lock receptacle—125/250V h GFI reset button
d Main circuit breaker i Twist-lock receptacle—125V
e Voltage Selector Switch (VSS) - ---

22

Operation GV 5600A

4.9 Ground Fault Interrupt (GFI)

See Graphic: wc_gr003960

Each of the 125V, 20 Amp receptacles (f) is equipped with a ground
fault circuit interrupt (GFI). The GFI shuts off power to the receptacle
when a ground fault occurs 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 the GFI:

4.9.1 Disconnect all equipment from the generator.

4.9.2 Start the generator.

4.9.3 Push in the TEST button (g) on the receptacle. Pushing the TEST

button in shuts off power to the receptacle and causes the RESET
button (h) to pop out. If the RESET button does not pop out, the GFI is
not working. Do not operate the generator until the problem can be
corrected.

4.9.4 Push in the RESET button to restore power to the receptacle.
If the RESET button pops out during operation, stop the generator and

check the equipment attached to the generator for defects.

4.10 Main Circuit Breaker

See Graphic: wc_gr003960

The generator is protected by a two-pole, 15-Amp per pole, main
circuit breaker (d) located on the control panel.

The main circuit breaker protects the generator from severe overloads
or short circuits. If the main circuit breaker opens, turn the engine off
immediately and determine the cause before restarting. Check the
appliances and tools attached to the generator for defects and make
sure their power requirements do not exceed the power rating of the
generator or the current limit of the receptacles.

23

GV 5600A Operation

4.11 Voltage Selection

See Graphic: wc_gr003960

The voltage selector switch (VSS) (e) switches the generator output
between the single-voltage mode (120V) and the dual-voltage (120/
240V) mode.

In single-voltage mode, the full rated power of the generator is shared
between the two 125V GFI duplex receptacles and the 125V twist-lock
receptacle.

In dual-voltage mode, generator power is shared between the 125/
250V twist-lock receptacle, the 125V GFI duplex receptacles, and the
125V twist-lock receptacle. To achieve full power, use only the 125/
250V twist-lock receptacle. Note: Only use the 125/250V twist-lock

receptacle (j) when the VSS is in the 120V/240V position.
NOTICE: NEVER change the position of the VSS when the main

breaker is in the ON position. This can cause arcing and can damage
the generator. Turn all tools and appliances off and place the main
circuit breaker (d) in the OFF position before changing the position of
the voltage selector switch.

4.12 Engine Auto Idle

See Graphic: wc_gr003960

The auto idle switch (b) automatically reduces engine speed 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.

24

Operation GV 5600A

4.13 Before Starting

4.13.1 Read and understand the safety and operating labels and instructions
at the beginning of this manual.

4.13.2 Inspect the generator for any signs of damage which may affect
operation or pose a safety hazard.

4.13.3 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.

4.13.4 Fill the fuel tank to the red LEVEL ring only with fresh, regular,
unleaded grade gasoline. Do not overfill the fuel tank. 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.

25

GV 5600A Operation

4.14 To Start

Before starting, be sure you read and understand all the safety and
operating instructions in this manual.

4.14.1 Disconnect all loads from the generator and place the main breaker in

the "OFF" position (a2).

4.14.2 Set the Auto Idle Switch (c) to "OFF".

4.14.3 Open the fuel valve (d1).

Note: If the engine is cold, move the choke lever to the closed position
(e2). If the engine is hot, set the choke to the open position (e1).

4.14.4 Turn the engine switch to "ON" (b1).

4.14.5 Pull the starter rope (f).

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.

4.14.6 As the engine warms up, move the choke lever to the OPEN position

(e1).

4.14.7 Allow the engine to warm up for a few minutes before placing the main

MAIN BREAKER

breaker in the "ON" position (a1) and attaching loads.

a1

a2

b1

b2

IDLE

c

OFFAUTO

26

Operation GV 5600A

4.15 To Stop

4.15.1 Turn off and disconnect all tools and appliances attached to the
generator.

4.15.2 Place the main circuit breaker in the OFF position (a2).

4.15.3 Place the engine switch to OFF (b2).

4.15.4 Close the fuel valve (d2).

Note: To stop the engine quickly in an emergency, turn the engine
switch to OFF (b2).

27

GV 5600A Maintenance

5. Maintenance

5.1 Engine Maintenance

The chart below lists basic machine and engine maintenance. Refer to
your engine Operator’s Manual for additional information on engine
maintenance.

5.2 Periodic Maintenance Schedule

Check the fuel level.
Check the engine oil level.
Inspect the air filter. Replace as

needed.
Check external hardware.
Check condition of the fuel lines.

Replace when necessary.
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.

Daily

before

starting











After

first

20 hrs.



Every

50

hrs.



Every

100

hrs.







Every

300

hrs.

Check and adjust the valve clearance.
Clean the fuel tank.*

*Service more frequently in dusty conditions.

wc_tx000877gb.fm 28





Maintenance GV 5600A

5.3 Engine Oil

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 section Technical Data for oil quantity and
type.

5.3.5 Install the oil filler plug.

wc_tx000877gb.fm 29

wc_gr000022

GV 5600A Maintenance

5.4 Servicing 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:

5.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or

tears. Replace the element if it is damaged.

5.4.2 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_tx000877gb.fm 30

wc_gr002815

Maintenance GV 5600A

5.5 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 while it is hot.

WARNING

Note: Refer to section 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.

NOTICE: A loose spark plug can become very hot and may cause
engine damage.

wc_tx000877gb.fm 31

GV 5600A Maintenance

5.6 Cleaning the Sediment Cup

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.

b

a

wc_gr000029

wc_tx000877gb.fm 32

Maintenance GV 5600A

5.7 Storage

Before storing the generator for a long period of time:

5.7.1 Close the fuel valve and remove and empty the sediment cup or fuel
strainer.

5.7.2 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.

Gasoline is extremely flammable. Drain the fuel tank in a well­ventilated area. DO NOT drain the fuel tank in an area with flames or

WARNING

5.7.3 Loosen the drain screw on the carburetor and drain any remaining fuel

5.7.4 Change the engine oil.

5.7.5 Remove the spark plug and pour approximately 30 ml (1 ounce) of

sparks.

from the carburetor.

clean engine oil into the cylinder. Crank the engine a few turns to
distribute the oil to the inside of the cylinder walls.

5.7.6 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.

5.7.7 Store the generator in a clean, dry area.

wc_tx000877gb.fm 33

GV 5600A Maintenance

5.8 Transport

Let the engine cool before transporting the generator or storing it
indoors, to avoid burns or fire hazards.

WARNING

When transporting the generator:

5.8.1 Turn the engine fuel valve to the OFF position.

5.8.2 Position the generator level to prevent fuel from spilling.

5.8.3 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

WARNING

when lifting the machine, bend the knees to pick it up rather than
bending your back only.

wc_tx000877gb.fm 34

Maintenance GV 5600A

5.9 Troubleshooting

Problem / Symptom Reason / Remedy

If engine does not start, check

that:

If engine starts but there is no
power at receptacles, 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.

• Circuit breaker is closed.

• Connector from generator to control panel is tight.

wc_tx000877gb.fm 35

GV 5600A GV 5600A Technical Data

6. GV 5600A Technical Data

6.1 Generator

Item No. GV 5600A

0620335

Generator

Maximum output
Continuous output

W

W

5600
5000

Type Single phase,

self-exciting, 2-pole, field rotating

AC voltages available

Frequency
Power factor

Volts

phase

Hz

cos ø

120/240

1

60

1.0

AC receptacles:
125V GFI duplex (2)
125V twist lock
125/250V twist lock

Main circuit breaker

Amp
Amp
Amp

Amp

20
30
30

15 per pole

(two pole)
L x W x H
Weight (dry)

mm (in.)

kg (lbs.)

710 x 550 x 515 (28.0 x 21.6 x 20.3)

79 (174.2)

36

GV 5600A Technical Data GV 5600A

6.2 Engine

Engine Power Rating

Net power rating per SAE J1349. Actual power output may vary due to
conditions of specific use.

Item No. GV 5600A

0620335

Engine

Engine make Honda
Engine model GX 340 R1
Max. rated power @

kW (Hp)

7.1 (9.5) @ 3600 rpm

rated speed
Spark plug BPR6ES (NKG)
Electrode gap
Operating speed
Air cleaner
Engine lubrication
Engine oil capacity
Fuel
Fuel tank capacity
Fuel consumption
Running time -

mm (in.)

rpm

type

oil grade

l (qts.)

type

l (gal.)

l (qts.)/hr.

hrs.

0.7–0.8 (0.028–0.031)
3600

Oil-wetted foam

SAE 10W30 service class SF or SG

1.1 (1.2)

Regular unleaded gasoline

21 (5.5)

3.5 (3.7)

6.2

continuous load

37

GV 5600A GV 5600A Technical Data

6.3 Electrical Schematic

19

6

6

24

17

5

15 16

20

18

8

9

10

21

11

13

C

1

14

AB

3

12

22 23

2

4

38

GV 5600A Technical Data GV 5600A

6.4 Schematic Components

Ref. Description Ref. Description Ref. Description

A Generator B Control Box C Engine

Ref. Description Ref. Description

1 Main stator winding 13 Spark plug
2 Secondary winding 14 Slip ring
3 Rotor winding 15 Auto idle unit
4 Automatic voltage regulator 16 Voltage selector switch
5 Main circuit breaker 17 Twist lock receptacle—125/250V
6 GFI duplex receptacle—125V 18 Auto idle switch
7 --- 19 Idle solenoid
8 Engine ON-OFF switch 20 Capacitor

9 Oil alert module 21 Fuel stop solenoid
10 Oil level switch 22 Auxiliary winding
11 Ignition coil 23 DC rectifier
12 Ground terminal 24 Twist lock receptacle—125V

Wire Colors

B Black V Violet Or Orange

G Green W White Pr Purple

L Blue Y Yellow Sh Shield
P Pink Br Brown LL Light Blue
R Red Cl Clear G/Y Green/Yellow
TTan GrGray

39

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: [phone] - 0 · Fax: +49 - (0)89-3 54 02-3 90

Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : [phone] · Fax: [phone] · Tel. : [phone]

Wacker
Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. [phone] · Fax: [phone]