Wacker Neuson GP 6600A Operator's Manual
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Wacker Neuson GP 6600A Operator's Manual

Non-carb
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See also: Repair Manual
Operator's Manual
Portable Generator
GP 6600A
GPS 6600A
non-CARB
5000186340
04
0311
5
0
0
0
1
8 6
3
4
0

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Summary of Contents for Wacker Neuson GP 6600A

  • Page 1 Operator’s Manual Portable Generator GP 6600A GPS 6600A non-CARB 5000186340 0311...
  • Page 2 Copyright notice © Copyright 2011 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC.
  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    GP/GPS 6600A Table of Contents Foreword Safety Information Signal Words Used in this Manual ............7 Machine Description and Intended Use ..........8 Operating Safety .................. 9 Operator Safety while Using Internal Combustion Engines ....11 Service Safety ..................12 Labels Label Locations ..................

  • Page 6: Schematics

    Technical Data Generator ....................43 Engine ....................45 Emission Control Systems Information and Warranty Emission Control System Background Information ......47 Limited Defect Warranty for Wacker Neuson Emission Control Systems ....................48 Schematics Wire Colors ..................52 US Machines—Electrical Schematic ...........52 CSA Machines—Electrical Schematic ..........54 Engine Wiring ..................56...

  • Page 7: Safety Information

    GP/GPS 6600A Safety Information Safety Information Signal Words Used in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol.

  • Page 8: Machine Description And Intended Use

    Safety Information GP/GPS 6600A Machine Description and Intended Use This machine is a portable electric power source. The Wacker Neuson Portable Generator consists of a tubular steel frame surrounding a fuel tank, a gasoline engine, a control panel, and an electric alternator.

  • Page 9: Operating Safety

    GP/GPS 6600A Safety Information Personal injury from improper lifting techniques To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine. Operating Safety DANGER Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO).
  • Page 10 Safety Information GP/GPS 6600A 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.

  • Page 11: Operator Safety While Using Internal Combustion Engines

    GP/GPS 6600A Safety Information 1.3.15 ALWAYS keep the machine at least one meter (three feet) away from structures, buildings, and other equipment during use. 1.3.16 ALWAYS keep the area immediately surrounding and underneath the machine clean, neat, and free of debris and combustible materials. Make sure that the area overhead is clear of debris that could fall onto or into the machine or exhaust compartment.

  • Page 12: Service Safety

    Safety Information GP/GPS 6600A 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.
  • Page 13 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.

  • Page 14: Labels

    Labels GP/GPS 6600A Labels Label Locations wc_gr003142 wc_si000561gb.fm...

  • Page 15: Label Meanings

    GP/GPS 6600A Labels Label Meanings Wacker Neuson machines use international pictorial labels where needed. These labels are described below. Engine Choke Control WARNING! Hot surface! — DANGER! Read the Operator’s Manual. No sparks, flames, or burning objects near the machine.
  • Page 16 Labels GP/GPS 6600A — — 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. —...
  • Page 17 GP/GPS 6600A Labels — 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.
  • Page 18 Labels GP/GPS 6600A WARNING Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrester may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements. A nameplate listing the model number, item number, revision number, and serial number is attached to each unit.

  • Page 19: Operation

    3.0.2 Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance. 3.0.3 Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for.

  • Page 20: Determining Power Requirements

    Check with your nearest Wacker Neuson dealer, or contact the manufacturer or dealer of the tool or appliance, with questions regarding its power requirements.

  • Page 21: Installation

    Before using an oxygenated fuel, confirm the fuel's contents. Some states / Provinces require this information to be posted on the fuel pump. The following are Wacker Neuson approved percentages of oxygenates: - (ethyl or grain alcohol) 10% by volume. You may use...

  • Page 22: Battery Tray Installation (Gps Only)

    Operation GP/GPS 6600A Battery Tray Installation (GPS only) 3.4.1 Align the holes found in the battery tray (a) to the holes on the frame cross-member 3.4.2 Insert M8 x 14 screws (b) through the tray then through the holes of the cross-member.

  • Page 23: Wheel Kit

    GP/GPS 6600A Operation Wheel Kit The wheel kit (Part No. 0161308) is a standard item on Item Number 0620012, 0620015, 0620043 and 0620046 only. It is available as an option on all other models. 3.5.1 Hoist the generator, and align the axle (c) with the lower cross-member of frame.
  • Page 24 Operation GP/GPS 6600A wc_tx000792gb.fm...

  • Page 25: Generator Derating

    GP/GPS 6600A Operation 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.

  • Page 26: Grounding The Generator

    Operation GP/GPS 6600A Grounding the Generator Location A ground connection (a) is located on the generator frame. wc_gr000544 Function This ground connection is used for electrically grounding the generator when necessary to comply with the National Electrical Code and other federal, state, and local regulations. For grounding requirements in your area, consult with a qualified electrician, electrical inspector, or local agency having jurisdiction over electrical compliance.

  • Page 27: Use Of Extension Cords

    GP/GPS 6600A Operation 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.

  • Page 28: Control Panel

    Operation GP/GPS 6600A 3.10 Control Panel Ref. Description Ref. Description Engine Switch GFCI test button Auto Idle Switch GFCI reset button Twist-lock receptacle - 120V Twist-lock receptacle - 120/240V Main Circuit Breaker Ignition Switch (GPS only) Voltage Selector Switch 20A circuit breaker (CAN only) Duplex receptacle - 120V 30A circuit breaker (CAN only) wc_gr003143...

  • Page 29: Ground Fault Interrupt (Gfi / Gfci)

    GP/GPS 6600A Operation 3.11 Ground Fault Interrupt (GFI / GFCI) The GFCI should be tested for proper operations every time the generator is used. Normal operating state - sensing device green LED is “ON” and circuit breaker is at “ON” position. 3.11.1 Press “TEST”...

  • Page 30: Twist-Lock Receptacles

    Operation GP/GPS 6600A 3.12 Twist-Lock Receptacles Twist-lock receptacles (c, j) are used at the 120V Amp and 120/240V outlets. These receptacles are protected by the GFCI. To attach a power cord to a twist-lock receptacle, insert plug into receptacle and turn it clockwise to lock it in place. 3.13 Engine Auto Idle The auto idle switch (b) automatically reduces engine speed...

  • Page 31: Voltage Selector Switch

    GP/GPS 6600A Operation 3.15 Voltage Selector Switch The voltage selector switch (e) allows the generator to operate in either single (120V) or dual voltage (120/240V) mode. In single-voltage mode, use only the 120V twist-lock (c) and duplex receptacles (f1, f2). The full rated power of the generator is shared between the three receptacles.

  • Page 32: Before Starting

    Operation GP/GPS 6600A 3.16 Before Starting 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.

  • Page 33: Stopping

    GP/GPS 6600A Operation 3.17.5 On recoil start engines, turn the engine switch to “ON” (b1) and pull the starter rope (f). 3.17.6 On electric start engines, press the ignition switch (k) and hold until the engine starts. Release the switch after the engine starts. NOTICE: DO NOT run the starter motor more than 5 seconds at a time or damage to the starter motor may occur.

  • Page 34: Emergency Shutdown Procedure

    Operation GP/GPS 6600A 3.19 Emergency Shutdown Procedure Procedure If a breakdown or accident occurs while the machine is operating, follow the procedure below: 3.19.1 Stop the engine. 3.19.2 Turn off the fuel supply. 3.19.3 Disconnect tools from the machine. 3.19.4 Allow the machine to cool. 3.19.5 Contact the rental yard or machine owner for further instructions.

  • Page 35: Maintenance

    WACKER NEUSON. The use of service parts that are not equivalent in performance and durability to authorized parts may impair the effectiveness of the emission control system and may have a bearing on the outcome of a warranty claim.

  • Page 36: Engine Oil

    Maintenance GP/GPS 6600A Engine Oil 4.3.1 Drain the oil while the engine is still warm. 4.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off.

  • Page 37: Servicing The Air Cleaner

    GP/GPS 6600A Maintenance Servicing the Air Cleaner Service the air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run the engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner.

  • Page 38: Spark Plug

    Maintenance GP/GPS 6600A 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”...

  • Page 39: Cleaning The Sediment Cup

    GP/GPS 6600A Maintenance Cleaning the Sediment Cup 4.6.1 Turn the fuel valve off. 4.6.2 Remove the sediment cup (a) and the O-ring (b). 4.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 4.6.4 Turn the fuel valve on and check for leaks. wc_tx000800gb.fm...

  • Page 40: Carburetor Adjustment

    Maintenance GP/GPS 6600A Carburetor Adjustment 4.7.1 Start the engine and allow it to warm up to operating temperature. 4.7.2 Set the pilot screw (a) two turns out. See Note. 4.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm.

  • Page 41: Long-Term Storage

    GP/GPS 6600A Maintenance Long-Term Storage Before storing the generator for a long period of time: 4.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 4.9.2 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.

  • Page 42: Troubleshooting

    Maintenance GP/GPS 6600A 4.11 Troubleshooting Problem / Symptom Reason / Remedy If engine doesn't start, check • Engine switch is on “Start”. that: • 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.

  • Page 43: Technical Data

    GP/GPS 6600A Technical Data Technical Data Generator Item No. GP 6600A GP 6600A GPS 6600A 0620385 0620384 0620386 Generator Maximum Output 6600 Continuous Output 6000 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages Avail- volts 120 / 240...
  • Page 44 Technical Data GP/GPS 6600A Item No. GP 6600A CAN GP 6600A CAN GPS 6600A CAN 0620100 0620101 0620102 Generator Maximum Output 6600 Continuous Output 5500 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages Avail- 120 / 240...

  • Page 45: Engine

    GP/GPS 6600A Technical Data Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 6600A GP 6600A GPS 6600A GPS 6600A 0620385 0620100 0620386 0620102 0620384...
  • Page 46 Technical Data GP/GPS 6600A wc_td000243gb.fm...

  • Page 47: Emission Control Systems Information And Warranty

    Carbon monoxide does not react in the same way, but it is toxic. Wacker Neuson utilizes lean carburetor settings and other systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. Evaporative Emissions...

  • Page 48: Limited Defect Warranty For Wacker Neuson Emission Control Systems

    Tampering and Altering Tampering with or altering the emission control system may increase emissions beyond the legal limit. If evidence of tampering is found, Wacker Neuson may deny a warranty claim. Among those acts that constitute tampering are: Removing or altering of any part of the air intake, fuel, or exhaust systems.

  • Page 49: Limited Defect Warranty For Wacker Neuson Evaporative

    Any implied warranties are limited to the duration of this written warranty. What is covered Wacker Neuson recommends the use of genuine Wacker Neuson parts, or the equivalent, whenever maintenance is performed. The use of replacement parts not equivalent to the original parts may impair the effectiveness of the engine/ equipment emission controls systems.
  • Page 50 Wacker Neuson dealer/ service center. The engine/equipment must be presented to an authorized Wacker Neuson dealer/ service center as soon as a problem exists. Contact Wacker Neuson Product wc_tx001754gb.fm...
  • Page 51 For owners located more than 100 miles from an authorized dealer/service center (excluding the states with high-altitude areas as identified in 40 CFR Part 1068, Appendix III), Wacker Neuson will pay for pre-approved shipping costs to and from an authorized Wacker Neuson dealer/service center.

  • Page 52: Schematics

    Schematics GP / GPS 6600A Schematics Wire Colors Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Light blue US Machines—Electrical Schematic Ref. Description Ref. Description Generator Honda Engine Control box Electric start engines (GPS) Ref.

  • Page 53: Gp / Gps 6600A

    GP / GPS 6600A Schematics wc_tx001775gb.fm...

  • Page 54: Csa Machines-Electrical Schematic

    Schematics GP / GPS 6600A CSA Machines—Electrical Schematic Ref. Description Ref. Description Generator Honda Engine Control box Electric start engines (GPS) Ref. Description Ref. Description Main stator winding 1 Engine ON / OFF switch Main stator winding 2 Rectifier Auto idle unit Rotor winding/brushes Main circuit breaker Secondary (excitation) winding...
  • Page 55 GP / GPS 6600A Schematics wc_tx001775gb.fm...

  • Page 56: Engine Wiring

    Schematics GP / GPS 6600A Engine Wiring Ref. Description Ref. Description Generator Honda Engine Control box Electric start engines (GPS) Ref. Description Ref. Description Idle solenoid Solenoid (GPS only) Fuel cut solenoid Starter (GPS only) Oil level sender Charging coil (GPS only) Spark plug Battery (GPS only) Coil...
  • Page 58 Tel. : (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) 3605 5360, Fax: (852) 2758 0032...

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