- DL manuals
- Wacker Neuson
- Portable Generator
- GP 4000
- Operator's Manual
Wacker Neuson GP 4000 Operator's Manual
Summary of GP 4000
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5000192915 01 0512 5 0 0 0 1 9 2 9 1 5 operator’s manual portable generator gp 4000 en.
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Copyright notice © copyright 2012 by wacker neuson production americas llc all rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permissio...
Page 3: Foreword
Foreword wc_tx001706gb.Fm 3 foreword save these instructions—this manual contains important instructions for the machine models listed below. These instructions must be followed during installation and maintenance of the generator (and battery, if equipped). Machines covered in this manual machine d...
Page 4: Foreword
Foreword 4 wc_tx001706gb.Fm manufacturer’s approval this manual contains references to approved parts, attachments, and modifica- tions. The following definitions apply: approved parts or attachments are those either manufactured or provided by wacker neuson. Approved modifications are those perform...
Page 5: Table of Contents
Wc_bo5000192915_01toc.Fm 5 table of contents gp 4000 foreword 3 1 safety information 7 1.1 signal words used in this manual ....................................................... 7 1.2 machine description and intended use ............................................... 8 1.3 operating safety .........
Page 6: Table of Contents
6 wc_bo5000192915_01toc.Fm table of contents gp 4000 4 maintenance 36 4.1 maintaining the emission control system ...........................................36 4.2 periodic maintenance schedule ..........................................................36 4.3 engine oil .................................
Page 7: Gp 4000
Wc_si000236gb.Fm 7 gp 4000 safety information 1 safety information 1.1 signal words used in this manual this manual contains danger, warning, caution, notice, and note signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. Noti...
Page 8: Safety Information
Wc_si000236gb.Fm 8 safety information gp 4000 1.2 machine description and intended use this machine is a portable electric power source. The wacker neuson portable generator consists of a tubular steel frame surrounding a fuel tank, a gasoline engine, a control panel, and an electric alternator. The...
Page 9: Gp 4000
Wc_si000236gb.Fm 9 gp 4000 safety information 1.3 operating safety operator training before operating the machine: read and understand the operating instructions contained in all manuals delivered with the machine. Familiarize yourself with the location and proper use of all controls and safety devi...
Page 10: Safety Information
Wc_si000236gb.Fm 10 safety information gp 4000 safety devices, controls, and attachments only operate the machine when: all safety devices and guards are in place and in working order. All controls operate correctly. The machine is set up correctly according to the instructions in the operator’s man...
Page 11: Gp 4000
Wc_si000236gb.Fm 11 gp 4000 safety information transporting and installing the machine never allow untrained personnel to operate or service the generator. The generator set should be set up by a certified electrician. Do not stand under the machine while it is being hoisted or moved. Do not attach ...
Page 12: Safety Information
Wc_si000236gb.Fm 12 safety information gp 4000 1.4 operator safety while using internal combustion engines refueling safety when refueling the engine: do not smoke. Do not refuel if the generator is sitting in a truck fitted with a plastic bed liner. Static electricity can ignite the fuel or fuel va...
Page 13: Gp 4000
Wc_si000236gb.Fm 13 gp 4000 safety information 1.5 service safety service training before servicing or maintaining the machine: read and understand the instructions contained in all manuals delivered with the machine. Familiarize yourself with the location and proper use of all controls and safety d...
Page 14: Safety Information
Wc_si000236gb.Fm 14 safety information gp 4000 cleaning when cleaning and servicing the machine: keep the machine clean and free of debris such as leaves, paper, cartons, etc. Keep the labels legible. When cleaning the machine: do not clean the machine while it is running. Never use gasoline or othe...
Page 15: Gp 4000
Gp 4000 labels wc_si000557gb.Fm 15 2 labels 2.1 label locations 2.2 label meanings wacker neuson machines use international pictorial labels where needed. These labels are described below. A engine choke control b warning! Hot surface wc_gr003142 c l g b e f n k j d a m.
Page 16: Labels
Labels gp 4000 16 wc_si000557gb.Fm c — danger! Read the operator’s manual. No sparks, flames, or burning objects near the machine. Stop the engine before refueling. — gfci test instructions - test before each use normal operating state - sensing device green led is "on" and circuit breaker is at "on...
Page 17: Gp 4000
Gp 4000 labels wc_si000557gb.Fm 17 — close the choke. — turn the engine switch to the on position. — pull the rewind starter. — open the choke. — turn the engine switch to “off”. — close the fuel flow valve. — danger using a generator indoors can kill you in minutes. Generator exhaust contains carbo...
Page 18: Labels
Labels gp 4000 18 wc_si000557gb.Fm — only use outside and far away from windows, doors, and vents. — warning! To reduce the risk of electrical shock and arc flash, read the operator’s manual. Improper connection of the generator to a building’s electrical system can allow electrical current from the...
Page 19: Gp 4000
Gp 4000 labels wc_si000557gb.Fm 19 k this machine may be covered by one or more patents. L warning! Test gfci before each use. See label above. M important emissions information this equipment meets california evp emission regulations for small off-road engines. N emission control information this e...
Page 20: Operation
Operation gp 4000 20 wc_tx000788gb.Fm 3 operation preparing for first use to prepare your machine for first use: 3.0.1 make sure all loose packaging materials have been removed from the machine. 3.0.2 check the machine and its components for damage. If there is visible damage, do not operate the mac...
Page 21: Gp 4000
Gp 4000 operation wc_tx000788gb.Fm 21 3.1 recommended fuel type this engine/equipment requires regular unleaded gasoline. • use only fresh (no older than three months old), clean gasoline. • use a fuel stabilizer per the fuel stabilizer manufacturer’s instructions. Use of oxygenated fuels some conve...
Page 22: Operation
Operation gp 4000 22 wc_tx000788gb.Fm 3.2 refueling the machine requirements • machine shut down • engine cool • machine/fuel tank level with the ground • fresh, clean fuel supply procedure perform the procedure below to refuel the machine. 3.2.1 remove the fuel cap. 3.2.2 fill the fuel tank until t...
Page 23: Gp 4000
Gp 4000 operation wc_tx000788gb.Fm 23 3.3 determining power requirements this generator is designed to operate single-phase, 60 hz appliances running at 120 vac or 240 vac. Check the nameplate or label provided on tools and appliances to make sure their power requirements match the power output of t...
Page 24: Operation
Operation gp 4000 24 wc_tx000788gb.Fm 3.4 installation place the generator in an area where it will not be exposed to rain, snow, or direct sunlight. Make sure it is positioned on firm, level ground, so it will not slide or shift. Position the engine exhaust away from areas where people may be prese...
Page 25: Gp 4000
Gp 4000 operation wc_tx000788gb.Fm 25 3.5.15 align the holes found in the handles (a, j) to the holes of the brackets (1) on the frame. 3.5.16 insert m6 x 16 screws (l) through the handles, then through the brackets on the frame. 3.5.17 insert nuts (m) onto the screws and tighten. Torque to 7.5 nm (...
Page 26: Operation
Operation gp 4000 26 wc_tx000788gb.Fm 3.6 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...
Page 27: Gp 4000
Gp 4000 operation wc_tx000788gb.Fm 27 3.7 grounding the generator location a ground connection (a) is located on the generator frame. Function this ground connection is used for electrically grounding the generator when necessary to comply with the national electrical code and other federal, state, ...
Page 28: Operation
Operation gp 4000 28 wc_tx000788gb.Fm 3.9 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 incr...
Page 29: Gp 4000
Gp 4000 operation wc_tx000788gb.Fm 29 3.10 control panel ref. Description ref. Description a engine switch g gfci test button b auto idle switch h gfci reset button c twist-lock receptacle - 120v j twist-lock receptacle - 120/240v d main circuit breaker m 20a circuit breaker (can only) e voltage sel...
Page 30: Operation
Operation gp 4000 30 wc_tx000788gb.Fm 3.11 ground fault interrupt (gfi / gfci) the gfci should be tested for proper operation 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” button (g) . Green le...
Page 31: Gp 4000
Gp 4000 operation wc_tx000788gb.Fm 31 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 ...
Page 32: Operation
Operation gp 4000 32 wc_tx000788gb.Fm 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...
Page 33: Gp 4000
Gp 4000 operation wc_tx000788gb.Fm 33 3.16 before starting 3.16.1 read and understand the safety and operating labels and instructions at the beginning of this manual. 3.16.2 inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 3.16.3 check: • oil level i...
Page 34: Operation
Operation gp 4000 34 wc_tx000788gb.Fm 3.17 starting before starting, be sure you read and understand all the safety and operating instructions in this manual. 3.17.1 ensure that the generator is properly installed in an outdoor location. See sections installation and operator safety while using inte...
Page 35: Gp 4000
Gp 4000 operation wc_tx000788gb.Fm 35 3.18 stopping 3.18.1 turn off and disconnect all tools and appliances attached to the generator. 3.18.2 place the main circuit breaker in the off position (a2) . 3.18.3 place the engine switch to off (b2) . 3.18.4 close the fuel valve (d2) . Note: to stop the en...
Page 36: Maintenance
Maintenance gp 4000 36 wc_tx000796gb.Fm 4 maintenance 4.1 maintaining the emission control system normal maintenance, replacement, or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a dealer/ser...
Page 37: Gp 4000
Gp 4000 maintenance wc_tx000796gb.Fm 37 4.3 engine oil 4.3.1 drain the oil while the engine is still warm. 4.3.2 remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: in the interests of environmental protection, place a plastic sheet and a container under the machine to coll...
Page 38: Maintenance
Maintenance gp 4000 38 wc_tx000796gb.Fm 4.4 servicing the air cleaner service the air cleaner frequently to prevent carburetor malfunction. Notice : never run the engine without the air cleaner. Severe engine damage will occur. Never use gasoline or other types of low flash-point solvents for cleani...
Page 39: Gp 4000
Gp 4000 maintenance wc_tx000796gb.Fm 39 4.5 spark plug clean or replace the spark plug as needed to ensure proper operation. Refer to your engine operator’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it ...
Page 40: Maintenance
Maintenance gp 4000 40 wc_tx000796gb.Fm 4.6 long-term storage before storing the generator for a long period of time: 4.6.1 close the fuel valve and remove and empty the sediment cup or fuel strainer. 4.6.2 disconnect the fuel line from the carburetor. Place the open end of the fuel line into a suit...
Page 41: Gp 4000
Gp 4000 maintenance wc_tx000796gb.Fm 41 4.8 troubleshooting problem / symptom reason / remedy if engine doesn't start, check that: • engine switch is on “start”. • fuel valves under fuel tank and on engine are open. • fuel tank has fuel. • choke lever is in correct position. Choke should be closed w...
Page 42: Technical Data
Technical data gp 4000 42 wc_td000239gb.Fm 5 technical data 5.1 generator item no. Gp 4000 generator maximum output w 4000 continuous output w 3600 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 recept...
Page 43: Gp 4000
Gp 4000 technical data wc_td000239gb.Fm 43 5.2 engine engine power rating net power rating per sae j1349. Actual power output may vary due to conditions of specific use. Item no. Gp 4000 engine engine type 4-stroke, overhead valve, single cylinder engine make wacker neuson engine model wm 270 max. R...
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Emission control systems information and warranty 44 wc_tx001773gb.Fm 6 emission control systems information and warranty the emission control warranty and associated information is valid only for the u.S.A., its territories, and canada. 6.1 emission control system background information introductio...
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Emission control systems information and warranty wc_tx001773gb.Fm 45 tampering and altering tampering with or altering the emission control system may increase emissions beyond the legal limit. If evidence of tampering is found, wacker neuson may deny a warranty claim. Among those acts that constit...
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Emission control systems information and warranty 46 wc_tx001773gb.Fm applicable epa regulations. All defective parts replaced under this warranty become property of wacker neuson. Exhaust emissions * indicates expendable maintenance items. Warranted only to first scheduled replacement point. Evapor...
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Emission control systems information and warranty wc_tx001773gb.Fm 47 what is not covered failures other than those resulting from defects in material or workmanship. Any systems or parts which are affected or damaged by owner abuse, tampering, neglect, improper maintenance, misuse, improper fueling...
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Emission control systems information and warranty 48 wc_tx001773gb.Fm 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 cost...
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Emission control systems information and warranty wc_tx001773gb.Fm 49 6.3 california evaporative emission control warranty statement your warranty rights and obligations the california air resources board and wacker neuson sales americas, llc, n92 w15000 anthony avenue, menomonee falls, wi 53051, (h...
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Emission control systems information and warranty 50 wc_tx001773gb.Fm all failures caused by abuse, neglect, or improper maintenance are not covered. In addition, the use of add-on or modified parts will be grounds for disallowing a warranty claim. What is covered the repair or replacement of any wa...
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Emission control systems information and warranty wc_tx001773gb.Fm 51 6.4 california exhaust emission control warranty statement.
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Emission control systems information and warranty 52 wc_tx001773gb.Fm.
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Wc_tx001778gb.Fm 53 notes.
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Schematics gp 4000 54 wc_tx001778gb.Fm 7 schematics 7.1 wire colors 7.2 us machines—electrical schematic components wire colors b black r red y yellow or orange g green t tan br brown pr purple l blue v violet cl clear sh shield p pink w white gr gray ll light blue ref. Description ref. Description ...
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Gp 4000 schematics wc_tx001778gb.Fm 55 7.3 us machines—electrical schematic 2 brn 2 brn 33 8 blu 8 blu 3 brn 3 brn 33 5 brn 5 brn 55 2 brn 2 brn 22 66 77 7 brn 7 brn 103 gry 103 gry 11 12 12 33 1 brn 1 brn 3 brn 3 brn 44 104 gry 104 gry 11 brn 11 brn 16 awg 16 awg 10 10 10 brn 16 awg 10 brn 16 awg 1...
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Schematics gp 4000 56 wc_tx001778gb.Fm 7.4 csa machines—electrical schematic components ref. Description ref. Description a generator d wacker neuson engine b control box ref. Description ref. Description 1 main stator winding 1 13 rectifier 2 main stator winding 2 14 rotor winding/brushes 3 auto id...
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Gp 4000 schematics wc_tx001778gb.Fm 57 7.5 csa machines—electrical schematic 2 brn 2 brn 8 blu 8 blu 3 brn 3 brn 101 blu 101 blu 5 brn 5 brn 88 55 8 blu 8 blu 5 brn 5 brn 22 2 brn 2 brn 9 brn 9 brn 7 brn 7 brn 103 gry 103 gry 77 66 3 brn 3 brn 1 brn 1 brn 104 gry 104 gry 33 11 44 11 11 brn 11 brn 16...
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Schematics gp 4000 58 wc_tx001778gb.Fm 7.6 engine wiring ref. Description ref. Description a generator d wacker neuson engine b control box c electric start engines (gps) ref. Description 1 idle solenoid 2 spark plug 3 oil level sender 4 oil level switch 5 coil org blk blk blk/wht wht wht d a b c wc...
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Wacker neuson produktion gmbh & co. Kg, preußenstraße 41, d-80809 münchen, tel.: +49-(0)89-3 54 02-0 fax: +49 - (0)89-3 54 02-390 wacker neuson production americas llc, n92w15000 anthony ave., menomonee falls, wi 53051 tel. : (262) 255-0500 fax: (262) 255-0550 tel.: (800) 770-0957 wacker neuson limi...