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  5. Operator's Manual

Wacker Neuson GP 4000 Operator's Manual

Other manuals for GP 4000: Operator's Manual

Summary of GP 4000

  • Page 1

    5000192915 02 0813 5 0 0 0 1 9 2 9 1 5 operator’s manual portable generator gp 4000 en.

  • Page 2

    Copyright notice © copyright 2013 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: Gp 4000

    Gp 4000 foreword wc_tx003404gb.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 m...

  • Page 4: Foreword

    Foreword gp 4000 4 wc_tx003404gb.Fm machine identification a nameplate listing the model number, item number, revision number, and serial number is attached to this machine. The location of the nameplate is shown above. Serial number (s/n) for future reference, record the serial number in the space ...

  • Page 5: Gp 4000

    Gp 4000 foreword wc_tx003404gb.Fm 5 california proposition 65 warning combustion exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the state of california to cause cancer and birth defects or other reproductive harm. Laws pertaining to spark arreste...

  • Page 6: Foreword

    Foreword gp 4000 6 wc_tx003404gb.Fm.

  • Page 7: Table of Contents

    Wc_bo5000192915_02toc.Fm 7 table of contents gp 4000 foreword 3 1 safety information 9 1.1 signal words used in this manual ....................................................... 9 1.2 machine description and intended use ............................................. 10 1.3 operating safety ..........

  • Page 8: Table of Contents

    8 wc_bo5000192915_02toc.Fm table of contents gp 4000 5 maintenance 42 5.1 maintaining the emission control system ...........................................42 5.2 periodic maintenance schedule ..........................................................42 5.3 engine oil .................................

  • Page 9: Gp 4000

    Wc_si000791gb.Fm 9 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 10: Safety Information

    Wc_si000791gb.Fm 10 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. Th...

  • Page 11: Gp 4000

    Wc_si000791gb.Fm 11 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 dev...

  • Page 12: Safety Information

    Wc_si000791gb.Fm 12 safety information gp 4000 application area be aware of the application area. Keep unauthorized personnel, children, and pets away from the machine. Remain aware of changing positions and the movement of other equipment and personnel in the application area/job site. Be aware of ...

  • Page 13: Gp 4000

    Wc_si000791gb.Fm 13 gp 4000 safety information installing as backup power special hazards exist when installing this machine as a backup power supply. Improper connection of generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines. Th...

  • Page 14: Safety Information

    Wc_si000791gb.Fm 14 safety information gp 4000 = after use 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. Cleaning when cleaning and servicing the machine: keep the machine clean and free of debris such as lea...

  • Page 15: Gp 4000

    Wc_si000791gb.Fm 15 gp 4000 safety information 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 16: Safety Information

    Wc_si000791gb.Fm 16 safety information gp 4000 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 17: Gp 4000

    Wc_si000791gb.Fm 17 gp 4000 safety information 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 18: Labels

    Wc_si000792gb.Fm 18 labels gp 4000 2 labels 2.1 label locations wc_gr010975 a b c d e f j k h l g.

  • Page 19: Gp 4000

    Wc_si000792gb.Fm 19 gp 4000 labels 2.2 label meanings a engine choke control b warning hot surface c 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 regulat...

  • Page 20: Labels

    Wc_si000792gb.Fm 20 labels gp 4000 e notice lifting point f emission control information this equipment meets u.S. Epa evap standards. Evaporative family: cw1xnheqcl2 g important emissions information this equipment meets california evp emission regulations for small off-road engines. H — — use only...

  • Page 21: Gp 4000

    Wc_si000792gb.Fm 21 gp 4000 labels — 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 carbon monoxide. This is...

  • Page 22: Labels

    Wc_si000792gb.Fm 22 labels gp 4000 — warning to reduce the risk of electrical shock and arc flash, read the operator’s manual. Improper connection of the generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines. This may result in ele...

  • Page 23: Gp 4000

    Wc_tx003405gb.Fm 23 gp 4000 lifting and transporting 3 lifting and transporting lifting the machine this generator, while compact, is heavy enough to cause injury if proper lifting techniques are not used. Observe the following guidelines when lifting the generator. Do not attempt to lift and carry ...

  • Page 24: Operation

    Wc_tx003406gb.Fm 24 operation gp 4000 4 operation 4.1 preparing the machine for first use 1. Make sure all loose packaging materials have been removed from the machine. 2. Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your wacker neu...

  • Page 25: Gp 4000

    Wc_tx003406gb.Fm 25 gp 4000 operation 4.2 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 conventio...

  • Page 26: Operation

    Wc_tx003406gb.Fm 26 operation gp 4000 4.3 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. 1. Remove the fuel cap. 2. Fill the fuel tank until the fuel level ...

  • Page 27: Gp 4000

    Wc_tx003406gb.Fm 27 gp 4000 operation 4.4 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 28: Operation

    Wc_tx003406gb.Fm 28 operation gp 4000 4.5 positioning the generator for operation requirements position the generator according to the following requirements. These instructions continue on the next page. Danger carbon monoxide. Using a generator indoors can kill you in minutes. Generator exhaust co...

  • Page 29: Gp 4000

    Wc_tx003406gb.Fm 29 gp 4000 operation continued from the previous page. Do not operate the generator anywhere inside a home or building. This includes the garage (c), entryway, porch, or sunroom (d), living area or work space (e), or basement or crawl space (f). Operating the generator inside a home...

  • Page 30: Operation

    Wc_tx003406gb.Fm 30 operation gp 4000 4.6 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. 1. Hoist the generator, and align the axle (c) with the lower cross-member of frame. 2....

  • Page 31: Gp 4000

    Wc_tx003406gb.Fm 31 gp 4000 operation wc_gr010938 a b c d e f g h j k l m n o p 1 l l n.

  • Page 32: Operation

    Wc_tx003406gb.Fm 32 operation gp 4000 4.7 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 33: Gp 4000

    Wc_tx003406gb.Fm 33 gp 4000 operation 4.8 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 34: Operation

    Wc_tx003406gb.Fm 34 operation gp 4000 4.10 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 inc...

  • Page 35: Gp 4000

    Wc_tx003406gb.Fm 35 gp 4000 operation 4.11 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 36: Operation

    Wc_tx003406gb.Fm 36 operation gp 4000 4.12 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. 1. Press “test” button (a). Green led sho...

  • Page 37: Gp 4000

    Wc_tx003406gb.Fm 37 gp 4000 operation 4.13 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 38: Operation

    Wc_tx003406gb.Fm 38 operation gp 4000 4.16 voltage selector the voltage selector switch (a) 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 (b) and duplex receptacles (c1, c2). The full rated power of the g...

  • Page 39: Gp 4000

    Wc_tx003406gb.Fm 39 gp 4000 operation 4.17 before starting 1. Read and understand the safety and operating labels and instructions at the beginning of this manual. 2. Inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 3. Check: oil level in engine fuel ...

  • Page 40: Operation

    Wc_tx003406gb.Fm 40 operation gp 4000 4.18 starting before starting, be sure you read and understand all the safety and operating instructions in this manual. 1. Ensure that the generator is properly installed in an outdoor location. See sections installation and operator safety while using internal...

  • Page 41: Gp 4000

    Wc_tx003406gb.Fm 41 gp 4000 operation 4.19 stopping 1. Turn off and disconnect all tools and appliances attached to the generator. 2. Place the main circuit breaker in the off position (a2). 3. Place the engine switch to off (b2). 4. Close the fuel valve (d2). Note: to stop the engine quickly in an ...

  • Page 42: Maintenance

    Wc_tx003407gb.Fm 42 maintenance gp 4000 5 maintenance 5.1 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 43: Gp 4000

    Wc_tx003407gb.Fm 43 gp 4000 maintenance 5.3 engine oil 1. Drain the oil while the engine is still warm. 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 an...

  • Page 44: Maintenance

    Wc_tx003407gb.Fm 44 maintenance gp 4000 5.4 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. To service: 1. Remove the air cleaner cover (a). Inspect the element (b) ...

  • Page 45: Gp 4000

    Wc_tx003407gb.Fm 45 gp 4000 maintenance 5.5 spark plug clean or replace the spark plug as needed to ensure proper operation. Refer to your 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 ...

  • Page 46: Maintenance

    Wc_tx003407gb.Fm 46 maintenance gp 4000 5.6 storage before storing the generator for a long period of time: 1. Close the fuel valve and remove and empty the sediment cup or fuel strainer. 2. Disconnect the fuel line from the carburetor. Place the open end of the fuel line into a suitable container a...

  • Page 47: Gp 4000

    Wc_tx003408gb.Fm 47 gp 4000 troubleshooting 6 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 when st...

  • Page 48: Technical Data

    Wc_td000566gb.Fm 48 technical data gp 4000 7 technical data 7.1 generator machine 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 recepta...

  • Page 49: Gp 4000

    Wc_td000566gb.Fm 49 gp 4000 technical data 7.2 engine engine power rating net power rating per sae j1349. Actual power output may vary due to conditions of specific use. Machine gp 4000 engine engine type 4-stroke, overhead valve, single cylinder engine make wacker neuson engine model wm 270 max. Ra...

  • Page 50: Technical Data

    Wc_td000566gb.Fm 50 technical data gp 4000 notes.

  • Page 51

    Emission control systems information and warranty wc_tx001773gb.Fm 51 8 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. 8.1 emission control system background information introductio...

  • Page 52

    Emission control systems information and warranty 52 wc_tx001773gb.Fm 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...

  • Page 53

    Emission control systems information and warranty wc_tx001773gb.Fm 53 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. System...

  • Page 54

    Emission control systems information and warranty 54 wc_tx001773gb.Fm evaporative emissions 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, mi...

  • Page 55

    Emission control systems information and warranty wc_tx001773gb.Fm 55 owner’s warranty responsibility the engine/equipment owner is responsible for the performance of the required maintenance listed in the wacker neuson engine/equipment operator’s manual. Wacker neuson recommends that all receipts c...

  • Page 56

    Emission control systems information and warranty 56 wc_tx001773gb.Fm 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...

  • Page 57

    Emission control systems information and warranty wc_tx001773gb.Fm 57 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. What is covered the repair or r...

  • Page 58

    Emission control systems information and warranty 58 wc_tx001773gb.Fm 8.4 california exhaust emission control warranty statement.

  • Page 59

    Emission control systems information and warranty wc_tx001773gb.Fm 59.

  • Page 60

    Emission control systems information and warranty 60 wc_tx001773gb.Fm.

  • Page 61

    Schematics wc_tx003409gb.Fm 61 9 schematics.

  • Page 62

    Schematics gp 4000 62 wc_tx003409gb.Fm 9.1 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...

  • Page 63

    Gp 4000 schematics wc_tx003409gb.Fm 63 9.2 wire colors 9.3 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 a generator d...

  • Page 64

    Schematics gp 4000 64 wc_tx003409gb.Fm 9.4 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...

  • Page 65

    Gp 4000 schematics wc_tx003409gb.Fm 65 9.5 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 aut...

  • Page 66

    Schematics gp 4000 66 wc_tx003409gb.Fm 9.6 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 ...

  • Page 68

    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...