0171947en 0609 Generator GP 4000 Non-CARB OPERATOR’S MANUAL 0 1 7 1 9 4 7 E N 002
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.
1. Foreword 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.
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GP 4000 1. Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 1.5 1.6 2. Table of Contents Laws Pertaining to Spark Arresters ...................................................... 7 Operating Safety .................................................................................. 8 Operator Safety while using Internal Combustion Engines .................. 9 Service Safety .................................................................................... 11 Label Locations .........................
Table of Contents 3. Maintenance 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 4. GP 4000 32 Engine Maintenance ............................................................................32 Periodic Maintenance Schedule ..........................................................32 Engine Oil ............................................................................................33 Servicing Air Cleaner ...........................................................................34 Spark Plug ....
GP 4000 1. Safety Information 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.
Safety Information 1.2 GP 4000 Operating Safety DANGER DANGER WARNING 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 doors and windows are open. Only use this generator OUTSIDE and far away from windows, doors, and vents.
GP 4000 1.3 Safety Information 1.2.8 NEVER allow untrained personnel to operate or service the generator. The generator set should be set up by a certified electrician. 1.2.9 NEVER stand on the machine. 1.2.10 DO NOT stand under the machine while it is being hoisted or moved. 1.2.11 DO NOT attach equipment to the machine when it is suspended. 1.2.12 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. 1.2.
Safety Information 1.3.9 GP 4000 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. 1.3.10 Refill the fuel tank in a well-ventilated area. 1.3.11 Replace the fuel tank cap after refueling. 1.3.12 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.
GP 4000 1.4 Safety Information Service Safety WARNING Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. If the generator is experiencing problems or is being serviced, attach a “DO NOT START” sign to the control panel to notify other people of its condition. 1.4.
Safety Information Label Locations GND 12 88897 1.
GP 4000 1.6 Safety Information Safety and Operating Labels Wacker Neuson machines use international pictorial labels where needed. These labels are described below: Label Meaning WARNING! Hot surface! CAUTION Lifting point. GND 88897 Electrical ground Press circuit breaker switch to OFF position. Check the fuel level.
Safety Information Label GP 4000 Meaning Open the fuel flow valve. Press engine switch to ON position. GPS - Press ignition switch. GP - Pull the rewind starter. Press circuit breaker switch to ON position. Press engine switch to OFF position. Close the fuel flow valve. 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.
GP 4000 Label Safety Information Meaning 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 generator to backfeed into utility lines. This may result in electrocution of utility workers, fire, or explosion.
Safety Information Label GP 4000 Meaning DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling. Read the Operator’s Manual for machine information. GFCI TEST INSTRUCTIONS - TEST BEFORE EACH USE Normal operating state - sensing device green LED is "ON" and circuit breaker is at "ON" position. Step 1: Press "TEST" button. Green LED should go "OUT" and red LED should come "ON" and circuit breaker should trigger to "OFF" position.
GP 4000 Safety Information Notes: 17
Operation 2. GP 4000 Operation 2.1 Determining Power Requirements This generator is designed to operate single-phase, 60 Hz appliances running at 120 VAC or 240 VAC. Check the nameplate or label provided on tools and appliances to make sure their power requirements match the power output of the generator. Some appliances and tools require a surge of current when starting. This means that the amount of power needed to initially start the equipment is larger than the power required to keep it running.
GP 4000 2.2 Operation 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. DANGER DANGER Using a generator indoors CAN KILL YOU IN MINUTES.
Operation 2.3 GP 4000 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. 2.3.1 Hoist the generator, and align the axle (c) with the lower cross-member of frame. 2.3.2 Insert the axle brackets (k) over the axle and align the holes found in the axle bracket to the holes of the cross-member. Ensure that the brackets extend under the tube of the frame. 2.3.
GP 4000 Operation 21
Operation 2.4 GP 4000 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.
GP 4000 2.5 Operation 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. wc_gr000544 2.6 Operating Heavy Loads Limit operations requiring the maximum rated output of 4000 W to 20– 30 minutes. For continuous operation do not exceed the continuous rated output of 3600 W.
Operation 2.7 GP 4000 Use of Extension Cords WARNING Current 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.
GP 4000 2.8 Ref. Operation Control Panel Description Ref.
Operation 2.9 GP 4000 Ground Fault Circuit Interrupter (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. 2.9.1 Press “TEST” button (g). Green LED should go “OUT” and red LED should come “ON” and circuit breaker should trigger to “OFF” position (d). 2.9.2 If sensing device LED or breaker does not trip or change state, “DO NOT USE”.
GP 4000 Operation 2.10 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. 2.11 Engine Auto Idle The auto idle switch (b) automatically reduces engine speed approximately 7 seconds after all appliances or tools attached to the generator have been turned off.
Operation GP 4000 2.13 Voltage Selection 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. In dual voltage mode both the 120V and 120/240V receptacles are powered; lower watts are available on receptacles (f1, f2, c).
GP 4000 Operation 2.14 Before Starting 2.14.1 Read and understand the safety and operating labels and instructions at the beginning of this manual. 2.14.2 Inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 2.14.3 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.
Operation GP 4000 2.15 To Start Before starting, be sure you read and understand all the safety and operating instructions in this manual. 2.15.1 Ensure that the generator is properly installed in an outdoor location. See Sections Installation and Operator Safety while using Internal Combustion Engines for installation warnings and safety guidelines. 2.15.2 Disconnect all loads from the generator and place the main breaker in the "OFF" position (a2). 2.15.3 Set the Auto Idle Switch (c) to "OFF". 2.15.
GP 4000 Operation 2.16 To Stop 2.16.1 Turn off and disconnect all tools and appliances attached to the generator. 2.16.2 Place the main circuit breaker in the OFF position (a2). 2.16.3 Place the engine switch to OFF (b2). 2.16.4 Close the fuel valve (d2). Note: To stop the engine quickly in an emergency, turn the engine switch to OFF (b2).
Maintenance 3. GP 4000 Maintenance 3.1 Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to your engine operator’s manual for additional information on engine maintenance. 3.2 Periodic Maintenance Schedule Daily before starting Check the fuel level. Check the engine oil level. Inspect the air filter. Replace as needed. Check external hardware. After first 20 hrs. Clean the air cleaner element.* Every 50 hrs. Every 100 hrs. Every 300 hrs.
GP 4000 3.3 Maintenance Engine Oil 3.3.1 Drain the oil while the engine is still warm. 3.3.2 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. 3.3.3 Install the drain plug. 3.3.
Maintenance 3.4 GP 4000 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: 3.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 3.4.
GP 4000 3.5 Maintenance 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. 3.5.1 Remove the spark plug and inspect it. 3.5.
Maintenance 3.6 GP 4000 Storage Before storing the generator for a long period of time: 3.6.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 3.6.2 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. WARNING 3.7 Gasoline is extremely flammable. Drain the fuel tank in a wellventilated area. DO NOT drain the fuel tank in an area with flames or sparks. 3.6.
GP 4000 3.8 Maintenance 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 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.
Maintenance GP 4000 3.10 Electrical Schematic Ref. Description A Generator B Control box Ref. Description Ref. D Ref.
GP 4000 Maintenance 39
Maintenance GP 4000 3.11 Electrical Schematic (CAN models only) Ref. Description A Generator B Control box Ref. Description Ref. D Ref.
GP 4000 Maintenance 41
Maintenance GP 4000 3.12 Engine Schematic Ref. Description Ref. A Generator D B Control box C Electric start engines (GPS) Ref.
GP 4000 Maintenance 43
Technical Data 4. GP 4000 Technical Data 4.1 Generator Item No. GP 4000 0620380 0620090 Generator Maximum Output W 4000 Continuous Output W 3600 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 20 Main Circuit Breaker amp 2-pole, 17 amp each pole LxWxH mm (in.
GP 4000 4.2 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 4000 0620380 0620090 Engine Engine Type 4-stroke, overhead valve, single cylinder Engine Make Wacker Neuson Engine Model WM 270 Max. Rated Power @ Rated Speed kW (Hp) 6.6 (9) @ 4000 rpm Spark Plug Electrode Gap (NGK) BR 6HS Champion RL86C 0.6–0.7 (0.024–0.028) mm (in.
Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · 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.
