Operator’s Manual Portable Generator GP 4000 EN 5000192915 5 0 0 0 01 1 9 0512 2 9 1 5
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 permission from Wacker Neuson Production Americas LLC. Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights.
Foreword 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).
Foreword Manufacturer’s This manual contains references to approved parts, attachments, and modificaapproval tions. The following definitions apply: Approved parts or attachments are those either manufactured or provided by Wacker Neuson. Approved modifications are those performed by an authorized Wacker Neuson service center according to written instructions published by Wacker Neuson. Unapproved parts, attachments, and modifications are those that do not meet the approved criteria.
GP 4000 1 Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 1.5 2 Signal Words Used in this Manual ....................................................... 7 Machine Description and Intended Use ............................................... 8 Operating Safety .................................................................................. 9 Operator Safety while Using Internal Combustion Engines ............... 12 Service Safety ......................................................................
Table of Contents 4 Maintenance 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5 Maintaining the Emission Control System ...........................................36 Periodic Maintenance Schedule ..........................................................36 Engine Oil ............................................................................................37 Servicing the Air Cleaner .....................................................................38 Spark Plug ...................................................
GP 4000 1 1.1 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. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.
Safety Information 1.2 GP 4000 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 control panel includes controls and receptacles. As the engine runs, the generator converts mechanical energy into electric power. The operator connects loads to the electric power receptacles.
GP 4000 1.3 Safety Information Operating Safety 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. f NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Safety Information Safety devices, controls, and attachments GP 4000 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 Manual. The machine is clean. The machine’s labels are legible. To ensure safe operation of the machine: Do not operate the machine if any safety devices or guards are missing or inoperative.
GP 4000 Transporting and installing the machine Safety Information General Safety Generator vibration After use = Cleaning 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 equipment to the machine when it is suspended. Always transport the generator in an upright position.
Safety Information 1.4 GP 4000 Operator Safety while Using Internal Combustion Engines WARNING Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety standards could result in severe injury or death. f Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. DANGER f Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO).
GP 4000 1.5 Safety Information 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 devices. Only trained personnel shall troubleshoot or repair problems occurring with the machine. Contact Wacker Neuson for additional training if necessary.
Safety Information Cleaning GP 4000 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 other types of fuels or flammable solvents to clean the machine. Fumes from fuels and solvents can become explosive.
GP 4000 2 2.1 Labels Labels Label Locations B G C A E N M F L J K D wc_gr003142 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_si000557gb.
Labels GP 4000 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" 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 Labels — 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 carbon monoxide. This is a poison you cannot see or smell. — wc_si000557gb.fm NEVER use inside a home or garage, EVEN IF doors and windows are open.
Labels GP 4000 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.
GP 4000 Labels 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 equipment meets U.S. EPA EVAP standards. Evaporative Family: CWIXNHEQCL2 wc_si000557gb.
Operation 3 GP 4000 Operation 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. f NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
GP 4000 3.1 Operation 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 conventional gasolines are blended with alcohol. These gasolines are collectively referred to as oxygenated fuels. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requirement.
Operation 3.2 GP 4000 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. WARNING Fire hazard. Fuel and its vapors are extremely flammable. Burning fuel can cause severe burns. f Keep all sources of ignition away from the machine while refueling. f Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner.
GP 4000 3.3 Operation 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.
Operation 3.4 GP 4000 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. 3.5 Wheel Kit The wheel kit (Part No.
GP 4000 wc_tx000788gb.fm Operation 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 (5.25 ft.lbs.).
Operation 3.6 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 3.7 Operation 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. 3.
Operation 3.9 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 3.10 Ref. Operation Control Panel 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 Selector Switch n 30A circuit breaker (CAN only) f Duplex receptacle - 120V wc_tx000788gb.
Operation 3.11 GP 4000 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 LED should go “OUT” and red LED should come “ON” and circuit breaker should trigger to “OFF” position (d). 3.11.2 If sensing device LED or breaker does not trip or change state, “DO NOT USE”. Consult an electrician for assistance. 3.
GP 4000 3.12 Operation 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 approximately 7 seconds after all appliances or tools attached to the generator have been turned off.
Operation 3.15 GP 4000 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. In dual voltage mode both the 120V and 120/240V receptacles are powered; lower watts are available on receptacles (f1, f2, c).
GP 4000 3.16 Operation Before Starting DANGER f 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. 3.16.1 Read and understand the safety and operating labels and instructions at the beginning of this manual. 3.16.
Operation 3.17 GP 4000 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 Internal Combustion Engines for installation warnings and safety guidelines. 3.17.2 Disconnect all loads from the generator and place the main breaker in the "OFF" position (a2). 3.17.3 Set the Auto Idle Switch (c) to "OFF". 3.17.
GP 4000 3.18 Operation 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 engine quickly in an emergency, turn the engine switch to OFF (b2). 3.19 Emergency Shutdown Procedure Procedure If a breakdown or accident occurs while the machine is operating, follow the procedure below: 3.19.
Maintenance 4 4.1 GP 4000 Maintenance 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/service center authorized by Wacker Neuson.
GP 4000 4.3 Maintenance 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. Dispose of this liquid in accordance with environmental protection legislation. 4.3.3 Install the drain plug. 4.3.
Maintenance 4.4 GP 4000 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. A fire or explosion could result. WARNING To service: 4.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 4.4.
GP 4000 4.5 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. 4.5.1 Remove the spark plug and inspect it. 4.5.
Maintenance 4.6 GP 4000 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 suitable container and open the fuel valve to drain the fuel from the tank. WARNING 4.7 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.
GP 4000 4.8 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.
Technical Data 5 GP 4000 Technical Data 5.1 Generator Item No. GP 4000 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.) 685 x 530 x 537 (27 x 21 x 21.
GP 4000 5.2 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 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.
Emission Control Systems Information and Warranty 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 Introduction Wacker Neuson spark-ignited engines/equipment must conform with applicable Environmental Protection Agency (EPA) and the State of California emissions regulations.
Emission Control Systems Information and Warranty 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. Altering or defeating the speed-adjusting mechanism causing the engine to operate outside its design parameters. 6.
Emission Control Systems Information and Warranty applicable EPA regulations. All defective parts replaced under this warranty become property of Wacker Neuson.
Emission Control Systems Information and Warranty 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, improper storage, accident and/or collision; the incorporation of, or any use of, add-on or modified parts, or unsuitable attachments, or the alteration of any part.
Emission Control Systems Information and Warranty 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.
Emission Control Systems Information and Warranty 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, (hereinafter “Wacker Neuson”), are pleased to explain the evaporative emission control system (EECS) warranty on your model year 2008 and later portable generator.
Emission Control Systems Information and Warranty 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.
Emission Control Systems Information and Warranty 6.4 California Exhaust Emission Control Warranty Statement wc_tx001773gb.
Emission Control Systems Information and Warranty 52 wc_tx001773gb.
Notes wc_tx001778gb.
Schematics 7 7.1 GP 4000 Schematics Wire Colors Wire Colors 7.2 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 US Machines—Electrical Schematic Components Ref. Description A Generator B Control box Ref. Description Ref. D Ref.
GP 4000 7.
Schematics 7.4 GP 4000 CSA Machines—Electrical Schematic Components Ref. Description A Generator B Control box Ref. Description Ref. D Ref.
GP 4000 CSA Machines—Electrical Schematic A WHT 18 AWG B BLK 18 AWG ORG 18 AWG YEL 18 AWG 3 BRN 22 BRN 21 BRN 12AWG LINE 4 1 BLK 5 BRN 20 8 BLU 8 BLU YEL 29 BRN 102 BRN 2 2 2 BRN 28 BRN 12 AWG 102 BRN 2 29 BRN 28 BRN 12 AWG 2 BRN 43 BLU 16 AWG RED LOAD 101 BLU 21 BRN 12 AWG 7.
Schematics Engine Wiring Description Ref. A Generator D B Control box C Electric start engines (GPS) A B Ref. Description 1 Idle solenoid 2 Spark plug 3 Oil level sender 4 Oil level switch 5 Coil Description Wacker Neuson Engine D WHT 1 WHT 3 ORG Ref. BLK/WHT 7.6 GP 4000 BLK C BLK 4 5 2 wc_gr008240 58 wc_tx001778gb.
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 Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
