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Summary of Contents for Wacker Neuson GP 4000
- Page 1 Operator’s Manual Portable Generator GP 4000 5000192915 0512...
- Page 2 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.
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Page 3: Foreword
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.
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Page 5: Table Of Contents
GP 4000 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 ....12 Service Safety ..................13 Labels Label Locations .................. - Page 6 Generator ....................42 Engine ....................43 Emission Control Systems Information and Warranty Emission Control System Background Information ......44 Limited Defect Warranty for Wacker Neuson Emission Control Systems ....................45 California Evaporative Emission Control Warranty Statement ....49 California Exhaust Emission Control Warranty Statement ....51 Schematics Wire Colors ..................54...
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Page 7: Safety Information
GP 4000 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. -
Page 8: Machine Description And Intended Use
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. -
Page 9: Operating Safety
Familiarize yourself with the location and proper use of all controls and safety devices. Contact Wacker Neuson for additional training if necessary. When operating this machine: Do not allow improperly trained people to operate the machine. People operating the machine must be familiar with the potential risks and hazards associated with it. - Page 10 Do not operate the machine if any safety devices or guards are missing or inoperative. Do not modify or defeat the safety devices. Only use accessories or attachments that are approved by Wacker Neuson. Safe When operating this machine: operating Remain aware of the machine’s moving parts.
- Page 11 GP 4000 Safety Information Transporting Never allow untrained personnel to operate or service the generator. The and installing generator set should be set up by a certified electrician. the machine Do not stand under the machine while it is being hoisted or moved.
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Page 12: Operator Safety While Using Internal Combustion Engines
Safety Information 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. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. -
Page 13: Service Safety
Machine When servicing or maintaining the machine: modifications Use only accessories/attachments that are approved by Wacker Neuson. When servicing or maintaining the machine: Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker Neuson. - Page 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.
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Page 15: Labels
GP 4000 Labels Labels Label Locations wc_gr003142 Label Meanings Wacker Neuson machines use international pictorial labels where needed. These labels are described below. Engine Choke Control WARNING! Hot surface wc_si000557gb.fm... - Page 16 Labels GP 4000 — 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 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.
- Page 18 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.
- Page 19 GP 4000 Labels This machine may be covered by one or more patents. WARNING! Test GFCI before each use. See label above. Important Emissions Information This equipment meets California EVP emission regulations for small off-road engines. Emission Control Information This equipment meets U.S. EPA EVAP standards.
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Page 20: 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 21: Recommended Fuel
Before using an oxygenated fuel, confirm the fuel's contents. Some states and provinces require this information to be posted on the fuel pump. The following is the Wacker Neuson approved percentage of oxygenates: - (ethyl or grain alcohol) 10% by volume. You may use... -
Page 22: Refueling The Machine
Operation 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. -
Page 23: 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 24: Installation
Operation 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. - Page 25 GP 4000 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.
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Page 26: Generator Derating
Operation 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. -
Page 27: Grounding The Generator
GP 4000 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... -
Page 28: Use Of Extension Cords
Operation GP 4000 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 29: Control Panel
GP 4000 Operation 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 20A circuit breaker (CAN only) Voltage Selector Switch... -
Page 30: Ground Fault Interrupt (Gfi / Gfci)
Operation GP 4000 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. -
Page 31: Twist-Lock Receptacles
GP 4000 Operation 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. -
Page 32: Voltage Selector Switch
Operation GP 4000 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 33: Before Starting
GP 4000 Operation 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 34: Starting
Operation GP 4000 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 Internal Combustion Engines for installation warnings and safety guidelines. -
Page 35: Stopping
GP 4000 Operation 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). -
Page 36: 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 37: Engine Oil
GP 4000 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. -
Page 38: Servicing The Air Cleaner
Maintenance 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. -
Page 39: Spark Plug
GP 4000 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. -
Page 40: Long-Term Storage
Maintenance 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. -
Page 41: Troubleshooting
GP 4000 Maintenance 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 42: Technical Data
Technical Data GP 4000 Technical Data Generator Item No. GP 4000 Generator Maximum Output 4000 Continuous Output 3600 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages Available 120 / 240 volts phase 1ø Frequency Power Factor AC receptacles:... -
Page 43: Engine
GP 4000 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... -
Page 44: 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 45: 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 46 Emission Control Systems Information and Warranty applicable EPA regulations. All defective parts replaced under this warranty become property of Wacker Neuson. Exhaust Emissions Systems Covered Components Fuel metering system Carburetor and internal parts Air/fuel ratio feedback system (if applicable) Cold start enrichment system...
- Page 47 The engine/equipment must be presented to an authorized Wacker Neuson dealer/ service center as soon as a problem exists. Contact Wacker Neuson Product Support Department (1-800-770-0957) or visit wackerneuson.com to find a dealer/ service center in your area, or to answer questions regarding warranty rights and responsibilities.
- Page 48 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.
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Page 49: California Evaporative Emission Control Warranty Statement
Wacker Neuson at no charge to you. The owner shall not be charged for diagnostic labor that leads to determination that a warranted part is in fact defective, provided that such diagnostic work is performed at a Wacker Neuson authorized service center. - Page 50 What is covered The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if Wacker Neuson demonstrates that the portable generator has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part.
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Page 51: California Exhaust Emission Control Warranty Statement
Emission Control Systems Information and Warranty California Exhaust Emission Control Warranty Statement wc_tx001773gb.fm... - Page 52 Emission Control Systems Information and Warranty wc_tx001773gb.fm...
- Page 53 Notes wc_tx001778gb.fm...
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Page 54: Schematics
Schematics GP 4000 Schematics Wire Colors Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Light blue US Machines—Electrical Schematic Components Ref. Description Ref. Description Generator Wacker Neuson Engine Control box Ref. Description Ref. -
Page 55: Us Machines-Electrical Schematic
GP 4000 Schematics US Machines—Electrical Schematic WHT 18 AWG WHT 18 AWG BLK 18 AWG BLK 18 AWG YEL 18 AWG YEL 18 AWG 18 18 LOAD LOAD LINE LINE 3 BRN 3 BRN 70 BRN 12 AWG 70 BRN 12 AWG... -
Page 56: Csa Machines-Electrical Schematic Components
Schematics GP 4000 CSA Machines—Electrical Schematic Components Ref. Description Ref. Description Generator Wacker Neuson Engine Control box Ref. Description Ref. Description Main stator winding 1 Rectifier Main stator winding 2 Rotor winding/brushes Auto idle unit Secondary (excitation) winding Main circuit breaker... -
Page 57: Csa Machines-Electrical Schematic
GP 4000 Schematics CSA Machines—Electrical Schematic WHT 18 AWG WHT 18 AWG BLK 18 AWG BLK 18 AWG YEL 18 AWG YEL 18 AWG 18 18 3 BRN 3 BRN LINE LINE 22 BRN 22 BRN 21 BRN 12AWG 21 BRN 12AWG... -
Page 58: Engine Wiring
Schematics GP 4000 Engine Wiring Ref. Description Ref. Description Generator Wacker Neuson Engine Control box Electric start engines (GPS) Ref. Description Idle solenoid Spark plug Oil level sender Oil level switch Coil wc_gr008240 wc_tx001778gb.fm... - Page 60 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...