Wacker Neuson GP 4000 Operator'S Manual Download Page 2 | Manualshive

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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 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. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their
respective owners.

Manufacturer

Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com

Original instructions

This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.

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Summary of Contents for 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: ...distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights Violators will be prosecuted Trademarks All trademarks referenced in this manual are...

Page 3: ...R use a generator inside homes buildings garages crawlspaces or other partly enclosed areas Deadly levels of carbon monoxide can build up in these areas Using a fan or opening windows and doors does N...

Page 4: ...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 E...

Page 5: ...ding spark arresters consult the engine distributor or the local Health and Safety Administrator Manufacturer s approval This manual contains references to approved parts attachments and modifica tion...

Page 6: ...Foreword GP 4000 6 wc_tx003404gb fm...

Page 7: ...24 4 1 Preparing the Machine for First Use 24 4 2 Recommended Fuel 25 4 3 Refueling the Machine 26 4 4 Determining Power Requirements 27 4 5 Positioning the Generator for Operation 28 4 6 Wheel Kit 3...

Page 8: ...Systems Information and Warranty 51 8 1 Emission Control System Background Information 51 8 2 Limited Defect Warranty for Wacker Neuson Emission Control Systems 52 8 3 California Evaporative Emission...

Page 9: ...personal hazards f Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury f To avoid death or seriou...

Page 10: ...ts that are incompatible with the generator output Overloading the generator with a load that draws excessive power during either continuous running or start up Operating the generator in a manner tha...

Page 11: ...INUTES 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 c...

Page 12: ...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 Saf...

Page 13: ...d earthen ground per national and local regulations Always remove all tools cords and other loose items from the generator before starting it General Safety Do not operate the generator when open cont...

Page 14: ...reach of children 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 c...

Page 15: ...e if fuel leaks are present or the fuel lines are loose Do not run the engine near open flames Do not start the engine if fuel has spilled or a fuel odor is present Move the generator away from the sp...

Page 16: ...rate the machine with a known problem or deficiency All repairs and adjustments shall be completed by a qualified technician Turn off the machine before performing maintenance or making repairs Remain...

Page 17: ...aining this machine Close fitting work clothes that do not hinder movement Safety glasses with side shields Hearing protection Safety toed footwear In addition before servicing or maintaining the mach...

Page 18: ...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: ...ing 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 St...

Page 20: ...s 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: ...r 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 Only operate...

Page 22: ...ical current from the generator to backfeed into utility lines This may result in electrocution of utility workers fire or explosion Connections to a building s electrical system must be made by a qua...

Page 23: ...ached securely and has enough weight bearing capacity to lift or hold the generator safely Remain aware of the location of other people nearby when lifting the generator Transporting the machine Obser...

Page 24: ...are breathing CO But even if you cannot smell the exhaust you could be breathing CO f NEVER use a generator inside homes buildings garages crawlspaces or other partly enclosed areas Deadly levels of c...

Page 25: ...el 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 ETHANOL ethyl or gr...

Page 26: ...o refuel the machine is now complete 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 refu...

Page 27: ...er or dealer of the tool or appliance with questions regarding its power requirements NOTICE If a tool or appliance does not reach full speed within a few seconds when switched on turn it off immediat...

Page 28: ...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...

Page 29: ...gs windows doors and vents Also point the engine exhaust away from combustible materials Position the generator on firm level ground so that it will not slide or shift CO Detectors Alarms Install CO d...

Page 30: ...of the axle and separate the legs of the pins 7 Align the holes found in the leg bracket b to the holes of the lower cross member 8 Insert M6 x 16 screws l through the outer holes on the cross member...

Page 31: ...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: ...so affects the cooling capacity of air the higher the altitude the less dense the air is and thus the lower its ability to transfer heat For every increase in altitude of 500 m 1650 ft above 1000 m 33...

Page 33: ...local agency having jurisdiction over electrical compliance If the generator is used at a construction site there may be additional regulations which must be observed In some areas generators are req...

Page 34: ...ss Damaged extension cords can cause electrical shock resulting in serious injury or death DO NOT use worn bare or frayed cords Replace damaged cords immediately Use the chart below as a guide for sel...

Page 35: ...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...

Page 36: ...at ON position 1 Press TEST button a Green LED should go OUT and red LED should come ON and circuit breaker should trigger to OFF position b 2 If sensing device LED or breaker does not trip or change...

Page 37: ...ull speed when a tool or appliance is turned back on To turn the auto idle feature on push the auto idle switch to AUTO The AUTO setting is recommended while the generator is running to minimize fuel...

Page 38: ...cles In dual voltage mode both the 120V and 120 240V receptacles are powered lower watts are available on receptacles c1 c2 b The 120 240V twist lock receptacle d should be used in dual mode only To a...

Page 39: ...in the engine drops too low the engine will not start 4 Fill the fuel tank with fresh regular unleaded grade gasoline DO NOT use an oil gas mixture The use of gasohol or any fuel containing more than...

Page 40: ...main breaker in the OFF position a2 3 Set the Auto Idle Switch c to OFF 4 Open the fuel valve d1 Note If the engine is cold move the choke lever to the closed position e2 If the engine is hot set the...

Page 41: ...4 Close the fuel valve d2 Note To stop the engine quickly in an emergency turn the engine switch to OFF b2 4 20 Emergency Shutdown Procedure Procedure If a breakdown or accident occurs while the mach...

Page 42: ...table below lists basic machine and engine maintenance Tasks designated with check marks may be performed by the operator Tasks designated with square bullet points require special training and equipm...

Page 43: ...environmental protection legislation 3 Install the drain plug 4 Fill the engine crankcase with the recommended oil up to the level of the plug opening c See section Technical Data for oil quantity an...

Page 44: ...the element b for holes or tears Replace the element if it is damaged 2 Wash the foam element b in a solution of mild detergent and warm water Rinse it thoroughly in clean water Allow the element to d...

Page 45: ...ine Do not touch the muffler while it is hot Note Refer to section Technical Data for the recommended spark plug type and the electrode gap setting 1 Remove the spark plug and inspect it 2 Replace the...

Page 46: ...tank in a well ventilated area Do not drain the fuel tank in an area with flames or sparks 3 Loosen the drain screw on the carburetor and drain any remaining fuel from the carburetor 4 Change the eng...

Page 47: ...ap is tight Engine oil level is adequate If engine starts but there is no power at receptacles check that Circuit breaker is closed Connector from generator to control panel is tight If engine starts...

Page 48: ...Dual voltage single phase Auto voltage regulator system AC voltages available volts phase 120 240 1 Frequency Hz 60 Power factor 1 0 AC receptacles 125V duplex 125V duplex 125V twist lock 125V 250V t...

Page 49: ...ke Wacker Neuson Engine model WM 270 Max rated power rated speed kW hp 6 6 9 4000 rpm Spark plug NGK BR 6HS Champion RL86C Electrode gap mm in 0 6 0 7 0 024 0 028 Operating speed rpm 3600 Air cleaner...

Page 50: ...wc_td000566gb fm 50 Technical Data GP 4000 Notes...

Page 51: ...time of purchase Exhaust Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under ce...

Page 52: ...warranted parts during the warranty period Limited Defect Warranty Period for Wacker Neuson Emission Control Systems The warranty period for this engine equipment begins on the date of sale to the ini...

Page 53: ...al parts Air fuel ratio feedback system if applicable Cold start enrichment system if applicable Regulator assembly if applicable Exhaust system Catalytic muffler if applicable Exhaust manifold if app...

Page 54: ...sted in the maintenance section of the engine equipment operator s manual such as spark plugs and filters Incidental or consequential damages such as loss of time or the use of the engine equipment or...

Page 55: ...ill be advised of the appropriate dealer service center where warranty repair can be performed All repairs qualifying under this limited warranty must be performed by an authorized Wacker Neuson deale...

Page 56: ...d part that is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repair or replace as necessary shall be warranted for two years...

Page 57: ...en 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 That notwithstanding any adjustm...

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: ...AWG 71 BRN 12 AWG LINE LINE ORG ORG 18 18 AWG AWG 102 BRN 102 BRN 5 BRN 5 BRN 43 BLU 16 AWG 43 BLU 16 AWG 72 BRN 72 BRN GRN YEL GRN YEL 42 BLU 42 BLU 73 BRN 73 BRN 40 BLU 40 BLU 70 BRN 12 AWG 70 BRN...

Page 63: ...D Wacker Neuson Engine B Control box Ref Description Ref Description 1 Main stator winding 1 12 Engine ON OFF switch 2 Main stator winding 2 13 Rectifier 3 Auto idle unit 14 Rotor winding brushes 4 M...

Page 64: ...N 12 AWG 12 AWG 8 BLU 8 BLU 28 BRN 12 AWG 28 BRN 12 AWG 101 BLU 101 BLU 29 BRN 29 BRN LINE LINE LOAD LOAD ORG ORG 18 18 AWG AWG 5 BRN 5 BRN 102 BRN 102 BRN 43 BLU 16 AWG 43 BLU 16 AWG 20A 20A 24 BRN 2...

Page 65: ...nding brushes 3 Auto idle unit 15 Secondary excitation winding 4 Main circuit breaker 16 DC winding 5 Voltage selector switch 120 240V position shown 17 Automatic voltage regulator AVR 6 Duplex recept...

Page 66: ...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...

Page 67: ......

Page 68: ...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 G...

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