We Power Your World! Owner’s Manual of Generator for GPG4000CW Green-Power America,LLC
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4000W Generator Topi c Page Limited Warrant y 3 S a fet y G u i d e l i n e s 5 G e n e r a l Pr e c a u t i o n s 6 Assembly and Installation 15 Operation 18 Inspection，Cleaning,Maintenance and Storage 23 Speci fications 30 G e n e r a l Pa r t s L i s t i n g 31 GREEN-POWER AMERICA，LLC（HEREINAFTER IN SHORT “GREEN-POWER” OR “GPA” ） 2
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4 000W Generator Green-Power Green-Pow
Owner’s Manual Safety Guidelines - Definitions This manual contains important information that you need to know and understand in order to protect YOUR SAFETY and to PREVENT EQUIPMENT PROBLEMS. The following symbols help you recognize this information. Please read the manual and pay attention to these sections. Save These Important Safety Instructions! Read and understand all of these safety instructions. Be sure to retain them for future use.
4 000W Generator General Precautions WARNING! FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE INJURY OR DEATH. CAUTION: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN ALSO RESULT IN DAMAGE TO THE TOOL AND/OR THE ITEM YOU ARE WORKING ON. DANGER CARBON MONOXIDE Using a generator indoors WILL KILL YOU IN MINUTES. Generator exhaust contains high levels of carbon monoxide (CO), a poisonous gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO.
Owner’s Manual General Precautions (cont’d) Gasoline and Oil (cont’d) • Fuel or oil spills must be cleaned up immediately. Dispose of fluids and cleaning materials as per any local, state, or federal codes and regulations. Store oily rags in a covered metal container. • Never store fuel or other flammable materials near the generator. • Do not smoke, or allow sparks, flames or other sources of ignition around the engine and fuel tank. Fuel vapors are explosive.
4 000W Generator General Precautions (cont’d) Work Area • Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. • Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Generators create sparks which may ignite the dust or fumes. • Keep bystanders, children, and visitors away while operating a generator. Provide barriers or shields as needed.
Owner’s Manual General Precautions (cont’d) Electrical Safety (cont’d) • All connections and conduits from the generator to the load must only be installed by trained and licensed electricians, and in compliance with all relevant local, state, and federal electrical codes and standards, and other regulations where applicable. • The generator must be earth-grounded for fixed installations in accordance with all relevant electrical codes and standards before operation.
4 000W Generator General Precautions (cont’d) Personal Safety (cont’d) • Avoid accidental starting. Make sure the power switch is in its “OFF” position, and disconnect the spark plug wire when not in use. • Remove adjusting keys or wrenches before turning the generator on. A wrench or a key that is left attached to a rotating part of the generator may result in personal injury. • Do not overreach. Keep proper footing and balance at all times. • Use safety equipment. Always wear eye protection.
Owner’s Manual General Precautions (cont’d) Servicing Maintain labels and name plates on the generator and engine. These carry important information. If unreadable or missing, contact our service center toll free immediately for a replacement. Generator service must be performed only qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. When servicing a generator, use only identical replacement parts.
4 000W Generator General Precautions (cont’d) Installation (cont’d) • If the generator is installed outdoors, it must be weatherproofed and should be soundproofed. It should not be run outdoors without protection to the generator and wiring conduit. • The generator might weigh over 100 lbs Two or more people should assist when moving or lifting this product. Never lift the generator using the engine or alternator lifting lugs.
Owner’s Manual General Precautions (cont’d) Mechanical (cont’d) • Do not operate the generator with safety guards removed. While the generator is running, do not attempt to reach around the safety guard for maintenance or any other reason. • Keep hands, arms, long hair, loose clothing, and jewelry away from moving parts. Be aware that when engine parts are moving fast they cannot be seen clearly. • Keep access doors on enclosures closed and locked when access is not required.
4 000W Generator General Precautions (cont’d) Extension Cord If an extension cord (not included) is used, make sure to use only UL approved cords having the correct gauge and length according to the following table: Nameplate Amps (@ full load) Cord Lengths 0 ft.- 50 ft. 50 ft.-100 ft. 100 ft.-150 ft. 150 ft.-200 ft. 0-5 5.1 - 8 16 AWG 16 AWG 16 AWG 14 AWG 12 AWG 10 AWG 12 AWG - 8.1 - 12 12.
Assembly and Installation Unpacking 1. Remove the generator and loose parts box from the carton. 2. Compare the Hardware Kit included with the inventory list below. Loose Parts (Wheel kit and handle) Check all loose parts against the following list. Contact your dealer toll free at 888.834.4218 if any of the loose parts shown are not included with your generator Hardware Check: Your Hardware Kit should include: 1) Two Handles with bolts, nuts.
4000W Generator Installation NOTE: PRIOR TO POWERING TOOLS AND EQUIPMENT MAKE SURE THE GENERATOR’S RATED VOLTAGE, WATTAGE AND AMPERAGE CAPACITY IS ADEQUATE TO SUPPLY ALL ELECTRICAL LOADS THAT THE UNIT WILL POWER. IF POWERING EXCEEDS THE GENERATOR’S CAPACITY, IT MAY BE NECESSARY TO GROUP ONE OR MORE OF THE TOOLS AND/OR EQUIPMENT FOR CONNECTION TO A SEPARATE GENERATOR. Electrical and other permits may be required for the installation of emergency power systems.
Owner’s Manual Installation (cont’d) Supporting and Mounting Mount the generator on a concrete slab capable of supporting the weight of the generator. The slab must extend on all sides beyond the frame by at least one foot. Contact a cement contractor for slab specifications if necessary. Attach the frame to the concrete slab using 3/8” diameter expansion anchor bolts (not supplied).
4000W Generator Operation NOTE: THE PARTS LISTED ABOVE ARE HELPFUL FOR LOCATING THE CONTROLS MENTIONED BELOW. Before Starting the Generator CAUTION: PRIOR TO FIRST USING THE GENERATOR, THE ENGINE MUST BE FILLED WITH HIGH QUALITY SAE 10W-30 GRADE ENGINE OIL. TO DO SO, UNSCREW AND REMOVE THE ENGINE’S OIL DIPSTICK LOCATED AT THE BOTTOM OF THE ENGINE CRANKCASE. FILL THE ENGINE CRANKCASE UNTIL THE OIL LEVEL IS LEVEL WITH THE UPPER MARKED LINE ON THE DIPSTICK. THEN SCREW THE DIPSTICK BACK INTO THE OIL FILL HOLE.
Owner’s Manual Operation (cont’d) Starting 1. Turn the engine switch to the ON position. The engine switch enables and disables the ignition system. OFF: To stop the engine ON: To run the engine 2. The fuel valve is located under the fuel tank . When the valve lever is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sur to return the fuel valve lever to the OFF position after stopping the engine. OFF ON 3.
4000W Generator Operation (cont’d) Starting 4. Operate the Recoil Starter: Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently. Pulling the starter grip operates the recoil starter to crank the engine Starter Grip Choke Lever 5. If the choke has been moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up. ON OPEN Stopping Engine 1. Turn the engine switch to the OFF position. 2.
Owner’s Manual Operation (cont’d) Powering 120 Volt AC Tools And Equipment: 1. Prior to powering tools and equipment, make sure the generator’s rated voltage, and amperage capacity is adequate to supply all electrical loads that the unit will power. If powering exceeds the generator’s capacity, it may be necessary to group one or more of the tools and/or equipment for connection to a separate generator.
4000W Generator Operation (cont’d) Powering 12 Volt DC tools and Equipment: 1. Prior to powering tools and equipment, make sure the generator’s rated voltage, and amperage capacity (12V DC) is adequate to supply all electrical loads that the unit will power. If powering exceeds the generator’s capacity, it may be necessary to group one or more of the tools and/or equipment for connection to a separate generator. 2. Connect the power cord of a 12 VDC powered tool or equipment to the DC Terminals.
Owner’s Manual Inspection, Cleaning, and Maintenance WARNING! ALWAYS MAKE SURE THE ENGINE POWER SWITCH IS IN ITS “OFF” POSITION. DISCONNECT THE SPARK PLUG WIRE FROM THE ENGINE. AND ALLOW SUFFICIENT TIME FOR THE ENGINE AND GENERATOR TO COMPLETELY COOL BEFORE PERFORMING ANY INSPECTIONS, MAINTENANCE, OR CLEANING. Spark Plug Maintenance In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: TORCH F6RTC but we recommend our OEM spark plug.
4000W Generator Fuel Sediment Cup Cleaning(If It Is Applied) The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned. 1. Turn the fuel valve to the OFF position. Remove the sediment c up, and O-ring. 2. Clean the sediment cup, and O-ring, in nonflammable or high flash point solvent. 3. Reinstall O-ring, and sediment cup. 4. Turn the fuel valve ON and check for leaks.
Owner’s Manual Maintenance Guide (If It Is Applied) Periodic maintenance and adjustment is necessary to keep the generator in good operating condition. WARNING! Exhaust gas contains poisonous carbon monoxide. Shut off the engine before performing any maintenance. If the engine must be run, make sure the areas is well ventilated. • Before each use, inspect the generator.
4000W Generator Air cleaner Maintenance A dirty air cleaner will restrict air flow to the carburetor. lower generator output power and deteriorate the engine emission To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the generator in extremely dusty areas. WARNING! Using gasoline or flammable solvent to clean the filter element can cause a fire or explosion. Use only soapy water or nonflammable solvent.
Owner’s Manual 27
4000W Generator Transporting/Storage 28
Owner’s Manual Wiring Diagram for GPG4000CW G DC PROTECTOR R DC WINDING W AC CIRCUIT BREAKER R Y/G R R B BR W HOURMETER B W Y/G MAIN WINDING1 Y/G MAIN WINDING 2 ENGINE SWITCH B B B BR BR B Y SECONDARY WINDING AVR Y B Y OIL SENSOR 29 SPARK PLUG IGNITION COIL
Owner’s M anual Specifications AC electrical Current Output 120V AC @ 27.5A 60Hz Running Watts 3,300 Starting Watts 4,000 Two 120V 20A NEMA 5-20 Receptacle one 120V 30A NEMA L5-30 Receptacle Outlet DC electrical Outlet 12V@8.3A Gasoline engine Type 4-cycle OHV air-cool ed recoil start Displacement 208cc Oil c apacity 0.63 quart (0.6liter) EPA approved yes Fuel Type Unleaded g asoline Capacity 4 gallons Running t ime 11 hours (approx.) on 1/2 load Weight Approximate weight 30 102 lbs.
4000W Generator LCT engine parts cylinder head system assy. 4 GPA Parts No. LCT Parts No. Description Qty PGH40025 CYLINDER HEAD COMP. GPG4000-A-02 PGH49028 FLANGE BOLT (M8X58) 1 4 GPG4000-A-03 PGH44726 SPAR K PLUG 1 GPG4000-A-04 PGH40075 CYLINDER HEAD SEALING PAD 1 GPG4000-A-05 PGH40653 HEAD COVER COMP.
4000W Generator LCT engine parts Cylinder barrel Qty LCT Parts No. Description GPG4000-B-01 PGH40907 CRANK CASE 1 GPG4000-B-02 PGH44750 OIL LEVEL SWITCH ASSY. 1 GPG4000-B-03 PGH45125 GOVERNOR GEAR ASSY.
4000W Generator LCT engine parts Crankcase cover system assy. GPA Parts No. LCT Parts No.
4000W Generator LCT engine parts Crankshaft system assy. GPA Parts No. LCT Parts No. Description Qty GPG4000-D-01 PGH42101 CRANKSHAFT COMP.
4000W Generator LCT engine parts Piston and connecting rod system assy. Description Qty GPA Parts No. LCT Parts No.
4000W Generator LCT engine parts Valve Train Assembly 12 10 11 13 15 GPA Parts No. LCT Parts No. GPG4000-F-01 PGH40525 PIVOT ADJUSTING NUT 2 GPG4000-F-02 PGH40550 ROCKER ARM PIVOT 2 GPG4000-F-03 PGH40500 ROCKER ARM 2 GPG4000-F-04 PGH40475 PIVOT BOLT (M8) 2 GPG4000-F-05 PGH40275 PUSH ROD GUIDE PLATE 1 GPG4000-F-06 PGH40350 PUSH ROD 2 GPG4000-F-07 PGH40325 VALVE LIFTER 2 GPG4000-F-08 PGH41902 CAMSHAFT 1 GPG4000-F-09 PGH40300 OIL SEAL 2 GPG4000-F-10 PGH40150 I N .
4000W Generator LCT engine parts Recoil Starter Assy. 11 10 9 7 8 5 6 2 4 2 3 2 1 13 12 15 14 . Qty GPA Parts No. LCT Parts No. Description GPG4000-G-01 PGH46050.1.1 ELASTIC CYLINDRICAL PIN 1 GPG4000-G-02 PGH46050.1.2 WASHER ￠10 3 GPG4000-G-03 PGH46050.1.3 PRESSURE SPRING 1 GPG4000-G-04 PGH46050.1.4 SPRING RETAINER 1 GPG4000-G-05 PGH46050.1.5 STARTER RATCHET 2 GPG4000-G-06 PGH46050.1.6 RETURN SPRING 2 GPG4000-G-07 PGH46050.1.
4000W Generator LCT engine parts Fan cover system assy. 7 7 3 8 GPA Parts No. LCT Parts No. Description Qty GPG4000-H-01 PGH46145 FAN COVER COMP.
00W Generator LCT engine parts Carburetor system assy. 2 1 3 4 Qty GPA Parts No. LCT Parts No. Description GPG4000-I-01 PGH44070 CARBURETOR ASSY.
4000W Generator LCT engine parts Flywheel system assy. 2 3 LCT Parts No. Description Qty GPG4000-J-01 PGH42461 FLYWHEEL 1 GPG4000-J-02 PGH42475 FLYWHEEL NUT (M14X1.5 ) 1 GPG4000-J-03 PGH42500 COOLING FAN 1 GPG4000-J-04 PGH46142 STARTER PULLEY 1 GPA Parts No.
4000WGenerator LCT engine parts Ignition System Assy. Qty GPA Parts No. LCT Parts No. GPG4000 -K-01 PGH44675.2-1 NOISE SUPPERSSOR CAP ASSY 1 GPG4000 -K-02 PGH44675.2-2 IGNITION COIL ASSY 1 GPG4000 -K-03 PGH44675.
4000W Generator LCT engine parts Control system assy. GPA Parts No. LCT Parts No. GPG4000-M-01 PGH45078 CONTROL UNIT ASSY. 1 GPG4000-M-02 PGH45078-2 CONTROL BASE COMP.
4000W Generator LCT engine parts Air cleaner 8 GPA Parts No. LCT Parts No. GPG4000-N-01 PGH42160 GPG4000-N-02 PGH42160.2-2 GPG4000-N-03 PGS40003 GPG4000-N-04 PGH42160.2-4 GPG4000-N-05 PGH42160.2-5 GPG4000-N-06 PGH42160.2-1 GPG4000-N-07 PGH44104 GPG4000-N-08 PGS20000-M6 8 DESC RIPTION AIR C LEANER C OV ER C OMP AIR C LEANER ELEMENT.
4000W Generator Equipment Parts excluded in LCT Engine Muffler System Assy. 5 3 5 4 4 1 6 2 8 O 7 Qty GPA Parts No. LCT Parts No. Descript io n GPG4000-O-01 BGG30211 MUFFLER STAY COMP.
4000W Generator Equipment Parts excluded in LCT Engine Fuel tank system assy. GPA Parts No. LCT Parts No. Descript io n Qty GPG4000 -P-01 BGG21006.1.5-1.2 FUEL FILLER CAP COMP 1 GPG4000 -P-02 BGG21006.1.5-1.1 FUEL FILTER 1 GPG4000 -P-03 BGG21006.1.5-1C FUEL TANK COMP. 1 GPG4000 -P-04 BGG21006.1.5-1.
4000W Generator Equipment Parts excluded in LCT Engine Control panel assy. 2 1 7 3 8 9 5 6 4 Description Qty GPA Parts No. LCT Parts No. GPG4000 -Q-01 BGG50200 ENGINE SWITCH ASSY.
4000W Generator Equipment Parts excluded in LCT Engine Frame Comp ASSY. 2 4 6 3 5 7 1 2 R GPA Parts No. LCT Parts No.
4000W Generator Equipment Parts excluded in LCT Engine Generator. 7 19 11 GPA Parts No. LCT Parts No Description GPG4000-S-01 BGG12151.1.2 STATOR COVER 1 GPG4000-S-02 BGG12151.1.3 STATOR ASSY. 1 GPG4000-S-03 BGG12151.1.4 COOLING FAN 1 GPG4000-S-04 BGG13100 BRUSH ASSY. 1 GPG4000-S-05 BGS40078 TAPPING SCREW 6 GPG4000-S-06 BGG13300 GENERATOR STAY 1 GPG4000-S-07 BGS10001 NUT (5mm) 4 GPG4000-S-08 BGG14022 FLANGE BOLT (M6X164) 4 GPG4000-S-09 BGG12508 AUTO VOLTAGE REG. ASSY.
4000W Generator Equipment Parts excluded in LCT Engine Wheel & Hand Assy. 3 3 1 2 4 1 1 4 2 1 7 5 5 6 9 11 8 GPA Parts No. 9 9 9 7 6 10 11 8 LCT Parts No. GPG 4000-T-01 T Description QTY. COTTER PIN 4 GPG 4000-T-02 BGS20006.
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