Wacker Neuson GP 3800A Operator's Manual
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Wacker Neuson GP 3800A Operator's Manual

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See also: Repair Manual
Operator's Manual
Portable Generator
GP 3800A
non-CARB
EN
5000186190
05
0713
5
0
0
0
1
8 6
1
9
0

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Summary of Contents for Wacker Neuson GP 3800A

  • Page 1 Operator’s Manual Portable Generator GP 3800A non-CARB 5000186190 0713...
  • Page 2 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.

  • Page 3: Foreword

    GP 3800A 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). Machines covered in Machine Item Number this manual...
  • Page 4 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 5 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.
  • Page 6 Foreword GP 3800A wc_tx003410gb.fm...

  • Page 7: Table Of Contents

    GP 3800A Table of Contents Foreword Safety Information Signal Words Used in this Manual ............9 Machine Description and Intended Use ..........10 Operating Safety ................11 Operator Safety while Using Internal Combustion Engines ....15 Service Safety ..................16 Labels Label Locations ..................
  • Page 8 Engine ....................49 Emission Control Systems Information and Warranty Emission Control System Background Information ......51 Limited Defect Warranty for Exhaust Emission Control System ..52 Limited Defect Warranty for Wacker Neuson Evaporative Emission Control Systems ..........53 Schematics Wire Colors ..................56 Electrical Schematic ................56 Engine Wiring ..................58...

  • Page 9: Safety Information

    GP 3800A 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 10: Machine Description And Intended Use

    GP 3800A 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 11: 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 12 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 13 GP 3800A Safety Information Installing as Special hazards exist when installing this machine as a backup power supply. backup power Improper connection of 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.
  • Page 14 Safety Information GP 3800A After use 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. Cleaning When cleaning and servicing the machine: Keep the machine clean and free of debris such as leaves, paper, cartons, etc.

  • Page 15: Operator Safety While Using Internal Combustion Engines

    GP 3800A Safety Information 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 16: 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 17 GP 3800A Safety Information 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.

  • Page 18: Labels

    Labels GP 3800A Labels Label Locations wc_gr010937 wc_si000794gb.fm...

  • Page 19: Label Meanings

    GP 3800A Labels Label Meanings Engine choke control WARNING Hot surface WARNING Operation of this equipment may create sparks that can start fires around dry vegetation. A spark arrester may be required. The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements.
  • Page 20 Labels GP 3800A NOTICE Lifting point Emission Control Information This equipment meets U.S. EPA EVAP standards. Evaporative Family: CWIXNHEQCL2 This equipment does not meet California EVP emission regulations for small off-road engines. — — Use only clean, filtered gasoline fuel.
  • Page 21 GP 3800A Labels — 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.
  • Page 22 Labels GP 3800A — 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 23: Lifting And Transporting

    GP 3800A Lifting and Transporting Lifting and Transporting Lifting the This generator, while compact, is heavy enough to cause injury if proper lifting Machine techniques are not used. Observe the following guidelines when lifting the generator. Do not attempt to lift and carry the generator unassisted. Use appropriate lifting equipment such as slings, chains, hooks, ramps, or jacks.

  • Page 24: Operation

    1. Make sure all loose packaging materials have been removed from the machine. 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.

  • Page 25: Determining Power Requirements

    The information in “Approximate Starting Power Requirements” is offered only as a general guideline to help you in determining power requirements for different types of equipment. 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 26: Positioning The Generator For Operation

    Operation GP 3800A Positioning the Generator for 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.
  • Page 27 GP 3800A Operation Continued from the previous page. Do not operate the generator anywhere inside a home or building. This includes the garage (c), entryway, porch, or sunroom (d), living area or work space (e), or basement or crawl space (f). Operating the generator inside a home or building can be fatal even if fans, open doors, or open windows are used for ventilation.

  • Page 28: 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: ETHANOL - (ethyl or grain alcohol) 10% by volume. You may use gasoline containing up to 10% ethanol by volume (commonly referred to as E10).
  • Page 29 GP 3800A Operation 13.Insert M6 x 20 screws (m) through the leg bracket, then through the holes of the rubber foot mounts. 14.Insert the nuts (n) onto the screws and tighten. Torque to 7.5 Nm (5.25 ft.lbs.). 15.Align the holes found in the handles (a, j) to the holes of the brackets (1) on the frame.

  • Page 30: Generator Derating

    Operation GP 3800A 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 31: Grounding The Generator

    GP 3800A Operation Grounding the Generator Location A ground connection (a) is located on the generator frame. wc_gr010579 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.

  • Page 32: Use Of Extension Cords

    Operation GP 3800A 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 33: Control Panel

    GP 3800A Operation 4.10 Control Panel Ref. Description Ref. Description Engine switch GFI test button Auto idle switch GFI reset button Twist-lock receptacle—120V Twist-lock receptacle—120/240V Main circuit breaker 20A circuit breaker (CSA only) Voltage Selector Switch (VSS) 30A circuit breaker (CSA only) GFI duplex receptacle—120V...

  • Page 34: Ground Fault Interrupt (Gfi / Gfci)

    Operation GP 3800A 4.11 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 35: Twist-Lock Receptacles

    GP 3800A Operation 4.12 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 36: Voltage Selector

    Operation GP 3800A 4.15 Voltage Selector The voltage selector switch (a) 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 (b) and duplex receptacles (c1, c2). The full rated power of the generator is shared between the three receptacles.

  • Page 37: Before Starting

    GP 3800A Operation 4.16 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 38: Starting

    Operation GP 3800A 4.17 Starting Before starting, be sure you read and understand all the safety and operating instructions in this manual. 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 39: Stopping

    GP 3800A Operation 4.18 Stopping 1. Turn off and disconnect all tools and appliances attached to the generator. 2. Place the main circuit breaker in the OFF position (a2). 3. Place the engine switch to OFF (b2). 4. Close the fuel valve (d2).

  • Page 40: 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 41: Engine Oil

    GP 3800A Maintenance Engine Oil 1. Drain the oil while the engine is still warm. 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 42: Servicing The Air Cleaner

    Maintenance GP 3800A 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. WARNING Explosion and fire hazards. Never use gasoline or other types of low flash point solvents for cleaning the air filter.

  • Page 43: Spark Plug

    GP 3800A Maintenance Spark Plug Clean or replace the spark plug as needed to ensure proper operation. Refer to your engine owner’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 44: Cleaning The Sediment Cup

    Maintenance GP 3800A Cleaning the Sediment Cup 1. Turn the fuel valve off. 2. Remove the sediment cup (a) and the O-ring (b). 3. Wash both thoroughly in a nonflammable solvent. Dry and re-install them. 4. Turn the fuel valve on and check for leaks.

  • Page 45: Adjusting The Carburetor

    GP 3800A Maintenance Adjusting the Carburetor 1. Start the engine and allow it to warm up to operating temperature. 2. Set the pilot screw (a) two turns out. See Note. 3. With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm.

  • Page 46: Storage

    Maintenance GP 3800A Storage Before storing the generator for a long period of time: 1. Close the fuel valve and remove and empty the sediment cup or fuel strainer. 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 47: Troubleshooting

    GP 3800A Troubleshooting 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 48: Technical Data

    Technical Data GP 3800A Technical Data Generator GP 3800A Machine GP 3800A GP 3800A Item No. 0620485 0620379 0620104 Generator Maximum output 3800 Continuous output 3400 Type Dual voltage, single phase, Auto voltage regulator system AC voltages available volts 120 / 240 phase 1ø...

  • Page 49: Engine

    GP 3800A Technical Data Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Machine GP 3800A Item No. 0620485, 0620379, 0620104 Engine Engine type Single cylinder, 4-cycle, air-cooled, gasoline engine...
  • Page 50 Technical Data GP 3800A Notes wc_td000567gb.fm...

  • Page 51: 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 52: Limited Defect Warranty For Exhaust Emission Control System

    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 53: Limited Defect Warranty For Wacker Neuson Evaporative Emission Control Systems

    Any implied warranties are limited to the duration of this written warranty. What is covered Wacker Neuson recommends the use of genuine Wacker Neuson parts, or the equivalent, whenever maintenance is performed. The use of replacement parts not equivalent to the original parts may impair the effectiveness of the engine/ equipment emission controls systems.
  • Page 54 Wacker Neuson dealer/ service center. The engine/equipment must be presented to an authorized Wacker Neuson dealer/ service center as soon as a problem exists. Contact Wacker Neuson Product wc_tx001769gb.fm...
  • Page 55 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.

  • Page 56: Schematics

    Schematics GP 3800A Schematics Wire Colors Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Light blue Electrical Schematic Ref. Description Ref. Description Generator Honda Engine Control box — — Electric start engines (GPS) —...
  • Page 57 GP 3800A Schematics wc_tx003415gb.fm...

  • Page 58: Engine Wiring

    Schematics GP 3800A Engine Wiring Ref. Description Ref. Description Generator Honda Engine Control box — — Electric start engines (GPS) — — Ref. Description Ref. Description Idle solenoid Solenoid (GPS only) Fuel cut solenoid Starter (GPS only) Oil level sender...
  • 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...

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