Wacker Neuson GP 3800A Operator's Manual
Portable generator
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Also See for GP 3800A:
- Repair manual (130 pages) ,
- Operator's manual (60 pages) ,
- Operator's manual (240 pages)
Related Manuals for Wacker Neuson GP 3800A
Summary of Contents for Wacker Neuson GP 3800A
- Page 1 Operator’s Manual Portable Generator GP 3800A 5000192885 0511...
- Page 2 Copyright notice © Copyright 2011 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 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 3800A Table of Contents Foreword Safety Information Signal Words Used in this Manual ............7 Machine Description and Intended Use ..........8 Operating Safety ................10 Operator Safety while Using Internal Combustion Engines ....12 Service Safety ..................13 Labels Label Locations .................. -
Page 6: Schematics
Emission Control Systems Information and Warranty Emission Control System Background Information ......45 Limited Defect Warranty for Exhaust Emission Control System ..46 Limited Defect Warranty for Wacker Neuson Evaporative Emission Control Systems ..............47 California Evaporative Emission Control Warranty Statement ....50 Limited Defect Warranty for Exhaust Emission Control System ..51 Schematics Wire Colors ..................52... -
Page 7: 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 8: Machine Description And Intended Use
Safety Information 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. - Page 9 GP 3800A Safety Information Personal injury from improper lifting techniques To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine. wc_si000233gb.fm...
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Page 10: Operating Safety
Safety Information GP 3800A 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. - Page 11 GP 3800A Safety Information If connected to a building’s electrical system the generator must meet the power, voltage, and frequency requirements of the equipment in the building. Differences in power, voltage, and frequency requirements may exist and improper connection may lead to equipment damage, fire, and personal injury or death.
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Page 12: Operator Safety While Using Internal Combustion Engines
Safety Information GP 3800A 1.3.17 ALWAYS remove all tools, cords, and other loose items from the generator before starting it. 1.3.18 ALWAYS make certain the machine is well-grounded and securely fastened to a good earthen ground per national and local regulations. -
Page 13: Service Safety
GP 3800A Safety Information • Do not start the engine if fuel has spilled or a fuel odor is present. Move the generator away from the spill and wipe the generator dry before starting. • Do not smoke while operating the machine. - Page 14 Leaking fuel and fumes are extremely explosive. 1.5.13 When replacement parts are required for this machine, use only Wacker Neuson replacement parts or those parts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material.
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Page 15: Labels
GP 3800A 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_si000555gb.fm... - Page 16 GP 3800A — 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.
- Page 17 GP 3800A — 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 18 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. This may result in electrocution of utility workers, fire, or explosion.
- Page 19 GP 3800A 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. Evaporative Family: BWIXNHEQCL2 wc_si000555gb.fm...
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Page 20: Operation
3.1.2 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. 3.1.3 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 / Provinces require this information to be posted on the fuel pump. The following are Wacker Neuson approved percentages of oxygenates: - (ethyl or grain alcohol) 10% by volume. You may use... -
Page 22: 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 23: Installation
GP 3800A Operation 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 24 Operation GP 3800A 3.5.14 Insert the nuts (n) onto the screws and tighten. Torque to 7.5 Nm (5.25 ft.lbs.). 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 25: Generator Derating
GP 3800A Operation 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 26: Grounding The Generator
Operation GP 3800A 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 27: Use Of Extension Cords
GP 3800A Operation 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 28: Control Panel
Operation GP 3800A 3.10 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 (CAN only) Voltage Selector Switch (VSS) 30A circuit breaker (CAN only) GFI duplex receptacle—120V... -
Page 29: Ground Fault Interrupt (Gfi / Gfci)
GP 3800A Operation 3.11 Ground Fault Interrupt (GFI / GFCI) The GFCI should be tested for proper operations every time the generator is used. Normal operating state - sensing device green LED is “ON” and circuit breaker is at “ON” position. -
Page 30: Twist-Lock Receptacles
Operation GP 3800A 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 31: Voltage Selector Switch
GP 3800A Operation 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 32: Before Starting
Operation GP 3800A 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 33: Starting
GP 3800A Operation 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 34: Stopping
Operation GP 3800A 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 35: 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 36: Engine Oil
Maintenance GP 3800A 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 37: Servicing The Air Cleaner
GP 3800A Maintenance 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 38: Spark Plug
Maintenance GP 3800A 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 39: Cleaning The Sediment Cup
GP 3800A Maintenance Cleaning the Sediment Cup 4.6.1 Turn the fuel valve off. 4.6.2 Remove the sediment cup (a) and the O-ring (b). 4.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 4.6.4 Turn the fuel valve on and check for leaks. -
Page 40: Adjusting The Carburetor
Maintenance GP 3800A Adjusting the Carburetor 4.7.1 Start the engine and allow it to warm up to operating temperature. 4.7.2 Set the pilot screw (a) two turns out. See Note. 4.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. -
Page 41: Long-Term Storage
GP 3800A Maintenance Long-Term Storage Before storing the generator for a long period of time: 4.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 4.9.2 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 42: Troubleshooting
Maintenance GP 3800A 4.11 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 43: Technical Data
GP 3800A Technical Data Technical Data Generator Item No. GP 3800A GP 3800A (CAN) Generator Maximum Output 3800 Continuous Output 3400 Type Dual voltage, single phase, Auto voltage regulator system AC Voltages Available volts 120 / 240 phase 1ø Frequency... -
Page 44: Engine
Technical Data GP 3800A Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 3800A Engine Engine type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine make... -
Page 45: 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 46: 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 47: 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 48 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_tx001772gb.fm...
- Page 49 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 50: California Evaporative Emission Control Warranty Statement
This EECS is warranted for two years from the initial date of purchase. If any evaporative emission-related part on your equipment is defective, the part will be repaired or replaced by Wacker Neuson Corporation 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 Corporation authorized service center. -
Page 51: Limited Defect Warranty For Exhaust Emission Control System
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 Corporation 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. -
Page 52: Schematics
Schematics GP 3800A Schematics Wire Colors Wire Colors Black Yellow Orange Green Brown Purple Blue Violet Clear Shield Pink White Gray Light blue US Machines—Electrical Schematic Ref. Description Ref. Description Generator Honda Engine Control box Electric start engines (GPS) Ref. - Page 53 GP 3800A Schematics wc_tx001777gb.fm...
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Page 54: Csa Machines-Electrical Schematic
Schematics GP 3800A CSA Machines—Electrical Schematic Ref. Description Ref. Description Generator Honda Engine Control box Electric start engines (GPS) Ref. Description Ref. Description Main stator winding 1 Engine ON / OFF switch Main stator winding 2 Rectifier Auto idle unit... - Page 55 GP 3800A Schematics wc_tx001777gb.fm...
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Page 56: 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 Charging coil (GPS only) - Page 58 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...