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Wacker Neuson GV 3800A Operator's Manual

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Operator's Manual
Portable Generator
GV 3800A
EN
5200003450
01
1011
5
2
0
0
0
0
3
4
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Summary of Contents for Wacker Neuson GV 3800A

  • Page 1 Operator’s Manual Portable Generator GV 3800A 5200003450 1011...
  • 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: 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.

  • Page 5: Table Of Contents

    GV 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 ....13 Service Safety ..................14 Labels Label Locations ..................
  • Page 6 Emission Control Systems Information and Warranty Emission Control System Background Information ......44 Limited Defect Warranty for Exhaust Emission Control System ..45 Limited Defect Warranty for Wacker Neuson Evaporative Emission Control Systems ..............45 California Evaporative Emission Control Warranty Statement ... 48 Limited Defect Warranty for Exhaust Emission Control System ..

  • Page 7: Safety Information

    GV 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

    GV 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 9 GV 3800A Safety Information Generator Generators vibrate in normal use. During and after the use of the generator, vibration inspect the generator as well as extension cords and power supply cords connected to it for damage from vibration. Have damaged items repaired or replaced as necessary.

  • Page 10: 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 11 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 12 Safety Information GV 3800A WARNING Backfeed from the generator into the public power distribution system can cause serious injury or death to utility workers! Connections to a building’s electrical system must be made by a qualified elec- trician and comply with all applicable laws and electrical codes.

  • Page 13: Operator Safety While Using Internal Combustion Engines

    GV 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 14: Service Safety

    Always let the engine cool before transporting or servicing the machine. Machine When servicing or maintaining the machine: modifications Use only accessories/attachments that are approved by Wacker Neuson. wc_si000624gb.fm...
  • Page 15 GV 3800A Safety Information When servicing or maintaining the machine: Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker Neuson. Replacing Replace worn or damaged components. parts and Replace all missing and hard-to-read labels.

  • Page 16: Labels

    Labels GV 3800A Labels Label Locations wc_gr005146 Label Meanings Wacker Neuson machines use international pictorial labels where needed. These labels are described below. DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling. WARNING! Hot surface...
  • Page 17 GV 3800A Labels 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 work- ers, fire, or explosion. Connections to a build- ing’s electrical system must be made by a...
  • Page 18 Labels GV 3800A — Open the choke. — Open main circuit breaker. — Turn the engine switch to “OFF”. — Close the fuel flow valve. Electrical ground DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon mon- oxide.
  • Page 19 GV 3800A Labels A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the infor- mation found on this nameplate so it will be available should the nameplate become lost or damaged.

  • Page 20: Lifting And Transporting

    Lifting and Transporting GV 3800A Lifting and Transporting Lifting the Machine This generator, while compact, is heavy enough to cause injury if proper lifting 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 21: Operation

    4.0.2 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. 4.0.3 Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for.

  • Page 22: 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 23: Refueling The Machine

    GV 3800A Operation 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 24: 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 25: Installation

    GV 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 26: Generator Derating

    Operation GV 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 27: Grounding The Generator

    GV 3800A Operation Grounding the Generator Location A ground connection (a) is located on the generator frame. 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 GV 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 29: Control Panel

    GV 3800A Operation 4.10 Control Panel TEST RESET wc_gr008765 Ref. Description Ref. Description Engine switch Main circuit breaker Auto idle switch Duplex receptacle—120V Twist-lock receptacle—120/240V GFI test button Voltage Selector Switch (VSS) GFI reset button wc_tx001890gb.fm...

  • Page 30: Testing The Ground-Fault Interrupt (Gfi)

    Operation GV 3800A 4.11 Testing the Ground-Fault Interrupt (GFI) Overview The GFI should be tested for proper operation every time the generator is used. In the normal operating state, the green “POWER” LED is illuminated and the circuit breaker is in the “ON” position.

  • Page 31: 4.13 Voltage Selector Switch

    GV 3800A Operation 4.13 Voltage Selector Switch The voltage selector switch (e) switches the generator output between the single-voltage mode (120V) and the dual-voltage (120/240V) mode. In single-voltage mode, the full rated power of the generator is shared between the two 120V duplex receptacles.

  • Page 32: Before Starting

    Operation GV 3800A 4.15 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

    GV 3800A Operation 4.16 Starting Before starting, be sure you read and understand all the safety and operating instructions in this manual. 4.16.1 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 GV 3800A 4.17 Stopping 4.17.1 Turn off and disconnect all tools and appliances attached to the generator. 4.17.2 Place the main circuit breaker in the OFF position (a2). 4.17.3 Place the engine switch to OFF (b2). 4.17.4 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 GV 3800A Engine Oil 5.3.1 Drain the oil while the engine is still warm. 5.3.2 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

    GV 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 GV 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

    GV 3800A Maintenance Cleaning the Sediment Cup 5.6.1 Turn the fuel valve off. 5.6.2 Remove the sediment cup (a) and the O-ring (b). 5.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 5.6.4 Turn the fuel valve on and check for leaks.

  • Page 40: Storage

    Maintenance GV 3800A Storage Before storing the generator for a long period of time: 5.7.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 5.7.2 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

    GV 3800A Troubleshooting Troubleshooting Problem / Symptom Reason / Remedy If engine does not 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 GV 3800A Technical Data Generator Item No. GV 3800A Generator Maximum output 3800 Continuous output 3400 Type Single phase, self-exciting, 2-pole, field rotating AC voltages available 120/240 Volts phase Frequency Power factor cos ø AC receptacles: 125V duplex (2)

  • Page 43: Engine

    GV 3800A 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. GV 3800A Engine Engine make Honda Engine model GX 240 U1 VWS Max. rated power @ 5.3 (7.1) @ 3600 rpm...

  • 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 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 46 For the components listed in the following table, an authorized Wacker Neuson dealer/service center will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine/equipment complies with the applicable EPA regulations.
  • Page 47 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 48: 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 49: 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 50 Emission Control Systems Information and Warranty wc_tx001772gb.fm...
  • Page 51 GV 3800A Notes wc_tx001896gb.fm...

  • Page 52: Schematics

    Schematics GV 3800A Schematics Electrical Schematic wc_gr008687 wc_tx001896gb.fm...

  • Page 53: Components

    GV 3800A Schematics Components Ref. Description Ref. Description Ref. Description Generator Control Box Engine Ref. Description Ref. Description Main stator winding Spark plug Secondary winding Slip ring Rotor winding Auto idle unit Automatic voltage regulator Voltage selector switch 20A circuit breaker Twist lock receptacle—125/250V...
  • Page 56 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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