1. DL manuals
  2. Wacker Neuson
  3. Portable Generator
  4. GP 3800A
  5. Operator's Manual

Wacker Neuson GP 3800A Operator's Manual

Other manuals for GP 3800A: Repair Manual, Operator's Manual

Summary of GP 3800A

  • Page 1

    5000192885 01 0511 5 0 0 0 1 9 2 8 8 5 operator’s manual portable generator gp 3800a en.

  • 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 permissio...

  • Page 3: Foreword

    Foreword wc_tx001703gb.Fm 3 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 this manual machine d...

  • Page 4: Foreword

    Foreword 4 wc_tx001703gb.Fm approved modifications are those performed by an authorized wacker neuson service center according to written instructions published by wacker neuson. Unapproved parts, attachments, and modifications are those that do not meet the approved criteria. Unapproved parts, atta...

  • Page 5: Table of Contents

    Wc_bo5000192885_01toc.Fm 5 table of contents gp 3800a foreword 3 1 safety information 7 1.1 signal words used in this manual ....................................................... 7 1.2 machine description and intended use ............................................... 8 1.3 operating safety ........

  • Page 6: Table of Contents

    6 wc_bo5000192885_01toc.Fm table of contents gp 3800a 4 maintenance 35 4.1 maintaining the emission control system ...........................................35 4.2 periodic maintenance schedule ..........................................................35 4.3 engine oil ................................

  • Page 7: Gp 3800A

    Gp 3800a safety information wc_si000233gb.Fm 7 1 safety information 1.1 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. Not...

  • Page 8: Safety Information

    Safety information gp 3800a 8 wc_si000233gb.Fm 1.2 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. Th...

  • Page 9: Gp 3800A

    Gp 3800a safety information wc_si000233gb.Fm 9 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..

  • Page 10: Safety Information

    Safety information gp 3800a 10 wc_si000233gb.Fm 1.3 operating safety operator qualifications only trained personnel are permitted to start, operate, and shut down the machine. They also must meet the following qualifications: • have received instruction on how to properly use the machine • are famil...

  • Page 11: Gp 3800A

    Gp 3800a safety information wc_si000233gb.Fm 11 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...

  • Page 12: Safety Information

    Safety information gp 3800a 12 wc_si000233gb.Fm 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. 1.4 operator ...

  • Page 13: Gp 3800A

    Gp 3800a safety information wc_si000233gb.Fm 13 • 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. Generator vibration generators vibrate in normal use...

  • Page 14: Safety Information

    Safety information gp 3800a 14 wc_si000233gb.Fm 1.5.6 do not allow untrained personnel to service this equipment. Only trained electrical technicians should be allowed to service the electrical components of this equipment. 1.5.7 keep the machine clean and labels legible. Replace all missing and har...

  • Page 15: Gp 3800A

    Gp 3800a wc_si000555gb.Fm 15 2 labels 2.1 label locations 2.2 label meanings wacker neuson machines use international pictorial labels where needed. These labels are described below. A engine choke control b warning! Hot surface! Wc_gr003142 c l g b e f n k j d a m.

  • Page 16: Gp 3800A

    Gp 3800a 16 wc_si000555gb.Fm c — 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" posi...

  • Page 17: Gp 3800A

    Gp 3800a wc_si000555gb.Fm 17 — 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. This is a poi...

  • Page 18: Gp 3800A

    Gp 3800a 18 wc_si000555gb.Fm — 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 electroc...

  • Page 19: Gp 3800A

    Gp 3800a wc_si000555gb.Fm 19 l warning! Test gfci before each use. See label above. M important emissions information this equipment meets california evp emission regulations for small off-road engines. N emission control information this equipment meets u.S. Epa evap standards. Evaporative family: ...

  • Page 20: Operation

    Operation gp 3800a 20 wc_tx000785gb.Fm 3 operation 3.1 preparing for first use to prepare your machine for first use: 3.1.1 make sure all loose packaging materials have been removed from the machine. 3.1.2 check the machine and its components for damage. If there is visible damage, do not operate th...

  • Page 21: Gp 3800A

    Gp 3800a operation wc_tx000785gb.Fm 21 3.2 recommended fuel type this engine/equipment requires regular unleaded gasoline. • use only fresh (no older than three months old), clean gasoline. • use a fuel stabilizer per the fuel stabilizer manufacturer’s instructions. Use of oxygenated fuels some conv...

  • Page 22: Operation

    Operation gp 3800a 22 wc_tx000785gb.Fm 3.3 determining power requirements this generator is designed to operate single-phase, 60 hz appliances running at 120 vac or 240 vac. Check the nameplate or label provided on tools and appliances to make sure their power requirements match the power output of ...

  • Page 23: Gp 3800A

    Gp 3800a operation wc_tx000785gb.Fm 23 3.4 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 pres...

  • Page 24: Operation

    Operation gp 3800a 24 wc_tx000785gb.Fm 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 bra...

  • Page 25: Gp 3800A

    Gp 3800a operation wc_tx000785gb.Fm 25 3.6 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 thu...

  • Page 26: Operation

    Operation gp 3800a 26 wc_tx000785gb.Fm 3.7 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,...

  • Page 27: Gp 3800A

    Gp 3800a operation wc_tx000785gb.Fm 27 3.9 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 inc...

  • Page 28: Operation

    Operation gp 3800a 28 wc_tx000785gb.Fm 3.10 control panel ref. Description ref. Description a engine switch g gfi test button b auto idle switch h gfi 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 29: Gp 3800A

    Gp 3800a operation wc_tx000785gb.Fm 29 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. 3.11.1 press “test” button (g). Green l...

  • Page 30: Operation

    Operation gp 3800a 30 wc_tx000785gb.Fm 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...

  • Page 31: Gp 3800A

    Gp 3800a operation wc_tx000785gb.Fm 31 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 ...

  • Page 32: Operation

    Operation gp 3800a 32 wc_tx000785gb.Fm 3.16 before starting 3.16.1 read and understand the safety and operating labels and instructions at the beginning of this manual. 3.16.2 inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 3.16.3 check: • oil level ...

  • Page 33: Gp 3800A

    Gp 3800a operation wc_tx000785gb.Fm 33 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 int...

  • Page 34: Operation

    Operation gp 3800a 34 wc_tx000785gb.Fm 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). Note: to stop the engi...

  • Page 35: Gp 3800A

    Gp 3800a maintenance wc_tx000793gb.Fm 35 4 maintenance 4.1 maintaining the emission control system normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a dealer/ser...

  • Page 36: Maintenance

    Maintenance gp 3800a 36 wc_tx000793gb.Fm 4.3 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 col...

  • Page 37: Gp 3800A

    Gp 3800a maintenance wc_tx000793gb.Fm 37 4.4 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 cleani...

  • Page 38: Maintenance

    Maintenance gp 3800a 38 wc_tx000793gb.Fm 4.5 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...

  • Page 39: Gp 3800A

    Gp 3800a maintenance wc_tx000793gb.Fm 39 4.6 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: Maintenance

    Maintenance gp 3800a 40 wc_tx000793gb.Fm 4.7 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 high...

  • Page 41: Gp 3800A

    Gp 3800a maintenance wc_tx000793gb.Fm 41 4.9 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 sui...

  • Page 42: Maintenance

    Maintenance gp 3800a 42 wc_tx000793gb.Fm 4.11 troubleshooting problem / symptom reason / remedy if engine doesn't start, check that: • engine switch is on “start”. • fuel valves under fuel tank and on engine are open. • fuel tank has fuel. • choke lever is in correct position. Choke should be closed...

  • Page 43: Gp 3800A

    Gp 3800a technical data wc_td000236gb.Fm 43 5 technical data 5.1 generator item no. Gp 3800a gp 3800a (can) generator maximum output w 3800 continuous output w 3400 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase 120 / 240 1ø frequency hz 60 power fac...

  • Page 44: Technical Data

    Technical data gp 3800a 44 wc_td000236gb.Fm 5.2 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 honda engine model gx 240 ...

  • Page 45

    Emission control systems information and warranty wc_tx001772gb.Fm 45 6 emission control systems information and warranty the emission control warranty and associated information is valid only for the u.S.A., its territories, and canada. 6.1 emission control system background information introductio...

  • Page 46

    Emission control systems information and warranty 46 wc_tx001772gb.Fm 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 constit...

  • Page 47

    Emission control systems information and warranty wc_tx001772gb.Fm 47 6.3 limited defect warranty for wacker neuson evaporative emission control systems the emission control warranty is valid only for the u.S.A., its territories, and canada. Wacker neuson sales americas, llc, n92 w15000 anthony aven...

  • Page 48

    Emission control systems information and warranty 48 wc_tx001772gb.Fm what is not covered failures other than those resulting from defects in material or workmanship. Any systems or parts which are affected or damaged by owner abuse, tampering, neglect, improper maintenance, misuse, improper fueling...

  • Page 49

    Emission control systems information and warranty wc_tx001772gb.Fm 49 support department (1-800-770-0957) or visit wackerneuson.Com to find a dealer/ service center in your area, or to answer questions regarding warranty rights and responsibilities. How to make a claim in the event that any emission...

  • Page 50

    Emission control systems information and warranty 50 wc_tx001772gb.Fm 6.4 california evaporative emission control warranty statement your warranty rights and obligations the california air resources board and wacker neuson corporation, inc., are pleased to explain the evaporative emission control sy...

  • Page 51

    Emission control systems information and warranty wc_tx001772gb.Fm 51 what is not covered all failures caused by abuse, neglect, or improper maintenance are not covered. In addition, the use of add-on or modified parts will be grounds for disallowing a warranty claim. What is covered the repair or r...

  • Page 52: Schematics

    Schematics gp 3800a 52 wc_tx001777gb.Fm 7 schematics 7.1 wire colors 7.2 us machines—electrical schematic wire colors b black r red y yellow or orange g green t tan br brown pr purple l blue v violet cl clear sh shield p pink w white gr gray ll light blue ref. Description ref. Description a generato...

  • Page 53: Gp 3800A

    Gp 3800a schematics wc_tx001777gb.Fm 53 2 brn 3 8 blu 3 brn 3 5 brn 5 2 brn 2 6 7 7 brn 12 3 1 brn 3 brn 11 brn 16 awg 10 10 brn 16 awg 1 12 brn 16 awg 41 blu 1 brn grn/yel 9 8 blu 8 9 brn wht/red 16 awg wht/red 16 awg grn 16awg wht 16 awg blk 16 awg red 16 awg 6 4 on off 12 brn 11 brn 10 brn grn/ye...

  • Page 54: Schematics

    Schematics gp 3800a 54 wc_tx001777gb.Fm 7.3 csa machines—electrical schematic ref. Description ref. Description a generator e honda engine b control box c electric start engines (gps) ref. Description ref. Description 1 main stator winding 1 12 engine on / off switch 2 main stator winding 2 13 recti...

  • Page 55: Gp 3800A

    Gp 3800a schematics wc_tx001777gb.Fm 55 2 brn 8 blu 3 brn 101 blu 5 brn 8 5 8 blu 5 brn 2 2 brn 9 brn 7 brn 103 gry 7 3 brn 1 brn 3 1 4 1 11 brn 16 awg 12 brn 16 awg 12 20a 104 gry 23 brn 1 brn 41 blu 103 gry wht/red 16 awg wht/red 16 awg wht 16 awg grn 16awg off on blk 16 awg 4 6 3 1 12 brn wht/red...

  • Page 56: Schematics

    Schematics gp 3800a 56 wc_tx001777gb.Fm 7.4 engine wiring ref. Description ref. Description a generator d honda engine b control box c electric start engines (gps) ref. Description ref. Description 1 idle solenoid 6 solenoid (gps only) 2 fuel cut solenoid 7 starter (gps only) 3 oil level sender 8 ch...

  • Page 58

    Wacker neuson se, preußenstraße 41, d-80809 münchen, tel.: +49-(0)89-3 54 02-0 fax: +49 - (0)89-3 54 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 & 1...