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  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

    5000186190 05 0713 5 0 0 0 1 8 6 1 9 0 operator’s manual portable generator gp 3800a non-carb en.

  • 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 permissio...

  • Page 3: Gp 3800A

    Gp 3800a foreword wc_tx003410gb.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 ...

  • Page 4: Foreword

    Foreword gp 3800a 4 wc_tx003410gb.Fm machine identification a nameplate listing the model number, item number, revision number, and serial number is attached to this machine. The location of the nameplate is shown above. Serial number (s/n) for future reference, record the serial number in the space...

  • Page 5: Gp 3800A

    Gp 3800a foreword wc_tx003410gb.Fm 5 california proposition 65 warning combustion exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the state of california to cause cancer and birth defects or other reproductive harm. Laws pertaining to spark arrest...

  • Page 6: Foreword

    Foreword gp 3800a 6 wc_tx003410gb.Fm.

  • Page 7: Table of Contents

    Wc_bo5000186190_05toc.Fm 7 table of contents gp 3800a foreword 3 1 safety information 9 1.1 signal words used in this manual ....................................................... 9 1.2 machine description and intended use ............................................. 10 1.3 operating safety .........

  • Page 8: Table of Contents

    8 wc_bo5000186190_05toc.Fm table of contents gp 3800a 5 maintenance 40 5.1 maintaining the emission control system ...........................................40 5.2 periodic maintenance schedule ..........................................................40 5.3 engine oil ................................

  • Page 9: Gp 3800A

    Wc_si000793gb.Fm 9 gp 3800a safety information 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 10: Safety Information

    Wc_si000793gb.Fm 10 safety information gp 3800a 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. T...

  • Page 11: Gp 3800A

    Wc_si000793gb.Fm 11 gp 3800a safety information 1.3 operating safety operator training before operating the machine: read and understand the operating instructions contained in all manuals delivered with the machine. Familiarize yourself with the location and proper use of all controls and safety de...

  • Page 12: Safety Information

    Wc_si000793gb.Fm 12 safety information gp 3800a application area be aware of the application area. Keep unauthorized personnel, children, and pets away from the machine. Remain aware of changing positions and the movement of other equipment and personnel in the application area/job site. Be aware of...

  • Page 13: Gp 3800A

    Wc_si000793gb.Fm 13 gp 3800a safety information installing as backup power special hazards exist when installing this machine as a backup power supply. Improper connection of generator to a building’s electrical system can allow electrical current from the generator to backfeed into utility lines. T...

  • Page 14: Safety Information

    Wc_si000793gb.Fm 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 le...

  • Page 15: Gp 3800A

    Wc_si000793gb.Fm 15 gp 3800a safety information 1.4 operator safety while using internal combustion engines refueling safety when refueling the engine: do not smoke. Do not refuel if the generator is sitting in a truck fitted with a plastic bed liner. Static electricity can ignite the fuel or fuel v...

  • Page 16: Safety Information

    Wc_si000793gb.Fm 16 safety information gp 3800a 1.5 service safety service training before servicing or maintaining the machine: read and understand the instructions contained in all manuals delivered with the machine. Familiarize yourself with the location and proper use of all controls and safety ...

  • Page 17: Gp 3800A

    Wc_si000793gb.Fm 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. Never use gasoline or oth...

  • Page 18: Labels

    Wc_si000794gb.Fm 18 labels gp 3800a 2 labels 2.1 label locations wc_gr010937 a b c d e f j k h l g.

  • Page 19: Gp 3800A

    Wc_si000794gb.Fm 19 gp 3800a labels 2.2 label meanings a engine choke control b warning hot surface c 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 regula...

  • Page 20: Labels

    Wc_si000794gb.Fm 20 labels gp 3800a e notice lifting point f emission control information this equipment meets u.S. Epa evap standards. Evaporative family: cwixnheqcl2 g this equipment does not meet california evp emission regulations for small off-road engines. H — — use only clean, filtered gasoli...

  • Page 21: Gp 3800A

    Wc_si000794gb.Fm 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. This i...

  • Page 22: Labels

    Wc_si000794gb.Fm 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. This may result in el...

  • Page 23: Gp 3800A

    Wc_tx003411gb.Fm 23 gp 3800a lifting and transporting 3 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...

  • Page 24: Operation

    Wc_tx003412gb.Fm 24 operation gp 3800a 4 operation 4.1 preparing the machine for first use 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 ne...

  • Page 25: Gp 3800A

    Wc_tx003412gb.Fm 25 gp 3800a operation 4.2 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 26: Operation

    Wc_tx003412gb.Fm 26 operation gp 3800a 4.3 positioning the generator for operation requirements position the generator according to the following requirements. These instructions continue on the next page. Danger carbon monoxide. Using a generator indoors can kill you in minutes. Generator exhaust c...

  • Page 27: Gp 3800A

    Wc_tx003412gb.Fm 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 hom...

  • Page 28: Operation

    Wc_tx003412gb.Fm 28 operation gp 3800a 4.4 recommended fuel use of oxygenated fuels some conventional gasolines are blended with alcohol. These gasolines are collectively referred to as oxygenated fuels. If you use an oxygenated fuel, be sure it is unleaded and meets the minimum octane rating requir...

  • Page 29: Gp 3800A

    Wc_tx003412gb.Fm 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 brack...

  • Page 30: Operation

    Wc_tx003412gb.Fm 30 operation gp 3800a 4.6 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 31: Gp 3800A

    Wc_tx003412gb.Fm 31 gp 3800a operation 4.7 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 32: Operation

    Wc_tx003412gb.Fm 32 operation gp 3800a 4.9 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 33: Gp 3800A

    Wc_tx003412gb.Fm 33 gp 3800a operation 4.10 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 (csa only) e voltage selector...

  • Page 34: Operation

    Wc_tx003412gb.Fm 34 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. 1. Press “test” button (a). Green led sh...

  • Page 35: Gp 3800A

    Wc_tx003412gb.Fm 35 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...

  • Page 36: Operation

    Wc_tx003412gb.Fm 36 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 ...

  • Page 37: Gp 3800A

    Wc_tx003412gb.Fm 37 gp 3800a operation 4.16 before starting 1. Read and understand the safety and operating labels and instructions at the beginning of this manual. 2. Inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 3. Check: oil level in engine fuel...

  • Page 38: Operation

    Wc_tx003412gb.Fm 38 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 interna...

  • Page 39: Gp 3800A

    Wc_tx003412gb.Fm 39 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). Note: to stop the engine quickly in an...

  • Page 40: Maintenance

    Wc_tx003413gb.Fm 40 maintenance gp 3800a 5 maintenance 5.1 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/se...

  • Page 41: Gp 3800A

    Wc_tx003413gb.Fm 41 gp 3800a maintenance 5.3 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 a...

  • Page 42: Maintenance

    Wc_tx003413gb.Fm 42 maintenance gp 3800a 5.4 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. To service: 1. Remove the air cleaner cover (a). Inspect the element (b)...

  • Page 43: Gp 3800A

    Wc_tx003413gb.Fm 43 gp 3800a maintenance 5.5 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...

  • Page 44: Maintenance

    Wc_tx003413gb.Fm 44 maintenance gp 3800a 5.6 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. A b wc_gr000029.

  • Page 45: Gp 3800A

    Wc_tx003413gb.Fm 45 gp 3800a maintenance 5.7 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: Maintenance

    Wc_tx003413gb.Fm 46 maintenance gp 3800a 5.9 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 ...

  • Page 47: Gp 3800A

    Wc_tx003414gb.Fm 47 gp 3800a troubleshooting 6 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 when s...

  • Page 48: Technical Data

    Wc_td000567gb.Fm 48 technical data gp 3800a 7 technical data 7.1 generator machine item no. Gp 3800a 0620485 gp 3800a 0620379 gp 3800a can 0620104 generator maximum output w 3800 continuous output w 3400 type dual voltage, single phase, auto voltage regulator system ac voltages available volts phase...

  • Page 49: Gp 3800A

    Wc_td000567gb.Fm 49 gp 3800a technical data 7.2 engine engine power rating net power rating per sae j1349. Actual power output may vary due to conditions of specific use. Machine item no. Gp 3800a 0620485, 0620379, 0620104 engine engine type single cylinder, 4-cycle, air-cooled, gasoline engine engi...

  • Page 50: Technical Data

    Wc_td000567gb.Fm 50 technical data gp 3800a notes.

  • Page 51

    Emission control systems information and warranty wc_tx001769gb.Fm 51 8 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. 8.1 emission control system background information introductio...

  • Page 52

    Emission control systems information and warranty 52 wc_tx001769gb.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 53

    Emission control systems information and warranty wc_tx001769gb.Fm 53 8.3 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 54

    Emission control systems information and warranty 54 wc_tx001769gb.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 55

    Emission control systems information and warranty wc_tx001769gb.Fm 55 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 56: Schematics

    Wc_tx003415gb.Fm 56 schematics gp 3800a 9 schematics 9.1 wire colors 9.2 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 generator d honda en...

  • Page 57: Gp 3800A

    Wc_tx003415gb.Fm 57 gp 3800a schematics 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 58: Schematics

    Wc_tx003415gb.Fm 58 schematics gp 3800a 9.3 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 sen...

  • Page 60

    Wacker neuson produktion gmbh & co. Kg, 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 limi...