www.wackergroup.com
Generator
G 3.3AE
OPERATOR’S MANUAL
0154607en 004
0403
wam
0154607EN
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.
• NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed
areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh air.
• ONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the home. ALWAYS use a
battery-powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh
air RIGHT AWAY. See a doctor. You could have carbon monoxide poison.
G 3.3AE Table of Contents
wc_bo0154607enTOC.fm 1
1. Foreword 3
2. Safety Information 4
2.1 Laws Pertaining to Spark Arresters ...................................................... 4
2.2 Operating Safety .................................................................................. 5
2.3 Operator Safety while using Internal Combustion Engines .................. 6
2.4 Service Safety ...................................................................................... 7
2.5 Label Locations .................................................................................... 8
2.6 Safety and Operating Labels ................................................................ 9
3. Technical Data 13
3.1 Generator ........................................................................................... 13
3.2 Engine ................................................................................................ 14
3.3 Sound Specifications .......................................................................... 14
4. Operation 15
4.1 Application and Power Requirements ................................................ 15
4.2 Indoor Installation ............................................................................... 16
4.3 Outdoor Installation ............................................................................ 16
4.4 Grounding the Generator .................................. ............................ ..... 17
4.5 Generator Derating ............................................................................. 18
4.6 Use of Extension Cords ...................................................................... 19
4.7 Earth-leakage Circuit Breaker ............................................................ 20
4.8 Control Panel ...................................................................................... 21
4.9 Before Starting ...................................................................................22
4.10 To Run ................................................. ..... .......................................... 23
4.11 To Stop ............................................ .... ..... ..... ..................................... 23
Table of Contents G 3.3AE
wc_bo0154607enTOC.fm 2
5. Maintenance 24
5.1 Engine Maintenance ............................................................................24
5.2 Periodic Maintenance Schedule ..........................................................24
5.3 Engine Oil ............................................................................................25
5.4 Air Cleaner ..........................................................................................26
5.5 Spark Plug ...........................................................................................27
5.6 Cleaning the Sediment Cup ................................................................28
5.7 Carburetor Adjustment ........................................................................28
5.8 Engine Speed ......................................................................................29
5.9 Storage ................................................................................................30
5.10 Transport .............................................................................................30
5.11 Troubleshooting ...................................................................................31
5.12 Wiring Schematic ...............................................................................32
Foreword
wc_si000053gb.fm 3
1. Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker m odel. For your o wn safety an d protectio n
from injury, carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especi ally copying and distribution rights, are reserved.
Copyright 2003 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permissi on from Wacker Corp or at ion.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.
Safety Information G 3.3A
wc_si000053gb.fm 4
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note:
Contains additional information important to a procedure.
2.1 Laws Pertaining to Spark Arresters
Notice: State Health Safety Codes and Public Resources Codes
specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.
DANGER
WARNING
CAUTION
G 3.3A Safety Information
wc_si000053gb.fm 5
2.2 Operating Safety
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER
DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR
DEATH TO UTILITY WORKERS!
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.
Connections to a building's electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical
codes.
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.
Familiarity and proper train ing are required for the safe operation of
equipment! Equi p me nt o pe ra te d i m properly or by untr ained personnel
can be dangerous! Read the operating instructions contained in both
this manual and the engine manual and familia rize yourself with the
location and prop er use of al l controls. In experienced op erators should
receive instruction from someone familia r with the equipment before
being allowed to operate the machine.
2.2.1 NEVER operate generator when open containers of fuel, paint, or
other flammable liquids are near.
2.2.2 NEVER operate generator, o r tools att ached to the generator, w ith wet
hands.
2.2.3 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
2.2.4 NEV ER run electrical cor ds under the generator , or over vibrating or
hot parts.
2.2.5 NEVER enclose or cover generator whe n in use or when hot.
2.2.6 NEVER overload generator. The total amperage of the tools and
equipment attached to the generator must not exceed the load rating
of the generator.
2.2.7 NEVER operate mach ine in snow, rain, or s tanding water.
2.2.8 NEVER allow u ntrained personn el to operate or ser vice the genera tor.
The generator set should be set up by a trained electric ian.
2.2.9 ALWAYS store equipment properly when it is not being used.
Equipment should be st ored i n a clean, d ry loca tion out of the reach of
children.
2.2.10 ALWAYS be sure machine is on a firm, level sur face and will not tip,
roll, slide, or fall while operating.
DANGER
WARNING
Safety Information G 3.3A
wc_si000053gb.fm 6
2.2.11 ALWAYS transport generator in an upright position.
2.2.12 ALWAYS keep machine at least one meter (three feet) away from
structures, buildings and other equipment during use.
2.2.13 ALWAYS keep the area immediately surrounding the generator clean,
neat and free of debris. Make sure that the area overhead is clear of
debris that could fall onto or into the generator, or exhaust
compartment.
2.2.14 ALWAYS r emove all tools, cord s, and other loose it ems from generator
before starting it.
2.2.15 ALWAYS make certain machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.
2.3 Operator Safety while using Internal Combustion Engines
Internal combustion eng ine s present sp ecial ha zard s during op eratio n
and fueling! Read and follow warning instructions in engine owner's
manual and safety guidelines below. Failure to follow warnings and
safety guidelines could result in severe injury or death.
2.3.1 DO NOT run machine indoors or in an enclosed area such as a deep
trench unless adequate ventilation, through such items as exhaust
fans or hoses, is provided. Exhaust gas from the engine contains
poisonous carbon monoxide gas; exposure to carbon monoxide can
cause loss of consciousness and may lead to death.
2.3.2 DO NOT smoke while operating machine.
2.3.3 DO NOT smoke when refueling eng i ne .
2.3.4 DO NOT refuel hot or running engine.
2.3.5 DO NOT refuel engine near open flame.
2.3.6 DO NOT spill fuel when refueling engine.
2.3.7 DO NOT run engine near open flames.
2.3.8 DO NOT start engine if fuel has spilled or an odor of fuel is present.
Move generator away from the spill and wipe generator dry before
starting.
2.3.9 ALWAYS refill fuel tank in well -ventilated area.
2.3.10 ALWAYS re pl ace fuel tank cap after refueling.
2.3.11 ALWAYS check fuel lines and fuel tank for leaks and cracks before
starting en gine. Do not run machine if fu el leaks are present or fue l
lines are loose.
DANGER
G 3.3A Safety Information
wc_si000053gb.fm 7
2.4 Service Safety
Poorly maintained equipment can become a safety hazard! In order
for the equipment to operate safely and properly over a long period of
time, periodic maintenance and occasi onal repairs are necessa ry. If
the generator is experiencin g problem s or is being serviced, attach a
"DO NOT START" sign to the control panel to notify other people of its
condition.
2.4.1 DO NOT use gasoline or othe r typ es of fuels or fl amm ab le sol ven ts to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
2.4.2 DO NOT attempt to clean or service machine while it is running.
2.4.3 DO NOT modify the equipmen t without express wri tten approval of the
manufacturer.
2.4.4 DO NOT allow water to accumulate around the base of the machine.
If water is present, move the machine and allow it to dry before
servicing.
2.4.5 DO NOT service machine if clothing or skin is wet.
2.4.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to se rvice the electric al
components of this equipment.
2.4.7 ALWAYS keep machine clean and labels legible. Replace all missing
and hard-to-read labels. Labels provide important operating
instructions and warn of dangers an d hazards.
2.4.8 ALWAYS replace safety devices and guards after repairs and
maintenance.
2.4.9 ALWAYS let engine cool before transporting or servicing.
2.4.10 ALWAYS keep hands, feet , and loose clothi ng away from movin g parts
on generator and engine.
2.4.11 ALWAYS turn engine off before servicing generator. If the engine has
electric start, disconnect negative terminal on battery
2.4.12 ALWAYS keep fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.
WARNING
Safety Information G 3.3A
wc_si000053gb.fm 8
2.5 Label Locations
wc_gr000675
GND
88897
D A N G E R
G E F A H R
D A N G E R
P E L I G R O
S T O P
2 -
1
5
1 1 5 6
G 3.3A Safety Information
wc_si000053gb.fm 9
2.6 Safety and Operating Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label Meaning
DANGER!
Engines emit carb on monoxide; oper ate only in well vent ilated area. Read the operator's
manual.
No sparks, flames or burning objects near machine. Shut off engine before refueling.
DANGER!
Electric shock ha zard. Read operator’s manual for instructions.
WARNING!
Hot surface.
CAUTION!
Read and underst and the supplied operator's
manual before operating this machine. Failure
to do so increases the risk of injury to yourself
or others.
CAUTION!
Lifting point
Electrical ground.
D A N G E R
G E F A H R
D A N G E R
P E L I G R O
S T O P
GND
88897
Safety Information G 3.3A
wc_si000053gb.fm 10
Open main circuit breaker.
Open fuel flow valve.
Close choke.
Push or turn engine switch to ON position.
Pull rewind starter.
Press engine crank switch to "CRANK" position.
Open choke.
Label Meaning
1
2
3
65
3
2
4
1
G 3.3A Safety Information
wc_si000053gb.fm 11
Close main circuit breaker.
Push or turn engine switch to OFF position.
Press engine crank switch to "OFF" position.
Close fuel flow valve.
Potential Earth - Hook up cable from grounding rod to this point.
Guaranteed sound power level in dB(A ).
Label Meaning
2 -
1 5 1 1 5 6
Safety Information G 3.3A
wc_si000053gb.fm 12
A nameplate listing the Model Number, Item
Number, Revision, and Serial Number is
attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or
damaged. When ordering parts or requesting
service information, you will alwa ys be asked
to specify the model, item number, revision
number, and serial number of the unit.
This machine may be covered by one or more
patents.
Label Meaning
MENOMONEE FALLS, WI USA 53051
110635
Rev. Serial No.
A
kW
hz
N/M
Item No.
Vclass
lbs
kg
Model
Man.
Yr.
MADE
IN USA
Insul.
Class
GENERATING SET ISO 8528
G 3.3A Technical Data
wc_td000056gb.fm 13
3. Technical Data
3.1 Generator
Item No. G3.3AE
0008259
Generator
Output
kVA
3.3
Type Single voltage, single phase, brush-type system
AC Voltages Available
volts / phase
230 / 1ø
Frequency
Hz
50
Power Factor
cos Ø
1.0
AC receptacles
qty / amp
2 / 16
Main Circuit Breaker
amp
15
Dimensions
mm
685 x 585 x 530
Weight (dry)
Kg
71
Technical Data G 3.3A
wc_td000056gb.fm 14
3.2 Engine
3.3 Sound Specifications
The required sound specification, Paragraph 1.7.4.f of 89/392/EEC
Machinery Directive, is:
Guaranteed sound power level (LWA) = 99 dB(A).
This sound value were determined according to ISO 3744 for the
sound power level (LWA).
Item No. G3.3AE
0008259
Engine
Engine Make Honda
Engine Model GX 240 K1 QA2
Rated Power
kW
4.8
Spark Plug NGK BPR 6ES
Electrode Gap
mm
0.7 - 0.8
Engine Speed - full load
rpm
3000 ± 100
Engine Speed - no load
rpm
3100 ± 100
Air Cleaner
type
Dual element
Engine Lubrication
oil grade
SAE 10W30 service class SG or SF
Engine Oil Capacity
ml
1100
Fuel
type
Regular unleaded gasoline
Fuel Tank Capacity
liters
19.5
Fuel Consumption
liters/hr.
2.38
Running Time
hrs.
8.2
Valve clearance (cold)
mm
Inlet: 0.15
Outlet: 0.20
G 3.3A Operation
wc_tx000150gb.fm 15
4. Operation
4.1 Application and Power Requirements
This generator is designed to oper ate single-phas e, 50 Hz appliances
running at 230 VAC.
CAUTION: Do not excee d the pow er outp ut of the generat or. Dama ge
to tools or generator will occur. See
Technical Data
.
Check the nameplate or label provided on tools and appliances to
make sure their powe r requirements are met by the power output of the
generator. If the wattage is not given for a particular tool or appliance,
contact the tool manufacturer for wattage requirements.
Some appliances and tools require a surge of current when starting.
This means that the amount of power needed to initially start the
equipment is larger than th e power required to keep it running. The
generator must be capable of supplying this "surge" current. Other
types of applianc es require mo re power than is actu ally stated o n their
nameplate.
The information in “Approximate Starting Power Requirements” is
offered only as a general guideline to help you determine power
requirements for di fferent types of e quipment. Check w ith your nearest
Wacker dealer, or contact the manufacturer or dealer of the tool or
appliance, if you have questions regarding power requirements.
CAUTION: DO NOT exceed the rated current limit of any receptacle.
CAUTION: If a tool or appl iance does not reach full speed wi thin a fe w
seconds after it is switched on, turn it off immediately to avoid damage.
Approximate Starting Power Requirements
• Incandescent lights and appliances such as irons and hot plates,
which use a resisti ve-type hea ting eleme nt, r equir e the same watt age
to start and run as is stated on their nameplates.
• Fluorescent an d mercury lamps require 1.2–2 times their stated wattage to start.
• Electrical motors and many types of electrical tools often require a
large starting current. The amount of starting current depends on the
type of motor and its use.
• Most electrical tools require 1.2–3 times their stated wattage for starting.
• Loads such as submersible pumps and air compressors require a
very large force to sta rt. They need as much as 3–5 times the watta ge
stated on the nameplate in order to start.
If the wattage is not given for a particular tool or appliance, it can be
calculated by multiplying its voltage and amperage requirements:
VOLTS x AMPS = WA TTS
Operation G 3.3A
wc_tx000150gb.fm 16
4.2 Indoor Installation
If the generator must be installed indoors, adequate ventilation or
exhaust hoses must be provided. When venting exhaust fumes, make
sure the exhaust piping is large enough to prevent excessive back
pressure to the engine. Back pressure reduces engine efficiency and
may cause the engine to ove rheat.
Exhaust gas from the engine contains poisonous carbon monoxide
gas; exposure to carbon monoxide can cause loss of consciousness
and may lead t o d eat h. Never run gene ra to r indoors or in an enclosed
area unless adequate ventilation, through such items as exhaust
hoses or fans, is provided.
When installed indoors, steps to prevent fire and explosion such as
providing a good earthen ground, removing all flammable materials
near generator, and using only electrical cables in good condition,
must be observed. See
Operating Saf ety.
4.3 Outdoor Installation
Place the generator in an area where it will not be exposed to rain,
snow or direct sunlight. Make sur e it is positioned on fi rm, level ground
so it will not slide or shift. Position e ngine exhaust away from areas
where people may be present.
If operating the generator inside a tunnel or deep trench, make sure
there is adequate ventilation. Precautions similar to those required
when operating indoors may be necessary.
The surrounding area must be free from water and moisture. All
components must be protected from excessive moisture.
DANGER
G 3.3A Operation
wc_tx000150gb.fm 17
4.4 Grounding the Generator
See Graphic: wc_gr00054 4
The generator should be grounded to a good ground source in
compliance with state and local regulations.
Use 10 mm2 wire and secure one end to the ground terminal (a)
provided on the genera tor frame and the other end to a suita ble ground
source.
w c _ g r 0 0 0 5 4 4
=
Operation G 3.3A
wc_tx000150gb.fm 18
4.5 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 lack of air pressure. This translates into a
lack of power and thus reduction in generator output. Temperature
affects both engine and generator performance. As temperature
increases, an engine will run less efficiently and the more resistance
will be found in electrical components. Therefore, as the temperature
increases, the output of the generator decreases. Altitude also affects
the cooling capacity of air—the higher the altitude the less dense the
air is and thus the lower its ability to transfer heat.
For every increase in altitude of 500 m (1650 ft.) above 1000 m (3300
ft.), the output of the generator will be reduced by 3%. For every
increase of 5° C (9° F) in ambient temperature above 40° C (104° F),
the output of the generator will be reduced by 3%. Use the tables
shown for altitude and temperature deration factors. It may be
necessary to consider bot h a lt it ud e an d a m bien t te mperature deration
factors to determine true generator output.
Ambient Temp.
°C (°F)
Derate Factor
45 (113) 3 % 0.97
50 (122) 6 % 0.94
55 (131) 9 % 0.91
60 (140) 12 % 0.88
Altitude
m (ft.)
Derate Factor
1500 (4900) 3 % 0.97
2000 (6600) 6 % 0.94
2500 (8200) 9 % 0.91
3000 (9900) 12 % 0.88
3500 (11500) 15 % 0.85
4000 (13100) 18 % 0.82
G 3.3A Operation
wc_tx000150gb.fm 19
4.6 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 in creases th e amount o f current draw or reduces
performance. A cord with a larger cross section will reduce the voltage
loss.
CAUTION: Operating equipment at low voltage can cause it to
overheat.
Use the table as a g uide for selecting proper cable siz e.
Use only tough rubber-sheathed cable in accordance with IEC 245-4.
Damaged cords can cause electrical shock. Electric shock can cause
serious injury or death. DO NOT use worn, bare, or frayed cords.
Replace damaged cords immediately.
Minimum Extension Cord Size 230V
Volts Total length of cord in meters
230 V 0 - 30 30 - 60
Amp Rating
Cross sectional area of wire in mm
2
2 0.75 1.5
41.5 2.5
61.5 4
82.5 4
10 2.5 6
15 4 10
20 6 10
25 6 16
30 10 16
WARNING
Operation G 3.3A
wc_tx000150gb.fm 20
4.7 Earth-leakage Circuit Breaker
See Graphic: wc_gr000 66 1
Generator models ending with an “AE” are equipped with an earthleakage circuit breaker. The circuit breaker is current-operated and
shuts off the power to the receptacles when a ground fault of 30 milliAmps or greater occurs in the generator or to a piece of equipment
attached to the gen er ato r. The ci r cui t br ea ker i s l oc ate d o n the con tr ol
panel and should be tested for proper operation every time the
generator is used.
To test the earth-leakage circuit breaker:
4.7.1 Start the generator.
4.7.2 Place main circuit br eaker in closed position.
4.7.3 Push the TEST button (a) on the circuit breaker. The circuit breaker
lever will lower to the open position (b2). Power is now off at both
receptacles.
If the lever does not lowe r, the circuit breaker is no t working. Do not
use the generator until the problem can be corrected.
4.7.4 To restore power to the receptacles, raise the circuit breaker lever to
the closed position (b1).
If the circuit brea ker lever low ers to the open position during o peration,
stop the generator and check it and equipment for defects. Repair all
defects before operating generator.
wc_gr000661
a
a
b1
b2
G 3.3A Operation
wc_tx000150gb.fm 21
4.8 Control Panel
See Graphic: wc_gr00067 9
The generator is protected by a 15 amp circuit breaker (a) located on
the control panel.
The circuit breaker protects the generator from severe overloads or
short circuits. If the circuit breaker opens, turn the engine off
immediately and determine the cause before restarting. Check the
appliances an d tools att ached to t he generat or for defec ts and make
sure their power requ irements do not exc eed the power rating of the
generator or the current limit of the receptacles.
When the circuit breaker open s, the breaker lever will snap down. To
reset circuit breaker, lift lever up.
Control Panel
Ref. Description Ref. Description
a Main circuit breaker - 15 amps c Earth-leakage circuit breaker
(models “AE” only)
b Receptacles
wc_gr000679
1
2
365
3
2
4
1
T
E
S
T
a
c
b
Operation G 3.3A
wc_tx000150gb.fm 22
4.9 Before Starting
4.9.1 Read and unde rstand safety a nd opera ting instructio ns at begi nning of
this manual.
4.9.2 Read and understand the meanings of all warning and operating
labels.
4.9.3 Check:
• oil level in engine.
• fuel level.
• condition of air cleaner.
• tightness of external fasteners.
• condition of fuel lines.
G 3.3A Operation
wc_tx000150gb.fm 23
4.10 To Run
See Graphic: wc_gr000679 a nd wc_gr000665
4.10.1 Disconnect all loads from the generator and place main circuit breaker
lever in open posi tion (O).
4.10.2 Open fuel valve by moving lever to the right (a1).
4.10.3 If engine i s col d , move cho k e le ver to cl osed po siti on (b1). If engine is
hot, set choke to open position (b2).
4.10.4 Turn engine switch to "ON" (c1) and pull starter rope (d).
Note:
If the oil level in the engine is low, the engine will not start. If this
happens, check oil level and add oil as needed.
4.10.5 Open choke as engine warms (b2).
4.10.6 Place mai n circ uit br ea ker in clos ed positi on (l). Allow engine to warm
up a few minutes before attaching loads. On models ending with an
“AE” check the function of the earth-leakage circuit breaker. See
Earth-leakage Circuit Breaker
.
4.11 To Stop
See Graphic: wc_gr000679 a nd wc_gr000665
4.11.1 Turn off and disconnect all tools and appliances attached to the
generator.
4.11.2 Place main circuit breaker in open position (O).
4.11.3 Turn the engine switch to "OFF" (c2).
4.11.4 Close fuel valve by moving lever to the left (a2).
Note:
To stop engine quickly in an emergency, turn engine switch to
"OFF".
wc_gr000665
a1
a2
b1
b2
c1
c2
d
Maintenance G 3.3A
wc_tx000161gb.fm 24
5. Maintenance
5.1 Engine Maintenance
The chart below lists b asic machine and engine mai ntenance. Refer to
engine manufactu rer’s Opera tor’s Manua l for ad ditional inf ormation o n
engine maintenance.
5.2 Periodic Maintenance Schedule
Daily
before
starting
After
first
20 hrs.
Every
50
hrs.
Every
100
hrs.
Every
300
hrs.
Check fuel level. •
Check engine oil level. •
Inspect air filter. Replace as needed. •
Check and tighten external hardware. •
Clean air cleaner element.* •
Inspect shockmounts for damage. •
Change engine oil.* ••
Clean sediment cups. •
Check and clean spark plug. •
Check and adjust valve clearance. •
Clean fuel tank.* •
Check condition of fuel line. Replace
when necessary.
•
*Service more frequently in dusty conditions.
G 3.3A Maintenance
wc_tx000161gb.fm 25
5.3 Engine Oil
See Graphic: wc_gr00002 2
5.3.1 Drain oil while the engine is still warm.
5.3.2 Remove the oil fill plug (a) and drain plug (b) to drain oil.
Note:
In the interests of environmen tal protection, place a plastic sheet
and a contain er under the ma chine to collect any liquid whic h drains
off. Dispose of this liquid in accordance wit h environmen tal protec tion
legislation.
5.3.3 Install drain plug .
5.3.4 Fill the engine cra nkcase with recommend ed oil up to the level of the
plug opening (c). See
Technical Data
for oil quantity and type.
5.3.5 Install the oil filler plug.
Maintenance G 3.3A
wc_tx000161gb.fm 26
5.4 Air Cleaner
See Graphic: wc_gr000 02 5
The engine is equ ipped with a dual element air cleane r. Service air
cleaner frequently to prevent carburetor malfunction.
CAUTION: NEVER run engine without air cleaner. Severe engine
damage will occur.
NEVER use gasoline or other types of low flash point solvents for
cleaning the air cleaner. A fire or explosion could result.
To service:
5.4.1 Remove air cleaner cover (a). Remove both elements and inspect
them for holes or tears. Replace damaged elements.
5.4.2 Wash foam element (b) in solution of mild detergent and warm water.
Rinse thoroughly in clean water. Al low element to dry thoroughly. Soak
element in clean engine oil and squeeze out excess oil.
5.4.3 Tap paper element (c) lightly to remove excess dirt. Replace paper
element if it appears heavily soiled.
WARNING
G 3.3A Maintenance
wc_tx000161gb.fm 27
5.5 Spark Pl ug
See Graphic: wc_gr00002 8
Clean or replace spark plug as needed to ensure proper operation.
Refer to the engine Owner’s Manual.
The muffler becom es very hot during oper ation a nd r emains h ot fo r a
while after stop ping the engine. Do not touc h the muffle r while it is hot.
Note:
Refer to the Technical Data for the recommended spark plug
type and the electrode gap setting.
5.5.1 Remove spark plug and inspect it.
5.5.2 Replace plug if the insulator is cracked or chipped.
5.5.3 Clean spark plug electrodes with a wire brush.
5.5.4 Set the electrode gap (a).
5.5.5 Tighten spark plug securely.
CAUTION: A loose spark plug can become very hot and may cause
engine damage.
WARNING
Maintenance G 3.3A
wc_tx000161gb.fm 28
5.6 Cleaning the Sediment Cup
See Graphic: wc_gr000 02 9
5.6.1 Turn fuel valve off.
5.6.2 Remove sediment cup (a) and O-ring (b).
5.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall
them.
5.6.4 Turn fuel valve on and check for leaks.
5.7 Carburetor Adjustment
See Graphic: wc_gr001 06 1
The pilot screw (a) is fitted with a limiter cap to prevent excessive
enrichment of the air-fuel mixture in order to comply with emission
regulations. The mixture is set a t the factory and no adjustment shou ld
be necessary. Do not attempt to remove th e limiter cap. The limiter cap
cannot be remov ed without breaking the pil ot screw.
wc_gr001061
a
G 3.3A Maintenance
wc_tx000161gb.fm 29
5.8 Engine Speed
See Graphic: wc_gr00011 4
Adjust engine to the no load or idle speed per the Technical Data.
5.8.1 Start the engine and allow it to warm up to normal operating
temperature.
5.8.2 Tur n the throt tle stop scr ew (a) in to increa se spee d, out to dec rease
speed. Make sure the throttle lever is touching the stop screw before
measuring rpm.
wc_gr000114
a
Maintenance G 3.3A
wc_tx000161gb.fm 30
5.9 Storage
Before storing generator for a long period of time:
5.9.1 Close the fuel valve and remove and empty sediment cup under
carburetor.
5.9.2 Disconnect the fuel line from the carburetor. P lace open end o f fuel line
into a suitable container and open fuel val ve to drain fue l from tank.
Gasoline is extrem ely flammable. Drai n fuel tank in a well ve ntilated
area. DO NOT drain tank in an area with flames or sparks.
5.9.3 Loosen the drain screw on the carburetor and drain any remainin g fuel
from carburetor.
5.9.4 Change the engine oil.
5.9.5 Remove the spark plug and pour approximately 30 ml (1 ounce) of
clean engine oil into the cylinder. Crank the engine a few turns to
distribute the oil to the inside of the cylinder walls.
5.9.6 Pull the starter rope slowly until resistance is felt and leave handle in
this position. This ensures that the intake and exhaust valves are
closed.
5.9.7 Store generator in a clean, dry area.
5.10 Transport
Let the engine cool before transporting the generator or storing
indoors, to avoid burns or fire hazards.
When transporting the generator:
5.10.1 Turn the engine fuel valve to the OFF position.
5.10.2 Position the generator level to prevent fuel from spilling.
5.10.3 Secure the generator by tying it down with a suitable rope.
WARNING
WARNING
G 3.3A Maintenance
wc_tx000161gb.fm 31
5.11 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 when starting a cold engine.
• All loads are disconnected from generator.
• Spark plug is in good condition.
• Spark plug cap is tight.
• Engine oil level is adequate.
If engine starts bu t th er e is n o
power at receptacles, check
that:
• Circuit breaker is closed.
• Conn ector from generator to contro l panel is ti ght .
If engine starts but runs erratically, check that:
• Hose routing from the fuel tank to the engine is correct. For proper operation, the hose must run
through the bushing in the lifting bracket. Refer to
the Parts Book for illustration.
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
Maintenance G 3.3A
wc_tx000161gb.fm 32
5.12 Wiring Schematic
See Graphic: wc_gr000 68 0
Ref. Description Ref. Description Ref. Description
A Generator B Control Box C Engine
Ref. Description Ref. Description
1. Main stator winding 7. RFI suppressor
2. Main circuit breaker 8. Rotor winding
3. Earth-leakage circuit breaker
(“AE” models only)
9. Automatic voltage regulator
4. 16A receptacle 10. Ignition switch
5. Choke 11. Oil level switch
6. Auxilliary winding 12. Coil
wc_gr000680
OFF
ON
1
2
T
2
4
3
1
2
F2
F1
4
Z1
Z1
Z2
Z2
R
W
LL/W
R/B
LL/B
R/B
LL/B
R/B
R/Gr
LL/B
LL/Gr
G/Y
G/Y
G/Y
L/L
L
Br
B
R
B
B
Y
B/R
G
10
C
11
4
BA
3
2
1
7
9
8
6
5
12
1
3
L1
L2
F1
F2
Z3
Z3
R/W
1
R
1
2
4
LL/W
Br
G/Y
G/Y
2003-CE-Generators33Q.fm
William Lahner Dan Domanski
Vice President of Engineering Manager, Product Engineering
WACKER CORPORATION
Date / Datum / Fecha / Date
EC DECLARATION OF CONFORMITY
CE-KONFORMITÄTSERKLÄRUNG
DECLARACIÓN DE CONFORMIDAD DE LA CE
DÉCLARATIO N DE CONFORMITÉ C.E.
WACKER CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA
hereby certifies that the construction equipment specified hereunder/ bescheinigt, daß das Baugerät / certifica que la máquina de
construcción / atteste que le matériel:
1. Category / Art / Categoría / Catégorie
Power Generators
Kraftstromerzeuger
Grupos Electrógenos
Groupe Électrogènes de Puissance
2. Type - Typ - Tipo - Type
G3.3A, G3.3AE, G3.3AI
3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel :
0008251, 0008252, 0008253, 0008254, 0008255,
0008256, 0008257, 0008258, 0008259, 0009036
4. Electric power / Elektrische Leistung/ Potencia eléctrica / Force motrice :
3,3 kW
Has been sound tested per Directive 2000/14/EC / In Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist / Ha sido
ensayado en conformidad con la norma 2000/14/CE / A été mis à l’épreuve conforme aux dispositionsde la directive 2000/14/CEE :
and has been produced in accordance with the following standards:
und in Übereinstimmung mit folgenden Richtlinien hergestellt worden i st:
y ha sido fabricado en conformidad con las siguientes nor mas:
et a été produit conforme aux dispositions des directives européennes ci-après :
2000/14/EC
89/336/EEC
98/37/EEC
AUTHORIZED REPRESENTAT IVE IN THE EUROPEAN UNION
BEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFT
REPRESENTANTE AUTORIZADO EN LA UNIÓN EUROPEA
REPRÉSENTANT AGRÉÉ AUPRÈS DE L’UNION EUROPÉENNE
WACKER CONSTRUCTION EQUIPMENT AG
Preußenstraße 41
80809 München
Conformity Assessment Procedure /
Konformitätsbe w ertungsv erfahren /
Procedimiento para ensayar
conformidad/ Procédé pourl’épreuv e
de conformité
Name and address of notified
body / Bei folgender
einbezogenerPrüfstelle/
Oficina matriculadora /
Organisme agrée
Measured sound power level /
Gemessener Schallleistungspegel / Nivel de potencia
acústica determinado/ Niveaude
puissance acoustique fixé
Guaranteed sound power level/
Garantierter Schallleistungspegel/
Nivel de potencia acústica
garantizado/ Niveau de puissance
acoustique garanti
Annex VIII / Anhang VIII
Anexo VIII / Annexe VIII
BSI, 389 Chiswick High
Road, London W4 4AL
United Ki ngdom
97 dB(A) 99 dB(A)
09.04.03
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-354 02 - 0 · Fax: +49 - (0)89-354 02-390
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : +1-(1)(262) 255-0500 · Fax: +1-(1)(262) 255-0550 · Tel. : (800) 770-0957
Wacker Asia Pacific Operations · Sunley Center, Unit 912, 9/F · 9 Wing Qin Street, Kwai Chung, N.T. · Hong Kong · Tel. + 852 2406 60 32 · Fax: + 852 2406 60 21
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