Wacker Neuson GP 3800A Operator's Manual

Page 1
Operator’s Manual
Portable Generator
GP 3800A
non-CARB
EN
5000186190 05 0713
5000186190
Page 2
© 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 permission from Wacker Neuson Production Americas LLC.
Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights. Violators will be prosecuted.
Trademarks
All trademarks referenced in this manual are the property of their respective owners.
Manufacturer
Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A. Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original instructions
This Operator’s Manual presents the original instructions. The original language of this Operator’s Manual is American English.
Page 3
GP 3800A Foreword
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 Item Number
GP 3800A 5000620104, 5000620379, 5000620485
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. f NEVER use a generator inside homes, buildings, 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.
f ONLY use a generator outside, and far away from homes, buildings, windows,
doors, and vents. Windows, doors, and vents can pull in generator exhaust.
f Point the engine exhaust away from homes, buildings, windows, doors, and
vents. Also, point the engine exhaust away from combustible materials.
f Even when you use a generator correctly, CO may leak into the home or build-
ing. ALWAYS use a battery-powered or battery-backup CO alarm in the home or building.
f 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 poisoning.
wc_tx003410gb.fm 3
Page 4
Foreword GP 3800A
wc_gr010936
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)
Machine documentation
Expectations for information in this manual
For future reference, record the serial number in the space provided below. You will need the serial number when requesting parts or service for this machine.
Serial Number:
From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
Keep a copy of the Operator’s Manual with the machine at all times. Use the separate Parts Book supplied with the machine to order replacement
parts.
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.
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to reduce the risk of injury, carefully read, understand, and observe all instructions described in this manual.
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change any portion of this information without notice.
The illustrations, parts, and procedures in this manual refer to Wacker Neuson
factory-installed components. Your machine may vary depending on the requirements of your specific region.
4 wc_tx003410gb.fm
Page 5
GP 3800A Foreword
CALIFORNIA Proposition 65 Warning
Laws pertaining to spark arresters
Manufacturer’s approval
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.
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.
This manual contains references to approved parts, attachments, and modifica­tions. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
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, attachments, or modifications may have the following conse­quences:
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.
wc_tx003410gb.fm 5
Page 6
Foreword GP 3800A
6 wc_tx003410gb.fm
Page 7
GP 3800A
Table of Contents
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 ................................................................................ 11
1.4 Operator Safety while Using Internal Combustion Engines ............... 15
1.5 Service Safety .................................................................................... 16
2 Labels 18
2.1 Label Locations .................................................................................. 18
2.2 Label Meanings .................................................................................. 19
3 Lifting and Transporting 23
4 Operation 24
4.1 Preparing the Machine for First Use ................................................... 24
4.2 Determining Power Requirements ..................................................... 25
4.3 Positioning the Generator for Operation ............................................. 26
4.4 Recommended Fuel ........................................................................... 28
4.5 Wheel Kit ............................................................................................ 28
4.6 Generator Derating ............................................................................. 30
4.7 Grounding the Generator ................................................................... 31
4.8 Operating Heavy Loads ...................................................................... 31
4.9 Use of Extension Cords ...................................................................... 32
4.10 Control Panel ...................................................................................... 33
4.11 Ground Fault Interrupt (GFI / GFCI) ................................................... 34
4.12 Twist-Lock Receptacles ..................................................................... 35
4.13 Engine Auto Idle ................................................................................. 35
4.14 Engine Speed ..................................................................................... 35
4.15 Voltage Selector ................................................................................. 36
4.16 Before Starting ................................................................................... 37
4.17 Starting ............................................................................................... 38
4.18 Stopping ............................................................................................. 39
4.19 Emergency Shutdown Procedure ....................................................... 39
wc_bo5000186190_05TOC.fm 7
Page 8
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 ............................................................................................41
5.4 Servicing the Air Cleaner .....................................................................42
5.5 Spark Plug ...........................................................................................43
5.6 Cleaning the Sediment Cup ................................................................44
5.7 Adjusting the Carburetor .....................................................................45
5.8 Engine Speed ......................................................................................45
5.9 Storage ................................................................................................46
6 Troubleshooting 47
7 Technical Data 48
7.1 Generator ............................................................................................48
7.2 Engine .................................................................................................49
8 Emission Control Systems Information and Warranty 51
8.1 Emission Control System Background Information .............................51
8.2 Limited Defect Warranty for Exhaust Emission Control System .........52
8.3 Limited Defect Warranty for Wacker Neuson
Evaporative Emission Control Systems ..............................................53
9 Schematics 56
9.1 Wire Colors ..........................................................................................56
9.2 Electrical Schematic ............................................................................56
9.3 Engine Wiring ......................................................................................58
8 wc_bo5000186190_05TOC.fm
Page 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.
This is the safety alert symbol. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
f To avoid death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
f To avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
f To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
wc_si000793gb.fm
9
Page 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. The control panel includes controls and receptacles. As the engine runs, the generator converts mechanical energy into electric power. The operator connects loads to the electric power receptacles.
This machine is intended for the purpose of supplying electrical power to connected loads. Refer to the product specifications for the output voltage and frequency of this generator, and the maximum output power limit of this generator.
This machine has been designed and built strictly for the intended use described above. Using the machine for any other purpose could permanently damage the machine or seriously injure the operator or other persons in the area. Machine damage caused by misuse is not covered under warranty.
The following are some examples of misuse:
Connecting a load that has voltage and frequency requirements that are
incompatible with the generator output
Overloading the generator with a load that draws excessive power during either
continuous running or start-up
Operating the generator in a manner that is inconsistent with all federal, state
and local codes and regulations
Using the machine as a ladder, support, or work surfaceUsing the machine to carry or transport passengers or equipmentOperating the machine outside of factory specificationsOperating the machine in a manner inconsistent with all warnings found on the
machine and in the Operator’s Manual.
This machine has been designed and built in accordance with the latest global safety standards. It has been carefully engineered to eliminate hazards as far as practicable and to increase operator safety through protective guards and labeling. However, some risks may remain even after protective measures have been taken. They are called residual risks. On this machine, they may include exposure to:
Heat, noise, exhaust, and carbon monoxide from the engineFire hazards from improper refueling techniquesFuel and its fumesElectric shock and arc flashPersonal 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.
10
wc_si000793gb.fm
Page 11
GP 3800A Safety Information
1.3 Operating Safety
DANGER Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.
f NEVER use a generator inside homes, buildings, 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.
f ONLY use a generator outside, and far away from homes, buildings, windows,
doors, and vents. Windows, doors, and vents can pull in generator exhaust.
f Point the engine exhaust away from homes, buildings, windows, doors, and
vents. Also, point the engine exhaust away from combustible materials.
f Even when you use a generator correctly, CO may leak into the home or build-
ing. ALWAYS use a battery-powered or battery-backup CO alarm in the home or building.
f 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 poisoning.
Operator training
Operator qualifications
WARNING
Risk of electric shock or electrocution.
f Do not operate this generator in rain, snow, or standing water.
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
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.
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 machineare familiar with required safety devices
The machine must not be accessed or operated by:
childrenpeople impaired by alcohol or drugs
wc_si000793gb.fm
11
Page 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 the application area.
Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
Safety devices,
controls, and attachments
Safe operating
practices
Only operate the machine when:
All safety devices and guards are in place and in working order.All controls operate correctly.The machine is set up correctly according to the instructions in the Operator’s
Manual.
The machine is clean.The machine’s labels are legible.
To ensure safe operation of the machine:
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.
When operating this machine:
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
When operating this machine:
Do not operate a machine in need of repair.Do not consume the operating fluids used in this machine. Depending on your
machine model, these operating fluids may include water, wetting agents, fuel (gasoline, diesel, kerosene, propane, or natural gas), oil, coolant, hydraulic fluid, heat transfer fluid (propylene glycol with additives), battery acid, or grease.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while operating this machine:
Close-fitting work clothes that do not hinder movementSafety glasses with side shieldsHearing protectionSafety-toed footwear
12
wc_si000793gb.fm
Page 13
GP 3800A Safety Information
Installing as backup power
Transporting and installing the machine
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. This may result in electrocution of utility workers, fire, or explosion.
WARNING
Backfeed from the generator into the public power distribution system can cause serious injury or death to utility workers!
f Connections to a building’s electrical system must be made by a qualified elec-
trician 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.
Never allow untrained personnel to operate or service the generator. The
generator set should be set up by a certified electrician.
Do not stand under the machine while it is being hoisted or moved.Do not attach equipment to the machine when it is suspended.Always transport the generator in an upright position.Always position and operate the generator on a firm, noncombustible, level
surface.
Always make certain the machine is well-grounded and securely fastened to a
good earthen ground per national and local regulations.
Always remove all tools, cords, and other loose items from the generator before
starting it.
General Safety
Generator vibration
wc_si000793gb.fm
Do not operate the generator when open containers of fuel, paint, or other
flammable liquids are near.
Do not operate the generator, or tools attached to the generator, with wet hands.Do not run the electrical cords under the generator, or over vibrating or hot
parts.
Do not enclose or cover the generator when it is in use or when it is hot.Do not overload the generator. The total amperage of the tools and equipment
attached to the generator must not exceed the load rating of the generator.
Do not operate the machine in snow, rain, or standing water.Do not stand on the machine.
Generators vibrate in normal use. During and after the use of the generator, 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.Do not use plugs or or cords that show signs of damage such as broken or
cracked insulation or damaged blades.
13
Page 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 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 other types of fuels or flammable solvents to clean the
machine. Fumes from fuels and solvents can become explosive.
14
wc_si000793gb.fm
Page 15
GP 3800A Safety Information
1.4 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. f Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
f 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.
Refueling safety
Operating 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 vapors.
Do not refuel a hot or running engine.Do not refuel the engine near an open flame.
When refueling the engine, always:
Refill the fuel tank in a well-ventilated area.Replace the fuel tank cap after refueling.
When operating the generator:
Check the fuel lines and the fuel tank for leaks and cracks before starting the
engine.
Do not run the machine if fuel leaks are present or the fuel lines are loose.Do not run the engine near open flames.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.
wc_si000793gb.fm
15
Page 16
Safety Information GP 3800A
1.5 Service Safety
Service training
Precautions
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
devices.
Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
Do not allow improperly trained people to service or maintain the machine.
Personnel servicing or maintaining the machine must be familiar with the associated potential risks and hazards.
Follow the precautions below when servicing or maintaining the machine.
Read and understand the service procedures before performing any service to
the machine.
All adjustments and repairs must be completed before operating the machine.
Do not operate the machine with a known problem or deficiency.
All repairs and adjustments shall be completed by a qualified technician.Turn off the machine before performing maintenance or making repairs.Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
Re-install the safety devices and guards after repair and maintenance
procedures are complete.
Machine modifications
Replacing parts and
labels
When servicing or maintaining the machine:
Use only accessories/attachments that are approved by Wacker Neuson.
When servicing or maintaining the machine:
Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker
Neuson.
Replace worn or damaged components.Replace all missing and hard-to-read labels.When replacing electrical components, use components that are identical in
rating and performance to the original components.
When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material.
16
wc_si000793gb.fm
Page 17
GP 3800A Safety Information
Cleaning
Personal Protective
Equipment (PPE)
Precautions
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 other types of fuels or flammable solvents to clean the
machine. Fumes from fuels and solvents can become explosive.
Wear the following Personal Protective Equipment (PPE) while servicing or maintaining this machine:
Close-fitting work clothes that do not hinder movementSafety glasses with side shieldsHearing protectionSafety-toed footwear
In addition, before servicing or maintaining the machine:
Tie back long hair.Remove all jewelry (including rings).
Do not allow water to accumulate around the base of the machine. If water is
present, move the machine and allow the machine to dry before servicing.
Do not service the machine if your clothing or skin is wet.Always turn the engine off before servicing the machine. If the engine has
electric start, disconnect the negative terminal on the battery before servicing the machine.
Always let the engine cool before transporting or servicing the machine.
wc_si000793gb.fm
17
Page 18
Labels GP 3800A
2 Labels
2.1 Label Locations
D
C
B
E
A
F
G
H
J
L
K
wc_gr010937
18
wc_si000794gb.fm
Page 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 regulations relating to fire prevention requirements.
D
DANGER
Read the Operator’s Manual.No sparks, flames, or burning objects near
the machine.
Stop the engine before refueling.
GFCI TEST INSTRUCTIONS - TEST BEFORE EACH USE
Normal operating state - sensing device green LED is “ON” and circuit breaker is at “ON” position. Step 1: Press “TEST” button. Green LED should go “OUT”, red LED should come “ON”, and circuit breaker should trigger to “OFF” position. Step 2: If sensing device LED or breaker does not trip or change state, DO NOT USE. Consult an electrician for assistance.
Step 3: Press “RESET” button. Red LED should turn “OFF” and green LED should turn “ON”. Step 4: Manually reset (switch) circuit breaker to “ON” position to restore circuit power.
wc_si000794gb.fm
19
Page 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 gasoline fuel.
Check the fuel level.
Open the fuel flow valve.
Close the choke.
20
wc_si000794gb.fm
Page 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 is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN
IF doors and windows are open.
Only use OUTSIDE and far away from
windows, doors, and vents.
wc_si000794gb.fm
21
Page 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 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.
J Electrical ground
88897
GND
K WARNING
Test GFCI before each use. See label above.
L This machine may be covered by one or more
patents.
22
wc_si000794gb.fm
Page 23
GP 3800A Lifting and Transporting
3 Lifting and Transporting
Lifting the Machine
Transporting 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.
Make sure lifting equipment is attached securely and has enough weight-
bearing capacity to lift or hold the generator safely.
Remain aware of the location of other people nearby when lifting the generator.
Observe the following guidelines when transporting the generator to and from the job site.
Allow the engine to cool before transporting the generator.Drain the fuel tank.Close the fuel valve.Ensure that the generator is securely strapped down in the transport vehicle to
prevent it from sliding or tipping.
Do not refuel the generator in or on the transport vehicle. Move the generator to
its operating location and then fill the fuel tank.
wc_tx003411gb.fm
23
Page 24
Operation GP 3800A
4 Operation
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.
f NEVER use a generator inside homes, buildings, 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.
f ONLY use a generator outside, and far away from homes, buildings, windows,
doors, and vents. Windows, doors, and vents can pull in generator exhaust.
f Point the engine exhaust away from homes, buildings, windows, doors, and
vents. Also, point the engine exhaust away from combustible materials.
f Even when you use a generator correctly, CO may leak into the home or build-
ing. ALWAYS use a battery-powered or battery-backup CO alarm in the home or building.
f 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 poisoning.
WARNING
Risk of electric shock or electrocution.
f Do not operate this generator in rain, snow, or standing water.
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 Neuson dealer immediately for assistance.
3. Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for.
4. Attach component parts not already attached.
5. Add fluids as needed and applicable, including fuel, engine oil, and battery acid.
6. Move the machine to its operating location.
24
wc_tx003412gb.fm
Page 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 the generator.
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 the power required to keep it running. The generator must be capable of supplying this “surge” current. Other types of appliances require more power than is actually stated on their nameplate.
The information in “Approximate Starting Power Requirements” is offered only as a general guideline to help you in determining power requirements for different types of equipment. Check with your nearest Wacker Neuson dealer, or contact the manufacturer or dealer of the tool or appliance, with questions regarding its power requirements.
NOTICE: If a tool or appliance does not reach full speed within a few seconds when 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
resistive-type heating element, require the same wattage to start and run as is stated on their nameplates.
Fluorescent and 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 start. They need as much as 3–5 times the wattage 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:
Single Phase: VOLTS x AMPS = WATTS
wc_tx003412gb.fm
25
Page 26
Operation GP 3800A
4.3 Positioning the Generator for Operation
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.
f Do not operate this generator unless it is properly positioned. Read and obey all
instructions provided below.
WARNING
Risk of electric shock or electrocution.
f Do not operate this generator in rain, snow, or standing water.
Requirements
Position the generator according to the following requirements.
c
d
e
a
f
These instructions continue on the next page.
wc_gr010480
wc_tx003412gb.fm
26
Page 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 home or building can be fatal even if fans, open doors, or open windows are used for ventilation.
ONLY use a generator outside (a), and far away from homes, buildings,
windows, doors, and vents. Windows, doors, and vents can pull in generator exhaust.
Point the engine exhaust (b) away from homes, buildings, windows, doors, and
vents. Also, point the engine exhaust away from combustible materials.
Position the generator on firm, level ground so that it will not slide or shift.
CO Detectors/ Alarms
Install CO detectors/alarms in all areas that may be occupied by people or animals while the generator is operating. CO detectors/alarms provide an extra measure of protection against this poison that you cannot see or smell.
Install battery-operated CO detectors/alarms or plug-in CO detectors/alarms with battery backup, according to the manufacturer’s instructions. CO detectors/alarms should be certified to the requirements of the latest safety standards (UL 2034, IAS 6-96, or CSA 6.19.01). Test the CO detector/alarm batteries regularly according to the manufacturer’s instructions.
wc_tx003412gb.fm
27
Page 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 requirement.
Before using an oxygenated fuel, confirm the fuel’s contents. Some states and provinces require this information to be posted on the fuel pump.
The following is the Wacker Neuson approved percentage of oxygenates:
ETHANOL - (ethyl or grain alcohol) 10% by volume. You may use gasoline containing up to 10% ethanol by volume (commonly referred to as E10). Gasoline containing more than 10% ethanol (such as E15, E20, or E85) may not be used because it could damage the engine.
If you notice any undesirable operating symptoms, try another service station, or switch to another brand of gasoline.
Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty.
4.5 Wheel Kit
The wheel kit (Part No. 0161308) is a standard item on Item Number 0620012, 0620015, 0620043 and 0620046 only. It is available as an option on all other models.
1. Hoist the generator, and align the axle (c) with the lower cross-member of frame.
2. Insert the axle brackets (k) over the axle and align the holes found in the axle bracket to the holes of the cross-member. Ensure that the brackets extend under the tube of the frame.
3. Insert M6 x 16 screws (l) through the outer holes on the cross-member, then through the holes of the axle bracket.
4. Insert M6 nuts (m) onto the screws and tighten. Torque to 7.5 Nm (5.25 ft.lbs.).
5. Assemble the washers (g) next to the rings (h), then add the wheels (d).
6. Add the washers (g) next to the wheels, then insert the pins (f) into the holes of the axle and separate the legs of the pins.
7. Align the holes found in the leg bracket (b) to the holes of the lower cross­member.
8. Insert M6 x 16 screws (l) through the outer holes on the cross-member, then through the holes of the leg bracket.
9. Insert M6 nuts (n) onto the screws and tighten. Torque to 7.5 Nm (5.25 ft.lbs.).
10.Insert M8 x 30 screw (o) through the hole in the leg bracket and through the hole in cross-member.
11.Insert M8 nut (p) onto the screw and tighten. Torque to 18.75 Nm (13.5 ft.lbs.).
12.Align the holes in the rubber foot mounts (e) to the holes of the leg bracket.
28
wc_tx003412gb.fm
Page 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 brackets (1) on the frame.
16.Insert M6 x 16 screws (l) through the handles, then through the brackets on the frame.
17.Insert nuts (m) onto the screws and tighten. Torque to 7.5 Nm (5.25 ft.lbs.).
j
1
l
c
h
l
f
a
d
p
n
l
m
e
o
n
k
g
b
wc_gr010938
wc_tx003412gb.fm
29
Page 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 thus reduction in generator output. Temperature affects both engine and generator performance. As temperature increases, an engine will run less efficiently and 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 both altitude and ambient temperature deration factors to determine true generator output.
Ambient Temperature
°C (°F)
45 (113) 3 % 0.97
50 (122) 6 % 0.94
55 (131) 9 % 0.91
60 (140) 12 % 0.88
Altitude
m (ft)
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
Derate Factor
Derate Factor
30
wc_tx003412gb.fm
Page 31
GP 3800A Operation
4.7 Grounding the Generator
Location
Function
A ground connection (a) is located on the generator frame.
a
wc_gr010579
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 requirements in your area, consult with a qualified electrician, electrical inspector, or local agency having jurisdiction over electrical compliance.
If the generator is used at a construction site, there may be additional
regulations which must be observed.
In some areas, generators are required to be registered with local utility
companies.
There is a conductor between the generator (stator neutral winding) and the
frame.
4.8 Operating Heavy Loads
Limit operations requiring the maximum rated output of 3800 W to 20–30 minutes. For continuous operation do not exceed the continuous rated output of 3400 W.
NOTICE: DO NOT exceed the current limit specified on the control panel for any receptacle.
wc_tx003412gb.fm
31
Page 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 increases the amount of current draw or reduces performance. A heavier cord with a larger wire size will reduce the voltage loss.
Damaged extension cords can cause electrical shock, resulting in serious injury or death. DO NOT use worn, bare, or frayed cords. Replace damaged cords
WARNING
immediately.
Use the chart below as a guide for selecting proper cable size.
Current Load in Watts Maximum Cable Length in Feet
(Amps) 120V 240V #10 #12 #14 #16
2.5 300 600 1000. 600 375 250
5 600 1200 500 300 200 125
7.5 900 1800 350 200 125 100
10 1200 2400 250 150 100
15 1800 3600 150 100 65
20 2400 4800 125 75 50
Use only extension cords rated for outdoor use and equipped with a third-wire ground.
NOTICE: Operating equipment at low voltage can cause it to overheat.
32
wc_tx003412gb.fm
Page 33
GP 3800A Operation
3
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 Switch (VSS) n 30A circuit breaker (CSA only)
f GFI duplex receptacle—120V
a
b
e
g
d
m
f
h
n
c
j
wc_gr010939
wc_tx003412gb.fm
33
Page 34
Operation GP 3800A
3
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 should go “OUT” and red LED should come “ON” and circuit breaker should trigger to “OFF” position (b).
2. If sensing device LED or breaker does not trip or change state, “DO NOT USE”. Consult an electrician for assistance.
3. Press “RESET” button (c). Red LED should turn “OFF” and green LED should turn “ON”.
4. Manually reset (switch) circuit breaker to “ON” position to restore circuit power (b).
a
b
c
wc_gr010940
wc_tx003412gb.fm
34
Page 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 in place.
4.13 Engine Auto Idle
The auto idle switch (b) automatically reduces engine speed approximately 7 seconds after all appliances or tools attached to the generator have been turned off. The engine automatically returns to full speed when a tool or appliance is turned back on.
To turn the auto idle feature on, push the auto idle switch to “AUTO”. The AUTO setting is recommended while the generator is running to minimize fuel consumption. To avoid extended engine warm-up periods, keep switch set to “OFF” when starting the engine and until the engine reaches operating temperature.
4.14 Engine Speed
Generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constant speed. See Techn i cal Dat a. There is no throttle control. Use the Auto Idle switch on the generator to control engine speed.
wc_tx003412gb.fm
35
Page 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 generator is shared between the three receptacles.
In dual voltage mode both the 120V and 120/240V receptacles are powered; lower watts are available on receptacles (c1, c2, b). The 120/240V twist-lock receptacle (d) should be used in dual mode only. To achieve full power in this receptacle it should be used alone.
NOTICE: Never switch the voltage selector switch with the main breaker on! This can cause arcing and can damage the generator. Turn all tools and appliances off and place main breaker (e) in the OFF position before changing voltage switch position.
c2
a
e
c1
b
d
wc_gr010941
36
wc_tx003412gb.fm
Page 37
GP 3800A Operation
4.16 Before Starting
DANGER
f 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.
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 level
condition of air cleaner
tightness of external fasteners
condition of fuel lines.
Note: The engine is equipped with an oil alert system. If the oil level in the engine drops too low, the engine will not start.
4. Fill the fuel tank with fresh, regular, unleaded grade gasoline. Do not exceed the fuel tank capacity (see Technical Data).
NOTICE: Fill the tank after placing the machine on level ground.
5. DO NOT use an oil/gas mixture to fill the tank. The use of gasohol or any fuel containing more than 10% ethanol is not recommended. Consult the engine owner's manual for complete fuel specifications.
wc_tx003412gb.fm
37
Page 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 Internal Combustion Engines for installation warnings and safety guidelines.
2. Disconnect all loads from the generator and place the main breaker in the "OFF" position (a2).
3. Set the Auto Idle Switch (c) to "OFF".
4. Open the fuel valve (d1).
Note: If the engine is cold, move the choke lever to the closed position (e2). If the engine is hot, set the choke to the open position (e1).
5. Turn the engine switch to "ON" (b1).
6. Pull the starter rope (f).
Note: If the oil level in the engine is low, the engine will not start. If this happens, check the oil level and add oil as needed.
7. As the engine warms up, move the choke lever to the OPEN position (e1).
8. Allow the engine to warm up for a few minutes before placing the main breaker in the "ON" position (a1) and attaching loads.
wc_gr010942
wc_tx003412gb.fm
38
Page 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 emergency, turn the engine switch to OFF
(b2).
4.19 Emergency Shutdown Procedure
Procedure
If a breakdown or accident occurs while the machine is operating, follow the procedure below:
1. Stop the engine.
2. Turn off the fuel supply.
3. Disconnect tools from the machine.
4. Allow the machine to cool.
5. Contact the rental yard or machine owner for further instructions.
wc_tx003412gb.fm
39
Page 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/service center authorized by 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.
5.2 Periodic Maintenance Schedule
The table below lists basic machine and engine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment.
Refer to the engine owner’s manual for additional information.
Check the fuel level.
Daily
before
starting
3
After
first
20 hr
Every
50 hr
Every
100
hr
Every
300
hr
Check the engine oil level.
Inspect the air filter. Replace as needed.
Check external hardware.
Clean the air cleaner element.
Inspect the shockmounts for damage.
Change the engine oil.
Clean the sediment cup or fuel strainer.
Check and clean the spark plug.
Check and adjust the valve clearance.
Clean the fuel tank.
Check condition of the fuel lines. Replace when necessary.
1
Service more frequently in dusty conditions.
1
1
1
3
3
3
3

40
wc_tx003413gb.fm
Page 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 any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation.
3. Install the drain plug.
4. Fill the engine crankcase with the recommended oil up to the level of the plug opening (c). See section Technical Data for oil quantity and type.
5. Install the oil filler plug.
a
c
b
wc_gr010582
WARNING
Most used oil contains small amounts of materials that can cause cancer and other health problems if inhaled, ingested, or left in contact with skin for prolonged periods of time.
f Take steps to avoid inhaling or ingesting used engine oil. f Wash skin thoroughly after exposure to used engine oil.
wc_tx003413gb.fm
41
Page 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.
WARNING
Explosion and fire hazards.
f Never use gasoline or other types of low flash point solvents for cleaning the air
filter. Use only compressed air, mild detergent, and warm water.
To service:
1. Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged.
2. Wash the foam element (b) in a solution of mild detergent and warm water. Rinse it thoroughly in clean water. Allow the element to dry thoroughly. Soak the element in clean engine oil and squeeze out excess oil.
b
a
wc_gr010583
42
wc_tx003413gb.fm
Page 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 hot.
WARNING
Note: Refer to section “Technical Data” for the recommended spark plug type and
the electrode gap setting.
1. Remove the spark plug and inspect it.
2. Replace the spark plug if the insulator is cracked or chipped.
3. Clean the spark plug electrodes with a wire brush.
4. Set the electrode gap (a).
5. Tighten the spark plug securely.
NOTICE: A loose spark plug can become very hot and may cause engine damage.
wc_gr000028
wc_tx003413gb.fm
43
Page 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.
b
a
wc_gr000029
44
wc_tx003413gb.fm
Page 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.
4. After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
Note: On some engines the pilot screw is fitted with a limiter cap (c) to prevent excessive enrichment of the air-fuel mixture in order to comply with emission regulations. The mixture is set at the factory and no adjustment should be necessary. Do not attempt to remove the limiter cap. The limiter cap cannot be removed without breaking the pilot screw.
5.8 Engine Speed
Generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constant speed. There is no throttle control.
c
b
a
wc_gr010584
To set the engine to the proper speed:
Turn the speed adjusting screw (b) in or out to obtain a no-load speed. See Technical Data.
NOTICE: Setting the engine speed too high or too low may damage tools and other appliances attached to the generator.
wc_tx003413gb.fm
45
Page 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 and open the fuel valve to drain the fuel from the tank.
Gasoline is extremely flammable. Drain the fuel tank in a well-ventilated area. Do not drain the fuel tank in an area with flames or sparks.
WARNING
3. Loosen the drain screw on the carburetor and drain any remaining fuel from the carburetor.
4. Change the engine oil.
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.
6. Pull the starter rope slowly until resistance is felt and leave the handle in this position. This ensures that the intake and exhaust valves are closed.
7. Store the generator in a clean, dry area.
46
wc_tx003413gb.fm
Page 47
GP 3800A Troubleshooting
6 Troubleshooting
Problem / Symptom Reason / Remedy
If engine doesn't start, check that:
If engine starts but there is no power at receptacles, check that:
If engine starts but runs erratically, check that:
If the GFCI trips when a load is connected, 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.
Circuit breaker is closed.Connector from generator to control panel is tight.
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.
The connected equipment may be wired incorrectly
or faulty. Contact equipment supplier.
See section Determining Power Requirements.
wc_tx003414gb.fm
47
Page 48
Technical Data GP 3800A
7 Technical Data
7.1 Generator
Machine Item No.
Maximum output W 3800
Continuous output W 3400
Type Dual voltage, single phase,
AC voltages available volts
Frequency Hz 60
Power factor 1.0
AC receptacles: 125V duplex 125V duplex 125V twist-lock 125V/250V twist-lock
Generator
phase
A A A A
GP 3800A
0620485
Auto voltage regulator system
GP 3800A
0620379
120 / 240
20 20 30 20
GP 3800A
CAN
0620104
Main circuit breaker A 2-pole, 16 amp each pole
L x W x H mm (in.) 1005 x 685
x 660
(39.5 x 27 x
26)
Weight (dry) kg (lb) 94 (208) 73 (160)
685 x 530 x 520 (27 x 21 x
20.5)
48
wc_td000567gb.fm
Page 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.
Engine
Engine type Single cylinder, 4-cycle,
Engine make Honda
Engine model GX 240 RT2
Max. rated power @ rated speed kW (hp) 5.9 (7.9) @ 3600 rpm
Spark plug BPR6ES / W20EPR-U
Electrode gap mm (in.) 0.7 - 0.8 (0.028–0.031)
Operating speed rpm 3600
Air cleaner type Dry type with oil-wetted foam pre-
Auto idle VAC high idle
low idle
Engine lubrication oil grade SAE 10W30 service class SJ or higher
Engine oil capacity L (qt) 1.1 (1.2)
0620485, 0620379, 0620104
air-cooled, gasoline engine
GP 3800A
cleaner
119
90
wc_td000567gb.fm
Fuel type Regular unleaded gasoline
Fuel tank capacity L (gal) 18.7 (4.94)
Fuel consumption L (qt)/hr 2.38 (2.52)
Running time hr 7.8
49
Page 50
Technical Data GP 3800A
Notes
50
wc_td000567gb.fm
Page 51
Emission Control Systems Information and Warranty
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
Introduction
Wacker Neuson spark-ignited engines/equipment must conform with applicable Environmental Protection Agency (EPA) emissions regulations. There are two types of emissions that fall under these regulations: 1) exhaust, and 2) evaporative. These regulations require that manufacturers warrant the emission control systems for defects in materials and workmanship.
Furthermore, EPA regulations require all manufacturers to furnish written instructions describing how to operate and maintain the engines/equipment including the emission control systems. This information is provided with all Wacker Neuson engines/equipment at the time of purchase.
Exhaust Emissions
The combustion process produces carbon monoxide, oxides of nitrogen, and hydrocarbons. Control of hydrocarbons and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. 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
Evaporative emissions are fuel emissions and generally include emissions that result from permeation of fuel through the fuel-system materials or from ventilation of the fuel system.
Wacker Neuson utilizes low-permeation fuel lines and fuel tanks where applicable to reduce evaporative emissions.
Problems that may affect Emissions
If any of the following symptoms arise, have the engine/equipment inspected and repaired by a Wacker Neuson dealer/service center.
Hard starting or stalling after startingRough idlingMisfiring or backfiring under loadAfterburning (backfiring)Presence of black exhaust smoke during operationHigh fuel consumption
wc_tx001769gb.fm 51
Page 52
Emission Control Systems Information and Warranty
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.Altering or defeating the speed-adjusting mechanism causing the engine to
operate outside its design parameters.
8.2 Limited Defect Warranty for Exhaust Emission Control System
See the supplied engine owner’s manual for the applicable emission warranty statement.
52 wc_tx001769gb.fm
Page 53
Emission Control Systems Information and Warranty
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 Avenue, Menomonee Falls, WI 53051, (hereinafter “Wacker Neuson”) warrants to the initial retail purchaser and each subsequent owner, that this engine/equipment, including all parts of its evaporative emission control system, have been designed, built, and equipped to conform at the time of initial sale to all applicable evaporative emission regulations of the U.S. Environmental Protection Agency (EPA), and that the engine/equipment is free of defects in materials and workmanship which would cause this engine/equipment to fail to conform to EPA regulations during its warranty period.
Wacker Neuson is also liable for damages to other engine/equipment components caused by a failure of any warranted parts during the warranty period.
Limited Defect Warranty Period for Wacker Neuson Evaporative Emission Control Systems
The warranty period for this engine/equipment begins on the date of sale to the initial purchaser and continues for a minimum of two (2) years. For the warranty terms for your specific engine/equipment, visit wackerneuson.com.
Any implied warranties are limited to the duration of this written warranty.
What is covered
Wacker Neuson recommends the use of genuine Wacker Neuson parts, or the equivalent, whenever maintenance is performed. The use of replacement parts not equivalent to the original parts may impair the effectiveness of the engine/ equipment emission controls systems. If such a replacement part is used in the repair or maintenance of the engine/equipment, assure yourself that such part is warranted by its manufacturer to be equivalent to the parts offered by Wacker Neuson in performance and durability. Furthermore, if such a replacement part is used in the repair or maintenance of the engine/equipment, and an authorized Wacker Neuson dealer/service center determines it is defective or causes a failure of a warranted part, the claim for repair of the engine/equipment may be denied. If the part in question is not related to the reason the engine/equipment requires repair, the claim will not be denied.
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. All defective parts replaced under this warranty become property of Wacker Neuson.
wc_tx001769gb.fm 53
Page 54
Emission Control Systems Information and Warranty
System Covered Components
Evaporative emissions Fuel tank (if applicable)
Fuel tank cap (if applicable)
Fuel line (if applicable)
Fuel line fittings (if applicable)
Clamps (if applicable)
Carbon canister (if applicable)
Purge port connector (if applicable)
Miscellaneous parts associated with the evaporative emission control system
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, improper storage, accident and/or collision; the incorporation of, or any use of, add-on or modified parts, or unsuitable attachments, or the alteration of any part.
Replacement of expendable maintenance items made in connection with
required maintenance services after the item’s first scheduled replacement as listed in the maintenance section of the engine/equipment operator’s manual, such as spark plugs and filters.
Incidental or consequential damages such as loss of time or the use of the
engine/equipment, or any commercial loss due to the failure of the engine/ equipment.
Diagnosis and inspection charges that do not result in warranty-eligible
service being performed.
Any non-authorized replacement part, or malfunction of authorized parts due
to use of-non authorized parts.
Clamps
Gaskets
Mounting brackets
Owner’s Warranty Responsibility
The engine/equipment owner, is responsible for the performance of the required maintenance listed in the Wacker Neuson engine/equipment operator’s manual. Wacker Neuson recommends that all receipts covering maintenance on the engine/equipment be retained, but Wacker Neuson cannot deny warranty coverage solely for the lack of receipts or for the failure to ensure the performance of all scheduled maintenance.
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 an authorized Wacker Neuson dealer/ service center.
The engine/equipment must be presented to an authorized Wacker Neuson dealer/ service center as soon as a problem exists. Contact Wacker Neuson Product
54 wc_tx001769gb.fm
Page 55
Emission Control Systems Information and Warranty
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-related part is found to be defective during the warranty period, you shall notify Wacker Neuson Product Support Department (1-800-770-0957, or technical.support@wackerneuson.com, or wackerneuson.com), and you will be advised of the appropriate dealer/service center where warranty repair can be performed. All repairs qualifying under this limited warranty must be performed by an authorized Wacker Neuson dealer/ service center.
You must take your Wacker Neuson engine/equipment along with proof of original purchase date, at your expense, to the authorized Wacker Neuson dealer/service center during their normal business hours.
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.
Claims for repair or adjustment found to be caused solely by defects in material or workmanship will not be denied because the engine/equipment was not properly maintained and used.
The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
wc_tx001769gb.fm 55
Page 56
Schematics GP 3800A
9 Schematics
9.1 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
9.2 Electrical Schematic
Ref. Description Ref. Description
A Generator D Honda Engine
B Control box
C Electric start engines (GPS)
Wire Colors
Ref. Description Ref. Description
1 Main stator winding 1 12 Engine ON / OFF switch
2 Main stator winding 2 13 Rectifier
3 Auto idle unit 14 Rotor winding/brushes
4 Main circuit breaker 15 Secondary (excitation) winding
5 Voltage selector switch
(120/240V position shown)
6 Duplex receptacle—120V 17 Automatic voltage regulator
7 Twist-lock receptacle—120V 18 15A fuse (GPS only)
8 Twist-lock receptacle—120/240V 19 Ignition switch (GPS only)
9 Auto idle switch 20 GFCI
10 5A fuse 21 Neutral bond wire
11 Capacitor
16 DC winding
(AVR)
56
wc_tx003415gb.fm
Page 57
GP 3800A Schematics
41 BLU
GRN/YEL
AWG
102 BRN
5 BRN
43 BLU 16 AWG
72 BRN
42 BLU
73 BRN
GRN/YEL
71 BRN 12 AWG
RED 16 AWG
BLK 16 AWG
YEL
WHT
GRN
5
AMP
YEL
RED/WHT
0
3
5
6
9
g
5
D
A
C
B
E
H
G
F
I
r00823
wc_
1
9
B
A
wc_tx003415gb.fm
1
1
1
57
Page 58
Schematics GP 3800A
WHT/RED
WHT/RED
WHT 16 AWG
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 sender 8 Charging coil (GPS only)
4 Spark plug 9 Battery (GPS only)
5Coil ——
D
A B
C D
E F
G H
8
I
2
3
4
9
wc_gr008237
wc_tx003415gb.fm
58
Page 59
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 Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI 53051
Tel. : (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957
Tel: (852) 3605 5360, Fax: (852) 2758 0032
Loading...