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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.
GP 3800A Table of Contents 1. Foreword 2. California Evaporative Emission Control Warranty Statement 6 3. Safety Information 3.1 3.2 3.3 3.4 3.5 3.6 4. 8 Laws Pertaining to Spark Arresters ...................................................... 8 Operating Safety .................................................................................. 9 Operator Safety while using Internal Combustion Engines ................ 11 Service Safety ...............................................................
Table of Contents 6. GP 3800A Maintenance 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 34 Engine Maintenance ............................................................................34 Periodic Maintenance Schedule ..........................................................34 Engine Oil ............................................................................................35 Servicing Air Cleaner ...........................................................................
WARNING 1. CALIFORNIA Proposition 65 Warning: Engine 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. Foreword This manual provides information and procedures to safely operate and maintain this Wacker model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual.
California Evaporative Emission Control Warranty Statement 2. California Evaporative Emission Control Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Wacker Corporation, Inc. are pleased to explain the evaporative emission control system (EECS) warranty on your model year 2006 and later portable generator. In California, new portable generators must be designed, built and equipped to meet the State’s stringent anti-smog standards.
California Evaporative Emission Control Warranty Statement OWNER’S WARRANTY RESPONSIBILITIES: As the portable generator owner, you are responsible for performance of the required maintenance listed in your owner’s manual. Wacker Corporation recommends that you retain all receipts covering maintenance on your portable generator, but Wacker Corporation cannot deny warranty solely for the lack of receipts.
Safety Information 3. GP 3800A Safety Information This manual contains DANGER, WARNING, CAUTION, NOTICE 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.
GP 3800A 3.2 Safety Information Operating Safety DANGER WARNING 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.
Safety Information GP 3800A 3.2.12 ALWAYS store the equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children. 3.2.13 ALWAYS position and operate noncombustible, level surface. the generator on a firm, 3.2.14 ALWAYS transport the generator in an upright position. 3.2.15 ALWAYS keep the machine at least one meter (three feet) away from structures, buildings, and other equipment during use. 3.2.
GP 3800A 3.3 Safety Information Operator Safety while using Internal Combustion Engines DANGER Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the warnings and safety guidelines could result in severe injury or death. 3.3.
Safety Information 3.4 GP 3800A Service Safety WARNING 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 occasional repairs are necessary. If the generator is experiencing problems or is being serviced, attach a “DO NOT START” sign to the control panel to notify other people of its condition. 3.4.
GP 3800A Label Locations GND 13 88897 3.
Safety Information 3.6 GP 3800A Safety and Operating Labels Wacker machines use international pictorial labels where needed. These labels are described below: Label Meaning WARNING! Hot surface! CAUTION! Read and understand the supplied Operator’s Manuals before operating this machine. Failure to do so increases the risk of injury to yourself or others. CAUTION! Lifting point.
GP 3800A Label Safety Information Meaning Press circuit breaker switch to OFF position. Check the fuel level. Open the fuel flow valve. Press engine switch to ON position. GPS - Press ignition switch. GP - Pull the rewind starter. Press circuit breaker switch to ON position. Press engine switch to OFF position.
Safety Information Label GP 3800A Meaning Close the fuel flow valve. DANGER! Asphyxiation hazard. Read the operator’s manual for instructions. Use in a well-ventilated area. Do not use indoors or near open windows. Fumes can cause death. WARNING! To reduce the risk of electrical shock, 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.
GP 3800A Label Safety Information Meaning Important Emissions Information This equipment meets California EVP emission regulations for small off-road engines. This machine may be covered by one or more patents. DANGER! No sparks, flames or burning objects near machine. Shut off the engine before refueling.
Technical Data 4. GP 3800A Technical Data 4.1 Generator Item No. GP 3800A 0620010 GP 3800A CAN 0620041 Generator Maximum Output W 3800 Continuous Output W 3400 Type AC Voltages Available Frequency Dual voltage, single phase, Auto voltage regulator system 120 / 240 1ø volts phase 60 Hz Power Factor 1.0 AC receptacles: 125V GFI duplex 125V GFI duplex 125V twist-lock 125V/250V twist-lock amp amp amp amp 20 20 30 20 Main Circuit Breaker amp 2-pole, 16 amp each pole LxWxH mm (in.
GP 3800A 4.2 Technical Data Engine Item No. GP 3800A 0620010 GP 3800A CAN 0620041 Engine Engine Type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine Make Honda Engine Model GX 240 Rated Power 6 (8) kW (Hp) Spark Plug Electrode Gap BPR6ES / W20EPR-U 0.7–0.8 (0.028–0.031) mm (in.) Operating Speed (max.
Operation 5. GP 3800A Operation 5.1 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.
GP 3800A 5.2 Operation Outdoor Installation Place the generator in an area where it will not be exposed to rain, snow, or direct sunlight. Make sure it is positioned on firm, level ground, so it will not slide or shift. Position the engine exhaust away from areas where people may be present. 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.
Operation 5.4 GP 3800A Wheel Kit See Graphic: wc_gr002658 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. 5.4.1 Hoist the generator, and align the axle (c) with the lower cross-member of frame. 5.4.2 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. 5.4.
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Operation 5.5 GP 3800A Generator Derating All generators are subject to derating for altitude and temperature. Internal combustion engines, unless modified, run less efficiently at higher altitudes due to the reduction of air pressure. This translates into a lack of power and thus reduction in generator output. 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.
GP 3800A 5.6 Operation Grounding the Generator See Graphic: wc_gr000544 A ground connection (a) is located on the generator frame. For proper operating safety, this ground terminal must be connected to a good ground source. This ground connection must comply with National Electrical Code standards, and state and local regulations. 5.7 Operating Heavy Loads Limit operations requiring the maximum rated output of 3800 W to 20– 30 minutes.
Operation 5.8 GP 3800A Use of Extension Cords WARNING Current 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.
GP 3800A 5.9 Operation Control Panel See Graphic: wc_gr002327 Ref. Description Ref.
Operation GP 3800A 5.10 Ground Fault Interrupt (GFI) See Graphic: wc_gr002327 The two receptacles (f) are protected by a ground fault circuit interrupt (GFI). The GFI shuts off the power to the receptacle when a ground fault occurs in the generator or to a piece of equipment attached to the generator. The GFI should be tested for proper operation every time the generator is used. To test the GFI: Start the generator. Turn the auto idle “OFF”. Push the TEST button (h) on the receptacle in.
GP 3800A Operation 5.12 Engine Auto Idle See Graphic: wc_gr002327 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.
Operation GP 3800A 5.14 Voltage Selection See Graphic: wc_gr002497 The voltage selector switch (e) allows the generator to operate in either single (120V) or dual voltage (120/240V) mode. In single-voltage mode, use only the 120V twist-lock (c) and duplex receptacles (f1, f2). The full rated power 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 (f1, f2, c).
GP 3800A Operation 5.15 Before Starting 5.15.1 Read and understand the safety and operating labels and instructions at the beginning of this manual 5.15.2 Inspect the generator for any signs of damage which may affect operation or pose a safety hazard. 5.15.3 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.
Operation GP 3800A 5.16 To Start See Graphic: wc_gr002499 Before starting, be sure you read and understand all the safety and operating instructions in this manual. 5.16.1 Disconnect all loads from the generator and place the main breaker in the "OFF" position (a2). 5.16.2 Set the Auto Idle Switch (c) to "OFF". 5.16.3 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). 5.16.
GP 3800A Operation 5.17 To Stop See Graphic: wc_gr002499 5.17.1 Turn off and disconnect all tools and appliances attached to the generator. 5.17.2 Place main circuit breaker in the "OFF" position (a2). 5.17.3 Turn the engine switch to "OFF" (b2). 5.17.4 Close fuel valve (d2). Note: To stop the engine quickly in an emergency, turn the engine switch to "OFF" (b2).
Maintenance 6. GP 3800A Maintenance 6.1 Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to the engine manufacturer’s Operator’s Manual for additional information on engine maintenance. 6.2 Periodic Maintenance Schedule Daily before starting Check the fuel level. Check the engine oil level. Inspect the air filter. Replace as needed. Check external hardware. After first 20 hrs. Clean the air cleaner element.* Every 50 hrs. Every 100 hrs.
GP 3800A 6.3 Maintenance Engine Oil See Graphic: wc_gr000022 6.3.1 Drain the oil while the engine is still warm. 6.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation. 6.3.3 Install the drain plug. 6.3.
Maintenance 6.4 GP 3800A Servicing Air Cleaner See Graphic: wc_gr002815 Service the air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run the engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING To service: 6.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 6.4.
GP 3800A 6.5 Maintenance Spark Plug See Graphic: wc_gr000028 Clean or replace the spark plug as needed to ensure proper operation. Refer to the 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 the Technical Data for the recommended spark plug type and the electrode gap setting. 6.5.1 Remove the spark plug and inspect it. 6.5.
Maintenance 6.6 GP 3800A Cleaning the Sediment Cup See Graphic: wc_gr000029 6.7 6.6.1 Turn the fuel valve off. 6.6.2 Remove the sediment cup (a) and the O-ring (b). 6.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 6.6.4 Turn the fuel valve on and check for leaks. Carburetor Adjustment See Graphic: wc_gr000032 6.7.1 Start the engine and allow it to warm up to operating temperature. 6.7.2 Set the pilot screw (a) two turns out. See Note. 6.7.
GP 3800A 6.8 Maintenance Adjusting Engine Speed See Graphic: wc_gr000032 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. 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.
Maintenance 6.9 GP 3800A Storage Before storing the generator for a long period of time: 6.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 6.9.2 Disconnect the fuel line from the carburetor. Place open end of fuel line into a suitable container and open fuel valve to drain fuel from tank. WARNING Gasoline is extremely flammable. Drain the fuel tank in a wellventilated area. DO NOT drain the fuel tank in an area with flames or sparks. 6.9.
GP 3800A Maintenance 6.11 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.
Maintenance GP 3800A 6.13 Electrical Schematic Ref. Description Ref. Description A Generator C Engine B Control box D Electric start engines Ref. Description Ref.
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Maintenance GP 3800A 6.14 Electrical Schematic (CAN models only) Ref. Description Ref. Description A Generator C Engine B Control box D Electric start engines Ref. Description Ref.
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Maintenance GP 3800A 6.15 Engine Schematic See Graphic: wc_gr002580 Ref. Description Ref. Description A Generator D Wacker Engine B Control box E Honda Engine C Electric start engines (GPS) Ref. Description Ref.
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Maintenance GP 3800A Notes 48
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel.
