Operator’s Manual Portable Generator GP 3800A EN 5000192885 5 0 0 0 01 1 9 0511 2 8 8 5
Copyright notice © Copyright 2011 by Wacker Neuson Production Americas LLC All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written 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.
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).
Foreword 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.
GP 3800A 1 Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 1.5 2 Signal Words Used in this Manual ....................................................... 7 Machine Description and Intended Use ............................................... 8 Operating Safety ................................................................................ 10 Operator Safety while Using Internal Combustion Engines ............... 12 Service Safety ......................................................................
Table of Contents 4 Maintenance 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5 Maintaining the Emission Control System ...........................................35 Periodic Maintenance Schedule ..........................................................35 Engine Oil ............................................................................................36 Servicing the Air Cleaner .....................................................................37 Spark Plug .....................................
GP 3800A 1 1.1 Safety Information Safety Information 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.
Safety Information 1.2 GP 3800A 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.
GP 3800A Safety Information Personal injury from improper lifting techniques To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine. wc_si000233gb.
Safety Information 1.3 GP 3800A 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, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
GP 3800A WARNING Safety Information 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 training are required for the safe operation of the machine. Machines operated improperly or by untrained personnel can be hazardous.
Safety Information GP 3800A 1.3.17 ALWAYS remove all tools, cords, and other loose items from the generator before starting it. 1.3.18 ALWAYS make certain the machine is well-grounded and securely fastened to a good earthen ground per national and local regulations. 1.4 Operator 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.
GP 3800A Safety Information • Do not start the engine if fuel has spilled or a fuel odor is present. Move the generator away from the spill and wipe the generator dry before starting. • Do not smoke while operating the machine. Generator vibration Generators vibrate in normal use. 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. 1.5 • Have damaged items repaired or replaced as necessary.
Safety Information GP 3800A 1.5.6 DO NOT allow untrained personnel to service this equipment. Only trained electrical technicians should be allowed to service the electrical components of this equipment. 1.5.7 Keep the machine clean and labels legible. Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards. 1.5.8 ALWAYS replace the safety devices and guards after repairs and maintenance. 1.5.
GP 3800A 2 2.1 Labels Label Locations B G C A E N M F L J K D 2.2 wc_gr003142 Label Meanings Wacker Neuson machines use international pictorial labels where needed. These labels are described below. A Engine Choke Control B WARNING! Hot surface! wc_si000555gb.
GP 3800A C — DANGER! Read the Operator’s Manual. No sparks, flames, or burning objects near the machine. Stop the engine before refueling. — GFCI TEST INSTRUCTIONS - TEST BEFORE EACH USE Normal operating state - sensing device green LED is "ON" and circuit breaker is at "ON" position. Step 1: Press "TEST" button. Green LED should go "OUT" and red LED should come "ON" and circuit breaker should trigger to "OFF" position.
GP 3800A — 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_si000555gb.
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. E NOTICE Lifting point.
GP 3800A L WARNING! Test GFCI before each use. See label above. M Important Emissions Information This equipment meets California EVP emission regulations for small off-road engines. N Emission Control Information This equipment meets U.S. EPA EVAP standards. Evaporative Family: BWIXNHEQCL2 wc_si000555gb.
Operation 3 GP 3800A 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, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
GP 3800A 3.2 Operation Recommended Fuel Type This engine/equipment requires regular unleaded gasoline. • Use only fresh (no older than three months old), clean gasoline. • Use a fuel stabilizer per the fuel stabilizer manufacturer’s instructions. Use of oxygenated fuels Some 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.
Operation 3.3 GP 3800A 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 3.4 Operation 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. The surrounding area must be free from water and moisture. All components must be protected from excessive moisture. 3.5 Wheel Kit The wheel kit (Part No.
Operation GP 3800A 3.5.14 Insert the nuts (n) onto the screws and tighten. Torque to 7.5 Nm (5.25 ft.lbs.). 3.5.15 Align the holes found in the handles (a, j) to the holes of the brackets (1) on the frame. 3.5.16 Insert M6 x 16 screws (l) through the handles, then through the brackets on the frame. 3.5.17 Insert nuts (m) onto the screws and tighten. Torque to 7.5 Nm (5.25 ft.lbs.). 24 wc_tx000785gb.
GP 3800A 3.6 Operation 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.
Operation 3.7 GP 3800A Grounding the Generator Location A ground connection (a) is located on the generator frame. wc_gr000544 Function 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. 3.
GP 3800A 3.9 Operation 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.
Operation 3.10 Ref. GP 3800A Control Panel Description Ref. Description a Engine switch g GFI test button b Auto idle switch h GFI reset button c Twist-lock receptacle—120V j Twist-lock receptacle—120/240V d Main circuit breaker m 20A circuit breaker (CAN only) e Voltage Selector Switch (VSS) n 30A circuit breaker (CAN only) f GFI duplex receptacle—120V 28 wc_tx000785gb.
GP 3800A 3.11 Operation Ground Fault Interrupt (GFI / GFCI) The GFCI should be tested for proper operations every time the generator is used. Normal operating state - sensing device green LED is “ON” and circuit breaker is at “ON” position. wc_tx000785gb.fm 3.11.1 Press “TEST” button (g). Green LED should go “OUT” and red LED should come “ON” and circuit breaker should trigger to “OFF” position (d). 3.11.2 If sensing device LED or breaker does not trip or change state, “DO NOT USE”.
Operation 3.12 GP 3800A 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. 3.13 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.
GP 3800A 3.15 Operation Voltage Selector Switch The voltage selector switch (e) allows the generator to operate in either single (120V) or dual voltage (120/240V) mode. In single-voltage mode, use only the 120V twist-lock (c) and duplex receptacles (f1, f2). The full rated power 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).
Operation 3.16 GP 3800A 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. 3.16.1 Read and understand the safety and operating labels and instructions at the beginning of this manual. 3.16.
GP 3800A 3.17 Operation Starting Before starting, be sure you read and understand all the safety and operating instructions in this manual. 3.17.1 Ensure that the generator is properly installed in an outdoor location. See Sections Installation and Operator Safety while using Internal Combustion Engines for installation warnings and safety guidelines. 3.17.2 Disconnect all loads from the generator and place the main breaker in the "OFF" position (a2). 3.17.3 Set the Auto Idle Switch (c) to "OFF". 3.
Operation 3.18 GP 3800A Stopping 3.18.1 Turn off and disconnect all tools and appliances attached to the generator. 3.18.2 Place the main circuit breaker in the OFF position (a2). 3.18.3 Place the engine switch to OFF (b2). 3.18.4 Close the fuel valve (d2). Note: To stop the engine quickly in an emergency, turn the engine switch to OFF (b2). 3.19 Emergency Shutdown Procedure Procedure If a breakdown or accident occurs while the machine is operating, follow the procedure below: 3.19.1 Stop the engine.
GP 3800A 4 4.1 Maintenance Maintenance 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.
Maintenance 4.3 GP 3800A Engine Oil 4.3.1 Drain the oil while the engine is still warm. 4.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation. 4.3.3 Install the drain plug. 4.3.
GP 3800A 4.4 Maintenance Servicing the Air Cleaner Service the air cleaner frequently to prevent carburetor malfunction. NOTICE: NEVER run the engine without the air cleaner. Severe engine damage will occur. NEVER use gasoline or other types of low flash-point solvents for cleaning the air cleaner. A fire or explosion could result. WARNING To service: 4.4.1 Remove the air cleaner cover (a). Inspect the element (b) for holes or tears. Replace the element if it is damaged. 4.4.
Maintenance 4.5 GP 3800A Spark Plug Clean or replace the spark plug as needed to ensure proper operation. Refer to your engine operator’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. WARNING Note: Refer to section “Technical Data” for the recommended spark plug type and the electrode gap setting. 4.5.1 Remove the spark plug and inspect it. 4.5.
GP 3800A 4.6 Maintenance Cleaning the Sediment Cup wc_tx000793gb.fm 4.6.1 Turn the fuel valve off. 4.6.2 Remove the sediment cup (a) and the O-ring (b). 4.6.3 Wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 4.6.4 Turn the fuel valve on and check for leaks.
Maintenance 4.7 GP 3800A Adjusting the Carburetor 4.7.1 Start the engine and allow it to warm up to operating temperature. 4.7.2 Set the pilot screw (a) two turns out. See Note. 4.7.3 With the engine idling, turn the pilot screw (a) in or out to the setting that produces the highest rpm. 4.7.4 After the pilot screw is adjusted, turn the throttle stop screw (b) to obtain the standard idle speed. See Technical Data.
GP 3800A 4.9 Maintenance Long-Term Storage Before storing the generator for a long period of time: 4.9.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer. 4.9.2 Disconnect the fuel line from the carburetor. Place the open end of the fuel line into a suitable container and open the fuel valve to drain the fuel from the tank. WARNING 4.10 Gasoline is extremely flammable. Drain the fuel tank in a wellventilated area.
Maintenance 4.11 GP 3800A 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.
GP 3800A 5 Technical Data Technical Data 5.1 Generator Item No. GP 3800A GP 3800A (CAN) 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 duplex 125V 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.
Technical Data 5.2 GP 3800A Engine Engine Power Rating Net power rating per SAE J1349. Actual power output may vary due to conditions of specific use. Item No. GP 3800A Engine Engine type Single cylinder, 4-cycle, air-cooled, gasoline engine Engine make Honda Engine model GX 240 RT2 Max. rated power @ rated speed 5.9 (7.9) @ 3600 rpm kW (Hp) Spark plug Electrode gap BPR6ES / W20EPR-U 0.7 - 0.8 (0.028 - 0.031) mm (in.
Emission Control Systems Information and Warranty 6 Emission Control Systems Information and Warranty The Emission Control Warranty and associated information is valid only for the U.S.A., its territories, and Canada. 6.1 Emission Control System Background Information Introduction Wacker Neuson spark-ignited engines/equipment must conform with applicable Environmental Protection Agency (EPA) and the State of California emissions regulations.
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. 6.
Emission Control Systems Information and Warranty 6.3 Limited Defect Warranty for Wacker Neuson Evaporative Emission Control Systems The Emission Control Warranty is valid only for the U.S.A., its territories, and Canada.
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 Clamps Gaskets Mounting brackets What is not covered Failures other than those resulting from defects in m
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.
Emission Control Systems Information and Warranty 6.4 California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Wacker Neuson Corporation, Inc., are pleased to explain the evaporative emission control system (EECS) warranty on your model year 2008 and later portable generator. In California, new portable generators must be designed, built and equipped to meet the State’s stringent antismog standards.
Emission Control Systems Information and Warranty What is not Covered All failures caused by abuse, neglect, or improper maintenance are not covered. In addition, the use of add-on or modified parts will be grounds for disallowing a warranty claim.
Schematics 7 GP 3800A Schematics 7.1 Wire Colors 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 7.2 Ref. US Machines—Electrical Schematic Description A Generator B Control box C Electric start engines (GPS) Ref. Description Ref. E Ref.
14 53 - + WHT BRN BRN BLK ORG ORG/GRN 16 15 5 BLU YEL BRN YEL BLU 4 1 BLK 16 AWG 5 AMP 17 10 RED 16 AWG 3 BLU BLK 16 AWG RED 16 AWG 11 BRN 16 AWG BLK RED/WHT WHT/BLK 10 BRN 16 AWG 51 GRN/YEL 12 BRN 16 AWG 104 GRY 103 GRY 101 BLU 102 BRN GRN 4 3 1 2 BLU GRN BLK YEL RED RED/WHT 21 1 2 43 BLU 16 AWG RED 16 AWG AWG 71 BRN 12 AWG 5 BRN 102 BRN BLK 16 AWG RED 16 AWG 4 BLK 18 AWG 71 BRN 12 AWG 3 BRN 70 BRN 12 AWG YEL 18 AWG 7 71 BRN 12 AWG LOAD WHT 18
Schematics 7.3 Ref. CSA Machines—Electrical Schematic Description A Generator B Control box C Electric start engines (GPS) Ref. GP 3800A Description Ref. E Ref.
13 A 14 + WHT 55 BRN BRN BLK BLU 15 BLU ORG ORG/GRN BLK 16 AWG RED 16 AWG 11 BRN 16 AWG BLU BLK RED/WHT WHT/BLK 10 BRN 16 AWG 51 GRN/YEL 104 GRY 103 GRY 101 BLU 12 BRN 16 AWG 4 3 1 GRN GRN BLK YEL 2 102 BRN RED/WHT 21 1 2 RED 16 4 43 BLU 16 AWG RED 16 AWG 10 3 BRN YEL YEL BLU RED 16 AWG 3 1 BLK 16 AWG AMP 17 4 LOAD (BREAKER NOT USED FOR GP3800) RED 16 AWG 5 BRN BLK 16 A 102 BRN 30A BLK 18 AWG 20A 7 30 BRN 11 101 BLU 28 BRN 12 AWG 29 BRN 28 B
Schematics 7.4 Ref. GP 3800A Engine Wiring Description Ref. A Generator B Control box C Electric start engines (GPS) Description D Honda Engine Ref. Description Ref.
Wacker Neuson SE, Preußenstraße 41, D-80809 München, Tel.: +49-(0)89-3 54 02-0 Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI 53051 Tel. : (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
