Wacker Neuson GV 3800A User manual

www.wackergroup.com
Generator
GV 3800A
OPERATOR’S MANUAL
0170812en 003
0108
0170812EN

DANGER
CARBON MONOXIDE
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or
smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot
smell the exhaust, you could be breathing CO.
• NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed
areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh air.
• ONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the home. ALWAYS use a
battery-powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh
air RIGHT AWAY. See a doctor. You could have carbon monoxide poison.

GV 3800A Table of Contents
wc_bo0170812en_003TOC.fm 3
1. Foreword 5
2. Safety Information 6
2.1 Laws Pertaining to Spark Arresters ...................................................... 6
2.2 Operating Safety .................................................................................. 7
2.3 Operator Safety while using Internal Combustion Engines .................. 9
2.4 Service Safety .................................................................................... 10
2.5 Label Locations .................................................................................. 11
2.6 Safety and Operating Labels .............................................................. 12
3. Operation 15
3.1 Determining Power Requirements ..................................................... 15
3.2 Installation .......................................................................................... 16
3.3 Installing Spark Arrester ..................................................................... 16
3.4 Generator Derating ............................................................................. 17
3.5 Grounding the Generator ................................................................... 18
3.6 Operating Heavy Loads ...................................................................... 18
3.7 Use of Extension Cords ...................................................................... 19
3.8 Control Panel ...................................................................................... 20
3.9 Ground Fault Interrupt (GFI) ............................................................... 21
3.10 Main Circuit Breaker ........................................................................... 21
3.11 Voltage Selection ............................................................................... 22
3.12 Engine Auto Idle ................................................................................. 22
3.13 Before Starting ................................................................................... 23
3.14 To Start ............................................................................................... 24
3.15 To Stop ............................................................................................... 25

wc_bo0170812en_003TOC.fm 4
Table of Contents GV 3800A
4. Maintenance 26
4.1 Engine Maintenance ............................................................................26
4.2 Periodic Maintenance Schedule ..........................................................26
4.3 Engine Oil ............................................................................................27
4.4 Servicing Air Cleaner ...........................................................................28
4.5 Spark Plug ...........................................................................................29
4.6 Cleaning the Sediment Cup ................................................................30
4.7 Storage ................................................................................................31
4.8 Transport .............................................................................................32
4.9 Troubleshooting ...................................................................................33
5. GV 3800A Technical Data 34
5.1 Generator ............................................................................................34
5.2 Engine .................................................................................................35
5.3 Electrical Schematic ............................................................................36
5.4 Schematic Components ......................................................................37

wc_tx000001gb.fm 5
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.
1. 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.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.
WARNING

Safety Information GV 3800A
wc_si000207gb.fm 6
2. 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.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE:Used without the safety alert symbol, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
2.1 Laws Pertaining to Spark Arresters
Notice: State Health Safety Codes and Public Resources Codes
specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.
DANGER
WARNING
CAUTION

GV 3800A Safety Information
wc_si000207gb.fm 7
2.2 Operating Safety
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 this generator inside a home or garage, EVEN IF
doors and windows are open. Only use this generator OUTSIDE and
far away from windows, doors, and vents.
BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER
DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR
DEATH TO UTILITY WORKERS!
Improper connection of generator to a building’s electrical system can
allow electrical current from the generator to backfeed into utility lines.
This may result in electrocution of utility workers, fire, or explosion.
Connections to a building’s electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical
codes.
If connected to a building’s electrical system the generator must meet
the power, voltage, and frequency requirements of the equipment in
the building. Differences in power, voltage, and frequency
requirements may exist and improper connection may lead to
equipment damage, fire, and personal injury or death.
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the machine before
being allowed to operate it.
2.2.1 NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
2.2.2 NEVER operate the generator, or tools attached to the generator, with
wet hands.
2.2.3 NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
2.2.4 NEVER run the electrical cords under the generator, or over vibrating
or hot parts.
2.2.5 NEVER enclose or cover the generator when it is in use or when it is
hot.
2.2.6 NEVER overload the generator. The total amperage of the tools and
equipment attached to the generator must not exceed the load rating
of the generator.
DANGER
DANGER
WARNING

Safety Information GV 3800A
wc_si000207gb.fm 8
2.2.7 NEVER operate the machine in snow, rain, or standing water.
2.2.8 NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a trained electrician.
2.2.9 NEVER stand on the machine.
2.2.10 DO NOT stand under the machine while it is being hoisted or moved.
2.2.11 DO NOT attach equipment to the machine when it is suspended.
2.2.12 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.
2.2.13 ALWAYS position and operate the generator on a firm,
noncombustible, level surface.
2.2.14 ALWAYS transport the generator in an upright position.
2.2.15 ALWAYS keep the machine far away from structures, buildings, and
other equipment during use.
2.2.16 ALWAYS keep the area immediately surrounding and underneath the
machine clean, neat, and free of debris and combustible materials.
Make sure that the area overhead is clear of debris that could fall onto
or into the machine or exhaust compartment.
2.2.17 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
2.2.18 ALWAYS make certain the machine is well-grounded and securely
fastened to a good earthen ground per national and local regulations.

GV 3800A Safety Information
wc_si000207gb.fm 9
2.3 Operator Safety while using Internal Combustion Engines
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.
2.3.1 NEVER use this generator inside a home or garage, EVEN IF doors
and windows are open. Only use OUTSIDE and far away from
windows, doors, and vents. Using a generator indoors CAN KILL YOU
IN MINUTES. Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell.
2.3.2 NEVER use a generator inside an enclosed area such as a tunnel or a
trench.
2.3.3 DO NOT smoke while operating the machine.
2.3.4 DO NOT smoke when refueling the engine.
2.3.5 DO NOT refuel a hot or running engine.
2.3.6 DO NOT refuel the engine near an open flame.
2.3.7 DO NOT spill fuel when refueling the engine.
2.3.8 DO NOT run the engine near open flames.
2.3.9 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.
2.3.10 ALWAYS refill the fuel tank in a well-ventilated area.
2.3.11 ALWAYS replace the fuel tank cap after refueling.
2.3.12 ALWAYS 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.
DANGER

Safety Information GV 3800A
wc_si000207gb.fm 10
2.4 Service Safety
Poorly maintained equipment can become a safety hazard! In order
for the equipment to operate safely and properly over a long period of
time, periodic maintenance and 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.
2.4.1 DO NOT use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
2.4.2 DO NOT attempt to clean or service the machine while it is running.
2.4.3 DO NOT modify the machine without the express written approval of
the manufacturer.
2.4.4 DO NOT allow water to accumulate around the base of the machine.
If water is present, move the machine and allow the machine to dry
before servicing.
2.4.5 DO NOT service the machine if your clothing or skin is wet.
2.4.6 DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
2.4.7 ALWAYS 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.
2.4.8 ALWAYS replace the safety devices and guards after repairs and
maintenance.
2.4.9 ALWAYS let the engine cool before transporting or servicing it.
2.4.10 ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
2.4.11 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.
2.4.12 ALWAYS keep the fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.
WARNING

GV 3800A Safety Information
wc_si000207gb.fm 11
2.5 Label Locations

Safety Information GV 3800A
wc_si000207gb.fm 12
2.6 Safety and Operating Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label Meaning
DANGER!
No sparks, flames or burning objects near
machine.
Shut off the engine before refueling.
WARNING!
Hot surface!
Improper connection of generator to a
building’s electrical system can allow electrical
current from the generator to backfeed into
utility lines. This may result in electrocution of
utility workers, fire, or explosion. Connections
to a building’s electrical system must be made
by a qualified electrician and comply with all
applicable laws and electrical codes.
Close main circuit breaker.
CAUTION!
Use only clean, filtered gasoline fuel.
Check the fuel level.

GV 3800A Safety Information
wc_si000207gb.fm 13
Open the fuel flow valve.
Close the choke.
Turn the engine switch to the ON position.
Pull the rewind starter.
Open the choke.
Open main circuit breaker.
Turn the engine switch to “OFF”.
Close the fuel flow valve.
Label Meaning

Safety Information GV 3800A
wc_si000207gb.fm 14
Electrical ground
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.
A nameplate listing the model number, item
number, revision number, and serial number is
attached to each unit. Please record the
information found on this plate so it will be
available should the nameplate become lost or
damaged. When ordering parts or requesting
service information, you will always be asked
to specify the model number, item number,
revision number, and serial number of the unit.
This equipment does not meet California EVP
emission regulations for small off-road
engines.
Label Meaning
A
MADE IN USA
MADE IN USA
Model
Model
Item No.
Item No.
Rev.
Rev.
Serial No.
Serial No.
kg
kg V
kW Max
kW Max
lbs
lbs Ø
P.F.
P.F.
164329
164329
hz
hz

GV 3800A Operation
wc_tx000705gb.fm 15
3. Operation
3.1 Determining Power Requirements
This generator is designed to operate single-phase, 60 Hz appliances
running at 120 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 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
Three Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS

Operation GV 3800A
wc_tx000705gb.fm 16
3.2 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.
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 this generator inside a home or garage, EVEN IF
doors and windows are open. Only use this generator OUTSIDE and
far away from windows, doors, and vents.
NEVER install a generator in an enclosed area such as a tunnel or a
trench. Using a generator in a tunnel or a trench CAN KILL YOU IN
MINUTES. Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell. NEVER use this generator inside a
tunnel or a trench.
3.3 Installing Spark Arrester
A spark arrester is available as an accessory for this machine. Install
the spark arrester prior to using the machine in areas where spark
arresters are required.
To install spark arrester:
3.3.1 Position the spark arrester (a) on the engine exhaust pipe (b).
3.3.2 Secure the spark arrester with screw (c) included with spark arrester.
DANGER
DANGERDANGER

GV 3800A Operation
wc_tx000705gb.fm 17
3.4 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 Temp.
°C (°F) Derate Factor
45 (113) 3 % 0.97
50 (122) 6 % 0.94
55 (131) 9 % 0.91
60 (140) 12 % 0.88
Altitude
m (ft.) Derate Factor
1500 (4900) 3 % 0.97
2000 (6600) 6 % 0.94
2500 (8200) 9 % 0.91
3000 (9900) 12 % 0.88
3500 (11500) 15 % 0.85
4000 (13100) 18 % 0.82

Operation GV 3800A
wc_tx000705gb.fm 18
3.5 Grounding the Generator
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.
3.6 Operating Heavy Loads
Limit operations requiring the maximum rated output of 3800 Watts to
20–30 minutes. For continuous operation, do not exceed the
continuous rated output of 3400 Watts.
NOTICE: DO NOT exceed the current limit specified on the control
panel for any receptacle.
a

GV 3800A Operation
wc_tx000705gb.fm 19
3.7 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 immediately.
Use the chart below as a guide for selecting proper cable size.
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.
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 -
WARNING

Operation GV 3800A
wc_tx000705gb.fm 20
3.8 Control Panel
Ref. Description Ref. Description
a Engine switch e Voltage Selector Switch (VSS)
b Auto idle switch f GFI duplex receptacle—120V
c Twist-lock receptacle—120/240V g GFI test button
d Main circuit breaker h GFI reset button