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Service Manual
50 Hz Portable Inverter Generator Set
EGMBJ / P3200ie
08hsilgnE − 4198002 −0511 (Issue 3)
EGMBK / P4300ie
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SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL
before operating the generator set. Safe
operation and top performance can only be
attained when equipment is operated and
maintained properly.
The following symbols, found throughout this
manual, alert you to potentially dangerous
conditions to operators, service personnel and
equipment.
This symbol alerts you to an
immediate hazard that will result in severe
personal injury or death.
This symbol alerts you to a
hazard or unsafe practice that can result in
severe personal injury or death.
This symbol alerts you to a
hazard or unsafe practice that can result in
personal injury or damage to equipment or
property.
Electricity, fuel, exhaust, moving parts and
batteries present hazards against which
precautions must to taken to prevent severe
personal injury or death.
Exhaust Gas Is Deadly
x Operate the generator set outdoors only.
Stay away from the exhaust outlet.
x Make sure generator set exhaust will not
enter windows, doors, vents or air intakes of
adjacent buildings, vehicles or boats.
x NEVER USE THE GENERTOR SET
INSIDE a home, garage, crawl space,
barn, shed, cabin, boat, boat house, RV or
tent, or in a confined outdoor space such as
an alley, ditch, parking garage or courtyard,
or in any other space where exhaust can
accumulate. Note that HAZARDOUS
CARBON MONOXIDE LEVELS FROM
ENGINE EXHAUST CAN ACCUMULATE
INDOORS EVEN WHEN ALL WINDOWS
AND DOORS ARE OPEN AND FANS ARE
RUNNING.
Gasoline is Flammable / Explosive
x
Refuel the generator set outdoors only.
x Static electric sparks caused by fuel flowing
through a service station pump nozzle can
ignite gasoline. Never fill the generator set
with a service station pump nozzle. Instead,
fill a safety tank sitting on the ground and
then slowly transfer fuel to the generator set
from the safety tank.
x DO NOT fill fuel tanks while the engine is
running. A hot engine can ignite the fuel.
x To prevent fire due to fuel leakage, always
close the fuel valve and let the generator set
cool before transporting it or storing it in a
confined space.
x DO NOT SMOKE OR ALLOW AN OPEN
FLAME near the generator set. Keep flames,
sparks, electrical switches, pilot lights,
electrical arcs, arc-producing equipment and
all other sources of ignition well away.
Generator Voltage is Deadly
x DO NOT CONNECT THE GENERATOR
SET DIRECTLY TO ANY BUILDING
ELECTRICAL SYSTEM. Back-feed could
cause electrocution of utility line workers and
damage to equipment. An approved
switching device must be used to prevent
interconnections. A trained and experienced
electrician must make electrical connections
when the generator set is used for
emergency power.
x Make sure clothing, shoes and skin are dry
when handling electrical equipment.
xNever operate the generator set in rain or
snow or when it is sitting on wet ground.
Moving Parts Can Cause Severe
Personal Injury or Death
x Before performing any maintenance on the
generator set, disconnect the spark plug
wire.
x Always keep hands away from moving parts.
x Do not wear loose clothing or jewelry while
servicing the generator set. Loose clothing
and jewelry can become caught in moving
parts. Jewelry can short out electrical
contacts causing sparks, flame and electrical
shock.
x Make sure that fasteners and clamps on the
generator set are tight. Keep guards in
position over fans, rotors, etc.
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SAFETY PRECAUTIONS
Battery Gases are explosive
x
Wear safety glasses when servicing
batteries.
x Do not smoke.
x To reduce arcing when disconnecting or
reconnecting battery cables, always
disconnect the negative (–) cable of the
battery first and reconnect it last.
General Precautions
x Keep children away from the generator set.
x Wear hearing protection when near an
operating generator set.
x Keep a multi-class ABC fire extinguisher
readily at hand. Class A fires involve
ordinary combustible materials such as
wood and cloth. Class B fires involve
combustible and flammable liquids and
gaseous fuels. Class C fires involve live
electrical equipment. (ref. NFPA No. 10)
x Benzene and lead may be found in gasoline
and have been identified by some state and
federal agencies as causing cancer or
reproductive toxicity. Do not ingest, inhale or
contact gasoline.
x Used engine oils have been identified by
some state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
inhale or contact used engine oil or its
vapors.
x Keep the generator set clean and dry at all
times. Excess grease and oil can catch fire
and/or accumulate dirt, which can cause
overheating.
x Do not store anything on the generator set,
such as oil cans, oily rags, chains or wooden
blocks. A fire could result or operation could
be adversely affected
x Do not work on the generator set when you
are mentally or physically fatigued or have
consumed alcohol or drugs.
Failure to properly follow instructions and precautions can cause
you to be seriously hurt or killed.
Follow the procedures and precautions in this manual carefully.
Improper service or repairs can create an unsafe condition that
can cause your customer or others to be seriously hurt or killed.
Follow the procedures and precautions in this manual and other
service materials carefully.
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CONTENTS
Section Title Page
1. SPECIFICATIONS .............................................................................. 6
2. GENERAL DESCRIPTION .................................................................. 8
2-1 EXTERNAL VIEW ........................................................................ 8
2-2 CONTROL P
ANEL
..................................................................... 12
2-3 LOCATION OF SERIAL NUMBER AND
PRODUCTION NUMBER
........................................................... 14
2-4 ALTERNA
TOR ............................................................................ 15
3. RANGE OF APPLICATIONS
............................................................ 16
4. MEASURING AND CHECKING PROCEDURES .............................. 19
4-1 MEASURING INSTRUMENTS ................................................... 19
4-2 AC OUTPUT MEASURING ........................................................ 22
4-3 DC OUTPUT MEASURING ........................................................ 22
4-4 MEASURING INSULA
TION RESIST
ANCE ................................. 23
4-5 CHECKING FUNCTIONAL MEMBERS ..................................... 24
5. DISASSEMBL
Y AND ASSEMBL
Y .................................................... 27
5-1 PREPARA
TION AND PRECAUTIONS ........................................ 27
5-2 SPECIAL TOOLS ....................................................................... 27
5-3 DISASSEMBL
Y PROCEDURES
................................................ 28
5-4 REASSEMBLY PROCEDURES ..................................................
43
5-5 RECOIL STAR
TER ..................................................................... 54
6. TROUBLE SHOOTING .................................................................... 59
7. WIRING DIAGRAM .......................................................................... 62
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1. SPECIFICATIONS
Model
Type
Starting System
Hz
W
L
mm
mL(cc)
L
kg
Model
Type
Frequency
kVARated Output
AC
Rated Output
Fuel Tank Capacity
h
Lubrication Oil Capacity
Ignition System
Dry Weight
Specifications are subject to change without notice.
Dimensions L× W× H
Displacement
Air-Cooled 4-stroke OHC Gasoline engine
Oil Sensor STD
Multi Monitor STD
Over-current Protection
Spark Plug NGK BR6HS
487× 432× 475
10.0 10.8
Solid-state flywheel magneto
Continuous Operating
Hours at Rated Output
6.0 4.5
0.6 1.0
Fuel Unleaded Automobile Gasoline
100
For AC Output Electronic Circuit Breaker
For DC Output
Circuit Breaker
VVoltage 12
ACurrent 8.3
DC
Power Factor 1.0
Voltage Regulator
PWM Controlling
Voltage Regulation Within 10%
50 / 60
P3200i P4300i
Multi-Pole, Rotating Field Inverter Generator
38
2.8 3.8
220 220
12.7 17.3
240 240
11.7 15.8
110 110
25.5 34.5
120 120
23.3 31.7
230 230
12.2 16.5
- - -
- -
-
Voltage V
Rated Current
A
Voltage V
Rated Current
A
50Hz
60Hz
EX21
EX27
52.5
523× 477× 508
211 265
Engine Alternator
Equipment
Recoil Starter
Electric Starter / Recoil
P3200ie & P4300ie - 6 - 01-08
Page 8
Model
Type
Starting System
Hz
W
L
mm
mL(cc)
L
kg
Model
Type
Frequency
Rated Output
Fuel Tank Capacity
h
Lubrication Oil Capacity
Ignition System
Dry Weight
Dimensions L× W× H
Displacement
Air-Cooled 4-stroke OHC Gasoline engine
Oil Sensor STD
Multi Monitor STD
Over-current Protection
Electric Starter / Recoil
Spark Plug NGK BR6HS
537× 482× 583
10.8 12.8
Continuous Operating
Hours at Rated Output
6.5 5.3
0.6 1.0
Fuel Unleaded Automobile Gasoline
100
For AC Output Electronic Circuit Breaker
For DC Output
Circuit Breaker
VVoltage 12
ACurrent 8.3
DC
Power Factor 1.0
P3 200ie P4300ie
Multi-Pole, Rotating Field Inverter Generator
59
EX21
EX27
74
580× 527× 618
211 265
Engine
Equipment
kVARated Output
Solid-state flywheel magneto
Voltage Regulator PWM Controlling
Voltage Regulation Within 10%
50 / 60
2.8
3.8
AC
220 220
12.7 17.3
240 240
11.7 15.8
110 110
25.5 34.5
120 120
23.3 31.7
230 230
12.2 16.5
- - -
- -
-
Voltage V
Rated Current
A
Voltage V
Rated Current
A
50Hz
60Hz
Alternator
Specifications are subject to change without notice.
P3200ie & P4300ie - 7 - 01-08
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2. GENERAL DESCRIPTION
2-1-1) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE
DC TERMINALS
DRAIN PLUG
GROUND TERMINAL
AC RECEPTACLES
DC CIRCUIT BREAKER
FUEL TANK
OIL LEVEL GAUGE
FUEL LEVEL GAUGE
MULTI MONITOR
SPARK PLUG
FRAME
SPECIFICATIONS LABEL
AIR CLEANER
MUFFLER
(EXHAUST OUTLET)
ENGINE SWITCH
TANK CAP
RECOIL STARTER HANDL
P3200i
2-1-2) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE WITH ELECTRIC STARTER
DC TERMINALS
DRAIN PLUG
GROUND TERMINAL
AC RECEPTACLES
DC CIRCUIT BREAKER
FUEL TANK
OIL LEVEL GAUGE
FUEL LEVEL GAUGE
MULTI MONITOR
SPARK PLUG
FRAME
SPECIFICATIONS LABEL
AIR CLEANER
MUFFLER
(EXHAUST OUTLET)
ENGINE SWITCH
TANK CAP
RECOIL STARTER HANDLE
BATTERY
COVER
BATTERY
KEY SWITCH
P4300i
P3200ie & P4300ie - 8 - 01-08
Page 10
2-1-2) EXTERNAL VIEW OF GENERATOR : OPEN FRAME TYPE WITH ELECTRIC STARTER
DC TERMINALS
DRAIN PLUG
GROUND TERMINAL
AC RECEPTACLES
DC CIRCUIT BREAKER
FUEL TANK
OIL LEVEL GAUGE
FUEL LEVEL GAUGE
MULTI MONITOR
SPARK PLUG
FRAME
SPECIFICATIONS LABEL
AIR CLEANER
MUFFLER
(EXHAUST OUTLET)
ENGINE SWITCH
TANK CAP
RECOIL STARTER HANDLE
BATTERY
COVER
BATTERY
KEY SWITCH
P4300i
P3200ie & P4300ie - 9 - 01-08
Page 11
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