Wacker Neuson GPi 3200, GPSi 3200, GPi 4300, 0620781, 0620960 Operator's Manual

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Copyright notice

©Copyright All rights, including copying and distribution rights, are reserved. This publication may be photocopied by the original purchaser

machine. Any other type written permission from Wacker Neuson Production Americas LLC.

Any type Neuson Production Americas copyrights. Violators

2013 by Wacker Neuson Production.Americas LLC

of

reproduction is prohibited without express

of

reproduction

or

distribution not authorized by Wacker

LLC

represents an infringement

will be prosecuted.

of

the

valid

Trademarks

Manufacturer

Original

instructions

All trademarks referenced respective owners.

Wacker Neuson Production Americas LLC N92W15000 Anthony Avenue Menomonee Tel:

(262) 255-0500 · Fax: (262) 255-0550 ·

www.wackerneuson.com

This Operator's Manual presents the original instructions. The original language

Falls, WI 53051 U.S.A.

of

this Operator's Manual is American English.

in

this manual are the property

Tel:

(800) 770-0957

··-····-----------------------------

of

their

GPi 3200

Foreword

/4300

Foreword

Machines covered

this

manual

in

SAVE THESE the machine models listed below. These instructions must be followed during installation and maintenance

Machine Item Number

GPi

3200 0620781,0620960

GPSi

3200 0620936,0620961

GPi

4300 0620784,0620962

GPSi

4300

DANGER

Carbon Generator exhaust contains carbon monoxide see or even if you cannot

•

· enough fresh air.

• ONLY use a generator outside, and far away from homes, buildings, windows,

• Point the engine exhaust away from homes, buildings, windows, doors, and

• Even when you use a generator correctly, CO may leak into the home

• If you start to feel sick, dizzy, or weak after the generator has been running,

monoxide.

smell.

NEVER use a generator inside homes, buildings, garages, crawlspaces, or other partly these areas. Using a fan

doors, and vents. Windows, doors, and vents can

vents. Also, point the engine exhaust away from combustible materials. ing. ALWAYS use a battery-powered

building. move to fresh air RIGHT

poisoning.

INSTRUCTIONS-

This manual contains important instructions for

of

the generator (and battery, if equipped).

0620937,0620963

Using a generator indoors CAN KILL YOU

(CO). This is a poison you cannot

If

you can smell the generator exhaust, you are breathing CO. But

smell the exhaust,

enclosed areas. Deadly levels

or

opening windows and doors does NOT supply

AWAY.

you

could be breathing CO.

of

or

battery-backup CO alarm in the home or

See a doctor.

carbon monoxide can build up in

pull

You

could have carbon monoxide

IN

MINUTES.

in

generator exhaust.

or

build-

wc_tx001874gb.fm

3

W.\.CKER

NEUSON

Foreword

GPi

3200

I 4300

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Machine A nameplate listing the model number, item number, revision number, and serial identification number is attached to this machine. The location

of

the nameplate is shown above.

Serial number For future reference, record the serial number (S/N) need the serial number when requesting parts or service for this machine.

in

the space provided below.

I Serial Number:

Machine • From this point forward documentation 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.

• If you are missing either order a

replacement

• When ordering parts or requesting service information, be prepared to provide

Expectations • for information in this manual

the machine

This manual provides information and procedures to safely operate and maintain the above Wacker Neuson risk

of

injury, carefully read, understand, and observe all instructions described

in this

manual.

model number, item number, revision number, and serial number.

• Wacker Neuson expressly reserves the right to make technical modifications, even without notice, which improve the performance machines.

• The information contained in this manual is based up

until the time

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

of

requirements

your specific region.

in

this documentation, Wacker Neuson Production

of

these documents, please contact Wacker Neuson to

or

visit www.wackerneuson.com.

model(s). For your own safety and to reduce the

or

safety standards

on

machines manufactured

publication. Wacker Neuson reserves the right to change

You

of

will

its

W~CKER

NEUSON

4

wc_tx001874gb.fm

GPi

3200

/4300

Foreword

CALIFORNIA Proposition 65Warning

Laws

pertaining spark arresters

Manufacturer's This manual contains references to approval tions. The following definitions apply:

Combustion exhaust, some

contain or emit chemicals known to the

birth defects

NOTICE: State Health Safety Codes and Public Resources Codes specify that

to

certain locations spark arresters be used

hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge and rated by the United with local laws regarding spark arresters, consult the engine distributor

Health and

•

Approved

Wacker Neuson.

•

Approved son service center according to written instructions published by Wacker Neuson.

•

Unapproved meet the approved criteria.

Unapproved parts, attachments, or modifications may have the quences:

• Serious injury hazards to the operator and persons

• 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

other reproductive harm.

of

sparks

or

flames from the engine exhaust. Spark arresters are qualified

Safety Administrator.

parts

or

modifications

parts,

unapproved parts, attachments, or modifications.

of

its constituents, and certain vehicle components

States Forest Service for this purpose.

attachments

are those performed by

attachments,

State of California to cause cancer and

on

internal combustion engines that use

In

order to comply

or

the local

approved parts, attachments, and modifica-

are those either manufactured or provided by

an

authorized Wacker Neu-

and

modifications

are those that do not

following conse-

in

the work area

in

wc_tx001874gb.fm

5

W4CKEit

NEUSON

Foreword

GPi 3200 I 4300

W-'.CKER

NEUSON

6

wc_tx001874gb.fm

GPi

3200/4300

Table

of

Contents

Foreword

1 Safety Information

1.1

1.2

1.3

1.4

1.5

Signal Words Used

Machine Description and Intended Use ............................................. 10

Safety Guidelines for Operating the Machine .....................................

Operator Safety while Using Internal Combustion Engines ...............

Service Safety

2 Labels

2.1

2.2

3 Lifting

4 Operation

Label Locations ..................................................................................

Label Meanings ..................................................................................

and

Transporting

in

..

. . . . . . . . . .

3

9

this Manual ....................................................... 9

11 13

..

. . . . . . .

.. . ..

..

. . . . . . . . . . . . .

..

. .

.. ..

. . . . . . . .

..

. .

..

. . . . . . . . . . . .

14

16

16 17

19

20

4.1

4.2 Preparing the Machine for First Use ...................................................

4.3 Features and Controls ........................................................................ 22

4.4 Components ....................................................................................... 23

4.5 Wheel Brakes (if equipped) ................................................................ 23

4.6 Positioning the Generator for Operation ............................................. 24

4.

7 Connecting and Maintaining the Battery ............................................ 26

4.8 Use

4.9 Power Requirements .......................................................................... 29

4.1

4.11

4.12 Customer Connections ....................................................................... 33

4.13 Grounding the Generator ................................................................... 35

4.14 Fueling the Machine ........................................................................... 36

4.15 Before Starting ................................................................................... 37

4.16 Starting the Generator

4.17 Starting the Generator (Manual

4.18 Using

4.19 Using

4.20 Stopping the Generator ...................................................................... 44

4.21

Overview ............................................................................................ 20

21

of

Extension Cords ...................................................................... 28

0 Control Panel ...................................................................................... 30

Components .......................................................................................

{S

Models) ..................................................... 38

Start Only) ........................................ 39

AC

Power ................................................................................. 40

DC

Power ................................................................................. 42

Emergency Shutdown Procedure ....................................................... 45

31

wc_bo5200002205_02TOC.fm

7

W~CKER

NEUSON

Table

of

Contents

GPi 3200

/4300

5 Maintenance 46

5.1

5.2 Detaching the Side Panels

5.3 Checking the Engine

5.4 Cleaning the Air Cleaner .....................................................................

5.5 Cleaning and Checking the Spark Plug ...............................................

5.6 Changing the Engine Oil ..................................................................... 52

5.7 Cleaning the Spark Arrester ................................................................ 53

5.8 Cleaning the Fuel Strainer ................................................................... 54

5.9 Storing the Generator .......................................................................... 55

Periodic Maintenance Schedule ......................................................... .46

(S

Models) ............................................... .48

Oil ..................................................................... .49

50

51

6 Basic Troubleshooting 57

7 Technical Data 58

7.1

7.2 Generator ............................................................................................ 59

8 Emission Control Systems Information and Warranty

Engine ................................................................................................. 56

61

9 Schematics 66

9.1

9.2 Electrical Schematic

9.3 Electrical

9.4 Electrical Schematic

9.5 Electrical Schematic-(Manual Start Models,

9.6 Electrical Schematic Components-(Manual Start Models, non-CSA) .

9.

7 Electrical Schematic-(Manual Start Models, CSA) ............................ 72

9.8 Electrical Schematic Components-(Manual Start Models,

Electrical

Schematic-(S

Schematic-(CSA)

Models, non-CSA) ...................................... 66

Components-(S

Components-(CSA)

Models, non-CSA) ................. 67

............................................................... 68

......................................... 69

non-CSA) .................... 70

71

CSA) ...... 73

W~CKER

NEUSON

8

wc_bo5200002205_02TOC.fm

GPi

3200/4300

1.3 Safety Guidelines for Operating the Machine

DANGER Carbon monoxide. Using a generator indoors CAN KILL YOU

Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or even

~

smell. If you can smell the generator exhaust, you are breathing CO. But

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 Using a fan or opening windows and doors does

ONLY use a generator outside and far away from windows, doors, and vents. These openings can

Even when you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-backup CO alarm If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air poison.

pull

RIGHT

of

carbon monoxide can build up

in

generator exhaust.

AWAY.

See a doctor.

You

Safety Information

IN

MINUTES.

in

these areas.

NOT supply enough fresh air.

in

the home.

could have carbon monoxide

Operator

qualifications

Personal Protective Equipment (PPE}

WARNING

Machines operated improperly or by untrained personnel can

~

Read the operating instructions contained the engine operator's

~

Familiarize yourself with the location and proper use of all controls.

~

Inexperienced operators should receive instruction from someone familiar with the machine before being

Only trained personnel are permitted to start, operate, and shut down the machine.

also must meet the following qualifications:

They

• have received instruction on how to properly use the machine

• are familiar with required safety devices The machine must not be accessed or operated by:

• children

• people impaired by alcohol or drugs

Wear the machine:

• Close-fitting work clothes that do not hinder movement

• Safety glasses with side shields

Hearing protection

•

• Safety-toed footwear

following Personal Protective Equipment (PPE) while operating this

manual.

allowed to operate

in

both this Operator's Manual and

it.

be

hazardous.

Before starting the machine

wc_si000619gb.fm

Before starting this machine:

• Follow starting and stopping instructions described

operate and stop the generator before starting it.

11

in

this manual. Know how to

W.\CKEit

NEUSON

Safety Information

GPi

3200 I 4300

Electrical safety

• Do not start a machine

• Make sure the machine is on a firm, level surface and will not tip, roll, slide, or fall while operating.

• Remove all tools, cords, and other loose items from the generator before starting it.

To

increase electrical safety while operating this machine:

• Do not operate the generator, or tools attached

• Do not use worn electrical cords. Severe electrical shock and equipment damage may result.

• Do not operate generator in standing water.

• Make certain the machine is well-grounded and securely fastened to a good earthen ground per national and local regulations.

• Do not overload the generator. attached to the generator must not exceed the load rating

WARNING Backfeed from the generator into the public power distribution system can seriously injure or

..,.

..,. ..,.

kill utility workers!

Improper connection electrical current from the generator to backfeed into utility lines. This may result in electrocution

Connections to a building's electrical system must be made by a qualified elec-

trician and comply with

If connected to a building's electrical system, the generator must meet the

power, voltage, and frequency requirements

of

in

need

of

repair.

to

the generator, with wet hands.

The

total amperage

of

generator to a building's electrical system can allow

utility workers, fire,

all applicable laws and electrical codes .

or

explosion .

of

the tools and equipment

of

the generator.

the equipment

in

the building.

Generator vibration

Operating

safety

Generators vibrate 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 cracked insulation or damaged blades.

To

increase operating safety while running this machine:

• Do not operate the generator when open containers flammable liquids are

• Do not place flammable material

• Do not operate the machine indoors.

• Do not touch the hot engine, exhaust, result.

Always

•

• Keep the machine at least one meter (three feet) away from structures,

do

the following:

Wear hearing protection when operating equipment.

buildings, and other equipment during use.

in

normal use. During and after the use

or

or cords that show signs

in

the vicinity

of

the generator.

or

liquids near the generator.

or

of

damage such as broken

generator components. Burns will

of

the generator, inspect

of

fuel, paint, or other

or

W4CKEa

NEUSON

12

wc_si000619gb.fm

GPi

3200/4300

1 Safety Information

Safety Information

1.1

Signal Words Used

This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility damage to the equipment, or improper service.

is

This

~

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result or serious injury.

~

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result death or serious injury.

~

the safety alert symbol. It is used to alert you to potential personal hazards.

Obey all safety messages that follow this symbol.

To

avoid death or serious injury from this type

messages that

To

avoid possible death or serious injury from this type of hazard, obey all safety

messages that

in

this Manual

follow this signal word.

of

personal injury,

of

hazard, obey all safety

in

death

in

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result minor or moderate injury.

~

To

avoid possible minor or moderate injury from this type

safety messages that follow this signal word.

NOTICE: Used without the safety alert symbol, NOTICE indicates a situation

which, if not avoided,

Note: A Note contains additional information important to a procedure.

could result in property damage.

of

hazard, obey all

in

wc_si000619gb.fm

9

W.\.CKER

NEUSON

Safety Information

1.2 Machine Description and Intended Use

This machine is a portable electric power source. The Wacker Neuson Inverter Generator consists inverter. side into receptacles or DC terminals.

Controls and receptacles are provided on a control panel mounted on the

of

the machine. As the engine runs, the generator converts mechanical energy

AC power and DC power. The operator connects loads to the AC power

of

a gasoline engine, a fuel tank, and an electric alternator and

GPi

3200/4300

This machine is intended for the purpose connected frequency generator.

This machine has been designed and above. Using the machine for any other purpose machine or damage caused by misuse is not covered under warranty.

following practices are some examples

The

• 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

and local codes and regulations. Using the machine as a ladder, support, or work surface

•

• Using the machine to carry or transport passengers or equipment

• Operating the machine outside

• Operating the machine

machine and

loads.

of

Referto

this generator, and for the maximum output power limit

seriously injure the operator or other persons

in

the Operator's Manual

the product specifications for the output voltage and

in

a manner that is inconsistent with all federal, state

of

in

a manner inconsistent with all warnings found on the

of

supplying electrical power to

of

this

built strictly for the intended use described

could permanently damage the

in

the area. Machine

of

misuse:

factory specifications

This machine has been designed and built 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

• Heat, noise, exhaust, and carbon monoxide from the engine

• Fire hazards from improper refueling techniques

• Fuel and its fumes

• Electric shock and arc flash

• Personal To

safety information presented

W-'CKEil

NEUSON

in

accordance with the latest global

called residual risks. On this machine, they may include exposure to:

injury from improper lifting techniques

protect yourself and others, make sure you thoroughly read and understand the

in

this manual before operating the machine.

wc_si000619gb.fm

10

GPi

3200/4300

• Keep the area immediately surrounding and underneath the machine clean, neat, and free overhead is compartment.

Safety Information

of

debris and combustible materials. Make sure that the area

clear

of

debris that could fall onto or into the machine or exhaust

Storing the machine

Store the machine stored

in

a clean, dry location out

properly when it is not being used. The machine should be

of

the reach of children.

1.4 Operator Safety while Using Internal Combustion Engines

WARNING

Internal combustion engines present special hazards during operation and fueling.

~

ill

Failure

death.

~

DANGER

~

to follow the warnings and safety standards could result

Read and follow the warning instructions safety

Carbon monoxide. Using a generator indoors CAN KILL YOU

Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or even if you cannot

guidelines below.

smell. If you can smell the generator exhaust, you are breathing CO. But

smell the exhaust, you could be breathing CO.

in

the engine owner's manual and the

in

severe injury or

IN

MINUTES.

Refueling

safety

Operating safety

When refueling the engine:

• Do not smoke.

• Do not refuel if the generator is sitting 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

• 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

• Do not run the machine if fuel leaks are present or the fuel lines are loose.

•

• Do not smoke while operating the machine.

the fuel tank

engine.

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

in

a well-ventilated area.

spill and wipe the generator dry before starting.

in

a truck fitted with a plastic bed liner.

wc_si000619gb.fm

13

W.lCKEa

NEUSON

Safety

Information

1.5 Service Safety

WARNING A poorly maintained machine can be a personal injury hazard .

..,.

Follow the Periodic Maintenance schedule

..,.

Repair or replace any damaged or defective components immediately.

GPi 3200 I 4300

in

this Operator's Manual.

Personal Protective Equipment (PPE)

Prerequisites

Ground connection

Wear the maintaining this machine:

• Close-fitting work clothes that do not hinder movement

• Safety glasses with side shields Hearing protection

•

• Safety-toed footwear

In addition, before servicing or maintaining the machine:

• Tie back long hair.

• Remove all jewelry (including rings).

Before servicing this machine:

• Stop the engine.

• If the engine has an electric starter, disconnect the negative terminal on the battery.

• Attach a "DO NOT START" sign to the machine. This will notify everyone that

the machine is being serviced and

inadvertently trying to start the machine.

• The generator must be connected to a good earthen ground for proper operating safety!

• Ground the generator state, and

following Personal Protective Equipment (PPE) while servicing or

in

accordance with the standards defined

local regulations.

will reduce the chance

of

someone

in

national,

Personal injury avoidance

Service safety

W~CKEil

NEUSON

• Let the engine and muffler cool before transporting or servicing the machine.

• Do not service the machine if your clothing or skin is wet.

• Do not allow untrained personnel to service this machine. Only trained electrical

technicians should be allowed to service the electrical components

machine.

• Do not modify the machine without the express written approval manufacturer.

• 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.

of

this

of

the

wc_si000619gb.fm

14

GPi

3200/4300

Safety Information

Replacing parts

and

labels

• Replace worn or damaged components.

• Use only spare parts recommended by Wacker Neuson.

• Keep the fuel lines extremely explosive!

• Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn

• Check all external fasteners at regular intervals.

in

serviceable condition. Leaking fuel and fumes are

of

dangers and hazards.

wc_si000619gb.fm

15

W.4.CKEit

NEUSON

Labels

2 Labels

GPi

3200/4300

2.1

Label

Locations

W.._CKEil

NEUSON

16

wc_si000618gb.fm

GPi

3200/4300

2.2 Label Meanings

A DANGER

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or

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.

Labels

smell.

or

NEVER use inside a home and windows are open.

Only operate the generator OUTSIDE, and far away from homes, buildings, windows, doors, and vents. Always point the engine exhaust away from homes, buildings, windows, doors, vents, and combustible materials

8

Do not connect the generator to a commercial power source.

Keep open

Attention!

Read the Operator's

machine.

Attention!

Stop the engine before

during use.

flames and sparks away from the generator.

Manual before operating this

garage, EVEN IF doors

household or

refueling.

wc_si000618gb.fm

17

W.lCKEil

NEUSON

Labels

GPi

3200/4300

c

D

WARNING

Do not use AC and DC at the same time.

WARNING To

reduce the risk

understand instruction

of

injury, user must read and

manual. Exhaust gas contains poisonous carbon monoxide. Do not use

in

poorly ventilated area.

The operator may suffer severe elecrtric shock.

Do not touch with wet hands.

The operator may suffer burns. Do not touch hot muffler. Potential danger

of

explosion or fire. Stop engine during fuel supply. Keep flammable things away. Be careful not to

spill fuel during refueling. Use unleaded gasoline only. Keep open flames away from the generator. Do not operate

in

rain or snow.

Do not connect to a household circuit.

E

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or

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in

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WARNING Hot surface! Do not touch.

DANGER Risk

of

carbon monoxide poisoning.

Keep a safe distance away from the machine.

This equipment regulations

does not meet California EVP emission

for-small off-road engines.

(GPi 3200 only)

WARNING Improper

connection electrical system can generator to backfeed into utility lines. This may result electrocution

of Connections to a building's electrical system must made by a qualified electrician and comply with all applicable laws and electrical codes.

of

the generator to a building's

allow electrical current from the

utility workers, fire, or explosion.

be

in

W.._CKEil

NEUSON

18

wc_si000618gb.fm

GPi 3200 I 4300

3 Lifting and Transporting

Lifting and Transporting

Lifting machine

Transporting the

the

machine

This generator, while compact, is heavy enough to cause injury 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 weightbearing capacity to lift or hold the generator safely.

• Remain aware

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 prevent it from sliding or tipping.

• Do not refuel the generator its operating location and then fill the fuel tank.

of

the location of other people nearby when lifting the generator.

in

or on the transport vehicle. Move the generator to

if

proper lifting

the transport vehicle to

wc_tx003497gb.fm

19

W4CKEit

NEUSON

Operation

4 Operation

DANGER Carbon monoxide. Using a generator indoors CAN KILL YOU

Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see even

...

.., ..,

..,

GPi

or

smell. If you can smell the generator exhaust, you are breathing CO. But

if

you cannot smell the exhaust, you could be breathing CO .

NEVER use a generator inside homes, buildings, garages, crawlspaces, or other partly these areas. Using a fan or opening windows and doors does

enough fresh air .

ONLY use a generator outside, and far away from homes, buildings, windows, doors, and vents. Windows, doors, and vents can Point the engine exhaust away from homes, buildings, windows, doors, and

vents. Also, point the engine exhaust away from combustible materials .

Even when you use a generator correctly, CO may leak into the home or building. ALWAYS use a battery-powered or battery-backup CO alarm in the home building . If you start to feel sick, dizzy, or weak after the generator has been running, move poisoning.

enclosed areas. Deadly levels

to

fresh air RIGHT

AWAY.

of

carbon monoxide can build up in

pull in generator exhaust.

See a doctor. You could have carbon monoxide

3200 I 4300

IN

MINUTES.

NOT supply

or

WARNING

Risk

of

electric shock

..,

Do not operate this generator in rain, snow, or standing water.

4.1

Generator application

Safety notices • Do not exceed the power output

Overview

This generator is an exceptionally quiet and compact machine designed single phase power for construction, commercial, and residential applications.

State-of-the-art inverter technology ensures a consistent flow power suitable for operating not only tools, but also delicate electronic equipment.

can occur. Refer to

• When using the generator the voltage and phase rotation lines. Failure to match phase rotation and voltage may cause equipment connected to the generator to operate incorrectly! This could create unsafe operating conditions.

• Do not exceed the rated current limit

or

electrpcution .

Technical Data.

as

a stand-by or substitute power supply, make sure

of

clean and stable

of

the generator. Damage to tools

the line connections match those

of

any receptacle.

to

provide

or

generator

of

the main

W4CKER

NEUSON

20

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GPi

3200/4300

4.2 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

for assistance.

3.

Take inventory 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.

of

all items included with the machine and verify that all loose

Operation

dealer immediately

wc_tx001875gb.fm

21

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NEUSON

Operation

GPi

3200/4300

4.3 Features and

Controls

W~CKER

NEUSON

22

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3200/4300

4.4 Components

Ref. Description Ref. Description

Operation

A

Control panel K Spark plug cap

B

c

D Right side panel (if equipped)

E Oil drain plug 0 Oil filler I gauge

Fuel tank L Air cleaner Fuel gauge M Fuel strainer

F Recoil starter

G

Wheel brake (if equipped)

H Fuel tank cap R

J

Frame s Rear cover

4.5 Wheel Brakes (if equipped)

Description

The two rear wheels

brakes movement. Lock both rear wheels after the generator has been placed

operating position.

{g) . These brakes help to prevent the generator from unintentional

on

your generator (if equipped) feature spring-operated

N Battery (if equipped)

p

Q

Left side panel (if equipped) Exhaust outlet Spark arrester

in

its

Locking and unlocking wheels

wc_tx001875gb.fm

the

•

To

lock the wheel, press the brake tab {g1) until the brake snaps

against the wheel.

•

To

unlock the wheel, lift the brake tab.

23

wc_gr006842

in

place

W-'CKER

NEUSON

Operation

4.6 Positioning the Generator for Operation

DANGER

Carbon monoxide. Using a generator indoors CAN KILL YOU

Generator exhaust contains carbon monoxide (CO). see or even if you cannot

..,.

WARNING

Risk

..,.

smell. If you can smell the generator exhaust, you are breathing CO. But

smell the exhaust, you could be breathing CO .

Do not operate this generator unless it is properly positioned. Read and obey all instructions provided below.

of

electric shock or electrocution .

Do not operate this generator

in

rain, snow, or standing water.

GPi

This

is a poison you cannot

3200/4300

IN

MINUTES.

Requirements

Position the generator according to the

0

following requirements.

These instructions continue on the next page.

W~CKEil

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24

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GPi

CO Alarms

3200/4300

Continued from the previous page.

• Do not operate the generator anywhere inside a home or building. This includes the garage (c), entryway, porch, or sun room (d), living area or work space (e), or basement or can be fatal even

• ONLY windows, doors, and vents. Windows, doors, and vents can pull exhaust.

• Point the engine exhaust (b) away from homes, buildings, windows, doors, and vents.

Position the generator on firm, level ground so that it will not slide or shift.

•

Detectors/ Install CO detectors/alarms

while the generator is operating. CO detectors/alarms provide an extra measure

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. should be certified to the requirements 6-96, or CSA 6.19.01 the manufacturer's instructions.

use a generator outside (a), and far away from homes, buildings,

Also, point the engine exhaust away from combustible materials.

crawl space (f). Operating the generator inside a home or building

Operation

if

fans, open doors, or open windows are used for ventilation.

in

generator

in

all areas that may be occupied by people or animals

CO detectors/alarms

of

the latest safety standards (UL 2034, lAS

).

Test the CO detector/alarm batteries regularly according to

of

wc_tx001875gb.fm

25

W.lCK.Eit

NEUSON

Operation

4.

7 Connecting and Maintaining the Battery

GPi

3200 I 4300

Location and description

An automotive-style battery (n) is installed on the machine. The battery is located

to

Explosion hazard. Batteries can emit explosive hydrogen gas.

111-

Ill-

the air cleaner.

wc_gr006680

Keep all sparks and flames away from the battery. Do not short-circuit battery posts.

Battery

connections

Maintaining

the battery

WARNING

Battery fluid is poisonous and corrosive.

Ill-

In

the event

immediately.

To

connect the battery:

• Connect the positive ( +} battery cable to the battery.

• Connect the negative (-) battery cable to the battery.

To

disconnect the battery:

• Stop the engine.

• Place all electrical switches

• Disconnect the negative (-) battery cable from the battery.

• Disconnect the positive ( +) battery cable from the battery.

• Follow the battery manufacturer's maintenance recommendations.

• Keep battery terminals clean and connections tight.

• When necessary, tighten the cables and grease the cable clamps with petroleum

Maintain the battery at full charge to improve cold weather starting.

•

of

jelly.

ingestion

or

contact with skin

in

the OFF position.

or

eyes, seek medical attention

Precautions

W4CKER

NEUSON

Observe the following precautions to prevent serious damage to the electrical system.

26

wc_tx001875gb.fm

GPi

3200/4300

• Do not disconnect the battery while the machine is running.

• Do not attempt to run the machine without a battery.

• Do not attempt to jump-start the machine.

•

In

the event that the machine has a discharged battery, either replace the battery with a battery charger.

• Dispose of waste batteries

Operation

fully charged battery or charge the battery using an appropriate

See Technical Data for the equivalent battery specification.

in

accordance with local environmental regulations.

wc_tx001875gb.fm

27

W.\CKER

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Operation GPi 3200

/4300

4.8 Use

of

Extension Cords

When a long extension cord is used

generator, a voltage loss This results in less voltage being supplied the amount wire size

WARNING Electric shock hazard. Damaged extension cords can cause electrical shock,

resulting in serious injury

IJII.

Replace damaged cords immediately.

the

Use

Current Load in Watts Maximum Cable Length in Feet (Amps)

of

current draw or reduces performance. A heavier cord with a larger

will reduce the voltage loss.

chart below

120V

2.5 5

7.5

300 600 900

occurs-the

or

death.

as

a guide for selecting proper cable size.

240V

600 1000 600 1200 1800

to

connect an appliance

longer

Do

not use worn, bare, or frayed cords.

#10

to

the

cord, the greater the voltage loss.

the

appliance

#12 #14 #16

or

tool

or

tool and increases

375 500 350

300 200

200

125

to

the

250 125 100

10 15 20

Use only extension cords rated for outdoor use and equipped with a third-wire ground.

NOTICE: Operating equipment at low voltage can cause it

1200

2400 250 1800 3600 2400 4800

150

125

150 100

75

100

to

overheat.

65

50

-

WACKER

NEUSON

28

wc_tx001875gb.fm

Operation.

4.9 Power Requirements

GPi 3200

/.

4300

Application

About power requirements

Approximate starting power requirements

This generator is designed to operate single-phase, 60 Hz equipment running 120 VAC. It also provides DC power strictly intended for charging 12V automotive style batteries.

Check the power requirements are met by the power output not given for a for wattage requirements.

NOTICE: Do not exceed the continuous rated output

tools

Some pieces means that the amount than the power required to keep it running. The generator must be capable supplying this "surge" current. Other equipment may require more power than is actually stated on its nameplate.

The information in the following chart is offered only as a general guideline to help you determine power requirements for different types of equipment. Contact your nearest Wacker Neuson equipment, with questions regarding power requirements.

nameplate or label provided on tools and equipment to make sure their

of

the generator. If the wattage is

particular tool or piece of equipment, contact the tool manufacturer

of

the generator. Damage to

or

generator can occur. See Technical Data.

of

equipment and tools require a surge

of

power needed to initially start the equipment is larger

dealer, or the manufacturer

of

current when starting. This

or

dealer

of

the tool or

at

of

Equipment

Incandescent lights Same wattage as is stated on These have resistive-

•

Appliances such as

•

irons and hot plates Fluorescent and 1

•

mercury lamps Electrical motors Depends on motor type and use

•

Certain electrical tools

•

Most electrical tools

•

Submersible pumps

•

Air compressors

•

Other equipment

•

type

Wattage needed

their nameplates

.2-2

times their stated wattage

1.2-3

times their stated wattage

3-5

times their stated wattage

Calculate by multiplying its voltage and amperage requirements

to

start

Comments

type heating

ments.

Volts x Amps = Watts

ele-

W-'CKEil

NEUSON

29

wc_tx001875gb.fm

Operation

4.1

0 Control Panel

GPi

3200

GPi

4300

GPi

•

·

3200/4300

GPi

(CSA)

GPi

(CSA)

3200

4300

wc_gr008626

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NEUSON

30

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tx001875gb.fm

GPi 3200 I 4300 Operation

4.11

Multi

Components

monitor

(a}

AC

receptacles (b,

c)

Ref. Description Ref.

A Multi monitor K Operation hour indicator light

B AC receptacles, 20A L Voltage indicator light

AC receptacle, 30A

c

D

Ground lug N LED display changeover switch

E DC terminals 0 Auto-power saving switch

F DC circuit breaker

G Key switch

H Engine switch

LCD s GFCI

J

The multi monitor generator is operating.

AC power is supplied through two receptacle (c). Use only grounded, three-leg electrical plugs when connecting AC equipment to the machine.

(a}

displays the status

of

20A receptacles (b) and a 30A twist-lock

Description

M Frequency indicator light

p

Auto-power saving indicator

Q Engine oil level warning indicator light

AC circuit breaker

R

various machine functions while the

Ground

DC

terminals

(e)

DC

circuit

breaker

Key

switch

lug

(f)

(d)

The ground lug (d) is the terminal for grounding the generator. See topic Ground

Lug

for more information.

The generator provides DC power for charging batteries. The red terminal is positive(+); the black terminal is negative(-). See topic

The DC circuit breaker (f) shuts off the electrical current when the current exceeds

in

its limit, or a malfunction occurs generator.

• The DC circuit breaker has activated when the button pops out.

•

To

reset the DC circuit breaker, press the button.

(g)

The key switch (g) is used to start and stop the engine. See topic Starting the

Generator (Electric Start).

a piece of equipment connected to the

Using

DC

Power.

wc_tx001875gb.fm

31

W.\CKEit

NEUSON

Operation

Engine switch The engine switch (h) controls the function of the choke and the fuel valve. There (h) are three positions:

GPi

3200/4300

LCD (j)

LCD changeover switch (n) and indicator lights

Symbol Meaning

Choke valve is Turn the switch to this position when starting a cold

1'1

iilt

closed

Normal operating Turn the switch to this position after the engine starts. position

Fuel valve is Turn the switch to this position to stop the engine. closed

Description

engine.

Note: A warm engine can be started with the switch in

this position.

-

®

The LCD (j) displays machine operating status such as voltage, frequency, and operating hours. The LCD also displays overload condition.

The green LCD changeover switch (n) various machine status modes described above.

• Operating hours are displayed when the machine starts. The red operator hour indicator light (k)

•

Pressing the LCD changeover switch after starting changes the LCD display to

voltage. The red voltage indicator light

Pressing the LCD changeover swiitch a second time changes the LCD display

•

to frequency. The

•

Pressing the LCD changeover switch a third time changes the LCD display back

to operating hours. The red operator hour indicator light (k)

illuminates.

red

frequency indicator light (m) illuminates.

0

_Lod

allows the operator to cycle through the

(I) illuminates.

when the generator is

illuminates.

in

an

Auto-power

saving switch (o) and indicator

Engine oil level

indicator

(q)

AC breakers (r)

Ground-Fault Circuit Interrupter (GFCI)

light

warning

light

circuit

(s)

W4CKER

NEUSON

When pressed, the red auto-power saving switch (o) activates the auto-power saving function. The green auto-power saving indicator light (p)

When the engine oil level falls below the specified operating level, the indicator light (q) illuminates and the engine stops. The oil level is detected by an internal sensor.

An AC circuit breaker (r) shuts off the electrical current when the current exceeds

its

limit,

or

a malfunction occurs

generator.

• An AC circuit breaker has activated when the toggle switch moves to the OFF

position.

•

To

reset an AC circuit breaker, move the toggle switch to the

GFCI cuts power to the receptacles when a ground fault occurs to a piece

The equipment attached to the generator. See topic Customer Connections for operating information.

in

a piece

of

equipment connected to the

32

illuminates.

ON

position.

wc_tx001875gb.fm

oil

of

GPi

3200/4300

4.12 Customer Connections

Operation

Description

The generator is equipped with:

• (CSA fault circuit interrupt (GFCI), and one 120V 30A twist-lock receptacle (c).

• (CARB

• one pair of DC terminals (e) exclusively intended for charging 12V automotive-

GSA

models)-one

lock receptacle (c), both protected by a separate ground fault circuit interrupt (GFCI) (s).

style batteries. See Using DC Power for more information.

120V 20A duplex receptacle (b) with an integral ground

120V 20A duplex receptacle (b) and one 120V 30A twist-

®

@@

0

GSA

0

RESET

0

~

®

I?

&

¥~

Testing operation (CSA machines)

wc_tx001875gb.fm

GFCI

CARS

wc_gr008630

The GFCI cuts power to the receptacles when a ground fault occurs to a piece equipment attached to the generator.

Follow the procedure below to test the GFCI for proper operation every time the

generator is used.

1.

Disconnect all equipment from the generator.

2.

Start the generator.

3.

Push the black TEST button (b1)

cuts power to the receptacle and causes the red RESET button (b2} to pop out.

NOTICE: If the RESET button does not pop out, the GFCI is not working. Do not

operate the generator

4.

Push the RESET button to restore power to the receptacle.

until the problem can be corrected.

33

on

the receptacle. Pushing the TEST button

W.4.CKE~

NEUSON

of

in

Operation

GPi 3200 I 4300

If the RESET button pops out during operation, stop the generator and check the equipment attached to the generator for defects.

Testing GFCI operation (CARB

machines)

In the normal operating state, the sensing device green LED is illuminated and the circuit breaker is in the

Follow the procedure below to test the GFCI for proper operation every time the generator is used.

1.

Disconnect all equipment from the generator.

2.

Start the generator.

3.

Push the black TEST button (s1) on the receptacle. Pushing the TEST button

cuts power to the receptacles. The green LED goes out, the red LED

illuminates, and the circuit breaker moves to the OFF position.

NOTICE: If the red LED does not illuminate,

to

OFF, the GFCI is not working. Do not operate the generator until the problem

can be corrected.

4.

Push the RESET button (s2). The red LED goes out, and the green LED

illuminates.

5.

Manually move the circuit breaker to the

receptacles.

ON position.

or

the circuit breaker does not move

ON

position to restore power to the

in

W.\.CKER

NEUSON

34

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GPi

3200/4300

4.13 Grounding the Generator

Operation

Location The ground lug (d) is located to the right

Function

This ground connection is used for electrically grounding the generator when

necessary to

local regulations. For grounding requirements electrician, 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.

comply with the National Electrical Code and other federal, state, and

inspector, or local agency having jurisdiction over electrical

of

the DC terminals.

in

your area, consult with a qualified

wc_gr006664

Connection

Connect the ground compliance with NEC and local standards. The following options may be used:

• Connect the ground lug to a grounding spike (w) and drive the grounding spike

into the earth.

• Connect the ground lug to

lug to a good earthen ground for proper operating safety

an

existing grounded conductor.

in

wc_tx001875gb.fm

35

W.\CKEit

NEUSON

Operation

4.14 Fueling the Machine

Fuel

filler

cap

The fuel filler cap (C) is located on top counter-clockwise to open; clockwise to close.

®---~

WARNING

Fire/burn hazards. Gasoline is flammable and can ignite

Ill-

Keep all open flames, sparks, and cigarettes away from the machine while refueling.

111-

Do not refuel

Static electricity can ignite the fuel

Ill-

Do not refuel when the engine

if

the generator is sitting in a truck fitted with a plastic bed liner.

of

the fuel tank. Turn the fuel filler cap

or

fuel vapors.

is

running or hot.

GPi 3200

or

explode.

/4300

wc_gr006665

Filling

the

tank

Using

gasoline I ethanol blends

fuel

Follow the guidelines below when filling the fuel tank.

• Turn the engine switch

• Refuel only with clean, fresh unleaded gasoline.

• Add fuel through the fuel filter the fuel tank.

• Fill only until the fuel level reaches the "F" mark on the fuel level gauge (C2). Do not

overfill!

Close the fuel filler cap tightly and clean up spilled fuel before operating the

• machine.

(h)

to STOP before refueling.

(C1

),

making sure that dirt

or

water do not enter

CAUTION

Fire and health hazard. Fuel expands when heated. Expanding fuel in an over-filled

tank can lead to spills and leaks.

Ill-

Do not overfill the fuel tank.

This portable generator is not for use with gasoline ethanol.

I ethanol blends with over 15%

W-'CKER

NEUSON

36

wc_tx001875gb.fm

GPi

3200/4300

4.15 Before Starting

Operation

~

Explanation

Exterior

checks

DANGER

~

Carbon monoxide. Using a generator indoors CAN KILL YOU

Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or smell. even if you cannot

Before putting the generator into service, review each item on the following checklist. It is important to make sure that the machine is set up properly to reduce

the possibility of malfunction.

WARNING

Personal injury hazard. Failure to follow the listed procedures may cause injury to personnel or damage to the generator.

~

Make sure that all persons setting up the generator are certified or fully trained on the installation and operation

Before starting the generator:

• check for damage that may have occurred during towing or travel to the jobsite

• check for fuel leaks

• check for loose or missing fasteners

• make sure the exhaust pipe is not clogged with debris

• make sure that the generator is level

• make sure the generator is not resting on against any adjacent wiring

• make sure that the generator air vents are not blocked

• make sure that the generator is grounded to a good earthen ground per local regulations and NEC standards

If you can smell the generator exhaust, you are breathing CO. But

smell the exhaust, you could be breathing CO.

of

the generator.

IN

MINUTES.

Internal and pre-operation

checks

wc_tx001875gb.fm

• check engine oil and fuel

• determine voltage needs

• review and follow safety instructions found

levels-fill

as required

37

in

the front

of

this Operator's Manual

W-'CKEit

NEUSON

Operation

4.16 Starting the Generator (S Models)

CAUTION

Personal injury attached can damage the generator start-up can cause personal injury.

IIJI>

Disconnect all equpment from the generator before starting it.

or

machine damage hazards. Starting the generator with equipment

or

GPi 3200

the equipment. Unexpected equipment

/4300

Starting procedure

Follow the procedure below to start the machine.

1.

Turn the engine switch (h) to the CHOKE position (or the RUN position if the engine is warm or the ambient temperature is high).

wc_gr006666

2. Insert the starting key into the key switch (g).

3. Turn the starting key clockwise to the "I" (ON) position, then farther to the START position. The engine will start.

NOTICE:

for more than five seconds.

ON position, wait approximately 10 seconds, and then try again.

To

avoid machine damage, do not engage the starter motor continuously

If the engine fails to start, return the starting key to the

Troubleshooti ng

W4CKER

NEUSON

to

Do not turn the key switch

4.

If

you started the engine with the engine switch in the CHOKE position, allow the engine to run for position.

5.

Use the LED changeover switch (n) to switch to display voltage on the LCD. A reading

• If the engine does not start after several attempts, repeat the starting procedure with the engine switch turned to the RUN position.

• Try starting the machine manually. See Starting the Generator (Manual Start

Models).

•

If

the engine still does not start, refer to the Troubleshooting chapter.

of

120V indicates that the generator is operating properly.

20-30

the START position when the engine is running.

seconds and then turn the engine switch to the RUN

38

wc_tx001875gb.fm

GPi

3200/4300

Operation

4.17 Starting

CAUTION

Personal attached can damage the generator or the equipment. Unexpected equipment start-up can cause

~

Starting procedure

Follow the procedure below to start the machine.

1.

the

Generator {Manual

injury or machine damage hazards. Starting the generator with equipment

personal injury.

Disconnect all equpment from the generator before starting it.

Turn the engine switch (h) to the CHOKE position (or the RUN position if the engine is warm or the ambient temperature is high).

STOP

Start

Only)

~·

Troubleshooting

wc_gr006840

2.

Pull the recoil starter (f) slowly until you feel resistance.

3.

After you feel resistance, return the recoil starter to its original position and pull

quickly.

4.

If you started the engine with the engine switch

engine to run for

position.

5.

Use the LED changeover switch (n) to switch to display voltage on the LCD. A reading

If the engine does not start after several attempts, repeat the starting procedure with the engine switch turned to the RUN position. refer to the

The engine will start.

in

the CHOKE position, allow the

20-30

of

120V indicates that the generator is operating properly.

Troubleshooting chapter.

seconds and then turn the engine switch to the RUN

If the engine still does not start,

wc_tx001875gb.fm

39

W-'CKEit

NEUSON

Operation

4.18 Using AC Power

Prerequisites • Verify that the engine is operating.

• Verify that the voltage displayed on the LCD (j) is approximately 120V.

Turn off the equipment to be connected to the generator.

•

• Confirm that the equipment to be connected to the generator does not exceed the maximum rated power output and specifed amperage.

WARNING

Electric shock hazard. Failure to properly ground the generator could lead to

electrical sparks, especially

• Make sure the generator is properly grounded. See Grounding the Generator.

if

the connected electrical equipment is grounded.

GPi 3200 I 4300

Engine switch Leave the engine switch {h) position

in

the RUN position while the machine is operating.

0

'E::::n

~t(GJ0]

we

_gr008631

Connecting equipment

Overload fault Excessive current draw on the generator will cause an overload fault. When this

W4CKER

NEUSON

1.

Insert the equipment plug into the 20A receptacle (b) or the 30A twist-lock receptacle (c).

To

Note:

turn it clockwise to the

2.

Turn on the power switch for the equipment.

fault occurs, AC power is cut off and To

clear an overload fault, stop the engine immediately and remedy the overload

condition. Then re-start the engine.

use the 30A twist-Jock receptacle, insert the plug into the receptacle

LOCK

position.

O_Lod

displays on the LCD.

40 wc_tx001875gb.fm

and

GPi

3200/4300

Operation

Circuit breaker activation

Disconnecting equipment

Your machine's circuit breakers (r) shut off the electrical current when the current exceeds its equipment connected to the generator.

• Reset circuit breakers by returning the switches to the ON position.

• Stop the machine and identify the cause if a circuit breaker activates repeatedly.

1.

Turn off the power switch for the equipment.

2.

Remove the plug from the 20A receptacle

Note:

counter-clockwise

limit. Circuit breakers also activate

To

remove the plug from the 30A twist-lock receptacle, first turn the plug

to

unlock

it.

if

a malfunction occurs

or

the 30A twist-lock receptacle.

in

a piece

of

wc_tx001875gb.fm

41

W.\CKER

NEUSON

Operation

GPi

3200 I 4300

4.19 Using

Overview

Prerequisites

DC

Power

The DC terminals (e) are to be used only for charging 12V batteries. Maximum available power is

WARNING

Risk

of

machine damage and electric shock.

lit>

Do not use

• Verify that the engine is operating.

• Verify that the voltage displayed on the LCD (j) is approximately 120V.

Verify that nothing is connected to the

•

• Make sure that the charging cables to be used are rated for 12V and the maximum

WARNING Personal injury hazard. Battery acid is corrosive to metallic surfaces and harmful to human skin.

lit>

Wear protective clothing, goggles and gloves when working near batteries.

lit>

If

battery acid contacts the skin

seek immediate medical attention.

12V-8.3A

AC

power and DC power at the same time.

CCA rating

(100W).

of

the battery.

AC

outlets.

or

eyes, rinse immediately with clear water and

Engine

position

switch

WARNING Explosion hazard. Explosive hydrogen gas is discharged through battery vent holes during the charging process.

lit>

Do not use open flames

lit>

Do not place metallic objects on or near the battery terminals. Metallic objects in contact with both poles ignite explosive battery gases.

Leave the engine switch (h) in the RUN position while the generator is operating.

or

smoke near batteries.

of

the battery will generate extreme heat and potentially

wc_gr006668

WACKER

NEUSON

42

wc_tx001875gb.fm

GPi

3200/4300

Operation

Connecting and charging a battery

Disconnecting When the battery is fully charged: the battery

If the DC circuit breaker activates

Follow the procedure below to connect and charge a battery.

1.

Connect the positive terminal {e1) (red) battery

2.

Connect the negative terminal {e2) (black) battery

3.

Charge the battery for the recommended length battery manufacturer.

1.

Disconnect the cable from the negative (-) terminals

generator.

2.

Disconnect the cable from the positive ( +) terminals

generator.

The DC circuit breaker for either

• Defective

• Excessive current draw from a large capacity battery or a totally discharged battery-use generator.

terminal.

{f)

may activate while a battery is charging. This may occur

of

the following reasons:

battery-check

an AC battery charger to charge the battery instead

the battery before replacing the DC breaker

on

the generator to the positive(+)

on

the generator to the negative(-)

of

time prescribed by the

of

the battery and the

of

the battery and the

of

the

wc_tx001875gb.fm

43

W-4CKEil

NEUSON

Operation

4.20 Stopping the Generator

G Pi 3200 I 4300

Before stopping

Stopping procedure

Inform other personnel

the power shutdown

pumps, heaters,

To

stop the generator:

1.

Switch off and disconnect all equipment from the generator.

2.

Allow the generator to run at no load for approximately 3 minutes.

3.

Turn the engine switch (h) to the STOP position.

or

on

the jobsite that power is being turned off. Make sure that

will not create any hazards by turning off devices such as

lights that may need to be kept on,

0

®~ART

4. (Electric start models only): Turn the key switch (g) to the

"0"

~:.

i

/

1

~N/

we Qr006678

(STOP) position.

W-'CKER

NEUSON

44 wc_tx001875gb.fm

GPi

3200/4300

Operation

4.21

Procedure

Emergency Shutdown Procedure

If a breakdown or accident occurs while the machine is operating, follow the procedure

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.

below:

wc_tx001875gb.fm

45

W"CKEil

NEUSON

Maintenance

5 Maintenance

GPi 3200

/4300

5.1

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.

Clean generator enclosure.

Check for loose

teners.

Check engine oil level and refill as needed.

Check AC receptacles or

blockage; test GFI .

Check DC terminals for dam-

or

age

dirt.

or

missing fas-

for

dirt

Every

8

hours

(daily)

./ ./

./

Every

50

hours hours hours

(weekly) (biweekly)

Every

100

Every

200

(monthly)

Every

500

hours

Every

1000

hours

Check engine switch and multi monitor for proper operation.

Clean spark plug. Clean air cleaner. Change engine oil. Clean spark arrester. Replace air cleaner element. Clean fuel strainer.

Clean and adjust spark plug and electrodes.

Replace spark plug.

Remove carbon from cylinder

2

head.

Check and adjust valve clear-

2

ance. Clean and adjust carburetor. Clean and replace carbon

brushes.

1

2

./

•

W4CKER

NEUSON

46

wc_tx001240gb.fm

GPi 3200 I 4300

Maintenance

Replace fuel lines. Overhaul engine. Check generator rotor. Check generator stator. Replace engine mount.

3

2

1 Perform initial oil change after first 20 hours 2 Refer to the engine service manual 3 Replace yearly

Every

8

hours hours

{daily} {weekly} {biweekly}

Every

50

Every Every

100

hours hours

of

operation.

or

consult

an.

authorized Wacker Neuson service center

200

(monthly}

Every Every

500

hours

1000

hours

•

wc_tx001240gb.fm

47

W.\.CKEit

NEUSON

Maintenance

. , GPi

3200/4300

5.2 Detaching the Side Panels

Description

Removing the

side panel

left

Electric start machines are equipped with two sound attenuation panels. The panels remain in place during normal operation. The left side panel (p) must be detached and removed to perform routine maintenance.

Follow the procedure below to detach and remove the left side panel.

1.

Using a flat bladed screwdriver, loosen the two mounting screws (p1) at the top

of

the panel.

Note:

only until the screws spin freely.

It

is

not

necessary to completely remove the mounting screws. Loosen them

(S

Models)

we

Qr006841

2. The bottom edge of the panel rests in a metal channel (p2). Grasp the rubber seal

at

the top edge

body.

3.

Remove the panel by lifting it out arrow.

Detaching the The right side

right side the recoil starter. However, the right side panel can be detached if necessary by

panel following steps 1 and 2 above.

Re-attach the

panel (d) cannot easily be removed from the generator because

panels when maintenance work is complete.

of

the panel and pull the panel away from the generator

of

the channel in the direction of the white

of

W~CKE~

NEUSON

48

wc_tx001240gb.fm

GPi

3200/4300

Maintenance

5.3 Checking the Engine Oil

When Check engine oil daily before starting the engine, or more than 5 minutes after

stopping the engine.

Prerequisites • Engine is stopped

• Machine is on a level surface

• Fresh oil is available (see Technical Data for type and quantity)

WARNING

Burn hazard. The engine and exhaust pipe become extremely hot during operation.

~

Stop the engine and allow the machine to cool before checking the engine oil.

Procedure

Follow

1.

2.

3.

4.

5.

the procedure below to check the engine oil level.

The oil filler cap the engine exhaust pipe.

Unscrew and remove the oil filler cap from the oil fill port. Wipe the level gauge clean and insert it into the oil fill port. Remove the level gauge from the oil fill port and check the oil level. The oil level

should fall If the oil level is too low, add oil until the level reaches the upper mark (01

(0)

with level gauge is located at the rear

we

_gr006663

between the upper and lower marks

(01,

02).

of

the machine below

).

wc_tx001240gb.fm

6.

Reinstall the oil filler cap and tighten it securely.

Note: Change the oil

Engine

WARNING

Most used oil contains small amounts health problems periods of time.

~

Oil."

Take steps to avoid inhaling or ingesting used engine oil. Wash skin thoroughly after exposure to used engine oil.

if

it appears dark, dirty,

of

if

inhaled, ingested, or left

or

contaminated. See "Changing the

materials that can cause cancer and other

in

contact with skin for prolonged

49

W-'.CKEit

NEUSON

Maintenance

5.4 Cleaning the Air Cleaner

GPi

320014300

When

Prerequisite

Description

Procedure

Clean the air cleaner every 50 hours

Engine is stopped and cool to the touch

The air cleaner assembly consists cleaner body. A clean air cleaner prevents dirt from entering and damaging the engine.

of

operation.

of

two urethane forms housed inside the air

WARNING

Burn hazard. The engine and exhaust pipe become extremely hot during operation.

11>-

Stop the engine and allow the machine to cool before cleaning the air cleaner.

Follow

the procedure below to clean the air cleaner.

wc_gr006670

1.

The air cleaner assembly (L) is located on the right side the control panel. Unhook and remove the air

2.

Remove the urethane forms (L2) from the air cleaner body.

3.

Rinse the urethane forms with clean water. Squeeze out excess water {do not

twist) and dry the urethane forms thoroughly.

of

4. Wipe the inside

5.

Reinstall the urethane forms inside the air cleaner body.

6.

Reinstall the air cleaner body cover.

the air cleaner body with a clean, dry cloth.

cleaner body cover

of

the machine behind

(L1).

W"CKEit

NEUSON

50 wc_tx001240gb.fm

GPi

3200/4300

Maintenance

5.5 Cleaning

When Clean the spark plug and check the electrode gap every 200 hours

Prerequisite

Removing and Follow the procedure below to remove and clean the spark plug. cleaning the

spark

plug

and

Checking the Spark Plug

(monthly).

Engine is stopped and cool to the touch

WARNING

Burn hazard. Engine and exhaust pipe become extremely hot during operation.

~

Stop the engine and allow the machine to cool before cleaning and adjusting the

spark

1.

The spark plug cap (K) is located on the side cleaner.

plug.

of

the engine behind the air

of

operation

Checking the electrode gap

Re-installing

the spark plug

wc_gr006676

2.

Disconnect the spark plug cap from the spark plug (K2).

3.

Using the provided spark plug wrench

plug.

4.

If the electrode is covered with carbon deposits, use a wire brush or spark plug

cleaner

NOTICE: If the spark plug is cracked or damaged, replace it. See Technical Data.

5.

The electrode gap should measure between 0.6 to 0.7 mm (0.024 to 0.028 in.). Adjust the gap if necessary.

6.

Re-install the spark plug and tighten it securely.

NOTICE: A loose spark plug can become very hot and may cause engine dam-

age. Make sure that the spark

7.

Re-connect the spark plug cap.

to remove the carbon.

plug is properly seated and tightened.

(K1

),

unscrew and remove the spark

wc_tx001240gb.fm

51

W-'CKER

NEUSON

Maintenance

5.6 Changing the Engine Oil

GPi

3200 /4300

When Change the engine oil after the first 20 hours

thereafter.

Prerequisites

Changing the engine

oil

• Engine is stopped, but still warm

• Machine is on a level surface

• Fresh engine oil (see engine operator's manual)

• Plastic cloth and a container

Note:

mental protection regulations.

WARNING

Burn hazard. Engine and exhaust pipe become extremely hot during operation .

..,.

Follow

1.

2. Unscrew and remove the oil

Collect, store

Stop the engine and allow the machine to cool before changing the engine oil.

the procedure below to change the engine oil

Place a plastic cloth and a collection container beneath the machine.

and

dispose

of

sufficient volume to collect drained oil

of

drained oil in accordance with current environ-

filler cap

(0)

of

operation, and every 50 hours

from the oil fill port.

3.

4.

5.

WARNING Most used oil contains small amounts health problems

periods

..,. ..,.

W-'CKEil

NEUSON

The oil drain plug (E) is located at the base the oil drain plug. Drain the oil into a suitable container.

Re-install the oil drain plug.

Add new engine oil to the upper line the proper oil level is reached,

of

Oil.

time .

if

inhaled, ingested,

Engine

Take steps to avoid inhaling or ingesting used engine oil. Wash skin thoroughly after exposure to used engine oil.

of

re-install the oil filler cap. See Checking the

of

or

left

of

the engine. Unscrew and remove

the level gauge on the oil filler cap. When

materials that can cause cancer and other

in

contact with skin for prolonged

52 wc_tx001240gb.fm

wc_gr006669

GPi 3200 I 4300 Maintenance

5.

7 Cleaning the Spark Arrester

When Clean the spark arrester after every 100 hours

Prerequisite

Description

Procedure

Engine is stopped and cool to the touch

The spark arrester is a

If

the spark arrester is not cleaned regularly, it will become clogged with carbon

deposits and impair engine performance.

• Engine exhaust gases will not flow. Engine output will be reduced.

•

• More fuel will be consumed.

• Starting will become difficult.

CAUTION

Personal injury hazards. The spark arrester screen is made

Sharp wire ends can puncture or cut skin. Carbon dust can get into eyes .

..,.

Wear protective gloves and eye protection when cleaning the spark arrester.

Follow the procedure below to clean the spark arrester.

cylindrical metal element fastened inside the exhaust outlet.

s

of

operation.

of

stiff metal wire.

wc_tx001240gb.fm

wc_gr006679

1.

Remove the four flange bolts from the rear cover (s}, and remove the rear cover.

2.

Remove the nut (r2} and screw (r3} from the tail screen cover (r4}, and remove

tail screen cover.

the

3.

Remove the tail screen (r5} and spark arrester (r} from the exhaust outlet (q}.

4.

Use a stiff brush to remove carbon deposits from the spark arrester screen.

NOTICE: Avoid damaging the spark arrester screen during the cleaning process.

5.

Inspect the spark arrester screen for holes or cracks. If the screen is damaged, replace

6.

Re-insert the spark arrester screen into the exhaust outlet.

7.

Re-install the tail screen and tail screen cover, and fasten with the nut and screw.

8.

Replace the rear cover and re-install the flange bolts.

it.

53

W"CKER

NEUSON

Maintenance

5.8 Cleaning the Fuel Strainer

GPi

3200/4300

When

Prerequisite

Description

Procedure

Clean the fuel strainer monthly,

Engine is stopped and cool to the touch.

The fuel strainer

carburetor. Water and sediment

WARNING

Fire/burn hazards. Gasoline is flammable and can ignite

lftl>

Keep all open flames, sparks, and cigarettes away from the machine while cleaning the fuel strainer.

lftl>

Do not clean the fuel strainer while the engine is running

Follow the procedure below

(M) removes dirt and water from the fuel before it enters the

or

after every 200 hours

collect

to

clean the fuel strainer.

in

the fuel strainer cup (M1).

of

operation.

or

explode.

or

hot.

wc_gr006673

1.

Using a wrench, remove the fuel strainer cup, gasket (M2), and screen (M3) from the generator.

2.

Empty collected water and sediment from the fuel strainer cup.

3.

Using a clean dry cloth, wipe any remaining water and sediment from the

of

screen, the gasket, and the inside

4. Re-assemble and leaks.

re-install the fuel strainer. Tighten securely to prevent fuel

the fuel strainer cup.

W4CKEa

NEUSON

54

wc_tx001240gb.fm

GPi 3200 I 4300

Maintenance

5.9 Storing the Generator

When Follow the procedures described below if you intend to take your generator out of

service and store it for at

least six months.

Tasks The following tasks must be performed

1.

Drain fuel from the fuel tank.

2.

Drain fuel from the carburetor.

3.

Change the engine oil.

4.

Check for loose or missing fasteners; tighten or replace as needed.

5.

Clean the machine.

6.

Store the machine.

Prerequisites • Engine is stopped and cool to the touch

• Machine is on a level surface

• Fresh engine oil (see engine operator's manual)

• Clean,

• Plastic cloth

Note: Collect, store and dispose

dry shop cloths

and containers of sufficient volume to collect drained fuel and oil

in

order to prepare the generator for storage:

of

drained fuel and oil

environmental protection regulations.

WARNING

Fire/burn hazards. Gasoline is flammable and can ignite or explode.

~

Keep all open flames, sparks, and cigarettes away from the machine while draining the fuel tank and carburetor.

~

Do not drain fuel while the engine is running or hot.

in

accordance with current

Draining the fuel tank

wc_tx001240gb.fm

Follow the procedure below to drain the fuel tank.

wc_gr006814

1.

Place a plastic cloth and a collection container beneath the machine.

2.

Locate the fuel line (M4). Pinch the fuel line with locking pliers or a hose pincher and disconnect it from the

3.

Open the fuel line and drain fuel into the collection container.

fuel strainer (M).

55

W..\CKE~

NEUSON

Maintenance

4. Reconnect the fuel line to the fuel strainer.

5.

Draining the carburetor

1.

2. Locate the fuel drain screw (a). The screw is either recessed or exposed

3.

GPi

Dispose of drained fuel.

Place a plastic cloth and a collection container beneath the machine.

wc_gr006674

depending Unscrew and remove the fuel drain screw. Fuel will drain from the attached

plastic tube.

on

your machine model.

3200/4300

Change the engine

Check fasteners

Clean the machine

Store the

machine

oil

4. Collect and dispose

5.

Re-install the fuel drain screw.

See Changing the Engine Oil.

Check the machine for loose

1.

Using a clean, dry shop cloth, wipe the outside remove dust and contaminants.

2.

Spray the machine with a protectant such as Armor-All®.

NOTICE: Do not use water to clean the machine! Water is corrosive and can per-

manently damage the machine and operating

Store

the machine

of

drained fuel.

or

missing fasteners. Tighten or replace as needed.

of

electronics.

in

a well-ventilated, low humidity area.

the machine thoroughly to

W-'CKER

NEUSON

56

wc_tx001240gb.fm

GPi

3200/4300

6 Basic Troubleshooting

Basic Troubleshooting

Problem

Engine is difficult to start

Engine does not start

Engine power output is low

Engine stops

Cause

1.

Fuel is contaminated

2.

Spark plug gap setting is incorrect

1.

Engine switch position

2.

No fuel

3.

Equipment is connected

to the generator

in

wrong

4. Loose spark plug cap

5. Fouled spark plug

Low engine oil

6.

1.

Air cleaner is dirty

2.

Engine is overheated

1.

Engine malfunction

2.

Fuel tank

is

empty

Remedy

1.

Clean fuel filter and fuel tank. Remove water, dirt, and other impurities.

2.

Check and adjust spark plug gap clearance if necessary.

1.

Turn engine switch to position.

2.

Refill fuel tank. Switch off equipment and dis-

3.

connect from the generator.

Push spark plug cap firmly onto

4.

spark plug. Remove spark plug and

5.

electrode.

6.

Add engine

1.

Clean air cleaner.

2.

Consult engine owner's manual.

1.

Consult engine owner's manual.

2.

Refill

oil.

fuel tank.

CHOKE

clean

No electricity is generated at

receptacle load indicator light illumi-

1.

Overload fault (red over-

nates)

DC circuit breaker is

2.

OFF

3. GFI has activated

4. Loose connection at AC

receptacle or DC terminals

5. Engine was started after

equipment was connected

1.

Stop engine and check equipment and/or generator for overloading.

Press the

2.

ON

equipment for normal operation.

Press the RESET button

3.

AC receptacle after checking equipment for normal operation.

Tighten connection.

4.

Switch off equipment and dis-

5.

connect from the generator. Reconnect after re-starting engine.

DC circuit breaker to

position after checking

on

the

wc_tx001242gb.fm 57

W~CKEit

NEUSON

Technical Data

7 Technical Data

GPi 3200

/4300

7.1

Engine

Engine Power Rating

Engine power rating per conditions

Model

Engine make Engine model Number Displacement Operating speed Max. rated power

rated speed Engine oil type

of

cylinders

specific use.

cm3 (in

@

kW (hp)

180/TR

3

)

rpm

14396. Actual power output may vary

GPi 3200 GPSi 3200 GPi 4300 GPSi 4300

Engine

Robin

EX21

1

211

(12.87) 265 (16.17)

2800-3600 2800-3700

4.8 (6.4) @ 3600 rpm 6.3 (8.2) @ 3600 rpm

4-stroke

SAE

API SE, 1

OW-30

SG, or 1

OW-40

SH, or SJ

EX27

due

to

Engine Starting system

Spark plug Battery

Fuel type Fuel tank capacity Fuel consumption

oil capacity

@ continuous load

Running time

@ continuous load

L (qt)

type

L (gal)

L (gal)/

hr hr

0.6 (0.63) 1.0(1.06)

Manual Manual Manual Manual and

and

Electric

NGK BR

12V-6A-h

Yuasa

GS

Interstate YTX7L-BS Interstate YB12AL-A

GNB

Sears 44024

13 (3.4) 14 (3.7)

7.6 8.2

or

larger YTX7L-BS GTX7L-BS

1.7 (0.45)

7L-BS GNB 12AL-A

-6HS or equivalent 12V-12A-h

Yuasa YB12AL-A2

GS

Sears 44052

Unleaded gasoline

2.4 (0.64)

5.8

Electric

or

larger

GM12AZ-3A-2

CB12AL-A

16 (4.2)

6.7

W.tCKER

NEUSON

58

wc_td000355gb.fm

GPi

3200/4300

7.2 Generator

Technical Data

Machine

Generator type Generator speed Rated

AC voltage

Rated frequency

AC current

Rated Continuous Rated power factor Rated Rated DC current Safety device type Grounding system

AC connections

AC output

DC voltage

rpm

v

Hz

A

w

v

A

GPi 3200

Machine

2800-3600

Neutral ground (Neutral bonded to frame)

GPSi 3200

Multi-pole revolving field inverter

23.3

2800

Current breaker

(1) NEMA (1) NEMA 50-3R

GPi 4300 GPSi 4300

2800-3700

120

60

1.0 12

8.3

50-2R

31.7

3800

DC

connection

oC

kg

(oF)

mm (in.)

(in.)

(lb)

Maximum ambient

temperature rating

Length

Width mm

Height mm

Dry weight

Screw-on terminals ( + I - )

40

(1

04)

487 (19.2) 537 (21.1) 523 (20.6)

(17.0)

432

475 (18.7) 583 (23.0)

38 (83.8)

482 (19.0)

65 (143.3)

477 (18.8)

507 (19.9)

45 (99.2)

(22.8)

580

527

(20.8)

618 (24.3)

80 (176.4)

wc_td000355gb.fm

59

W.\.CKEil

NEUSON

Technical Data

Notes

GPi

3200/4300

W-'CKEil

NEUSON

wc_td000355gb.fm

60

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.

A

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING:

A

NOTICE

FEDERAL EMISSION COMPONENT DEFECT WARRANTY and CALIFORNIA EMISSION CONTROL generators (California Air Resources Board) emission regulations

complied with EPA (Environmental Protection Agency) and GARB

WARRANTY are applicable to only those engines/

in

the U.S.A.

NOTICE

To

the engines/generators exported

U.S.A., warranty service shall

accordance

with

the

standard

Robin

to

and

used

in

the countries other than

be

performed

engine/generator warranty policy as applicable.

by

the

distributor

in

each

the

country

AIR INDEX

in

To show compliance with California emission regulations, a hangtag has been provided

The Air time. A bar graph show exhaust from

The period of time (in hours) that the Air the periods can be used to measure the Air

Descriptive Term Moderate

Intermediate 125 hours (engine from 0 to 80 cc)

Extended

Notice

only be removed by the ultimate purchaser before operation.

displaying the Air Index level and durability period of this engine.

Index level defines how clean

scaled from "0" (most clean) to

an

engine's Air Index level. A lower Air Index level represents cleaner

an

engine.

durability period. Depending

Applicable to Emissions Durability Period

50 hours (engine from 0

125 hours

250 hours 300 hours (engine from 0 to 80 cc)

500 hours (engine greater than 80 cc)

: This hangtag must remain on this engine or piece of equipment, and

an

engine's exhaust is over a period of

"1

0" (least clean)

Index level

on

the size of the engine, a selection of time

Index level (see below).

(engine greater than

to

is

measured is known as

80 cc)

is

used to

wc_tx001789gb.fm

61

W.\CKEit

NEUSON

Emi.ssion Con.trol Systems Information and Warranty

FEDERAL

EMISSIONS COMPONENT

California. Fuji Heavy Industries Ltd. and Robin America Inc., 905 Telser Road, Lake Zurich, Illinois 60047, (herein "ROBIN AMERICA") warrant(s) to the Initial retail

purchaser and each subsequent owner, that this Non-road engine (herein sale to all applicable regulations which would cause this engine to

For the components diagnosis, repair,

EMISSION The warranty period for this engine begins

purchaser and continues for a period PARTS

COVERED

Listed below are the parts covered Warranty. maintenance and are warranted up to the first scheduled replacement

lor

that part.

point EXHAUST

(1) Fuel Metering System

(i) Carburetor and internal parts (and/or pressure regulator

injection system).

(ii) Air/fuel ratio feedback and control system,

(iii)

Cold start enrichment system,

(iv) Regulator

(2) Air Induction System

(i) Intake manifold,

(!I)

Air filter.

(3) Ignition

(4) Catalyst or

(5) Miscellaneous

EVAPORATIVE

*Fuji is not

REPLACEMENT Replacement

customers.

America Inc., 905 Telser Road, Lake Zurich, Illinois 60047. question America website.warranty@robinamerlca.com

OBTAINING To

Robin America service dealer . Bring your sales receipts indicating date purchase AMERICA reasonable amount All property

FUJI For

center, (excluding the states with high-altitude areas)

* Fuji

•

System (I) Spark (ii) Magneto

Spark advance/retard system.

(iii)

(i) Catalytic Converter,

Thermal Reactor, If applicable

(ii) (iii) Exhaust Manifold, if applicable

(i) Electronic controls, (II)

Hoses, belts, connectors, and assemblies.

(iii) Filter lock assy (gaseous fuel,

(1) Fuel Line (2) Fuel Line Fittings (3) Clamps

Tank

(4) Fuel (5) Fuel Cap (6) Vapor Hoses

Carbon Canister

(7) (8)

Carbon Canister Mounting Brackets

(9) Air Cleaner

liable for the warranty on these parts

prepared and equipped the equipment manufacturer's warranty.

regarding

Inc. at Hl00-277 -6246 (toll-free phone number)

obtain warranty service,

for

will

parts

and

of

ROBIN AMERICA.

HONOR

owners

the

will either pay for the shipping costs

from an authorized service center . Or

Fuji will provides for a service technician to come to the

make the warranty repair. Or

Fuji will pay for the repair

center.

listed under PARTS COVERED, the service dealer authorized by ROBIN AMERICA will,

or

replacement necessary

COMPONENT

Some

of

the

EMISSIONS

assy (gaseous fuel,

if

plugs.

or

electronic ignition system.

Thermal Reactor System

Items Used in Above Systems

EMISSIONS

Purge Port Connector

PARTS

parts

are

Replacement

your

WARRANTY

this

engine.

perform the

of

time and furnish you with a copy

accessories

WARRANTY

located

more

following

will

DEFECT

of

fail to conform with

DEFECT

parts

listed

applicable

if

applicable

if

applicable

by

the equipment manufacturer. Please refer to

DISTRIBUTION

provided

parts distribution

replacement

SERVICE

take

your engine to the nearest authorized

The

service

necessary

replaced

CLAIMING

than

100

be

provided

to

be made

EMISSIONS

COMPONENT

DEFECT

WARRANTY

WARRANTY COVERAGE - This emission warranty is applicable

the U.S. Environmental Protection Agency (EPA), and that the engine is free

WARRANTY

of

three years.

by

the Emission Components Defect

below

if

applicable.

if

applicable)

if

applicable.

if

applicable)

to

the

part, you should

(e-mail address)

repairs

under

miles

at

EPA

regulations during its warranty period.

to

ensure that the engine complies with applicable U.S. EPA regulations.

on

dealer

to

PERIOD

the dale

of

sale to the initial

may

require

if

applicable.

if

these parts are

CENTER

market

upon

center

this

from

those

of

a local nonauthorized service

request

Is

located

If

you have a

contact

authorized

or

adjustments

of

the repair order.

warranty

become

an

authorized service

applicable

replacement parts

"engine") has been designed, built, and equipped

WHAT

IS

NOT

COVERED

resulting

they

were made

damages such as loss

or

equipment, etc.

of

non-authorized parts.

WARRANTY

or

for

your

engine

owner,

abuse,

neglect,

1-800-277-6246 (toll-free phone number)

YOU

SHOULD

SYSTEM

of

regular maintenance in the event questions arise. These

and

maintenance

will not be denied, however, solely because

WARRANTY

THAT

ARE

TO

BEARING than

the

parts

replacements

their performance and durability.

TO

MAKE A CLAIM

autholized by ROBIN AMERICA. In the event that any

scheduled

or

fuel

by

the

at

Robin Robin

by

ROBIN

within a

the

owners.

to

and

owner

*Conditions

(unless

AMERICA during a warranty repair), alteration, accident, failure

the recommended fuel and

services. *The replacement parts used for required maintenance *Consequential

of

the engine

*Diagnosis and inspection charges that

service being performed. *Any non-authorized replacement part,

due to use

OWNER'S As

the. engine owner, you are responsible required maintenance listed in your owner's manual. recommends that you retain all receipts covering maintenance on engine, but ROBIN AMERICA cannot deny warranty solely for the lack receipts maintenance.

As

the AMERICA may deny warranty coverage due

to

modifications. You are responsible for presenting

dealer authorized by If

you have any questions regarding your warranty rights and responsibilities, you should contact the Robin America customer service department at webs!te.warranty@robinamerica.com (e-mail address) for the information.

THINGS CONTROL

You are responsible for the proper maintenance You should keep all receipts pertorrnance receipts subsequent owner deny warranty coverage Warranty claims required maintenance or failure to keep maintenance records.

MAINTENANCE, CONTROL DEVICES REPAIR ESTABLISHMENT HOWEVER, SERVICE DEALER AUTHORIZED PARTS DURABILITY EFFECTIVENESS OF HAVE A

of

If

other maintenance emission control, you should assure yourself that such parts are warranted by

their manufacturer to be equivalent

AMERICA In HOW

All repairs qualifying under this limited warranty must be performed by a

service dealer emission-related part is found to

shall notify Robin America customer service department

you 6246 (loll-free phone number) website.warranty@robinamerica.com

to

(e-mail address) and you

service dealer or service providers where the warranty repair can be

performed.

from

by

RESPONSIBILITIES

failure to ensure the performance

you

ROBIN AMERICA when a problem exists.

KNOW

WARRANTY

of

the engine. ROBIN AMERICA reserves the right

if

the engine has not been properly maintained.

REPLACEMENT

AND

SYSTEMS MAY BE PERFORMED BY

OR

REPAIRS

NOT

EQUIVALENT

AUTHORIZED

THE

ON

THE OUTCOME

authorized

will

In

all Slates. except the state

to

conform

at

of

defects in materials and workmanship

at

no cost to you, make the necessary

tampering,

the

oil, or not performing required maintenance

should

improper

records

EMISSION CONTROL SYSTEM AND MAY

or

be

misuse,

service

dealer

of

time, inconvenience, loss

do

not result in warranty-eligible

or

malfunction

however

if

your

maintenance

your

engine to the nearest service

ABOUT

THE

MAINTENANCE

and

maintenance

should

OR

REPAIR

INDIVIDUAL;

MUST

BY

ROBIN AMERICA. THE USE

IN

PARTS

OF

A WARRANTY CLAIM.

by

ROBIN

for

the

repair

to

the parts authorized

be

defective during the warranty period,

advised

of

the appropriate warranty

the

improper authorized

services.

of

authorized parts

for

the performance

ROBIN

of

be

aware

engine

or

EMISSION

AND

of

the engine.

records

be

transferred

OF

BE

PERFORMED

PERFORMANCE

MAY

AMERICA

of

components

of

time

of

in~ial

adjustment

by

ROBIN

to

of

AMERICA

all scheduled

that

ROBIN

a part has failed

unapproved

REPAIRS

covering

to

each

of

the lack

EMISSION

BY

are

used affecting

by

at

1-800-277-

AND THE

ROBIN

IMPAIR

use

the

your

the

ANY

OF

for

of

to

of

A

W-'CKEit

NEUSON

62

wc_tx001789gb.fm

Emission Control Systems Information and Warranty

CALIFORNIA

YOUR

The California Air Resources Board and Fuji Heavy Industries Ltd. (herein "FUJI") are pleased to explain the emissions control system warranty on your small off-road engine designed, built and equipped to meet the State's stringent anti-smog standards. control system on your improper maintenance

Your emissions control system may include parts such as the carburetor, fuel-injection system, the ignition system, catalytic converter, fuel tanks, fuel lines, fuel caps, valves, canisters, filters, vapor hoses, clamps, connectors, and other associated emission-related components.

Where a warrantable condition exist, parts and labor.

EMISSIONS

WARRANTY

SOREs for the periods

of

your SOREs.

FUJI will repair your small off-road engine at no cost to you including diagnosis,

CONTROL

RIGHTS

of

time listed below provided there has been no abuse, neglect

WARRANTY

AND

(SORE).

OBLIGATIONS

In

California, new SOREs must be

FUJI must warrant the emissions

STATEMENT

or

MANUFACTURER'S WARRANTY COVERAGE:

This emissions control system is warranted for two years. If any emissions-related part on your engine

the part will be repaired or replaced by

FUJI.

is

defective,

OWNER'S WARRANTY RESPONSIBILITIES:

-As the SORE owner, you are responsible for performance of the required maintenance listed owner's manual.

FUJI cannot deny warranty solely for the lack

SORE owner, you should however be aware that FUJI may deny you warranty coverage if your

-As the

SORE or a part has failed due to abuse, neglect, or improper maintenance

-You are responsible for presenting your AMERICA Inc. 905 exists. The warranty repairs should be completed

If you have a question regarding your warranty coverage, you should contact the Robin America Inc. Customer Service Department at 1-800-277-6246. (E-mail

FUJI recommends that you retain all receipts covering maintenance on your

of

receipts.

or

unapproved modifications.

SORE to distribution center

Telser Road, Lake Zurich, Illinois 60047 (herein ROBIN AMERICA) as soon as the problem

in

a reasonable amount

address:

Website.Warranty@robinamerica.com)

or

service center authorized by ROBIN

of

time, not to exceed 30 days.

in

your

SORE,

but

GENERAL EMISSIONS WARRANTY COVERAGE

-

California

FUJI warrants to the ultimate purchaser and each subsequent purchaser that the SORE (1) has been designed, built

as

and equipped so workmanship that cause the failure terms and conditions stated below.

(a) The warranty period begins on the date the engine

service. The warranty period

(b) Subject to certain conditions and exclusions as stated below, the warranty

follows:

(1) Any warranted part that is not scheduled for replacement as required maintenance

warranted for the warranty period stated above. If the part fails during the period part will be repaired or replaced by replaced under warranty will be warranted for the remainder

(2) Any warranted part that

warranty period stated above. Any such part repaired or replaced under warranty will be warranted for the remaining warranty period.

wc_tx001789gb.fm

to conform with all applicable regulations; and (2)

of

a warranted part to conform with those regulations as may be applicable to the

is

two years.

FUJI according to subsection (4) below. Any such part repaired

is

scheduled only for regular inspection

Only

is

free from defects

is

delivered to an ultimate purchaser

on

emissions related parts is as

of

the period.

in

your owner's manual is warranted for the

in

materials and

or

first placed into

in

your owner's manual

of

warranty coverage, the

or

63

is

W.\CKER

NEUSON

Emission Control Systems Information

(3)

Any warranted part that is scheduled for replacement as required maintenance warranted for the period of time before the first scheduled replacement date for that part.

will

be

before the first scheduled replacement, the part

(4) below. Any such part repaired or replaced under warranty period prior to the first scheduled replacement point for the part.

(4)

Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner.

(5)

Notwithstanding the provisions herein, warranty services or repair will be provided

centers that are franchised to service the subject engines.

(6)

The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is

in fact defective, provided that such diagnostic work is performed at a warranty station.

(7}

FUJI is liable for damages to other engine components proximately caused by a failure under warranty

any warranted part.

(8)

Throughout the engine warranty period stated above, FUJI will maintain a supply

to

sufficient

(9}

Any

provided without charge to the owner. Such use

(1

O)

Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use any non-exempted add-on or modified parts by the ultimate purchaser will warranty claims. exempted add-on or modified part.

meet the expected demand for such parts.

replacement part may be used

FUJI will not be liable to warrant failures of warranted parts caused by the use

in

the performance of any warranty maintenance or repairs and must be

repaired

will not reduce the warranty obligations of FUJI.

or

will be warranted for the remainder of the

and

replaced by FUJI according to subsection

Warranty

in

your owner•s manual is

If the part fails

at

all of our distribution

of

warranted parts

be

grounds for disallowing a

of

a non-

(c)

WARRANTED PARTS:

of

The repair or replacement such warranty coverage if maintained, and that such abuse , neglect ,or improper maintenance was the direct cause

of

replacement properly operating, adjustment limiting device is warranty parts

EXHAUST (1}

Fuel Metering System (A) Carburetor and internal parts.

(2)

Air Induction System (A)

(3)

Ignition System (A) Spark plugs. (B) Magneto

*EVAPORATIVE EMISSIONS

(1)

Fuel Tank

(2)

Fuel Cap

(3)

Fuel Line

(4)

Fuel Line Fittings

(5)

Clamps

NOTE: This list based upon the items found in Title 13 Section 2405(d) for exhaust emissions and Section 2760(d)

the part. That notwithstanding, any adjustment of a component that has a factory installed, and

list are covered.

EMISSIONS

Air filter.

or

electronic ignition system.

for evaporative emissions.

any warranted part otherwise eligible for warranty coverage may be excluded from

FUJI demonstrates that the engine has been abused, neglected,

still eligible for warranty coverage. The following emissions

(6)

Vapor Hoses

(7)

Carbon Canister

(8)

Canister Mounting Brackets

(9)

Air Cleaner Purge Port Connector

or

improperly

of

the need for repair or

*Fuji is not

manufacture. Please refer to the equipment manufactures warranty.

W~CKEi::t.

liable for the warranty

NEUSON

on

these parts

if

these parts are installed

64

on

the engine by the equipment

wc_tx001789gb.fm

Emission Control Systems Information and Warranty

MAINTENANCE

MAINTENANCE, REPLACEMENT AND ESTABLISHMENT

SYSTEMS

MAY

BE

OR

INDIVIDUAL.

OR

REPAIR OF THE EMISSION CONTROL DEVICES

PERFORMED

BY

ANY

DAILY INSPECTION

Before running the generator, check the following service items:

Safe surroundings )

'--·

___

C

( Leakage

( Enough clean engine

(

AC

and

NONROAD

.:::,__

__

of

gasoline and engine oil )

oil )

DC

terminals

for

damage )

ENGINE

__

REPAIR

PERIODIC MAINTENANCE

Periodic maintenance is vital to safe and efficient operation of your generator.

Check the table below for periodic maintenance intervals.

IT IS ALSO NECESSARY FOR THE USER OF THIS GENERATOR TO

CONDUCT THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION· RELATED PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL SYSTEM

The emission control system consists of the following parts : (1) Carburetor and internal parts (5) (2)

(3) Intake manifold, if applicable (4) Air cleaner elements

The maintenance schedule indicated in the table is based on the normal generator operation. generator must be shortened depending on the contamination of

EFFECTIVE.

Cold start enrichment system, if

applicable

be

operated in extremely dusty condition or in heavier loading condition, the maintenance intervals

Spark plug

(6) Magneto or electronic ignition

system

Spark advance/retard

(7)

system, if

applicable

oil, clogging of filter elements, wear of parts, and so on.

(8) Exhaust manifold, if

applicable

(9) Hoses, belts, connectors, and

assemblies

Should the

wc_tx001789gb.fm

65

W-'CKEit

NEUSON

Schematics

9 Schematics

GPi 3200

I 4300

9.1

Electrical

B

Schematic-(S

--il:bi-

--ICDi-Gry

--ICDi-

--ii:Di-

Models, non-CSA)

Org

y

--=e-----l

y

--=J-------'

Bill W Ill<

Gm

N

Blu

y

0

W R

Bm

R

c

GmiY

v

W.\.CKEil

NEUSON

R

wW

Blk

_lL_.

66

wc_gr008627

wc_tx001876gb.fm

GPi 3200 I 4300

Schematics

9.6 Electrical Schematic Components-(Manual Start Models, non-

CSA)

Ref. Component

Engine

A

Generator

B

Control panel

c

D

Diode rectifier

E DC coil

F Coil (1)

Coil (2)

G

Main coil

H

DC circuit breaker

J

K DC output terminal

L Circuit breaker

Blk

Blk/W

Blu Blue

LBiu Pink

y

Black Black/White

Yellow

Wire Colors

Brn Brown

Brn/W

Grn Green

Grn/W

W/Bik

Brown/White

Green/White White/Black

R~onent

N Inverter and engine control unit

0 Monitor control unit

p

Engine switch

Q

AC

receptacle, 120V 20A

Ground terminal

R

Stepping motor

s

Oil level switch

T

u Ignition coil

X Spark plug

y

GFCI sensing module

z AC receptacle, 120V 30A

Org

Gry

R

w

Grn/Y

Orange

Gray

Red White Green/Yellow

Pur

Purple

-

wc_tx001876gb.fm

71

W4CKER

NEUSON

Schematics

GPi 3200/4300.

9.7 Electrical Schematic-(Manual Start Models, CSA)

Blu

W

L--------Blu

R

W

--O::::li-

-ICDI-

----ll=l--

W

N

Blu

w

0

R

~

S~

r-----------'c:!o---Drg

I

Pur-k:D\----______j

ry

-~---------'

----'

,,__,.,_,---Bik

------'

Blu1

Pt.

L-------W----

L--------~GmN~-----~

___;__

~-----_L

I

__

_j

wc_gr007415

W.lCKEit

NEUSON

72

wc_tx001876gb.fm

GPi 3200 I 4300

Schematics

9.2 Electrical Schematic

Ref.

Component

A

Engine Generator

B

Control panel

c

D

Diode rectifier

E

DC winding

Coil (1)

F

Coil (2)

G H

Main coil

DC circuit breaker

J

DC output terminal

K

Regulator

L

Key switch

M

Inverter and engine control unit

N

Blk

Black Brn

Components-(S

Ref.

0 Monitor control unit

p

Q

R

s Stepping motor

T

u

v Starting motor

w Battery

X Spark plug

y

z

AA

Wire Colors

Brown Org

Models, non-CSA)

Component

Engine switch

AC

receptacle, 120V

Ground terminal

Oil level sensor Ignition coil

GFCI sensing module

AC

receptacle, 120V

Circuit breaker

20A

30A

Orange

Blk/W

Blu

LBiu

y

Pur

Black/White Brn/W Blue Grn Pink Grn/W

Yellow W/Bik

Purple

-

Brown/White Green Green/White White/Black Grn/Y

-

Gry

R

w

-

Gray Red White Green/Yellow

-

wc_tx001876gb.fm

67

W4CKEit

NEUSON

Schematics

GPi 3200 I 4300

9.3 Electrical

Schematic-(CSA)

0 W4.CKEit

\8'

NEUSON

68

wc_tx001876gb.fm

GPi 3200

/4300

9.4 Electrical Schematic Components-(CSA)

Schematics

Ref.

A

B

c

D

E

F

G

H

J

K

L

M

N

0

Blk

Component

Engine Generator Control panel Diode rectifier DC Winding T Oil level sensor Coil (1) Coil

(2)

coil w

Main DC circuit breaker

output terminal

DC Regulator Key switch Inverter and engine control unit Monitor control unit

Wire Colors

Black Brn

Ref.

Component

p

Engine switch

Q

AC Ground terminal

R

receptacle, 120V 20A

s stepping motor u Ignition coil

v starting motor

Battery Fuse, 10A

X

y

Relay

z

AC

receptacle, 120V 30A

AA

Brown

Circuit breaker Spark plug

BB

-

Org

Orange

Blk/W

Blu

LBiu

y

Pur

Black/White Blue Pink Yellow Purple

Brn/W

Grn Green

Grn/W

W/Bik

-

Brown/White

Green/White White/Black

-

Gry

R

w

Grn/Y

-

Gray Red White Green/Yellow

-

wc_tx001876gb.fm

69

W"CKEit

NEUSON

Schematics

G Pi 3200 I 4300

9.5 Electrical Schematic-(Manual Start Models, non-CSA)

l_s

__________________________________________________

r

______________________

:J

_____________________________________________________________

c

__

[ !

!

E~

i

~

F

'----------Bm

G

~,---=========~G;_

~~

LL~

'-------Bm

-A-~

"'

---j=f--

~~

-b!

i i

-_

--1--i

GG_,:::::JI:::::J_

_r- i

L__

____

~-----48~W

: 1 1

L __ -----

·--------------------------------------------------------1

--

---

--

---

_l_

-lcd--R

i

--

-f~Bik

-r-

~o-----@+

I

••

:========~==========~f-------1

!

i

!

i

Blu

j

i

Blu

W

w

o-

Gm

Blu

Y-

K

-

.--------

Blu

I I

W

0

Bm

GrnN

p

GrnN

R

,------<:P+-----------1

s

f-------[9--Bik

A

L------------------------------------------------------1_

L

w

i

__

_____jBm

,r;¢

GrnN

__j_

__________________________________________________________________________________________

~

w

wc_gr008628

_

W.\.CKEa

NEUSON

70

wc_tx001876gb.fm

GPi 3200

/4300

Schematics

9.8

Electrical Schematic

Ref.

Blk/W Black/White

Component

Engine

A B Generator

Control panel

c

D Diode rectifier

Coil (1)

E

F Coil (2)

Coil (3)

G

H Main coil

DC circuit breaker

J

K DC output terminal

M Micro switch

Blk

Black

Components-(Manual

Wire Colors

Brn

Brn/W

Ref.

Brown Brown/White

Component

N

Inverter and engine control unit Monitor control unit

0

p

Engine switch

Q

AC

receptacle, 120V 20A

R Ground terminal

Stepping motor

s

Oil level switch

T

Ignition coil

u

X

Spark plug

AC

z

-

receptacle, 120V 30A

-

Start Models, CSA)

Org Gry

Orange Gray

Blu Blue

LBiu

y

Pur

Pink

Yellow

Purple

Grn

Grn/W

W/Bik

Green Green/White White/Black

R

w

Grn/Y

Red White GreenNellow

wc_tx001876gb.fm

73

W.\CKEit

NEUSON

Important: For spare parts information, please see your Wacker Neuson Dealer, Wacker Neuson website at http://www.wackerneuson.com/.

Wichtig!

besuchen Important :

distributeur Wacker Neuson, ou de visiter http://www.wackerneuson.com/.

lmportante : Para saber mas sabre las piezas de repuesto, p6ngase en contacto con su distribuidor de Wacker Neuson o acceda

http://www. wackerneuson. com/. lmportante :

visitare Viktigt :

Wacker Neusons webbplats pa http://www.wackerneuson.com/.

Tiirkei:ii:i

web-sivustolla osoitteessa http://www.wackerneuson.com/ Viktig :

bes0k Vigtigt : Hvis du

forhandler eller Belangrijk! Neem contact op

Neuson lmportante : Para obter informac;:oes sabre

fornecedor da Wacker Neuson ou aceda ao site

http://www.wackerneuson.com

Wazne : W celu uzyskania informacji na temat przedstawicielem firmy Wacker Neuson http://wackerneuson.com/.

Dulezite upozorneni! Pro informace o nahradnich dilech, prosim, kontaktujte sveho Neuson dealera, nebo navstivte

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stranice tvrtke Wacker Neuson: http://www.wackerneuson.com/. Onemli : Yedek

sitesini ziyaret edin. http://www.wackerneuson.com/

:m!J!

jJ-

m:J!

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Important : Pentru informatii referitoare Ia piesele distribuitorului Wacker Neuson sau http://www.wackerneuson.com/.

BalKHO : 3a

Ha http://www. wackerneuson .com/.

lnformationen Ober Ersatzteile erhalten Sie von lhrem Wacker Neuson Handler

Sie

die Wacker Neuson Website unter http://www.wackerneuson.com/.

Pour

des informations

Per

il

site di

For

: Pyyda varaosatietoja

For

Wacker Neusons nettside pa http://www.wackerneuson.com/.

op

.Q11s:1

Za

:>.::~ll'~J',O)·tw¥Gf;:"'=lv'""Cf'i,

/

-1

'./

~~*141~.lfi!!,,

Wacker Neuson

informazioni sui pezzi di ricambio, contattare

Wacker

information om reservdelar, kontakta din

informasjon om reservedeler, vennligst kontakt din Wacker Neuson-forhandler,

bes121g

http://www.wackerneuson.com/

03HaKoMneH!-lfl c l-1H¢opMal..l!-leH

mprosoMy

:

fia

TIAI")poq>opiE<;

rezervne dijelove obratite

parc;:a

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Wacker Neuson Produktion GmbH & Co.

Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI.

Wacker Neuson Limited- Room 1701-03 & 1717-20,

Road West, Mongkok, Kowloon, Hongkong.

Tel.:

+49-(0)89-3

Tel.: (262) 255-0500 Fax: (262) 255-0550

54

KG,

02-0 Fax:

17/F.

Tel:

PreuBenstraBe 41, D-80809 MOnchen,

+49-

(0)89-3 54 02-390

Tel.: Tower (852) 3605 5360, Fax: (852) 2758 0032

(800) 770-0957

1,

Grand Century Place, 193 Prince Edward

53051

W~CKEil

NEUSON

all ;r

----

fai<es!

&WARNING

Cancer and Reproductive Harm

www.P65Warnings.ca.gov

&

ADVERTENCIA

Cancer y dafio reproductive

www.P65Warnings.ca.gov

&

AVERTISSEMENT

Cancer ou malformations

congenitales

www.P65Warnings.ca.gov

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Wacker Neuson GPi 3200, GPSi 3200, GPi 4300, 0620781, 0620960 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual