Wacker Neuson GPi 3200, GPSi 3200, GPi 4300, GPSi 4300 Operator's Manual
Operator’s Manual
Inverter Generator
GPi 3200 / GPSi 3200
GPi 4300 / GPSi 4300
0179740en 004 0311
0179740EN
Copyright
notice
© Copyright 2010 by Wacker Neuson Corporation.
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by W acker Neuson Corp oration
represents an infringement of valid copyrights. Violators will be prosecuted.
T ra d emarks
Manufacturer
All trademarks referenced in this manual are the property of their respective owners.
Wacker Neuson Corporation
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original
instructions
This Operator’s Manual presents the original instructions. The original language of this
Operator’s Manual is American English.
Foreword
Machines
covered in
this manual
Foreword
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models listed below. These instructions must be followed during
installation and maintenance of the generator (and battery, if equipped).
Machine Item Number
GPi 3200
GPSi 3200
GPi 4300
GPSi 4300
0620781, 0620779
0620780, 0620936
0620782, 0620784
0620783, 0620937
Machine
documentation
Expectations
for
information in
this manual
CALIFORNIA
Proposition
65 Warning
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 of these documents, please contact Wacker Neuson
Corporation to order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
This manual provides information and procedures to safely operate and main-
tain the above W acker Neuson model(s). For your own safety and to reduce the
risk of injury, carefully read, understand, and observe all instructions described
in this manual.
Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson Corporation reserves the right
to change any portion of this information without notice.
Engine exhaust, some of its constituents, and certain vehicle components, contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Laws
pertaining to
spark
arresters
NOTICE: State Health Safety Codes and Public Resources Codes specify that in
certain locations spark arresters be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this purpose. In order to comply
with local laws regarding spark arresters, consult the engine distributor or the local
Health and Safety Administrator.
wc_tx001238gb.fm 3
Foreword
Manufacturer’s
approval
This manual contains references to approved parts, attachments, and modifications. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker Neu-
son service center according to written instructions published by Wacker Neuson.
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following consequences:
Serious injury hazards to the operator and persons in the work area
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 unapproved parts, attachments, or modifications.
4 wc_tx001238gb.fm
GPi 3200 / 4300 Table of Contents
Foreword 3
1 Safety Information 7
1.1 Signal Words Found in this Manual ...................................................... 7
1.2 Machine Description and Intended Use ............................................... 8
1.3 Safety Guidelines for Operating the Machine ....................................... 9
1.4 Operator Safety While Using Internal Combustion Engines ............... 11
1.5 Guidelines for Service Safety ............................................................. 12
1.6 Label Locations .................................................................................. 13
1.7 Machine Labels .................................................................................. 14
1.8 Safety and Warning Labels ................................................................ 14
2 Operation 17
2.1 Overview ............................................................................................ 17
2.2 Preparing the Machine for First Use ................................................... 17
2.3 Features and Components ................................................................. 18
2.4 Lifting and Transporting ...................................................................... 20
2.5 Wheel Brakes (if equipped) ................................................................ 20
2.6 Installation .......................................................................................... 21
2.7 Connecting and Maintaining the Battery ............................................ 22
2.8 Use of Extension Cords ...................................................................... 23
2.9 Power Requirements .......................................................................... 24
2.10 Control Panel ...................................................................................... 25
2.11 Customer Connections ....................................................................... 28
2.12 Grounding the Generator ................................................................... 29
2.13 Fueling the Machine ........................................................................... 30
2.14 Before Starting ................................................................................... 31
2.15 Starting the Generator (S Models) ..................................................... 32
2.16 Starting the Generator (Manual Start Models) ................................... 33
2.17 Using AC Power ................................................................................. 34
2.18 Using DC Power ................................................................................. 35
2.19 Stopping the Generator ...................................................................... 36
2.20 Emergency Shutdown Procedure ....................................................... 37
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Table of Contents GPi 3200 / 4300
3 Maintenance 38
3.1 Periodic Maintenance Schedule ..........................................................38
3.2 Detaching the Side Panels (S Models) ................................................39
3.3 Checking the Engine Oil ......................................................................40
3.4 Cleaning the Air Cleaner .....................................................................41
3.5 Cleaning and Checking the Spark Plug ...............................................42
3.6 Changing the Engine Oil .....................................................................43
3.7 Cleaning the Spark Arrester ................................................................44
3.8 Cleaning the Fuel Strainer ...................................................................45
3.9 Storing the Generator ..........................................................................46
4 Schematics 48
4.1 Electrical Schematic (S Models, non-CSA) .........................................48
4.2 Electrical Schematic Components (S Models, non-CSA) ....................49
4.3 Electrical Schematic (CSA) .................................................................50
4.4 Electrical Schematic Components (CSA) ............................................51
4.5 Electrical Schematic (Manual Start Models, non-CSA) .......................52
4.6 Electrical Schematic Components (Manual Start Models, non-CSA) ..53
4.7 Electrical Schematic (Manual Start Models, CSA) ..............................54
4.8 Electrical Schematic Components (Manual Start Models, CSA) .........55
5 Basic Troubleshooting 56
6 Technical Data 57
6.1 Engine .................................................................................................57
6.2 Generator Data ....................................................................................58
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GPi 3200 / 4300 Safety Information
1 Safety Information
1.1 Signal Words Found in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE
signal words which must be followed to reduce the possibility of personal injury,
damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
f Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
To avoid death or serious injury from this type of hazard, obey all safety messages that
f
follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
f
To avoid possible death or serious injury from this type of hazard, obey all safety messages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
To avoid possible minor or moderate injury from this type of hazard, obey all safety mes-
f
sages that follow this signal word.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
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Safety Information GPi 3200 / 4300
1.2 Machine Description and Intended Use
This machine is a portable electric power source. The Wacker Neuson Inverter
Generator consists of a gasoline engine, a fuel tank, and an electric alternator and
inverter. Contr ols and recept acles are provided on a control pa nel mounted on the
side of the machine. As the engine runs, the generator convert s mechanical energy
into AC power and DC power. The operator connects loads to the AC power
receptacles or DC terminals.
This machine is intended for the purpose of supplying electrical power to
connected loads. Refer to the product specifications for the output voltage and
frequency of this generator, and for the maximum output power limit of this
generator.
This machine has been designed and built strictly for the intended use described
above. Using the machine for any other purpose could permanently damage the
machine or seriously injure the operator or other persons in the area. Machine
damage caused by misuse is not covered under warranty.
The following practices are some examples of misuse:
Connecting a load that has voltage and freque ncy requirements that are
incompatible with the generator output
Overloading the generator with a load that draws excess ive power during either
continuous running or start-up
Operating the generator in a manner that is inconsiste nt with all federal, state 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 of factory spec ifications
Operating the machine in a manner inconsistent with all warnings found on the
machine and in the Operator’s Manual
This machine has been designed and built in accordance with the latest global
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 rema in even after protective measures have been t aken.
They are called residual risks. On this machine, they may include exposure to:
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 injury from improper liftin g techniques
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.
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GPi 3200 / 4300 Safety Information
1.3 Safety Guidelines for Operating the Machine
DANGER
Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot
see or smell. If you can smell the generator exhaust, you are breathing CO. But
even if you cannot smell the exhaust, you could be breathing CO.
f NEVER use a generator inside homes, garages, crawlspaces, or other partly
enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Using a fan or opening windows and doors does NOT supply enough fresh air.
f ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
f Even when you use a generator correctly , CO may leak into the home. ALW AYS
use a battery-powered or battery-backup CO alarm in the home.
f If you start to feel sick, dizzy, or weak after the generator has been running,
move to fresh air RIGHT AW AY. See a doctor. You could have carbon monoxide
poison.
WARNING
Machines operated improperly or by untrained personnel can be hazardous.
f Read the operating instructions contained in both this Operator’s Manual and
the engine operator’s manual.
f Familiarize yourself with the location and proper use of all controls.
f Inexperienced operators should receive instruction from someone familiar with
the machine before being allowed to operate it.
Operator
qualifications
Personal
Protective
Equipment
(PPE)
Before
starting the
machine
Only trained personnel are permitted to start, operate, and shut down the machine.
They also must meet the following qualifications:
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 following Personal Protective Equipment (PPE) while operating this
machine:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
Before starting this machine:
Follow starting and stopping instructions described in this manual. Know how to
operate and stop the generator before sta rting it.
Do not start a machine in need of rep air.
wc_si000348gb.fm 9
Safety Information GPi 3200 / 4300
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.
Electrical
safety
To increase electrical safety while operating this machine:
Do not operate the generator, or tools attached to the generator, with wet hands.
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 we ll-grounded and securely fastened to a go od earthen
ground per national and local regulations.
Do not overload the generator. The total amperage of the tools and equipment
attached to the generator must not exceed the load rating of the generator .
.
WARNING
Backfeed from the generator into the public power distribution system can seriously
injure or kill utility workers!
f Improper connection of generator to a building’s electrical system can allow
electrical current from the generator to backfeed into utility lines. This may re sult
in electrocution of utility workers, fire, or explosion.
f Connections to a building’s electrical system must be made by a qualified elec-
trician and comply with all applicable laws and electrical codes.
f If connected to a building’s electrical system, the generator must meet the
power, voltage, and frequency requirements of the equipment in the building.
Generator
vibration
Operating
safety
Generators vibrate in normal use. During and after the use of the gene rator , inspect
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 n ecessary.
Do not use plugs or or cords that show signs of damage such as broken or cra cked
insulation or damaged blades.
To increase operating safety while running this machine:
Do not operate the generator when open containers of fuel, paint, or other
flammable liquids are in the vicinity of the generator.
Do not place flammable material or liquids near the generator.
Do not operate the machine indoors.
Do not touch the hot engine, exhaust, or generator component s. Burns will result.
Always do the following:
Wear hearing protection when operating equipment.
Keep the machine at least one meter (three feet) away from structures, buildings,
and other equipment during use.
Keep the area immediately surrounding and underneath the machine clean, neat,
and free of debris and combustible materials. Make sure that the area overhead is
clear of debris that could fall onto or into the machine or exhaust compartment.
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GPi 3200 / 4300 Safety Information
Storing the
machine
Store the machine properly when it is not being used. The machine should be
stored in a clean, dry location out 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.
Failure to follow the warnings and safety standards could result in severe injury or
death.
f Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot
see or smell. If you can smell the generator exhaust, you are breathing CO. But
even if you cannot smell the exhaust, you could be breathing CO.
Refueling
safety
Operating
safety
When refueling the engine:
Do not smoke.
Do not refuel if the generator is sitting in a truck fitted with a plastic bed liner. 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 the fuel tank in a well-ventilated area.
Replace the fuel tank cap after refueling.
When operating the generator:
Check the fuel lines and the fuel tank for leaks an d cracks before starting the en gine.
Do not run the machine if fuel leaks are present or the fuel lines are loose.
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 spill and wipe the gene rator dry before starting.
Do not smoke while operating the machine.
wc_si000348gb.fm 11
Safety Information GPi 3200 / 4300
1.5 Guidelines for Service Safety
WARNING
A poorly maintained machine can be a personal injury hazard.
f Follow the Periodic Maintenance schedule in this Operator’s Manual.
f Repair or replace any damaged or defective components immediately.
Personal
Protective
Equipment
(PPE)
Prerequisites
Ground
connection
Wear the following Personal Protective Equipment (PPE) while servicing or
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 machin e. This will notify everyone that the
machine is being serviced and will reduce the chance of someone inadvertently
trying to start the machine.
The generator must be connected to a good earthen ground for proper operating
safety!
Ground the generator in accordance with the sta nd ards defined in national, state,
and local regulations.
Personal
injury
avoidance
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 com ponents of this machine.
Service safety
Do not modify the machine without the express written approval of the ma nufacturer.
Do not allow water to accumulate around the base of the mach ine. If water is
present, move the machine and allow the machine to dry before servicing.
..
Replacing
parts and
labels
Replace worn or damaged component s.
Use only spare parts recommended by Wacker Neuson.
Keep the fuel lines in serviceable condition. Leaking fuel and fumes are extremely
explosive!
Replace all missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
Check all external fasteners at regular intervals.
12 wc_si000348gb.fm
GPi 3200 / 4300 Safety Information
G
G
1.6 Label Locations
A
B
H
D
C
E
G
F
wc_si000348gb.fm 13
Safety Information GPi 3200 / 4300
1.7 Machine Labels
Wacker Neuson machines use international pictorial labels where needed. These
labels are described below.
1.8 Safety and Warning Labels
Ref. Label Meaning
ADANGER
Using a generator indoors CAN KILL
YOU IN MINUTES. Generator
exhaust contains carbon monoxide.
This is a poison you cannot see or
smell.
NEVER use inside a home or garage,
EVEN IF doors and windows are
open.
Only use OUTSIDE and far away
from windows, doors, and vents.
B Do not connect the generator to a household
or commercial power source.
Keep open flames and sparks away from the
generator.
Attention!
Read the Operator’s Manual before
operating this machine.
Attention!
Stop the engine before refueling.
CWARNING
Do not use AC and DC at the same time.
14 wc_si000348gb.fm
GPi 3200 / 4300 Safety Information
Ref. Label Meaning
D WARNING
To reduce the risk of injury, user must read
and understand instruction 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.
Potent ial da ng e r of ex plos ion 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 WARNING
Hot surface! Do not touch.
DANGER
Risk of carbon monoxide poisoning.
Keep a safe distance away from the
machine.
F This equipment does not meet California
EVP emission regulations for small off-road
engines.
G WARNING
Improper connection of the generator to a
building’s electrical system can allow
electrical current from the generator to
backfeed into utility lines. This may result in
electrocution of utility workers, fire, or
explosion. Connections to a building’s
electrical system must be made by a
qualified electrician and comply with all
applicable laws and electrical codes.
wc_si000348gb.fm 15
Safety Information GPi 3200 / 4300
Ref. Label Meaning
H
A nameplate listing the model
number, item number, revision
number, and serial number is
attached to each unit. Please record
the information found on this
nameplate so it will be available
should the nameplate become lost or
damaged. When ordering parts or
requesting service information, you
will always be asked to specify the
model number, item number, revision
number, and serial number of the
unit.
16 wc_si000348gb.fm
GPi 3200 / 4300 Operation
2 Operation
DANGER
Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot
see or smell. If you can smell the generator exhaust, you are breathing CO. But
even if you cannot smell the exhaust, you could be breathing CO.
f NEVER use a generator inside homes, garages, crawlspaces, or other partly
enclosed areas. Deadly levels of carbon monoxide can build up in these areas.
Using a fan or opening windows and doors does NOT supply enough fresh air.
f ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
f Even when you use a generator correctly , CO may leak into the home. ALW AYS
use a battery-powered or battery-backup CO alarm in the home.
f If you start to feel sick, dizzy, or weak after the generator has been running,
move to fresh air RIGHT AW AY. See a doctor. You could have carbon monoxide
poison.
2.1 Overview
Generator
application
This generator is an exceptionally quiet and compact machine desig ned to provide
single phase power for construction, commercial, and residential applications.
State-of-the-art inverter technology ensures a consistent flow of clean and stable
power suitable for operating not only tools, but also delicate electronic equipment.
Safety notices
Do not exceed the power output of the generator . Damage to tools or generator
can occur. Refer to Technical Data.
When using the generator as a stand-by or substitute power supply, make sure
the voltage and phase rotation of the line connections match those of the main
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 of any receptacle.
2.2 Preparing the Machine for First Use
Preparing for
first use
To prepare your 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 dealer immediately
for assistance.
3. Take inventory of all items included with the machine and verify that all loose
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.
wc_tx001239gb.fm 17
Operation GPi 3200 / 4300
2.3 Features and Components
l
A
S
B
C
D
E
F
H J
Q
R
G
P
O
K
E
L
M
N
wc_gr006662
18 wc_tx001239gb.fm
GPi 3200 / 4300 Operation
Ref. Description Ref. Description
A Control panel K Spark plug cap
B Fuel tank L Air cleaner
C Fuel gauge M Fuel strainer
D Right side panel (if equipped) N Battery (if equipped)
E Oil drain plug O Oil filler / gauge
F Recoil starter P Left side panel (if equipped)
G Wheel brake (if equipped) Q Exhaust outlet
H Fuel tank cap R Spark arrester
J Frame S Rear cover
wc_tx001239gb.fm 19
Operation GPi 3200 / 4300
2
2.4 Lifting and Transporting
Lifting the
Machine
Transporting
the Machine
This generator, while compact, is heavy enough to cause injury if proper lifting
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 weight-
bearing capacity to lift or hold the generator safely.
Remain aware of the location of other people nearby when lifting the generator.
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 in the transport vehicle to
prevent it from sliding or tipping.
Do not refuel the generator in or on the transp ort vehicle. Move the generator to
its operating location and then fill the fuel tank.
2.5 Wheel Brakes (if equipped)
Description
Locking and
unlocking the
wheels
The two rear wheels on your generator (if equipped) feature spring-operated
brakes (g) . These brakes help to prevent the generator from unintentional
movement. Lock both rear wheels after the generator has been placed in its
operating position.
To lock the wheel, press the brake tab (g1) until the brake snaps in place
against the wheel.
To unlock the wheel, lift the brake tab.
g
g1
wc_gr00684
20 wc_tx001239gb.fm
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