PORTABLE GASOLINE
GENERATORS
SUPPLEMENTAL INSTRUCTIONS FOR FACTORY INSTALLED
AUTO-IDLE EQUIPPED GENERATORS
IMPORTANT
Read and understand this manual before operating or servicing
generator. Improper use of generator can cause serious injury.
Keep this manual for future reference.
10,000 Watt Portable Generators
(See Owner's Manual and Installation Manual for General Operation)
R
E
S
E
T
T
E
S
T
1
2
0
V
O
L
T
S
R
E
SET
2
40 V
O
LT
S
O
F
F
A
u
to
-I
d
le
O
N
R
ES
E
T
EN
M
00000005
H
O
U
R
S
1
/1
0
F
U
E
L
F
2
103166
HONDA
ENGINE SW.
OFF
ON
START
RESET
TEST
S
RESET
240 VOLTS
OFF
Auto-Idle
ON
RESET
RESET
RESET
ENM
00000005
HOURS 1/10
WARNING: Improper installation, adjustment, al-
teration, service, or maintenance can cause injury or
property damage. Only a qualified electrical service
person should service and repair generator.
• Generator produces high voltage. Use extreme
caution when working on electrical parts.
• Turn off generator and let cool before installation.
Severe burns may result.
• Remove spark plug wire from spark plug before
installation. This will prevent accidental starting.
• Use only factory-approved replacement parts.
Figure 2 - Engine Key Switch
Figure 1 - Auto-Idle Switch Location
Auto-Idle Switch
(Rocker Switch)
Key Switch
Notice:
The 250 volt/50 amp receptacle is not connected through the
auto-idle circuit. Auto-idle rocker switch must be turned off to get
full power out of this receptacle (see Figure 1).
250 volt/50 amp
receptacle
STARTING
IMPORTANT:
The loaded engine speed is preset. The throttle is
locked in preset position. Do not adjust throttle. Preset position lets
engine run at 3600 RPM under load. The engine must maintain 3600
RPM for generator to create correct voltage. Running engine at
lower speeds will damage generator and powered items.
IMPORTANT:
Never start generator with electrical loads con-
nected. Start engine before adding electrical loads.
OPERATION INSTRUCTIONS
1. If the engine is cold, turn Auto-Idle switch off (see Figure 1).
2. Start Engine. Allow engine to warm up with no load for five
minutes.
3. Turn Auto-Idle switch on. Engine will slow to idle speed. En-
gine idle speed is preset. Idle speed adjustment should not be
necessary.
4. Operate generator according to specifications outlined in
owner’s manual.
5. Engine will automatically increase to normal operating speed
when you plug load into any generator outlet.
6. Auto-Idle system should be turned off when generator is shut
down.
WARNING: Only responsible adults should use
generator. Never let anyone operate generator with-
out proper instructions.
PRESTART
Operate generator on a firm, dry, and clean surface. The surface must
be level. Protect generator from heavy dust, sand, dirt, rain, or snow.
Do not locate generator near standing water and snow. Make sure
area is well-vented.
Note:
If oil level is too low, oil alert system will keep engine from
starting (see Oil Alert System in owner’s manual, page 8). Make sure
oil level is full before starting. See Engine Oil in owner’s manual,
page 8.
Before starting the engine, disconnect all electric loads from generator.
STOPPING ENGINE
IMPORTANT:
The loaded engine speed is preset. The throttle is
locked in preset position. Do not adjust throttle.
Follow the steps below to stop engine.
1. Remove all electrical loads from generator (see Disconnecting
Electrical Loads in owner’s manual, page 13). Remove elec-
trical loads one at a time.
2. Let engine run for two or three minutes after removing electri-
cal loads. This lets engine cool slightly.
3. Turn engine key switch to the OFF position (see Figure 1).
4. Turn fuel valve off. Do this by rotating valve, located under
fuel tank, clockwise to the horizontal position (see Figure 3).
3
103166
Key Part
No. Number Description Qty.
1 100324-03 Solenoid Assembly (includes 1
plunger, nut, and lock washer)
2 22822000 Roll Pin 1
3 100755-01 Linkage Rod 1
4 26499000 Hex Head Screw, 10-32 x 3/4" 4
5 26514000 Lock Nut, 10-32 4
6 100320-01 Yellow Wire 1
7 100322-01 White Wire (with 2 flags) 1
8 100322-02 White Wire (with 1 flag 1
and 1 spade)
9 102939-01 Solenoid Mounting Bracket 1
10 100366-01 Rocker Switch 1
11 100105-01 Control Board Assembly 1
12 100321-01 Nylon Spacer 4
13 01076002 Flat Washer, #10 4
14 103811-01 Nylon Washer 1
15 103812-01 Retaining Ring 1
∆ 103257-01 PC Board Kit 1
† 103258-02 Solenoid Assembly Kit 1
∆ Includes Parts 4, 5, 6, 7, 8, 10, 11, 12, and 13
† Includes Parts 1, 2, 3, 9, 14, and 15
D
ESA INTE
RN
A
TIO
N
AL
S2
S1
L1
L2
OFF
5. Lock Nut
13. Flat
Washer
12. Nylon Spacer
11. Control Board
Assembly
4. Screw
11. Control
Box
Figure 3 - Fuel Valve In Off Position
Fuel Valve Lever
(Off Position)
WARNING: Always set the idle speed before
turning on the Auto-Idle. If idle speed is not set, the
large resistor on the control board may become hot.
Heat from the resistor may damage the protective
coating on the control board.
3. Slowly pull solenoid and bracket away from engine. This will
slow the engine. Make sure to hold plunger into solenoid dur-
ing this step.
4. With a volt meter, check the no-load output voltage at the 120-
volt duplex receptacle. At proper idle speed (2680 minimum
RPM) the meter should read 50-60 volts. Lower settings will
cause the auto-idle to not operate properly.
5. Locate proper solenoid mounting bracket positioning. Line up
solenoid body so that plunger will fully engage into body with-
out any interference.
6. Turn Auto-Idle switch on. Make sure solenoid is engaged.
When solenoid is engaged, the solenoid pulls plunger back
into solenoid.
7. If the engine speed is too slow, the engine will want to “hunt.”
When engine hunts, it speeds up and then slows down repeat-
edly. When this occurs, increase engine speed by adjusting
throttle stop screw on carburetor (refer to Carburetor Adjust-
ment in Honda Engine Manual).
ADJUSTING THE IDLE SPEED
IMPORTANT:
Adjust the idle speed
• Only if the idle speed becomes too high
• If engine idle speed will not regulate (engine idles and speeds up
again and again).
1. Turn Auto-Idle switch off. Start engine. Allow engine to warm
up with no load for five minutes.
1. Solenoid Assembly
(Includes Plunger, Nut,
and Lock Washer)
2. Roll Pin
3. Linkage Rod
9. Solenoid
Mounting Bracket
Governor Spring
Engine Governor Arm
2. Hold plunger in solenoid body to manually engage solenoid
and set idle speed.
WARNING: Guard against burns. Hot muffler,
exhaust manifold, and engine parts can cause severe
injury. Use caution and remain alert when adjusting
or using generator.
Plunger
2. Roll Pin
9. Solenoid
Mounting Bracket
Nut
Lock Washer
Plunger
3. Linkage Rod
15. Retaining Ring
14. Nylon Washer
Resistance in Ohms
Rated Stator Main Stator Auxiliary Rotor Primary Rotor Secondary Capacitor, Diodes,
Watts Winding * Winding ∆ Winding † Winding † MFD 450 Volt (2) 800 Volt
10,000 0.4 0.9 0.37 0.5 80 70Amp
P.O. Box 90004
Bowling Green, KY 42102-9004
Technical Service Department 1-800-858-8501
www.desatech.com
103166-01
Rev. D
07/03
250V 30A
Receptacle
250V 50A
Receptacle
125V, 15A
Receptacle
GFCI 125V, 15A
Receptacle
125V, 30A
Receptacle
Circuit
Breaker
20A
Circuit
Breaker
20A
Green
Green
Black
Black
White
Black
Red
Black
Black
Black Black
Black
WhiteWhite
White
Green
Black
Black
Black
Red
Red
Red
Red
Yellow
Yellow
White
White
Auto-Idle
Control Board
Yellow
WhiteWhite
White
Circuit
Breaker
30A
Circuit
Breaker
30A
Circuit
Breaker
45A
Circuit
Breaker
45A
Green
T2
Green
Black
Red
White
Main
Windings
T1
T3
T4
Wh
T1 T2T3T4
Rotor
Diode
Diode
Stator
Capacitor
White
White
Run
Light
Hour Meter
Green
L1
S2
Solenoid
S1
T1-3
L2
To
Auto-Idle
Solenoid
Stator
110/120V
T1 T2 T3 T4
L2
L1
110/120V
220/240V
* Connect T2 and T3. Measure resistance between T1 and T4.
∆ Disconnect capacitor leads in order to read auxillary winding resistance.
† Remove diodes to check resistance.
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1
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2
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3
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