Generac 5943-5 Owner's manual

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introduction.............................................................1

ReadthisiVlanualThoroughly.................................1

Safety Rules...........................................................1

StandardsIndex.............................................................3

Generalinformation................................................4

1.1 Unpacking......................................................................4

1.1.1 Accessories.......................................................4

1.2 Assembly.......................................................................4

1.2.1 Assemblingthe AccessoryKit............................4

1.2.2 BatteryCableConnection(ElectricStart Only)....4

1.3 EmissionsInformation....................................................5

Operation................................................................5

2.1 Knowthe Generator.......................................................5

2.2 Hourmeter......................................................................6

2.3 ConnectionPlugs...........................................................6

2.3.1 120 VAC,20 Amp, DuplexReceptacle...............6

2.3.2 120 VAC,20 Amp, GFCIDuplexReceptacle

(CARBonly)......................................................7

2.3.3 120/240VAC,30 Amp, Receptacle....................7

2.4 Howto Usethe Generator..............................................7

2.4.1 Groundingthe GeneratorWhenUsedas a

Portable.............................................................8

2.4.2 Connectingthe Generatorto a Building's

ElectricalSystem...............................................8

2.5 Don'tOverloadthe Generator..........................................8

2.6 WattageReferenceGuide...............................................9

2.7 BeforeStartingtheGenerator.........................................9

2.7.1 Adding EngineOil..............................................9

2.7.2 Adding Gasoline...............................................10

2.8 Starting Pull Start Engines............................................10

2.9 Starting ElectricStart Engines......................................11

2.9.1 ManualStart....................................................11

2.10 Stoppingthe Engine.....................................................11

2.11 LowOil LevelShutdownSystem..................................11

2.11.1 SensingLowOil Level......................................11

2.12 Chargingthe Battery(ElectricStart UnitsOnly).............12

Maintenance.........................................................12

3.1 PerformingScheduledMaintenance.............................12

3.2 MaintenanceSchedule.................................................12

3.3 ProductSpecifications..................................................12

3.3.1 GeneratorSpecifications..................................12

3.3.2 EngineSpecifications.......................................12

3.4 GeneralRecommendations...........................................13

3.4.1 GeneratorMaintenance....................................13

3.4.2 ToCleanthe Generator.....................................13

3.4.3 EngineMaintenance.........................................13

3.4.4 CheckingOil Level...........................................13

3.4.5 Changingthe Oil..............................................13

3.4.6 Replacingthe SparkPlug.................................13

3.4.7 BatteryReplacement(IfApplicable).................14

3.5 ServiceAir Filter...........................................................14

3.5.1 CleanSparkArrestor Screen(CARBModels)...14

3.6 ValveClearance............................................................15

3.7 General........................................................................15

3.8 Long TermStorage.......................................................15

3.9 OtherStorageTips.......................................................15

Troubleshooting....................................................16

4.1 TroubleshootingGuide..................................................16

Notes....................................................................17

MANUALDELPROPIETARIO.....................19

MANUELD'ENTRETIEN......................................39

INTRODUCTION

Thankyou for purchasingthis modelby GeneracPowerSystems,

Inc. This model is a compact, high performance, air-cooled,

engine driven generatordesigned to supply electrical power to

operateelectrical loads where no utility power is availableor in

placeof utility dueto a poweroutage.

BEADTHiSMANUALTHOROUGHLY

If anyportion ofthis manualis notunderstood,contactthenearest

AuthorizedDealerfor starting, operatingandservicingprocedures.

The operator is responsible for proper and safe use of the

equipment.We strongly recommendthat the operator read this

manualandthoroughlyunderstandall instructionsbeforeusingthe

equipment.Wealsostronglyrecommendinstructingotherusersto

properlystart andoperatethe unit.This preparesthem ifthey need

to operatetheequipmentin an emergency.Savethese instructions

for future reference.If you loan this deviceto someone,ALWAYS

loanthese instructionsto the individualaswell.

Thegeneratorcan operatesafely,efficiently and reliablyonly if it

is properlylocated,operatedand maintained.Beforeoperatingor

servicingthe generator:

• Becomefamiliarwith and strictly adhereto all local, stateand

nationalcodes and regulations.

• Study all safety warnings in this manual and on the product

carefully.

• Becomefamiliarwith thismanualandthe unitbeforeuse.

Themanufacturercannot anticipateevery possible circumstance

that might involvea hazard.Thewarnings in this manual,and on

tags and decals affixedto the unit are,therefore,not all inclusive.

If usinga procedure,work method or operatingtechniquethat the

manufacturerdoes not specifically recommend,ensurethat it is

safe for others. Also make sure the procedure,work method or

operatingtechnique utilizeddoes not renderthe generatorunsafe.

THE INFORMATIONCONTAINEDHEREIN WAS BASED ON

MACHINESIN PRODUCTIONAT THE TIME OF PUBLICATION.

GENERACRESERVESTHERIGHTTOMODIFYTHISMANUALAT

ANYTIME.

SAFETYRULES

Throughoutthis publication,and on tags and decals affixedto the

generator,DANGER,WARNING,CAUTIONand NOTEblocks are

usedto alert personnelto special instructionsabout a particular

operation that may be hazardous if performed incorrectly or

carelessly.Observethem carefully.Theirdefinitionsareasfollows:

INDICATESAHAZARDOUSSiTUATiONORACTIONWHICH,IF

NOTAVOIDED,WILLRESULTIN DEATHORSERIOUSINJURY.

Indicatesa hazardoussituationor action which,if not

avoided, couldresultindeathorseriousinjury.

_CAUTION!

Indicatesa hazardoussituationor action which,if not

avoided, couldresultinminoror moderateinjury.

NOTE:

Notescontainadditionalinformationimportantto a procedure

and willbe foundwithinthe regular textbodyofthis manual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliancewith the special

instructionswhile performingtheaction or serviceareessentialto

preventingaccidents.

Four commonly used safety symbols accompany the DANGER,

WARNINGand CAUTIONblocks. The type of information each

indicatesis asfollows:

,_This symbol points out important safety

information that, if not followed, could

endanger personal safety and/or property of

others.

This symbol points out potential explosion

hazard.

WARNING!

California Proposition 65

Engine exhaust and some of its constituents are known to the state of California to cause cancer,

birth defects, and other reproductive harm.

WARNING!

California Proposition 65

This product contains or emits chemicals known to the state of California to cause cancer,

birth defects, and other repoductive harm.

i/_This symbol points out potential fire hazard.

This symbol points out potential electrical

shock hazard.

GENERAL HAZARDS

* NEVERoperatein an enclosed area, in a vehicle, or indoors

EVENIFdoorsand windows areopen.

* For safety reasons, the manufacturer recommends that the

maintenanceof this equipmentis carried out by an Authorized

Dealer.Inspectthe generatorregularly,and contactthe nearest

AuthorizedDealerfor parts needingrepair or replacement.

* Operategeneratoronly on levelsurfacesandwhereit will notbe

exposedto excessivemoisture,dirt, dust or corrosivevapors.

* Keep hands, feet, clothing, etc., away from drive belts, fans,

and othermoving parts. Neverremoveanyfan guardor shield

whilethe unitis operating.

* Certain parts of the generator get extremely hot during

operation. Keep clear of the generatoruntil it has cooled to

avoidsevereburns.

* Do NOToperategeneratorin the rain.

* Do not alter the construction of the generator or change

controlswhich might createan unsafeoperatingcondition.

* Never start or stop the unit with electrical loads connected

to receptaclesAND with connecteddevicesturned ON. Start

the engine and let it stabilize before connecting electrical

loads. Disconnectall electricalloadsbeforeshuttingdown the

generator.

* Do notinsert objectsthrough unit's coolingslots.

* When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally

fatigued.

* Neverusethe generatoror anyof its parts as a step. Stepping

on the unit can stress and break parts, and may result in

dangerousoperating conditions from leakingexhaust gases,

fuel leakage,oil leakage,etc.

NOTE:

This generatormaybe equippedwith a spark arrestormuffler.

The spark arrestor must be maintainedin effective working

orderbytheowner/operator.In theStateofCalifornia, a spark

arrestor is required by law (Section 4442 of the California

Public Resources Code). Other states may havesimilar laws.

Federallawsapply on federallands.

EXHAUST & LOCATIONHAZARDS

• Neveroperatein anenclosedareaor indoors!NEVERuse in

thehome,in a vehicle, or in partlyenclosedareas suchas

garages,EVENiF doors and windowsare open! ONLYuse

outdoors and far from open windows,doors, vents,andinan

areathatwill notaccumulate deadly exhaust.

Using a generator indoors CAN KiLL YOU iN MINUTES.

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smeJJ.

NEVER use insidea home

or garage, EVEN iF doors

and windows areopen.

Only use OUTSIDE and

far away from windows,

doors, and vents.

* The engine exhaustfumes contain carbon monoxide, which

you cannot see or smell. This poisonous gas, if breathedin

sufficientconcentrations,cancause unconsciousnessor even

death.

* Adequate, unobstructed flow of cooling and ventilating air

is critical to correct generator operation. Do not alter the

installation or permit even partial blockage of ventilation

provisions, as this can seriously affect safe operationof the

generator.ThegeneratorMUSTbeoperatedoutdoors.

* This exhaustsystem must be properlymaintained.Do nothing

thatmightrendertheexhaustsystemunsafeorinnoncompliance

with any localcodes and/orstandards.

* Alwaysusea batteryoperatedcarbonmonoxidealarmindoors,

installedaccordingto themanufacturer'sinstructions.

* If you start to feel sick, dizzy,or weak after the generatorhas

beenrunning,move tofresh air IMMEDIATELYSeea doctor,as

you couldhavecarbonmonoxidepoisoning.

ELECTRICALHAZARDS

• The generator produces dangerously high voltage when in

operation.Avoidcontactwith barewires,terminals,connections,

etc., whilethe unitis running,evenon equipmentconnectedto

thegenerator.Ensureall appropriatecovers,guardsandbarriers

are in placebeforeoperatingthe generator.

• Never handle any kind of electrical cord or device while

standingin water,whilebarefootor while handsor feet arewet.

DANGEROUSELECTRICALSHOCKMAYRESULT.

• TheNationalElectricCode(NEC)requirestheframeandexternal

electrically conductive parts of the generator be properly

connectedto an approvedearth ground.Localelectricalcodes

may also require proper grounding of the generator.Consult

with a localelectricianfor groundingrequirementsin thearea.

• Use a ground fault circuit interrupterin any damp or highly

conductivearea(such as metaldecking or steelwork).

• Do not useworn, bare,frayedor otherwisedamagedelectrical

cord setswith the generator.

• Beforeperforminganymaintenanceonthegenerator,disconnect

the engine starting battery (if equipped)to preventaccidental

start up. Disconnectthe cablefrom the battery post indicated

by a NEGATIVE,NEGor (-) first. Reconnectthatcable last.

• In caseof accidentcausedby electricshock,immediatelyshut

down the source of electrical power. If this is not possible,

attempt to free the victim from the live conductor. AVOID

DIRECTCONTACTWITH THE VICTIM. Use a non-conducting

implement,such asa ropeor board,to freethevictim from the

live conductor.If the victim is unconscious,applyfirst aid and

getimmediatemedical help.

FIREHAZARDS

• GasolineishighlyFLAMMABLEanditsvaporsare EXPLOSIVE.

Never permit smoking,open flames, sparksor heat in the

vicinitywhile handlinggasoline.

• Neveraddfuel while unitis runningor hot.Allow engineto cool

completelybeforeaddingfuel.

• Never fill fuel tank indoors, Comply with all laws regulating

storageand handlingof gasoline.

• Do not overfill the fuel tank. Always allow room for fuel

expansion.If tank is over-filled,fuel can overflow onto a hot

engineandcause FIREor an EXPLOSION.Neverstoregenerator

with fuel in tank where gasolinevapors might reachan open

flame, spark or pilot light (as on a furnace, water heateror

clothes dryer). FIREor EXPLOSIONmay result. Allow unit to

cool entirelybeforestorage.

• Wipe up any fuel or oil spills immediately. Ensure that no

combustiblematerialsareleft onor nearthe generator.Keepthe

areasurroundingthe generatorcleanand freefrom debrisand

keepa clearanceof five (5) feet on all sideto allow for proper

ventilationofthe generator.

• Do notinsert objectsthrough unit's cooling slots.

• Never operate the generator if connected electrical devices

overheat,if electricaloutputislost, if engineor generatorsparks

or ifflames or smokeare observedwhileunit is running.

• Keepafire extinguishernearthe generatoratalltimes.

STANDARDS/NDEX

1. NationalFireProtectionAssociation(NFPA)70:TheNATIONAL

ELECTRICCODE(NEC)availablefrom www.nfpa.org

2. NationalFire ProtectionAssociation (NFPA)5000: BUILDING

CONSTRUCTIONAND SAFETYCODEavailablefrom www.

nfpa.org

3. InternationalBuildingCodeavailablefrom www.iccsafe.org

4. Agricultural Wiring Handbookavailablefrom www.rerc.org ,

Rural ElectricityResourceCouncil RO.Box 309 Wilmington,

OH45177=0309

5. ASAEEP-364.2Installationand Maintenanceof FarmStandby

Electric Power available from www.asabe.org, American

Society of Agricultural & Biological Engineers2950 Niles

Road,St. Joseph,MI 49085

This list is not all inclusive.Checkwith theAuthority HavingLocal

Jurisdiction (AHJ)for any localcodes or standardswhich may be

applicableto yourjurisdiction.

MODELNO:

SERIALNO:

Unit ID Location

DATA

DECAL

1.1 UNPACKING

• Removeallpackagingmaterial.

• Removeseparateaccessorybox.

• Removethe generatorfrom carton.

1.1.1 ACCESSORIES

Checkall contents.If anyparts aremissing or damaged,locatean

authorizeddealerat 1-888-436-3722.

• 1 - Owner'sManual • 1 - HandleAssembly

• 1-LiterOiISAE30 • 2-FrameFoot

• 2 - Never-FlatWheels • 1 - 20' PowerCord

• 3 - ProductRegistrationCards (006110-3 only)

• 1 - ServiceWarranty • 1 - EmissionsWarranty

e

1 - Battery Charger (Electric Start Models)

1 - Hardware Bag (containing the following):

- 2-RubberFeet 6-M8 Bolt (Long)

- 2-1/2" AxlePins 2-M6 Bolts (Long)

- 2-Cotter Pins 2-M8 Acorn Nut

- 2-1/2" FlatWashers 4-HexFlangedM8Nuts

- 2-HexFlangedM6 Nuts

1.2 ASSEMBLY

The generator requires some assembly prior to using it. If

problems arise when assemblingthe generator,please call the

GeneratorHetplineat 1-888-436-3722.

1.2.1 ASSEMBLINGTHEACCESSORYKIT

The wheels are designed into the unit to greatly improve the

portability ofthe generator.

You will needthe following tools to properlyinstall the accessory

kit.

• NeedleNosePliers

• Ratchetand8mm, lOmm, and13mm sockets

• 8mm, lOmm, and13mm boxwrenches

NOTE:

The wheels are not intendedfor over-the-road use.

1. Refer to Figure 1 and install the Wheels as follows:

- Slidethe AxlePinthroughtheWheel, 1/2" FlatWasher,andWheel

Bracketon theframe.

- Insertthe CotterPinthroughthe AxlePinthenbendthetabs (ofthe

OotterPins)outwardto lock into place.

2. Refer to Figure 1 and install the Frame Foot and Rubber

Bumpers as shown.

- Slidethe RubberBumperstuds throughthe FrameFoottheninstall

the LockingFlangeNuts.

- Slidethe HexHeadBoltsthrough theholes inthe FrameRail.

- Slide the Frame Foot onto the Hex Head Bolts then install the

LockingFlangeNuts.

3. Refer to Figure 1 and install the Handle as shown.

- Slidethe long Bolts through the HandleBracketand Handle,then

installthe HexNuts.

Figure 1 - Wheel & Handle Assembly

2 XM8BOLT(LONG)

2 XM8ACORNNUT

ASSEMBLY

4 X M8 BOLT

,(LONG)

2 X COTTER PIN

2 X I/2" FLATWASHER

2 X WHEEL

2 X AXLE PIN

_-'_ ....... 2 X FRAME FOOT

_Z'_ 4XM8NUTS

2 XRUBBER FOOT---_ _ 2 XM6 NUTS

2 XM6BOLT

(LONG)

1.2.2 BATTERYCABLECONNECTION(ELECTR/CSTART

ONLY_

The unit has been deliberatelyshipped with the battery cables

disconnected.

Toconnectthe battery,you will needtwo 8mm boxwrenchesto

connectthe batterycables.(seeFigure16 for connectiondetails):

1. Cut off cable ties securing battery cables and remove red

coversfrom batteryterminals.

2. First,connecttheredcableto thepositive(+) batteryterminal

with the bolt andnut supplied.

3. Makesureconnectionsare secureandsliderubber boot over

thepositive (+) batteryterminal and connectionhardware.

4. Connectthe black cable to the negative(-) batteryterminal

with thebolt and nut suppliedand slide rubber boot overthe

negative(-) batteryterminal and connectionhardware.

5. Makesure all connectionsaresecure.

NOTE:

If the battery is unable to start the engine,chargeit with the

12V chargerincludedinthe accessory box(seethe "Charginga

Battery"section for details).

1.3 EMiSSiONSiNFORMATiON

TheEnvironmentalProtectionAgency (andCaliforniaAir Resource

Board for generators certified to CA standards) requires that

this generator comply with exhaust and evaporative emission

standards.Locatethe emissions compliancedecal on the engine

to determinewhatstandardsthegeneratormeets,andto determine

which warranty applies.This generatoris certifiedto operateon

gasoline. The emission control system includes the following

components(if equipped):

• AirInductionSystem

- IntakePipe/ Manifold

- AirCleaner

• FuelSystem

- Carburetor

- FuelTank/Cap

- FuelLines

- EvaporativeVentLines

- CarbonCanister

• IgnitionSystem

- SparkPlug

- IgnitionModule

• ExhaustSystem

- ExhaustManifold

- Muffler

- PulsedAirValve

- Catalyst

2.1 KNOWTHEGENERATOR

Read the Owner'sManual and Safety Rules before operating

thisgenerator.

Compare the generator to Figures 2 through 4 to become

familiarizedwith thelocationsof variouscontrolsandadjustments.

Savethis manualfor future reference.

1. 120 Volt AC, 20 Amp, Duplex Receptacle - Supplies

electrical power for the operationof 120 Volt AC, 20 Amp,

single-phase, 60 Hz electrical lighting, appliance, tool and

motor loads (CARBmodelsare equippedwith GFCIoutlets).

2. 120/240 Volt AC, 30 Amp LockingReceptacle - Supplies

electricalpowerfor the operationof 120 and/or240 VoltAC,

30 Amp, single-phase,60 Hz, electrical lighting, appliance,

tool andmotor loads.

3. CircuitBreakers (AC)- Eachreceptacleis providedwith a

push-to-resetcircuit breakerto protectthe generatoragainst

electricaloverload.

4. Oil Drain- Useto drainengineoil.

5. Air Filter- Filtersintakeairas itisdrawn intothe engine.

6. ChokeKnob- Usedwhen startinga coldengine.

7. FuelTank- SeegeneratorSpecificationsfor tank capacity.

8. GroundingLug- Groundthe generatorto an approvedearth

groundhere.See"GroundingtheGenerator"for details.

9. Run/Stop Switch- Controls the operationof the generator

(pull start models).

9A. Start Switch - Used to start engine from the starter motor

(electricstart modelsonly).

10. Muffler- Quietsthe engine.

11. Handle - Pivot and retract for storage. Press the spring-

loadedbuttonto move handles.

12. GasCap- Fuelfill location.

l& FuelGauge- Showsfuel levelin tank.

14. Oil Fill- Add oil here.

15. Recoil Starter - Useto start enginemanually.

15. FuelShut Off - Valvebetweenfueltank and carburetor.

17. Roll OverValve- Passesfuelto the engineairbox.

18. Recovery Hose- Installbetweenthe carboncanisterandthe

roll overvalve (if equipped).

19. Hourmeter- Trackshoursof operation.

20. Battery ChargerInput - This receptacleallowsthe capability

to rechargethe 12 volt DO storage battery provided with

the 12 Volt Adaptor Plug Chargerwhich is included in the

Accessory Box. Located behindthe battery chargerinput is

a 1.50 Amp in-line fuse which is insidethe control panelto

protectthe battery(electricstart models only).

21. Battery - Powersthe electric starter (electric start models

only).

22. Spark Arrestor - Reducesfire hazardsby containing sparks

(CARBmodels only).

Figure 2.4 - Contro/ Panel (49 State Models)

Figure 2B - Contro/ Panel (CARB Models)

Figure 2C - Contro/ Pane/ (CSA Models)

Figure3 - GeneratorControls

2.2 HOURMETER

TheHourmetertrackshoursofoperationforscheduledmaintenance

(Figure5):

Therewill bea"CHGOIL"messageevery100hours.Themessage

will flash one hour before and one hour after each 100 hour

interval,providinga two hourwindow to perform service.

This messagewill actuallybeginflashing at 99 hoursand disable

itselfat 101 hoursagain,providingatwo hourwindow to perform

theservice.

Every200 hoursthe "SVC"icon on the lower left hand corner of

thedisplay will flash. Themessagewill flash one hourbeforeand

onehour aftereach200 hourintervalprovidingatwo hourwindow

to perform service.

Figure5 - Hourmeter

HOUR GLASS

GRAPHIC

O000.O

RESETBUTTON

(IF EQUIPPED)

Figure4 - Generator Controls

Whenthe hour meter is inthe FlashAlert mode, the maintenance

message will always alternate with elapsedtime in hours and

tenths. The hours wilt flash four times, then alternatewith the

maintenancemessagefourtimes untilthemeter resetsitself.

* 100 hours- CHGOIL-- OilChangeInterval(Every100 hrs)

* 200 hours- SVC-- ServiceAir Filter(Every200 hrs)

Note:

The hour glass graphic will flash on and off when the engine

is running.This signifies that the meter is tracking hours of

operation.

2.3 CONNECTIONPLUGS

2.3.1 120VAC,20AMP,DUPLEXRECEPTACLE

This is a 120 Volt outlet protectedagainst overloadby a 20 Amp

push-to-resetcircuitbreaker(Figure6). Useeachsocketto power

120 VoltAC, singlephase,60 Hzelectricalloadsrequiringupto a

combined 2400 watts (2.4 kW) or 20 Amps of current.Use only

high quality,well-insulated, 3-wire grounded cord sets ratedfor

125 Volts at 20 Amps (or greater).

Keep extensioncords as short as possible, preferablyless than

15 feet long, to preventvoltage drop and possibleoverheatingof

wires.

Figure 6 - 120 Vo/t AC, 20 Amp, Duplex Receptac/e

2.3.2 120VAC,20AMP,GFC/DUPLEXRECEPTACLE

(CARBONLY)

This is a 120 Volt outlet protectedagainst overloadby a 20 Amp

push-to-reset circuit breaker (Figure 6A). Use each socket to

power 120 VoltAO,single phase,60 Hz electricalloadsrequiring

upto a combined2400 watts (2.4 kW)or 20 Amps of current.Use

only high quality,well-insulated,3-wire groundedcord sets rated

for 125 Volts at 20 Amps (or greater).

Keepextensioncords asshort as possibleto preventvoltagedrop

and possibleoverheatingof wires.

Figure 6A - 120 Vo/t AC, 20 Amp, GFC/Duplex

Receptac/e

2.3.3 120/240VAC,30AMPRECEPTACLE

Use a NEMA L14-30 plug with this receptacle (rotate to lock!

unlock). 0onnect a suitable4-wire groundedcord set to the plug

andto thedesiredtoad.Thecordset shouldbe ratedfor 250 Volts

ACat30 Amps (or greater)(Figure7).

Use this receptacleto operate120 Volt AC, 60 Hz, singlephase

loads requiringup to 3600 watts (3.6 kW) of powerat 30 Amps

or 240 Volt AC, 60 Hz,single phase loadsrequiring up to 7200

watts (7.2 kW) of power at 30 Amps. The outlet is protectedby

two 25 Amp (5.5kW)ortwo 30 Amp (6.5kW)push-to-resetor one

30 Amp 2-pole toggleswitch or two 30 Amppush buttonto reset

(6.5/7.5kW) circuit breaker.

Figure 7 - 120/240 VAC, 30 Amp Receptac/e

120V/240V

30A

2.4 HOW TO USETHEGENERATOR

Seethe "To Startthe Engine"sectionfor how to safelystart and

stop the generatorand how to connect and disconnect loads. If

there are any problems operatingthe generator,pleasecall the

generatorhelplineat 1-888-436-3722.

_t ever operate in an enclosed area or indoors!

NEVER use in the home, in a vehicle, or in

partly enclosed areas such as garages, EVEN

IF doors and windows are open! ONLY use

outdoors and far from open windows, doors,

vents, and in an area that will not accumulate

deadly exhaust.

_t The engine exhaust fumes contain carbon

monoxide, which you cannot see or smell.

This poisonous gas, if breathed in sufficient

concentrations, can cause unconsciousness or

even death.

,_Adequate, unobstructed flow of cooling and

ventilating air is critical to correct generator

operation. Do not alter the installation or permit

even partial blockage of ventilation provisions,

as this can seriously affect safe operation

of the generator. The generator MUST be

operated outdoors.

_t This exhaust system must be properly

maintained. Do nothing that might render the

exhaust system unsafe or in noncompliance

with any local codes and/or standards.

_t Always use a battery operated carbon

monoxide alarm indoors, installed according to

the manufacturer's instructions.

Using a generator indoors CAN KiLL YOU iN MINUTES.

GroundingtheGeneratorinaBuildingStandbyApplicati0n

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell.

NEVER use inside a home

or garage, EVENiF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors, and vents.

2.4.1 GROUNO/NGTHEGENERATORWHENUSEDASA

PORTABLE

This generator has an equipment ground that connects the

generatorframe componentsto the ground terminals on the AC

output receptacles (see NEC 250.34 (A) for explanation).This

allows the generatorto be used as a portablewithout grounding

the frame ofthe generatorasspecifiedin NEC250.34.

SpecialRequirements

There may be Federalor State OccupationalSafety and Health

Administration(OSHA)regulations,localcodes,or ordinancesthat

applyto the intendeduse ofthe generator.

Pleaseconsult a qualified electrician,electrical inspector, or the

local agencyhavingjurisdiction:

* In some areas, generators are requiredto be registeredwith

local utilitycompanies.

* If the generatoris used at a construction site, there may be

additionalregulationswhich must be observed.

2.4.2 CONNECT/NGTHEGENERATORTOABU/LD/NG'$

ELECTRICALSYSTEM

Connectionsfor standby power to a building's electricalsystem

must be made by a qualifiedelectricianand in strict compliance

with all national and local electrical codes and laws. The

connectionmust isolatethegeneratorpowerfrom utility poweror

otheralternativepowersources.

NOTE:

Becausethe generator equipmentground is bondedto the AC

neutralwiresin thegenerator,eithera 3-poletransferswitchor

a 2 poletransferswitchwith a switchingneutralkit is required

to connectthisgenerator to a buildingload.In this application

the generator becomesa separatelyderived system(see NEC

250.20 (D)), and must be grounded in accordance with the

nationalor localelectricalcoderequirements.

,_The National Electrical Code requires that the

frame and external electrically conductive parts

of this generator be properly connected to an

approved earth ground,

Local electrical codes may also require proper grounding of

the unit (Figure8). Forthat purpose, connectinga No. 10 AWG

(AmericanWireGauge)strandedcopperwireto the groundinglug

and to an earth-drivencopperor brass grounding rod (electrode)

provides adequateprotection against electrical shock. However,

local codes may vary widely.Consultwith a localelectricianfor

grounding requirementsin thearea.

Proper groundingof the generatorwill help preventelectrical

shockin theeventof a groundfault conditioninthe generatoror in

connectedelectricaldevices.Propergroundingalsohelpsdissipate

static electricity,which often buildsup in ungroundeddevices.

Figure8 - GroundingtheGenerater

GROUNDING

2.5 DON'TOVERLOADTHEGENERATOR

Overloadinga generatorin excess of its ratedwattage capacity

can result in damageto the generatorandto connectedelectrical

devices.Observethefollowing to preventoverloadingthe unit:

* Addupthetotal wattageofall electricaldevicesto be connected

at one time. This total should NOT be greater than the

generator'swattagecapacity.

* The ratedwattageof lights can betaken from light bulbs. The

ratedwattageof tools, appliancesand motors can usually be

foundon a datalabelor decalaffixedto the device.

* If the appliance,tool or motor does not give wattage,multiply

voltstimes ampereratingto determinewatts (voltsx amps =

watts).

* Some electric motors, such as induction types, require about

threetimes morewatts of powerfor startingthan for running.

This surge of power lasts only a few seconds when starting

such motors.Makesureto allowfor high startingwattagewhen

selectingelectricaldevicesto connectto the generator:

1. Figurethe watts neededto start the largestmotor.

2. Add to that figure the running watts of alt other connected

loads.

TheWattageReferenceGuideis providedto assist in determining

how many itemsthe generatorcan operateatonetime.

NOTE:

All figures are approximate. See data label en appliancefor

wattage requirements.

2.6 WATTAGEREFERENCEGUIDE

Device ................................... RunningWatts

*Air Conditioner(12,000 Btu).......................... 1700

*Air Conditioner(24,000 Btu).......................... 3800

*Air Conditioner(40,000 Btu).......................... 6000

BatteryCharger(20 Amp).............................. 500

BeltSander(3") .................................... 1000

ChainSaw ........................................ 1200

CircularSaw(6-1/2") ........................... 800 to 1000

*Clothes Dryer(Electric) ............................. 5750

*Clothes Dryer(Gas) ................................. 700

*Clothes Washer ................................... 1150

CoffeeMaker ...................................... 1750

*Compressor (1 HP)................................. 2000

*Compressor (3/4 HP)............................... 1800

*Compressor (1/2 HP)............................... 1400

CurlingIron......................................... 700

*Dehumidifier....................................... 650

Disc Sander(9").................................... 1200

EdgeTrimmer....................................... 500

Electric Blanket...................................... 400

Electric NailGun.................................... 1200

Electric Range(per element)........................... 1500

Electric Skillet...................................... 1250

*Freezer............................................ 700

*FurnaceFan(3/5 HP) ................................ 875

*GarageDoor Opener............................ 500to 750

HairDryer......................................... 1200

Hand Drill.................................... 250 to 1100

HedgeTrimmer...................................... 450

Impact Wrench...................................... 500

Iron.............................................. 1200

*Jet Pump ......................................... 800

Lawn Mower....................................... 1200

Light Bulb.......................................... 1O0

Microwave Oven............................... 700 to 1000

*Milk Cooler....................................... 1100

OilBurneron Furnace................................. 300

OilFiredSpaceHeater(140,000 Btu) ..................... 400

OilFiredSpaceHeater(85,000 Btu) ...................... 225

OilFiredSpaceHeater(30,000 Btu) ...................... 150

*Paint Sprayer,Airless (1/3 HP) ......................... 600

PaintSprayer,Airless (handheld)......................... 150

Radio ......................................... 50 to 200

*Refrigerator........................................ 700

SlowCooker........................................ 200

*Submersible Pump(1-1/2 HP) ........................ 2800

*SubmersiblePump (1 HP) ........................... 2000

*SubmersiblePump (1/2 HP).......................... 1500

*Sump Pump................................. 800 to 1050

*Table Saw(10") ............................. 1750to 2000

Television..................................... 200to 500

Toaster..................................... 1000to 1650

WeedTrimmer ...................................... 500

* Allow 3 times the listedwatts for starting these devices.

2.7 BEFORESTARTINGTHEGENERATOR

Priorto operatingthe generator,engineoil and gasolinewill need

to be added,asfollows:

2.7.1 ADDING ENGINEO/L

All oil should meet minimum American PetroleumInstitute (API)

Service Class SJ, SL or better.Use no special additives. Select

the oil's viscosity grade according to the expected operating

temperature(also seechart).

* Above40° F,useSAE30

* Below40° Fand downto 10° F,use10W-30

* All temperatures,usesynthetic5W-30

411lIE

!

°F =20 =10 0 10 20 32

!

40

mml,

60 80 100

Temperature Range of Expected Use

ACAUTION!

,_ Any attempt to crank or start the engine

before it has been properly serviced with the

recommended oil may result in an engine

failure.

1. Placegeneratoron a levelsurface (notto exceed15° inany

direction).

2. Cleanareaaroundoil fill andremoveoil fill cap anddipstick.

3. Wipedipstick clean.

4. Slowly fill engine with oil through the oil flit opening until it

reachesthe fult mark. Stopfilling occasionally to check oil

level.Be carefulnette ever fill.

5. Installoil fill capandfingertighten securely.

6. Checkengineoil levelbeforestarting eachtime thereafter.

2.7.2 ADD/NGGA$O/./NE

Never fill fuel tank indoors. Never fill fuel tank

when engine is running or hot. Avoid spilling

gasoline on a hot engine. Allow engine to cool

entirely before filling fuel tank. DO NOT light a

cigarette or smoke when filling the fuel tank.

Do not overfill the fuel tank. Always leave room

for fuel expansion, if the fuel tank is overfilled,

fuel can overflow onto a hot engine and cause

FiRE or EXPLOSION. Wipe up any spilled fuel

immediately.

Never light a cigarette or smoke when filling

the fuel tank. Gasoline is highly FLAMMABLE

and its vapors are EXPLOSIVE. Never permit

smoking, open flames, sparks or heat in the

vicinity while handling gasoline.

1. UseregularUNLEADEDgasolinewith thegeneratorengine.Do

not use anygasolinewith morethan 10% addedethanol. Do

not useE85 gasoline.Donot mix oil with gasoline.

2. Cleanareaaroundfuelfill cap, removecap.

3. Slowly add unleadedregulargasolineto fuel tank. Becareful

nott0 overfill(Figure9).

4. Installfuel cap andwipe up any spilledgasoline.

Figure9 - FuelTank

FueiTank

_ /

T

Fuel/ Do NOTFillAboveLip

IMPORTANT:It isimportantto preventgumdepositsfrom forming

in fuel system parts such as the carburetor,fuel hose or tank

during storage. Alcohol-blendedfuels (called gasohol, ethanol

or methanol)can attract moisture, which leadsto separationand

formation of acids duringstorage.Acidic gascandamagethefuel

system of an enginewhile in storage.Toavoid engineproblems,

the fuel system should be emptiedbefore storageof 30 daysor

longer.Seethe "Storage"section. Neveruseengineor carburetor

cleanerproductsin thefueltank aspermanentdamagemay occur.

2.8 STARTINGPULLSTARTENGINES

Never start or stop engine with electrical

devices plugged into the receptacles AND

devices turned on.

1. Unplugall electricalloads from the unit's receptaclesbefore

startingthe engine.

2. Makesurethe unit is in a levelposition (notto exceed15° in

anydirection).

3. OPENthe FuelShut-offValve(Figure10).

4. TurnengineRUN/STOPswitch to ONposition(Figure11).

5. Slide engine choke to the LEFT to FULL CHOKEposition

(Figure12).

6. Tostart engine,firmly graspthe recoilhandleandpull slowly

until increasedresistanceisfelt. Pullrapidlyup and away.

7. Whenenginestarts, movechokeknobto 1/2-CHOKEposition

until engine runs smoothly and then fully into RUNposition.

If enginefalters,move chokeback outto 1/2-CHOKEposition

until engineruns smoothly andthento RUNposition.

NOTE:

If engine fires, but does not continueto run,movechokelever

to FULLCHOKEand repeatstartinginstructions.

iMPORTANT:Donotoverloadthe generator.Also, do not overload

individual panel receptacles.These outlets are protectedagainst

overload with push-to-reset-type circuit breakers. If amperage

rating of any circuit breakeris exceeded,that breakeropensand

electricaloutputtothat receptacleis lost.Read"Don't Overloadthe

Generator"carefully.

Figure 10- FuelShut-o#Valve

1o

Figure 11 - Engine ON/OFF Switch

ENGINE ON/OFF SWITCH

(PULL START ENGINES ONLY)

Figure 12 - Choke Position

CHOKELEVER

LEFT= CHOKE(START)

RIGHT= RUN

2.9 STARTINGELECTRICSTARTENGINES

Never start or stop engine with electrical

devices plugged into the receptacles AND

devices turned on.

1. Unplugall electrical loadsfrom the unit's receptaclesbefore

startingthe engine.

2. Make surethe unitis in a levelposition (notto exceed15° in

anydirection).

3. Openthefuel shut-off valve (Figures10).

4. Move engine CHOKEknoboutward to FULLCHOKEposition

(Figure12).

5. Tostart engine,press and hold the Start/Run/Stopswitch in

the"Start" position.Theenginewill crankandattemptto start.

Whentheenginestarts, releasethe switchto the run position.

.

Whenthe engine starts, move choke knob to "1/2 Choke"

position untilthe enginerunssmoothly andthenfully into the

"Run" position.If enginefalters, movechokeknobbackoutto

"1/2 Choke"position untiltheengine runssmoothly andthen

to "Run" position.

2.9.1 MANUALSTART

This generatoris alsoequippedwith a manualrecoilstarterwhich

may be usedif the batteryis discharged.

NOTE:

The switch must be in the RUN position. Use one of the

generator's receptacleoutlets along with the includedbattery

chargerto chargethe battery whilethe generator is running.

Tostart manually,firmly graspthe recoilhandleand pull slowly

until increasedresistance is felt. Pull rapidly up and away to

start engine.Thenfollow the samechoke sequence.

NOTE:

if enginefires, but does not continueto run,move chokelever

to FULLCHOKEand repeatstartinginstructions.

IMPORTANT:Donotoverloadthe generator.Also, do not overload

individual panel receptacles.These outlets are protectedagainst

overload with push-to-reset-type circuit breakers. If amperage

rating of any circuit breakeris exceeded,that breakeropensand

electricaloutputtothat receptacleis lost.Read"Don't Overloadthe

Generator"carefully.

2.10STOPPINGTHEENGINE

1. Shut off all loads, then unplug the electrical loads from

generatorpanel receptacles.Never start or stop the engine

with electricaldevicespluggedin andturnedon.

2. Let enginerun at no-load for severalminutesto stabilizethe

internaltemperaturesof engineand generator.

3. Move Run/Stopswitch to OFFposition.

4. Closefuelvalve.

2.11LOWOiLLEVELSHUTDOWNSYSTEM

Theengineis equippedwith a low oil levelsensorthat shutsdown

theengineautomaticallywhenthe oil leveldropsbelowa specified

level. If the engine shuts down by itself and the fuel tank has

enoughgasoline,checkengineoil level.

2.11.1 SENSINGLOWOILLEVEL

If the system senses a low oil levelduring operation,the engine

shuts down. Theenginewill not run untilthe oil has beenrefilled

to theproper level.

11

2.12CHARGINGTHEBATTERY(ELECTRICSTART

UNITSONLY)

Storage batteries give off explosive hydrogen

gas while recharging. An explosive mixture will

remain around the battery for a long time after

it has been charged. The slightest spark can

ignite the hydrogen and cause an explosion.

Such an explosion can shatter the battery and

cause blindness or other serious injury.

Do not permit smoking, open flame, sparks or

any other source of heat around a battery. Wear

protective goggles, rubber apron and rubber

gloves when working around a battery. Battery

electrolyte fluid is an extremely corrosive

sulfuric acid solution that can cause severe

burns. If spill occurs flush area with clear water

immediately.

NOTE:

Thebattery shippedwith the generator has been fully charged.

A battery may 10sesome of its chargewhen not in use for

pr0i0ngedperiodsof time. if the battery is unable to crankthe

engine, plugin the 12V chargerincludedin the accessorybox.

RUNNING THE GENERATOR DOES NOT CHARGE THE BATTERY.

Usebatterychargerplugto keepthe batterychargedandreadyfor

use. Batterychargingshouldbe done in a dry location.

1. Plugchargerinto "Battery ChargerInput"jack, locatedon the

control panel.Plug wall receptacleend of the batterycharger

into a 120 VoltACwalt outlet.

2. Unplugbatterychargerfrom walt outletand control paneljack

whengeneratoris goingto be in use.

NOTE:

Do not use the battery chargerfor more than48 hours at one

charge.

Figure13- Battery ChargerJack

BATTERY

CHARGER

iNPUT

3.1 PERFORMINGSCHEDULEDMAINTENANCE

It is importantto perform serviceas specifiedin the Maintenance

Schedulefor proper generatoroperation,and to ensurethat the

generatorcomplieswith the applicableemissionstandardsfor the

durationof its useful life.Serviceandrepairsmay be performedby

any capablepersonor repairshop. Additionally,emissionscritical

maintenancemust be performed as scheduled in order for the

Emissions Warrantyto be valid. Emissions critical maintenance

consists of servicing the air filter and spark plugs in accordance

with the MaintenanceSchedule.

3.2 MAINTENANCESCHEDULE

Follow the calendar intervals. More frequent service is required

whenoperatingin adverseconditionsnotedbelow.

CheckOilLevel AtEachUse

ChangeOil$ *Every100hoursorEverySeason

CheckValveClearance ***EverySeason

ServiceAirFilter ** Every200hoursorEverySeason

ReplaceSparkPlug EverySeason

:i: Changeoil after first 30 hours of operationthenevery season.

* Changeoiland oilfilter everymonthwhenoperatingunderheavyload or in high

temperatures.

** Clean more often under dirty or dusty operating conditions. Replaceair filter

parts if they cannot beadequatelycleaned.

*** Check valve clearance and adjust if necessary after first 50 hours of

operationand every 100 hours thereafter.

3.3 PRODUCTSPECIFICATIONS

3.3.1 GENERATORSPECIFICATIONS

RatedPower............................................................... 5.5/6.5/7.5 kW**

SurgePower....................................................... 6.875/8.125/9.375 kW

RatedACVoltage...................................................................... 120/240

RatedAC Load

Current@ 240V (5.5/6.5/7.5 kW)..................22.9/27.1/31.3 Amps**

Current@ 120V (5.5/6.5/7.5 kW)..................45.8/54.2/62.5 Amps**

RatedFrequency.................................................... 60 Hz@ 3600 RPM

Phase................................................................................ SinglePhase

** OperatingTemperatureRange: -18deg.C(0deg.F)to40Deg.C(104Deg.

F).Whenoperatedabove25deg.C(77deg.F)theremaybea decreasein

power.

** Maximumwattageandcurrentaresubjectto,andlimitedby,suchfactors

asfuelBtucontent,ambienttemperature,altitude,enginecondition,etc..

Maximumpowerdecreasesabout3.5%foreach1,000feetabovesealevel;

andwillalsodecreaseabout1%for each6° C(10° F)above16° C(60° F)

ambienttemperature.

3.3.2 ENGINESPECIFICATIONS

5.5/6.5kW

Displacement.............................................................................. 389 cc

SparkPlugType................................ NHSPLDF7TCor ChampionN9YC

SparkPlug PartNo........................................................... 0G84420101

SparkPlug Gap.............................0.028-0.031 inch or (0.70-0.80 mm)

GasolineCapacity..........................................25.6 L (6.77 U.S.gallons)

OilType.................. SeeChartin "Before Startingthe Generator"Section

OilCapacity................................................................. 1.0 L (1.06 Qts.)

RunTimeat 50% Load.............................................................10 Hours

12

7.5kW

Displacement............................................................................... 420cc

SparkPlugType................................ OhampionN9YOor NHSPLDF7TO

SparkPlug PartNo........................................................... 0G84420101

SparkPlug Gap.............................0.028-0.031 inch or (0.70-0.80 ram)

GasolineOapacity............................................28.4 L (7.5 U.S.gallons)

OilType.................. SeeOhartin "BeforeStartingthe Generator"Section

OilOapacity.......................................................... 1.0 Liters (1.06 Qts.)

RunTime (50%Load)..............................................................12 Hours

3.4 GENERALRECOMMENDATIONS

Thewarrantyof thegeneratordoes notcover itemsthat havebeen

subjectedto operator abuseor negligence.To receivefull value

from the warranty, the operator must maintain the generatoras

instructed inthis manual.

Some adjustmentswilt need to be made periodically to properly

maintainthegenerator.

All adjustmentsin the Maintenancesectionof this manualshould

be madeat leastonceeachseason.Followthe requirementsinthe

"MaintenanceSchedule".

NOTE:

Once a year replacethe spark plug and replacethe air filter.

A new spark plug and clean air filter assure properfuel-air

mixtureand helpthe engine runbetter and lastlonger.

3.4.1 GENERATORMAINTENANCE

Generatormaintenanceconsistsof keepingthe unitcleanand dry.

Operateand storethe unit in a cleandry environmentwhereit will

not be exposedto excessivedust,dirt, moistureor any corrosive

vapors.Coolingair slotsin thegeneratormustnot becomeclogged

with snow, leaves,or anyotherforeign material.

Checkthe cleanlinessof the generatorfrequentlyand cleanwhen

dust, dirt, oil, moistureor otherforeign substancesarevisible on

its exteriorsurface.

,&,CAUTION!

,_ Never insert any object or tool through the air

cooling slots, even if the engine is not running.

NOTE:

DONOTusea gardenhoseto cleangenerator. Water canenter

theenginefuel systemand causeproblems,in addition, ifwater

enters thegenerator throughcoolingair slots,somewaterwill

be retainedin voidsand crevicesof therotorand stator winding

insulation.Water and dirt buildup on the generator internal

windingswill eventually decreasetheinsulationresistanceof

thesewindings.

3.=/.2 TOCLEANTHEGENERATOR

* Usea dampcloth to wipe exteriorsurfaces clean.

. A soft, bristle brush may be usedto loosencaked on dirt, oil,

etc.

. A vacuumcleanermay be usedto pick up loosedirt anddebris.

. Low pressure air (not to exceed 25 psi) may be used to

blow away dirt. Inspect cooling air slots and openingson the

generator.Theseopeningsmustbekeptcleanandunobstructed.

3.4.3 ENGINEMAINTENANCE

When working on the generator, always

disconnect spark plug wire from spark plug and

keep wire away from spark plug.

3.4.4 CHECKINGOILLEVEL

Seethe "BeforeStartingtheGenerator"sectionfor informationon

checkingthe oil level.The oil levelshouldbe checkedbeforeeach

use, or at least every eight hours of operation. Keepthe oil level

maintained.

3.4.5 CHANGINGTHEOIL

Changethe oil after every 100 hours. If running this unit under

dirty or dusty conditions, or in extremelyhot weather,changethe

oil moreoften.

,A CAUTION!

,_Hot oil may cause burns. Allow engine to

cool before draining oil. Avoid prolonged

or repeated skin exposure with used oil.

Thoroughly wash exposed areas with soap.

Use thefollowing instructionsto changetheoil after the engine

coolsdown:

1. Cleanareaaroundoil drainplug.

2. Removeoil drain plugfrom engineand oil fill plug to drainoil

completelyinto a suitablecontainer.

3. When oil has completely drained, install oil drain plug and

tightensecurely.

4. Fill engine with recommendedoil. (See "Before Startingthe

Generator"for oil recommendations).

5. Wipeup anyspilledoil.

6. Disposeof usedoil at a propercollectioncenter.

3.4.6 REPLACINGTHESPARKPLUG

Use ChampionN9YCspark plug or equivalent.Replacetheplug

every 200 hours.This will help the engine start easier and run

better.

1. Stopthe engineand pull the spark plug wire off of the spark

plug.

2. Cleanthe area aroundthe spark plug and remove it from the

cylinder head.

3. Setthe spark plug'sgap to 0.70-0.80 mm (0.028-0.031 in.).

Installthe correctly gappedspark plug intothe cylinder head

(Figure14).

Figure 14 - Spark Plug Gap

13

3.4.7 BATTERYREPLACEMENT(IFAPPL/CABLE_

NOTE:

Thebattery shippedwith thegenerator hasbeenfully charged.

A battery may lose some of its chargewhen not in use for

prolongedperiodsof time. if the battery is unable to crank

the engine,plug in the 12V chargerincludedin the accessory

box (see the Charging a Battery section). RUNNING THE

GENERATORDOESNOTCHARGETHEBATTERY.Thepartnumber

forthis battery is 0Gg44g.

,A CAUTION!

,_The NEGATWE battery terminal should:

1. Always beDISCONNECTEDFIRST.

2. Alwaysbe CONNECTEDLAST.

Figure15- Battery Connections

RED(+)

BLACK(-)

3.5 SERVICEAIRFILTER

Theenginewill not run properlyand may be damagedif usinga

dirty air filter. Cleanthe air filter every 50 hours or once a year

(Figure16). Cleanor replacemore often if operatingunderdusty

conditions.Theair filter part numberis 0G84420151.

1. Removeairfilter cover.

2. Washinsoapywater.Squeezefilter dry incleancloth (DONOT

TWIST).

3. Cleanair filter cover beforere-installingit.

NOTE:

Toordera new air filter, pleasecontactthe nearestauthorized

service centerat 1-888-436-3722.

Figure 16- Air Filter

KNOBTOOPENAIR BOX

351 CLEANSPARKARRESTORSCREEN(CARB

MOOELS

The engineexhaustmuffler has a spark arrestor screen. Inspect

and cleanthe screenat least onceeachyear(Figure17). If unit is

usedregularly,inspectand cleanmoreoften.

//_lf using the generator on any forest=covered,

brush=covered or grass=covered unimproved

land, it must equipped with a spark arrestor.

The spark arrestor must be maintained in good

condition by the owner/operator.

Cleanandinspectthe sparkarrestorwhentheengineisat ambient

temperatureasfollows:

1. Remove the spark arrestor screen from the muffler by

looseningthe clamp andremovingthe screw.

2. Inspect screen and replace if torn, perforated or otherwise

damaged. DONOT USEa defective screen. If screen is not

damaged,cleanit with commercialsolvent.

3. Replacethe spark arrestor and secure with the clamp and

screw.

Figure 17 - Spark Arrestor Screen

14

Spark _'i

Arrestor_ i

Cone i_ Spark

..../Arrestor

_ Screen

C,amp

NOTE:

Toordera newair filteror sparkarrestorscreen,pleasecontact

thenearestauthorizedservicecenterat 1-800-333-1322,

3.6 VALVECLEARANCE

• Intake-- 0.15 _ 0.02mm (cold), (0.006" _ 0.0008" inches)

• Exhaust-- 0.20 _ 0.02mm (cold) (0.008" _ 0.0008" inches)

After the first 50 hours of operation, checkthe valve clearance

in the engine and adjustif necessary.

Important: If feelinguncomfortableaboutdoing this procedureor

theproper tools are not available,pleasetake the generatorto the

nearestservicecenterto havethevalveclearanceadjusted.This is

a very importantstepto ensurelongestlifefor theengine.

3.7 GENERAL

Thegeneratorshould be started at least once every 30 days and

be allowedto run at least 30 minutes. If this cannot be done and

the unit must be stored for morethan 30 days, use thefollowing

informationas a guideto prepareitfor storage.

NEVER store engine with fuel in tank indoors

or in enclosed, poorly ventilated areas where

fumes may reach an open flame, spark or pilot

light as on a furnace, water heater, clothes dryer

or other gas appliance.

,_Ailow unit to cool entirely before storage.

3.B LONGTERMSTORAGE

It is importantto preventgum depositsfrom forming in essential

fuel systemparts such asthe carburetor,fuel hoseor tank during

storage. Also, experience indicates that alcohol-blended fuels

(called gasohol,ethanolor methanol)can attract moisture,which

leadsto separationandformation of acids during storage.Acidic

gascan damagethefuel systemof an enginewhile in storage.

To avoid engine problems, the fuel system should be emptied

beforestorageof 30 daysor longer,asfollows:

1. Addaqualitygasolinestabilizertothefuelperthemanufacturer's

specifications,and run the unitfor 10-15 minutes.

2. After engine cools down, remove all gasolinefrom the fuel

tank. Use a commerciallyavailable, non-conductivevacuum

siphon.

Drain fuel into approved container outdoors,

away from open flame. Be sure engine is cool.

Do not smoke.

3. Start and run engineuntilenginestopsfrom lackof fuel.

4. After engine cools down, drain oil from engine. Refill with

recommendedgrade.

5. Remove spark plug and pour about 1/2 ounce (15 mt) of

engineoil intothecylinder.Coverspark plugholewith rag.Pull

the recoil starter a coupletimes to lubricatethe piston rings

and cylinder bore.A fogging agent can also be used in the

placeof oil.

ACAUTION!

,_Avoid spray from spark plug hole when

cranking engine.

6. Installandtightenspark plug.Donot connectsparkplugwire.

7. Cleanthe generatorouter surfaces. Check that cooling air

slots andopeningson generatorareopenand unobstructed.

8. Storethe unit in a clean, dry place.

3.9 OTHERSTORAGETiPS

• Do notstoregasolinefrom oneseasonto another.

• Replacethe gasolinecan if it starts to rust. Rustand/ordirt in

the gasolinewill cause problems with the carburetor and fuel

system.

• If possible,storethe unit indoorsandcoverit to giveprotection

from dust anddirt. BESURETOEMPTYTIdEFUELTANK.

• If it is not practicalto empty the fuel tank and the unit is to

be stored for some time, use a commercially availablefuel

stabilizer added to the gasoline to increase the life of the

gasoline.Runthe unitfor 10-15 minutes,turn off thefuelvalve

and allowto run untilenginestopsfrom lack of fuel.

• Coverthe unit with a suitable protective cover that does not

retainmoisture.

,_ NEVER cover the generator while engine and

exhaust areas are warm.

15

4.1TBOUBLESHOOTINGGUIDE

Engineis running,but no AC output

isavailable.

1. Circuitbreakeris open.

2. Poorconnectionor defectivecord set.

3. Connecteddeviceis bad.

4. Faultin generator.

1. Resetcircuit breaker.

2. Checkand repair.

3. Connectanotherdevicethat is in goodcondition.

4. ContactAuthorizedServiceFacility.

Engineruns well hut bogs down 1. Short circuit in a connectedload. 1. Disconnectshorted electricalload.

whenloadsare connected. 2. Generatoris overloaded. 2. See"Don't Overloadthe Generator".

3. Enginespeedis too slow. 3. ContactAuthorizedServiceFacility.

4. Shorted generatorcircuit. 4. ContactAuthorizedServiceFacility.

I I

Enginewill notstart;orstartsand

runsrough.

1. FuelShut-off is OFF.

2. Dirty airfilter.

3. Outof gasoline.

4. Stalegasoline.

5. Sparkplug wire not connectedto sparkplug.

1. TurnFuelShut-off ON.

2. Cleanor replaceairfilter.

3. Fillfuel tank.

4. Drainfuel tank andfill with fresh fuel.

5. Connectwire to sparkplug.

6. Badsparkplug.

7. Waterin gasoline.

8. Overchoking.

9. Low oil level.

10. Excessiverichfuel mixture.

11. Intakevalvestuck openor closed.

12. Enginehas lostcompression.

6. Replacespark plug.

7. Drainfuel tank;fill with fresh fuel.

8. Putchokeknobto No Chokeposition.

9. Fillcrankcaseto properlevel.

10. ContactAuthorizedServiceFacility.

11. ContactAuthorizedServiceFacility.

12. ContactAuthorizedServiceFacility.

= I

Engineshuts downduring 1. Outof gasoline. 1. Fillfuel tank.

operation. 2. Low oil level. 2. Fillcrankcaseto properlevel.

3. Faultin engine. 3. ContactAuthorizedServiceFacility.

m R

Enginelacks power. 1. Loadis too high. 1. Reduceload(see"Don't Overloadthe Generator").

2. Dirty airfilter. 2. Cleanor replaceairfilter.

3. Engineneedsto be serviced. 3. ContactAuthorizedServiceFacility.

= I

Engine"hunts" or falters. 1. Chokeis openedtoo soon. 1. Movechoketo halfway positionuntil engineruns

smoothly.

2. Carburetoris runningtoo rich or too lean. 2. ContactAuthorizedServiceFacility.

16

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