Coleman PM0555523 User Manual

Operator-Parts List Manual

Manuel de l’opérateur – Liste de pièces

Manual del operador – Lista de piezas

Vertex Series – ELECTRIC GENERATOR

Vertex Series – GÉNÉRATRICE ÉLECTRIQUE

Vertex Series – GENERADOR ELECTRICO

IMPORTANT – Please make certain that persons who are to use this equipment thoroughly read and understand these instructions prior to operation.

IMPORTANT – Veiller à ce que toute personne amenée à utiliser cet appareil lise soigneusement ces instructions et les comprenne avant de procéder à son utilisation.

IMPORTANTE – Favor de cerciorarse de que toda persona que use el generador Coleman Powermate lea y entienda todas las instrucciones antes de la operación.

Record the model and serial numbers of your Generator below:

Model No.			Serial No.
Inscrire les numéros de modèle et de série du génératrice :
Nº de modèle			Nº de série

Tome nota de lo números de serie y de modelo de su generador a

	continuación:
No. de modelo		No. de serie

HELPLINE 1-800-445-1805

Solamente Valido en E.U.A.

© Coleman Powermate, Inc. 0056014.05 12/02

TABLE OF CONTENTS

Safety and operation rules . . . . . . . . . . . . . . . . . . . . . . . . . . .	3	Low oil shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 8
Determining total wattage. . . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Electric start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 8
Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Basic wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 9
Generator features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Idle control operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
Assembly instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Idle control trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . .	10
Pre-start preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Service and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
Handle assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
Lifthook assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
Before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
Grounding the generator . . . . . . . . . . . . . . . . . . . . . . . . .	6	Inspecting the brushes . . . . . . . . . . . . . . . . . . . . . . . . .	11
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Exciting the generator . . . . . . . . . . . . . . . . . . . . . . . . . .	11
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
Generator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Engine carburetor icing . . . . . . . . . . . . . . . . . . . . . . . . .	11
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
Break-in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
Shutting the generator off . . . . . . . . . . . . . . . . . . . . . . . .	7	Service information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
Applying load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
Major features on control panel . . . . . . . . . . . . . . . . . . . . . . .	7	Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
50 amp power plug connection . . . . . . . . . . . . . . . . . . . .	8	Parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	38
Circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8

TABLE DES MATIÈRES

Régles d’opération et de sécurité . . . . . . . . . . . . . . . . . . . . .	13	Arrêt en cas de niveau d’huile . . . . . . . . . . . . . . . . . . . .	18
Détermination de la puissance . . . . . . . . . . . . . . . . . . . . . . .	14	Démarreur électrique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	19
Tension de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . . .	15	Schéma de câblage de base . . . . . . . . . . . . . . . . . . . . . . . .	19
Caracteristiques de la génératrice . . . . . . . . . . . . . . . . . . . .	15	Fonctionnement de la commande du ralenti . . . . . . . . . . . .	20
Instructions de montage . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16	Dépannage de la commande du ralenti . . . . . . . . . . . . . . . .	20
Préparatifs au démarrage . . . . . . . . . . . . . . . . . . . . . . . .	16	Entretien et remisage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
Montage de la poignée . . . . . . . . . . . . . . . . . . . . . . . . . .	16	Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
Montage du crochet de levage . . . . . . . . . . . . . . . . . . . .	16	Entretien . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
Avant de mettre en marche . . . . . . . . . . . . . . . . . . . . . . . . .	16	Génératrice balais. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
Mise à la terre de la génératrice . . . . . . . . . . . . . . . . . . .	16	Inspection des balais . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
Lubrification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16	S,rtçage de la génératrice. . . . . . . . . . . . . . . . . . . . . . . .	22
Carburant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16	Écran de thermique. . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
Fonctionnement de la génératrice . . . . . . . . . . . . . . . . . . . .	17	Moteur givrage du carburateur . . . . . . . . . . . . . . . . . . . .	22
Démarrage du moteur. . . . . . . . . . . . . . . . . . . . . . . . . . .	17	Entretien de la batterie . . . . . . . . . . . . . . . . . . . . . . . . . .	22
Rodage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17	Entretien du moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
Arrêt de la génératrice . . . . . . . . . . . . . . . . . . . . . . . . . .	17	Service à la clientèle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
Branchement des appareils . . . . . . . . . . . . . . . . . . . . . .	17	Garantie limitée . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
Caractéristiques principales du tableau de commande . . . .	17	Liste des composants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
Connexion de la fiche d’alimentation de 50 A. . . . . . . . .	18	Dessin des piéces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	38

Caractéristiques du dispositif de protection des circuits . 18

INDICE

Reglas de seguridad y de funcionamiento . . . . . . . . . . . . . . 24 Como determinar el vatage total . . . . . . . . . . . . . . . . . . . . . 25 El requerimiento de voltaje . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Características del generador . . . . . . . . . . . . . . . . . . . . . . . 26 Instrucciones de montaje . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Preparcion previa al arranque . . . . . . . . . . . . . . . . . . . . 27 Montaje del mango . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Montaje del gancho de elevacion . . . . . . . . . . . . . . . . . . 27 Antes de la operacion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Puesta a tierra del generador . . . . . . . . . . . . . . . . . . . . . 27 Lubricacion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Combustible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Operacion del generador . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Arranque del motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Procedimiento de arranque inicial . . . . . . . . . . . . . . . . . 28 Apagado del generador . . . . . . . . . . . . . . . . . . . . . . . . . 28 Cómo aplicar una carga . . . . . . . . . . . . . . . . . . . . . . . . . 28 Caracteristicas principales en el panel de control . . . . . . . . 28 Conexion del tomacorriente de 50 amperios . . . . . . . . . 29 Características CA del disyuntor del circuito . . . . . . . . . 29

Detencion por poca cantidad de aceite . . . . . . . . . . . . . 29 Arranque electrico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Diagrama de cableado basico . . . . . . . . . . . . . . . . . . . . . . . 30 Funcionamiento de control en vacio. . . . . . . . . . . . . . . . . . . 31 Deteccion de fallos de control en vacio . . . . . . . . . . . . . . . . 31 Servicio y almacenamiento. . . . . . . . . . . . . . . . . . . . . . . . . . 32 Instalacion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Generador escobillas . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Para revisar las escobillas . . . . . . . . . . . . . . . . . . . . . . . 33 Excitacion del generador . . . . . . . . . . . . . . . . . . . . . . . . 33 Escudo de calor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Motor congelamiento del carburador . . . . . . . . . . . . . . . 33 Mantenimiento de la bateria . . . . . . . . . . . . . . . . . . . . . . 33 Mantenimiento del motor . . . . . . . . . . . . . . . . . . . . . . . . 33

Inrormacion de servicio al cliente . . . . . . . . . . . . . . . . . . . . . 34 Garantía limitada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Lista de componentes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Diagrama de piezas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2

SAFETY AND OPERATION RULES

Safety precautions are essential when any mechanical equipment is involved. These precautions are necessary when using, storing, and servicing mechanical equipment. Using this equipment with the respect and caution demanded will considerably lessen the possibilities of personal injury. If safety precautions are overlooked or ignored, personal injury or property damage may occur.

The following symbols shown below are used extensively throughout this manual. Always heed these precautions, as they are essential when using any mechanical equipment.

This warning symbol identifies specific instructions or procedures which if not correctly followed could result in personal injury or death.

This caution symbol identifies specific instructions or procedures which, if not strictly observed, could result in damage to, or destruction of equipment.

This unit was designed for specific applications. It should not be modified and/or used for any application other than which it was designed. If there are any questions regarding its application, write or call Customer Service at 1-800-445-1805.

When using this product basic precautions should always be followed, including the following:

1.Read this manual carefully - know your equipment. Consider the applications, limitations, and the potential hazards specific to your unit.

2.Equipment must be placed on a firm, supporting surface.

3.Load must be kept within rating stated on generator nameplate. Overloading will damage the unit or shorten its life.

4.Engine must not be run at excessive speeds. Operating an engine at excessive speeds increases the hazard of personal injury. Do not tamper with parts which may increase or decrease the governed speed.

5.To prevent accidental starting, always remove the spark plug or cable from the spark plug before adjusting the generator or engine.

6.Units with broken or missing parts, or without protective housing or covers, should never be operated. Contact your service center for replacement parts.

7.Units should not be operated or stored in wet or damp conditions or on highly conductive locations such as metal decking and steel work. Always use rubber gloves and boots, and a ground fault current interrupter if these conditions may be present during use.

8.Keep the generator clean and free of oil, mud and other foreign matter.

9.Extension cords, power cords, and all electrical equipment must be in good condition. Never operate electrical equipment with damaged or defective cords.

10.Store the generator in a well ventilated area with the fuel tank empty. Fuel should not be stored near the generator.

11.Your generator should never be operated under these conditions:

a.Change in engine speed.

b.Electrical output loss.

c.Overheating in connected equipment.

d.Sparking.

e.Damaged receptacles.

f.Engine misfire.

g.Excessive vibration.

h.Flame or smoke.

i.Enclosed compartment.

j.Rain or inclement weather.

12.Check the fuel system periodically for leaks or signs of deterioration such as chafed or spongy hose, loose or missing clamps, or damaged tank or cap. All defects should be corrected before operation.

13.The generator should be operated, serviced, and refueled only under the following conditions:

a.Good ventilation - avoid areas where vapors may be trapped such as pits, basements, cellars, excavations, and boat bilges. Air flow and temperatures are important for air cooled units. Temperatures should not exceed 100 degrees F (40 degrees C).

b.Dangerous exhaust gases should be piped from enclosed areas. The engine exhaust contains carbon monoxide, a poisonous, odorless, invisible gas which, if breathed, causes serious illness and possible death.

c.Refuel the generator in a well lighted

area. Avoid fuel spills and never refuel while the generator is running. Allow engine to cool for two minutes prior to refueling.

d.Do not refuel near open flames, pilot lights, or sparking electrical equipment such as power tools, welders, and grinders.

e.The muffler and air cleaner must be installed and in good condition at all times as they function as flame arresters if backfiring occurs.

f.Do not smoke near the generator.

14.Ensure that generator is properly grounded. (See “Grounding the generator” section in this manual.)

English		3

15.Do not wear loose clothing, jewelry, or anything that may be caught in the starter or other rotating parts.

16.Unit must reach operating speed before electrical loads are connected. Disconnect loads before turning off engine.

17.To prevent surging that may possibly damage equipment, do not allow engine to run out of fuel when electrical loads are applied.

18.When powering solid state equipment, a

Power Line Conditioner should be used to avoid possible damage to equipment. (See Caution Statement on this page.)

19.Do not stick anything through ventilating slots, even when the generator is not operating. This can damage the generator or cause personal injury.

20.Before transporting the generator in a vehicle, drain all fuel to prevent leakage that may occur.

21.Use proper lifting techniques when transporting the generator from site to site. Improper lifting techniques may result in personal injury.

DETERMINING TOTAL WATTAGE

In order to prevent overloading and possible damage to your generator it is necessary to know the total wattage of the connected load. To determine which tools and/or appliances your generator will run follow these steps:

1.Determine if you want to run one item or multiple items simultaneously.

2.Check wattage requirements for the items

you will be running by referring to the load’s nameplate or by calculating it (multiply amps x volts = watts).

3.Total the watts for each item. If the nameplate

only gives volts and amps, multiply volts x amps = watts.

1 KW = 1,000 watts.

4.Motorized appliances or tools require more than their rated wattage for start up.

NOTE: Allow 2 1/2 to 3 1/2 times the listed wattage for starting equipment powered by electric motors.

5.The generator’s rated watts should match or exceed the total number of watts required for the

equipment you want to run.

6.Always connect the heaviest load to the generator first, then add other items one at a time.

22.To avoid burns, do not touch engine muffler or other engine or generator surfaces which became hot during operation.

SPARK ARRESTING MUFFLER

THIS PRODUCT IS NOT EQUIPPED WITH A SPARK ARRESTING MUFFLER. If the product will be used around flammable materials, such as agricultural crops, forests, brush, grass, or other similar items, then an approved spark arrester should be installed and is legally required in the State of California. The California statutes requiring a spark arrester are Sections 13005(b), 4442 and 4443. Spark Arresters are also required on some U.S. Forest Service land and may also be legally required under other statutes and ordinances. An approved spark arrester is available from your Coleman Powermate dealer, or may be ordered from Coleman Powermate, Inc., P.O. Box 6001, Kearney, Nebraska 68848. 1-800-445-1805.

OPERATING VOLTAGE

CAUTION: Operating voltage and frequency requirement of all electronic equipment should be checked prior to plugging them into this generator. Damage may result if the equipment is not designed to operate within a +/- 10% voltage variation, and +/- 3 hz frequency variation from the generator name plate ratings. To avoid damage, always have an additional load plugged into the generator if solid state equipment (such as a television set) is used. A power line conditioner may also be necessary for some solid state applications.

Typical example of solid state equipment include: Garage door openers

Kitchen appliances with digital displays Televisions

Stereos

Personal computers Quartz clocks Copy machines

Telephone equipment

For more information, contact our Customer Service Department at 1-800-445-1805.

4		English

GENERATOR FEATURES

5

English

ASSEMBLY INSTRUCTIONS		BEFORE OPERATION

PRE-START PREPARATION

Before starting the generator, check for loose or missing parts and for any damage which may have occurred during

shipment.
List of loose parts:
(A) Handle -1	(D) Lift hook -1
(B) 1/4” nyloc nut -6	(E) 1/4-20 x 2.0” bolts - 2
(C) 1/4-20 x 1.5” bolts -2	(F)1/4-20 Curved Hd Blt - 2

WARNING: This generator must not be operated without all factory installed

shields in place. Failure to comply may cause personal injury or damage to the generator.

HANDLE ASSEMBLY

Tools Required: Two 7/16” wrenches or an adjustable wrench (cresent).

1.Insert the handle (A) into the upright tube frames as shown in the diagram.

2.Align the holes in the inner and outer tubes. Insert the 1/4 - 20 x 1.5” bolts (C) through the tubes.

3.Thread the 1/4” nyloc nuts (B) onto the bolts and tighten.

LIFT HOOK ASSEMBLY

Certain models include a lift hook for hoist assisted lifting. If your model includes this feature, assemble as follows:

1.Align the holes in the lift hook (D) with the holes in the top frame.

2.Insert the 1/4 - 20 curved Head bolts (F) through the frame and lifthook as shown in the diagram.

3.Insert two 1/4-20 x 2.0” bolts (E) through the front of the frame and the lifthook, as shown in the diagram.

4.Thread the 1/4” nyloc nut (B) onto all the bolts and tighten.

GROUNDING THE GENERATOR

The National Electric Code requires that this product be properly connected to an appropriate earth ground to help prevent electric shock. A ground terminal bolted to the frame of the generator has been provided for this purpose. Connecting a length of heavy gauge (12 AWG min.) copper wire between the generator Ground Terminal and a copper rod driven into the ground should provide a suitable ground connection. However, consult with a local electrician to insure that local codes are being adhered to.

WARNING: Do not use a pipe carrying combustible material as the ground source.

Generator

Ground Lug

LUBRICATION

DO NOT attempt to start this engine without filling the crank case with the proper amount and type of oil. (See the accompanying engine manual for this information.) Your generator has been shipped from the factory without oil in the crankcase. Operating the unit without oil will damage the engine.

FUEL

Fill the tank with clean, fresh unleaded automotive gasoline. Regular grade gasoline may be used provided a high octane rating is obtained (at least 85 pump octane).

CAUTION: Do not overfill the tank. Keep maximum fuel level 1/4 inch below the top of the fuel tank. This will allow expansion in hot weather and prevent overflow.

WARNING: Gasoline is very dangerous. Serious injury may result from fire caused by gasoline contacting hot surfaces.

1.Do not fill fuel tank with engine running.

2.Do not spill fuel while refilling tank.

3.Do not mix oil with gasoline.

6		English

PC0557523.8 & PC0555523.01

PM0557523.9 & PM0555523

PM0558023

GENERATOR OPERATION		MAJOR FEATURES on CONTROL PANEL

STARTING THE ENGINE

1.Check oil level and fuel.

2.Disconnect all electrical loads from the unit.

3.Adjust choke as necessary.

4.Set the engine switch to the “ON" position.

5.On electric start models, turn the key switch to “START”. Release key switch after the engine starts. As the engine warms up, readjust the choke.

WARNING: Provide adequate ventilation for toxic exhaust gases and cooling air flow.

BREAK-IN PROCEDURE

Controlled break-in helps insure proper engine and generator operation. Follow engine procedure outlined in engine manual.

CAUTION: Do not apply heavy electrical load during break-in period (the first two to three hours of operations).

CAUTION: Allow generator to run at no load for five minutes upon each initial start-up to permit engine and generator to stabilize.

SHUTTING THE GENERATOR OFF

1.Remove entire electrical load.

2.Let the engine run for a few minutes without load.

3.Move the engine switch to the “OFF” position. (Turn the key switch to “OFF” on the electric start models).

4.Do not leave the generator until it has completely stopped.

5.Let unit completely cool prior to applying any protection covers.

APPLYING LOAD

This unit has been pretested and adjusted to handle its full capacity. When starting the generator, disconnect all load. Apply load only after generator is running. Frequency and voltage are automatically regulated for correct output. Do not attempt to adjust engine speed.

CAUTION: When applying a load, do not exceed the maximum wattage rating of the generator when using one or more receptacles. Also, do not exceed the amperage rating of any one receptacle.

A.120 V/20 Ampere Duplex Receptacle

NOTE: PC models use 120V/15 Ampere Duplex

Receptacles

There are five receptacles on the control panel. These receptacles may be used in any combination provided that the total wattage supplied by all receptacles at one time does not exceed the name plate wattage rating of the generator.

There are two - 120 volt 20 amp duplex receptacles (A) and one 120/240 volt high

power receptacle (B). Do not draw more than 20 amps from any one of the four 120 volt receptacles

(A). Also, if more than one of the four receptacles are used at the same time, the load should be split between the left and right duplexes.

The high power receptacle (B) should be used to connect 240 volt loads or high amperage 120 volt loads. (refer to power cord connections to determine proper connection to this receptacle.)

B. 120/240 Volt Heavy Duty Receptacle

This receptacle is rated for the maximum output of the PM series units. PC series uints have 30 amp rated receptacles. If this receptacle is used along with the 120 volt receptacles, the total load drawn must not exceed the nameplate ratings.

C. and F. Circuit Breakers

All receptacles are protected by an AC circuit breaker. (See Circuit Protection).

D.Idle Control Switch

Some models are equipped with an idle control switch. (See Idle Control).

E. Key Start

	Used on electric start models.
	H. CordKeeper™
		Proper Use Of
	The CordKeeper™ is a
		CordKeeper™
	unique feature used to prevent
	plugs from being pulled out of the
	120-volt receptacles.

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50 AMP POWER PLUG CONNECTION

120-Volt Connection

ELECTRIC START

An “Off-On-Start” rotary key switch is provided on the control panel. All necessary wiring is provided. The battery is not included - must be purchased separately. To ensure reliable starting in the winter, Coleman recommends a 12V battery with a minimum of 235 cold cranking amps.

A battery compartment is provided on all electric start models. Selected models also include a battery. To install the battery and the battery pan in the battery panel, place the battery belt laying on the panel and pan (as shown in the diagram). Check to insure the battery pan is hooked over the panel face and setting entirely on the lower shelf. After placing the battery in the opening, connect the belt around the battery.

240-Volt Connection

Battery Panel

The above plug wiring diagrams depict a floating neutral connection which is required in some localities. Check with your electrician to determine proper grounding requirements. If a grounded neutral connection is desired a jumper should be installed between the white neutral connection and the green ground connection in the plug.

CIRCUIT PROTECTION AC FEATURES

The receptacles are protected by AC circuit breakers. If the generator is overloaded or an external short circuit occurs, a circuit breaker will trip. If this occurs, disconnect all electrical loads and try to determine the cause of the problem before attempting to use the generator again. If overloading causes the circuit breaker to trip, reduce the load. NOTE: Continuous tripping of the circuit breaker may cause damage to generator or equipment. The circuit breaker may be reset by pushing the button of the breaker or moving the arm on 2 pole breakers to “ON” position if so equipped.

LOW OIL SHUTDOWN

All units are equipped with low oil shutdown. If the oil level becomes lower than required, the generator set will automatically shut off. This protects your generator set from operating without proper lubrication.

If generator shuts off and the oil level is according to specifications, check to see if generator is sitting at an angle that forces oil to shift. Place on an even surface to correct this. If engine fails to start, the oil level may not be sufficient to deactivate low oil level switch. Be sure the sump is completely full of oil.

NOTE: Maximum incline degree of the generator set cannot be more then 25° from horizontal.

Battery Pan

Battery Belt

#8 AWG (American Wire Gauge) copper wire lead with ring terminals make battery hookup quite simple. Connect the black lead hooked to the chassis to the negative (-) battery terminal and the red lead from the starter solenoid to the positive (+) battery terminal with the provided bolts, lock washers and nuts. Place the red terminal cover securely over the positive battery terminal. Insure that each battery cell contains the proper amount of fluid.

WARNING: Batteries contain sulfuric acid (when filled) and may emit explosive gasses. Always abide by safety warnings provided with the battery.

-Keep sparks, flame and cigarettes away.

-Hydrogen gas is generated during charging and discharging.

-Always shield eyes, protect skin and clothing when working near batteries.

The engine contains an internal battery charger which is connected to the positive (Red) battery lead. Battery charging will occur when the engine is running.

CAUTION: Do Not allow the positive (Red) battery terminal to come in contact with any metal parts of the unit. Engine or battery damage may result.

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BASIC WIRING DIAGRAM (Electric Start Models)

IDLE CONTROL OPERATION

The Idle Control circuit is designed to extend engine life and improve fuel usage by slowing the engine down to approximately 2700 RPM in a “No Load” condition. The noise is also greatly reduced during this condition.

When power is required from the generator an electronic control module automatically senses current flow in the electrical outlet and allows the engine to return to full speed or standard operating condition. Likewise, when the load is removed, the generator will automatically return to the idle condition after a 4-5 second delay.

A convenient switch is mounted in the control panel for easy access and will disable the Idle Control circuitry when in the off position.

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IDLE CONTROL TROUBLE SHOOTING

PROBLEM		POSSIBLE CAUSE				SOLUTION
Unit will not idle		Control panel switch not on				Turn to idle on position
		Load plugged into receptacle				Unplug load
		Poor connection or faulty cord				Check & repair
		Defective I.C. module;				Replace
		Defective electro-magnet;
		Defective stator				Call Product Services, 1-800-445-1805
Unit idles even with load plugged in		Load not heavy enough				Turn idle switch to off position
						Increase load
		Defective I.C. module				Replace
						Call Product Services, 1-800-445-1805
Unit tries to idle but won’t stay latched		Electro-magnet or solenoid position				Reset magnet or solenoid position for
		incorrect				2700 RPM idle speed
						Consult dealer
		Flapper bracket loose or bent				Tighten or straighten
						Replace flapper. Readjust to 2700 RPM
		Engine not running smoothly				Adjust carburetor
						Call Product Services, 1-800-445-1805
SERVICE AND STORAGE					INSTALLATION

INFREQUENT SERVICE

If the unit is used infrequently, difficult starting may result. To eliminate hard starting, run the generator at least 30 minutes every month. Also, if the unit will not be used for some time, it is a good idea to drain the fuel from the carburetor and gas tank.

LONG TERM STORAGE

When the generator set is not being operated or is being stored more than one month, follow these instructions:

1.Replenish engine oil to upper level.

2.Drain gasoline from fuel tank, fuel line and carburetor.

3.Pour about one teaspoon of engine oil through the spark plug hole, pull the recoil starter several times and replace the plug. Then pull the starter until you feel the piston is on its compression stroke and leave it in that position. This closes both the intake and exhaust valves to prevent the inside of the cylinder from rusting.

4.Cover the unit and store in a clean, dry place that is well ventilated away from open flame or sparks.

NOTE: The use of a fuel additive, such as Coleman

Powermate Generator Fuel Additive®, or an equivalent, will minimize the formulation of fuel gum deposits during storage. Such an additive may be added to the gasoline in the fuel tank of the engine, or to the gasoline in a storage container.

WARNING: To avoid possible personal injury or equipment damage, a registered electrician or an authorized service representative should perform installation and all service. Under no circumstances should an unqualified person attempt to wire into an utility circuit.

To avoid backfeeding into utility systems, isolation of the residence electrical system is required.

Before temporary connection of the generator to the residence electrical system, turn off the main switch.

If your generator is to be used as a stand-by power source in case of utility power failure, it should be installed by a registered electrician and in compliance with all applicable local electrical codes.

Proper use requires that a double throw transfer switch be installed by a licensed qualified electrician so that the building's electrical circuits may be safely switched between utility power and the generator's output, thereby preventing backfeed into the power utility's electrical system.

WARNING: To avoid backfeeding into utility systems, isolation of the residence electrical system is required. Before temporary connection of a generator to the residence electrical system turn off the main switch. Before making permanent connections a double throw transfer switch must be installed. To avoid electrocution or property damage, only a trained electrician should connect generator to residence electrical system. California law requires isolation of the residence electrical system before connecting a generator to residence electrical systems.

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MAINTENANCE

GENERATOR: Brushes

The brushes in the generator should be inspected once every year for chips and cracks. Brushes should be replaced when they are worn to 1/4 inch (7mm).

NOTE: Replace brushes in sets only, never separately.

INSPECTING THE BRUSHES

Tip unit as shown to access the endbell. Place a block under the handle to prevent damage to the fuel tank.

1.Remove cover plate (A).

2.Remove 4 stator bolts (B) and endbell.

3.Disconnect the green (-) or blue (+) brush wires from the tab.

4.Remove brush mounting screws (C).

5.Slide brushes (D) from holders.

6.Replace if worn to 1/4 inch (7mm).

7.Do not over tighten screws.

NOTE: Replace only with brushes specified in parts list. Other brushes may appear to be identical but may have completely different mechanical and electrical characteristics.

EXCITING THE GENERATOR

If there is a loss of residual magnetism (voltage will not build up), it may be necessary to re-excite the unit.

1.Use a 6-volt lantern battery (dry cell).

2.Remove the brush cover.

3.Attach the "-" lead of the battery to the negative brush. Very briefly, touch the "+" lead of the battery to the positive brush as shown.

4.Replace the brush cover, tip the generator to an

upright position and start the engine. Measure output voltage by using a plug-in voltmeter. If voltage is not present, turn the engine off and repeat the excitation procedure.

HEAT SHIELD

Inspect to ensure that all heat shields and heat deflectors are intact and in place.

ENGINE: Carburetor Icing

During the winter months, rare atmospheric conditions may develop which will cause an icing condition in the carburetor. If this develops, the engine may run rough, loose power, and may stall. This temporary condition can be overcome by deflecting some of the hot air from the engine over the carburetor area.

WARNING: If a deflector is used, it must be made of metal.

BATTERY MAINTENANCE

Read all cautions and warnings provided by the battery manufacturer before doing maintenance on your battery.

For Batteries with Filler Openings: Check battery fluid level by removing the filler caps. If necessary, fill the battery with distilled water to the indicator fill level only.

Use a terminal post brush to clean the battery terminal posts and terminals. Good, clean terminals are necessary for good contact.

ENGINE MAINTENANCE

NOTE: Refer to the engine manufacturer's manual for service and maintenance of the engine.

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SERVICE INFORMATION		LIMITED WARRANTY
		(NOT VALID IN MEXICO)

CONTACT THE COLEMAN POWERMATE CUSTOMER SERVICE DEPARTMENT AT 1-800-445-1805

to obtain warranty service information or to order replacement parts or accessories.

HOW TO ORDER REPLACEMENT PARTS

Even quality built equipment such as the Coleman Powermate electric generator you have purchased, might need occasional replacement parts to maintain it in good condition over the years. To order replacement parts, please give the following information:

1.Model No. and Serial No. and all specifications shown on the Model No./Serial No. plate.

2.Part number or numbers as shown in the Parts List section of this manual.

3.A brief description of the trouble with the generator.

NOTE: If replacement parts are required for the engine, contact one of the engine manufacturer's service centers.

Coleman Powermate, Inc.

ATTN: Customer Service Department

P. O. Box 6001

Kearney, NE 68848

This product is warranted by Coleman Powermate, Inc. to the original retail consumer against defects in material and workmanship for a period of two (2) years from the date of retail purchase and is not transferable. This two year warranty applies only to products used in consumer applications. If these generators are used in a commercial application, then the period of warranty coverage is limited to one (1) year from the date of purchase.

Please complete and return the enclosed Customer Information Card so that we can reach you in the unlikely event a safety recall is needed. Return of this card is not required to validate this warranty.

WHAT IS COVERED: Replacement parts and labor.

WHAT IS NOT COVERED: Transportation charges to Coleman Powermate, Inc. for defective products. Transportation charges to consumer for repaired products. Brushes, rubber feet, and receptacles. Damages caused by abuse, accident, improper repair, or failure to perform normal maintenance. Power units or engines which are covered exclusively by the warranties of their manufacturer. Sales outside of the United States and Canada. Any other expense including consequential damages, incidental damages, or incidental expenses, including damage to property. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

IMPLIED WARRANTIES: Any implied warranties, including the Implied Warranties of Merchantability and Fitness For A Particular Purpose, are limited in duration to one (1) year from the date of retail purchase. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

HOW TO OBTAIN WARRANTY PERFORMANCE:

Replacement parts and service are available from Coleman Powermate, Inc. Service Centers. Locate your nearest Service Center by calling TOLL FREE 1-800-445-1805. In the unlikely event a Service Center can not be located you may call Coleman Powermate, Inc. for a return authorization number.

Any unit returned WITHOUT an authorization number will be refused.

To the extent any provision of this warranty is prohibited by federal, state, or municipal law, and cannot be preempted, it shall not be applicable. This warranty gives you specific rights, and you may also have other rights which vary from state to state.

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RÉGLES D’OPÉRATION ET DE SÉCURITÉ

Les mesures de sécurité sont des éléments essentiels lorsqu’il s’agit d’équipement mécanique. Ces mesures sont nécessaires lorsqu’on utilise, range et fait l’entretien d’équipement mécanique. Le fait d’utiliser cet équipement avec le respect et les précautions voulus permettra de diminuer considérablement les risques de blessures corporelles. Si on ignore ou néglige les mesures de sécurité, il pourrait en résulter des blessures ou des dommages matériels.

Les symboles suivants sont utilisés fréquemment dans l’ensemble de ce manuel. Il faut tenir compte de ces précautions en tout temps, car elles sont essentielles lors de l’utilisation de tout équipement mécanique.

Ce symbole de danger identifie des instructions ou des procédures précises qui peuvent éviter des blessures et même mort si on les suit correctement.

Ce symbole de mise en garde identifie des instructions ou des procédures précises qui peuvent éviter, si on les observe, des dommages à l’appareil et même sa destruction.

Cet appareil a été conçu pour des applications précises. Il ne doit être ni modifié, ni utilisé pour une application autre que celles pour lesquelles il a été conçu. En cas de questions quant à l’application, écrire au Service à la clientèle ou composer le 1-800-445-1805.

Lors de l’utilisation de ce produit, il faut respecter certaines précautions de base, dont les suivantes:

1.Lire attentivement ce manuel; apprendre à connaître l’équipement. Tenir compte

des applications, limites et dangers possibles de l’appareil.

2.Placer l’équipement sur une surface de support solide.

3.La charge doit être maintenue dans les normes spécifiées sur la plaque signalétique de la génératrice. Toute surcharge abîme la génératrice et en raccourcit sa durée de vie utile.

4.Le moteur ne doit pas tourner à des vitesses excessives, car cela fait augmenter les risques de blessures corporelles. N’effectuer aucune intervention non autorisée sur les pièces qui font augmenter ou diminuer la vitesse régulée.

5.Afin d’empêcher les démarrages imprévus, toujours enlever la bougie ou le câble de la bougie avant de régler la génératrice ou le moteur.

6.Un appareil dont les pièces sont cassées, auquel il manque des pièces ou qui n’a pas de boîter ou de couvercle protecteur ne doit en aucun cas être utilisé. Communiquer avec le centre de service après-vente pour obtenir des pièces de rechange.

7.Ne pas faire fonctionner ou remiser l’appareil dans un endroit humide ni sur une surface mouillée, ni dans un endroit où il sera en contact avec des surfaces conductrices, telles que des supports métalliques ou des charpentes en acier.

Toujours porter des gants et des bottes en caoutchouc et utiliser un disjoncteur de fuite à la terre si de telles conditions sont présentes.

8.Garder la génératrice propre et libre de toute huile, boue ou autre corps étranger.

9.Les rallonges, les cordons d’alimentation et tout appareil électrique doivent être en bon état. Ne jamais faire fonctionner un appareil électrique dont le cordon d’alimentation est abîmé ou défectueux.

10.Ranger la génératrice dans un endroit bien ventilé en s’assurant que le réservoir est vide. Il ne faut pas ranger d’essence àproximité de la génératrice.

11.Il ne faut jamais utiliser la génératrice dans les conditions suivantes :

a.Un changement de vitesse du moteur.

b.Perte de puissance électrique.

c.Surchauffe d’appareils branchés.

d.Jaillissement d’étincelles.

e.Prises endommagées.

f.Le moteur a des ratés.

g.Vibrations excessives.

h.Flammes ou fumée.

i.Endroit clos.

j.Pluie ou température défavorable.

12.Vérifier le système de carburant régulièrement pour toute fuite ou signes de détérioration, tels qu’un tuyau spongieux ou usé, une bride desserrée ou manquante ou un réservoir ou couvercle endommagé. On doit corriger ces problèmes avant de faire fonctionner l’appareil.

13.Faire fonctionner l’appareil, le réparer ou faire le plein uniquement dans les conditions suivantes :

a.Une bonne ventilation - éviter les endroits où les vapeurs peuvent être immobilisées, comme dans des fosses, sous-sols, caves, trous et dans le fond d’un bateau. La circulation de l’air et la température ambiante sont importantes pour les appareils refroidis par air. La température ne devrait pas dépasser 40° C (100° F).

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