Honeywell 6039 User Manual
Owner's Manual
Portable Generator
1-855-GEN-INFO or www.honeywellgenerators.com
DEADLY EXHAUST FUMES! ONLY use OUTSIDE
far away from windows, doors and vents!
NOT INTENDED FOR USE IN CRITICAL LIFE
SUPPORT APPLICATIONS.
SAVE this Manual. Provide this manual to any
operator of the generator.
Table of Contents
Introduction ............................................................. 1
Read this Manual Thoroughly ................................. 1
Safety Rules ........................................................... 1
Standards Index .............................................................3
General Information ................................................ 4
1.1 Unpacking ......................................................................4
1.1.1 Accessory Box ..................................................4
1.2 Assembly .......................................................................4
1.2.1 Assembling the Accessory Kit............................4
1.2.2 Battery Cable Connection (Electric Star t Only) ....5
Operation ................................................................ 5
2.1 Know the Generator .......................................................5
2.2 Connection Plugs ...........................................................6
2.2.1 120 VAC, 20 Amp, Duplex Receptacle ...............6
2.2.2 120 VAC, 20 Amp, GFCI Duplex Receptacle .......6
2.2.3 120/240 VAC, 30 Amp, Receptacle ....................7
2.3 How to Use the Generator ..............................................7
2.3.1 System Ground ..................................................7
2.3.2 Grounding the Generator ....................................7
2.3.3 Connecting Electrical Loads ...............................8
2.4 Don’t Overload the Generator ..........................................8
2.5 Wattage Reference Guide ...............................................8
2.6 Before Starting the Generator .........................................9
2.6.1 Adding Engine Oil ..............................................9
2.6.2 Adding Gasoline .................................................9
2.7 Starting Pull Start Engines ............................................10
2.8 Starting Electric Start Engines ......................................10
2.9 Stopping the Engine .....................................................11
2.10 Low Oil Level Shutdown System ..................................11
2.10.1 Sensing Low Oil Level ......................................11
2.11 Charging the Battery (Electric Start Units Only) .............11
Maintenance ......................................................... 11
3.1 Performing Scheduled Maintenance .............................11
3.2 Maintenance Schedule .................................................12
3.3 Product Specifications ..................................................12
3.3.1 Generator Specifications ..................................12
3.3.2 Engine Specifications .......................................12
3.3.3 Emissions Information .....................................12
3.4 General Recommendations ...........................................12
3.4.1 Generator Maintenance ....................................13
3.4.2 To Clean the Generator .....................................13
3.4.3 Engine Maintenance .........................................13
3.4.4 Checking Oil Level ...........................................13
3.4.5 Changing the Oil ..............................................13
3.4.6 Replacing the Spark Plug .................................13
3.4.7 Battery Replacement ........................................13
3.5 Service Air Filter ...........................................................14
3.5.1 Clean Spark Arrestor Screen (CARB models) ...14
3.6 Valve Clearance ............................................................15
3.7 General ........................................................................15
3.8 Long Term Storage .......................................................15
3.9 Other Storage Tips .......................................................15
Troubleshooting .................................................... 16
4.1 Troubleshooting Guide ..................................................16
Notes .................................................................... 17
Warranty ............................................................... 18
Introduction
Thank you for purchasing this Honeywell model portable generator
by Generac Power Systems, Inc. This model is a compact, high
performance, air-cooled, engine driven generator designed to
supply electrical power to operate electrical loads where no utility
power is available or in place of utility due to a power outage.
If any portion of this manual is not understood, contact the
nearest Authorized Dealer for starting, operating and servicing
procedures.
The operator is responsible for proper and safe use of the
equipment. We strongly recommend that the operator read this
manual and thoroughly understand all instructions before using the
equipment. We also strongly recommend instructing other users to
properly start and operate the unit. This prepares them if they need
to operate the equipment in an emergency.
The generator can operate safely, efficiently and reliably only if it
is properly located, operated and maintained. Before operating or
servicing the generator:
Become familiar with and strictly adhere to all local, state and
national codes and regulations.
Study all safety warnings in this manual and on the product
carefully.
Become familiar with this manual and the unit before use.
The manufacturer cannot anticipate every possible circumstance
that might involve a hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive.
If using a procedure, work method or operating technique that the
manufacturer does not specifically recommend, ensure that it is
safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
THE INFORMATION CONTAINED HEREIN WAS BASED ON
MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION.
GENERAC RESERVES THE RIGHT TO MODIFY THIS MANUAL AT
ANY TIME.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or
carelessly. Observe them carefully. Their definitions are as
follows:
INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF
NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation or action which, if not
avoided, could result in minor or moderate injury.
NOTE:
Notes contain additional information important to a procedure
and will be found within the regular text body of this manual.
These safety warnings cannot eliminate the hazards that they
indicate. Common sense and strict compliance with the special
instructions while performing the action or service are essential to
preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
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.
This symbol points out potential fire hazard.
This symbol points out potential electrical
shock hazard.
GENERAL HAZARDS
NEVER operate in an enclosed area, in a vehicle, or indoors
EVEN IF doors and windows are open.
For safety reasons, the manufacturer recommends that the
maintenance of this equipment is carried out by an Authorized
Dealer. Inspect the generator regularly, and contact the nearest
Authorized Dealer for parts needing repair or replacement.
Operate generator only on level surfaces and where it will not be
exposed to excessive moisture, dirt, dust or corrosive vapors.
Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving parts. Never remove any fan guard or shield
while the unit is operating.
Certain parts of the generator get extremely hot during
operation. Keep clear of the generator until it has cooled to
avoid severe burns.
Do NOT operate the generator in the rain.
Do not alter the construction of the generator or change controls
which might create an unsafe operating condition.
Never start or stop the unit with electrical loads connected
to receptacles AND with connected devices turned ON. Start
the engine and let it stabilize before connecting electrical
loads. Disconnect all electrical loads before shutting down the
generator.
Do not insert objects through the unit’s cooling slots.
When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
1
Safety Rules
Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in
dangerous operating conditions from leaking exhaust gases,
fuel leakage, oil leakage, etc.
On electric start models, disconnect the POSITIVE (+) battery
cable from the engine starter OR the NEGATIVE (-) battery
cable from the battery terminal, whichever is easier, before
transporting the generator.
EXHAUST & LOCATION HAZARDS
• NEVER operate in an enclosed area or indoors! NEVER use in
the home, 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.
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.
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.
Always use a battery operated carbon monoxide alarm indoors,
installed according to the manufacturers instructions.
If you star t to feel sick, dizzy, or weak after the generator has
been running, move to fresh air IMMEDIATELY. See a doctor, as
you could have carbon monoxide poisoning.
ELECTRICAL HAZARDS
The generator produces dangerously high voltage when in
operation. Avoid contact with bare wires, terminals, connections,
etc., while the unit is running, even on equipment connected
to the generator. Ensure all appropriate covers, guards and
barriers are in place before operating the generator.
Never handle any kind of electrical cord or device while
standing in water, while barefoot or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
The National Electric Code (NEC) requires the frame and external
electrically conductive parts of the generator be properly
connected to an approved earth ground. Local electrical codes
may also require proper grounding of the generator. Consult
with a local electrician for grounding requirements in the area.
Use a ground fault circuit interrupter in any damp or highly
conductive area (such as metal decking or steel work).
Do not use worn, bare, frayed or otherwise damaged electrical
cord sets with the generator.
Before performing any maintenance on the generator, disconnect
the engine starting battery (if equipped) to prevent accidental
start up. Disconnect the cable from the battery post indicated
by a NEGATIVE, NEG or (–) first. Reconnect that cable last.
In case of accident caused by electric shock, immediately shut
down the source of electrical power. If this is not possible,
attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a non-conducting
implement, such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply first aid and
get immediate medical help.
FIRE HAZARDS
• Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE.
Do not permit smoking, open flames, sparks or heat in the
vicinity while handling gasoline.
Never add fuel while unit is running or hot. Allow engine to cool
completely before adding fuel.
• Never fill fuel tank indoors. Comply with all laws regulating
storage and handling of gasoline.
• Do not overfill the fuel tank. Always allow room for fuel
expansion. If tank is over-filled, fuel can overflow onto a hot
engine and cause FIRE or an EXPLOSION. Never store generator
with fuel in tank where gasoline vapors might reach an open
flame, spark or pilot light (as on a furnace, water heater or
clothes dr yer). FIRE or EXPLOSION may result. Allow unit to
cool entirely before storage.
Wipe up any fuel or oil spills immediately. Ensure that no
combustible materials are left on or near the generator. Keep the
area surrounding the generator clean and free from debris and
keep a clearance of five (5) feet on all side to allow for proper
ventilation of the generator.
2
Safety Rules
Do not insert objects through the unit’s cooling slots.
• Do not operate the generator if connected electrical devices
overheat, if electrical output is lost, if engine or generator sparks
or if flames or smoke are observed while unit is running.
Keep a fire extinguisher near the generator at all times.
1. National Fire Protection Association (NFPA) 70: The NATIONAL
ELECTRIC CODE (NEC) available from www.nfpa.org
2. National Fire Protection Association (NFPA) 5000: BUILDING
CONSTRUCTION AND SAFETY CODE available from www.
nfpa.org
3. International Building Code available from www.iccsafe.org
4. Agricultural Wiring Handbook available from www.rerc.org ,
Rural Electricity Resource Council P.O. Box 309 Wilmington,
OH 45177-0309
5. ASAE EP-364.2 Installation and Maintenance of Farm Standby
Electric Power available from www.asabe.org, American
Society of Agricultural & Biological Engineers 2950 Niles
Road, St. Joseph, MI 49085
This list is not all inclusive. Check with the Authority Having Local
Jurisdiction (AHJ) for any local codes or standards which may be
applicable to your jurisdiction.
MODEL NO:
SERIAL NO:
Unit ID Location
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
3
General Information
Remove all packaging material.
Remove separate accessory box.
Remove the generator from carton.
Check all contents. If any parts are missing or damaged, locate an
authorized dealer at 1-855-GEN-INFO.
1-Owner’s manual
1-Bottle of Oil SAE 30
3-Product Registration Cards (English, Spanish, French)
1-Oil Funnel
4-Curved Head Bolts (A)
4-Acorn Nuts (B)
2-Small Washers (C)
2-Rubber Feet (D)
2-Foot Brackets (E)
2-Long Hex Head Bolts (F)
8-Short Hex Head Bolts (G)
10-Nuts (H)
1-Axle (J)
1-Axle Bracket (K)
2-Wheels (L)
2-Large Washers (M)
2-Hair Pins (N)
6. Use four short bolts (G) and four nuts (H) to secure the axle
(J) & bracket (K) to the frame.
7. Slide wheel (L) and washer (M) onto axle (J). Secure parts
with pin (N).
8. Repeat steps 6 & 7 for the opposite wheel.
Figure 1A Handle Assembly
Figure 1B Foot Assembly
The generator requires some assembly prior to using it. If
problems arise when assembling the generator, please call the
Generator Helpline at 1-855-GEN-INFO.
The wheels are designed to greatly improve the portability of the
generator. You will need the following tools to properly install the
accessory kit:
Ratchet and a 10mm socket
10mm box wrench
Refer to the instructions below and figures 1A, 1B, and 1C to
install the handles, feet, and wheels. Note: the handle components
are already pre-assembled from the factory.
1. Install the handle assembly to the frame by using bolts (A) and
nuts (B).
2. Repeat step one for opposite handle.
3. Place washer (C) inside rubber foot (D). Secure parts to
bracket (E) with bolt (F) and nut (H).
4. Install foot assembly to the frame using the short bolts (G)
and nuts (H).
5. Repeat steps 3 & 4 for other foot.
4
Figure 1C Wheel Assembly
Operation
Read the Owner’s Manual and Safety Rules before operating
this generator.
Compare the generator to Figures 2 through 4 to become
familiarized with the locations of various controls and adjustments.
Save this manual for future reference.
1. 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies electrical
power for the operation of 120 Volt AC, 20 Amp, single-phase,
60 Hz electrical lighting, appliance, tool and motor loads.
2. 120/240 Volt AC, 30 Amp Locking Receptacle – Supplies
electrical power for the operation of 120 and/or 240 Volt AC,
30 Amp, single-phase, 60 Hz, electrical lighting, appliance,
tool and motor loads.
3. Circuit Breakers (AC) – Each receptacle is provided with
a circuit breaker to protect the generator against electrical
overload.
4. Oil Drain – Use to drain engine oil.
5. Air Filter – Filters intake air as it is drawn into the engine.
6. Choke Knob – Used when starting a cold engine.
7. Fuel Tank – See generator Specifications for tank capacity.
8. Grounding Lug – Ground the generator to an approved earth
ground here. See "Grounding the Generator" for details.
9. Run/Stop Switch – Controls the operation of the generator
(pull start models).
9A. Start Switch – Used to star t engine from the starter motor
(electric star t models only).
10. Muffler – Quiets the engine.
11. Handles – Pivot and retract for storage. Press the spring-
loaded button to move handles.
12. Gas Cap – Fuel fill location.
13. Fuel Gauge – Shows fuel level in tank.
14. Oil Fill – Add oil here.
15. Recoil Starter – Use to star t engine manually.
16. Fuel Shut Off – Valve between fuel tank and carburetor.
The unit has been deliberately shipped with the battery cables
disconnected. You will need a 10mm wrench to secure the battery
cables.
To connect the battery (see Figure 15 for connection details):
1. Cut off cable ties securing battery cables.
2. First, connect the red cable to the positive (+) battery terminal
with the supplied bolt.
3. Connect the black cable to the negative (-) battery terminal
with the supplied bolt.
4. Make sure all connections are secure. Slide the rubber boots
over the terminals and connection hardware.
NOTE:
If the battery is unable to start the engine, charge it with the
12V charger included in the accessory box (see the "Charging a
Battery" section for details).
Figure 2 - Control Panel
5
Operation
17. Battery Charger Input – This receptacle allows the capability
to recharge the 12 volt DC storage battery provided with
the 12 Volt Adaptor Plug Charger which is included in the
Accessory Box. Located behind the battery charger input is
a 1.50 Amp in-line fuse which is inside the control panel to
protect the battery (electric star t models only).
18. Battery – Powers the electric star ter (electric start models
only).
Figure 3 - Generator Controls
This is a 120 Volt outlet protected against overload by a 20 Amp
push-to-reset circuit breaker (Figure 5). Use each socket to power
120 Volt AC, single phase, 60 Hz electrical loads requiring up to a
combined 2400 watts (2.4 kW) or 20 Amps of current. Use only
high quality, well-insulated, 3-wire grounded cord sets rated for
125 Volts at 20 Amps (or greater).
Keep extension cords as short as possible, preferably less than
15 feet long, to prevent voltage drop and possible overheating of
wires.
Figure 5 - 120 Volt AC, 20 Amp, Duplex Receptacle
Figure 4 - Generator Controls
This is a 120 Volt outlet protected against overload by a 20 Amp
push-to-reset circuit breaker (Figure 6). Use each socket to power
120 Volt AC, single phase, 60 Hz electrical loads requiring up to a
combined 2400 watts (2.4 kW) or 20 Amps of current. Use only
high quality, well-insulated, 3-wire grounded cord sets rated for
125 Volts at 20 Amps (or greater).
Keep extension cords as short as possible to prevent voltage drop
and possible overheating of wires.
Figure 6 - 120 Volt AC, 20 Amp, GFCI Duplex Receptacle
6
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