DANGER indicates a potentially
hazardous situation which, if not
avoided, WILL result in death or serious
injury.
WARNING:
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
SAFETY AND OPERATION RULES
WARNING:
Failure to follow these instructions and warnings can result in
death, personal injury, or property damage.
Read carefully and understand operator’s manual
prior to operation of this product. Read and understand engine manual prior to operation. Follow all
warnings and instructions.
Know your equipment. Consider the applications,
limitations, and the potential hazards specific to your
unit.
Equipment must be placed on a firm, supporting sur-
face.
Load must be kept within rating stated on genera-
tor nameplate. Overloading will damage the unit or
shorten its life.
Engine must not be run at excessive speeds. Oper-
ating an engine at excessive speeds increases the
hazard of personal injury.
Do not tamper with parts which may increase or
decrease the governed speed.
To prevent accidental starting, always remove the
spark plug or cable from the spark plug before maintaining the generator or engine.
Units with broken or missing parts, or without pro-
tective housing or covers, should never be operated.
Contact your service center for replacement parts.
Units should not be operated or stored in wet or
damp conditions or on highly conductive locations
such as metal decking and steel work.
Keep the generator clean and free of oil, mud and
other foreign matter.
Extension cords, power cords, and all electrical
equipment must be in good condition. Never operate electrical equipment with damaged or defective
cords.
Store the generator in a well-ventilated area with the
fuel tank empty. Fuel should not be stored near the
generator.
Your generator should never be operated under these
conditions:
a. Uncontrolled change in engine speed. (NOTE:
The optional idle control feature will reduce the
engine speed in a “No Load” condition.)
CAUTION:
CAUTION indicates a potentially
hazardous situation which, if not
avoided, may result in minor or
moderate personal injury, or property
damage.
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. Do not let the unit get wet when
operating.
Check the fuel system periodically for leaks or signs of dete-
rioration such as chafed or spongy hose, loose or missing
clamps, or damaged tank or cap. All defects should be corrected before operation.
The generator should be operated, serviced, and refueled
only under the following conditions:
a. Start and run the generator outdoors. Do not run the gen-
erator in an enclosed area, even if doors or windows are
open; avoid areas where vapors may be trapped, such as
pits, garages, cellars, excavations and boat bilges.
DANGER:
CARBON MONOXIDE HAZARD: The engine exhaust
contains carbon monoxide, a poisonous, odorless,
invisible gas which, if breathed, will cause death or
serious personal injury. If you start to feel sick, dizzy
or weak while using the generator, shut it off and get to fresh
air right away; you may have carbon monoxide poisoning.
b. Good ventilation for cooling. Air flow and temperatures are
important for air cooled units. Temperatures should not
exceed 104°F ambient (40°C).
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.
3
Ensure that generator is properly grounded. (See
“Grounding the generator” section in this manual.)
Do not wear loose clothing, jewelry, or anything that
may be caught in the starter or other rotating parts.
Unit must reach operating speed before electrical
loads are connected. Disconnect loads before turning off engine.
To prevent surging that may possibly damage equip-
ment, do not allow engine to run out of fuel when
electrical loads are applied.
When powering solid state equipment, a Power Line
Conditioner should be used to avoid possible damage to equipment.
Do not stick anything through ventilating slots, even
when the generator is not operating. This can damage the generator or cause personal injury.
Before transporting the generator in a vehicle, drain
all fuel to prevent leakage that may occur.
Use proper lifting techniques when transporting the
generator from site to site. Improper lifting techniques may result in personal injury.
To avoid burns, do not touch engine muffler or other
engine or generator surfaces which became hot during operation.
Do not alter or modify the heat shield.
Keep metal objects away from the battery terminals.
Metal objects can make a connection from one
terminal to another. Shorting the battery terminals
together may cause sparks, burns, or a fire.
SPARK ARRESTING MUFFLER
YOUR PRODUCT MAY NOT BE 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 our product dealers, or may be ordered from Techtronic Industries
North America, Inc., P.O. Box 35, Hwy. 8, Pickens, SC 29671,
1-866-340-3912.
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 is recommended for
some solid state applications.
A power line conditioner should be used when any of the
following solid state items:
Garage door openers
Kitchen appliances with digital displays
Televisions
Stereos
Personal computers
Quartz clocks
Copy machines
Telephone equipment
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:
Determine if you want to run one item or multiple items simul-
taneously.
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).
Total the watts for each item. If the nameplate only gives volts
and amps, multiply volts x amps = watts.
1 KW = 1,000 watts Motorized appliances or tools require more than their rated
wattage for start up.
NOTE: Allow 2-1/2 to 4 times the listed wattage for start-
ing equipment powered by electric motors.
The generator’s rated watts should match or exceed the total
number of watts required for the equipment you want to run.
Always connect the heaviest load to the generator first, then
add other items one at a time.
4
ELECTRICAL
GENERATOR CAPACITY
Make sure the generator can supply enough continuous
(running) and surge (starting) watts for the items you will
power at the same time. Follow these simple steps.
Surge wattage is the short burst of power needed to start
electric motor-driven tools or appliances such as a circular
saw or refrigerator. Because not all motors start at the same
time, total surge watts can be estimated by adding only the
item(s) with the highest additional surge watts to the total
rated watts from step 2.
Example:
Tool or Appliance
Window AC,
10,000 BTU
Continuous
(Running) Watts
12001800
Refrigerator7002200
1/3 HP Well Pump10002000
27 in. Television5000
Light (75 Watts)750
3475 Total
Running Watts
Total Continuous (Running) Watts 3475
Plus Highest Additional Surge Watts + 2200
Equals Total Generator Output Required 5675
POWER MANAGEMENT
To prolong the life of the generator and attached devices,
it is important to take care when adding electrical loads to
the generator. There should be nothing connected to the
generator outlets before starting its engine. The correct
and safe way to manage generator power is to sequentially
add loads as follows:
1. With nothing connected to the generator, start the engine as
described later in this manual.
2. Plug in and turn on the first load, preferably the largest load
you have.
3. Permit the generator output to stabilize (engine runs smoothly
and attached device operates properly).
4. Plug in and turn on the next load.
5. Again, permit the generator to stabilize.
6. Repeat steps 4 and 5 for each additional load.
Never add more loads than the generator capacity. Take
special care to consider surge loads in generator capacity
as previously described.
Surge
(Starting) Watts
2200 Highest
Surge Watts
CAUTION:
Do not overload the generator’s capacity. Exceeding the
generator’s wattage/amperage capacity can damage the
generator and/or electrical devices connected to it.
*Wattages listed are approximate. Check tool or appliance for actual wattage.
ELECTRICAL
EXTENSION CORD CABLE SIZE
Refer to the table below to ensure the cable size of the extension cords you use are capable of carrying the required
load. Inadequate size cables can cause a voltage drop, which can burn out the appliance and overheat the cord.
Current in
Amperes
2.5 300 6001000 ft.600 ft.375 ft.250 ft.
5 6001200 500 ft.300 ft.200 ft.125 ft.
7.5 9001800 350 ft.200 ft.125 ft.100 ft.
1012002400 250 ft.150 ft.100 ft. 50 ft.
1518003600 150 ft.100 ft. 65 ft.
2024004800175 ft. 125 ft. 75 ft.
2530006000150 ft. 100 ft.
3036007200125 ft. 65 ft.
4048009600 90 ft.
Load in WattsMaximum Allowable Cord Length
At 120VAt 240V#8 Wire#10 Wire#12 Wire#14 Wire#16 Wire
ELECTRIC MOTOR LOADS
It is characteristic of common electric motors in normal operation to draw up to six times their running current while
starting. This table may be used to estimate the watts required to start “Code G” electric motors; however, if an electric motor fails to start or reach running speed, turn off the appliance or tool immediately to avoid equipment damage.
Always check the requirements of the tool or appliance being used compared to the rated output of the generator.
Low lubricant alert system
Receptacles on control panel
Cord Retainers
Automatic voltage regulator (AVR)
8 gallon metal fuel tank
Analog Hour Meter
Portability Kit
A. 120 V, 20 Ampere Duplex Receptacle
20 amps of current may be drawn from each half of the receptacle. However, total power drawn must be kept within nameplate ratings. These receptacles may be used along with the twistlock receptacle provided the generator is not overloaded.
B. 120/240 V, 30 Ampere Twistlock Receptacle
A maximum of 30 amps may be drawn from the 120/240 volt
receptacle, provided it is the only receptacle used. However, current
must be limited to the nameplate rating. If the 120/240 volt receptacle
is used along with the 120 volt receptacle, the total load drawn must
not exceed the nameplate ratings.
C. Circuit Breakers
The receptacles are protected by an AC circuit breaker. If the
generator is overloaded or an external short circuit occurs, the 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.
D. Cord Retainer
The cord retainer is used to prevent plugs from being pulled out
of the 120-volt receptacles.
E. Analog Hour Meter
E
AB
D
C
7
1
2
3430
PORTABILITY KIT INSTALLATION
0
0
0
0
0
120V
AC/
CA
120V
AC/
CA
120V
/240 AC/C
A
NEU
TRAL
FLOAT
ING
NEU
TRAL
FLOTAS
Cord
Retainer
Cor
d
Ret
ain
er
TOOLS REQUIRED: 7/16", 1/2" and 9/16" sockets and ratchets, block(s) of wood (minimum of 6" tall).
Refer to the parts list on pages 36-39.
WHEEL INSTALLATION
1. Block up end of generator opposite the fuel tank cap to install wheel kit.
2. Insert wheel spacer (item 39) into the center of the wheel (item 28).
3. Slide 3/8 x 4.25" bolt (item 32) and 3/8 washer (item 27) through the wheel (item 28), then through the wheel bracket on the carrier, with
the offset side of the wheel hub against the wheel bracket.
4. Thread 3/8 nyloc nut (item 33) onto the bolt and tighten to securely clamp the wheel assembly to the carrier.
5. Repeat above instructions for the remaining wheel.
FOOT INSTALLATION
1. Assemble the rubber feet (item 29) to the foot bracket (item 43) using a 1/4-20 x 1.5" bolt (item 50). Thread a 1/4 washer (item 36) and
a 1/4 nyloc nut (item 10) to the bolt to secure the assembly. Caution: Do not over tighten so that the foot material collapses.
2. Blocking up the engine side of the generator, place the foot bracket under the carrier channel. Thread a 5/16-18 x 1" bolt (item 42) with
a 5/16 wide washer (item 41) through the mounting holes and thread a 5/16 wide washer (item 41) and a 5/16 nyloc nut (item 13) to
the bolt to secure the foot bracket to the carrier.
HANDLE INSTALLATION
1. Place handle (item 25) and spacer (item 46) on carrier on same end as feet, as shown in the diagram.
2. Slide 5/16 x 2.25" bolt (item 26) and 5/16 washers (item 12) through handle and handle bracket as shown in diagram and secure with
5/16" nyloc nut (item 13). Tighten until handle is securely clamped to the carrier.
3. Repeat above instructions for the remaining handle.
LOCKING HANDLE
1. Attach the lanyards (item 30) to the release pins (item
34) and carrier as shown in the illustration.
2. To lock the handle (item 25) in the extended position,
align the holes in the handle brackets with the holes
in the carrier brackets and insert the release pins
(item 34).
Tank removed for clarity.
8
INSTALLATION
WARNING:
To avoid possible personal injury or equipment damage,
registered electrician or an authorized service representative
should perform installation and all service. Under no
circumstances should an unqualified person attempt to wire
into a utility circuit.
To avoid backfeeding into utility systems, isolation of the
residence electrical system is required.
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. Temporary connection not recommended due to
backfeeding.
BEFORE OPERATION
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 connected 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.
GROUND TERMINAL LOCATION:
ground lug
WARNING:
Do not use a pipe carrying combustible material as the ground
source.
Always follow local codes and regulations that apply to
the installation of any item that concerns this product.
9
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