Milwaukee 4970-24, 4960-24 User Manual

OPERATOR'S MANUAL MANUAL DEL OPERADOR MANUEL D'UTILISATEUR

Cat. No. Nro. cat. No de catalogue 4960-24 & 4970-24

PORTABLE GENERATOR GENERADOR PORTÁTIL GÉNÉRATRICE PORTATIVE

TO REDUCE THE RISK OF DEATH OR SERIOUS INJURY, USER MUST READ OPERATOR'S MANUAL. PARA REDUCIR EL RIESGO DE MUERTE O LESIONES GRAVES, EL USUARIO DEBE LEER EL MANUAL DEL

OPERARIO. L’UTILISATEUR DOIT LIRE LE MANUEL D’UTILISATION AFIN DE RÉDUIRE LES RISQUES DE MORT OU DE

BLESSURES GRAVES.

Operator Safety

Equipment Description

Read this manual carefully and become familiar

with your generator. Know its applications, its limitations and any hazards involved.

The generator is an engine–driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliances, tools and motor loads. The generator’s revolving field is driven at about 3,600 rpm by a single-cylinder engine.

This generator incorporates GFCI (Ground Fault Circuit Interrupter) outlet protection and has its neutral bonded to ground to comply to OSHA inspections on job sites. This generator will not function when connected to a 2 pole transfer switch since the home or building main breaker box also has a neutral bonded to ground. When both the generator and the home or building breaker box contains a neutral bonded to ground, the generators GFCI will open and no outlets will function.

WARNING

Removing the neutral bond could result in death, bodily injury and/or property damage.

Safety Rules

This is the safety alert symbol. It is used to alert

you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

The safety alert symbol ( ) is used with a signal word (DANGER, WARNING, CAUTION), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. NOTICE indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death.

Hazard Symbols and Meanings

B C

• DO NOT remove the neutral bond.

NOTICE

Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage capacity. See Don’t Overload Generator in the Operation section.

Every effort has been made to ensure that the information in this manual is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise improve the generator and this documentation at any time without prior notice.

The Emission Control System for this generator is warranted for standards set by the Environmental Protection Agency and the California Air Resources Board.

The manufacturer cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and the tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique that the manufacturer does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure that the procedure, work method or operating technique that you choose does not render the generator unsafe.

A - Explosion G - Flying Objects B - Fire H - Moving Parts C - Electric Shock J - Lift Point D - Toxic Fumes K - Hand Crush E - Kickback L - Read Manual F - Hot Surface

E F

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WARNING

Running engine gives off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting, confusion, seizures, nausea, fainting or death.

• Operate generator ONLY outdoors.

• Install a battery operated carbon monoxide alarm near the bedrooms.

• Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes, or other openings.

• DO NOT start or run engine indoors or in an enclosed area, (even if windows and doors are open), including the generator compartment of a recreational vehicle (RV).

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

WARNING

Generator produces hazardous voltage. Failure to isolate generator from power utility

can result in death or injury to electric utility workers due to backfeed of electrical energy.

• When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility.

• Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area, such as metal decking or steel work.

• DO NOT touch bare wires or receptacles.

• DO NOT use generator with electrical cords which are worn, frayed, bare or otherwise damaged.

• DO NOT operate generator in the rain or wet weather.

• DO NOT handle generator or electrical cords while standing in water, while barefoot, or while hands or feet are wet.

• DO NOT allow unqualified persons or children to operate or service generator.

WARNING

Starter cord kickback (rapid retraction) can result in bodily injury. Kickback will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises, or sprains could result.

• When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in and turned on.

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WHEN ADDING OR DRAINING FUEL

• Turn generator OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

• Fill or drain fuel tank outdoors.

• DO NOT overfill tank. Allow minimum 3/4” (2 cm) from top of strainer to avoid fuel spillage from cap. Space remaining in tank provides room for fuel expansion and prevents fuel from spilling out vented fuel cap when generator is wheeled.

• If fuel spills, wait until it evaporates before starting engine.

• Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.

• DO NOT light a cigarette or smoke.

WHEN STARTING EQUIPMENT

• Ensure spark plug, muffler, fuel cap, and air cleaner are in place.

• DO NOT crank engine with spark plug removed.

WHEN OPERATING EQUIPMENT

• DO NOT tip engine or equipment at angle which causes fuel to spill.

• This generator is not for use in mobile equipment or marine applications.

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

• Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF.

• Disconnect spark plug wire.

WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK

• Store away from furnaces, stoves, water heaters, clothes dryers, or other appliances that have pilot light or other ignition source because they can ignite fuel vapors.

WARNING

• This generator does not meet U. S. Coast Guard Regulation 33CFR-183 and should not be used on marine applications.

• Failure to use the appropriate U. S. Coast Guard approved generator could result in death or serious injury and/or property damage.

WARNING

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

• Code of Federal Regulation (CFR) Title 36 Parks, Forests, and Public Property require equipment powered by an internal combustion engine to have a spark arrester, maintained in effective working order, complying to USDA Forest service standard 5100-1C or later revision. In the State of California a spark arrester is required under section 4442 of the California Public resources code. Other states may have similar laws.

WARNING

Starter and other rotating parts can entangle hands, hair, clothing, or accessories.

• NEVER operate generator without protective housing or covers.

• DO NOT wear loose clothing, jewelry or anything that may be caught in the starter or other rotating parts.

• Tie up long hair and remove jewelry.

WARNING

Unintentional sparking can result in fire or electric shock.

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR GENERATOR

• Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact spark plug.

WHEN TESTING FOR ENGINE SPARK

• Use approved spark plug tester.

• DO NOT check for spark with spark plug removed.

WARNING

Lifting Hazard. Falling generator can result in death, bodily injury, and/or property damage.

• Stand clear of generator. Center point lift is designed to carry only the weight of the generator.

• DO NOT overload center point lift bracket.

• DO NOT lift from center point lift gusset.

• DO NOT lift from folding handle.

WARNING

Crush Hazard. Center point lift bracket can crush and cut resulting in bodily injury.

• Keep hands clear of area between bracket and folding handle.

CAUTION

Excessively high operating speeds increase risk of injury and damage to generator.

Excessively low speeds impose a heavy load.

• DO NOT tamper with governed speed. Generator supplies correct rated frequency and voltage when running at governed speed.

• DO NOT modify generator in any way.

NOTICE

Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage capacity. See Don’t Overload Generator in the Operation section.

• Start generator and let engine stabilize before connecting electrical loads.

• Connect electrical loads in OFF position, then turn ON for operation.

• Turn electrical loads OFF and disconnect from generator before stopping generator.

NOTICE

Improper treatment of generator can damage it and shorten its life.

• Use generator only for intended uses.

• If you have questions about intended use, ask dealer or contact local service center.

• Operate generator only on level surfaces.

• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• DO NOT insert any objects through cooling slots.

• If connected devices overheat, turn them off and disconnect them from generator.

• Shut off generator if:

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

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Product Specifications

Specifications

Cat. No. 4960-24 (Model 030374)

Starting Wattage . . . . . . . . . . . . . . . . . . . . . . . . .8,250 Watts

Wattage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,500 Watts

AC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 120/240 Volts

at 240 Volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.9 Amps

at 120 Volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.8 Amps

Frequency . . . . . . . . . . . . . . . . . . . . . . . . .60 Hz at 3600 rpm

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Phase

Fuel Capacity. . . . . . . . . . . . . . 7.5 U.S. Gallons (28.4 Liters)

Cat. No. 4970-24 (Model 030375)

Starting Wattage . . . . . . . . . . . . . . . . . . . . . . . . .9,750 Watts

Wattage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,500 Watts

AC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 120/240 Volts

at 240 Volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.0 Amps

at 120 Volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.1 Amps

Frequency . . . . . . . . . . . . . . . . . . . . . . . . .60 Hz at 3600 rpm

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Phase

Fuel Capacity. . . . . . . . . . . . . . 7.5 U.S. Gallons (28.4 Liters)

Cat. No. 4960-24 (Model 030374) - This generator is rated for 5500W continuous output in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators).

Cat. No. 4970-24 (Model 030375) - This generator is rated for 6500W continuous output in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators).

Features and Controls

Read this Operator’s Manual and safety rules before operating your generator.

Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and adjustments. Save this manual for future reference.

A - Circuit Breakers (AC) — The receptacles are provided

with circuit breakers to protect the generator against electrical overload.

B - Idle Control Switch — Use this switch to turn the idle

control feature on and off.

C - Engine Switch — Set this switch to “On” before using

recoil starter. Set switch to “Off” to stop engine.

D - Double Pole Circuit Breaker (AC) — A double pole

circuit breaker is provided to protect the 120/240V, 20A receptacle against electrical overload.

E - GFCI Main Circuit Breaker — A GFCI circuit breaker is

provided to protect against electrical ground fault and protect the generator against electrical overload.

F - 120/240 Volt AC, 30 Amp Locking Receptacle — May

be used to supply 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.

G - 120 Volt AC, 30 Amp Locking Receptacle — May be

used to supply electrical power for the operation of 120 Volt AC, 30 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

H - 120 Volt AC, 20 Amp Locking Receptacle — May be

used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

J - 120 Volt AC, 20 Amp, Duplex Receptacles — May

be used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting, appliance, tool, and motor loads.

K - Grounding Fastener — Consult your local agency having

jurisdiction for grounding requirements in your area.

L - Spark Arrester Muffler — Exhaust muffler lowers engine

noise and is equipped with a spark arrester screen.

M - Air Cleaner — Protects engine by filtering dust and

debris out of intake air.

N - Oil Fill Cap/Dipstick — Check and add engine oil here. P - Recoil Starter — Used to start the engine. R - Engine Identification — Provides model, type and code

of engine. Please have these readily available if calling for assistance.

S - Fuel Valve — Used to turn fuel supply on and off to

engine.

T - Choke Lever — Used when starting a cold engine. U - Fuel Tank — Capacity of 7.5 U.S. gallons (28.4 L). V - Center Point Lift — The lift point in the center of the

unit makes lifting the machine for transportation and/or relocation easy.

Items Not Shown: Data Tag — Provides model, revision, and serial number of

generator. Please have these readily available when calling for assistance.

Oil Drain Plug — Drain engine oil here.

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Cord Sets and Receptacles

Use only high quality, well-insulated, grounded extension cords with the generator’s 120 Volt duplex receptacle. Inspect extension cords before each use.

Check the ratings of all extension cords before you use them. Extension cord sets used should be rated for 125 Volt AC loads at 20 Amps or greater for most electrical devices. Some devices, however, may not require this type of extension cord. Check the operator’s manuals of those devices for the manufacturer’s recommendations.

Keep extension cords as short as possible to minimize voltage drop.

WARNING

Overloaded electrical cords can overheat, arc, and burn resulting in death, bodily injury, and/or property damage.

• ONLY use cords rated for your loads.

• Follow all safeties on electrical cords.

120 Volt AC, 30 Amp Locking Receptacle

Use a NEMA L5–30 plug with this receptacle. Connect a 3–wire cord set rated for 125 Volt AC loads at 30 Amps to the plug.

3-Wire Cord Set

NEMA L5-30

Neutral 120V Hot

Ground (Green)

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3,600 watts (3.6 kW) of power at 30 Amps. The outlet is protected by a rocker switch circuit breaker and/or a 2 pole GFCI circuit breaker.

120/240 Volt AC, 30 Amp, Locking Receptacle

Use a NEMA L14-30 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volt AC loads at 30 Amps (or greater). You can use the same 4-wire cord if you plan to run a 120 Volt load.

4-Wire Cord Set

240V

120V

Y (Hot) X (Hot)

NEMA L14-30

This receptacle powers 120/240 Volt AC, 60 Hz, single phase loads requiring up to 6,500 watts of power (6.5 kW) at 27.0 Amps for 240 Volts or two independent 120 Volt loads at

27.0 Amps each. The outlet is protected by a 2 pole rocker switch circuit breaker and/or a 2 pole GFCI circuit breaker.

120V

W (Neutral)

Ground (Green)

120 Volt AC, 20 Amp Locking Receptacle

Use a NEMA L5–20 plug with this receptacle. Connect a 3–wire cord set rated for 125 Volt AC loads at 20 Amps to the plug.

3-Wire Cord Set

NEMA L5-20

Neutral 120V Hot

Ground (Green)

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 2,400 watts (2.4 kW) of power at 20 Amps. The outlet is protected by a rocker switch circuit breaker and/or a 2 pole GFCI circuit breaker.

120 Volt AC, 20 Amp, Duplex Receptacles

The duplex receptacles are protected against overload by rocker switch circuit breakers and/or a 2 pole GFCI circuit breaker.

NOTICE

Receptacles may be marked with rating value greater than generator output capacity.

• NEVER attempt to power a device requiring more amperage than generator or receptacle can supply.

• DO NOT overload the generator. See

Don’t Overload Generator.

Use each receptacle to operate 120 Volt AC, single–phase,

ARNING

60 Hz electrical loads requiring up to 2,400 watts (2.4 kW) at 20 Amps of current. Use cord sets that are rated for 125 Volt AC loads at 20 Amps (or greater).

Ground Fault Protection

This unit is equipped with a Ground Fault Circuit Interrupter (GFCI). This device meets applicable federal, state and local codes.

The GFCI protects against electrical shock that may be caused if your body becomes a path which electricity travels to reach ground. This could happen if you touch a “Live” appliance or wire, or are touching plumbing or other materials that connect to the ground.

When protected by a GFCI, one may still feel a shock, but the GFCI should cut current off quickly enough so that a person in normal health should not suffer any serious electrical injury.

WARNING

Generator produces hazardous voltage/current.

• The GFCI will not protect you against the following situations:

-Line-to-line shocks;

-Current overloads or line-to-line short circuits.

• The fuse or circuit breaker at the control panel must provide such protection.

Test GFCI Circuit Breaker

Test your GFCI circuit breaker every month, as follows:

1. Press “Reset” button. The green power LED should be

on.

2. While generator is running, press “Test” button. The

green LED should turn off, the red LED should start blinking, and the circuit breaker should trip to “Off” position), which will disconnect power to outlets.

3. Press “Reset” button. The red LED should turn off and

the green LED should turn on.

4. Press circuit breaker to “On” position to restore circuit

power.

CAUTION

If circuit breaker does not reset properly:

• DO NOT use generator.

• Call a Milwaukee Tool service center.

During Generator Use

If circuit breaker trips during use, it usually indicates faulty electrical equipment or cords. However, test the circuit breaker as follows;

1. Disconnect loads, reset and test circuit breaker as described earlier. Let generator run without any loads for 1 minute.

CAUTION

If circuit breaker trips in the 1 minute period:

• DO NOT use generator.

• Call a Milwaukee Tool service center.

2. If circuit breaker tests correctly, the electrical equipment or extension cords may be faulty. Replace faulty electrical equipment and cords before further use.

CAUTION

If circuit breaker tests correctly:

• Have qualified personnel check all electrical equipment and cords for any defects.

• Replace electrical equipment and cords or take to a qualified repair center.

WARNING

Generator produces hazardous voltage/current.

• DO NOT touch bare wires or receptacles.

• DO NOT use generator with electrical cords which are worn, frayed, bare or otherwise damaged.

• DO NOT operate generator in the rain or wet weather.

• DO NOT handle generator or electrical cords while standing in water, while barefoot, or while hands or feet are wet.

• DO NOT allow unqualified persons or children to operate or service generator or electrical loads.

CAUTION

If sensing module LED’s do not change or circuit breaker does not trip:

• DO NOT use generator.

• Call a Milwaukee Tool service center.

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Assembly

Your generator requires some assembly and is ready for use after it has been properly serviced with the recommended fuel and oil.

If you have any problems with the assembly of your generator, please call the generator helpline at 1-800-SAWDUST (1-800-729-3878). If calling for assistance, please have the model, revision, and serial number from the data tag available. See Generator Controls and Features for data tag location.

Unpack Generator

1. Set the carton on a rigid, flat surface.

2. Remove everything from carton except generator.

3. Open carton completely by carefully cutting each corner from top to bottom.

4. Leave generator on carton to install wheel kit.

The generator is supplied with:

• Engine oil bottle

• Operator’s manual

• Wheel kit

If any parts are missing or damaged, please call the generator helpline at 1-800-SAWDUST (1-800-729-3878).

Install Wheel Kit

The wheel kit is designed to greatly improve the portability of your generator.

NOTE: Wheel kit is not intended for over-the-road use. You will need the following tools to install these

components:

• 1/2” open end wrench

• Pliers

• Safety glasses

Install the wheel kit as follows:

1. Tip generator so that engine end is up.

2. Slide axle (A) through both mounting brackets.

3. Slide a wheel (B) over axle. NOTE: Be sure to install wheel with raised hub inboard.

4. Place a washer (C) on axle and then place an e-ring (D)

in axle groove.

CAUTION

E-rings can cause eye injury. E-rings can spring back and become airborne

when installing or removing.

• Always wear eye protection when installing/removing e-rings.

5. Install e-ring with pliers, squeezing from top of e-ring to bottom of axle.

6. Repeat steps 3 through 5 to secure second wheel.

7. Tip generator so that engine side is down.

8. Line up holes in support leg (E) with holes in generator frame.

9. Attach support leg using 4 carriage bolts (5/16-18 x .75) (F) and 4 lock hex nuts (G). Tighten with a 1/2” open end wrench.

10. Return generator to normal operating position (resting on wheels and support leg).

Moving Generator

1. Pull folding handle to the upright position until spring

pin (A) locks into place.

WARNING

Crush Hazard. Center point lift bracket can crush and cut resulting in bodily injury.

• Keep hands clear of area between bracket and folding handle.

2. Place your foot onto the round bar (B) located under

the recoil starter and pull back on the handle.

3. Push or pull generator to desired location.

4. Place foot on round bar and gently let generator tip forward to rest on support leg.

5. Pull on spring pin and push handle forward to fold down handle.

Add Fuel

NOTE: Refer to engine operator’s manual and follow fuel

recommendations.

WARNING

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WHEN ADDING FUEL

• Turn generator OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• If fuel spills, wait until it evaporates before starting engine.

• Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.

• DO NOT light a cigarette or smoke.

1. Clean area around fuel fill cap, remove cap.

2. Slowly add unleaded gasoline to fuel tank. Be careful

not to overfill. Allow minimum 3/4” (2 cm) (C) from top of strainer to avoid fuel spillage from cap.

Add Engine Oil

• Place generator on a level surface. NOTE: Verify provided oil bottles are the correct viscosity for

current ambient temperature.

• Refer to engine operator’s manual and follow oil recommendations and instructions.

NOTICE

Any attempt to crank or start the engine before it has been properly filled with the recommended oil will result in equipment failure.

• Refer to engine manual for oil information.

• Damage to equipment resulting from failure to follow this instruction will void warranty.

NOTE: Check oil often during engine break–in. Refer to engine operator’s manual for recommendations.

NOTE: Occasionally clear the fuel strainer of any dirt, rust, or other particulate matter.

3. Install fuel cap and let any spilled fuel evaporate before starting engine.

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System Ground

The generator has a system ground that connects the generator frame components to the ground terminals on the AC output receptacles. The system ground is connected to the AC neutral wire (the neutral is bonded to the generator frame).

Special Requirements

There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction:

• In some areas, generators are required to be registered with local utility companies.

• If the generator is used at a construction site, there may be additional regulations which must be observed.

Connecting to a Building’s Electrical System

Connections for standby power to a building’s electrical system must be made by a qualified electrician. The connection must isolate the generator power from utility power or other alternative power sources and must comply with all applicable laws and electrical codes.

WARNING

Generator Location

Clearances and Air Movement

WARNING

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

Place generator outdoors in an area that will not accumulate deadly exhaust gas. DO NOT place generator where exhaust gas (A) could accumulate and enter inside or be drawn into a potentially occupied building. Ensure exhaust gas is kept away from any windows, doors, ventilation intakes, or other openings that can allow exhaust gas to collect in a confined area. Prevailing winds and air currents should be taken into consideration when positioning generator.

Generator produces hazardous voltage. Failure to isolate generator from power utility

can result in death or injury to electric utility workers due to backfeed of electrical energy.

• When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility.

• Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area, such as metal decking or steel work.

• DO NOT touch bare wires or receptacles.

• DO NOT use generator with electrical cords which are worn, frayed, bare or otherwise damaged.

• DO NOT operate generator in the rain or wet weather.

• DO NOT handle generator or electrical cords while standing in water, while barefoot, or while hands or feet are wet.

• DO NOT allow unqualified persons or children to operate or service generator.

ENGINE

Operation

Starting the Engine

Disconnect all electrical loads from the generator. Use the following start instructions:

1. Make sure unit is on a level surface. IMPORTANT: Failure to start and operate the unit on a level

surface will cause the unit not to start or shut down during operation.

2. Turn the fuel valve (A) to the “On” position.

3. Make sure idle control switch is in “

4. Push engine switch to “On” position.

Off” position.

5. Start engine according to instructions given in the engine operator’s manual.

WARNING

Starter cord kickback (rapid retraction) can result in bodily injury. Kickback will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises, or sprains could result.

• When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid kickback.

• NEVER start or stop engine with electrical devices plugged in and turned on.

NOTE: If engine starts after 3 pulls but fails to run, or if unit shuts down during operation, make sure unit is on a level surface and check for proper oil level in crankcase. This unit may be equipped with a low oil protection device. See engine operator’s manual.

WARNING

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

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Connecting Electrical Loads

1. Let engine stabilize and warm up for a few minutes after starting.

2. Plug in and turn on the desired 120 and/or 240 Volt AC, single phase, 60 Hz electrical loads.

NOTE:

• DO NOT connect 240 Volt loads to the 120 Volt duplex receptacles.

• DO NOT connect 3-phase loads to the generator.

• DO NOT connect 50 Hz loads to the generator.

• DO NOT OVERLOAD THE GENERATOR. See Don’t

Overload Generator.

NOTICE

Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.

• DO NOT exceed the generator’s wattage/amperage capacity. See Don’t Overload Generator in the Operation section.

• Start generator and let engine stabilize before connecting electrical loads.

• Connect electrical loads in OFF position, then turn ON for operation.

• Turn electrical loads OFF and disconnect from generator before stopping generator.

Stopping the Engine

1. Turn OFF and unplug all electrical loads from generator panel receptacles. NEVER start or stop engine with electrical devices plugged in.

2. Move idle control switch to “Off” position.

3. Let engine run at no-load for several minutes to stabilize internal temperatures of engine and generator.

4. Turn engine off according to instructions given in the engine operator’s manual.

5. Push engine switch to “Off” position.

6. Move fuel valve to “Off” position.

Operating Automatic Idle Control

This feature is designed to greatly improve fuel economy. When this switch is turned to AUTO, the engine will only run at its normal high governed engine speed when electrical loads are connected. When electrical loads are removed, the engine will run at a reduced speed.

With the switch OFF, the engine will run at the normal high engine speed. Always have the switch off when starting and stopping the engine.

Using the Center Point Lift

Your generator is equipped with a single center point lift (A). Always lift your generator from the center point lift ONLY. NEVER lift from the center point lift gusset (B) or folding handle (C).

When lifting the generator, make sure no additional weight has been added or is hanging from the generator. Adding weight to the generator can cause damage to the center point lift causing an unsafe condition.

WARNING

Lifting Hazard. Falling generator can result in death, bodily injury, and/or property damage.

• Stand clear of generator. Center point lift is designed to carry only the weight of the generator.

• DO NOT overload center point lift bracket.

• DO NOT lift from center point lift gusset.

• DO NOT lift from folding handle.

WARNING

Crush Hazard. Center point lift bracket can crush and cut resulting in bodily injury.

• Keep hands clear of area between bracket and folding handle.

Don’t Overload Generator

Capacity

You must make sure your generator can supply enough rated (running) and surge (starting) watts for the items you will power at the same time. Follow these simple steps:

1. Select the items you will power at the same time.

2. Total the rated (running) watts of these items. This is the amount of power your generator must produce to keep your items running. See Wattage Reference Guide.

3. Estimate how many surge (starting) watts you will need. 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

Microwave Oven 1000 — Refrigerator 700 2200 Furnace Fan 800 2350 Light (75 Watts) 75 —

Total Rated (Running) Watts = 2575 Highest Additional Surge Watts = 2350 Total Generator Output Required = 4925

Power Management

To prolong the life of your generator and attached devices, it is important to take care when adding electrical loads to your 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 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.

Model 4960-24

Rated Surge AC Output (Watts) 8,250 Maximum AC Output (Watts) 6,000 Rated/ Continuous AC Output* 5,500

* Per CSA Standard 22.2 No. 100-04

Rated (Running)

Watts

2575 Total

Running Watts

Additional Surge (Starting) Watts

2350 Highest

Surge Watts

Model 4970-24

Rated Surge AC Output (Watts) 9,750 Maximum AC Output (Watts) 7,000 Rated/ Continuous AC Output* 6,500

* Per CSA Standard 22.2 No. 100-04

NEVER add more loads than the generator capacity. Take special care to consider surge loads in generator capacity, as described.

Wattage Reference Guide

Tool or Appliance Rated*

(Running)

Watts

Essentials

Light Bulb - 75 watt 75 — Furnace Fan Blower - 1/2 HP 800 2350 Sump Pump - 1/3 hp 800 1300 Refrigerator/Freezer 700 2200 Water Well Pump - 1/2 hp 1000 2100

Heating/Cooling

Window AC - 10,000 BTU 1200 3600 Central AC - 24,000 BTU 3800 11400

Kitchen

Microwave Oven - 1000 Watt 1000 — Coffee Maker 1000 —

Family Room

DVD/CD Player 100 — Color Television - 27 in 500 — Personal Computer w/17 in monitor 800 —

Other

Security System 500 — AM/FM Clock Radio 100 — Garage Door Opener - 1/2 hp 875 2350

DIY/Job Site

Quartz Halogen Work Light 1000 — Airless Sprayer - 1/3 hp 600 1200 Reciprocating Saw 960 — Electric Drill - 1/2 hp, 5.4 Amps 600 900 Circular Saw - 7-1/4 in 1400 2300 Miter Saw - 10 in 1800 1800 Table Planer - 6 in 1800 1800 Table Saw/Radial Arm Saw - 10 in 2000 2000 Air Compressor - 1 hp 1600 4500

* Wattages listed are approximate only. Check tool or

appliance for actual wattage.

Additional

Surge

(Starting)

Watts

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Maintenance

General Recommendations

Regular maintenance will improve the performance and extend the life of the generator. See an authorized dealer for service.

The generator’s warranty does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual and the engine operator’s manual.

• Some adjustments will need to be made periodically to properly maintain your generator.

• All maintenance in this manual and the engine operator’s manual should be made at least once each season.

• Once a year you should clean or replace the spark plug, clean or replace the air filter. A new spark plug and clean air filter assure proper fuel-air mixture and help your engine run better and last longer. Please refer to your engine operator’s manual for more details.

Generator Maintenance

Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture, or any corrosive vapors. Cooling air slots in the generator must not become clogged with snow, leaves, or any other foreign material.

NOTE: DO NOT use water or other liquids to clean generator. Liquids can enter engine fuel system, causing poor performance and/or failure to occur. In addition, if liquid enters generator through cooling air slots, some of the liquid will be retained in voids and cracks of the rotor and stator winding insulation. Liquid and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

Cleaning

Daily or before use, look around and underneath the generator for signs of oil or fuel leaks. Clean accumulated debris from inside and outside the generator. Keep the linkage, spring and other engine controls clean. Inspect cooling air slots and openings on generator. These openings must be kept clean and unobstructed.

Engine parts should be kept clean to reduce the risk of overheating and ignition of accumulated debris:

• Use a damp cloth to wipe exterior surfaces clean.

NOTICE

Improper treatment of generator can damage it and shorten its life.

• DO NOT expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• DO NOT insert any objects through cooling slots.

• Use a soft bristle brush to loosen caked on dirt or oil.

• Use a vacuum cleaner to pick up loose dirt and debris.

Fuel Valve Maintenance

The fuel valve is equipped with a fuel sediment cup, screen, retaining ring and o-ring that need to be cleaned every 100 hours or once a year (whichever occurs first).

1. Move fuel valve to “Off” position.

2. Remove sediment cup (A) from fuel valve. Remove o-ring (B), retaining ring (C) and screen (D) from fuel valve.

3. Wash sediment cup, o-ring, retaining ring, and screen in a nonflammable solvent. Dry them thoroughly.

4. Place screen, retaining ring, and o-ring into fuel valve. Install sediment cup and tighten securely.

5. Move fuel valve to “On” position, and check for leaks. Replace o-ring if there is any leakage.

Service Spark Arrester

The engine exhaust muffler has a spark arrester screen. Inspect and clean the screen every 100 hours of operation or once each year, whichever comes first.

If you use your generator on any forest-covered, brushcovered, or grass-covered unimproved land, it must have a spark arrester. The spark arrester must be maintained in good condition by the owner/operator.

If the engine has been running, the muffler will be very hot. Allow the muffler to cool before servicing the spark arrester.

WARNING

Contact with muffler area can result in serious burns.

Exhaust heat/gases can ignite combustibles, structures or damage fuel tank causing a fire.

• DO NOT touch hot parts and AVOID hot exhaust gases.

• Allow equipment to cool before touching.

• Keep at least 5 feet (1.5 m) of clearance on all sides of generator including overhead.

Clean and inspect the spark arrester as follows:

1. To remove muffler heat shield (A) from muffler (B),

remove four screws that connect guard to muffler bracket.

2. Remove three screws (

screen (D).

3. Inspect screen and obtain a replacement if torn, perforated or otherwise damaged. DO NOT use a defective screen. If screen is not damaged, clean it with commercial solvent. Dry thoroughly.

4. Reattach screen and muffler guard.

C) that attach spark arrester

Engine Maintenance

See the engine operator’s manual for instructions on how to properly maintain the engine.

CAUTION

Avoid prolonged or repeated skin contact with used motor oil.

• Used motor oil has been shown to cause skin cancer in certain laboratory animals.

• Thoroughly wash exposed areas with soap and water.

KEEP OUT OF REACH OF CHILDREN. DON’T

POLLUTE. CONSERVE RESOURCES. RETURN USED OIL TO COLLECTION CENTERS.

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Storage

The generator should be started at least once every seven days and allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than 30 days, use the following guidelines to prepare it for storage.

Generator Storage

• Clean the generator as outlined in Cleaning.

• Check that cooling air slots and openings on generator are open and unobstructed.

Long Term Storage Instructions

Fuel can become stale when stored over 30 days. Stale fuel causes acid and gum deposits to form in the fuel system or on essential carburetor parts. To keep fuel fresh, use Briggs & Stratton FRESH START™ fuel stabilizer, available as a liquid additive or a drip concentrate cartridge.

There is no need to drain gasoline from the engine if a fuel stabilizer is added according to instructions. Run the engine for 2 minutes to circulate the stabilizer throughout the fuel system. The engine and fuel can then be stored up to 24 months.

If gasoline in the engine has not been treated with a fuel stabilizer, it must be drained into an approved container. Run the engine until it stops from lack of fuel. The use of a fuel stabilizer in the storage container is recommended to maintain freshness.

WARNING

Storing the Engine

See the engine operator’s manual for instructions on how to properly prepare the engine for storage.

Other Storage Tips

1. DO NOT store fuel from one season to another unless it has been treated as described in Long Term Storage Instructions.

2. Replace fuel container if it starts to rust. Rust and/or dirt in fuel can cause problems if it’s used with this unit.

3. Cover unit with a suitable protective cover that does not retain moisture.

WARNING

Storage covers can be flammable.

• DO NOT place a storage cover over a hot generator.

• Let equipment cool for a sufficient time before placing the cover on the equipment.

4. Store generator in clean, dry area.

Fuel and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK

• Store away from furnaces, stoves, water heaters, clothes dryers, or other appliances that have pilot light or other ignition source because they can ignite fuel vapors.

WHEN DRAINING FUEL

• Turn generator OFF and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

• Drain fuel tank outdoors.

• Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.

• DO NOT light a cigarette or smoke.

Schematic (Cat. No. 4960-24 (Model 030374))

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