PENTAGON TORNADO PT6500E, GALE FORCE PT8500E Instruction Manual

INSTRUCTION MANUAL

Thank you for your purchase of the Tornado PT6500E or Gale Force PT8500E model generator. With proper care and maintenance this generator will give you a reliable source of electrical power in case of public utility outage and in areas where electrical power is not available.

IMPORTANT - All persons that will operate this equipment must read and become thoroughly competent with all operating procedures and safety precautions.

ELECTRIC

GENERATOR

IMPORTANT

Read Unpacking

Instructions First

(Separate Sheet)

GALE FORCE PT8500E

TORNADO PT6500E

Quiet Running OHV 4 Stroke Engine*, 69dBA Easy Starting Electric Low Oil Shutoff

6.6 Gallon All Steel Fuel Tank, 8-10 Hour Run Time (PT6500E), 10 Hour Run Time (PT8500E)** Fully Isolated Steel Roll Cage

Full Power Panel with Circuit Breaker Protection Hour Meter

DC 12v Output AC120v, & AC240v Output (4) 20 Amp 120v 3-Prong Sockets (1) 30 Amp 120v/240V Twist-Lock Socket

3-in-1 Digital Meter (Voltage, Frequency, Run Time)

**Tornado PT6500E has 13HP, Gale Force PT8500E has 16HP. *Running time based on medium duty draw, running times may vary with heavy usage.

CUSTOMER SERVICE

Customer service and product support are available on line at www.pentagontool.com.

WARRANTY AND RETURN POLICY

All Pentagon Tool generators are warrantied against defects in material and workmanship for a period of one year for residential and personal use under normal conditions. Warranty is limited to replacement parts.

All shipping damages must be claimed with the designated shipper. Check the shipping carton for damage before signing the bill of lading.

If an item is opened and deemed to be defective within 30 days from the date of delivery, please contact us at www.pentagontool.com for return instructions. A Pentagon Tool RMA is required when returning defective merchandise.

Pentagon

Our return policy allows 30 days from the date of delivery to return products, provided it is new, unused and in the original packaging as received. We highly recommend that the buyer thoroughly inspect the purchased product before using it. We charge a 20% restocking charge on all returned items. Return shipping is the responsibility of the buyer. We cannot accept returns for any reason after 30 days from the date of delivery. A credit will be issued after the item is inspected and accepted.

When returning your order please include a copy of your order

number with date purchased, your Tool RMA and the reason for the return. Warranty shall not apply to: products which are used for a purpose other than which they were

designed for or which have been altered in any way that would be detrimental to the performance or life of the product. Misapplication, misuse or negligence will revoke the warranty.

IMPORTANT - All persons that will operate this equipment must read and become thoroughly competent with all operating procedures and safety precautions. Misuse of this equipment may result in death, personal injury or property damage.

1.You will need this manual for the safety warnings and precautions, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover.

2.The warnings, cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

Keep this manual and invoice in

a safe and dry place for future reference.

DANGER! run the generator in an

enclosed garage, cellar, excavation, boat, RV compartment or any other type of enclosed structure. Carbon monoxide, an odorless, colorless, deadly gas may accumulate and cause serious injury or death. If you start to feel dizzy or nauseous while using your generator, shut it off immediately and move to fresh air. Call for help, you may have carbon monoxide poisoning. Use

in a well-ventilated outdoor area. Allow at least 4 feet clearance on all sides of the generator.

4Your generator is air cooled. It is important the

you operate it in a well ventilated area. Temperature should not exceed 104° F. ambient (40° C).

5. Do not let the generator get wet during operation. Protect generator from rain, snow, running or standing water. Do not approach a wet running generator, serious injury from electrical shock can occur.

6.When operating power tools outside, use an outdoor extension cord marked "W-A" or "W". These extension cords are rated for outdoor use, and reduce the risk of electric shock.

7.Stay alert. Watch what you are doing, and use common sense when operating a generator.

A moment of inattention while operating the generator may result in serious personal injury.

8 Do not

refuel near open flames , pilot lights, welders, grinders or sparking electric tools. Allow engine to cool before refueling. Avoid spills, clean up if

NEVER

ONLY

Do not operate generator in wet conditions.

Do not use a generator while tired or under the influence of drugs, alcohol, or medication.

Never refuel while generator is running.

SAFETY PRECAUTIONS

necessary.

9. Do not attempt

to force a small generator to do the work of a larger industrial generator. Choosing the right generator for the right job will improve efficiency and ensure the overall safety situation. Best results are ensured when the generator is operating at the rate for which it was designed.

10Do not use this

generator for a purpose for which it was not intended.

11.

Any generator that cannot be controlled with the Power Switch is dangerous and must be repaired.

12.

Such preventive safety measures reduce the risk of starting the generator accidentally.

13Do not use a

damaged generator. Tag damaged generators “Danger do not use until repaired”.

Service or maintenance performed by unqualified personnel could result in injury.

Do not smoke near refueling area.

Do not overload the generator. Use the correct generator for your application.

Do not modify this generator.

Do not use the generator if the Power Switch does not turn it on or off.

Make sure the Power Switch is in its "OFF" position and disconnect the spark plug wire before making any adjustments, changing accessories, or storing the generator.

Maintain generators with care.

Only qualified repair personnel should perform generator service.

Generators create sparks which may ignite dust or fumes.

Provide barriers or shields as needed

for their protection.

Loose clothes, jewelry, and long hair can be caught in moving parts.

Do not operate generators in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust.

Keep children and pets away while operating a generator.

Dress properly; do not wear loose clothing or jewelry. Contain long hair; keep hair, clothing, and gloves away from moving parts.

WARNING: The exhaust from this product

contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm

SAFETY PRECAUTIONS, WARNINGS & DANGER NOTICES

Be sure to read and heed the following precautions and warnings located on your generator. Failure to heed these warnings may result in serious injury or death. NEVER operate your generator indoors; operate only in well-ventilated outdoor LEVEL locations. ALWAYS ensure generator is properly grounded before use. DO NOT run generator in rainy or wet conditions. Keep out of reach of children or unqualified individuals. touch bare wires, receptacles or outlets.

DO NOT

WARNING:

Avoid all open

flames which may cause vapors to ignite.

During operation, generator may discharge highly flammable and explosive gases that may cause severe burns or death.

GENERATOR SPECIFICATIONS

Model

Start Type Fuel Tank Oil Capacity Ignition Displacement Noise Engine Run Time*

4-stroke OHV single cylinder with forced air cooling system

12 hrs.

10 hrs.< 69dB

< 69dB37 fl. oz.

(1.1 liters)

37 fl. oz. (1.1 liters)

389 cc

419 cc

non-contact transistor

PT6500E

PT8500E

Electric

6.6 gal. (25 liters)

*Based on 50% load

Model

Rated Wattage

Surge Wattage

Voltage Frequency Phase DC Voltage DC Amps

12V

8.3

Single

60Hz

120V/240V

PT6500E

PT8500E

5500W

Dimensions: Height=21.3”, Width=20”, Length=28”

12V

7000W

6500W

8500W

120V/240V

60Hz

Pentagon Tool models Tornado PT6500E and PT8500E meet federal EPA

standards.

Single

WARNING!

If the generator is installed indoors

DO NOT INSTALL INDOORS. If the generator is installed outdoors

Never lift the generator using the engine or alternator lifting lugs.

Before using the generator, read and understand the engine manufacturer's Operation, Maintenance, and Parts manual. Also, read the safety precautions in this manual. These should always be followed to reduce the risk of personal injury and damage to equipment.

Ensure installation meets all applicable safety, local and national electrical codes. Have installation performed by a qualified, licensed electrician and building contractor.

, exhaust fumes must be piped out of the building using leak-free, heat-resistant piping. Pipes and silencer should not be made of any flammable materials, nor should they be installed near any flammable materials. Generator exhaust fumes must be within legal limits, including all local codes and ordinances.

, it must be weatherproofed and should be soundproofed. It should not be run outdoors without protection for both the generator and wiring conduit.

Connect lifting equipment to the frame of the generator. Before lifting the generator, ensure the lift rigging and supporting structure are in good condition, and are rated to lift such a load.

The supporting floor/ground surface

, and strong enough to safely hold the weight of the generator. If the floor/ground surface is not level, strong cross members should be placed under the full length of the generator frame at its low side. For trailer installation, the generator should be mounted on the center point of the trailer, over the wheels.

All connections and conduits from the generator to the load must only be installed in compliance with all relevant local, state, and federal electrical codes and standards, and other regulations where applicable. Check with a qualified electrician. The generator must be properly earthgrounded by a qualified electrician in accordance with all relevant electrical codes

MUST

BE LEVEL

OPERATING PRECAUTIONS

and standards before operation. If an extension cord is used to provide power to a tool, make sure to use only UL® approved cords having the correct gauge and length.

Do not attempt to connect or disconnect load connections while standing in water, or on wet or soggy ground. Do not touch electrically energized parts of the generator and interconnecting cables or conductors with any part of the body, or with any noninsulated conductive object. Connect the generator only to a load or electrical system that is compatible with the electrical characteristics and rated capacities of the generator. Keep all electrical equipment clean and dry. Replace any wiring where the insulation is racked, cut, abraded or otherwise degraded. Replace terminals that are worn, discolored, or corroded. Keep terminals clean and tight.

10.

11.

12.

13.

14.

(See page

12)

15.Ensure that the generator is properly grounded before use

16.

17.

18.

. connect directly to a house or building electrical system without an electrician qualified to install the generator. Make sure that all connections comply with local codes.

Failing to comply with this warning could result in a power backflow which could seriously injure or kill electrical or utility personnel. If you are using this generator in highly conductive work areas such as around metal plating or a steel deck, be sure to use

Generator can reach temperatures as high as 150 degrees F (65 degrees C). Heed temperature warning labels on machine. Allow to cool before touching.

Become familiar with this manual and all safety precautions and warnings. Do not overload. Disconnect malfunctioning devices and do not exceed wattage capacity.

NEVER

DANGER!

CAUTION!

Misuse can shorten the life of your generator.

a ground fault circuit interrupter (GFCI), available with some extension cords.

GENERATOR COMPONENTS AND PACKAGE CONTENTS

The following tools should be included in your generator package: (1) Phillips-head screwdriver (A)

(1) Hex-head wrench (B) (1) Spark plug wrench (C)

COMPONENTS

Before operating your generator, be sure to become familiar with all usage instructions and the components listed below:

1. Air cleaner-

2. Choke lever-

3. Fuel gauge-

4. Fuel cap-

7. Voltage Selector

can be removed and cleaned to help keep your generator running at peak efficiency by preventing dirt from getting in to the engine.

Regulates engine air intake.

Gasoline level indicator.

Fuel tank cap.

-switch between 120V only and

120V/240V.

Voltage meter-

120 Volt AC receptacle-

120/ 240 Volt AC receptacle-

9. Circuit breaker

10.Ground terminal-

11. Idle Control Switch-

12. 12V DC batteries.

13. l2V DC receptacle-

Reads current voltage output.

Use to connect electrical devices that run 120 Volt, 60 Hz, single phase, AC current (2¡Áduplex GFCI).

Receptacle to connect electrical devices running 120/240 Volt, 60Hz, single phase, AC current (NEMA L14-30).

- Reset switch protecting generator from

overload.

Grounding wires connection point to

ensure proper grounding of generator.

Idle control will allow fuel savings when ON (use when there is no load on generator), when devices are attached leave in OFF position.

Receptacle only for charging 12

Volt automotive-type batteries.

14. Oil filler cap-

Oil fill and dipstick-

Recoil starter-

Fuel filter cup-

Fuel valve-Spark

plug-

Muffler-Quiets engine.

Access for checking oil levels and

adding oil.

Location for checking and filling

engine oil.

Pull-cord for starting engine.

Filters fuel.

Controls flow of fuel to engine.

Necessary for engine ignition.

21.

15.

Engine Switch

16.

17.

18.

19.

.While not required, you may elect to install the wheel kit that is included with your generator. To do this, follow the instructions below:

1.On a level surface, elevate your generator’s cage on wood or cement blocks to make it easier to assemble your wheel kit.

2.Attach the support leg to the cage using the cap screws and lock nuts provided (See Figure aa).

3.Attach the axle to the cage using the cap screws and lock nuts provided (See Figure bb).

4. Place

(See Figure cc, Figure dd, Figure ee). Make sure the wheel’s air valve is accessible. Install the wheel with the valve facing out.

5. Attach the handles to the cage using the cap screws and lock nuts provided (See Figure ff, Figure gg).

6. Double check that all screws, lock nuts and pins are secure.

Note:

a wheel over the axle, then slide a flat washer over the axle.

Tighten down the wheel with the retaining pin provided

GENERATOR WHEEL KIT ASSEMBLY

Note: Inflate your tires to between 15-30 PSI

Figure aa

Figure bb

Figure cc

Figure dd

Figure ee

Figure ff

Figure gg

RECOMMENDED OIL USAGE AT STARTING TEMPS

10W-30

SYNTHETIC OIL

40 60 80 10032200-20

°F

°C -30 -20 -10 0 10 80 30 40

5W-30 or 10W-30

Engines shipped from Pentagon Tool have oil in crankcase. Do not over-fill. Use a high quality detergent oil classified "For ServiceSF, SG, SH, SJ" or higher. Do not use special additives.

Choose the SAE viscosity grade of oil from the “Recommended Oil Usage At Starting Temps” chart below. Choose the oil that matches the starting temperature anticipated before the next oil change.

DO NOT

Before starting engine, fill with oil.

Do not mix oil with gasoline, do not use 2-

stroke gasoline engine oil.

OIL RECOMMENDATIONS

Note: Synthetic oil meeting ILSAC GF-2, API certification mark and API service symbol (shown here) with "SJ/CF ENERGY CONSERVING" or higher, is an acceptable oil at all temperatures. Use of synthetic oil does not alter required 0il change Intervals.

CHECK ENGINE OIL - EACH USE - BEFORE STARTING ENGINE (Oil capacity is 37 fluid oz. or 1.1 liter.)

SAE

5W-30

FOR

GASOLINE

ENGINES

Air cooled engines run hotter than automotive engines. The use of non-synthetic multi-viscosily oils (5W-30, 10W-30, etc.)in temperatures above 40° F (4 ° C) will result in higher than normal oil consumption. When using a multi-viscosity oil, check oil level more frequently. SAE30 0il, if used below 40°F(4°C),will result in hard starting and possible engine bore damage due to inadequate lubrication.

CHECK OIL FREQUENTLY

IMPORTANT STEPS BEFORE USE

5W-30

Recommended Oil: SAE 10W-30

1.Tank capacity is 6.6 U.S. gallons.

2.Use clean, fresh, lead-free, regular gasoline with a minimum of 87 octane.

3.Purchase fuel in quantity that can be used within 30 days. Do not use old gas.

4. Avoid getting water, oil or dirt mixed with the gasoline.

5. Do not fill to top of tank. Leave room for gasoline to expand. Check fuel gauge on top of tank for current fuel level.

6.Do not store gasoline in the tank for extended periods of time.

7.Be sure to wipe up any gasoline spills before starting the engine.

8.make sure that the generator is on a level surface when fueling.

ALWAYS

FUEL RECOMMENDATIONS

WARNING; Gasoline fumes are extremely flammable.

DO NOT SMOKE

Under certain

conditions fumes can travel many feet and take some time to dissipate. These fumes can be ignited by many sources such as; open flame, pilot lights, cooking stoves, sparks from electric and battery operated tools, sparks from metal hitting a hard surface, static electricity from carpet or curtains, friction from shoes rubbing a hard surface, heat and sparks from other gasoline engines and many others.

near the generator while refueling is taking place. A few minutes of common sense and precaution can help avoid unfortunate incidents.

1. Place engine on level surface and clean around oil fill cap.

2. Remove dipstick/cap, (see figure C) wipe with clean

cloth, check oil level on dipstick as shown.

3. Oil should be at FULL mark. (see figure B) If additional

oil is required, add slowly.

4. Replace and tighten dipstick/cap firmly before starting

engine.

DO NOT OVERFILL. Overfilling with oil may cause:

1. Smoking exhaust.

2. Hard starting.

3. Spark plug fouling.

4. Oil saturation of air filler

INITIAL OIL FILL

To ground the generator, first:

1. Tighten the grounding wing nut onto a grounding wire (see figure D).

2. Attach the other end of the grounding wire to a grounding rod (brass or copper) that is driven into the earth.

3. Since grounding codes may vary depending on location, please consult a local electrician to find out about codes for

GROUNDING THE GENERATOR

Whether this is the first time you will be using your generator or not, follow the checklist below before EACH use to ensure best maintenance and safety practices.

1. Place engine on level surface and clean around oil fill cap.

2. Remove dipstick/cap, (see figure C) wipe with clean

cloth, check oil level on dipstick as shown.

3. Oil should be at FULL mark. (see figure B) If additional

oil is required, add slowly.

4. Replace and tighten dipstick/cap firmly before starting

engine.

1. Use clean, fresh, lead-free, regular gasoline with a minimum of 87 octane.

2. Do not fill to top of tank. Leave room for gasoline to

expand. Check fuel gauge on top of tank for current fuel level.

3. make sure that the generator is on a level

surface when fueling.

4. Be sure to wipe up any gasoline spills before starting

the engine.

1. T

2. Do not fill to top of tank. Leave room for gasoline to

expand. Check fuel gauge on top of tank for current fuel level.

Check the oil:

Check the gas:

Ground the generator:

ALWAYS

ighten the grounding wing nut onto a grounding wire.

Attach the other end of the grounding wire to a

grounding rod (brass or copper) that is driven into the earth.

IMPORTANT STEPS BEFORE USE

DANGER! Failure to ground your generator properly can result in serious injury, shock or electrocution! Please follow the recommended grounding guidelines for your locality. Check with a certified electrician.

PRE-START CHECKLIST

WARNING:

The generator must be properly

grounded. Failure to properly ground the generator can result in electrocution. Ground the generator by attaching a stranded copper No. 12 AWG wire to the grounding nut located on the control panel. (figure D) The grounding wire should be connected with a clamp to a brass or copper rod that is driven into the earth. Consult a qualified electrician to insure a safe and proper grounding.

WARNING: To avoid back feeding 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 service disconnect. Consult a qualified electrician before use.

Grounding Wing Nut

Figure D

STARTING THE ENGINE

1. Follow the guidelines on page 10

(Grounding the Generator).

(located on top of gas tank) for adequate amount of fuel for task. Inspect tank for leaks. If the tank is even seeping a small amount of gas discontinue use until repaired. Wipe up all spilled gas before starting engine. If gas spills down in engine area, allow adequate time gasoline to evaporation.

The valve is located near the pull start chord.

Unplug any device or feed from the control

panel. Switch the circuit breaker to OFF.

When engine fires, you can adjust the choke for running.

First, be sure that your generator is properly grounded.

Check fuel gage

Next turn the fuel valve to the ON position.

Make sure there are no electrical devices pulling power from the generator.

Move the choke to the CLOSED position.

6. When engine fires, you can adjust

the choke for running.

8.When using the recoil start,

pull the cord slowly until you feel tension or resistance, then pull the cord quickly to start the generator.

once engine starts; to get the longest life from your recoil start, treat cord gingerly and refrain from allowing it to snap back into place. You may need to repeat this step a few times to initiate engine start. (If you still cannot start your generator, please see the Troubleshooting Guide on page 25).

Move the choke to the CLOSED position.

Move the engine switch to the ON or START position.

Note: Do not release cord quickly

Allow the engine to run for 1-2 minutes and then move the choke lever half way between OPEN and CLOSED. Wait 20 seconds and move the choke lever to the OPEN position.

1.Check and double check your electrical devices to ensure that they are OFF.

Refer to the chart (Figure E) for average wattage

reported from devices you may encounter. Most electrical devices will have the wattage requirements imprinted somewhere on the appliance. If the requirements are reported in volts and amps you may calculate the watts by this formula.

Be sure that the total running wattage of your

appliances does not exceed the running wattage of your generator.

It is better to combine totals that are less than the running rated wattage than to risk overload.

Before connecting electrical devices to your

generator you must calculate the wattage draw the devices will pull.Your electrical devices must not add up to more than the running wattage.

NOTE: The generator is designed to run at

maximum surge for a short period of time. That will allow a motor to start up without stalling the generator. Some appliances require short bursts of surge wattage to start or run their motors.

Watts= Amps x Volts

DO NOT COMBINE RUNNING WATTAGES THAT TOTAL THE SURGE WATTAGE OF YOUR GENERATOR AND ATTEMPT TO OPERATE.

If you find that your combined load will exceed the rating of your generator, you may need to group one or more devices on a separate Generator.

Tornado : Running Wattage: 5500 Surge Wattage: 6500

PT6500E

USING THE GENERATOR (AC)

9.Th

In case the battery is dead or

weak, the engine can be started with the pull start chord. Follow the same procedure as above.

urn te key to the right until the electric start motorengages. When the engine fires let the key returnto the run position.

Allow engine to warm up before pulling current from the generator.

Gale Force PT8500E: Running Wattage: 7000 Surge Wattage: 8500

3. Plug the devices into the proper receptacles. Standard 120 volt, single phase, 60 Hz loads only in the 120 Volt receptacles. All 120/240 Volt, single phase, 60 HZ loads with NEMA L14-30 male plug to the120/240 Volt receptacle (See Figure F below).

Make sure electrical devices are turned off.

Switch the circuit breaker into the position

ON.

Introduce electrical devices according to load. Heaviest wattage first, then add in lower wattage devices.

CAUTION: Do not attach 50Hz or 3-phase loads to your generator.

USING THE GENERATOR

Tool or ApplianceRatedWattsSurge Watts

Electric Water Heater (40 gal)40000 Hot Plate25000 Saw-Radial Arm20002000 Electric Stove15000 Saw-Circular15001500 Air Compressor (1 HP)15003000 Window Air Conditioner12001800

Saw12001200 Microwave10000 Well Water Pump10001000 Reciprocating Saw9601040 Sump Pump8001200 Refrigerator Freezer8001200 Furnace Blower8001300 Computer8000 Electric Drill600900 Television5000 Deep Freezer500500 Garage Door Opener4800 Stereo4000 Box Fan300600 Clock Radio3000 Security System1800 DVD Player1000 Common Light Bulb750

(running)

Miter-

Figure E

Note: This table shows estimated usage requirements, check

your device’s wattage information for actual requirements.

POWER CORD INFORMATION

WARNING!

To avoid damage to your machine, be sure to switch the circuit breaker OFF before changing the Voltage Selector Switch.

The voltage selector switch switches the main power of the generator into an 120V only mode or a 120V/240V mode.

In order to use a 240V appliance, you must have the selector set to 120V/240V mode. 120V appliances may be operated in either mode.

You may use both 240V and 120V devices simultaneously while in the 120V/240V mode, .but

do not use a 240V device in the 120V mode

VOLTAGE SELECTOR SWITCH INFORMATION

MINIMUM EXTENSION CORD GAUGE - 120 VOLT

EXTENSION CORD LENGTH

(At Full Load)

0-25’

16 16 14 12 10

25’-50’

16 16 14 12 10

50’-100’

16 14 12 10 10

100-150’

12 10

150’-200’

0-5

5.1 -8

8.1-12

12.1-15

15.1 -20

AMPS

Figure A

When using extension cords make sure that the cord is rated slightly higher than is recommended for the device you want to run. Cords that are too thin or that are too long can diminish the power flowing from your generator.

Follow the table below (Figure A) for some basic recommendations for extension cord length.

Make sure electrical devices are turned off.

Switch the circuit breaker into the ON position5..

Introduce electrical devices according to load. Heaviest wattage first, then add in lower wattage devices.

CAUTION: Do not attach 50Hz or 3-phase loads to your generator.

120V AC Receptacles

120/240V AC Recptacles

12V DC Receptacles

Disconnect electrical

load before

moving switch

SZB-T-F-V

GNAJ

HOUR METER

UL SOCKET

MAIN

BREAKER

CAUTION

AC 120V 20A

DC 12V

OFF

120V 120V/240V

OFF

DC PROTECTOR

AC 120V 20A

ON OFF

AC 120/240V 30A

OFF

RUN

STAR

Figure F

In the event of an overload, the circuit breaker will be tripped and the power running to any equipment or devices will be disrupted.

OFF ON

When this occurs the circuit breaker switch will be in the position…to reset, flip the switch to the position.

USING THE GENERATOR (DC)

WARNING:

CAUTION:

Do not use the DC receptacles to charge anything other than a 12V automotive type battery.

NEVER attempt to jump start a car with the generator.

Batteries contain acid and can become highly explosive when charged. Refrain from smoking or exposing batteries to open flames. ALWAYS wear protective clothing, safety goggles and gloves when recharging batteries. Flush skin with water that comes into contact with battery acid; flush eyes with water and consult a physician immediately. If you swallow battery acid, drink some milk and consult a physician immediately.

To attach a 12V battery to the DC receptacle:

1.Connect the positive end of the charging cable or wire to the positive end of the battery to be charged. Connect the negative end of the charging cable or wire to the negative end of the battery to be charged.

2. Next, connect the other end of the positive cable or wire to the positive receptacle of the generator. Start your generator.

3.Gently connect the free end of the negative charging cable or wire to the negative receptacle on the generator.

4. Take care to disconnect the charging cables or wires

from the generator first when done to avoid potential sparking.

DC output terminal (red) “+”, positive DC output terminal (black) “-“, negative

SHUTTING DOWN THE GENERATOR

To turn off the generator:

1.Turn off, then disconnect all devices and extension cords connected to the generator

2.Turn the circuit breaker to but run the generator for a few more minutes with no devices connected so that the generator’s temperature will cool slowly and evenly

3.Turn the engine switch to the position, then turn the fuel valve to the position.

4.Turn the engine switch to the position, then turn the fuel valve to the position.

OFF

THE CIRCUIT BREAKER

WARNING:

CAUTION:

Do not touch the generator until you have allowed it to cool. Touching the generator soon after shut off can result in burns or other injuries.

Never store your generator in areas of high heat or with fuel in the tank for long periods of time. Older gasoline, especially gasoline with ethanol, can become unstable quickly and make it more difficult to start your generator. Always disconnect the spark plug wire when storing. Store in a cool, dry place.

TRANSPORTATION AND STORAGE

If you anticipate storing your generator for long periods of time, or if you need to move your generator to another location, use the following procedures and recommendations:

Allow the generator to cool completely before

handling it or transporting it

Remove the gas

Disconnect your spark plug

1.Turn off, then disconnect all devices and extension cords connected to the generator

3. from the gas tank (see Empty Fuel Tank in the following Maintenance section)

5.Store in a cool, dry place and ensure that the generator has at least 4 feet of clearance on all sides

Make sure your

generator is OFF.

. Do not cover with

anything until cool!

GENERATOR MAINTENANCE AND THE HOUR METER

Performing regular maintenance, especially oil changes, is Important to long trouble free generator life. During prolonged power outages it is easy to lose track of exactly how many hours the generator has been in operation between oil changes. We have installed an hour meter to assist you in remembering to perform routine maintenance at recommended manufacturer’s guidelines.

Always make sure the ON/OFF Switch is in its

position. Disconnect the spark plug wire from the engine and allow sufficient time for the engine and generator to completely cool before performing any inspection, maintenance, or cleaning. Never carry out any maintenance procedure while the machine is running.

CAUTION! OFF

Be sure to check the overall condition of your generator.

Never use damaged equipment.

Remember to check the oil level in the generator's engine.

Make sure that there are no parts that are cracked, broken or misaligned. Be sure that moving parts are not impacted or bound in any way. Inspect the electrical wiring for obvious signs of wear or damage. If abnormal noise or vibration occurs you should diagnose and resolve the problem before further use.

Refer to the engine manufacturer's Operation,

Maintenance, and Parts Manual for specific information.

The amount of preventative upkeep and maintenance for any generator will depend upon the amount of use.

NOTE:

BEFORE EACH USE

Task

MAINTENANCE RECORD

Hours Date Initials

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Hours Date Initials

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Hours Date Initials

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Hours Date Initials Task Hours Date Initials Task

Hours Date Initials Task

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Hours Date Initials

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Hours Date Initials

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Hours Date Initials Task Hours Date Initials Task

Hours Date Initials Task

Hours Date Initials

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Hours Date Initials

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Hours Date Initials

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Hours Date Initials Task Hours Date Initials Task

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Recommended Maintenance Schedule

Air Filter: Check on each use, clean every 50 hrs/3 months Engine Oil: Check on each use, change and replace every 20 hrs/1 month Fuel Tank: Check level on each use, clean every 20 hrs/1 month and at 1yr Spark Plug: Check and clean every 100hrs/6 months Fuel Filter Cup: Check and clean every 100hrs/6 months

You should check the oil in your generator before every use. To do this:

1.As with any maintenance or operating procedure, make sure your machine is on an even, level surface

2.Remove the oil dipstick (see Figure G)

3.Wipe off any oil on the dipstick with a clean dry cloth and reinsert the dipstick into the oil filler hole. Remove again and check the level of the oil on the dipstick. If the oil level is low on the stick, or does not appear, you will need to fill the oil crankcase (see next section below).

4.Replace the oil dipstick and screw tight when done.

CHECK THE GENERATOR OIL

If water or contaminants have entered your oil crankcase, or if it is time for a scheduled oil change, follow the steps below to drain your oil:

1.First, place a pan beneath the generator to catch the oil as it drains.

2.Remove the oil drain plug located beneath the oil filler hole (see Figure I) and allow the oil to drain

3.Once oil has drained completely replace the oil drain plug with the wrench.

4.To refill the oil, first, make sure your machine is on an even, level surface

. Use a 10mm hex-head wrench.

Figure G

You should check the oil in your generator before every use. Follow the maintenance schedule for changing your oil as shown on page 14. The generator is equipped with a low oil automatic shutoff which will not allow the generator to run on insufficient oil levels. If your oil level is too low but it is still not time for an oil change, bring the oil level in the crankcase to the full level.

Note: The oil capacity of your generator is 37 fl. ounces.

CHANGING OR ADDING OIL

Figure H

5.Remove the oil dipstick (see Figure G)

6.Once oil has drained completely replace the oil drain plug with the wrench.

7.With the aid of

(see Figure H).

8. Please dispose of oil properly. Never pour

down drains or storm drains.

a funnel, add high detergent motor oil to the generator. See page 9 for recommendations (for most uses, SAE 10W-30). Check to see that the levels are near the top of the crankcase

CLEANING THE GENERATOR

You may clean the outside of your generator with a clean cloth, pressurized air, a soft bristle brush or vaccuum.

NEVER clean with water, as this may enter engine parts and compromise the life of your generator.

Figure I

FILLER CAP

DRAIN PLUG

Air cleaner maintenance is important to ensure proper airflow into the generator’s carburetor. Follow the maintenance schedule for checking and cleaning your air cleaner as shown on page 14.

When checking the air cleaner, visually inspect the cleaner to be sure that it is free from dirt and particles.

1.First, unclasp the springs on the bottom and top of the cleaner’s cover (see Figure J).

2.Remove the meshy components inside the air cleaner case

3.Wash with soapy warm water and let dry. Then coat and soak in engine oil and squeeze out any excess before returning to the air cleaner case.

4.Replace the cover and spring clasps.

MAINTAINING THE AIR CLEANER

Figure K

DRAINING THE FUEL TANK

Figure J

To inspect the spark plug, first:

1.Remove the spark plug cap and unscrew the spark plug using the spark plug wrench (See Figure K).

2.Look at the spark plug and check for defects such as cracks or chips. If any of these defects are visible, replace with a new spark plug

3.Next, measure the spark plug gap, which

4.If you are not replacing the spark plug, clean around the base of the one to be reused and then reset the gap. Screw the plug back in, using the spark plug wrench and replace the plug cap.

. Use a F6RTC

spark plug such as NGKBPR5ES.

should be

0.7-0.8 nun (0.028-0.031 in). See Figure K.

MAINTAINING THE SPARK PLUG

CLEANING THE FUEL FILTER CUP

The fuel filter cup helps to strain out dirt and impurities that are attempting to get into the engine. To clean this cup:

1.First, move the fuel valve to

2.Use a wrench to remove the cup from the fuel valve (see Figure L, below).

3.Clean the cup of debris using a clean cloth, q-tip or brush and then replace.

OFF.

Figure L

If you are storing your generator for long periods of time you should drain the gas tank to avoid starting trouble the next time you attempt to use it. To do this:

1.First, move the fuel valve to and remove the fuel filter cup (see above and Figure L). Empty the cup of any fuel present.

2.Place a drain pan or container underneath the generator to contain the gas to be drained, then turn the fuel valve to

3.Once all gas has drained, turn the fuel valve back to the position. Wipe any excess gas from the body of your generator and replace the fuel filter cup.

OFF

ON.

OFF

0.7-0.8mm (0.026-0.031 in)

PLUG CAP

PLUG WRENCH

COVER SPRING

AIR CLEANER COVER

ELEMENT

FUEL VALVE

FUEL FILTER CUP

CHANGING THE CARBON BRUSH

2 3

4 5 6

Dismantle the 2 bolts (M5 x 12) of electric machine back-cover.

Take down the installed bolts (M5 x 16) of carbon-brush.

Take down the carbon-brush from DC wire of excitation.

Install the electric machine back

-cover with 2 bolts (M5 x 12).

Insert and connect the DC wire of excitation according to anode-cathode.

Install the new carbon-brush with bolts (M5 x 16).

CHANGING THE AUTOMATIC VOLTAGE REGULATOR

2 3

4 5 6

Dismantle the 2 bolts (M5 x 12) of electric machine back-cover.

Take down the 2 installed bolts (M5 x 16) of AVR.

Disconnect the sample wire hindered.

Connect the sample wire hindered.

Install the new AVR with 2 bolts (M5 x 16)

Take down the AVR from carbon-brush

Insert and connect the DC wire of excitation according to anode-cathode.

Install the electric machine back-cover with 2 bolts (M5 x 12)

TORNADO PT6500E/GALE FORCE PT8500E WIRING DIAGRAM

PT6500E/PT8500E DETAIL VIEW AND PARTS LIST

Item Part Qty Description Item Part Qty Description

1 DJ188F-16121-C 1 Startercomp,recoil 43 DJ190FD-14100-A 1 Carburetorassy. 2 GBT5789-B6-8 3 FlangeboltM6×8 44 DJ188F-14003-B 1 Packing,carburetor 3 DJ188F-16120-A 1 Fan,covercomp 45 DJ188FD-14004-A 1 Insulator,carburetor 4 GBT5789-B6-12 13 FlangeboltM6×12 46 GBT6177/10-N-6 2 FlangenutM6 5 DJ188F-11012-A 1 Shroudcomp 47 DF6500H-14205-A 1 Stay,aircleaner 6 DJ168F-11039-A 3 Clip.Wiredarkness 48 DJ188FD-14203-A 1 Casecomp,aircleaner 7 DJ168F-16118-A 1 Grommetdrainhole 49 DJ188FD-14202-A 1 RetainerFilterElement 8 DJ188F-18600-A 1 Startmotor 50 GB/T6177-2000 6 FlangenutM5 9 GBT16674 2 FlangeboltM8× 35 51 DJ188FD-14204-A 1 Covercomp,aircleaner 10 GBT6177-N-14 1 FlangenutM14 52 DJ188FD-14207-A 2 Clip,aircleanerware 11 DJ188F-16000-A 1 Pulley,starter 53 DJ188FD-14201-A 1 Element,aircleaner 12 DJ188F-16002-A 1 Fan,cooling 54 DJ188FD-14206-A 1 Seal,aircleaner 13 DJ168F-12104-A 1 Key 55 DJ188F-14005-A 1 Packing,insulator 14 DJ188F-16200-G 1 Flywheelcomp 56 14601 4 Clip,tube 15 DJ188F-11014-A 2 Oilseal,35×52×8 57 14013 1 Valve,dashpotcheckassy. 16 DJ190F-11100-D 1 Crankcaseassy. 58 14034 1 Tube,fuel φ45×165 17 DJ168F-18300-A 1 Amplifier 59 DJ188FD-11013-A 1 Tube,breather 18 DJ188F-11004-A 2 Bolt,drainlug 60 GBT5787-B10-80 4 FlangeboltM10×80 19 DJ188F-11005-A 2 Washer,drainlug 61 DJ188F-11200-B 1 Headcomp,cylinder 20 DF2500H-34118-A 1 Clip,wire 62 DJ188F-14002-A 2 Bolthead,M8×48 21 34218-001 1 IdleControlComponent 63 DJ168F-18500-A 1 Plug,spark 22 GBT5789-B6-25 2 FlangeboltM6×25 64 DJ190F-13100-C 1 Camshaftassy. 23 DJ188FB-18106-A 1 Cordstopswitch 65 DJ190F-13009-A 2 Lifter,valve 24 DJ188F-11017-A 1 Grommetcord 66 DJ188F-13001-A 1 Valve,IN. 25 DJ188F-18100-C 1 Coilassy.ignition 67 DJ188F-13002-A 1 Valve,EX. 26 DJ188F-15009-A Oilseal, Φ8×φ14×5 68 DJ188F-13011-A 1 Seat,valvespring 27 DJ188F-11014-A 2 Oilseal,Φ 35×Φ52×8 69 DJ188F-13005-A 1 Retainer,EX.Valvespring 28 DJ188F-15001-A 1 Shaft,governorarm 70 DJ188F-13006-A 1 Rotator,valve 29 DJ188F-15003-A 1 Pin,lock 71 DJ188F-13004-A 1 Retainer,IN.Valvespring 30 DJ188F-15002-A 1 Washer, Φ8×1 72 DJ188F-13003-A 2 Spring,valve 31 GB/T6177-2000 1 FlangenutM10 73 DJ190F-13008-A 2 Rod,push 32 DJ188F-18202-A 1 O-ring,14mm 74 DJ188F-11011-A 1 Exhaustpiper 33 DJ188F-18200-A 1 OilSensor 75 DJ188F-11300-B 1 Covercomp,head 34 DJ188F-12004-A 1 BalancingShaft 76 DJ188F-11016-A 1 Washercompheadcover 35 DJ190F-12100-BB 1 Crankshaftcomp 77 DJ188F-11015-A 1 Bolt,headcover 36 GB276-89-6207 2 Radialballbearing(6207) 78 GBT6175-N-8 2 NutM8 37 DJ188F-11009-A 2 Pin,dowel,12 ×20 79 DJ188FD-14009-B 1 PipecompEX. 38 DJ190F-11010-C 1 Casket,cylinderhead 80 DJ188FD-14010-A 1 Casket(B)EX.Pipe 39 DJ188FD-14001-A 2 Bolthead,8×106 81 DJ188F-13300-A 1 Plate,pushrodguide 40 DJ188F-14027-A 2 Gasket,AirCleaner 82 DJ188F-13202-A 2 Bolt,pivot 41 DJ188F-14012-A 1 Stayassy.Manualchoke 83 DJ188F-13201-A 2 Arm,valverocker 42 DJ188F-14501 1 Grommetfender 84 DJ168F-13203-A 2 Nut, Arm,valverocker

85 DJ168F-13204-A 2 Nut,pivotadjusting 96 DJ190F-12001-B 1 Piston 86 GBT16674-B8-40 7 FlangeboltM8×40 97 DJ190F-12002-A 1 Pin,piston 87 DJ188FD-11001-B 1 Crankcasecover 98 DJ190F-12200-B 1 Connectingrodassy. 88 GBT818-S5-10 3 FlangeboltM5× 10 99 DJ188FD-15200-A 1 Controlassy. 89 DF3800H-11032-A 1 Fancover 100 DJ188F-15007-A 1 Spring,governor 90 DJ188F-11007-A 1 Capassy.oilfiller 101 DJ188F-15008-A 1 Spring,throttlereturn 91 DJ188F-15100-A 1 Governorkit 102 DJ188F-15004-B 1 Arm,governor 92 DJ188F-11003-B 1 Packing,casecover 103 DJ188F-15006-A 1 Rod,governor 93 DJ168F-11002-B 1 Pin,dowel,7×12 104 DJ188F-15005-A 1 Bolt,governorarm 94 DJ190F-12300-A 1 Pingsetassy.piston 105 DJ168F-11002-C 1 Pin,dowel,9×12 95 DJ188F-12003-A 2 Clip,pistonpin

PT8500E DETAIL VIEW AND PARTS LIST

Item Part QtyDescription Item Part Qty Description

106 1 Gasolineengine 149 DF6500H-31073-A 2 HandleHead 107 DF8000H-33013-A 4 Flangebolt 150 DF6500H-31074-A 4 Gasket,handle 108 DF3800H-33005-A 1 GeneratorStay 151 DF6500H-31058-F 1 HandpushF 109 DF8000H-33003-A 1 Bolt 152 DF6500H-31058-A 1 HandpushA 110 GB/T97.1-1987 1 Plainwasher Ф 10 153 GBT16674-B8-45 2 Bolt,handleM8×45 111 GB/T2776-1994 1 Bearing6204DU 154 GBT6183-N-8 10 NutM8 112 DF8000H-33110-B 1 RotorAssembly 155 GB6183-N-10 4 FlangenutM10 113 DF8000H-33104-A-23

610

1 Stator&RotorAssy. 156 GBT5789-86 4 FlangeboltM8x16

114 DF3800H-33023 1 GeneratorFan 157 DF2500H-31019-B 2 Ф 3.2Pin 115 DF8000H-33016 1 Statorcover 158 DF6500H-31017-O 2 Wheels10” 116 DF8000H-33120-B 1 StatorAssy. 159 XP8500E-31020-A 2 Foot 117

DF3800H-33001-A 1 BrushAssembly

160 XP8500E-31018-A 1 Wellshaft

118

DF8000H-33011-A 1 VoltageRegulator

161 DFD2500H-31061-A 1 batteryplate

119 DF3800H-33002-A 1 ConnectingPlate 162 31038-004 1 Positivewireof battery 120 GBT5789-B5-12 9 Screw M5×12 163 31040-004 1 NegativeWireofbattery 121 DF3800H-33006-B1 Generatorendcover 164 31300-002 1 9Ahbattery

122 DF3800H-14322-D 1 Stripe,fueltank 165 34107 1 EarthTerminalSet 123 DF3800H-14300-B 1 Fueltank 166 GBT5789-B6-16 4 BoltM6×16

124 14307 1 FuelFiller 167 34204-003 1 Receptacle(30A) 125 14310 1 Packingring 168 34204-005 2 Receptacle(20A) 126 14306 1 Fuelfillercapcomp 169 34206-049 1 Circuitprotector 127 14303 1 Fuelsensor 170 GBT801-B3-8 BoltM3x8 128 GB819-95 2 ScrewM5x10 171 34208-004 1 8ACircuit Protector 129 14313 1 GasketFuelSensor 172 34204-038 1 DCpoles A 130 GB/T5787-1996 4 FlangeboltM6x25 173 34204-039 1 DCpolesB 131 DF2500H-14311-A 4 Washer 174 34205-001 1 Hourmeter 132 14305 4 Collar 175 34211 1 Diodeassay 133 14304 4 Cushion 176 34244 1 Engineswitch 134 DJ188FD-14007-A 1 OutletPipe 177 34109 1 Boot,switchwire 135 DJ168F-14008-A 1 TubeCock 178 34109-B 1 Boot,mainwireharness 136 DJ168F-14008-A 1 TubeCock 179 34109-A 1 Boot,ACoutputwire 137 DF2500H-14302-A 1 FuelCock 180 34212-A 1 WireharnessAssy. 138 DF3800H-14403-A 1 OuterHood 181 34101-A 1 ControlPanel 139 GB5787-1996 2 FlangeboltM8X25 182 34208-028 1 Fuse 140 DJ188FD-14010-B 1 GasketExhaustPipe183 34102-A 1 Controlpanelcase 141 DF8000H-14400-D 1 MufferAssembly 184 34217-001 1 Currentsensor 142 DF3800H-14416-B 1 InnerHood 185 DFD6500H-34213-001 1 Wire 143 DF3800H-14403-A 1 SideHood 186 34225 1 Charger 144 GBT5789-B6-16 12 BoltM6x16 187 34226-001 1 lamp 145 XP8500E-31100-A 1 Framecomp 188 34203-005 1 IIdlecontrolswitch 146 DF3800H-31201-A 2

BottomrubberA (5KW)

189 34202-001 1 Voltageselector

147 DF3800H-31202-A 2

BottomrubberB (5KW)

148 GB6183-N-8 4 FlangenutM8

TROUBLESHOOTING GUIDE

Use caution and common sense when attempting to diagnose any problems you might be having with your generator. Please study the safety and operation precautions found earlier in this manual.

If you are having trouble starting your generator:

1.First, make sure that the .

2.Make sure the .

3.Check to see that you have . If you are attempting to start the generator after a long period of storage, . You may need to change the gas.

4. If low, fill to the proper level.

5.Make sure the spark plug is not dirty or broken;

6.Make sure the .

7.Make sure generator is on a level surface.

1.First, make sure that the .

2.Make sure that one of the . Remove all connected devices and try running one device at a time to check.

3. e

1.First, make sure you have not overloaded the generator. Remove all connected devices and try running one device at a time to check. Make sure that the connected devices do not exceeding the rated running wattage of your generator.

2.Make sure that one of the .

3.Make sure that the air cleaner does not need to be cleaned or replaced

4.Make sure that the length of your extension cords is not affecting the reduced draw

engine switch is ON

fuel valve is set to OPEN

enough gas to start the generator

make sure the gas is not old

Check your oil level.

clean the plug if necessary or replace if cracked,

chipped or broken

choke is closed

Attempting to start your generator while on uneven

ground may cause the automatic low oil shutoff to trigger.

circuit breaker is ON

devices connected to your generator is not faulty

Check your device cables or extension cordsto mak sure that they are not at fault.

devices connected to your generator is not faulty Remove all

conneced devices and try running one device at a time t check.

. Use the

shortest extension cords possible.

If your generator produces no electricity but is running:

If your generator cannot run all connected devices:

Customer service and product support are available on line at www.pentagontool.com.

PENTAGON TORNADO PT6500E, GALE FORCE PT8500E Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual