Poulan PPG 6000 User Manual

Page 1

Portable Electric Generator

Owner's Manual MODEL: PPG 6000

IMPORTANT - Please make certain the person

who uses this generator thoroughly reads these instructions and all other instructions provided to ensure proper safety, use, and care of your new portable electric generator.

420344 Rev. 1 05.05.08 CL Printed in U.S.A.

Page 2

TABLE OF CONTENTS

INTRODUCTION .................................................................................................2

SAFETY RULES ............................................................................................. 3-4

SYMBOLS ....................................................................................................... 5-7

FEATURES ..................................................................................................... 8-9

ASSEMBLY ................................................................................................. 10-12

OPERATION ............................................................................................... 13-15

ELECTRICAL ....................................................................................................16

MAINTENANCE .......................................................................................... 17-19

STORAGE .........................................................................................................19

TROUBLESHOOTING ......................................................................................20

WIRING DIAGRAM ...........................................................................................21

REPAIR PARTS .......................................................................................... 22-26

WARRANTY ................................................................................................ 27-29

PARTS ORDERING/SERVICING ................................................ BACK COVER

INTRODUCTION

This product has many features for making its use more pleasant and enjoyable. Safety, performance, and dependability have been given top priority in the design of this product, making it easy to maintain and operate.

In the State of California, a spark arrester is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands. The muffler is equipped with a spark arrester; it must be maintained in effective working order.

Replacement spark arresters may be obtained by calling 1-866-237-1049.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

IMPORTANT!

FILL OUT ENCLOSED PRODUCT REGISTRATION CARD AND MAIL

Page 3

SAFETY RULES

DANGER

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

Breathing carbon monoxide will cause nausea, fainting, or death.

• Operate generator ONLY outdoors.

• Keep clearance on all sides of generator for ventilation.

• DO NOT operate generator inside any building or enclosure, including the generator compartment of a recreational vehicle (RV).

adequate

DANGER

Failure to properly ground generator can result in electrocution, especially if the generator is equipped with a wheel kit.

• National Electric Code requires generator to be properly grounded to an approved earth ground. Call an electrician for local grounding requirements.

DANGER

Generator produces powerful 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 other forms of precipitation.

• 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

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 gas cap. Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• DO NOT overfill tank.Allow space for fuel expansion.

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

• DO NOT light a cigarette or smoke.

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 in the OFF position.

• 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 bodily injury and/or property damage.

Page 4

SAFETY RULES

WARNING

Unintentional sparking can result in fire or electric shock.

WHEN ADJUSTING OR MAKING REPAIRS TOYOUR GENERATOR

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

WARNING

Running engines produce heat. Temperature of muffler and nearby areas can reach or exceed 150°F (65°C).

Severe burns can occur on contact.

• DO NOT touch hot surfaces.

• Allow equipment to cool before touching.

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.

CAUTION

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

• See “Don’t Overload Generator” on page 16.

• 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.

CAUTION

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 your dealer or contact customer service at 1-866-237-1049.

• 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.

Page 5

SYMBOLS

Some of the following symbols may be used on this generator. Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the generator better and safer.

SYMBOL NAME DESIGNATION/EXPLANATION

V Volts Voltage

A Amperes Current

W Watt Power

min Minutes Time

Hertz Frequency (cycles per second)

Alternating Current Type of current

Direct Current Type of current

No Load Speed Rotational speed, at no load

Wet Conditions Alert Do not expose to rain or use in damp locations.

Read The Operator's Manual

Eye Protection

Safety Alert Precautions that involve your safety.

Electrocution

Electrical Shock

Electrical Shock Unintentional sparking can result in electric shock.

Toxic Fumes

To reduce the risk of injury, user must read and understand operator's manual before using this product.

Always wear safety goggles or safety glasses with side shields and a full face shield when operating this product.

Failure to properly ground generator can result in electrocution especially if the generator is equipped with a wheel kit.

Generator produces powerful voltage. Failure to isolate generator from power utility can result in death or injury to electrical utility workers due to backfeed of electrical energy.

Running generator gives off carbon monoxide, an odorless colorless, poison gas. Breathing carbon monoxide can cause nausea, fainting, or death.

Fire

Explosion

Hot Surface

Ground

Fuel and its vapors are extremely flammable. Fire can cause severe burns or death.

Fuel and its vapors are extremely explosive. Explosions can cause severe burns or death.

To reduce the risk of injury or damage, avoid contact with any hot surface.

Consult with local electrician to determine grounding requirements before operation.

Page 6

SYMBOLS

The following signal words and meanings are intended to explain the levels of risk associated with this product.

SYMBOL SIGNAL MEANING

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death

or serious injury

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death

or serious injury

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor

or moderate injury

CAUTION: (Without Safety Alert Symbol) indicates a situation that may result in property damage

SERVICE

Servicing requires extreme care and knowledge and should be performed only by a qualified service technician. For service we suggest you return the product to your nearest AUTHORIZED SERVICE DEALER for repair. When servicing, use only identical replacement parts.

WARNING:

DANGER:

To avoid death or serious personal injury, do not attempt to operate this product until you thoroughly read the owner's manual and understand it completely. Save this operator’s manual and review frequently for continuing safe operation and instructing others who may use this product.

Observe all normal safety precautions related to avoiding electrical shock.

WARNING:

The operation of any product can result in foreign objects being thrown into your eyes, which can result in severe eye damage. Before beginning operation, always wear safety goggles or safety glasses with side shields and full face shield when needed. We recommend Wide Vision Safety Mask for use over eyeglasses or standard safety glasses with side shields. Always wear eye protection which is marked to comply with ANSI Z87.1.

SAVE THESE INSTRUCTIONS

Page 7

SYMBOLS

SAFETY LABELS

The following labels are found on the generator. For your safety, please study and understand all of the labels before starting the generator.

If any of the labels come off the unit or become hard to read, contact an authorized service center for replacement.

FUEL WARNING

DO NOT SMOKE when filling with gasoline. Do not over

fill. Full level is 1 inch below the top of the fuel neck. Stop the engine two minutes before refueling to avoid the heat from the muffler igniting fuel vapors.

$!.'%2

You will be KILLED or SERIOUSLY HURT if you do not follow the Owner’s Manual

instructions.

Do not expose to rain or use in damp locations.

Risk of Fire. Do not add fuel while the product is operating.

Exhaust contains poisonous carbon monoxide gas that can cause unconsciousness or DEATH. Operate in well ventilated, outdoor

areas away from open windows or doors.

Generator is a potential source of electric shock. Do not expose to moisture, rain, or snow. Ground the system. Do not operate with wet hands or feet.

HOT MUFFLER WARNING

Do not touch the muffler or aluminum cylinder of the engine. They are very HOT and will cause severe burns. Don’t put any flammable or combustible materials in the direct path of the exhaust.

#HECKªFORªANYª

FUELªOVERFLOWªOR

LEAKING

3TOPªTHEªENGINE

BEFOREªREFUELING

ENGINE OIL WARNING

You must add oil before the first operation of the generator. The oil reservoir capacity is 1.2 quarts. Always check the oil level before each operation. The oil level should always register on the dipstick.

WARNING

HOT

MUFFLER

DO NOT

TOUCH

VENTILATION WARNING

Do not use the generator in an enclosed area or near open windows, vents, or doors. Fumes from the unit can kill.

Page 8

SPECIFICATIONS

FEATURES

ENGINE

Engine Type..............................4 Stroke, Overhead Valve

Cylinder Discharge Capacity...................................389 cc

Bore x Stroke..................................................3.5 x 2.5 in.

Cooling System...................................Forced Air Cooling

Ignition System........................Transistor Magnet Ignition

Spark Plug................................................NGK or BP6ES

Spark Plug Gap..............................................0.28 - .031 in.

Engine Oil Volume...................................................1.2 qt.

Oil Type (API-SG-SL).....................................SAE 10W30

Fuel Volume...........................................................6.6 gal.

Compression Ratio....................................................8.0:1

FUEL LEVEL

FUEL TANK

CAP

GAUGE

GENERATOR

Rated Voltage..................................................120V/240V

120V/240V Receptacle Plug Type..........................L14-30

Rated Frequency......................................................60 Hz

Rated Maximum Continuous Load Current........50/22.7 A

Maximum Rated Watts.........................................6,200 W

Continuous Wattage Capacity..............................5,800 W

DIMENSIONS

Length...................................................................26.7 in.

Width........................................................................20 in.

Height..................................................................21.25 in.

Dry Weight............................................................187 lbs.

FUEL TANK AC CIRCUIT

BREAKER

120 VOLTS AC

RECEPTACLES

CHOKE LEVER

AIR FILTER

FUEL VALVE

RECOIL STARTER

GRIP

ENGINE SWITCH

GROUNDING

TERMINAL

120/240 VOLTS AC

RECEPTACLES

OIL FILL CAP/DIPSTICK

OIL DRAINAGE BOLTS

Fig. 1

Page 9

FEATURES

KNOW YOUR GENERATOR

See Figure 1.

Before attempting to use this product, familiarize yourself with all operating features and safety rules.

GROUNDING TERMINAL

The grounding terminal is used to assist in properly grounding the generator to help protect against electrical shock. Consult with a local electrician for grounding requirements in your area.

RECEPTACLES

Your generator has the following single phase, 60 Hz outlets: four 120 Volt AC, 20 Amp, and one 120 Volt/240 Volt AC, 30 Amp. The receptacles can be used for operating appropriate appliances, electrical lighting, tools, and motor loads.

AC CIRCUIT BREAKER

The circuit breaker is provided to protect the generator against electrical overload and can be used to turn the generator’s power on or off.

ENGINE SWITCH

The engine switch is used in combination with the recoil starter grip to start the generator. It is also used to turn the generator off.

RECOIL STARTER GRIP

The recoil starter grip is used (along with the engine switch) to start the generator’s engine.

FUEL VALVE

The flow of fuel through the generator is controlled by the position of the fuel valve.

AIR FILTER

The air filter helps to limit the amount of dirt and dust drawn into the unit during operation.

CHOKE LEVER

Use the choke lever for starting a cold engine.

OIL DRAINAGE BOLT

When changing the engine oil, the oil drainage bolt is loosened to allow old engine oil to be drained.

FUEL LEVEL GAUGE

Consult the fuel level gauge to determine the amount of fuel remaining in the generator.

FUEL TANK

The fuel tank has a capacity of 6.6 gallons.

OIL FILL CAP/DIPSTICK

Remove the oil cap to check and add oil to the generator when necessary.

Page 10

ASSEMBLY

The following tools are required for assembly:

10 mm BOX-END WRENCH 12 mm OPEN-END WRENCH

UNASSEMBLED PARTS

The following assembly hardware items are included with the generator. (

Wheel Assembly..............................................................1

Handle Assembly.............................................................1

Foot Assembly.................................................................1

See Figure 3.)

Fig. 2

ITEM NUMBER QUANTITY

Fig. 3

Page 11

ASSEMBLY

INSTRUCTIONS

This product requires assembly.

■ Carefully remove the generator and any accessories

from the box. NOTE: The generator is heavy. To avoid back injury, lift with

your legs, not your back, and get help when needed.

■ Make sure that all items listed in the unassembled

parts list are included. (

■ Inspect the generator carefully to make sure no

breakage or damage occurred during shipping.

■ Do not discard the packing material until you have

carefully inspected and satisfactorily operated the generator.

■ If any parts are damaged or missing, please call

1-866-237-1049 for assistance.

See Figure 3.)

PACKING LIST

Generator Wheel Assembly Handle Assembly Foot Assembly Container of Oil Warranty Card Owner's Manual

INSTALLING HANDLE ASSEMBLY

See Figure 4.

■ Locate the following items:

Handle (5) Left and right handle brackets (2) 4 bolts (3) 4 square curved washers (14) 4 nuts (6) 4 flat washers (4)

■ Align left handle bracket with hole in left side of

generator frame. Insert bolt through handle bracket and frame. Slide curved washer on end of bolt, making sure the cupped side of washer faces the frame. Assemble nut; finger tighten. _

■ Repeat above step with right handle bracket.

■ Put one side of handle inside left handle bracket.

Slide washer over bolt, then insert bolt through the bracket handle and bracket. Push bolt through so that it exits on the other side of the handle, then add another washer and the nut. Finger tighten.

■ Repeat above step with other side of the handle and

the right handle bracket.

■ Return to the first bolt installed. While holding bolt

head steady with 10 mm box-end wrench, use 12 mm open-end wrench to tighten snugly. ( Repeat with remaining bolts.

See Figure 2.)

WARNING:

If any parts are missing, do not operate this generator until the missing parts are replaced. Failure to do so could result in possible serious personal injury.

WARNING:

Do not attempt to modify this generator or create accessories not recommended for use with this generator. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious personal injury.

WARNING:

Do not attempt to operate the generator until assembly is complete. Failure to comply could result in possible serious personal injury.

WARNING:

Do not attempt to lift the unit by the handle assembly. If it is necessary to lift the generator, always grasp by the frame. Use proper lifting techniques to avoid back injury.

Fig. 4

Page 12

ASSEMBLY

INSTALLING WHEEL ASSEMBLY

See Figure 5.

■ Locate the following items:

2 wheels 2 square curved washers (14) 2 flat washers (4) 2 hex nuts (11) 2 nuts (6)

■ Slide wheel over axle extension.

■ Slide flat washer on axle extension.

■ Install hex nut on axle extension and tighten to

secure.

■ Repeat for second wheel.

NOTE: Block up frame securely with wood blocks to provide clearance for frame bolts & wheel assembly.

■ Slide square curved washer, curved side down,

on bolt.

■ Place on frame and slide bolt through frame

hole.

■ Repeat for second bolt.

■ Lift axle and align hole with installed frame bolts.

■ Install nuts on 2 bolts and tighten to secure

Fig. 5

INSTALLING FOOT ASSEMBLY

See Figure 6.

■ Locate the following items:

2 foot supports (12) 6 bolts (13)

NOTE: Block up frame securely with wood blocks to provide clearance for foot support assembly.

■ Align foot support with 3 holes in frame cross member.

■ Insert 3 bolts into welded nuts on foot support.

■ Tighten bolts to secure

■ Repeat for second foot.

Fig. 6

Page 13

OPERATION

GROUNDING THE GENERATOR

The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the unit. For that purpose, a GROUNDING FASTENER is provided on the generator end (Figure 7).

Grounding Fastener

Fig. 7

Generally, connecting a No. 12 AWG (American Wire Gauge) stranded copper wire to the grounding fastener and to an earth-driven copper or brass grounding rod (electrode) provides adequate protection against electrical shock. Be careful to keep the grounding wire attached after connecting the stranded copper wire. However, local codes may vary widely.

WARNING:

Consult with a local electrician for grounding requirements in your area.

Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or in connected electrical devices, especially when the unit is equipped with a wheel kit. Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices.

Page 14

DANGER:

OPERATION

Failure to properly ground generator can result in electrocution, especially if the generator is equipped with a wheel kit. National Electric Code requires generator to be properly grounded to an approved earth ground. Call an electrician for local grounding requirements

WARNING:

Do not use any attachments or accessories not recommended by the manufacturer of this generator. The use of attachments or accessories not recommended can result in serious personal injury.

APPLICATIONS

This generator is designed to supply electrical power for operating compatible electrical lighting, appliances, tools, and motor loads.

BEFORE OPERATING THE UNIT

Position the generator on a flat surface before checking fluid levels or adding fluid.

CAUTION:

Attempting to start the engine before it has been properly filled with oil will result in equipment failure.

OIL DIPSTICK

OIL FILL HOLE

Fig. 8

RES

FUEL

CHECKING/ADDING OIL

See Figure 8.

Engine oil has a major influence on engine performance and service life. For general, all-temperature use, SAE 10W-30 is recommended. Always use a 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ.

NOTE: Non-detergent or 2-stroke engine oils will damage the engine and should not be used.

■ Unscrew the oil dipstick and remove.

■ Wipe dipstick clean and reseat in hole. Do not rethread

■ Remove dipstick again and check oil level. Oil level

should fall within the hatched area on the dipstick.

■ If level is low, add engine oil until the fluid level rises

to the upper portion of the hatched area on the dipstick.

■ Replace and secure the dipstick.

CHECKING/ADDING FUEL

See Figure 9.

■ Check the fuel level gauge. If fuel is needed,

continue with the next step.

■ Remove the fuel tank cap.

■ Fill the fuel tank to 1 in. below the tip of the fuel neck.

■ Replace and secure the fuel tank cap.

FUEL LEVEL

GAUGE

FUEL TANK CAP

NOTE: Always use unleaded gasoline with a pump octane

rating of 86 or higher. Never use old, stale, or contaminated gasoline, and do not use an oil/gas mixture. Do not allow dirt or water to enter the fuel tank.

FUEL TANK

OXYGENATED FUELS

Some conventional gasolines are blended with alcohol or an ether compound. These gasolines are collectively referred to as oxygenated fuels. To meet clean air standards, some areas of the United States use oxygenated fuels to help reduce emissions.

Fig. 9

Page 15

OPERATION

If using an oxygenated fuel, make sure it is unleaded and meets the minimum octane rating requirements. Before using an oxygenated fuel, try to confirm the fuel’s contents. Some states/provinces require this information to be posted on the pump. The following are the EPA approved percentages of oxygenates:

Ethanol (ethyl or grain alcohol) 10% by volume. You may use gasoline containing up to 10% ethanol by volume. Gasoline containing ethanol may be marketed under the name “Gasohol.”

MTBE (methyl tertiary butyl ether) 15% by volume. You may use gasoline containing up to 15% MTBE by volume.

Methanol (methyl or wood alcohol) 5% by volume. You may use gasoline containing up to 5% methanol by volume as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems. It may also damage metal, rubber, and plastic parts of the generator or your fuel system.

If you notice any undesirable operating symptoms, try another service station or switch to another brand of gasoline.

NOTE: Fuel system damage or performance problems resulting from the use of an oxygenated fuel containing more than the percentages of oxygenates mentioned above are not covered under warranty.

RECOIL

STARTING

GRIP

ENGINE

SWITCH

CIRCUIT

BREAKER

Fig. 10

OFF

FUEL

VALVE

WARNING:

On a level surface with the engine off, check the oil level before each use of the generator.

STARTING THE ENGINE

See Figures 10 - 12.

NOTE: If location of generator is not level, the unit may not start or may shut down during operation.

■ Unplug all loads from the generator.

■ Switch the circuit breaker to the ON position.

■ Turn the fuel valve to the ON position.

■ Move the choke lever to the ON (closed) position.

NOTE: When starting a warm engine, leave the choke in the OFF (open) position.

■ Put the engine switch in the ON position.

■ Pull the recoil starting grip lightly until you feel a

resistance, then pull it briskly. NOTE: Do not allow the grip to snap back after starting;

return it gently to its original place.

■ As the engine warms, slowly move the choke lever

to the OFF position.

STOPPING THE ENGINE

See Figures 10 - 12.

To stop the engine under normal operating conditions:

■ Remove any load from the generator.

Fig. 11

MOVE CHOKE

LEVER TO "ON"

POSITION TO

Fig. 12

■ Switch the AC circuit breaker to the OFF position.

■ Put the engine switch in the OFF position.

■ Turn the fuel valve to the OFF position.

To stop the engine in an emergency situation:

■ Put the engine switch in the OFF position.

Page 16

ELECTRICAL

DON'T OVERLOAD GENERATOR

CAPACITY

Make sure the 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 the generator must produce to keep the items running. See the wattage reference chart at the right.

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 Rated (Running)

Window Air Conditioner

Refrigerator 800 1600

Deep Freezer 500 500

Television 500 −

Light (75 Watts) 75 −

Watts

1200 1800

3075 Total

Running Watts

Total Rated (Running Watts) = 3075 5800 Highest Additional Surge Watts = 1800 Total Generator Output Required = 4875 6200

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 the 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 earlier 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

1800 Highest

Surge Watts

Maximum

Allowed

WARNING:

Do not overload generator's capacity. Exceeding generator's wattage/amperage capacity can damage generator and/or electrical devices connected to it.

Tool or Appliance

Essentials

Light Bulb-75 Watt 75 −

Deep Freezer 500 500

Sump Pump 800 1200

Refrigerator/Freezer - 18 Cu. Ft. 800 1600

Water Well Pump - 1/3 HP 100 2000

Heating/Cooling

Window AC - 10,000 BTU 1200 1800

Window Fan 300 600

Furnace Fan Blower - 1/2 HP 800 1300

Kitchen

Microwave Oven - 1000 Watt 1000 −

Coffee Maker 1500 −

Electric Stove - Single Element 1500 −

Hot Plate 2500 −

Family Room

DVD/CD Player 100 −

VCR 100 −

Stereo Receiver 450 −

Color Television - 27" 500 −

Personal Computer w/17" monitor 800 −

Other

Security System 180 −

AM/FM Clock Radio 300 −

Garage Door Opener - 1/2 HP 480 520

Electric Water Heater - 40 Gal. 4000 −

DIY/Job Site

Quartz Halogen Work Light 1000 −

Airless Sprayer - 1/3 HP 600 1200

Reciprocating Saw 960 960

Electric Drill - 1/2 HP 1000 1000

Circular Saw - 7-1/4" 1500 1500

Miter Saw - 10" 1800 1800

Planer/Jointer - 6" 1800 1800

Table Saw/Radial Arm Saw - 10" 200 2000

Air Compressor - 1-1/2 HP 2500 2500

*Wattages listed are approximate. Check tool or appliance for actual wattage.

Rated*

(Running)

Watts

Additional

Surge

(Starting)

Watts

Page 17

MAINTENANCE

WARNING:

When servicing, use only identical Poulan Pro replacement parts. Use of any other parts may create a hazard or cause product damage.

Only the parts shown on the parts list are intended to be repaired or replaced by the customer. All other parts should be replaced at a Poulan Pro Authorized Service Center.

GENERAL MAINTENANCE

Keep the generator in a clean and dry environment where it is not exposed to dust, dirt, moisture, or corrosive vapors. Do not allow the cooling air slots in the generator to become clogged with foreign material such as leaves, snow, etc.

Do not use a garden hose to clean the generator. Water entering the fuel system or other internal parts of the unit can cause problems that will decrease the life of the generator.

To clean the unit:

■ Use a soft bristle brush and/or vacuum cleaner to

loosen and remove dirt and debris.

■ Clean air vents with low pressure air that does not

exceed 25 psi.

■ Wipe the exterior surfaces of the generator with a

damp cloth.

CLEANING/REPLACING AIR FILTERS

See Figure 13.

For proper performance and long life, keep air filters clean:

■ Release the upper and lower retaining clips and

remove the air filter cover.

■ Remove the outer filter element and the inner

precleaner element.

■ If the filter elements are dirty, clean with warm, soapy

water. Rinse and let dry.

■ Apply a light coat of engine oil to the elements, then

squeeze it out.

■ Put the filter elements back together and replace

in the air filter compartment, being careful to place the outer filter element closest to the air filter cover.

■ Replace the cover and snap retaining clips back in

place to secure.

Fig. 13

OIL FILL TUBE

OIL DRAINAGE BOLT

OIL DIPSTICK

NOTE: Do not run the generator without the air filters.

Rapid engine wear will result.

CHANGING ENGINE OIL

See Figure 14

■ Remove the oil dipstick.

■ Place a container underneath the oil drainage bolt

to collect used oil as it drains.

■ Unscrew the oil drainage bolt and remove.

■ Allow oil to drain completely.

Fig. 14

■ Reinstall the oil drainage bolt and tighten securely.

■ Refill with oil following the instructions in the

“Checking/Adding Oil” section on page 14.

NOTE: Disposal of used oil should be at an approved disposal site. See your local oil retailer for more information.

Page 18

MAINTENANCE

CLEANING FUEL SEDIMENT CUP

See Figure 15.

The sediment cup prevents dirt and water that may have gotten into the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned before use.

■ Turn the fuel valve to the off position.

■ Remove the sediment cup using a 10 mm wrench.

■ Remove the o-ring and filter.

■ Clean each of the parts in a high flash-point solvent.

■ Reinstall the filter, o-ring, and sediment cup. Tighten

with 10 mm wrench to secure.

■ Return the fuel valve to the ON position and check

for leaks.

SPARK PLUG MAINTENANCE

See Figure 16.

The spark plug must be properly gapped and free of deposits in order to ensure proper engine operation.

To check the spark plug:

■ Remove the spark plug cap.

■ Clean any dirt from around the base of the spark

plug.

■ Remove the spark plug.

■ Inspect the spark plug for damage, and clean with

a wire brush before reinstalling. If the insulator is cracked or chipped, the spark plug should be replaced.

NOTE: If replacing, use the following recommended spark plugs or equivalent: NGK, BP6ES.

■ Measure the plug gap with a feeler gauge. The

correct gap is .028 - .031 in. Correct, if necessary, by carefully bending the side electrode.

■ Seat spark plug in position; thread in by hand to

prevent cross-threading.

■ Tighten with spark plug wrench to compress washer.

If spark plug is new, use 1/2 turn to compress washer appropriate amount. If reusing old spark plug, use 1/8 to 1/4 turn for proper washer compression.

Fig. 15

SPARK PLUG

Fig. 16

MAINTENANCE SCHEDULE

Check Engine Oil

Change Engine Oil

Check Air Filters

Replace Air Filters

Clean Fuel Sediment Cup

Replace Spark Plug

Clean or Replace Spark Arrester

Before operating

each time

■

After 25 hours of

operation

■■

■

■■

After 100 hours

of operation

or annually

■

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MAINTENANCE

CLEANING SPARK ARRESTER

See Figure 17.

■ Remove the eight 5 mm screws from the muffler

protector, then remove muffler protector.

■ Remove the 4 mm screw from the spark arrester and

remove the spark arrester.

■ Use a brush to remove carbon deposits from the

spark arrester screen.

■ Inspect the spark arrester for breaks or holes.

Replace if necessary.

■ Reinstall the spark arrester and muffler protector.

DRAINING CARBURETOR

See Figure 18.

■ Loosen the carburetor drain screw.

■ Allow gasoline to drain completely into suitable

container.

■ Retighten drain screw.

TRANSPORTING

■ Turn the engine switch and fuel valve OFF.

■ Make sure engine and exhaust system of unit is cool.

■ Keep the unit level to prevent fuel spillage.

■ Do not drop or strike the unit or place under heavy

objects.

SPARK ARRESTER

Fig. 17

DRAIN SCREW

Fig. 18

STORAGE

When preparing the generator for storage, follow the guidelines below.

STORAGE TIME PRIOR TO STORING

Less than 1 month ■ No special preparation is required.

1 to 2 months

2 months to 1 year ■ Fill with fresh gasoline and add a gasoline conditioner*.

1 year or more ■ Drain fuel tank.

*Use gasoline conditioners formulated to extend storage life. For recommendations, contact your nearest authorized service center.

■ Fill with fresh gasoline and add a gasoline conditioner*.

■ Drain fuel from carburetor.

■ Clean fuel sediment cup.

■ Drain fuel from the carburetor.

■ Clean fuel sediment cup.

■ Remove spark plug.

■ Put a tablespoon of engine oil into the spark plug cylinder. Turn the engine slowly with

the pull rope to distribute the oil.

■ Reinstall spark plug.

■ Change engine oil.

After removal from storage:

■ Fill with fresh gasoline.

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TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE SOLUTION

Engine will not start Engine switch is OFF Turn engine switch to ON.

No fuel Fill fuel tank.

Oil level is low Check engine oil level and fill, if necessary

Check spark plug condition Replace spark plug.

Fuel is not reaching carburetor Clean fuel sediment cup.

Fuel valve is in OFF position Move fuel valve to ON position

AC receptacle does not work Circuit breaker is OFF Turn ON the AC circuit breaker.

Item plugged in is defective Try a different item.

Generator makes a “spark knock” or “pinging” noise

If problem persists after trying the above solutions, please call 1-866-237-1049 for your nearest authorized service center.

An occasional light “knocking” or “pinging” under heavy load is not a cause for concern. However, if the knocking or pinging occurs under normal load at a steady engine speed, the problem may be with the brand of gasoline being used.

Switch to a different brand of gasoline, making sure that the octane rating is 86 or higher. If problem continues, contact your nearest authorized service center.

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