Poulan PPG 6000 User Manual

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.

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

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.

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.

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.

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

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.

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

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.

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

+ 22 hidden pages