Powermate CX1400, CX3500, CX5500, CX6500E, CX8000E Owner's Manual
CX1400/3500/5500 Portable
001593
(000209a)
This product is not intended to be used in
a critical life support application. Failure to
adhere to this warning could result in
death or serious injury.
Generator
Owner’s Manual
MODEL:________________________
SERIAL:________________________
DATE PURCHASED:______________
WARNING
Register your Powermate product at:
www.powermate.com
1-800-445-1805
SAVE THIS MANUAL FOR FUTURE REFERENCE
SAVE THIS MANUAL FOR FUTURE REFERENCE
Table of Contents
Section 1 Introduction and Safety 1
Introduction ..................................... 1
Safety Rules .................................... 1
Safety Symbols and Meanings ........ 1
Exhaust and Location Hazards ....... 2
Electrical Hazards ...........................3
Fire Hazards .................................... 3
Standards Index .............................. 3
Section 2 General Information and
Setup .............................................. 4
Know Your Generator ..................... 5
Emissions ........................................ 5
Connection Plugs ............................ 6
Remove Contents from Carton ....... 7
Assembly ......................................... 7
Add Engine Oil ................................9
Fuel ............................................... 10
Section 3 Operation ....................11
Operation and Use Questions ....... 11
Before Starting Engine ..................11
Prepare Generator for Use ............ 11
Grounding the Generator When In Use
11
Know Generator Limits .................. 12
Transporting/Tipping of the Unit .... 12
Starting Pull Start Engines ............ 13
Generator Shut Down ................... 13
Low Oil Level Shutdown System ... 13
Section 4 Maintenance and
Troubleshooting ..........................14
Maintenance ..................................14
Maintenance Schedule ..................14
Preventive Maintenance ................14
Engine Maintenance ......................14
Inspect Muffler and Spark Arrestor 16
Valve Clearance ............................16
Storage ..........................................16
Troubleshooting .............................18
Notes .............................................19
California Proposition 65. Engine exhaust and some
of its constituents are known to the state of California
to cause cancer, birth defects, and other reproductive
harm.
California Proposition 65. This product contains or
emits chemicals known to the state of California to
cause cancer, birth defects, and other reproductive
harm.
WARNING
(000004)
WARNING
(000005)
Section 1 Introduction and Safety
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Introduction
Thank you for purchasing a Powermate product. This unit has been designed to provide
high-performance, efficient operation, and
years of use when maintained properly.
If any section of the manual is not understood,
contact your nearest Independent Authorized
Service Dealer (IASD), or contact Powermate
Customer Service at 1-800-445-1805, or
www.powermate.com with any questions or
concerns.
The owner is responsible for proper maintenance and safe use of the equipment. Before
operating, servicing or storing this generator:
• Study all warnings in this manual and on
the product carefully.
• Become familiar with this manual and the
unit before use.
• Refer to the Assembly section of the manual for instructions on final assembly procedures. Follow the instructions completely.
Save these instructions for future reference.
ALWAYS supply this manual to any individual
that will use this machine.
THE INFORMATION CONTAINED HEREIN
WAS BASED ON MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION.
POWERMATE RESERVES THE RIGHT TO
MODIFY THIS MANUAL AT ANY TIME.
Safety Rules
The manufacturer cannot anticipate every
possible circumstance that might involve a
hazard. The warnings in this manual, and on
tags and decals affixed to the unit are, therefore, not all inclusive. If using a procedure,
work method or operating technique that the
manufacturer does not specifically recommend, verify that it is safe for others. Also
make sure the procedure, work method or
operating technique utilized does not render
the equipment unsafe.
Throughout this publication, and on tags and
decals affixed to the generator, DANGER,
WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions
about a particular operation that may be hazardous if performed incorrectly or carelessly.
Observe them carefully. Their definitions are
as follows:
NOTE: Notes contain additional information
important to a procedure and will be found
within the regular text of this manual.
These safety warnings cannot eliminate the
hazards that they indicate. Common sense
and strict compliance with the special instructions while performing the action or service
are essential to preventing accidents.
Safety Symbols and Meanings
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is
a poison you cannot see or smell.
NEVER use inside a home
or garage, EVEN IF doors
and windows are open.
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous gas.
Carbon monoxide, if not avoided,
will result in death or serious injury.
• If you start to feel sick, dizzy, or weak after
the generator has been running, move to
fresh air IMMEDIATELY. See a doctor, as
you could have carbon monoxide poisoning.
DANGER
Only use OUTSIDE and
far away from windows,
doors, and vents.
DANGER
000657
(000103)
Owner’s Manual for Portable Generator 1
(000179a)
DANGER
The exhaust system must be properly maintained. Do
not alter or modify the exhaust system as to render it
unsafe or make it noncompliant with local codes and/or
standards. Failure to do so will result in death
or serious injury.
Electrocution. Water contact with a power source,
(000116)
DANGER
Electrocution. Turn utility and emergency
power supplies to OFF before connecting power
source and load lines. Failure to do so will result
in death or serious injury.
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
(000178a)
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
WARNING
(000250)
WARNING
Equipment and property damage. Do not operate unit on
uneven surfaces, or areas of excessive moisture, dirt, dust
or corrosive vapors. Doing so could result in death, serious
injury, property and equipment damage.
(000111)
WARNING
Moving Parts. Keep clothing, hair, and appendages
away from moving parts. Failure to do so could
result in death or serious injury.
WARNING
Risk of injury. Do not operate or service this machine
if not fully alert. Fatigue can impair the ability to service
this equipment and could result in death or serious
injury.
(000215)
(000103)
DANGER
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous gas.
Carbon monoxide, if not avoided,
will result in death or serious injury.
(000178a)
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
WARNING
DANGER
if not avoided, will result in death or serious injury.
(000104)
Injury and equipment damage. Do not use generator
as a step. Doing so could result in falling, damaged
parts, unsafe equipment operation, and could result
in death or serious injury.
WARNING
Equipment damage. Do not attempt to start or operate
a unit in need of repair or scheduled maintenance.
Doing so could result in serious injury, death, or
equipment failure or damage.
• For safety reasons, it is recommended that
the maintenance of this equipment be performed by an IASD. Inspect the generator
regularly, and contact the nearest IASD for
parts needing repair or replacement.
CAUTION
(000216)
(000291)
000406
Exhaust and Location Hazards
WARNING
Hot Surfaces. When operting machine, do not
touch hot surfaces. Keep machine away from
combustables during use. Hot surfaces
could result in severe burns or fire.
WARNING
Do not insert any object through the air cooling slots.
Generator can start at any time and could result in
death, serious injury, and unit damage.
2 Owner’s Manual for Portable Generator
WARNING
(000108)
(000142)
The exhaust system must be properly maintained. Do
not alter or modify the exhaust system as to render it
unsafe or make it noncompliant with local codes and/or
standards. Failure to do so will result in death
or serious injury.
DANGER
(000179a)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
• If you start to feel sick, dizzy, or weak after
the generator has been running, move to
fresh air IMMEDIATELY. See a doctor, as
you could have carbon monoxide poisoning.
(000146)
Electrical Hazards
(000144)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000104)
DANGER
Electrocution. Water contact with a power source,
if not avoided, will result in death or serious injury.
(000145)
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
(000130)
WARNING
Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
on unit. Failure to do so could result in death
or serious injury.
(000105)
DANGER
Explosion and Fire. Fuel and vapors are extremely
flammable and explosive. Add fuel in a well
ventilated area. Keep fire and spark away. Failure to
do so will result in death or serious injury.
(000166)
DANGER
Do not overfill fuel tank. Fill to 1/2 in. of top of tank to
allow for fuel expansion. Overfilling may cause fuel to
spill onto engine causing fire or explosion, which will
result in death or serious injury.
(000142)
Do not insert any object through the air cooling slots.
Generator can start at any time and could result in
death, serious injury, and unit damage.
WARNING
WARNING
Fire risk. Fuel and vapors are extremely
flammable. Do not operate indoors. Doing so
could result in death, serious injury, or
property or equipment damage.
(000281)
WARNING
Explosion and fire risk. Do not smoke near unit.
Keep fire and spark away. Failure to do so could
result in death, serious injury, or property or
equipment damage.
(000282)
• The National Electric Code (NEC) requires
the frame and external electrically conductive parts of the generator be properly connected to an approved earth ground. Local
electrical codes may also require proper
grounding of the generator. Consult with a
local electrician for grounding requirements
in the area.
• Use a ground fault circuit interrupter in any
damp or highly conductive area (such as
metal decking or steel work).
Fire Hazards
WARNING
Explosion and fire risk. Do not smoke while
refueling unit. Failure to do so could result in
death, serious injury, or property or equipment
damage.
• Wipe up any fuel or oil spills immediately.
Verify that no combustible materials are left
on or near the generator. Keep the area
surrounding the generator clean and free
from debris and keep a clearance of five (5)
feet on all sides to allow for proper ventilation of the generator.
• Do not operate the generator if connected
electrical devices overheat, if electrical output is lost, if engine or generator sparks or if
flames or smoke are observed while unit is
running.
• Keep a fire extinguisher near the generator
at all times.
(000284)
Standards Index
1. National Fire Protection Association
(NFPA) 70: The NATIONAL ELECTRIC
CODE (NEC) available from www.nfpa.org
2. National Fire Protection Association
(NFPA) 5000: BUILDING CONSTRUCTION AND SAFETY CODE available from
www.nfpa.org
3. International Building Code available from
www.iccsafe.org
4. Agricultural Wiring Handbook available
from www.rerc.org, Rural Electricity
Resource Council P.O. Box 309 Wilmington, OH 45177-0309
5. ASAE EP-364.2 Installation and Mainte-
nance of Farm Standby Electric Power
available from www.asabe.org, American
Society of Agricultural & Biological Engineers 2950 Niles Road, St. Joseph, MI
49085
This list is not all inclusive. Check with the
Authority Having Jurisdiction (AHJ) for any
local codes or standards which may be applicable to your jurisdiction.
Owner’s Manual for Portable Generator 3
Section 2 General Information and Setup
001593
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002339
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6 16
5
Figure 2-1. Features and Controls
TABLE 1. Generator Components
1 120 Volt AC, 20 Amp Duplex Receptacle
2 120/240 Volt AC, 30 Amp Locking
Receptacle (NEMA L14-30R)
3 Circuit Breakers (AC)
4 On/Off Switch
5 Hour Meter
6 Ground Terminal
7 Choke Lever
8 Fuel Tank
9Oil Drain
10 Oil Fill
11 Air Cleaner
12 Recoil Handle
13 Fuel Shutoff Valve
14 Battery Charger
15 Circuit Breaker (DC)
16 120 Volt AC, 30 Amp Locking Receptacle
(NEMA L5-30R)
17 120 Volt AC, 30 Amp Receptacle (NEMA
18 2-pole Circuit Breaker (AC)
19 120 Volt AC, 20A GFCI Duplex
TT-30R)
Receptacle (CX5500 CARB only)
Figure 2-2. CX1400 Control Panel
Figure 2-3. CX3500 Control Panel (CSA/CARB)
002340
4 Owner’s Manual for Portable Generator
Replacement owner’s manuals are available
002341
18 5
19
4263
1
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
at www.powermate.com.
Emissions
The United States Environmental Protection
Agency (US EPA) (and California Air
Resources Board (CARB), for engines/equipment certified to California standards) requires
that this engine/equipment complies with
exhaust and evaporative emissions standards. Locate the emissions compliance decal
on the engine to determine applicable standards. For emissions warranty information,
please reference the included emissions warranty. It is important to follow the maintenance
Figure 2-4. CX5500 Control Panel (CSA/CARB)
Know Your Generator
Product Specifications
Generator Specifications 1400 3500 5500
Rated Power 1400W 3500W 5500W
Surge Power 1700W 4375W 6875W
Rated AC Voltage 120 120 120/240
Rated AC Load (Amps) 11.7** 29.2** 45.8 / 22.9**
Rated Frequency
Phase Single Phase Single Phase Single Phase
Unit Weight 60 lbs. (27.2 kg) 107 lbs. (48.5 kg) 173 lbs. (78.5 kg)
** Operating Temperature Range: -18 deg. C (0 deg. F) to 40 Deg. C (104 Deg. F). When operated
above 25 deg. C (77 deg. F) there may be a decrease in power.
** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambi-
ent temperature, altitude, engine condition, etc. Maximum power decreases about 3.5% for each
1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60°
F) ambient temperature.
Engine Specifications 1400 3500 5500
Displacement 98 cc 208 cc 420 cc
Spark Plug Part No.
Spark Plug Gap
Gasoline Capacity
Oil Type
Oil Capacity 0.4 L (0.4 qt.) 0.6 L (0.6 qt.) 1.0 L (1.0 qt.)
Run Time at 50% Load 9.5 Hours 12 Hours 12.5 Hours
* Go to www.powermate.com or contact an IASD for replacement parts.
60 Hz @ 3600
RPM
NGK BPR6HS or
equivalent
0.028-0.031 inch
(0.70-0.80 mm)
5.7 L (1.5 U.S.
gallons)
See Chart in
Engine Oil
specifications in the manual to ensure that the
engine complies with the applicable emissions
standards for the duration of the product’s life.
Add
60 Hz @ 3600
RPM
NGK BPR7ES or
equivalent
0.028-0.031 inch
(0.70-0.80 mm)
17 L (4.5 U.S.
gallons)
See Chart in Add
Engine Oil
60 Hz @ 3600
RPM
NGK BPR7ES or
equivalent
0.028-0.031 inch
(0.70-0.80 mm)
26.5 L (7 U.S.
gallons)
See Chart in Add
Engine Oil
Owner’s Manual for Portable Generator 5
Connection Plugs
120 VAC, 20 Amp, Duplex
Receptacle
The 120 Volt outlet is overload protected by a
20 Amp push-to-reset circuit breaker. See Fig-
ure 2-5. Each receptacle will power 120 Volt
AC, single phase, 60 Hz electrical loads
requiring up to 2400 watts (2.4 kW) or 20
Amps of current. Use only high quality, wellinsulated, 3-wire grounded cord sets rated for
125 Volts at 20 Amps (or greater).
NOTE: Limit length of extension cords to fifteen feet, or less, to prevent voltage drop and
overheating of wires.
120 VAC, 30 Amp Receptacle
Use a NEMA TT-30R plug with this receptacle.
Connect a suitable 3-wire cord set to the plug
and to desired load. The cord set should be
rated for 125 Volts AC at 30 Amps (or greater).
See Figure 2-7.
Use this receptacle to operate 120 Volt AC,
60Hz, single phase loads requiring up to 3600
watts (3.6kW) of power at 30 Amps. The outlet
is protected by a 30 Amp push-to-reset circuit
breaker.
002226
000424
Figure 2-5. 120 VAC, 20 Amp, Duplex
Receptacle NEMA 5-20R
120 VAC, 20 Amp, GFCI Duplex
Receptacle (if equipped)
The 120 Volt outlet is overload protected by a
20 Amp push-to-reset circuit breaker. See Fig-
ure 2-6. Each receptacle will power 120 Volt
AC, single phase, 60 Hz electrical loads
requiring up to 2400 watts (2.4 kW) or 20
Amps of current. Use only high quality, wellinsulated, 3-wire grounded cord sets rated for
125 Volts at 20 Amps (or greater). It also provides protection with a Ground Fault Circuit
Interrupter with a press to TEST and RESET
button.
NOTE: Limit length of extension cords to fifteen feet, or less, to prevent voltage drop and
overheating of wires.
000203
Figure 2-6. 120 VAC, 20 Amp, GFCI Duplex
Receptacle NEMA 5-20R
Figure 2-7. 120 VAC, 30 Amp Receptacle
NEMA TT-30R
120/240 VAC, 30 Amp Receptacle
Use a NEMA L14-30 plug with this receptacle
(rotate to lock/unlock). Connect a suitable 4wire grounded cord set to plug and desired
load. The cord set should be rated 250 Volts
AC at 30 Amps (or greater). See Figure 2-8.
Use this receptacle to operate 120 Volt AC, 60
Hz, single phase loads requiring up to 2760
Watts (2.7 kW) of power at 23 Amps or 240
Volt AC, 60 Hz, single phase loads requiring
up to 5520 watts (5.5 kW) of power at 23
Amps. The outlet is protected by a 2-pole 23
Amp toggle switch circuit breaker.
000204
Figure 2-8. 120/240 VAC, 30 Amp Receptacle
NEMA L14-30R
6 Owner’s Manual for Portable Generator
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