Powermate PM0612023 User Manual [en, es, fr]

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Operator-Parts List Manual

Manuel de l’opérateur – Liste de pièces

Manual del operador – Lista de piezas

Industrial Series – ELECTRIC GENERATOR

Industrial Series – GÈNÈRATRICE ÉLECTRIQUE

Industrial Series – GENERADOR ELECTRICO

IMPORTANT – Please make certain that persons who are to use this equipment thoroughly read and understand these instructions prior to operation.

IMPORTANT – Veiller à ce que toute personne amenée à utiliser cet appareil lise soigneusement ces instructions et les comprenne avant de procéder à son utilisation.

IMPORTANTE – Favor de cerciorarse de que toda persona que use el generador Coleman Powermate lea y entienda todas las instrucciones antes de la operación.

Record the model and serial numbers of your Generator below:

Model No._________________	Serial No.__________________
Inscrivez les numéros de modèle et de série du gènèratrice:
# modèle__________________	# de série ___________________

Tome nota de los números de serie y de modelo de su generador enseguida:

No. de modelo ________________No. de serie ________________

HELPLINE 1-800-445-1805

TABLE OF CONTENTS

Safety and operation rules . . . . . . . . . . . . . . . . . . . . . . . . . . .	3	Battery Installation. . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 7
Spark arresting muffler . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Low oil shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 7
Determining total wattage. . . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Infrequent service . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 7
Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4	Long term storage . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 7
Before operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Electric start wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 8
Grounding the generator . . . . . . . . . . . . . . . . . . . . . . . . .	5	Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 8
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Wiring diagram (Key switch on engine) . . . . . . . . . . . . . .	. . . 8
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Idle control operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Pre-start preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Idle control trouble shooting . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Break-in procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Exciting the generator . . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Shutting the generator off . . . . . . . . . . . . . . . . . . . . . . . .	5	Heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Power cord connection . . . . . . . . . . . . . . . . . . . . . . . . . .	5	Draining the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Applying load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Trouble Shooting the Generator . . . . . . . . . . . . . . . . . . . .	. . 10
Major features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6	Installation Instructions of the Portability Kit . . . . . . . . . . .	. . 11
Circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Customer service information. . . . . . . . . . . . . . . . . . . . . .	. . 12
AC features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 12
DC features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35-36
Battery Kit Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7	Parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	36-37

TABLE DES MATIÈRES

Régles d’opération et de sécurité . . . . . . . . . . . . . . . . . . . . .	13	Installation de la batterie. . . . . . . . . . . . . . . . . . . . . .	. . . 18
Silencieux pare-étincelles . . . . . . . . . . . . . . . . . . . . . . . .	14	Niveau d’huile bas. . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 18
Détermination de la puissance totale nécessaire . . . . . . . . .	14	Usage peu fréquent . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 18
Vérifier la tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15	Remisage à long terme. . . . . . . . . . . . . . . . . . . . . . . .	. . 18
Avant de mettre en marche . . . . . . . . . . . . . . . . . . . . . . . . .	15	Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 18
Mise à la terre de la génératrice . . . . . . . . . . . . . . . . . . .	15	Câblage du démarreur électrique . . . . . . . . . . . . . . . . . . .	. . 19
Lubrification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15	Entretien . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 19
Carburant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15	Excitation de la génératrice. . . . . . . . . . . . . . . . . . . . .	. . 19
Préparatifs au démarrage . . . . . . . . . . . . . . . . . . . . . . . .	15	Écran de chaleur. . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 19
Démarrage du moteur. . . . . . . . . . . . . . . . . . . . . . . . . . .	15	Vidage de l’huile . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 19
Rodage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16	Fonctionnement de la commande du ralenti . . . . . . . . . .	. . 20
Arrêt de la génératrice . . . . . . . . . . . . . . . . . . . . . . . . . .	16	Dépannage de la commande du ralenti . . . . . . . . . . . . . .	. . 20
Connexions du cordon d’alimentation. . . . . . . . . . . . . . .	16	Dépannage de la Génératrice électrique . . . . . . . . . . . . .	. . 21
Branchement des appareils . . . . . . . . . . . . . . . . . . . . . .	16	Instructions de la trousse de transport . . . . . . . . . . . . . . .	. . 22
Caracteristiques principales . . . . . . . . . . . . . . . . . . . . . . . . .	17	Service clients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 23
Protection des circuits. . . . . . . . . . . . . . . . . . . . . . . . . . .	17	Garantie limitée . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 23
AC features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17	Liste des composants . . . . . . . . . . . . . . . . . . . . . . . . . . .	35-36
DC features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17	Diagramme des pièces . . . . . . . . . . . . . . . . . . . . . . . . . .	36-37
Liste des pièces de la trousse de batteries . . . . . . . . . . . . .	17

INDICE

Reglas de seguridad y de funcionamiento . . . . . . . . . . . . . .	24	Batería Instalación . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 29
Silenciador apagachispas. . . . . . . . . . . . . . . . . . . . . . . .	25	Detencion por poca cantidad de aceite . . . . . . . . . .	. . . 29
Como determinar el vatiaje total. . . . . . . . . . . . . . . . . . . . . .	25	Servicio poco frecuente . . . . . . . . . . . . . . . . . . . . . . .	. . 29
El requerimiento de voltaje . . . . . . . . . . . . . . . . . . . . . . . . . .	26	Almacenamiento a largo plazo . . . . . . . . . . . . . . . . . .	. . 29
Antes de la operación. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26	Cableado de arranque electrico . . . . . . . . . . . . . . . . . . . .	. . 30
Puesta a tierra del generador . . . . . . . . . . . . . . . . . . . . .	26	Instalación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 30
Lubricación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26	Diagrama de cableado basico . . . . . . . . . . . . . . . . . . . . .	. . 30
Combustible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26	Funcionamiento de control en vacio. . . . . . . . . . . . . . . . .	. . 31
Preparacion antes de arrancar . . . . . . . . . . . . . . . . . . . .	26	Deteccion de fallos de control en vacio . . . . . . . . . . . . . .	. . 31
Arranque del motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26	Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 31
Procedimiento de arranque inicial . . . . . . . . . . . . . . . . .	27	Excitación del generador . . . . . . . . . . . . . . . . . . . . . .	. . 31
Apagado del generador . . . . . . . . . . . . . . . . . . . . . . . . .	27	Escudo de calor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 31
Conexiones del cable . . . . . . . . . . . . . . . . . . . . . . . . . . .	27	Drenado de aceite. . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 31
Cómo aplicar una carga . . . . . . . . . . . . . . . . . . . . . . . . .	27	Deteccion de Fallos de Generador. . . . . . . . . . . . . . . . . .	. . 32
Características principales . . . . . . . . . . . . . . . . . . . . . . . . . .	28	Instrucciones para el equipo portátil. . . . . . . . . . . . . . . . .	. . 33
Protección del circuito características CA. . . . . . . . . . . .	28	Servicio para los clientes . . . . . . . . . . . . . . . . . . . . . . . . .	. . 34
Características AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28	Garantía limitada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 34
Características CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28	Lista de componentes . . . . . . . . . . . . . . . . . . . . . . . . . . .	35-36
Lista de partes para el equipo de batería . . . . . . . . . . . . . . .	29	Dibujos de las partes. . . . . . . . . . . . . . . . . . . . . . . . . . . .	36-37

SAFETY AND OPERATION RULES

Safety precautions are essential when any mechanical equipment is involved. These precautions are necessary when using, storing, and servicing mechanical equipment. Using this equipment with the respect and caution demanded will considerably lessen the possibilities of personal injury. If safety precautions are overlooked or ignored, personal injury or property damage may occur.

The following symbols shown below are used extensively throughout this manual. Always heed these precautions, as they are essential when using any mechanical equipment.

This warning symbol identifies specific instructions or procedures which if not correctly followed could result in personal injury or death.

This caution symbol identifies specific instructions or procedures which, if not strictly observed, could result in damage to, or destruction of equipment.

This unit was designed for specific applications. It should not be modified and/or used for any application other than which it was designed. If there are any questions regarding its application, write or call Customer Service at 1-800-445-1805.

When using this product basic precautions should always be followed, including the following:

1.Read this manual carefully - know your equipment. Consider the applications, limitations, and the potential hazards specific to your unit.

2.Equipment must be placed on a firm, supporting surface.

3.Load must be kept within rating stated on generator nameplate. Overloading will damage the unit or shorten its life.

4.Engine must not be run at excessive speeds. Operating an engine at excessive speeds increases the hazard of personal injury. Do not tamper with parts which may increase or decrease the governed speed.

5.To prevent accidental starting, always remove the spark plug or cable from the spark plug before adjusting the generator or engine.

6.Units with broken or missing parts, or without protective housing or covers, should never be operated. Contact your service center for replacement parts.

7.Units should not be operated or stored in wet or damp conditions or on highly conductive locations such as metal decking and steel work. Always use rubber gloves and boots, and a ground fault current interrupter if these conditions may be present during use.

8.Keep the generator, tank and cap clean and free of oil, mud and other foreign matter.

9.Extension cords, power cords, and all electrical equipment must be in good condition. Never operate electrical equipment with damaged or defective cords.

10.Store the generator in a well ventilated area with the fuel tank empty. Fuel should not be stored near the generator.

11.Your generator should never be operated under these conditions:

a.Change in engine speed.

b.Electrical output loss.

c.Overheating in connected equipment.

d.Sparking.

e.Damaged receptacles.

f.Engine misfire.

g.Excessive vibration.

h.Flame or smoke.

i.Enclosed compartment.

j.Rain or inclement weather.

12.Check the fuel system periodically for leaks or signs of deterioration such as chafed or spongy hose, loose or missing clamps, or damaged tank or cap. All defects should be corrected before operation. Clean up any or all spills immediately.

13.The generator should be operated, serviced, and refueled only under the following conditions:

a.Good ventilation - avoid areas where vapors may be trapped such as pits, basements, cellars, excavations, and boat bilges. Air flow and temperatures are important for air cooled units. Temperatures should not exceed 100 degrees F (40 degrees C).

b.Dangerous exhaust gases should be piped from enclosed areas. The engine exhaust contains carbon monoxide, a poisonous, odorless, invisible gas which, if breathed, causes serious illness and possible death.

c.Refuel the generator in a well lighted

area. Avoid fuel spills and never refuel while the generator is running. Allow engine to cool for two minutes prior to refueling.

d.Do not refuel near open flames, pilot lights, or sparking electrical equipment such as power tools, welders, and grinders.

e.The muffler and air cleaner must be installed and in good condition at all times as they function as flame arresters if backfiring occurs.

f.Do not smoke near the generator.


English		3

14.Do not wear loose clothing, jewelry, or anything that may be caught in the starter or other rotating parts.

15.Unit must reach operating speed before electrical loads are connected. Disconnect loads before turning off engine.

16.To prevent surging that may possibly damage equipment, do not allow engine to run out of fuel when electrical loads are applied.

17.When powering solid state equipment, a

Power Line Conditioner should be used to avoid possible damage to equipment. (See Caution Statement on this page.)

18.Do not stick anything through ventilating slots, even when the generator is not operating. This can damage the generator or cause personal injury.

19.Before transporting the generator in a vehicle, drain all fuel to prevent leakage that may occur.

20.Use proper lifting techniques when transporting the generator from site to site. Improper lifting techniques may result in personal injury.

DETERMINING TOTAL WATTAGE

In order to prevent overloading and possible damage to your generator it is necessary to know the total wattage of the connected load. To determine which tools and/or appliances your generator will run follow these steps:

1.Determine if you want to run one item or multiple items simultaneously.

2.Check start and run wattage requirements for the items you will be running by referring to the load’s nameplate or by calculating it (multiply amps x volts = watts).

3.Total the start and run watts for each item. If the nameplate only gives volts and amps, multiply volts x amps = watts.

1 KW = 1,000 watts.

NOTE: Allow 2 1/2 to 4 times the listed wattage for starting equipment.

4.The generator’s start/surge and run/rated watts should match or exceed the total number of watts required for the equipment you want to run.

5.Always connect the heaviest load to the generator first, then add other items one at a time.

6.Motorized appliances or tools require more than their rated wattage for start up.

21.To avoid burns, do not touch engine muffler or other engine or generator surfaces which became hot during operation.

22.Never disconnect components that help in the scheduling of the maintance of the generator. This would shorten the life of the generator.

SPARK ARRESTING MUFFLER

THIS PRODUCT IS NOT EQUIPPED WITH A SPARK ARRESTING MUFFLER. If the product will be used around flammable materials, such as agricultural crops, forests, brush, grass, or other similar items, then an approved spark arrester should be installed and is legally required in the State of California. The California statutes requiring a spark arrester are Sections 13005(b), 4442 and 4443. Spark Arresters are also required on some U.S. Forest Service land and may also be legally required under other statutes and ordinances. An approved spark arrester is available from your Coleman Powermate dealer, or may be ordered from Coleman Powermate, Inc., P.O. Box 6001, Kearney, Nebraska 68848. 1-800-445-1805.

NOTE: Remember to clean the spark arrester screen frequently to ensure the generator is operating at its best performance.

OPERATING VOLTAGE

CAUTION: Operating voltage and frequency requirement of all electronic equipment should be checked prior to plugging them into this generator. Damage may result if the equipment is not designed to operate within a +/- 10% voltage variation, and +/- 3 hz frequency variation from the generator name plate ratings. To avoid damage, always have an additional load plugged into the generator if solid state equipment (such as a television set) is used. A power line conditioner may also be necessary for some solid state applications.

Typical example of solid state equipment include: Garage door openers

Kitchen appliances with digital displays Televisions

Stereos

Personal computers Quartz clocks Copy machines

Telephone equipment

For more information, contact our Customer Service Department at 1-800-445-1805.

English

BEFORE OPERATION

GROUNDING THE GENERATOR

Make sure that the generator is grounded to help prevent accidental shock. A ground screw has been provided for this purpose. Connect a length of heavy gauge wire between the generator screw and an external ground source, such as a water pipe or copper rod driven into the ground.

WARNING: Do not use a pipe carrying combustible material as the ground source.

Ground Screw

LUBRICATION

DO NOT attempt to start this engine without filling the crank case with the proper amount and type of oil. (See the accompanying engine manual for this information.) Your generator has been shipped from the factory without oil in the crankcase. Operating the unit without oil can damage the engine.

Note: To add oil to the unit a flexible, long necked funnel, supplied with most models will be needed to reach the Oil Fill. This funnel may be purchased through Coleman Powermate. The Oil Fill is located on top of the engine, (OHV) valve cover, battery side of the unit. Be sure the oil drain plug is closed before adding the oil.

FUEL

Fill the tank with clean, fresh unleaded automotive gasoline. Regular grade gasoline may be used provided a high octane rating is obtained (at least 85 pump octane).

CAUTION: Do not overfill the tank. Keep maximum fuel level 1/4 inch below the top of the fuel tank. This will allow expansion in hot weather and prevent overflow.

WARNING: Gasoline is very dangerous. Serious injury may result from fire caused by gasoline contacting hot surfaces.

1.Do not fill fuel tank with engine running.

2.Do not spill fuel while refilling tank.

3.Do not mix oil with gasoline.

PRE-START PREPARATION

Before starting the generator, check for loose or missing parts and for any damage which may have occurred during shipment.

WARNING: This generator must not be operated without all factory installed heat shields in place. Failure to comply may cause the fuel tank to overheat and result in personal injury from fire.

STARTING THE ENGINE

1.Check oil level and fuel.

2.Disconnect all electrical loads from the unit.

3.Open fuel shut off valve.

4.Adjust choke as necessary.

5.Set the engine switch to the “ON" position.

6.Pull on the starter rope with fast steady pull. As the engine warms up, readjust the choke. On electric start models, turn the key switch to “START”. Release key switch after the engine starts.

WARNING: Provide adequate ventilation for toxic exhaust gases and cooling air flow.

BREAK-IN PROCEDURE

Controlled break-in helps insure proper engine and generator operation. Follow engine procedure outlined in engine manual.

CAUTION: Do not apply heavy electrical load during break-in period (the first two to three hours of operations).

CAUTION: Allow generator to run at no load for five minutes upon each initial start-up to permit engine and generator to stabilize.

SHUTTING THE GENERATOR OFF

1.Remove entire electrical load.

2.Let the engine run for a few minutes without load.

3.Move the engine switch to the “OFF” position. (Turn the key switch to “OFF” on the electric start models).

4.Do not leave the generator until it has completely stopped.

5.Close the fuel shut off valve if the engine is to be put in storage or transported.

6.If cover is used, do not install until unit has cooled.

Fuel Valve

POWER CORD CONNECTIONS

Refer to the appropriate diagram for proper connection of power cord wires to the plug terminals.

CAUTION: Insure that the power cord used is well insulated and has a sufficient rating to match that of the plug.


English		5

120 volt 30 Amp Plug

120/240 Volts, 20 Ampere and 30 Ampere Plug

120/240 Volt Heavy Duty Plug

APPLYING LOAD

This unit has been pretested and adjusted to handle its full capacity. When starting the generator, disconnect all load. Apply load only after generator is running. Voltage is regulated via the engine speed adjusted at the factory for correct output. Readjusting is not advised.

CAUTION: When applying a load, do not exceed the maximum wattage rating of the generator when using one or more receptacles. Also, do not exceed the amperage rating of any one receptacle.

MAJOR FEATURES

A.120 V, 20 Ampere Duplex Receptacles

20 amps of current may be drawn from each of the duplex receptacles. However, total power drawn must be kept within nameplate ratings. These receptacles may be used along with the twistlock receptacle provided the generator is not overloaded.

B.120 Volt 30 Amp Twistlock Receptacle

You may draw a maximum of 30 amps or 3600 watts from this receptacle. If other receptacles are used at the same time, total power used must be kept within nameplate rateings.

D.Circuit Breakers

The receptacles are protected by an AC circuit breaker. (See Circuit Protection).

E.Idle Control Switch

Some models are equipped with an idle control switch. (See Idle Control).

F.120/240 V 30 Amp Twistlock Receptacle

A maximum of 30 amps may be drawn from the 120/240 volt receptacle, provided it is the only receptacle used. However, current must be limited to the nameplate rating. If the 120/240 volt receptacle is used along with the 120 volt receptacle, the total load drawn must not exceed the nameplate ratings.

J.240 Volt Heavy Duty Receptacle

This receptacle is rated at 50 amps but the current must be limited to the nameplate rating. If this receptacle is used along with the 120 volt receptacles, the total load drawn must not exceed the nameplate ratings.

K.Hour Meter

The hour meter will help the user schedual the maintance required to keep the unit in good working order.


6		English

CIRCUIT PROTECTION AC FEATURES

The receptacles are protected by an AC circuit breaker. If the generator is overloaded or an external short circuit occurs, the circuit breaker will trip. If this occurs, disconnect all electrical loads and try to determine the cause of the problem before attempting to use the generator again. If overloading causes the circuit breaker to trip, reduce the load. NOTE:

Continuous tripping of the circuit breaker may cause damage to generator or equipment. The circuit breaker may be reset by pushing the button of the breaker.

DC FEATURES

The charging system of the unit is supplied by the stater/alternator of the engne. 12 volts DC is constantly charging the battery when the unit is running . Disconnecting the battery will stop the charging of the battery.

Before charging a storage battery, check the electrolyte fluid level in all the cells. (Sealed batteries do not require checking). Add distilled water to each cell if necessary, to bring the level back up to the manufacturer’s required level.

WARNING: Storage batteries give off EXPLOSIVE hydrogen gas while charging. Do not allow smoking, open flames, sparks, or spark producing equipment in the area while charging.

WARNING: Battery electrolyte fluid is compressed of sulfuric acid that can be very dangerous and cause severe burns. Do not allow this fluid to contact eyes, skin, clothing, etc. If contact or spillage does occur, flush the area with water immediately.

BATTERY KIT PARTS LIST

Item	Description	Qty.
A.	*Bolt, 1/4-20X8”	2
B.	*Washer 1/4	2
C.	*Spacer	2
D.	Hold Down bar (PN 0036525.02)	1
E.	*Nyloc nut, 1/4-20	2

*All parts are standard parts at your local hardware store.

CAUTION: This battery charging system is intended to recharge wieak batteries, not to “boost start” vehicles.

Battery Installation

Coleman Powermate recommends a 12 v battery with at least 235 cranking amps. Model U1L, Lawn and Garden Battery. Place the battery in the position provided. Place the spacers on the bolts, then place the bolts through the loops on the Hold-Down bracket. Place the assembly over the battery and place the bolts through the holes on the battery pan and tighten down the Hold-Down assembly with the 1/4-20 nuts provided.

Spacers may be removed depending on the battery height.

WARNING: Batteries contain sulfuric acid (when filled). May contain explosive gasses. Always abide by safety warnings provided with the battery.

-Keep sparks, flame and cigarettes away.

-Hydrogen gas is generated during charging and discharging.

-Always shield eyes, protect skin and

clothing when working near batteries.

Connect the Rd 8ga. battery lead to the positive battery post and the black 8ga. battery to the negative battery post with the bolts and nuts provided.

LOW OIL SHUTDOWN

Some units are equipped with low oil shutdown. If the oil level becomes lower than required, the generator set will automatically shut off. This protects your generator set from operating without proper lubrication.

If generator shuts off and the oil level is according to specifications, check to see if generator is sitting at an angle that forces oil to shift. Place on an even surface to correct this. If engine fails to start, the oil level may not be sufficient to deactivate low oil level switch. Be sure the sump is completely full of oil.

INFREQUENT SERVICE

If the unit is used infrequently, difficult starting may result. To eliminate hard starting, run the generator at least 30 minutes every month. Also, if the unit will not be used for some time, it is a good idea to drain the fuel from the carburetor and gas tank.

LONG TERM STORAGE

When the generator set is not being operated or is being stored more than one month, follow these instructions:

1.Replenish engine oil to upper level.

2.Drain gasoline from fuel tank, fuel line and carburetor.

3.Pour about one teaspoon of engine oil through the spark plug hole, pull the recoil starter several times and replace the plug. Then pull the starter until you feel the piston is on its compression stroke and leave it in that position. This closes both the intake and exhaust valves to prevent the inside of the cylinder from rusting.

4.Cover the unit and store in a clean, dry place that is well ventilated away from open flame or sparks.

NOTE: The use of a fuel additive, such as STA-BIL®, or an equivalent, will minimize the formulation of fuel gum deposits during storage. Such an additive may be added to the gasoline in the fuel tank of the engine, or to the gasoline in a storage container.


English		7

ELECTRIC START WIRING

The generator is equipped with electric start, refer to FIGURE A

An “Off-On-Start” rotary key switch is provided on the recoil end panel on some models. All necessary wiring is provided. The battery is customer provided. #8 AWG (American Wire Gauge) copper wire lead with ring terminals make battery hookup quite simple.

Connect the lead hooked to the chassis to the negative (-) battery terminal and the lead from the starter solenoid to the positive (+) battery terminal with the appropriate bolts, lock washers and nuts. The orange wire connected to the solenoid and positive (+) battery terminal provides battery charging up to 16 amps.

Your engine may be equipped with a trickle charge system. The 14 AWG (American Wire Gauge) red wire which comes from the engine should be connected to the positive battery terminal (see engine operator manual).

INSTALLATION

WARNING: To avoid possible personal injury or equipment damage, a registered electrician or an authorized service representative should perform installation and all service. Under no circumstances should an unqualified person attempt to wire into an utility circuit.

To avoid backfeeding into utility systems, isolatin of the residence electrical system is required.

Before temporary connection of the generator the residence electrical system, turn off the main switch.

If your generator is to be used as a stand-by power source in case of utility power failure, it should be installed by a registered electrician and in compliance with all applicable local electrical codes.

Proper use requires that a double throw transter switch be installed bya licensed qualified electrician so that the building’s electrical circuits may be safely switched between utility power and the generator’s output, there by preventing backfeed into the power utility’s electrical system.

WARNING: To avoid backfeeding into utility systems, isolation of the residence electrical system is required. Before temporary connection of a generator to the residence electrical system turn off the main switch. Before making permanent connections a double throw transfer switch must be installed. To avoid electrocution or property damage, only a trained electrician should connect generator to residence electrical system. California law requires isolation of the residence electrical system before connecting a generator to residence electrical systems.

BASIC WIRING DIAGRAM

Electric Start Models (Models with Key Switch on Engine)

FIGURE A


8		English

MAINTENANCE		IDLE CONTROL OPERATION

EXCITING THE GENERATOR:

NOTE: If your generator is a brushless unit please contact your local service center or the Coleman Powermate Service Department for assistance with exciting your generator.

HEAT SHIELD:

Inspect to ensure that all heat shields and heat deflectors are intact and in place.

NOTE: Refer to the engine manufacturer's manual for service and maintenance of the engine.

DRAINING THE OIL

Place a catch container underneath the oil drain. Push in, turn and release the Quick Drain Plug. (Oil drainage will work best if the oil is warm.)

The Idle Control circuit is designed to extend engine life and improve fuel usage by slowing the engine down to approximately 2000 RPM in a “No Load” condition. The noise is also greatly reduced during this condition.

When power is required from the generator an electronic control module automatically senses current flow in the electrical outlet and allows the engine to return to full speed or standard operating condition. Likewise, when the load is removed, the generator will automatically return to the idle condition after a 4-5 second delay.

A convenient switch is mounted in the control panel for easy access and will disable the Idle Control circuitry when in the off position.

NOTE: On the PM0610023 and the PC0610023 a 12V battery must be installed in order for the idle control to function. For the PM0612023 or PC0612023 a battery is not required for the Idle control to work.

IDLE CONTROL TROUBLE SHOOTING

PROBLEM	POSSIBLE CAUSE	SOLUTION
Unit will not idle	Control panel switch not on	Turn to idle on position
	Load plugged into receptacle	Unplug load

	Poor connection or faulty cord	Check & repair

	Bad I.C. module; Bad electro-magnet	Replace
	or solenoids; Bad stator
		Consult dealer
Unit idles even with load plugged in	Load not heavy enough	Turn idle switch to off position

		Increase load

	Bad I.C. module	Replace

		Consult dealer
Unit tries to idle but won’t stay latched	Electro-magnet or solenoid position	Reset magnet or solenoid position for
	incorrect	2000 RPM idle speed

		Consult dealer

	Flapper bracket loose or bent	Tighten or straighten

		Replace flapper. Readjust to 2000 RPM

	Engine not running smoothly	Adjust carburetor

		Consult dealer

English			9

TROUBLE SHOOTING THE GENERATOR

PROBLEM	POSSIBLE CAUSE	SOLUTION
Alternator Excitation Failure.	Low speed.	Check rpm and set at nominal value.

	Faulty capacitor.	Check and replace.

	Faulty windings.	Check windings resistance.

High no-load voltage.	Speed too high.	Check and adjust rpm.

	Capacitor with high capacity.	Check and replace.

Low no-load voltage.	Speed to low.	Check and adjust rpm.
	Faulty rotary diodes.	Check and replace.

	Breakdown in windings.	Check winding resistance.

	Capacitor with low capacity.	Check and replace.

Proper no-load but low loaded voltage.	Low loaded speed.	Check and regulate rpm.

	Load too big.	Check and change.

	Rotary diodes short-circuited.	Check and replace.

Proper no-load but high loaded voltage.	High speed in load condition.	Check and regulate rpm.

Unstable voltage.	Loose contacts.	Check connections.

	Change in engine speed.	Check and regulate rpm.

Wont Start or run.	Foreign debris in muffler.	Check and clean muffler exhaust.

	No gas.	Add gas to tank.

		Turn fuel valve on.

	Spark pulg not connected.	Connect apark plug wire.
	Battery cable hooked up wrong.	Check and change if necessary.

	Air cleaner plugged.	Check and clean or replace.

Tank Expansion.	Fuel cap not venting.	Check and replace cap.


10		English

INSTALLATION OF THE

PORTABILITY KIT

Tools Required:

Hammer, 1/2” wrench, ratchet with a 1/2” socket, and wood blocks.

Refer to the drawing for proper alignment of Foot bracket and Wheel brackets.

	Parts List
A	Handle	0056240
B	Knob	0062177
C	Wheel	0056236
D	Wheel Bracket	0056406
E	Foot Bracket	0056237
F	Foot Bracket Strap	0056409
G	Axle Cap	0056444
H	Wheel Spacer	0056445
I	Bolt 5/16-18X1.75”	Note A
J	Nyloc Nut 5/16	Note A
K	Flat Washer 5/16	Note A
L	Bolt 5/16-18X1”	Note A
M	Handle Grip	0056239
N	Plastic Cap	0056030.01
O	Rubber Foot	0008433

Note A: These are standard parts available at your local hardware store.

Wheel Bracket & Wheel Installation

1.Block up end of generator , about 8” high, opposite the fuel tank cap to install wheels and wheel bracket assy.

2.Add 5/16 washer to the 1 3/4” bolts and insert bolts/washers through the holes located in the base pan of the carrier.

3.Place the wheel bracket through the bolts and add a 5/16 nyloc nut and tighten securely. (On the bottom side of the pan in-between the holes will be a 1” square brace, the wheel bracket will set on this brace).

4.Add wheel spacer to the axle.

5.Slide the wheel onto the axle until it is snug agaist the spacer. The wheel is on correctly if there is approximately a 1/2” gap between the carier tubing and the side of the wheel . If it is less then 1/2” from the carrier, turn the wheel over and reinstall. Align the wheels parallel to the carrier tubing and tighten nuts securly. To align correctly, the bolts holding the wheel bracket may have to be loosened.

6.With a hammer, add the plastic cap on end of axle.

7.Repeat above instrucitons for the remaining wheel.

Foot bracket Installation

1.Block up opposite end of. the unit, about 8” high.

2.Add 5/16 washer to 1” bolts and place through holes in the base pan.

3.Add foot bracket assy to bolts, add 5/16 nyloc nuts and tighten securely.

4.Add support bracket from foot bracket to the base pan. Secure in place with 1” bolts, washers and 5/16 nyloc nuts.

Handle Installation

1.Insert the threaded end of the knobs through the holes in the handles.

2.Line up handle with knob to the side of the carrier and place the threads into the holes at the handle location on the carrier. Tighten securely.

CAUTION, DO NOT OVER TIGHTEN.

Note: Handles can be placed in both directions. Along the carrier rails for storage and extended to move the unit.


English		11

SERVICE INFORMATION

CONTACT THE COLEMAN POWERMATE CUSTOMER SERVICE DEPARTMENT AT 1-800-445-1805

to obtain warranty service information or to order replacement parts or accessories.

HOW TO ORDER REPLACEMENT PARTS

Even quality built equipment such as the Coleman Powermate electric generator you have purchased, might need occasional replacement parts to maintain it in good condition over the years. To order replacement parts, please give the following information:

1.Model No. and Serial No. and all specifications shown on the Model No./Serial No. plate.

2.Part number or numbers as shown in the Parts List section of this manual.

3.A brief description of the trouble with the generator.

NOTE: If replacement parts are required for the engine, contact one of the engine manufacturer's service centers.

Coleman Powermate, Inc.

4970 Airport Road

P. O. Box 6001

Kearney, NE 68848

LIMITED WARRANTY (NOT VALID IN MEXICO)

This product is warranted by Coleman Powermate, Inc. to the original retail consumer against defects in material and workmanship for a period of two (2) years from the date of retail purchase and is not transferable. This two year warranty applies only to products used in consumer applications. If these generators are used in a commercial application, then the period of warranty coverage is limited to one (1) year from the date of purchase.

Please complete and return the enclosed Customer Information Card so that we can reach you in the unlikely event a safety recall is needed. Return of this card is not required to validate this warranty.

WHAT IS COVERED: Replacement parts and labor.

WHAT IS NOT COVERED: Transportation charges to Coleman Powermate, Inc. for defective products. Transportation charges to consumer for repaired products. Brushes, rubber feet, and receptacles. Damages caused by abuse, accident, improper repair, or failure to perform normal maintenance. Power units or engines which are covered exclusively by the warranties of their manufacturer. Sales outside of the United States and Canada. Any other expense including consequential damages, incidental damages, or incidental expenses, including damage to property. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

IMPLIED WARRANTIES: Any implied warranties, including the Implied Warranties of Merchantability and Fitness For A Particular Purpose, are limited in duration to one (1) year from the date of retail purchase. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

HOW TO OBTAIN WARRANTY PERFORMANCE:

Replacement parts and service are available from Coleman Powermate, Inc. Service Centers. Locate your nearest Service Center by calling TOLL FREE 1-800-445-1805. In the unlikely event a Service Center can not be located you may call Coleman Powermate, Inc. for a return authorization number.

Any unit returned WITHOUT an authorization number will be refused.

To the extent any provision of this warranty is prohibited by federal, state, or municipal law, and cannot be preempted, it shall not be applicable. This warranty gives you specific rights, and you may also have other rights which vary from state to state.


12		English

RÉGLES D’OPÉRATION ET DE SÉCURITÉ

Les mesures de sécurité sont des éléments essentiels lorsqu’on parle d’équipement mécanique. Ces mesures sont nécessaires lorsqu’on utilise, range, et fait l’entretien d’équipement mécanique. Le fait d’utiliser cet équipement avec le respect et les précautions voulues permettra de diminuer considérablement les possibilités de blessures personnelles. Si l’on ignore ou néglige les mesures de sécurité, des blessures personnelles ou des dommages à la propriété peuvent s’en suivre.

Les symboles suivants sont utilisés fréquemment dans l’ensemble de ce manuel. Tenez toujours compte de ces précautions car elles sont essentielles lorsque vous utilisez tout équipement mécanique.

Ce symbole de danger identifie des instructions ou des procédures précises qui peuvent éviter des blessures personnelles ou même mortelles si on les suit correctement.

Ce symbole de mise en garde identifie des instructions ou des procédures précises qui peuvent éviter, si on les observe, des dommages ou la destruction de l’équipement.

Cet appareil est conçu pour des applications précises. Il ne doit être ni modifié ni utilisé pour toute application autre que celles pour lesquelles il a été conçu. Si vous avez des questions quant aux applications, veuillez écrire ou communiquer avec la compagnie. N’utilisez pas cet appareil jusqu’à ce que vous ayez été avisé. Pour plus de renseignements, communiquez avec le service à la clientèle au 1-800-445-1805.

Lorsque vous utilisez ce produit, certaines précautions de base doivent être respectées, dont les suivantes:

1.Lisez attentivement ce manuel - apprenez à connaître votre équipement. Tenez compte des applications, limites et dangers possibles de votre appareil.

2.On doit placer l’équipement sur une surface support solide.

3.La charge doit être dans les normes spécifiées sur la plaque signalétique de la génératrice. Toute surcharge abîme la génératrice et en raccourcit la durée de vie utile.

4.Le moteur ne doit pas tourner à des vitesses excessives car ceci augmente les risques de blessures personnelles. Ne touchez pas aux pièces ce qui pourrait augmenter ou réduire la vitesse régulée.

5.Afin d’empêcher les démarrages imprévus, toujours enlever la bougie ou le câble de la bougie avant d’ajuster la génératrice ou le moteur.

6.Un appareil dont les pièces sont cassées, auquel il manque des pièces ou qui n’a pas de carter ou de coquille protectrice ne doit en aucun cas être utilisé. Contacter notre service après-vente pour des pièces de rechange.

7.Ne pas faire fonctionner ou remiser l’appareil dans un endroit humide ni sur une surface mouillée, ni dans un endroit où il sera en contact avec des surfaces conductrices telles que des planchers ou armatures métalliques. Toujours utiliser des gants et des bottes en caoutchouc ainsi qu’un interrupteur de circuit avec mise à la masse si de telles conditions sont présentes.

8.Garder la génératrice propre et libre de toute huile, boue ou autre matière étrangère.

9.Les rallonges, les cordons d’alimentation et tout appareil électrique doivent être en bon état. Ne jamais faire fonctionner un appareil électrique dont le cordon d’alimentation est abîmé ou défectueux.

10.Ranger le nettoyeur haute pression dans un endroit bien ventilé, réservoir d’essence vide. On ne doit pas ranger l’essence près de la génératrice.

11.Vous ne devez jamais utiliser votre nettoyeur sous ces conditions:

a.Un changement de vitesse du moteur.

b.Perte de puissance électrique.

c.Surchauffe d’appareils connectés.

d.Jaillissement d’étincelles.

e.Prises endommagées.

f.Le moteur qui a des ratés.

g.Vibrations excessives.

h.Flammes ou fumée.

i.Compartiment fermé.

j.Pluie ou température défavorable.

12.Vérifier le système de carburant régulièrement pour toute fuite ou signes de détérioration tels un tuyau spongieux ou usé, une bride qui manque ou desserrée ou un réservoir ou couvercle endommagé. On doit corriger ces problèmes avant de faire fonctionner l’appareil. Nettoyer immédiatement tout déversement.

13.On ne doit faire fonctionner, réparer et faire le plein que sous les conditions suivantes:

a.Une bonne ventilation - évitez les endroits où les vapeurs peuvent être immobilisées comme dans des fosses, sous-sols, caves, trous et dans le fond d’un bateau. La circulation de l’air et les températures sont importantes pour les appareils refroidis par air. Les températures ne devraient pas dépasser 40 degrés C (100 degrés F).


French		13

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