Stow G-4.5R User Manual

OPERATION AND PARTS MANUAL

MODEL G-4.5R

PORTABLE AC GENERATOR

(GASOLINE ENGINE)

S/N 5498030 AND BELOW

S/N 5498031 AND ABOVE

Revision #3 (03/13/06)

THIS MANUAL MUST ACCOMPANY

THE EQUIPMENT AT ALL TIMES.

PAGE 2 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

STOW MAIN OFFICE

Post Office Box 6254 888-252-STOW Carson, Ca 90749 Email: stow@multiquip.com Internet: www.stowmfg.com

PARTS DEPARTMENT

800-427-1244 FAX: 800-672-7877 310-537-3700 FAX: 310-637-3284

SERVICE DEPARTMENT

800-421-1244 FAX: 310-537-4259 310-537-3700

TECHNICAL ASSISTANCE

800-478-1244 FAX: 310-631-5032

WARRANTY DEPARTMENT

800-421-1244, EXT. 279 FAX: 310-537-1173 310-537-3700, EXT. 279

SALES DEPARTMENT

310-661-4242 FAX: 310-604-9237 877-289-7869 (877-BUY-STOW)

ON-HAND

WHEN CALLING

FAX:

310-537-1986

altered without written permission. All other trademarks are the property of thier respective owners and used with permission. This manual

remain with the unit if resold. The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations are

based on the design or the information published in this publication at any time without notice and without incurring any obligations.

MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should

G-2.9R Portable AC Generator.

STOW Construction Equipment reserves the right to discontinue or change specifications,

To find the latest revision of this

publication, visit our website at:

www.stowmfg.com

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 3

TABLE OF CONTENTS

STOW G-4.5R — AC Portable Generator

Here's How To Get Help ............................................ 3

Table Of Contents ..................................................... 4

Parts Ordering Procedures ....................................... 5

Dimensions ............................................................... 6

Specifications ............................................................ 7

Safety Alert Message Symbols .............................. 8-9

Rules for Safe Operation ................................... 10-12

Operation and Safety Decals Operation and Safety Decals

General Information ................................................ 16

Load Application ..................................................... 17

Controls and Indicators ...................................... 18-21

Generator Refueling ............................................... 22

Installation .......................................................... 23-24

Pre-Inspection ......................................................... 25

Pre-Inspection (Engine) .......................................... 26

Initial Start-up (Engine) ........................................... 27

Initial Start-up (Engine/Operation) ..................... 28-29

Preparation For Long Term Storage ....................... 30

Maintenance ...................................................... 32-33

Wiring Diagram Wiring Diagram

(S/N S/N 5498030 & Below) .......................... 34

(S/N 5498031 & Above) ................................. 35

Troubleshooting (Engine) ................................... 36-37

Troubleshooting (Generator) .................................. 38

Explanation Of Codes In Remarks Column ............ 40

Suggested Spare Parts ........................................... 41

(S/N 5498030 & Below) ...... 14

(S/N 5498031 & Above) ...... 15

ROBIN

EX270D20110

Engine (EPA)

Crankcase Assembly ......................................... 56-57

Crankshaft, Piston Assembly .............................58-59

Governor Assembly ........................................... 60-61

Intake and Exhaust Assembly ............................62-63

Air Cleaner Assembly.........................................64-65

Cooling Starting Assembly ................................. 66-67

Fuel Lubricant Assembly ...................................68-69

Flywheel Assembly ............................................70-71

Electric Device Assembly ...................................72-73

Terms and Conditions Of Sale — Parts .................. 74

As a continuing effort to

NOTE

update our parts book, contact the STOW literature department for the latest revision of your "Operation and Parts Manual"

Specification and part number are subject to change without notice.

Generator Component Drawings

Nameplate and Decals (S/N 5498030 & Below) ............ 42-43

Nameplate and Decals

Generator Assembly .......................................... 46-47

Control Box Assembly Control Box Assembly Pipe Frame Assembly Pipe Frame Assembly

PAGE 4 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

(S/N 5498031 & Above) ........... 44-45

(S/N 5498030 & Below) ............. 48-49

(S/N 5498031 & Above) ............ 50-51

(S/N 5498030 & Below) .............. 52-53

(S/N 5498031 & Above).............. 54-55

PARTS ORDERING PROCEDURES

When ordering parts,

please supply the following information:

❒❒

❒ Dealer account number

❒❒ ❒❒

❒ Dealer name and address

❒❒ ❒❒

❒ Shipping address (if different than billing address)

❒❒ ❒❒

❒ Return fax number

❒❒ ❒❒

❒ Applicable model number

❒❒ ❒❒

❒ Quantity, part number and description of each part

❒❒ ❒❒

❒ Specify preferred method of shipment:

❒❒

✓ FedEx or UPS Ground ✓ FedEx or UPS Second Day or Third Day ✓ FedEx or UPS Next Day ✓ Federal Express Priority One ✓ DHL ✓ Tr u ck

Note: Unless otherwise indicated by customer, all orders are treated as “Standard Orders”, and will ship within 24 hours. We will make every effort to ship “Air Shipments” the same day that the order is received, if prior to 2PM west coast time. “Stock Orders” must be so noted on fax or web forms.

Here’s how to get help...

Please have the model and serial number on hand when calling.

STOW MAIN OFFICE

18910 Wilmington Ave. 800-421-1244

FAX:

Carson, CA 90746 Email: stow@stowmfg.com Internet: www.stowmfg.com

SALES DEPARTMENT

310-661-4242 Fax: 310-604-9237

877-289-7869 (877-BUY-STOW)

PARTS DEPARTMENT

800-427-1244 310-537-3700

SERVICE DEPARTMENT

800-421-1244 310-537-3700

TECHNICAL ASSISTANCE

800-478-1244

WARRANTY DEPARTMENT

800-421-1244, 310-537-3700,

EXT. EXT.

279 279

310-537-3927

FAX:

800-672-7877

FAX:

310-637-3284

FAX:

310-537-4259

FAX:

310-631-5032

FAX:

310-537-1173

Place Your Parts Order Via Web or Fax

For Even More Savings!

(Domestic USA Dealers Only)

Extra Discounts!

All parts orders which include complete part numbers and are received by our automated web parts order system, or by fax qualify for the following extra discounts:

Ordered Standard Stock orders

via orders ($750 list and above)

Fax 3% 10%

Web 5% 10%

Special freight allowances when you order 10 or more line items via Web or Fax!**

FedEx Ground Service

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price) do not count towards the 10+ line items.

NOTE: DISCOUNTS ARE SUBJECT TO CHANGE

at no charge for freight

STOW CONSTRUCTION EQUIPMENTSTOW CONSTRUCTION EQUIPMENT

STOW CONSTRUCTION EQUIPMENT

STOW CONSTRUCTION EQUIPMENTSTOW CONSTRUCTION EQUIPMENT

A DIVISION OF MULTIQUIP INC.

POST OFFICE BOX 6254 CARSON, CA 90749 888-252-STOW [888-252-7869] 310-537-3700

FAX: 310-537-1986 FAX: 800-556-1986 E-MAIL: stow@multiquip.com INTERNET: www.stowmfg.com

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 5

Direct TOLL-FREE access

to our Parts Department:

Toll-free nationwide — 800-427-1244

Toll-free FAX — 800-6-PARTS-7

(800/672-7877)

STOW G-4.5R — DIMENSIONS

Figure 1. Dimensions

PAGE 6 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

STOW G-4.5R — SPECIFICATIONS

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Effects of Altitude and Heat

The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambient conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric reading of 29.92 inches and a temperature of 60 degrees fahrenheit.

°°

Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10

°°

fahrenheit above the standard temperature of 60

°°

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 7

STOW G-4.5R — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when operating this equipment. Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others.

This Owner's Manual has been developed to provide complete instructions for the safe and efficient

NOTE

Before using this generator, ensure that the operating individual has read and understands all instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words: DANGER,

operation of the STOW Model G-4.5R

Portable Generator

engine manufacturers instructions for data relative to its safe operation.

. Refer to the

HAZARD SYMBOLS

Potential hazards associated with the operation of a

G-4.5R Portable Generator

Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message Alert Symbols.

Engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air.

Gasoline is extremely flammable, and its vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids.

will be referenced with Hazard

Lethal Exhaust Gases

WARNINGWARNING

WARNING

WARNINGWARNING

WARNING

WARNINGWARNING

Lethal Exhaust Gas Hazards

Explosive Fuel Hazards

STOW

DANGERDANGER

DANGER

DANGERDANGER

You WILL be if you DO NOT follow these directions.

WARNINGWARNING

WARNING

WARNINGWARNING

You CAN be KILLED or you DO NOT follow these directions.

CAUTICAUTI

CAUTION

CAUTICAUTI

You CAN be these directions.

KILLED

INJURED

if you DO NOT follow

SERIOUSLY INJURED

DO NOT fill the fuel tank while the engine is running or hot. DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames.

WARNINGWARNING

WARNING

WARNINGWARNING

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. Never operate the engine with heat shields or heat guards removed.

WARNINGWARNING

WARNING

WARNINGWARNING

ALWAYS wear approved protection when required.

Burn Hazards

Respiratory Hazards

respiratory

PAGE 8 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

STOW G-4.5R — SAFETY MESSAGE ALERT SYMBOLS

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

NEVER operate equipment with covers, or guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

ALWAYS place the power source, circuit breakers or ON/OFF switch in the OFF position, when the generator is not in use, unless connected to transfer switch.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

ALWAYS wear approved eye and hearing protection.

Rotating Parts Hazards

Accidental Starting Hazards

Eye and Hearing Hazards

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Other important messages are provided throughout this manual to help prevent damage to your portable generator, other property, or the surrounding environment.

Equipment Damage

Hazards

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 9

STOW G-4.5R — RULES FOR SAFE OPERATION

DANGERDANGER

DANGER

DANGERDANGER

Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

Read this manual!

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator.

The following safety guidelines should always be used when operating the STOW G-4.5R Portable Generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment before reading this entire manual.

■

This equipment should not be operated by persons under 18 years of age.

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence of

drugs

alcohol

■

The engine section of this generator requires an adequate free flow of cooling air. any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. Remember the generator's engine gives off monoxide gas.

■

ALWAYS refuel in a well-ventilated area, away from sparks and open flames.

■

ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

DEADLY

NEVER

carbon

smoke

around or near the

operate the generator in

■

ALWAYS wear proper respiratory (mask), hearing and eye protection equipment when operating the generator.

■

Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications.

■

NEVER use accessories or attachments, which are not recommended by STOW for this equipment. Damage to the equipment and/or injury to user may result.

PAGE 10 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

■

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

bodily

harm or even death.

NEVER disconnect any

These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death! Disconnection of any of these devices will void all warranties.

"emergency or safety devices"

STOW G-4.5R — RULES FOR SAFE OPERATION

■

ALWAYS be sure the operator is familiar with proper safety precautions and operation techniques before using generator.

■

NEVER leave the generator unattended, turn off engine when unattended.

■

Unauthorized equipment modifications will void all warranties.

■

ALWAYS ensure generator is on level ground before use.

■

DO NOT place hands or fingers inside generator engine compartment when engine is running.

■

NEVER run engine without air cleaner. Severe engine damage

may occur.

■

NEVER change or adjust the engine speed which has been

set at the factory prior to shipping.

Power Cord Safety

■

NEVER let power cables or cords

■

NEVER is being transfer to a load.

■

NEVER use a defective or frayed power cable. Check the cable for cuts in the insulation.

■

NEVER use a extension cord that is frayed or damaged where the insulation has been cut.

■

ALWAYS make certain that proper power or extension cord has been selected for the job See Table 4.

stand in water

while AC power from the generator

lay in wate

Maintenance Safety

■

NEVER lubricate components or attempt service on a running machine.

High Temperatures – Always stop engine and allow the engine to cool before adding fuel, oil or performing service and maintenance

hot!

functions. Contact with cause serious burns.

Keep the machinery in proper running condition. Fix damage to the machine immediately and replace any

broken parts immediately.

ALWAYS replace any worn or damaged warning decals.

ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and un-authorized personnel.

The electrical voltage required to operate the generator can cause severe injury or even death through physical contact with live circuits. performing maintenance on the generator.

Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, fuel and fuel filters.

DO NOT use food or plastic containers to dispose of hazardous waste.

DO NOT pour waste, oil or fuel directly onto the ground, down a drain or into any water source.

Turn all circuit breakers OFF before

components can

Grounding Safety

■

ALWAYS make sure that electrical circuits are properly

grounded

local codes before operating generator. Severe

death!

ungrounded generator.

■

ALWAYS make sure generator is properly grounded to a suitable earth ground (GROUND ROD). See installation section in this manual.

■

NEVER use

per the

National Electrical Code

(NEC) and

injury

by electrocution can result from operating an

gas piping

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 11

as an electrical ground.

■

Removing the engine oil drain plug while the engine is hot will result in hot oil to gush out of the oil drain plug, therefore causing severe scalding to any persons in the general area of the generator.

STOW G-4.5R — RULES FOR SAFE OPERATION

DANGERDANGER

DANGER

DANGERDANGER

During operation of this generation, there exists the possibility of

electrical shock or burn

cause

DEATH!

To avoid these hazards:

severe bodily harm

NEVER use

ELECTROCUTION HAZARDSELECTROCUTION HAZARDS

ELECTROCUTION HAZARDS

ELECTROCUTION HAZARDSELECTROCUTION HAZARDS

damaged

electrocution

, which can

or even

worn

cables when connecting

equipment to the generator. Make sure power connecting cables are securely connected to the generator’s output receptacles, incorrect connections may cause damage to the generator and electrical shock.

Emergencies

■

ALWAYS know the location of the

nearest

■

ALWAYS know the location of the nearest

first aid kit

■

In emergencies

nearest phone or Also know the phone numbers of the nearest

ambulance, doctor

information will be invaluable in the case of an emergency.

NEVER grab or touch a live power cord with wet hands, the possibility exist of electrical shock, electrocution, and even

death!

fire extinguisher

always

know the location of the

keep a phone on the job site

and

fire department

. This

NEVER insert any objects into the output receptacles during operation. This is extremely dangerous. ALWAYS turn-off the generator and place all circuit breakers in the “OFF” position when contact with the output receptacles is required. There exist the possibility of

electrocution, electrical shock or burn, which can cause severe bodily harm or even death

Backfeed to a utility system can cause

electrocution

NEVER connect the generator to a

building's electrical system without a transfer switch or other approved device. All installations should be performed by

licensed electrician

a with all applicable laws and electrical codes. Failure to do so could result in electrical shock or burn causing serious injury or even death!

and or property damage.

in accordance

PAGE 12 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

NOTE PAGE

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 13

OPERATION AND SAFETY DECALS (S/N 5498030 AND BELOW)

Machine Safety Decals

The G-4.5R portable generator is equipped with a number of safety decals (Figures 2A and 2B). These decals are provided for operator safety and maintenance information. The illustration below shows these decals as they appear on the machine. Should any of these decals become unreadable, replacements can be obtained from your dealer.

P/N A3562000003

WARNING

Only operate machine in well ventilated areas.

DO NOT inhale exhaust gases.

S-4984

Only qualified personnel should

DANGEROUS GAS

install, use or service this

equipment.

P/N 8700611804

DANGER

Do not touch output terminals or internal wiring while unit is operating.

Turn off power before servicing.

S-4985

DANGEROUS GAS

3600 RPM ONLY

DAMAGE MAY RESULT IF

OPERATED AT LOWER SPEEDS

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch.

Serious injury or death may result without this transfer switch.

Only qualified personnel should install, use or service this equipment.

P/N 8700611904

CAUTION

OPERATE AT

FULL THROTTLE

()

P/N 7900636004

WARNING!

FUEL COCK

S-3704

P/N 1980680004

S-1123

P/N 0800628504

1. Before starting check the oil and fuel level.

2. Switch the circuit breaker to the “OFF” position.

3. Open the fuel valve.

4. Pull the choke knob.

5. Turn the operation switch to the "RUN" position and push.

6. Pull the recoil starter.

7. After the engine starts, gradually push in the choke valve.

8. Run the generator for 3-5 minutes without load.

9. Check for any abnormal noise or smell.

10. Switch the circuit breaker to the “ON” position.

11. When stopping, remove the load and allow it to continue to

12. Turn the operation switch to the "STOP" position.

13. After the engine completely stops. Close the fuel valve.

MODEL SERIAL NO.

CONTACT

STOW PARTS DEPT.

READ OWNER’S SERVICE MANUAL BEFORE OPERATING OR SERVICING THIS MACHINE.

ALWAYS KEEP UNAUTHORIZED, INEXPERIENCED, UNTRAINED PEOPLE AWAY FROM THIS MACHINE.

MAKE SURE ALL SAFETY DEVICESARE OPERNATIONAL BEFORE THIS MACHINE IS STARTED. MAKE SURE ENGINE IS TURNED OFF AND SPARKPLUG WIRE DISCONNECTED BEFORE SERVICING THE MACHINE OR COMING IN CONTACT WITHANY MOVING PART. IF EQUIPMENT IS POWERED BY AN ELECTRIC MOTOR, DISCONNECT ELECTRICAL PLUG.

NEVER LEAVE MACHINE UNATTENDEDWHEN OPERATING ALWAYS STOP ENGINE AND ALLOW ENGINETO COOL BEFORE ADDING FUEL OR OIL.

OPERATING INSTRUCTIONS

run for 2-3 minutes before stopping engine.

P/N 7900638204

CAUTION!

P/N 0820610304

DCS01

S-4607

P/N 0820610404

IDLE

G-4.5R

CONTROL

P/N A3512100502

OPERATION

SWITCH

RUN

STOP

OIL

ALARM

GFCI

GROUND

AC CIRCUIT

BREAKER

120V

240/120V

FULL POWER

SWITCH

AC VOLTMETER

240V

Figure 2A. Operation and Safety Decals (S/N 5498030 and Below)

PAGE 14 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

OPERATION AND SAFETY DECALS (S/N 5498031 AND ABOVE)

P/N A4561000203

WARNING

Only operate machine in well ventilated areas.

DO NOT inhale exhaust gases.

S-4984

Only qualified personnel should

DANGEROUS GAS

install, use or service this

equipment.

P/N 8700611804

DANGER

Do not touch output terminals or internal wiring while unit is operating.

Turn off power before servicing.

S-4985

DANGEROUS GAS

3600 RPM ONLY

()

DAMAGE MAY RESULT IF

OPERATED AT LOWER SPEEDS

Before connecting this generator to any building’s electrical system, a licensed electrician must install an isolation (transfer) switch.

Serious injury or death may result without this transfer switch.

Only qualified personnel should install, use or service this equipment.

P/N 8700611904

CAUTION

OPERATE AT

FULL THROTTLE

P/N 7900636004

WARNING!

P/N 0820610404

FUEL COCK

S-3704

P/N 1980680004

S-1123

P/N 0800628504

1. Before starting check the oil and fuel level.

2. Switch the circuit breaker to the “OFF” position.

3. Open the fuel valve.

4. Close the choke with the choke lever.

5. Turn the operation switch to the “ON” position

6. Pull the recoil starter.

7. After the engine starts, gradually push in the choke valve.

8. Run the generator for 3-5 minutes without load.

9. Check for any abnormal noise or smell.

10.Switch the circuit breaker to the “ON” position.

11. When stopping, remove the load for 2-3 minutes before

12. Turn the operation switch to the “OFF” position.

13. After the engine completely stops. Close the fuel valve.

MODEL SERIAL NO.

CONTACT

STOW PARTS DEPT.

To avoid injury, you MUST read and understand operator’s manual before using this machine.

This machine to be operated by qualified personnel only.

Ask for training as needed.

P/N 35137

OPERATING INSTRUCTIONS

stopping engine.

P/N A92120000

WARNING

P/N35137

A92120000

OFF

G-4.5R

AC CIRCUIT

BREAKER

120/240V

20A

AC VOLTMETER

IDLE

CONTROL

120V

30A

240/120V

FULLPOWER

OFF

OPERATION

120V

SWITCH

20A

SWITCH

20A

P/N A4511200402

Figure 2B. Operation and Safety Decals (S/N 5498031 and Above)

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 15

STOW G-4.5R — GENERAL INFORMATION

STOW G-4.5R Familarization

General Inspection Prior to Operation

This generator has been thoroughly inspected and accepted prior to shipment from the factory. However, be sure to check for damaged parts or components, or loose nuts and bolts,

Circuit Breaker

To protect the generator from an overload,

circuit breaker is provided on the control panel. Make sure to switch this circuit breaker to the "OFF" position prior to starting the engine.

which could have become disloged in transit. The

STOW Model G-4.5R

generator has been designed as a portable lightweight power source for 60 Hz (single-phase) vibrators, lighting facilities, power tools, submersible pumps and other industrial and construction machinery.

This generator is powered by a 9.0 HP ROBIN air-cooled gasoline engine. The alternator, a brushless revolving-field type, is permanently aligned to the engine through rigid coupling.

The generator is mounted on rubber vibration isolators that have a steel base backplate which is attached to the protective steel pipe carrying frame. The protective carrying frame is made of steel tubing and fully wraps around the generator to protect against damage.

This portable generator is supplied with a electrical

panel

. The control panel includes items as listed below.

control

Control Panel

The generator control panel has the following componets:

■

NEMA 5-20R, GFCI duplex receptacle, (120V, 20 amps)

Excitation System

The STOW G-4.5R generator uses a magnet attached to a flywheel to produce AC voltage from a lamp coil beneath the flywheel. As the magnet passes the coil it produces approximately 19-22 AC volts.

This voltage (19-22 VAC) is then sent to the control box that contains three rectifying diodes:

Excitation (diode 1)

Battery (diode 2)

Slow Down (diode 3)

The AC voltage will pass through the excitation diode that converts the voltage to DC power.

This DC power is then sent to the excitation windings housed within the main windings commonly called the "stator".

This voltage is then transferred into the rotor through induction. The rotor contains two diodes within it which rectify the DC voltage and send it out through the main windings, as AC voltage.

■

NEMA L5-20R, twist-lock receptacle (125V, 20 amps)

Engine

■

NEMA L5-30R, twist-lock receptacle (125V, 30 amps)

■

NEMA L6-20R, twist-lock receptacle (250V, 20 amps), (S/N 5498030 and below)

■

NEMA L14-20R, twist-lock receptacle (125/250V, 20 Amps), S/N 5498031 and above.

The four-cycle air-cooled to meet every performance requirement of this generator. Reference Table 1, for engine specifications.

Figures 3A through 3D shows the basic controls and indicators for the G-4.5R generator.

ROBIN

a 2-pole, 15 amp

gasoline engine is designed

■

Circuit breaker, 2-pole, 15 amps

■

AC Voltmeter

■

Operation Switch

■

Idle Control Switch

■

Full Power Switch

■

Oil Alarm Lamp (S/N 5498030 and below)

■

Ground Terminal (S/N 5498030 and below)

PAGE 16 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

NOTE

In keeping with

STOW's

policy of constantly improving its products, the specifications quoted herein are subject to change without prior notice.

STOW G-4.5R — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator and equipment to insure the wattage, amperage and frequency requirements are satisfactorily supplied by the generator for operating the equipment.

Generally, the wattage listed on the nameplate of the equipment is its rated output. Equipment may require 130— 150% more wattage than the rating on the nameplate, as the wattage is influenced by the efficiency, power factor and starting system of the equipment.

To determine the running wattage for your load, multiply the running wattage as indicated by steps 1, 2, and 3 below:

1. INCANDESCENT LOADS Lights, heaters and similar appliances. Total the running wattage and multiply by 1. Example: 29 light bulbs @ 100W each = 2.9 KW use a 3 KW generator.

2. SMALL MOTORS Drills and other small power tools. Total the running wattage and multiply by 2. Example:

NOTE

If wattage is not given on the equipment's name plate, approximate wattage may be

A 1 inch drill runs at 1 KW use a 2 KW generator.

determined by multiplying nameplate voltage by the nameplate amperage.

3. LARGE MOTORS Submersible pumps, table saws etc.

WATTS = VOLTAGE x AMPERAGE The power factor of this generator is 1.0 See Table 2 below

when connecting loads.

Total the running wattage and multiply by 3. Example: A conveyor belt runs at 8 KW use a 24 KW generator.

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CAUTIONCAUTION

CAUTION

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0.1

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Extension Cables

0.1

When electric power is to be provided to various tools or loads at some are normally used.

CAUTIONCAUTION

Motors and motor-driven equipment draw much greater current for starting than during operation. adequate size

extension cable

required load.

distance

from the generator, extension cords

Cables should be sized to allow for

Always

use an

which can carry the

distance in length and amperage so that the voltage drop between the generator and point of use (load) is held to a minimum

. Use the cable selection chart (Table 2 ) as a

guide for selecting proper cable size.

The idle control device is operated at a

NOTE

minimum load capacity of 100W. If the load capacity is less than 100W, place the idle control switch in the OFF position.

When using a combination of dual

NOTE

receptacles, total load

exceed

the rated capacity of the

should not

generator.

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 17

STOW G-4.5R — CONTROLS AND INDICATORS

Figure 3A. Generator Controls and Components

PAGE 18 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

STOW G-4.5R — CONTROLS AND INDICATORS

1. Idle Control Switch – This unit is provided with an automatic idle control for noise suppression and reduced fuel consumption. The automatic idle control automatically engages under a no-load condition. With the automatic idle control switched “ON”, the engine revolutions will automatically drop to about 2600 rpm (low-speed operation) within 3 seconds after the load stops. When the operation is resumed, the engine speed is automatically increased to about 3600 rpm (high-speed operation) as soon as the load is connected.

2. Operation Switch – Place this position (up) for normal operation. To turn-off the generator place this switch in the "STOP" position (down).

3. Main Circuit Breaker – This 2-pole 15 amp breaker protects the generator from short circuiting or overloading. When starting the generator placed in the "OFF" position.

4. Full Power Switch – This generator is provided with a full power switch. Figures 3B and 3C show simplified wiring diagrams of the dual voltage system. When the full power switch is in the 120 volt (up) position, you can take up

rated power

duplex receptacle, 120 volts at the 120 volt twist-lock receptacle, or a combination of both receptacles as long as the total load does not exceed the generator's capacity.

of the generator at 120 volts from the GFCI

rocker

switch in the "RUN"

always

have the circuit breaker

full

Figure 3C. Full Power Switch 120/240 VAC (Down)

Simplified Wiring Diagram

When the full

power switch

is in the 120

volt position, the 240V receptacle cannot

NOTE

5. AC-Voltmeter – This voltmeter indicates (with a mark) the rated 60 Hz, single phase output voltage. In addition the voltmeter can also be used as a diagnostic tool. If the voltmeter indicator (needle) is below the rated voltage, engine problems may exist (low/high RPM's). To prevent damage to the generator or power tools turn the generator OFF and consult your authorized STOW service dealer.

6. 240 VAC Receptacle, 20 Amps – This receptacle will provide 240V when the full power switch is placed in the 240/120 volt position (down). Applies to units with S/N 5498030 and below.

7. 120 VAC Receptacle, 30 Amps – This receptacle will provide 120V when the full power switch is placed in either the 120 or 240 volt position. Applies to units with S/N 5498030 and below.

be used.

8. GFCI Receptacle, 20 Amps – This receptacle will provide 120V at all times no matter the position of the full power switch. Applies to all units.

Figure 3B. Full Power Switch 120VAC (Up)

Simplified Wiring Diagram

When the full power switch is in the 240 volt (down) position, you can take up to half of the rated power of the generator at 120 volts from the GFCI receptacle and up to half of the rated power of the generator at 120 volts from the twist-lock 120 volt receptacle; or full rated power of the generator at 240 volts from the twist-lock 240 volt receptacle.

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 19

9. 120 VAC Receptacle, 30 Amps – This receptacle will provide 120V when the full power switch is placed in either the 120 or 240 volt position. Applies to units with S/N 5498031 and above.

10. 120 VAC Receptacle, 20 Amps – This receptacle will provide 120V when the full power switch is placed in either the 120 or 240 volt position. Applies to units with S/N 5498031 and above.

11. 240 VAC Receptacle, 20 Amps – This receptacle will provide 240V when the full power switch is placed in the 240/120 volt position (down). Applies to units with S/N 5498031 and above

STOW G-4.5R — CONTROLS AND INDICATORS

Figure 3D. Generator Controls and Components (continued)

PAGE 20 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

STOW G-4.5R — CONTROLS AND INDICATORS

12. GFCI Ground – This ground connection point should be connect to a good earth ground (ground rod).

13. Oil Alarm Indicator – This indicator will light in the event of low oil. Applies to units with S/N 5498030 and below.

This

ROBIN

engine is equipped with a low oil shutdown capability. A built in sensor will automatically

NOTE

ground. Placing the generator on level ground will ensure that the low oil sensor will function properly.

14. Choke Lever – Used for starting the engine. choke lever when starting a cold engine or in cold weather conditions. The choke enriches the fuel mixture. choke lever if starting a warm engine or in warm weather conditions.

15. Fuel Cock Lever – Turn this lever (down)the flow of fuel to the carburetor. Turn

stop (up)

16. Throttle Lever – Used to adjust engine RPM speed. This unit is set at the factory and is not adjustable.

17. Engine – This generator uses a 9.0 HP ROBIN aircooled, 4-stroke , single cylinder, overhead camshaft gasoline engine. Engine uses unleaded fuel.

the flow of fuel.

turn off the engine should the oil level fall below a safe operating condition. Make sure the generator is placed on level

Open

downward

start

upward

21. Oil Dipstick/ Filler Cap– Remove the filler cap dipstick when checking the engine oil level. Add engine oil through this filler port. See Table 4 for recommended type engine oil.

22. Oil Drain Plug – Remove this plug to drain engine oil from the crankcase.

23. Spark Plug – Provides spark to the ignition system. Set spark plug gap to 0.6 - 0.7 mm (0.024 - 0.028 inch). Clean spark plug once a week

24. Carburetor Fuel Cup – Inspect the fuel cup weekly for water and dirt. Clean as referenced in the maintenance section of this manual.

25. Generator Housing – Contains the rotor, rectifer field

the

coil assembly, aramature, bearings and other components that make up generator asembly.

26. Fuel Gauge – Read this gauge to determine when fuel is

low

27. Fuel Gauge/Tank – Remove this cap to add unleaded gasoline to the fuel tank.

gasoline. Make sure cap is tightened securely. DO NOT over fill. Fuel tank capacity is 5 gallons (19 liters).

28. Lifting Bail Eye – Attach a rope or chain to this lifting eye when lifting of the generator is required. Never stand underneath the generator while it is being lifted. Place lifting eye in down position when not in use.

with S/N 5498031 and above.

Replenish

with

clean unleaded

Applies to units

18. Recoil Starter (Pull Rope) – Used for manual-starting of the engine. Pull the starter grip until resistance is felt, then pull briskly and smoothly.

19. Air Cleaner – Prevents dirt and other debris from entering the fuel system. Remove wing-nut on top of air filter cannister to gain access to filter element. NEVER run the engine without an air cleaner.

20. Muffler/Heat Shield – Used to reduce noise and emissions. NEVER touch this use. Always allow time for the generator to cool down before performing maintenance.

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 21

heat shield

when the generator is in

STOW G-4.5R — GENERATOR REFUELING

DANGERDANGER

DANGER

DANGERDANGER

Adding fuel to the tank should be done only when the engine is stopped and has had an opportunity to cool down. In the event of a fuel spill, DO NOT attempt to start the engine until the fuel residue has been completely wiped up, and the area surrounding the engine is dry. If generator is placed in a truck bed with a plastic liner, REMOVE generator from truck bed and place on ground (Figure 4) to refuel. This possibility exist of

fire

explosion

due to static electricity.

Figure 4. Generator Refueling

PAGE 22 — STOW G-4.5R A.C. GENERATOR— OPERATION & PARTS MANUAL — REV. #3 (03/13/06)

STOW G-4.5R — INSTALLATION

Outdoor Installation

Install the generator in a area that is free of

bystanders

generator is on secure level ground so that it cannot slide or shift around. Also install the generator in a manner so that the exhaust will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture and dust. All electrical equipment should be protected from excessive moisture. Failure to do will result in deterioration of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive materials have a tendency to cause excessive wear to engine and alternator parts.

Pay close attention to ventilation when operating the generator inside tunnels and caves. The engine exhaust contains noxious elements.

, and

overhead obstructions

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

. Make sure the

debris

Indoor Installation

Exhaust gases from gasoline engines are extremely poisonous. Whenever an engine is installed indoors the exhaust fumes must be vented to the outside. The engine should be installed at least two feet from any outside wall. Using an exhaust pipe which is too long or too small can cause excessive back pressure which will cause the engine to heat excessively and possibly burn the valves.

Eliminate the danger of deadly carbon monoxide gas. Remember that exhaust fumes from any gasoline engine are very poisonous if discharged in a closed room, but harmless if allowed to mix with the outside air. If the generator is installed indoors, you must make provisions for venting the engine exhaust to the outside of the building.

Generator Grounding

To guard against electrical shock and possible damage to the equipment, it is important to provide a good EARTH ground. Always use the ground terminal on the generator to ground the generator.

Article 250 (Grounding) of the National Electrical Code (NEC) provides guide lines for proper grounding and specifies that the cable ground shall be connected to the grounding system of the building as close to the point of cable entry as practical.

Mounting

The generator should always be mounted on a flat level surface to isolate vibration of the generator when it is running. DO NOT place the generator on slopes, the possibility exists that the generator could slide.

NEC articles 250-64(b) and 250-66 set the following grounding requirements:

1. Use one of the following wire types to connect the generator to earth ground.

a. Copper - 10 AWG (5.3 mm2) or larger. b. Aluminum - 8 AWG (8.4 mm2) or larger.

2. When grounding the generator (Figure 3) connect the ground cable between the lock washer and the nut on the generator and tighten the nut fully. Connect the other end of the ground cable to earth ground.

3. NEC article 250-52(c) specifies that the earth ground rod should be buried a minimum of 8 ft. into the ground.

STOW G-4.5R A.C. GENERATOR — OPERATION & PARTS MANUAL — REV. #3 (03/13/06) — PAGE 23

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