BE 6.5HP Owner`s manual

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BE 6.5HP Owner`s manual | Manualzz

MODEL 3500

6.5HP Generator

Item # 56350

Owner's Manual

Manual del Propietario

DO NOT RETURN TO STORE

Questions?

Problems?

Please call our customer help line:

(888) 315-3080 M-F 84 CT

Thank you for purchasing a model 3500 generator.

This manual provides information regarding the operation and maintenance of this product.

We have made every effort to ensure the accuracy of the information in this manual.

Wen Products reserves the right to change this product at any time without prior notice.

Please keep this manual available to all users during the entire life of the generator.

rev. O1/21/05

MODEL

3500

6.5 HP Generator

FEATURES

3500 Surge Watt Output

3000 Rated Watt Output

Powerful Enough to Run Essential Appliances

During Power Outages

• 120 and 240 VoltAC Outputs

DC Output for Automotive Battery Charging

Low OilAutomatic Shutoff

Circuit Breaker for Overload Protection

4 Gallon Fuel Tank Capacity

Easily Portable- less than 100 lbs

Meets EPA and CARB emissions standards

TABLE OF CONTENTS

GENERAL SAFETY PROCEDURES ........................................................................

PACKAGE CONTENTS .......................................................................................

GENERATOR COMPONENTS ..............................................................................

PREPARING THE GENERATOR FOR USE ...............................................................

Using the Generator for the First Time ...............................................................

Step 1- Add Oil .................................................................................

Step 2- Add Gasoline ..........................................................................

Step 3- Ground the Generator ................................................................

Subsequent Use of the Generator .....................................................................

Step 1- Check the Oil ..........................................................................

Step 2- Check the Gas Level .................................................................

Step 3- Ground the Generator ................................................................

STARTING THE GENERATOR ..............................................................................

USING THE GENERATOR ...................................................................................

AC Usage ................................................................................................

DC Usage ................................................................................................

STOPPING THE GENERATOR ..............................................................................

MAINTENANCE / CARE .....................................................................................

Cleaning the Generator .................................................................................

Changing the Oil ........................................................................................

Changing/Adding Oil ..................................................................................

Air Cleaner Maintenance ..............................................................................

Fuel Filter Cup Cleaning ..............................................................................

Spark Plug Maintenance ...............................................................................

Emptying the Gas Tank ................................................................................

STORAGE / TRANSPORT PROCEDURES ...............................................................

SPECIFICATIONS ..............................................................................................

TROUBLESHOOTING .........................................................................................

EXPLODED VIEW AND PARTS LIST .....................................................................

WIRING DIAGRAM ...........................................................................................

Notice Regarding Emissions

Engines that are certified to comply with California and U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certified to operate on regular unleaded gasoline, and may include the following emission control systems: (EM) Engine

Modifications and (TWC) Three-Way Catalyst (if so equipped).

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GENERALSAFETYPROCEDURES

Please familiarize yourself with the following safety symbols and words:

The safety alert symbol A is used with one of the safety words (DANGER, CAUTION, or WARNING) to alert you to hazards. Please pay attention to these hazard notices both in this manual and on the generator.

DANGER: Indicates a hazard that will result in serious injury or death if instructions are not followed.

WARNING: Indicates a strong possibility of causing serious injury or death if instructions are not followed.

CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed.

{WJ If you have any questions regarding the hazard and safety notices listed in this manual or on the product, please call (888) 315-3080 M-F 8-5CT before using the generator.

A DANGER: This generator produces poisonous carbon monoxide gas when running.

This gas is both odorless and colorless.

Even if you do not see or smell gas, carbon monoxide may still be present. Breathing this poison can lead to headaches, dizziness, drowsiness, and eventually death.

• Use outdoors ONLY in non-confined areas.

• Keep several feet of clearance on all sides to allow proper ventilation of the generator.

A WARNING: The exhaust from this product contains chemicals known to the

State of California to cause cancer, birth defects, or other reproductive harm.

A WARNING: This generator may emit highly flammable and explosive gasoline

vapors, which can cause severe burns or even death. A nearby open flame can lead

to explosion even if not directly in contact with gas.

• Do not operate near open flame

• Do not smoke near generator.

• Always operate on a firm, level surface.

• Always turn generator off before refueling. Allow generator to cool for at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.

• Do not overfill gas tank. Gas may expand during operation.

Do not fill to the top of the tank.

• Always check for spilled gas before operating.

• Empty gasoline tank before storing or transporting the generator..

• Before transporting, turn fuel valve to off and disconnect spark plug.

WARNING: This generator produces powerful voltage, which can result in electrocution.

• ALWAYS ground the generator before using it (see the "Grounding the

Generator" portion of the "PREPARING THE GENERATOR FOR USE" section).

• Generator should only be plugged into electrical devices, either directly or with an extension cord. NEVER connect to a building electrical system without a qualified electrician.

Such connections must comply with local electrical laws and codes.

Failure to comply can create a backfeed, which may result in serious injury or death to utility workers.

• Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as metal decking or steel work. GFCIs are available in-line with some extension cords.

• Do not use in rainy or wet conditions.

• Do not touch bare wires or receptacles (outlets).

• Do not allow children or non-qualified persons to operate.

A WARNING: This generator produces heat when running.

Temperatures exhaust can exceed 150°F (65 ° C).

near

• Do not touch hot surfaces.

Pay attention to warning labels on the generator denoting hot parts of the machine.

• Allow generator to cool several minutes after use before touching engine or areas which heat during use.

CAUTION: Misuse of this generator can damage it or shorten its life.

• Use generator only for its intended purposes.

• Operate only on dry, level surfaces.

• Allow generator to run for several minutes before connecting electrical devices.

• Shut off and disconnect any malfunctioning devices from generator.

• Do not exceed the Wattage capacity of the generator by plugging in more electrical devices than the unit can handle (see "PRECAUTIONS-

OVERLOADING THE GENERATOR").

• Do not turn on electrical devices until after they are connected to the generator.

• Turn off all connected electrical devices before stopping the generator.

N

In additionto the abovesafetynotices,pleasefamiliarizeyourselfwith the safetyand hazardmarkingson the generator.

PACKAGE CONTENTS

Your generator comes with the items listed below.

Please check to see that all of the following items are included with your generator.

O If you are missing components

(888) 315-3080 M-F 8-5 CT for

DO NOT customer

RETURN service.

ITEM LIST

TO STORE, please call

NEMA L14-30 plug for connecting 240 Volt electrical devices i ZZ !i_¸

Three-prong plug for connecting 120 Volt electrical devices

Set of 2 DC connector wires for connecting 12 Volt automotivetype batteries

Spark plug wrench

GENERATOR COMPONENTS

Please familiarize yourself with the locations and functions of the various components and controls of your generator.

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3

I G

(1) Air cleaner- a removable, cleanable, sponge-like element that limits the alnount of dirt pulled into the engine.

(2) 120 Volt AC ReceptacleUse to connect electrical devices that run 120 Volt, 60 Hz, single phase, AC current.

(3) 120/240 Volt AC ReceptacleUse to connect electrical devices that mn 120 and/or 240 Volt, 60

Hz, single phase, AC current.

(4) 12 Volt DC ReceptacleUse for charging 12

Volt automotive-type batteries only.

(5) Circuit BreakerReset switch that protects the generator from electrical overload.

(6) Choke lever- Adjusts the amount of air let into the engine.

(7) Engine Switch- Used to start/stop engine.

(8) Fuel Cap- Access to the fuel tank for adding fuel.

(9) Fuel Filter (;up- Traps dirt and water fioln fuel before it enters the engine.

(10) Fuel Gauge- Indicates the amount of fuel in the tank.

(11) Fuel valve- Allows fuel to enter engine.

(12) Ground TerminalConnect grounding wires here to properly ground unit.

(13) Muffler- Reduces engine noise.

(14) Oil Fill and Dipstick- Location for checking and filling engine oil.

(15) Recoil StarterPull-cord for starting engine.

(16) Spark plug- Provides proper engine ignition.

(17) Volt Meter- Provides reading of voltage output.

PREPARING THE GENERATOR FOR USE

Using the Generator for the First Time

Q The following section describes steps you must follow to prepare your generator

for first-time use. If after reading this section, you are unsure about how to perform

any of the steps please call (888) 315-3080 M-F 8-5 CT for customer service.

Failure to perform these steps properly can damage your generator or shorten its life.

If you are using the generator for the first time, there are a few steps you must take to prepare it for operation:

Step 1- Add oil

The generator requires engine oil to operate properly.

The generator, when new from the package, contains no oil in the crankcase.

You must add the proper amount of oil before operating the generator for the first time.

This amount, which is equal to the oil capacity of the engine crankcase, can be found on the chart in figure 1. When filling the engine with oil in the future, please refer to this chart.

Figure 1- Generator Oil CapaciD _

Model number

Engine oil capacity

2200

20 fluid oz.

3500

20 fluid oz.

5500

37 fluid oz.

To add oil, follow these steps:

1.

Make sure the generator is on a level surface.

2.

Unscrew the oil filler/dipstick cap from the engine as shown in figure 2.

3.

Using a funnel, add the appropriate amount ofoil, as found in figure 1, into the crankcase.

You will know the crankcase is full when the oil level has reached the lower lip of the opening you have just poured the oil into (see figure 3).

4.

Replace oil filler cap.

Ott, _q_.LER

CAP

O_ FLLER

?

HOLE

Figure 2- Unscrewing the oil cap

10

Figure 3- Adding oil

Step 2- Add Gasoline

WARNING: Gasoline and gas fumes are highly flammable.

• Do not fill tank near an open flame.

• Do not overfill.

Always check for fuel spills.

To ensure that the generator runs smoothly use only FRESH, U2qLEADED GAS WITH

AN OCTANE RATING OF 87 OR HIGHER.

To add gasoline:

1.

Make sure the generator is on a level surface.

2.

Unscrew gas cap and set aside (NOTE: the gas cap may be tight and hard to unscrew).

3.

Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill.

Please refer to the chart in figure 4 to find the gas capacity of your generator model. The fuel gauge on the top of the generator indicates how much gasoline is in the generator gas tank.

NOTE: Gas can expand. Do not fill the gas tank to the very top.

4.

Replace fuel cap and wipe up any spilled gasoline with a dry cloth.

IMPORTANT:

• Never use an oil/gasoline mixture.

• Neveruse old gas.

• Avoid getting dirt or water in the fuel tank.

• Gas can age in the tank and make it hard to start up the generator in the future.

Never store generator for extended periods of time with fuel in the tank.

Figure 4- Gas Tank Capacity

Model number 2200

Gas tank 15 L (3.96 gallons) capacity

3500

15 L (3.96 gallons)

5500

25 L (6.60 gallons)

Step 3- Ground the Generator

A WARNING: Failure to properly ground the generator can result in electrocution.

Ground the generator by tightening the grounding nut against a grounding wire (see figure 5). A generally acceptable grounding wire is a No. 12 AWG (American Wire

Gauge) stranded copper wire.

This grounding wire should be connected at the other end to a copper or brass grounding rod that is driven into the earth.

Grounding codes can vary by location.

Please contact a local electrician to check the grounding regulations for your area.

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j A i' i!

Figure 5- Attaching the Grounding Wire to the Generator

Subsequent Use of the Generator

If this is not your first time using the generator there are still steps you should take to prepare it for operation.

IMPORTANT: At this point you should be familiar with the procedures described in the first portion of this section entitled "Using the Generator for the First Time."

If you have not yet read this section, go back and read it now.

Step 1- Check the Oil

The generator is equipped with an automatic shutoff to protect it from damage due to low oil. Nonetheless, you should check the oil level of the engine before each use to ensure that the engine crankcase has a sufficient amount.

To check the oil level:

1.

Make sure the generator is on a level surface.

2.

Unscrew the oil filler/dipstick cap.

3.

With a dry cloth, wipe the oil off of the stick on the inside of the cap.

4.

Insert the dipstick as if you were replacing the cap and then remove again.

There should now be oil on the stick.

If there is no oil on the stick, or oil only at the very end of the stick, you should add oil until the engine crankcase is filled (see

"Adding Oil" portion of the "Maintenance" section).

5.

Be sure to replace cap when finished checking oil.

NOTE: The oil capacity for your generator can be found in the "Specifications" section of this manual

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Step 2 - Check the Gas Level

Before starting the generator, check to see that there is sufficient gasoline in the gas tank.

The fuel gauge on top of the generator will indicate the gas level in the tank.

Add gas if necessary according to the steps in the "Adding Gasoline" portion of the "Maintenance" section.

A WARNING: Gasoline and gasoline fumes are highly flammable.

• Do not fill tank near an open flame.

• Always allow engine to cool for several minutes before refueling.

• Do not overfill (check the "Specifications" section for the tank capacity of your generator).

Always check for fuel spills.

IMPORTANT:

• Use only U2qLEADED gasoline with an octane rating of 87 or higher.

• Do not use old gas.

• Never use an oil/gasoline mixture.

• Avoid getting dirt or water in the fuel tank.

• Never store generator for extended periods of time with fuel in the tank.

Step 3- Ground the Generator

A WARNING: electrocution.

Failure to properly ground the generator can result in

Ground the generator by tightening the grounding nut against a grounding wire (see figure 5). A generally acceptable grounding wire is a No. 12 AWG (American Wire

Gauge) stranded copper wire.

This grounding wire should be connected at the other end to a copper or brass grounding rod that is driven into the earth.

Grounding codes can vary by location.

Please contact a local electrician to check the grounding regulations for your area.

13

STARTING THE GENERATOR

O Before starting the generator, make sure you have read andperformed the steps in

the "Preparing how to perform the Generator for Use" section of this manual.

any of the steps in this' manual please call (888)

If you are unsure about

315-3080 M-F 8-5

CT for customer service.

A CAUTION: to start.

Disconnect all electrical loads from the generator before attempting

To start your generator, perform the following steps:

1.

Make sure no electrical devices are connected to the generator.

Such devices can make it difficult for the engine to start.

2.

Check that the generator is properly grounded (see page 13, "Ground the

Generator").

3.

Turn the fuel valve to the "on" position (see figure 6).

4.

Move the choke lever to the "closed" position (see figure 7).

5.

Set the engine switch to the "on" position.

6.

Pull on the recoil starter handle slowly until a slight resistance is felt (see figure

8). Then pull quickly to start the engine. Return cord gently into the machine.

Never allow the cord to snap back.

7.

If engine fails to start, repeat step 4. NOTE: After repeated attempts to start the engine, please consult the troubleshooting guide before attempting again.

If problems persist please call (888) 315-3080 M-F 8-5 CT.

8.

Once the engine has started and run for about a minute, move the choke lever about half way towards the "open" position.

Wait another 30 seconds and then move the choke lever all the way to the "open" position.

9.

Allow the generator to run for several minutes before attempting to connect any electrical devices.

OFF

Models 2200 and 3500

CHOKE LEVER

ON

Figure 6- Fuel Valve in the "on" position

#

STARTER GRiP

/

//

CLOSBD ORE[N

Figure 7- Choke in the closed position page 9 for choke location) refer to

Figure 8- Pulling the start cord

14

USING THE GENERATOR

Once you have allowed the engine to run for several minutes, you may connect electrical devices to the generator.

AC Usage

You may connect electrical devices running on AC current according to their wattage requirements.

The chart in figure 9 shows the rated and surge wattage of your generator according to its model number.

The rated wattage corresponds to the maximum wattage the generator can output on a continuous basis.

The sul\qe wattage corresponds to the maximum amount of power the generator can output for a short period of time.

Many electrical devices such as refrigerators require short bursts of extra power, in addition the rated wattage listed by the device, to stop and start their motors.

The surge wattage ability of the generator covers this extra power requirement.

Model Number

2200

3500

5500

Rated(Running)Wattage

1800

3000

5000

Surge Wattage

2200

3500

5500

Figure 9- generator wattage by model number.

The total running wattage requirement of the electrical devices connected to the generator should not exceed the rated wattage of the generator itself. To calculate the total wattage requirement of the electrical devices you wish to connect, find the rated (or running) wattage of each device.

This number should be listed somewhere on the device or in its instruction manual.

If you cannot find this wattage, you may calculate it by multiplying the Voltage requirement by the Amperage drawn:

Watts = Volts x Amperes

If these specifications are not available you may estimate the Watts required by your device by using the chart in figure 10.

Once you have found the rated wattage requirement of each electrical device, add these numbers to find the total rated wattage you wish to draw from the generator.

If this number exceeds the rated wattage of the generator, DO NOT connect all these devices.

Select a combination of electrical devices, which has a total rated wattage lower than or equal to the rated wattage of the generator.

CAUTIONThe generator can run at its surge wattage capacity for only a short time.

Connect electrical devices requiring a rated (running) wattage equal to or less

15

than the rated wattage of the generator. Never connect devices requiring wattage equal to the surge wattage of the generator.

a rated tool or appliance electric water heater (40 gal) hot plate saw- radial arm electric stove saw- circular air compressor (1 HP) window air conditioner saw- miter microwave well water pump reciprocating saw sump pump refrigerator freezer furnace blower computer electric drill television deep freezer garage door opener stereo box fan clock radio security system dvd player/vcr common light bulb rated (running) Watts

4000

2500

2000

1500

1500

1500

1200

1200

1000

500

480

400

300

300

180

100

75

1000

960

800

800

800

800

600

500 additional surge Watts

0

0

2000

0

1500

3000

1800

1200

0

500

0

0

600

0

0

0

0

1000

1040

1200

1200

1300

0

900

0

NOTE: The above wattage figures are estimates.

Try to check the wattage listed on your electrical device before consulting this chart.

Figure 10- Estimated wattage requirements of common electrical devices.

Once you have determined what electrical devices you will be powering with the generator, connect these devices according to the following procedure:

1.

Plug in each electrical device with the device turned off.

NOTE: Be sure to attach appliances to the correct receptacle (outlet).

Connect standard 120 Volt, single phase, 60 Hz loads only to the 120 Volt receptacle.

Connect 120/240 Volt, single phase, 60Hz loads with a NEMA L14-30 plug only to the 120/240 Volt receptacle See Figure 11 for a depiction of each of these receptacles.

2.

Switch the circuit breaker to the "on" position.

3.

Turn on the connected electrical devices in the order of the amount of power they require beginning with the device with the highest rated wattage requirement.

16

CAUTION:

Do not connect 50Hz or 3-phase loads to the generator.

Figure 11- Receptacles available on the generator

SOME NOTES ABOUT POWER CORDS

Long or thin cords can drain the power provided to an electrical device by the generator.

When using such cords, allow for a slightly higher rated wattage requirement by the electrical device.

See Figure 12 for recommended cords based on the power requirement of the electrical device.

Amps

2.5

5

7.5

10

15

20

25

30

40

Device Requirements

Watts (120V)

300

600

900

1200

1800

2400

3000

3600

4800

*NR= not recommended

Watts(240

600

1200

1800

2400

3600

4800

6000

7200

9600

V) #8 wire

Max. Cord Length (ft) by Wire Gauge

#10 wire #12 wire #14 wire #16 wire

NR 1000 600 375 250

NR

NR

NR

NR

175

150

125

90

500

350

250

150

125

100

65

NR

300

200

150

100

75

60

NR

NR

200

125

100

65

50

NR

NR

NR

125

100

50

N R

NR

NR

NR

NR

Figure 12- Maximum Extension Cord Lengths by Power Requirement

DC Usage

CAUTION: The DC receptacle is for recharging 12 Volt automotive-type only.

Do not connect any other device to this receptacle.

17 batteries

CAUTION: Use the generator only to recharge 12 Volt batteries.

Never try to jumpstart a car with your generator.

To connect 12 Volt batteries to the DC receptacle:

1.

Connect one charging wire to the positive terminal on the battery and the other charging wire to the negative terminal.

2.

Connect the free end of the positive wire to the positive receptacle (outlet) on the generator.

3.

Start the generator.

4.

Carefully connect the free end of the negative wire to the negative receptacle on the generator.

5.

When disconnecting, always disconnect the wires from the generator first to avoid a spark.

A DANGER: Storage batteries emit highly explosive hydrogen gas when charged.

Batteries also contain acid, which can cause severe chemical burns.

• Do not allow open flames or cigarettes nearby for several minutes after charging a battery.

• Always wear protective goggles and rubber gloves when charging a battery.

If battery acid gets on your skin, flush with water.

If battery acid gets in your eyes, flush with water and call a physician immediately.

If battery acid is swallowed, drink large quantities of milk and call a physician immediately.

STOPPING THE GENERATOR

To stop the generator:

1.

Turn off, then unplug all connected electrical devices.

2.

Switch the circuit breaker to the "off' position.

3.

Allow the generator to run for several more minutes with no electrical devices connected.

This helps stabilize the temperature of the generator.

4.

Set the engine switch to the "off' position.

5.

Turn the fuel valve to the "off' position.

A WARNING: Allow the generator to cool for several minutes before touching

areas that become hot during use.

CAUTION: Allowing gas to sit in the generator tank for long periods of time without use can make it difficult to start the generator in the future. Never store generator for extended periods of time with fuel in the tank.

18

MAINTENANCE/CARE

Proper routine maintenance of your generator will help prolong the life of your machine.

Please perform maintenance checks and operations according the schedule in figure 13.

O If you have questions about any of the maintenance procedures listed in this manual, please call (888) 315-3080 M-F 8-5CT.

CAUTION: Never perform maintenance operations while the generator is running.

Recommended Maintenance Schedule

every 3 every 6

every month months or months or every year or 20 hrs 50 hrs 100 hrs or 300 hrs

Engine oil

Air cleaner

_heck level

"eplace sheck slean fuel filter cup slean spark plu_l

gas tank sheck/clean sheck gas level slean

each use x x x x x x x x

Figure 13- Recommended maintenance schedule

Cleaning the Generator

Always try to use your generator in a cool dry place.

However, in the event your generator becomes dirty you may clean the exterior with one or more of the following: a damp cloth a soft brush a vacuum pressurized air

Never clean your generator with a bucket of water or a hose.

Water can get inside the working parts of the generator and cause a short circuit or corrosion.

Checking the Oil

The generator is equipped with an automatic shutoff to protect it from running on low oil.

Nonetheless, you should check the oil level of the generator before each use to ensure that the generator crankcase has a sufficient amount.

To check the oil level:

1.

Make sure the generator is on a level surface.

2.

Unscrew the oil filler/dipstick cap (see figure 14).

3.

With a dry cloth, wipe the oil off of the stick on the inside of the cap.

4.

Insert the dipstick as if you were replacing the cap and then remove again.

There should now be oil on the stick.

If there is no oil on the stick, or oil only at the

19

.

very end of the stick, you should add oil until the engine crankcase is filled.

See

"Changing/Adding Oil" in this section.

Be sure to replace cap when finished checking oil.

Figure 14- Checking the oil

Changing/Adding Oil

You should check the oil level of your generator according to the maintenance schedule in figure 13. When the oil level is low you will need to add oil until the level is sufficient to run the generator.

The oil capacity of your generator engine is listed in figure 15.

Model number

Engine oil capacity

2200

20 fluid oz.

3500

20 fluid oz.

5500

37 fluid oz.

Figure 15- Engine Oil Capacity.

It is only necessary to drain the oil from the crankcase if it has become contaminated with water or dirt. In this case, you can drain the oil from the generator according to the following steps:

1.

Place a bucket underneath the generator to catch oil as it drains.

2.

Using a 10 mm hex wrench, unscrew the oil drain plug, which is located on the crankcase underneath the oil filler/dipstick cap (see figure 16). Allow all the oil to drain from the generator.

3.

Replace the oil drain plug and tighten with a 10 mm hex wrench.

To add

1.

2.

3.

oil to the crankcase, follow these steps:

Make sure the generator is on a level surface.

Unscrew the oil filler/dipstick cap from the engine as shown in figure 15 above.

Using a funnel, add high detergent motor oil to the crankcase.

We recommend

SAE 10W/30 motor oil for general use. When full, the oil level should come close to the top of the oil fill opening (see figure 17).

2O

DRAIN PLUG

Figure 16- Draining oil Figure 17- Adding oil

NOTE: Never dispose of used motor oil in the trash or down a drain.

Please call

your local recycling center or auto garage to arrange oil disposal.

Air Cleaner Maintenance

Routine maintenance of the air cleaner helps maintain proper air flow to the carburetor.

Occasionally check that the air cleaner is free of excessive dirt.

1. Unhinge the clasps at the top and bottom of the air cleaner cover (see figure 18).

2. Remove the sponge-like elements from the casing.

3. Wipe the dirt from inside the empty air cleaner casing

4. Wash the sponge-like elements in household detergent and warm water. Allow to dry.

5. Soak the dry elements in engine oil. Squeeze out any excess oil.

6. Replace the sponge-like elements in the air cleaner casing and replace the cover.

COVER

SPR_NG

A_R CLEANER

COVER

ELEMENT

...........

,

' "', g', 77{t_%÷_T<_& * v {,, i g ]

¢*%{ f

COVER

SPR_NG

Figure 18- Removing the air cleaner casing.

21

Fuel Filter Cup Cleaning

The fuel filter cup is a small well underneath the fuel valve.

It helps to trap dirt and water that may be in your fuel tank before it can enter the engine. To clean the fuel filter cup:

1.

Turn the fuel valve to the "off' position.

2.

Unscrew the fuel filter cup from the fuel valve using a wrench.

Turn the valve toward you to unscrew (see figure 19).

3.

Clean the cup of all sediment.

Using a rag or brush.

4.

Reinstall the fuel filter cup.

FUEL VALVE

FUEL FILTER CUP

Figure 19- Removing the Fuel Filter Cup

Spark Plug Maintenance

The spark plug is important for proper engine operation.

A good spark plug should be intact, free of deposits, and properly gapped.

To inspect you spark plug:

1. Pull on the spark plug cap to remove it.

2. Unscrew the spark plug from the generator using the spark plug wrench included with this product (see figure 20).

3. Visually inspect the spark plug. If it is cracked or chipped, discard and replace with a new spark plug. We recommend using a F6RTC spark plug such as NGK

BPR5ES.

4. Measure the plug gap with a gauge (see figure 21). The gap should be 0.7-0.8mm

(0.028-0.03 lin).

5. If you are re-using the spark plug, use a wire brush to clean any dirt from around the spark plug base and then re-gap the spark plug..

6. Screw the spark plug back into its place on the generator using the spark plug wrench. Replace the spark plug cap.

22

PLUG W_ENOH

_{_

O, 7@, 8 !_> z:, (00260031 n;

PLUG CAP

Figure 20- Removing the spark plug Figure 21- Measuring the spark plug gap

Emptying the Gas Tank

Before storing your generator for extended periods of time, you should drain your generator of gasoline.

To drain the generator of gas:

1.

Turn the fuel valve to the "off' position.

2.

Remove the fuel filter cup (see "Removing the Fuel Filter Cup" earlier in this section.

3.

Empty the fuel filter cup of any fuel.

4.

With a receptacle underneath the generator to catch the gas, turn the fuel valve to the "on" position.

Drain all the gas from the generator.

5.

Turn the fuel valve to the "off' position.

6.

Replace the fuel filter cup.

7.

Store the emptied gasoline in a suitable place.

A CAUTION: Do not store fuel from one season to another.

STORAGE

A CAUTION: still hot.

/ TRANSPORT PROCEDURES

Never place any type of storage cover on the generator while it is

When transporting or storing your generator for extended periods of time:

• Empty the gas tank (see "Elnptying the Gas Tank" in the "Maintenance" section).

• Disconnect the spark plug.

• Do not obstruct any ventilation openings.

• Keep the generator in a cool dry area.

23

SPECIFICATIONS

Generator

AC Output

R_edW_tage

_urgeW_tage

R_ed Voltage

R_ed Amperage

R_ed Frequency

Phase

DC Output

Voltage

Amperage

Dimensions(in):

Dry mass model2200

1800W

2200W

120/240 V

15 A/7.5A

60Hz

Single model3500

3000W

3500W

120/240 V

25 A/12.5A

60Hz

Single model5500

5000W

5500W

120/240 V

41A/20.5A

60Hz

Single model 2200

12V

8.3 A model

12V

3500

8.3 A model

12V

5500

8.3 A length = 23.25

width = 17 length = 23.25

width = length = 27 width=20 height = 17 17 height = 17 height = 21

99 lbs 99 lbs 168 lbs

Engine type

[gnition system model 2200

4-stroke OHVsingle cylinder with forced air cooling system non-contact transistor model 3500 model 5500

4-stroke OHVsingle 4-stroke OHVsingle

=ylinder with forced air cylinder with forced air

=ooling system cooling system non-contact transistor non-contact transistor

Displacement

Fuel tank zapacity:

Dil capacity

163 cm 3

15 L (3.96 US gal.)

0.6 L (20 fl oz.)

196cm 3

15 L (3.96 US gal.)

0.6 L (20 fl oz.)

337cm 3

25 L (6.60 US gal.)

1.1 L (37 fl oz.)

Run time on 50%

Load

21 hrs 15 hrs 15 hrs

24

TROUBLESHOOTING

IMPORTANT:

M-F 8-5.

If trouble persists please call our customer help line at (888) 315-3080

Problem

Engine will not start

Cause Solution

Engine switch is set

LO "Off".

Fuel valve is turned

Lo"closed".

Shoke is open.

Set engine switch to "on".

Turn fuel valve to "open" position.

Close the choke

Engine is out of gas.

Engine is filled with sontaminated or old gas

Spark plug is dirty.

Spark plug is

3roken.

Generator is not on evel surface.

:Dil is low

&dd gas.

Change the gas in the engine.

Clean spark plug.

Replace spark plug.

Move generator to a level surface to prevent low oil shutdown from triggering.

Add or replace oil.

Engine runs but there is no electrical output

Sircuit breaker is off.

Set the circuit breaker to the "on" position.

Bad connecting

Mres/cables.

If you are using an extension cord, try a different one.

Bad electrical device sonnected to generator.

Generator runs bul does not support all electrical devices connected.

Generator is

3verloaded

Try connecting a different device.

Try connecting fewer electrical loads to the generator.

Short in one of the sonnected devices.

_,ir cleaner is dirty.

Fry disconnecting any faulty or short-circuited electrical loads.

Clean or replace air cleaner.

25

b_

I

3O

31

32

33

3d

26

27

28

29

22

23

2,'I

25

19

20

21 fret11

Part

1

2 41100

41310

3

.,I 41320

GB6177 86

5

6 GB802 88

41350

7

8 GB5787 86

41116

9 i0 32520

32100 ii

12 32310

13

35510 i,'I GB5787 86

15

37300

16 37310

17

37321

68511

18

32116

31200

31936

31100

31370

31411

31938

31995

68512

35410

37420

31710

GB5787 86

GB6187 86

GBS19 85

32115

Oty DescriiKion

Gasoline engine

1 Frame comp

2 Bottom rubber A

2 Bottom rubber B

8 Flange nut M8

Nut M6 t t Cushion, frame

Bolt M6X 12

1 Rubber pad, frame

1 Earth terminal set

1 Wire harness Assy

1 Switch wire

1 Consent (30A)

3 Bolt M4X i0

1 Control panel Assy

1 Control panel

1 Control panel case

1 Panel switch mark,RH

1 Panel switch mark,LH

1 Ignition switch

1 Voltmeter

1 Circuit protector (10A)

Flange bolt M6 X 12

2 Nut M4

2 Pan screw M4 X 10

1 Boot, AC output wire

1 Boot, main wire harness

1 Stator Assy

1 Stator cover

1 Rotor comp.

1 Brush Assy

1 Generator stay

1 Generator end cover

3 Bolt M5 X 12

45

46

47

48

41

42

43

44

Item

35

36

37

38

39

40

49

50

51

52

57

58

59

60

61

62

53

54

55

56

63

64

65

66

67

68

Part

31600

GB276 89

31134

31931

31933

31141

31996

30100

16610

16500

16521

16916

37820

GB819 85

GB5787 86

16821

16811

16931

16937/168F

16930

16812

1682,t

37825

18300/168F

18611

GB5787 86

18110/168F

18221/168F

18720

18710

GB5787 86

GB6187 86

GB5787 86

12255/168F

BV

BV

BV

Oty Description

1 Voltage regulator

1 Bearing 6202-2RS

1 Plain washer

,t Flange bolt M6 X 125

1 Bolt M8X 180

1 Generator t:an

8 Bolt M5 X 14

1 Stator & rotor Assy

1 Fuel tank

1 Fuel filler cap comp.

1 Packing ring

1 Fuel filter

1 Fuel sensor

2 Screw M5 X 10

4 Flange bolt M6 X 22

4 Washer

4 Cushion

1 Outlet pipe

(1,9x d),t. 5x 130

2 Tube clip

1 Fuel cock

1 Stripe, fuel tank

,t Fitting brush, fuel tank

1 Gasket, fuel sensor

1 Muffler

1 Muffler guard

3 Flange bolt M8 X 16

1 Exhaust pipe comp.

1 Muffler gasket

1 Supporting plate

1 Muffler stay

2 Bolt M8 X 25

2 Nut M8

6 Flange bolt M6 X 12

1 Exhaust pipe gasket

27

Main col! 1

_ain coi! 2

Excitatio_ coil

Field col

BCcoil

Br (_ Br

BREAKER

q-,

AC 120V,2_0V

Bu

R ©

vO

L

BL

ENGSWITEH

AVR

FUSE R

YiO

Spark piub Ignition coil

Fuel level switch

ENGSWITEH

KG E

OFF (_ @

ON

BL Black R red

Y yellow W write

Br Brown BU blue

6 green

13

13

NOTES:

29

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