4750W DUAL FUEL GENERATOR

Transcription

1 4750W DUAL FUEL GENERATOR IMPORTANT: Model DF475 bit.ly/wenvideo Your new tool has been engineered and manufactured to WEN s highest standards for dependability, ease of operation, and operator safety. When properly cared for, this product will supply you years of rugged, trouble-free performance. Pay close attention to the rules for safe operation, warnings, and cautions. If you use your tool properly and for intended purpose, you will enjoy years of safe, reliable service. NEED HELP? CONTACT US! Have product questions? Need technical support? Please feel free to contact us at: (M-F 8AM-5PM CST) techsupport@wenproducts.com WENPRODUCTS.COM

2 TABLE OF CONTENTS Generator Identification 3 Service Record Introduction Safety Information General Safety Rules Know Your Generator Unpacking & Assembly Generator Preparation Starting the Generator Stopping the Generator Using the Generator Maintenance Storage & Transport Specifications Exploded View and Parts List Wiring Diagram Trouble Shooting Warranty Statement

3 GENERATOR IDENTIFICATION If assistance for information or service is required, please contact the Customer Service Help Line by calling ; customer will be asked to provide generator information when calling. Refer to the illustration below for the location of the serial number. Record generator information in the spaces provided below. GENERATOR MODEL NUMBER: DF475 DATE OF PURCHASE: PURCHASED FROM: ENGINE SERIAL NUMBER: SERVICE RECORD Record Service Dates: Serial Number Change Oil Change Spark Plug Clean Fuel Tank Clean Air Filter Date Date Date Date Date Date TO MAXIMIZE THE LIFESPAN OF THIS GENERATOR, MAKE SURE TO RUN IT AT LEAST ONCE A MONTH. IF YOU DO NOT RUN IT OFTEN, IT WILL GREAT- LY SHORTEN THE LIFESPAN AND PERFORMANCE OF THE GENERATOR. 3

4 INTRODUCTION Thank you for purchasing a WEN Dual Fuel Generator. This manual provides important information regarding the safe operation and maintenance of this product. Read all the information carefully before the assembly and operation of your generator to avoid personal injury and damage to the machine. Please keep this manual available to all users during the entire life of the generator. This manual contains special messages to bring attention to potential safety concerns and generator damage as well as helpful operating and servicing information. Please read all the information carefully to avoid injury and machine damage. QUESTIONS? PROBLEMS? In order to answer questions and solve problems in the most efficient and speedy manner, contact Customer Service at (800) , M-F 8-5 CST NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur. WEN reserves the right to change this product and specifications at any time without prior notice. NOTICE REGARDING EMISSIONS Engines that are certified to comply with 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). SAFETY INFORMATION Before operating this generator read and observe all warnings, cautions, and instructions both on the generator and in this owner s manual. NOTE: The following safety information is not meant to cover all possible conditions and situations that may occur. Common sense and strict compliance with the instructions are essential to eliminating accidents. This safety alert symbol is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard. DANGER indicates a hazard, which, if not avoided, will result in death or serious injury. WARNING indicates a hazard, which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard, which, if not avoided, might result in minor or moderate injury. CAUTION when used without the alert symbol, indicates a situation that could result in damage to the machine. 4

5 SAFETY INFORMATION SAVE THESE INSTRUCTIONS This manual contains important instructions for the WEN generator that should be followed during installation and maintenance of the generator. For any questions regarding the hazard and safety notices listed in this manual or on the product, please call (800) M-F 8-5 CST before using the generator. DANGER: CARBON MONOXIDE Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO. NEVER use a generator inside homes, garages, crawl spaces, or other partially enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air. ONLY use a generator outside and far away from windows, doors, and vents. These openings can pull in generator exhaust. Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-backup CO alarm in the home. If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning. WARNING: The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even if it isn t directly in contact with gasoline. WARNING: If this generator is used as a supply for a building s wiring system, the generator must be installed by a qualified electrician and connected to a transfer switch as a separately derived system in accordance with the National Electrical Code, NFPA 70. The generator shall be connected to a transfer switch that switches all conductors excluding the equipment grounding conductor. The frame of the generator shall be connected to an approved grounding electrode. WARNING: This generator produces heat when running. Temperatures near exhaust can exceed F (65 0 C). Do not touch hot surface. NOTE: For power outages, permanently installed stationary generators are better suited for providing backup power to the home. Even a properly connected portable generator can become overloaded. This may result in overheating or stressing of the components, possibly leading to a generator failure. 5

6 GENERATOR SAFETY RULES 1. ONLY use a generator outside and far away from windows, doors and vents. 2. Do not operate near open flame. 3. Do not smoke near generator. 4. Do not use in rainy or wet conditions. 5. Always operate on a dry, firm, level surface. 6. Only use generator for its intended purposes. 7. Do not allow children or non-qualified persons to operate the generator. 8. ALWAYS ground the generator before using it (see the Ground the Generator portion of the Generator Preparation section). 9. Do not overfill fuel tank. Gasoline may expand during operation. Do not fill to the top of the tank. Allow for expansion. 10. Always check for spilled fuel before operating. 11. Make sure to have damaged items repaired or replaced before operation. 12. Do not use plugs or cords that show signs of damage such as broken or cracked insulation. 13. 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. 14. NEVER connect the generator to a building s electrical system without a qualified electrician. Such connections must comply with local electrical laws and codes. Failure to comply can create a back-feed, which may result in serious injury or death to utility workers. 15. Do not touch bare wires or receptacles (outlets). 16. Do not touch hot surfaces. See warning labels on the generator identifying hot parts of the machine. 17. Allow generator to run for several minutes before connecting electrical devices. 18. Do not exceed the wattage capacity of the generator by plugging in more electrical devices than the unit can handle. 19. Do not turn on electrical devices until after they are connected to the generator. 20. Generators vibrate in normal use. During and after the use of the generator, inspect both the generator as well as extension and power supply cords for damage resulting from vibration. 21. Allow generator to cool down after use before touching engine or areas of the generator that become hot during use. 22. Turn off all connected electrical devices before stopping the generator. 23. Shut off and disconnect any malfunctioning devices from generator. 24. 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. 25. Turn the engine switch to OFF position when the engine is not running. 26. Empty fuel tank before storing or transporting the generator. 27. Liquid Petroleum Gas (LPG) is highly flammable and explosive. Flammable gas under pressure can cause a fire or explosion if ignited. 28. Do not use or store LP cylinder in a building, garage or enclosed area. Failure to do so will result in death or serious injury. 29. The cylinder valve should be left off (closed) when generator is not in use. Failure to do so could result in death or serious injury. 6

7 GENERATOR SAFETY RULES 30. In any petroleum gas fire, flames should not be extinguished unless the fuel supply valve is turned OFF. If a fire is extinguished and a supply of fuel is not turned OFF, an explosion hazard could be created. 31. Always keep the LPG cylinder in an upright position. 32. Contact with liquid contents of cylinder will cause freeze burns to the skin. If liquid contents contacts skin or eyes, seek immediate medical attention. 33. When exchanging LPG cylinders, be sure the cylinder valve is of the same type. KNOW YOUR GENERATOR Use the illustrations below to become familiar with the locations and functions of the various components and controls of this generator Gasoline Fuel Cap Fuel Gauge Gas Tank Choke Lever Air Filter Recoil Starter Engine Handle Generator Frame Fuel Selection Dial DC 12V Receptacle 5-20R GFCI RECEPTACLE. Voltage Selector NEMA L14-30R 120V/240V 30A Twistlock Circuit Breaker Grounding Nut Engine Switch Oil Fill and Dipstick Battery LPG Hose Connector 7

8 UNPACKING & ASSEMBLY Open the packaging and take out all loose parts from the box. Carefully lift the generator from the packaging and place it on a level work surface. Make sure all the accessories are accounted for before discarding the packaging. If any part is missing or broken, please contact our customer service at Accessory Qty. Foot Support Assembly (43) 2 Foot Support Isolator (44) 2 M6X40 Bolt (32) 4 M6 Nut (45) 6 Wheel (42) 2 Wheel Axle (48) 2 Flat Washer (16) 2 Cotter Pin (25) 2 Handle (19) 1 Handle Cover (67) 1 Accessory Qty. Handle Connector (49) 1 M8X35 Bolt (31) 2 M8 Hex Nut (64) 8 Handle Bolt (59) 1 Handle Fixing Clip (30) 1 M6X55 Bolt (15) 1 Spark Plug Wrench 1 First Stage Regulator 1 Oil Bottle 1 8 To install the feet: Slide two M6X40 bolts (32) through foot support assembly (43) and the frame, then tighten with M6 nuts (45). Repeat for both feet. NOTE: The rubber isolators (44) and (67) may have already been installed on to the foot and handle. To install the wheels: Slide the wheel axle (48) through the flat washer (16), wheel (42) and wheel bracket on the frame. Insert cotter pin (25) on the end of the the axle to keep the wheel in place. Repeat for both wheels. To install the handle: Slide the M8X35 bolts (31) through the handle connector (49) and the frame. Tighten with the M8 nuts (64). Slide the handle bolt (59) through the handle connector (49) and the handle (19), and tighten with M8 nut (64). Next, install the handle fixing clip (30). Insert the M6X55 bolt (15) through the frame and handle fixing clip (30) and tighten with M6 nut (45).

9 GENERATOR PREPARATION CAUTION: The following section describes the necessary steps to prepare the generator for use. Failure to perform these steps properly can damage the generator or shorten its life. If after reading this section, you are unsure about how to perform any of the steps please call (800) M-F 8-5 CST for customer service. STEP 1 - ADD OIL The generator is shipped without oil. User must add the proper amount of oil before operating the generator for the first time (Fig. 4). The oil capacity of the engine crankcase is 20.3 fl. oz. For general use (above 40 F), we recommend 30W, 4-stroke engine oil. The generator is equipped with a low-oil sensor and will not start without a sufficient amount of oil. To add oil, follow these steps: 1. Make sure the generator is on a level surface. Tilting the generator will cause oil to flow into the engine and cause damage. Keep the generator level! 2. Remove the dipstick from the engine (Fig. 5-1). ENGINE OIL RECOMMENDATIONS Select good quality detergent oil bearing the American Petroleum Institute (API) service classifications SJ, SL, or SM (synthetic oils may be used). Use the SAE viscosity grade of oil from the following chart that matches the starting temperature anticipated before the next oil changes. 3. Add oil slowly using a funnel, being careful not to overfill the unit. Fill the crank case to the lower fill line (Fig. 6). 4. To check the oil level, wipe the dipstick with a clean rag. Insert the dipstick into the oil fill opening without screwing it in. Remove the dipstick to check the oil mark. 5. Slowly add more oil and repeat step 4 until the oil mark reaches to the upper line of the dipstick (Fig. 6). Do not overfill the crankcase. Fig. 4 - Engine Oil Temperature Recommendation CAUTION: Air cooled engines run hotter than automotive engines. The use of non-synthetic multi-viscosity oils (5W-30, 10W-30, etc.) in temperatures above 40 F will result in higher than normal oil consumption. When using a multi-viscosity oil, check the oil level more frequently than you would otherwise. 6. Wipe clean any oil leaks with a rag and firmly tighten the dipstick. Oil Dipstick Upper Level Fill Line 1 Lower Level Fill Line Fig. 5 & 6 - Oil Fill Opening, Dipstick and Oil Level 9

10 GENERATOR PREPARATION WARNING: Keep generator away from open flame. This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even if not directly in contact with gasoline. STEP 2 - ADD FUEL This generator can be run with gasoline or liquid petroleum gas (LPG). Follow the steps below to supply the generator with the desired fuel. Refer to Option A for adding gasoline and Option B for adding LPG. OPTION A: GASOLINE Use fresh (within 30 days from purchase), lead-free gasoline with a minimum of 87 octane rating. Do not mix oil with gasoline. IMPORTANT: Never use an oil/gasoline mixture. Never use old gasoline. Avoid getting dirt or water into the fuel tank. Gasoline can age in the tank and make starting difficult. Never store generator for extended periods of time with fuel in the tank. To add gasoline, follow these steps: 1. Make sure the generator is on a level surface and in a well ventilated area 2. Unscrew fuel cap and set aside. NOTE: The fuel cap may be tight and hard to unscrew. 3. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. The capacity of the fuel tank is 4 gallons. CAUTION: Do not fill the fuel tank to the very top. Gasoline will expand and spill over during use even with the fuel cap in place. Leave room for fuel expansion. 4. Reinstall fuel cap and wipe clean any spilled gasoline with a dry rag. 10

11 OPTION B: LIQIUD PETROLEUM GAS (LPG) GENERATOR PREPARATION DANGER: Explosion and fire. LP vapors are extremely flammable and explosive. Do not use or store LP cylinder in a building, garage or enclosed area. Failure to do so will result in death or serious injury. WARNING: Explosion and fire. The cylinder valve should be left off (closed) when generator is not in use. Failure to do so could result in death or serious injury. NOTE: LPG regulator inlet pressure is approximately 30 PSI at 0 F, and 218 PSI at 100 F. Use only standard 20 or 30 pound capacity LPG tanks with Type 1, right hand Acme threads with this generator. Verify that the re-qualification date on tank has not expired. Do not use rusted or damaged cylinders. All new cylinders must be purged of air and moisture prior to filling. Used cylinders that have not been plugged or kept closed must also be purged. The purging process should be done by the propane gas supplier. (Cylinders from an exchange supplier should have been purged and properly filled by supplier). CONNECT LPG TANK 1. Take off the safety caps from the cylinder valve, generator mounted regulator, and regulator connecting hose ends. 2. With LPG tank closed, attach the LPG regulator connecting hose into the valve. Turn plastic coupling from the hose right (clockwise) to tighten hose assembly onto LPG tank (Fig. 7). 3. Connect the opposite regulator connecting hose end to the generator s LPG primary regulator with a 3/4 in. (19mm) wrench (not supplied) (Fig. 8). 4. Turn LPG tank valve ON (Fig. 9) and check for leaks by spraying soapy water to check connections. If bubbles appear, become larger in size, or increase in number, a leak exists. This must be corrected before using generator. Contact your local IASD for assistance. NOTE: Always position cylinder so the connection between the valve and regulator won t cause sharp bends or kinks in hose. WARNING: Risk of burns. Contact with liquid contents of cylinder will cause freeze burns to the skin. If liquid contents contacts skin or eyes, seek immediate medical attention. Fig. 7 Fig. 8 Fig. 9 NOTE: When transporting and storing, keep cylinder secured in an upright position with cylinder valve turned off. Keep cylinders ventilated and away from heat when in a vehicle. 11

12 STEP 3: CONNECT THE BATTERY GENERATOR PREPARATION WARNING: Battery gives off explosive hydrogen gas. Keep battery away from spark, flame, or cigarette. Do not connect or disconnect battery while generator is running. Service or use battery only in well ventilated areas. WARNING: Battery contains sulfuric acid. Battery acid is poisonous. Tilting the generator with the battery installed can cause battery acid to spill. Wear protective clothing and eye wear when servicing battery. Keep out of reach of children. Do not tilt generator with battery installed. If battery acid gets on your skin, wash with water immediately. If battery acid gets in your eyes, flush with water for at least 15 minutes and call a doctor immediately. If battery acid is swallowed, call a doctor immediately. Drink a large amount of water or milk. Then drink milk of magnesia or vegetable oil. The generator comes with the battery disconnected for safety. To connect the battery: 1. Cut off the cable ties securing the battery cables and remove the red cover from battery terminal. 2. Connect the red cable to the positive (+) battery terminal with the suitable nuts and bolts. 3. Attach the free end of the negative cable to the battery and secure the connection. 4. Make sure connections are secure and slide rubber boot over the positive (+) battery terminal and connection hardware. 5. Connect the black cable to the negative (-) battery terminal with the suitable nuts and bolts. 6. Make sure all connections are secure and slide rubber boot over the negative (-) battery terminal and connection hardware. NOTE: If you do not plan to use the generator for a long period of time, it is recommended to disconnect the negative battery cable from the battery to protect the battery from losing charge. After disconnecting the cable, cover the free end with an insulator such as electrical tape. 12

13 GENERATOR PREPARATION STEP 4 - GROUND THE GENERATOR Ground the generator by tightening the grounding nut on the front control panel against a grounding wire (Fig. 10). 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, brass, or steel-grounding rod that is driven into the earth. Wire and grounding rods are not included with the generator. Grounding codes can vary by location. Contact a local electrician to check the area codes. 1 Fig. 10 WARNING: Failure to properly ground the generator increases your risk of electric shock. NOTE: After completing the above preparation, the generator is ready to be started. STARTING THE GENERATOR Before starting the generator, make sure you have read and performed the steps in the Generator Preparation section of this manual. If you are unsure about how to perform any of the steps in this manual please call (800) M-F 8-5 CST for customer service. DANGER: CARBON MONOXIDE - USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES. Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide (CO). This is a poison gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO. NEVER use a generator inside homes, garages, crawl spaces, or other partially enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air. ONLY use a generator outside and far away from windows, doors, and vents. These openings can pull in generator exhaust. Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-backup CO alarm in the home. If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning. WARNING: The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING: This generator may emit highly flammable and explosive gasoline vapors, which can cause severe burns or even death if ignited. A nearby open flame can lead to explosion even if it isn t directly in contact with gasoline. 13

14 STARTING THE GENERATOR STARTING THE GENERATOR 1. Verify generator is on level ground and is in a well ventilated area. 2. Check that the oil level is sufficient. 3. Check that the generator is properly grounded. 4. Unplug all electrical devices from the generator before attempting to start. Fig Fuel Valve 5. Verify the fuel selection dial is turned to the desired fuel. Turn the dial up to 12 o clock position for gasoline and down to 6 o clock position for LPG. Check that there is adequatesupply for of the selected fuel. WARNING: LPG must be shut off when using gasoline. Gasoline must be shut off when using LPG. Fig. 12 Choke Lever To use gasoline, open the fuel shut-off valve to ON position (Fig. 11). To use LPG, make sure all of the LPG connectors and hoses are well connected and sealed. Then open the LPG tank valve. 7. Move the choke lever to the CLOSE/START position. (Fig. 12). To start the engine with electric starter: 8. Turn the engine switch to the START position for 2-3 seconds. NOTE: If the engine does not start after 2-3 seconds, release the switch from the start position. Keeping the switch in the START position too long can damage the starter. When engine starts, release the switch to the ON position. 9. When engine starts running, slowly move choke lever to OPEN/RUN position. If engine fires, but does not continue to run, move choke lever to CLOSE/START position and repeat starting instructions. 10. Allow the engine to run for several minutes before attempting to connect any electrical devices. This allows the generator to stabilize its speed and temperature. To start the engine with recoil starter: 8. Turn the engine switch to the ON position. 9. Pull on the recoil starter handle slowly until a slight resistance is felt, then pull quickly to start the engine. Return cord gently into the recoil starter. Never allow the cord to snap back. 10. If engine fails to start, repeat step 9. NOTE: After repeated failed attempts to start the engine, please consult the troubleshooting guide before attempting to start the generator. If problems persist please call (800) , M-F 8-5 CST. 11. Once the engine has started, slowly return the choke lever all the way to the OPEN/RUN position. 12. Allow the engine to run for several minutes before attempting to connect any electrical devices. This allows the generator to stabilize its speed and temperature.

15 STOPPING THE GENERATOR TO STOP THE GENERATOR 1. Turn off all electrical devices. Unplug the devices from the generator. Never start or stop the generator with electrical devices plugged in or turned on. 2. Let engine run at no-load for several minutes to stabilize internal temperatures of engine and generator. 3. Turn the engine switch to the OFF position. 4. Turn the fuel valve to the OFF (horizontal) position. If using LPG, turn the LPG tank valve to OFF position. IMPORTANT: Always ensure that the Fuel Valve and the Engine Switch are in the OFF position when the engine is not in use. 5. Turn the fuel selection dial to Gasoline position (12 o clock). 6. Drain the carburetor (See Draining the Carburetor on Page 19). WARNING: Allow the generator to cool for several minutes before touching areas that become hot during use. CAUTION: Gasoline stored in the fuel tank for long periods of time can make it difficult to start the generator in the future. Never store the generator for extended periods of time with fuel in the fuel tank. Refer to Generator Storage Section. CHANGING FUELS 1. Before changing the fuel source, make sure the generator is running under half-load. Do not change fuel when generator is over half-load. 2. If switching from LPG to gasoline, turn off the LPG tank valve and disconnect LPG fuel tank from generator. If switching from gasoline to LPG, turn off the fuel shut-off valve. Then follow the LPG connecting procedure in section Liquid Petroleum Gas (LPG). 3. Check fuel level of the selected fuel and make sure there is adequate fuel. 4. Turn the Fuel Selection Dial to the desired fuel. 5. Follow the electric start or recoil start procedure to start the generator. 15

16 16 USING THE GENERATOR WARNING: When this generator is used on a building s wiring system, the generator must be installed by a qualified electrician and connected to a transfer switch as a separately derived system in accordance with the National Electrical Code, NFPA 70. The generator shall be connected to a transfer switch that switches all conductors other than the equipment grounding conductor. The frame of the generator shall be connected to an approved grounding electrode. For power outages, permanently installed, stationary generators are better suited for providing backup power to the home. Even a properly connected portable generator can become overloaded. This may result in overheating or stressing the machine s components, possibly leading to a generator failure. Before connecting electrical devices, allow the generator to run for a few minutes to stabilize the speed and voltage output. CAUTION: Become familiar with the markings on the panel before connecting electrical devices. Connect electrical devices running on AC current according to their wattage requirements. The chart in Fig. 13 shows the rated and surge wattage of the generator. The rated (running) wattage is the wattage the generator can produce on a continuous basis. The surge wattage is the maximum amount of power the generator can produce for an extremely short period of time (seconds). Many electrical devices such as refrigerators require short bursts of extra power in addition to the rated wattage listed by the device to start their motors. The surge wattage ability of the generator covers this extra power requirement. Generator Fuel Type Rated (Running) Wattage Surge Wattage Gasoline 3800W 4750W DF475 LPG 3500W 4350W Fig Generator Wattage 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 plan 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 this wattage cannot be found, calculate it by multiplying the Voltage requirement by the Amperage drawn: Watts = Volts x Amperes Estimated wattages are available in Fig. 14. Do not solely rely on this chart - all electronics and appliances are built differently. These are not standard wattages across the board, only estimations. When the rated wattage requirement of each electrical device has been determined, add these numbers to find the total rated wattage needed. If this number exceeds the rated wattage of the generator, DO NOT connect all these devices. Select a combination of electrical devices, which have a total rated wattage lower than or equal to the rated wattage of the generator. CIRCUIT RESET BUTTONS help to prevent electrical overload. If your receptacle short circuits or becomes overloaded by an electrical device or devices with too great a wattage rating, the circuit protector may shut off power to the receptacle. If this happens, you will not be able to draw power from the overloaded receptacle. In the event of such an overload, disconnect all electrical devices from the generator and press the circuit reset buttons. If power still does not return to the receptacle, call our customer help line at

17 USING THE GENERATOR CAUTION: The 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 than the rated wattage of the generator. Never connect devices requiring a rated wattage equal to the surge wattage of the generator. This can trip the circuit protectors (circuit breakers). Tool or Appliance Rated (Running) Watts Surge (Starting) Watts Electric water heater (40 Gal) Hot plate Saw - radial arm Electric stove (each element) Saw - circular Air compressor (1 HP) Window air conditioner Saw - miter Microwave Well water pump Saw - reciprocating 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 75 0 Estimated wattage requirements of common electrical devices Note: The above wattage figures are estimates. Check the wattage listed on the electrical device before consulting this chart. Connect the devices according to the following procedure: 1. Make sure that all devices are turned off before plugging in each electrical device. 2. If the generator is overloaded, remove the plugged in load, then press the circuit breaker. Check the total wattage of the devices and reduce the load if it exceeds the capacity of the generator. Slowly plug the loads back in one by one. If the circuit breaker does not reset, wait several minutes and try again. 3. Stop the generator and unplug all devices before using the voltage selector switch to change the output voltage. 17

18 USING THE GENERATOR CAUTION: Do not connect 50Hz loads to 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. Device Requirements Max. Cord Length (ft) by Wire Gauge Amps Watts (120V) Watts (240V) #8 wire #10 wire #12 wire #14 wire #16 wire NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR NR *NR = Not Recommended Do not overload generator or individual panel receptacles. These outlets are overload protected with push-to-reset circuit breakers. If an overload occurs, shut down the generator. Unplug all electrical devices and wait five minutes. Then, start the unit back up again to get power back. Reduce the loads and plug them in. OIL LEVEL SHUTDOWN The generator is equipped with a low oil pressure shutoff that shuts down the engine when the oil level is too low to protect the unit from damage. The oil level of the engine should be checked before each use to ensure that the engine crankcase contains sufficient lubricant. HIGH ALTITUDE OPERATION ABOVE 3000 FEET The fuel system on this generator may be affected by operation at high altitudes. Proper operation can be ensured by installing an altitude kit at altitudes higher than 3000 feet above sea level. At elevations above 8000 feet, the engine may experience a decrease in performance, even with the proper altitude kit. Operating this generator without the high altitude kit may increase the engine s emissions and decrease both fuel economy and performance. The kit should be installed by a qualified mechanic. Refer to the instructions included with your altitude kit for more information about installation. WARNING: To prevent serious injury from fire, follow the kit installation procedures in a well-ventilated area away from ignition sources. If the engine is hot from use, shut the engine off and wait for it to cool before proceeding. Do not smoke near the generator. Warranty will be void if adjustments are not made for high altitude use. 18

19 MAINTENANCE Proper routine maintenance of the generator will help prolong the life of the machine. Please perform maintenance checks according to the schedule in Fig. 14. If there are any questions about the maintenance procedures listed in this manual, please call (800) M-F 8-5CT. Important tips: Drain your carburetor after every use. Do not store the generator with fuel inside the tank for more than 2 months. Run the generator every month for minutes to ensure proper function of the generator. CAUTION: Never perform maintenance operations while the generator is running. Recommended Maintenance Schedule Each 8 hours or daily x First 8 hours Every 25 hours Every 3 months or 50 hours Every 6 months or 100 hours Every year As necessary Engine oil Check level Replace x x* x* x Air cleaner Check x x cartridge Clean x Spark plug Check/clean x Change x x Fuel tank Check level x Clean x Carburetor Drain x Fig. 14 * Clean/change more often under dusty conditions or operating under heavy load. DRAINING THE CARBURETOR Prepare a container under the carburetor to collect the drained fuel. To drain the carburetor, open up the carburetor drain with a screwdriver and drain out any gasoline that has built up inside. Once the fuel has drained, close the drain back. It is recommended to do this after every use and is required before storing the generator for long periods of time. Fuel Drain Screw Fig Draining the Carburetor 19

20 MAINTENANCE CHECKING/ADDING THE OIL Check the oil level of the generator according to the Recommended Maintenance Schedule in Fig. 14. The generator is equipped with an automatic shutoff to protect it from running on low oil. The oil level should be checked before each use or every 8 hours of operation. This is a critical step for proper engine starting. To check the oil level: 1. Make sure the generator is on a level surface. Do not tilt the generator to assist in filling as oil will flow into engine areas and cause damage. Keep generator level! 2. Remove dipstick and wipe the dipstick with a clean rag. Insert the dipstick into the oil fill opening without screwing in. Remove the dipstick to check the oil mark. Add oil if the oil mark covers less than one half of the dipstick. 3. Using a funnel or appropriate dispenser, slowly add oil until the oil mark reaches to the top line of the dipstick. Do not over fill the crankcase. Reinstall the oil dipstick. 4. Reinstall dipstick and wipe clean any spill oil with a rag. CHANGING/DRAINING THE OIL Change the oil according to the Recommended Maintenance Schedule in Fig. 14. Change the oil more often if operating under heavy load or high ambient temperatures. It is also necessary to drain the oil from the crankcase if it has become contaminated with water or dirt. Changing the oil when the engine is warm allows for complete drainage. The oil capacity of the generator engine is 20.3 fluid ounces. Add oil when the oil level is low. For proper type and weight of oil refer to add oil portion of the Generator Preparation section. Drain the oil from the generator according to the following steps. 1. Place generator on a level surface. Prepare a container underneath the engine to catch the oil as it drains. 2. Unscrew the oil drain plug (Fig. 16). Allow the oil to drain from the engine completely. Oil Drain Plug Oil Dipstick Upper Level Fill Line 3. Reinstall the oil drain plug and tighten securely. NOTE: Never dispose of used engine oil in the trash or down a drain. Please call a local recycling center or auto garage to arrange oil disposal. Fig. 16 Lower Level Fill Line 20

21 MAINTENANCE CLEANING THE GENERATOR Keep the generator clean before each use to prevent improper operation or machine damage from dirt and debris. Inspect all cooling air openings on the generator. These openings must be kept clean and unobstructed. To clean the generator, use a damp cloth to wipe exterior surfaces. Use a soft bristle brush to loosen dirt and oil and use a vacuum to pick up loose dirt. Only use low pressure air (not to exceed 25 psi) to blow away dirt. CAUTION: Never clean the generator when it is running! Never clean with a bucket of water or a hose. Water can get inside the working parts of the generator and cause corrosion or a short circuit. AIR CLEANER MAINTENANCE Routine maintenance of the air cleaner helps maintain proper airflow to the carburetor. Occasionally check that the air cleaner is free of excessive dirt. Refer to Recommended Maintenance Schedule in Fig. 14. Clean air filter more frequently in dirty or dusty conditions. To clean the air cleaner: Cover Bolt 1. Unscrew the cover bolt, then remove the air cleaner cover. 2. Remove the air cleaner element from the casing (the sponge-like filter inside). Fig Wash the element in soapy water. Dry the element in clean cloth (DO NOT TWIST). Replace with a new one if the element has been damaged. 4. Wipe off excessive oil from the air cleaner case. Small amounts of oil in the element is normal and necessary for the engine to work properly. 5. Reinstall the air cleaner element and cover. CAUTION: Running the engine with dirty, damaged or missing air cleaner element will cause the engine to wear out prematurely. 21

22 MAINTENANCE SPARK PLUG MAINTENANCE Check the spark plug regularly for proper engine operation. Refer to the Recommended Maintenance Schedule in Fig. 14). A good spark plug should be intact, free of deposits, and properly gapped. To inspect the spark plug: 1. Pull on the spark plug cap to remove it (Fig. 19). Be careful not to tear the insulation or wire. 2. Unscrew the spark plug from the engine using the spark plug wrench provided (Fig. 20). 3. Visually inspect the spark plug for cracks or excessive electrode wear. NOTE: Replace spark plug if electrodes are worn, burned or porcelain is cracked. Replacement only with F7TC plug. 4. Measure the plug gap with a spark plug gap gauge. The gap should be 0.7 to 0.8 mm ( in.) (Fig. 21). 5. If you are re-using the spark plug, use a wire brush to clean any dirt from around the spark plug base then re-gap the spark plug. 6. Screw the spark plug back into the spark plug hole using the spark plug wrench. Recommended tightening is ½ to ¾ of a turn after the spark plug gasket contacts spark plug hole. Do not over-tighten the spark plug. Reinstall the spark plug cap. Attach the spark plug wire to the plug. Spark Plug Plug Wrench Spark Plug Cap Cylinder Assembly Fig. 19 Fig. 20 Fig

23 MAINTENANCE SPARK ARRESTER MAINTENANCE It is recommended to inspect and clean the spark arrester after every 200 hours of operation. 1. Allow the engine to cool completely before servicing the spark arrester. 2. Remove the screws holding the cover plate which retains the end of the spark arrester to the muffler. 3. Remove the spark arrester screen. 4. Carefully clean and remove the carbon deposits from the spark arrester screen with a wire brush. 5. Replace the spark arrester if it is damaged. 6. Position the spark arrester in the muffler and attach with the screws. BATTERY REPLACEMENT NOTE: The battery shipped with the generator has been fully charged. The battery will receive charge when the engine is running. If the generator is not used for a long period, it is recommended to disconnect the negative battery cable from the battery to protect the battery from losing charge. After disconnecting the cable, cover the free end with an insulator such as electrical tape. Optimally, you can also connect the battery to an automatic trickle charger to keep the battery charged. Remember to run the generator once a month for minutes to charge the battery to make sure the generator can properly function. To replace the battery: 1. Disconnect negative (-) battery terminal first (black wire). 2. Disconnect positive (+) battery terminal second (red wire). 3. To install a new battery, install the hold down bracket, insert the bolt and tighten with M6 nuts. 4. Connect positive (+) battery terminal (red wire) first. Slide rubber boot over connection hardware. 5. Connect negative (-) battery terminal (black wire) second. 6. Slide rubber boot over connection hardware. Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. 23

24 STORAGE & TRANSPORT DRAINING THE FUEL TANK Clean the fuel tank each year or before storing the generator for extended periods of time. To drain the fuel tank and carburetor: 1. Turn the fuel valve to the OFF position. 2. Remove the fuel line between the fuel valve and carburetor. CAUTION: A small amount of fuel may leak from the hose during removal. 3. Attach a fuel line (not included with the generator) to the exposed end of the fuel valve. 4. Position the fuel line into an appropriate container and open the fuel valve. 5. Once the fuel is drained, shut off the fuel valve. 6. Start and run the engine until the fuel runs out. 6. Store the emptied gasoline in a suitable place. STORING THE GENERATOR CAUTION: Do not store fuel for more than 3 months. CAUTION: Never place any type of storage cover on the generator while it is still hot. Gasoline stored over 30 days can go bad and damage fuel system components. If the generator is being stored for short periods of time (30 to 60 days) add stabilized fuel to the fuel tank until full. Filling the tank reduces the amount of air in the tank and helps reduce deterioration of fuel. Run the engine for 2 3 minutes allowing stabilized fuel mixture to circulate through the carburetor. Refer to the following list to prepare unit for storage. Drain the fuel tank (see Draining the Fuel Tank). Change engine oil. DO NOT place a storage cover on a hot generator. Allow unit to cool to room temperature before storage. Do not obstruct any ventilation openings. Keep the generator in a cool and dry area. Always store generator and fuel away from heat and ignition sources. Start and run the generator every month for minutes. TRANSPORTING THE GENERATOR Tighten fuel cap and vacuum relief valve. Drain the fuel tank if possible (see Draining the Fuel Tank) Keep the generator upright. Never place the generator side down. Doing so will make it difficult to start. 24 NOTE: WE SUGGEST RUNNING YOUR GENERATOR AT LEAST ONCE A MONTH IN ORDER TO MAXIMIZE THE LIFESPAN OF THE GENERATOR

25 SPECIFICATIONS Rated Wattage Surge Wattage Rated Voltage Rated Amperage Frequency Phase Weight Gasoline: 3800 Watts LPG: 3500 Watts Gasoline: 4750 Watts LPG: 4350 Watts AC: 120V/240V, DC: 12V AC: 32A/16A, DC: 8A 60 Hz Single lbs ENGINE Engine Type 4 stroke, OHV, single cylinder with forced air cooling system Engine Displacement 224 cc Engine Horsepower 6HP at 3600 RPM Fuel Type Gasoline and LPG Gas Tank Capacity 4 gallons (15 L) Oil Capacity 20.3 fl. oz (0.6 L) Spark Plug F7TC Spark Plug Gap mm ( in) Run Time on 50% Load Length of LPG cable Gasoline: 11 hours LPG (with 20 lbs tank): 7 hours 47 inches (1200 mm) 25

26 EXPLODED VIEW AND PARTS LIST LPG Hose

27 EXPLODED VIEW AND PARTS LIST No. Part No. Description Qty. 1 DF Rotor Stator Assembly DF Carbon Brush Assembly DF Grounding Post Assembly DF Rotor DF Stator 1 2 DF Motor Stand 1 3 DF Switch Dial Assembly 1 4 DF Hexagon Pattern Pan Head Screws M6X DF Nut M8 6 6 DF Wire Harness Clip 1 7 DF Frame 1 8 DF Isolator A 2 9 DF Isolator B 2 10 DF Fuel Filter 1 11 DF Fuel Tank Assembly 1 12 DF Fuel Cock 1 13 DF Regulator Assembly 1 14 DF Regulator 1 15 DF Bolt M6X DF Flat Washer 2 17 DF Bolt M8X1X DF Rotor Bolt Gasket Ø8.5X24X DF Handle Assembly 1 20 DF Bolt M6X DF Bolt M6X DF Nut M DF Air Cleaner Bracket 1 24 DF Exhaust Gasket 1 25 DF Cotter Pin 2 26 DF Muffler Comp 1 27 DF Spring Washer Ø DF Bolt M6X DF Panel Assembly DF Shut Down Switch DF DC Receptacle 12V DF Thermal Protector 8A/Csa DF Nema5-20R 120V 20A Duplex DF Thermal Protector 20A/Csa DF Change-Over Switch DF Thermal Protector 16A/Csa DF Nema L14-30R 125V/250V 30A Twistlock 1 30 DF Handle Clip 1 31 DF Bolt M8X DF Bolt M6X DF Automatic Voltage Regulator 1 No. Part No. Description Qty. 34 DF Bolt M5X DF Bolt M5X DF Fuel Tank Washer 4 37 DF Bolt M6X DF Generator End Cover 1 39 DF Positive Lead 1 40 DF Negative Lead 1 41 DF Battery 1 42 DF Wheel 2 43 DF Frame Support 2 44 DF Vibration Isolation Pad 2 45 DF Nut M DF Bolt M8X DF Clip Ø DF Wheel Axle 2 49 DF Handle Connector 1 50 DF Muffler Bracket 1 51 DF Battery Holder 1 52 DF Battery Pull Rod 2 53 DF Low Pressure Pipe 500mm 1 54 DF Low Pressure Pipe 250mm 1 55 DF Fuel Line (Ø8.5X4.5)/ Ø10X6)X DF Fuel Line Ø10X6X DF Connecting Pipe (Gas Tank) 1 58 DF Manual Choke Assembly 1 59 DF Handle Bolt 1 60 DF Fuel Line Clip Ø DF Fuel Line Clip, Ø DF Frame Wire 1 63 DF Fuel Line Clip Ø DF Nut M DF Tooth Type Gasket Ø DF Tooth Type Gasket Ø DF Handle Rubber 1 68 DF Bolt M6X DF Grounding Wire 1 70 DF Fuel Selector Switch 1 71 DF Bolt M6X DF Paper Washer 4 73 DF Fuel Tank Cap Assembly 1 74 DF LPG Regulator Cover 1 75 DF Carbon Tank Assembly 1 76 DF Connecting Pipe 1 77 DF Dustproof Sheet 1 78 DF Fuel Gauge 1 79 DF Fuel Tank Filter 1 80 DF Engine Complete 1 81 DF LPG Hose Assembly (not pictured) 1 27

28 EXPLODED VIEW AND PARTS LIST Engine:

29 EXPLODED VIEW AND PARTS LIST No. Part No. Description Qty. 1 DF Crankcase 1 2 DF Ball Bearing 2 3 DF Oil Seal 2 4 DF Governor Assembly 1 5 DF Governor Arm Shaft 1 6 DF Governor Arm Shaft Washer 1 7 DF Lock Pin 1 8 DF Drain Plug Bolt 2 9 DF Drain Plug Washer 2 10 DF Oil Level Switch Assembly 1 11 DF Bolt M6X DF Casecover Dowel Pin Ø8X DF Piston 1 14 DF Piston Scraper Ring Set 1 15 DF Connecting Rod Assembly 1 16 DF Piston Pin 1 17 DF Piston Clip 2 18 DF Crankcase Cover Assembly 1 19 DF Cylinder Head 1 20 DF In-Valve 1 21 DF Valve Exhaust 1 22 DF Intake Valve Returner 1 23 DF Valve Spring 2 24 DF In-Valve Spring Seat 1 25 DF Ex-Valve Spring Seat 1 26 DF Push Rod Guide Plate 1 27 DF Rocker Assembly 2 28 DF Rotator 1 29 DF Stud Bolt (Carburetor) 2 30 DF Stud Bolt 2 31 DF Carburetor Assembly 1 32 DF Fuel Line 1 33 DF Fuel Line Clip Ø DF Governor Arm 1 35 DF Governor Arm Bolt 1 36 DF Nut M DF Crankshaft Assembly 1 38 DF Valve Lifter 2 39 DF Casecover Gasket 1 No. Part No. Description Qty. 40 DF Camshaft Assembly 1 41 DF Dowel pin 2 42 DF Bolt M8X DF Cylinder Head Gasket 1 44 DF Bolt M8X DF Spark Plug 1 46 DF Push Rod 2 47 DF Shroud 1 48 DF Bolt M6x DF Headcover Gasket 1 50 DF Cylinder Head Cover 1 51 DF Wind Shield Assembly 1 52 DF Bolt M6x DF Recoil Starter Fan 1 54 DF Starter Pulley 1 55 DF Nut M DF Ignition Coil Assembly 1 57 DF Bolt M6X DF Intake Gasket 1 59 DF Carburetor Insulator 1 60 DF Carburetor Gasket 1 61 DF Carburetor Spacer 1 62 DF Governor Rod 1 63 DF Throttle Return Spring 1 64 DF Recoil Starter Assembly DF Recoil Starter 1 65 DF Upper Shroud Assembly 1 66 DF Air Cleaner Assembly DF Air Filter Element 1 67 DF Breather Tube 1 68 DF Fuel Rubber 1 69 DF Governor Spring 1 70 DF Clip 1 71 DF Dipstick 1 72 DF Bolt M6X DF Flywheel Assembly 1 74 DF Starting Motor Assembly 1 75 DF Adjuster Rocker Arm 2 76 DF Dustproof Sheet 1 77 DF Casecover Dowel Pin Ø 8x