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4000W Generator Topi c Page Limited Warrant y 3 S a fet y G u i d e l i n e s 5 G e n e r a l Pr e c a u t i o n s 6 Battery 15 Assembly 16 Operation 17 Spark Plug Service 22 Inspection, Cleaning, Maintenance and Storage 23 Installation 29 Compliance 31 Speci fications 32 G e n e r a l Pa r t s L i s t i n g 33 2
000W Generator
Owner’s Manual Safety Guidelines - Definitions This manual contains important information that you need to know and understand in order to protect YOUR SAFETY and to PREVENT EQUIPMENT PROBLEMS. The following symbols help you recognize this information. Please read the manual and pay attention to these sections. Save These Important Safety Instructions! Read and understand all of these safety instructions. Be sure to retain them for future use.
4000W Generator General Precautions WARNING! FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE INJURY OR DEATH. CAUTION: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN ALSO RESULT IN DAMAGE TO THE TOOL AND/OR THE ITEM YOU ARE WORKING ON. DANGER CARBON MONOXIDE Using a generator indoors WILL KILL YOU IN MINUTES. Generator exhaust contains high levels of carbon monoxide (CO), a poisonous gas you cannot see or smell. If you can smell the generator exhaust, you are breathing CO.
Owner’s Manual • Fuel or oil spills must be cleaned up immediately. Dispose of fluids and cleaning materials as per any local, state, or federal codes and regulations. Store oily rags in a covered metal container. • Never store fuel or other flammable materials near the generator. General Precautions (cont’d) Gasoline and Oil (cont’d) • Do not smoke, or allow sparks, flames or other sources of ignition around the engine and fuel tank. Fuel vapors are explosive.
4000W Generator General Precautions (cont’d) Work Area • Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. • Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Generators create sparks which may ignite the dust or fumes. • Keep bystanders, children, and visitors away while operating a generator. Provide barriers or shields as needed.
Owner’s Manual General Precautions (cont’d) Electrical Safety (cont’d) • All connections and conduits from the generator to the load must only be installed by trained and licensed electricians, and in compliance with all relevant local, state, and federal electrical codes and standards, and other regulations where applicable. • The generator must be earth-grounded for fixed installations in accordance with all relevant electrical codes and standards before operation.
4000W Generator General Precautions (cont’d) Personal Safety (cont’d) • Avoid accidental starting. Make sure the power switch is in its “OFF” position, and disconnect the spark plug wire when not in use. • Remove adjusting keys or wrenches before turning the generator on. A wrench or a key that is left attached to a rotating part of the generator may result in personal injury. • Do not overreach. Keep proper footing and balance at all times. • Use safety equipment. Always wear eye protection.
Owner’s Manual General Precautions (cont’d) Servicing Maintain labels and name plates on the generator and engine. These carry important information. If unreadable or missing, contact our service center toll free at 888-896-6881 immediately for a replacement. Generator service must be performed only qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. When servicing a generator, use only identical replacement parts.
4000W Generator General Precautions (cont’d) Installation (cont’d) • If the generator is installed outdoors, it must be weatherproofed and should be soundproofed. It should not be run outdoors without protection to the generator and wiring conduit. • The generator weighs 100 lbs (approx). Two or more people should assist when moving or lifting this product. Never lift the generator using the engine or alternator lifting lugs.
Owner’s Manual General Precautions (cont’d) Mechanical (cont’d) • Do not operate the generator with safety guards removed. While the generator is running, do not attempt to reach around the safety guard for maintenance or any other reason. • Keep hands, arms, long hair, loose clothing, and jewelry away from moving parts. Be aware that when engine parts are moving fast they cannot be seen clearly. • Keep access doors on enclosures closed and locked when access is not required.
4000W Generator General Precautions (cont’d) Extension Cord If an extension cord (not included) is used, make sure to use only UL approved cords having the correct gauge and length according to the following table: Nameplate Amps (@ full load) Cord Lengths 0 ft.- 50 ft. 50 ft.-100 ft. 100 ft.-150 ft. 150 ft.-200 ft. 0-5 5.1 - 8 16 AWG 16 AWG 16 AWG 14 AWG 12 AWG 10 AWG 12 AWG - 8.1 - 12 12.
Owner’s Manual Battery This product does not need a battery.
4000W Generator Assembly Unpacking 1. Remove the generator and loose parts box from the carton. 2. Compare the accessory with the inventory list below. Loose Parts (Wheel kit and handle) Check all loose parts against the following list. Contact your dealer toll free at 888.896.
Owner’s Manual Operation Choke lever Handle Oil plug Air filter Recoil Start NOTE: THE PARTS LISTED ABOVE ARE HELPFUL FOR LOCATING THE CONTROLS MENTIONED BELOW. CAUTION: PRIOR TO FIRST USING THE GENERATOR, THE ENGINE MUST BE FILLED WITH OIL OF A HIGH QUALITY SAE 10W-30 GRADE ENGINE OIL. TO DO SO, UNSCREW AND REMOVE THE ENGINE’S OIL DIPSTICK LOCATED AT THE BOTTOM OF THE ENGINE CRANKCASE. FILL THE ENGINE’S CRANKCASE UNTIL THE OIL LEVEL IS LEVEL WITH THE UPPER MARKED LINE ON THE DIPSTICK.
Operation (cont’d) Starting 1. Turn the engine switch to the ON position. The engine switch enables and disables the ignition system. OFF: To stop the engine ON: To run the engine 2. The fuel valve is located under the fuel tank . When the valve lever is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sur to return the fuel valve lever to the OFF position after stopping the engine. OFF ON 3. To start a cold engine, move the choke lever to the CLOSED position.
Owner’s Manual Operation (cont’d) Starting 4. Operate the Recoil Starter: Pull the starter grip lightly until you feel resistance, then pull briskly. Return the starter grip gently. Pulling the starter grip operates the recoil starter to crank the engine Starter Grip Choke Lever 5. If the choke has been moved to the CLOSED position to start the engine, gradually move it to the OPEN position as the engine warms up. ON OPEN Stopping Engine 1. Turn the engine switch to the OFF position. 2.
4000W Generator Operation (cont’d) Powering 120 Volt AC Tools And Equipment: 1. Prior to powering tools and equipment, make sure the generator’s rated voltage, and amperage capacity (120 V AC @ 27.5 AMPs) is adequate to supply all electrical loads that the unit will power. If powering exceeds the generator’s capacity, it may be necessary to group one or more of the tools and/or equipment for connection to a separate generator.
Owner’s Manual Operation (cont’d) Powering 12 Volt DC tools and Equipment: 1. Prior to powering tools and equipment, make sure the generator’s rated voltage, and amperage capacity (12V DC) is adequate to supply all electrical loads that the unit will power. If powering exceeds the generator’s capacity, it may be necessary to group one or more of the tools and/or equipment for connection to a separate generator. 2. Connect the power cord of a 12 VDC powered tool or equipment to the DC Terminals.
4000W Generator Spark Plug Service In order to service the spark plug, you will need a spark plug wrench (commercially available). Recommended spark plugs: NHSP LD F7TC or NGKBPRGES but we recommend our OEM spark plug. To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. 1. Remove the spark plug cap. 2. Clean any dirt from around the spark plug base. 3. Use a spark plug wrench to remove the spark plug. 4. Visually inspect the spark plug.
Owner’s Manual Inspection, Cleaning, and Maintenance WARNING! ALWAYS MAKE SURE THE ENGINE POWER SWITCH (2) IS IN ITS “OFF” POSITION. DISCONNECT THE SPARK PLUG WIRE FROM THE ENGINE. AND ALLOW SUFFICIENT TIME FOR THE ENGINE AND GENERATOR TO COMPLETELY COOL BEFORE PERFORMING ANY INSPECTIONS, MAINTENANCE, OR CLEANING.
4000W Generator Fuel Sediment Cup Cleaning The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned. 1. Turn the fuel valve to the OFF position. Remove the sedement cup, and O-ring. 2. Clean the sediment cup, and O-ring, in nonflammable or high flash point solvent. 3. Reinstall O-ring, and sediment cup. 4. Turn the fuel valve ON and check for leaks.
Owner’s Manual Maintenance Guide Periodic maintenance and adjustment is necessary to keep the generator in good operating condition. WARNING! Exhaust gas contains poisonous carbon monoxide. Shut off the engine before performing any maintenance. If the engine must be run, make sure the areas is well ventilated. • Before each use, inspect the generator.
4000W Generator Air cleaner service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfuncion, service the air cleaner regularly. Service more frequently when operating the generator in extremely dusty areas. WARNING! Using gasoline or flammable solvent to clean the filter element can cause a fire or explosion. Use only soapy water or nonflammable solvent. NOTE: Never run the generator without the air cleaner. Rapid engine wear will result. 1.
Owner’s Manual 27
4000W Generator Transporting/Storage 28
Owner’s Manual Installation NOTE: PRIOR TO POWERING TOOLS AND EQUIPMENT MAKE SURE THE GENERATOR’S RATED VOLTAGE, WATTAGE AND AMPERAGE CAPACITY IS ADEQUATE TO SUPPLY ALL ELECTRICAL LOADS THAT THE UNIT WILL POWER. IF POWERING EXCEEDS THE GENERATOR’S CAPACITY, IT MAY BE NECESSARY TO GROUP ONE OR MORE OF THE TOOLS AND/OR EQUIPMENT FOR CONNECTION TO A SEPARATE GENERATOR. Electrical and other permits may be required for the installation of emergency power systems.
4000W Generator Installation (cont’d) Supporting and Mounting Mount the generator on a concrete slab capable of supporting the weight of the generator. The slab must extend on all sides beyond the frame by at least one foot. Contact a cement contractor for slab specifications if necessary. Attach the frame to the concrete slab using 3/8” diameter expansion anchor bolts (not supplied).
Owner’s M anual Specifications AC electrical Current Output 120V AC @ 27.5A 60Hz Continuous/rated Wattage 3,300 Peak Wattage 4,000 Outlet Four 120V outlets, One 120V twist-lock DC electrical 12V 8.3 A Gasoline engine Type 4-cycle OHV air-cool ed recoil start Displacement 208cc Oil c apacity 0.63 quart (0.6liter) CARB pproved yes Fuel Type Unleaded g asoline Capacity 4 gallons Running t ime 8 hours (approx.) on 1/2 load Approximate weight 107 lbs.
4000W Generator Cylinder head system assy. APA Part No. Description APGG4000-A-01-JD CYLINDER HEAD COMP. APG3012-A-02-JD EX. VALVE GUIDE APG3012-A-03-JD IN. VALVE GUIDE APG3012-A-04-JD VALVE GUIDE CLIP APGG4000-A-05-JD CYLINDER HEAD SEALING PAD APG3012-A-06-JD HEAD COVER COMP. APG3012-A-07-JD HEAD COVER PACKING APG3012-A-08-JD TUBE APG3012-A-09-JD HEAD COVER COMP.
4000W Generator Cylinder barrel APA Part No. Description APGG4000-B-01-JD CRANK CASE APG3012-B-02-JD OIL LEVEL SWITCH ASSY. APG3012-B-03-JD GOVERNOR GEAR ASSY. APG3012-B-04-JD SLIDER SHAFT APG3012-B-05-JD GOVERNOR ARM SHAFT APG3012-B-06-JD LOCK PIN (8mm) APG3012-B-07-JD WASHER APG3012-B-08-JD DRAIN PLUG BOLT APG3012-B-09-JD THRUST WASHER (6mm) APG3012-B-10-JD DRAIN PLUG WASHER (10.
4000W Generator Crankcase cover system assy. APA Part No.
4000W Generator Crankshaft system assy. APA Part No.
4000W Generator Piston and connecting rod system assy. APA Part No.
4000W Generator Recoil starter system assy. APA Part No. Description APG3012-F-01-JD PIVOT ADJUSTING NUT APG3012-F-02-JD ROCKER ARM PIVOT APG3012-F-03-JD ROCKER ARM APG3012-F-04-JD PIVOT BOLT (M8) APG3012-F-05-JD PUSH ROD GUIDE PLATE APG3012-F-06-JD PUSH ROD APG3012-F-07-JD VALVE LIFTER APG3012-F-08-JD CAMSHAFT APG3012-F-09-JD VALVE ROTATOR APG3012-F-10-JD EX. VALVE SPRING RETAINER APG3012-F-11-JD VALVE SPRING APG3012-F-12-JD IN. VALVE SPRING RETAINER APG3012-F-13-JD IN.
4000W Generator Recoil starter system assy. 1 APA Part No. Description APGG4000-G-01-JD RECOIL STARTER ASSY.
00W Generator Fan cover system assy. 3 APA Part No. Description APGG4000-H-01-JD FAN COVER COMP.
4000W Generator Carburetor system assy. 1 2 3 4 APA Part No. Description APGG4000C-I-01-JD CARBURETOR ASSY.
4000W Generator Flywheel system assy. 2 2 APA Part No. Description APG3012-J-01-JD FLYWHEEL APG3012-J-02-JD FLANGE BOLT (M6 X 25) APG3012-J-03-JD COOLING FAN APG3012-J-04-JD STARTER PULLEY APG3012-J-05-JD FLYWHEEL NUT (M16) APG3012-J-06-JD STOP SWITCH CORD APG3012-J-07-JD IGNITION COIL ASSY. APG3012-J-08-JD SPARK PLUG CAP ASSY.
4000W Generator Control system assy. APA Part No. Description APG3012-M-01-JD CONTROL UNIT ASSY. APG3012-M-02-JD CONTROL BASE COMP.
4000W Generator Muffler System Assy. 8 7 10 9 N APA Part No. Descript io n APG3012-N-01- JD MUFFLER STAY COMP. APG3012-N-02- JD FLANGE BOLT (M8 X 40) APG3012-N-03-JD FLANGE BOLT (M6 X 16) APG3012-N-04- JD MUFFLER COMP. APG3012-N-05-JD MUFF. OUTER PROTECTOR COMP.
4000W Generator Air cleaner APA Part No. Description APG3012-O-01-JD AIR CLEANER COVER COMP APG3012-O-02-JD AIR CLEANER ELEMENT APG3012-O-03-JD FLANGE NUT (M5) APG3012-O-04-JD AIR CLEANER SEPARATOR APG3012-O-05-JD AIR CLEANER SEAL APG3012-O-06-JD AIR CLEANER CASE COMP.
4000W Generator Fuel tank system assy. 1 4 6 6 5 5 6 6 10 11 12 13 15 14 8 16 9 9 7 APA Part No. Descript io n APG4000-P-01-JD FUEL FILLER CAP COMP APG4000-P-02-JD FUEL FILTER APG4000-P-03-JD FUEL TANK COMP.
4000W Generator Control box assy. 2 3 8 1 4 5 6 7 APA Part No. Description APGG4000 -Q-01-JD ENGINE SWITCH ASSY.
4000W Generator Frame Comp Assy. 1 1 3 3 4 2 3 6 1 12 11 3 13 5 3 8 5 1 1 7 1 3 10 9 APA Part No.
4000W Generator Generator 7 19 11 21 20 APA Part No. Description APGG4000-S-01-JD STATOR COVER APGG4000-S-02-JD STATOR ASSY. APGG4000-S-03-JD COOLING FAN APGG4000-S-04-JD BRUSH ASSY. APGG4000-S-05-JD TAPPING SCREW APGG4000-S-06-JD GENERATOR STAY APGG4000-S-07-JD NUT (5mm) APGG4000-S-08-JD FLANGE BOLT (M6X155) APGG4000-S-09-JD AUTO VOLTAGE REG. ASSY. APGG4000-S-10-JD REAR COVER APGG4000-S-11-JD NUT APGG4000-S-12-JD FLANGE BOLT APGG4000-S-13-JD ROTOR COMP.
4000W Generator Wheel & Hand Assy. 3 7 16 14 14 15 12 1 2 7 7 6 4 6 5 15 12 14 14 16 4 7 6 6 3 2 1 17 13 9 11 8 9 9 9 13 17 10 11 8 APA Part No.
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