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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
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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
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TABLE OF CONTENTS GENERAL SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PACKAGE CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GENERATOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PREPARING THE GENERATOR FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Using the Generator for the First Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Step 1 - Add Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Step 2 - Add Gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 3 - Ground the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Subsequent Use of the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Step 1 - Check the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Step 2 - Check the Gas Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 3 - Ground the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 STARTING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 USING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 AC Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DC Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 STOPPING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 MAINTENANCE / CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cleaning the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Changing / Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Air Cleaner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fuel Filter Cup Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Spark Plug Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Emptying the Gas Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 STORAGE / TRANSPORT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 EXPLODED VIEW AND PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 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 .
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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 near exhaust can exceed 150 ° F ( 65 ° C ) . • 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 .
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In additionto theabovesafetynotices , pleasefamiliarizeyourselfwith thesafetyand hazardmarkingsonthegenerator . N
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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 DO NOT RETURN TO STORE , please call ( 888 ) 315 - 3080 M - F 8 - 5 CT for customer service . ITEM LIST NEMA L14 - 30 plug for connecting 240 Volt electrical devices Three - prong plug for connecting 120 Volt electrical devices i ZZ ! i _ ¸ Set of 2 DC connector wires for connecting 12 Volt automotive - type batteries Spark plug wrench
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GENERATOR COMPONENTS Please familiarize yourself with the locations and functions of the various components and controls of your generator . 10 3 2 5 I G ( 1 ) Air cleaner - a removable , cleanable , sponge - like ( 7 ) Engine Switch - Used to start / stop engine . element that limits the alnount of dirt pulled into the ( 8 ) Fuel Cap - Access to the fuel tank for adding fuel . engine . ( 9 ) Fuel Filter ( ; up - Traps dirt and water fioln fuel ( 2 ) 120 Volt AC Receptacle - Use to connect before it enters the engine . electrical devices that run 120 Volt , 60 Hz , single ( 10 ) Fuel Gauge - Indicates the amount of fuel in the tank . phase , AC current . ( 11 ) Fuel valve - Allows fuel to enter engine . ( 3 ) 120 / 240 Volt AC Receptacle - Use to connect electrical devices that mn 120 and / or 240 Volt , 60 ( 12 ) Ground Terminal - Connect grounding wires here Hz , single phase , AC current . to properly ground unit . ( 4 ) 12 Volt DC Receptacle - Use for charging 12 ( 13 ) Muffler - Reduces engine noise . Volt automotive - type batteries only . ( 14 ) Oil Fill and Dipstick - Location for checking and ( 5 ) Circuit Breaker - Reset switch that protects the filling engine oil . generator from electrical overload . ( 15 ) Recoil Starter - Pull - cord for starting engine . ( 6 ) Choke lever - Adjusts the amount of air let into ( 16 ) Spark plug - Provides proper engine ignition . the engine . ( 17 ) Volt Meter - Provides reading of voltage output .
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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 2200 3500 5500 Engine oil 20 fluid oz . 20 fluid oz . 37 fluid oz . capacity 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 . O _ FLLER HOLE Ott , _ q _ . LER CAP ? Figure 2 - Unscrewing the oil cap Figure 3 - Adding oil 10
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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 3500 5500 Gas tank 15 L ( 3.96 gallons ) 15 L ( 3.96 gallons ) 25 L ( 6.60 gallons ) capacity 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 . 11
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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 12
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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 : 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 . 13
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STARTING THE GENERATOR O Before starting the generator , make sure you have read andperformed the steps in the " Preparing the Generator for Use " section of this manual . If you are unsure about how to perform any of the steps in this ' manual please call ( 888 ) 315 - 3080 M - F 8 - 5 CT for customer service . A CAUTION : Disconnect all electrical loads from the generator before attempting to start . 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 / / / # refer to Figure 7 - Choke in the closed position page 9 for choke location ) Figure 8 - Pulling the start cord 14
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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 Rated ( Running ) Wattage Surge Wattage 2200 1800 2200 3500 3000 3500 5500 5000 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 . 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 15
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than the rated wattage of the generator . Never connect devices requiring a rated wattage equal to the surge wattage of the generator . tool or appliance rated ( running ) Watts additional surge Watts electric water heater ( 40 gal ) 4000 0 hot plate 2500 0 saw - radial arm 2000 2000 electric stove 1500 0 saw - circular 1500 1500 air compressor ( 1 HP ) 1500 3000 window air conditioner 1200 1800 saw - miter 1200 1200 microwave 1000 0 well water pump 1000 1000 reciprocating saw 960 1040 sump pump 800 1200 refrigerator freezer 800 1200 furnace blower 800 1300 computer 800 0 electric drill 600 900 television 500 0 deep freezer 500 500 garage door opener 480 0 stereo 400 0 box fan 300 600 clock radio 300 0 security system 180 0 dvd player / vcr 100 0 common light bulb 75 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
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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 . Device Requirements Max . Cord Length ( ft ) by Wire Gauge # 8 wire # 10 wire # 12 wire # 14 wire # 16 wire Amps Watts ( 120V ) Watts ( 240 V ) 2.5 300 600 NR 1000 600 375 250 5 600 1200 NR 500 300 200 125 7.5 900 1800 NR 350 200 125 100 10 1200 2400 NR 250 150 100 50 15 1800 3600 NR 150 100 65 N R 20 2400 4800 175 125 75 50 NR 25 3000 6000 150 100 60 NR NR 30 3600 7200 125 65 NR NR NR 40 4800 9600 90 NR NR NR NR * NR = not recommended Figure 12 - Maximum Extension Cord Lengths by Power Requirement DC Usage CAUTION : The DC receptacle is for recharging 12 Volt automotive - type batteries only . Do not connect any other device to this receptacle . 17
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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
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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 each use or 20 hrs 50 hrs 100 hrs or 300 hrs Engine oil _ heck level x " eplace x Air cleaner sheck x slean x fuel filter cup slean x spark plu _ l sheck / clean x gas tank sheck gas level x slean 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
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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 2200 3500 5500 20 fluid oz . 20 fluid oz . 37 fluid oz . Engine oil capacity 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 oil to the crankcase , 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 15 above . 3 . 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
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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 A _ R CLEANER SPR _ NG COVER ELEMENT . . . . . . . . . . . ' " ' , g ' , 77 { t _ % ÷ _ T < _ & * gQ * _ g * v { , , i ¢ * % { , g ] f COVER SPR _ NG Figure 18 - Removing the air cleaner casing . 21
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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
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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 / TRANSPORT PROCEDURES A CAUTION : Never place any type of storage cover on the generator while it is still hot . 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
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SPECIFICATIONS Generator AC Output model2200 model3500 model5500 R _ edW _ tage 1800W 3000W 5000W _ urgeW _ tage 2200W 3500W 5500W R _ ed Voltage 120 / 240 V 120 / 240 V 120 / 240 V R _ ed Amperage 15 A / 7.5A 25 A / 12.5A 41A / 20.5A R _ ed Frequency 60Hz 60Hz 60Hz Phase Single Single Single DC Output model 2200 model 3500 model 5500 Voltage 12V 12V 12V Amperage 8.3 A 8.3 A 8.3 A Dimensions ( in ) : length = 23.25 width = 17 length = 23.25 width = length = 27 width = 20 height = 17 17 height = 17 height = 21 Dry mass 99 lbs 99 lbs 168 lbs model 2200 model 3500 model 5500 Engine type 4 - stroke OHVsingle 4 - stroke OHVsingle 4 - stroke OHVsingle cylinder with forced air = ylinder with forced air cylinder with forced air cooling system = ooling system cooling system [ gnition system non - contact transistor non - contact transistor non - contact transistor Displacement 163 cm 3 196cm 3 337cm 3 Fuel tank 15 L ( 3.96 US gal . ) 15 L ( 3.96 US gal . ) 25 L ( 6.60 US gal . ) zapacity : Dil capacity 0.6 L ( 20 fl oz . ) 0.6 L ( 20 fl oz . ) 1.1 L ( 37 fl oz . ) Run time on 50 % 21 hrs 15 hrs 15 hrs Load 24
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TROUBLESHOOTING IMPORTANT : If trouble persists please call our customer help line at ( 888 ) 315 - 3080 M - F 8 - 5 . Problem Cause Solution Engine will not Engine switch is set start LO " Off " . Set engine switch to " on " . Fuel valve is turned Lo " closed " . Turn fuel valve to " open " position . Close the choke Shoke is open . Engine is out of gas . & dd gas . Engine is filled with sontaminated or old gas Change the gas in the engine . Spark plug is dirty . Clean spark plug . Spark plug is 3roken . Replace spark plug . Generator is not on Move generator to a level surface to prevent low oil shutdown evel surface . from triggering . : Dilis low Add or replace oil . Engine runs but there is no Sircuit breaker is off . electrical output 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 . Try connecting a different device . Generator runs bul does not support all electrical devices Generator is connected . 3verloaded Try connecting fewer electrical loads to the generator . Short in one of the sonnected devices . Fry disconnecting any faulty or short - circuited electrical loads . _ , ir cleaner is dirty . Clean or replace air cleaner . 25
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I b _
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fret11 Part Item Part Oty DescriiKion Oty Description 1 35 31600 1 Voltage regulator Gasoline engine 41100 2 1 Frame comp 36 GB276 89 1 Bearing 6202 - 2RS 41310 2 Bottom rubber A 1 Plain washer 3 37 31134 41320 2 Bottom rubber B . , I 38 31931 , t Flange bolt M6 X 125 GB6177 86 1 Bolt M8X 180 5 39 31933 8 Flange nut M8 GB802 88 Nut M6 1 Generator t : an 6 40 31141 41350 7 t Cushion , frame 41 31996 8 Bolt M5 X 14 GB5787 86 8 t Bolt M6X 12 42 30100 1 Stator & rotor Assy 41116 1 Fuel tank 9 1 Rubber pad , frame 43 16610 32520 1 Earth terminal set i0 44 16500 1 Fuel filler cap comp . 32100 ii 1 Wire harness Assy 45 16521 1 Packing ring 32310 1 Switch wire 1 Fuel filter 12 46 16916 35510 1 Consent ( 30A ) 1 Fuel sensor 13 47 37820 GB5787 86 3 Bolt M4X i0 2 Screw M5 X 10 i , ' I 48 GB819 85 37300 15 1 Control panel Assy 49 GB5787 86 4 Flange bolt M6 X 22 37310 4 Washer 16 50 16821 1 Control panel 37321 4 Cushion 17 51 16811 1 Control panel case 68511 16931 1 Panel switch mark , RH 1 Outlet pipe 18 52 ( 1,9x d ) , t . 5x 130 68512 1 Panel switch mark , LH 19 53 16937 / 168F 2 Tube clip 35410 1 Fuel cock 20 1 Ignition switch 54 16930 37420 1 Voltmeter 21 55 16812 1 Stripe , fuel tank 31710 56 1682 , t 22 , t Fitting brush , fuel tank 1 Circuit protector ( 10A ) GB5787 86 57 37825 1 Gasket , fuel sensor 23 Flange bolt M6 X 12 GB6187 86 2 Nut M4 58 18300 / 168F BV 1 Muffler 2 , ' I GBS19 85 2 Pan screw M4 X 10 59 18611 25 1 Muffler guard 32115 60 GB5787 86 26 1 Boot , AC output wire 3 Flange bolt M8 X 16 32116 1 Boot , main wire harness 61 18110 / 168F BV 27 1 Exhaust pipe comp . 31200 62 18221 / 168F BV 28 1 Stator Assy 1 Muffler gasket 31936 1 Stator cover 29 63 18720 1 Supporting plate 31100 3O 1 Rotor comp . 64 18710 1 Muffler stay 31370 2 Bolt M8 X 25 31 1 Brush Assy 65 GB5787 86 31411 2 Nut M8 32 1 Generator stay 66 GB6187 86 31938 1 Generator end cover 33 67 GB5787 86 6 Flange bolt M6 X 12 31995 3 Bolt M5 X 12 68 12255 / 168F 3d 1 Exhaust pipe gasket 27
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CONTROPLANELBLOCK BREAKER 13 Br ( _ Br q - , Main col ! 1 AC120V , 2 _ 0V 13 R © _ ain coi ! 2 L vO Bu ENGSWITEH BL _ ' I _ AVR Excitatio _ coil ENGINEBLOCK ENGSWITEH Field col KG E OFF ( _ @ ON FUSE R BCcoil BL Black R red YiO Y yellow W write BU blue Br Brown 6 green GENERtTOBRLOCK Fuel level switch Spark piub Ignition coil
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NOTES : 29
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