GENERATOR USER
MANUAL
Model Numbers
38862
38863
39408
39321
38863 Model Shown
MODEL & SERIAL NUMBERS
Enter the Model and Serial numbers of your generator in
the spaces provided below. Retain these numbers for
future reference. The Model and Serial numbers are
located on the generator data plate on the alternator
case or generator frame, along with other important
information.
Model Number
Serial Number
DOCCHI0009
06/14/00 Rev. 1
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Contents
LIMITED 1 YEAR WARRANTY STATEMENT .................................................................................................2
SECTION 1........................................................................................................................................................4
GENERAL INFORMATION .............................................................................................................................4
SAFETY RULES..............................................................................................................................................4
GENERAL SAFETY OPERATIONAL GUIDELINES..........................................................................................5
GENERAL MAINTENANCE ............................................................................................................................5
GENERATOR CLEANING...............................................................................................................................5
GENERAL STORAGE GUIDELINES ................................................................................................................6
ELECTRICAL LOADS AND GUIDELINES .......................................................................................................6
GENERATOR DESIGNED PERFORMANCE GUIDELINES ...............................................................................6
RECEPTACLE DETAILS .................................................................................................................................7
ENGINE LIMITATIONS ON GENERATOR PERFORMANCE ............................................................................7
LOADING YOUR GENERATOR SET ...............................................................................................................7
AMPERAGE RATE TABLE..............................................................................................................................7
SECTION 2........................................................................................................................................................8
38862/38863 GENERATOR PARTS AND PART LISTS ......................................................................................8
A.C. Wiring Schematic................................................................................................................................. 10
SECTION 3...................................................................................................................................................... 11
39408/39321 GENERATOR PARTS AND PART LISTS .................................................................................... 11
A.C. Wiring Schematic................................................................................................................................. 12
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SECTION 1
DANGER:
IF THE
104ºF/40ºC.
DO NOT OPERATE THIS GENERATOR
AMBIENT TEMPATURE EXCEEDS
GENERAL INFORMATION
This manual is provided for you so that your
generator may be properly, safely and effectively
applied and operated. Please read and understand
all aspects of this manual before operating your
generator set. Please also read and understand the
documentation supplied with this generator
regarding the engine. Keep this documentation in a
safe and accessible place so that reference can be
made as needed. All operators, users and
subsequent owners of this generator must read and
understand all aspects of this documentation before
operation.
SAFETY RULES
DANGER: This generator set is designed to be
operated in dry conditions and for outdoor areas
only. Never operate this generator indoors.
Never operate this generator in rain, snow, sleet or
generally wet conditions. Damage to the generator, bodily
injury, or death could result from electrocution.
DANGER: If this generator is connected to a
building, home, business, or any other electrical
circuit normally fed by utility power, steps must
be taken to insure the generator output and the utility
power are positively isolated. Failure to isolate the utility
and generator electrical systems will result in generator
damage and could result in injury or death to utility
workers due to the backfeed of electricity.
SPARK ARRESTING MUFFLER
Certain States and Jurisdictions require that engine
driven equipment be fitted with spark arresting mufflers.
Depending on the generator model, spark arresting
mufflers may or may not be fitted. If spark arresting
mufflers are required for your specific local and the
generator muffler is not spark arresting, contact your
local dealer for instructions for a retrofit.
CAUTION: Do not exceed the rated capacity of
the generator. The total electrical loads at each
outlet must be added to determine the total
electrical load. The total load must not exceed the rated
capacity of the generator. If the driven apparatus does not
list wattage, but only amperage, wattage may be
determined by multiplying amperage times voltage (watts
= amps X volts).
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system for this generator
complies to the standards set forth by the California Air
Resources Board (CARB) and the Environmental
Protection Agency (EPA). Warranties for the exhaust
emission system are administered by the respective
engine manufacturers. Refer to the engine
documentation for warranty information.
CAUTION: Do not tamper with the engine-
governed speed. The generator operates at a
nominal speed of 3600 rpm. Increases in speed
over the 3600 rpm nominal will increase the chance of
personal injury due to rotational stresses on the rotating
members. Operation of the generator at speeds below the
nominal 3600 rpm could cause damage to the generator
or driven apparatus due to low voltage output.
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
CAUTION: Do not modify or misapply your
generator set. Operation of the generator other
than intended, could result in generator set
damage, bodily injury or even death from electrocution.
THIS SYMBOL IS USED THROUGHOUT YOUR
OWNER’S MANUAL TO BRING ATTENTION TO
IMPORTANT SAFETY INSTRUCTIONS. FAILURE TO
FOLLOW SAFETY INSTRUCTIONS COULD ENDANGER YOU
OR OTHERS AND RESULT IN PERSONAL INJURY OR
DEATH.
READ
AND
UNDERSTAND
ALL
SAFETY
INSTRUCTIONS BEFORE OPERATION.
DO NOT OPERATE THIS GENERATOR WITHIN AN
ENCLOSED AREA. THE EXHAUST GASES OF THIS
GENERATOR
EMIT
“DEADLY”
CARBON
MONOXIDE. EXPOSURE TO CARBON MONOXIDE CAN
CAUSE CARBON MONOXIDE POISONING, HEADACHES,
NAUSEA, SEVERE SICKNESS OR DEATH.
DANGER: THIS GENERATOR SET PRODUCES
ELECTRICAL
GUIDELINES MUST BE FOLLOWED. IMPROPER
OF THIS GENERATOR CAN RESULT IN
CURRENT.
THEREFORE, SAFETY
USE
ELECTROCUTION, INJURY OR DEATH. DO NOT OPERATE,
SERVICE OR REPAIR THIS GENERATOR UNLESS FULLY
QUALIFIED TO DO SO.
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with sparks, a pilot light or an open flame. Improper
storage of this generator could result in an explosion
or fire.
GENERAL SAFETY OPERATIONAL
GUIDELINES
GROUNDING: The NATIONAL ELECTRICAL
CODE requires that the generator frame be properly
grounded to earth. A ground lug is provided on the
generator frame. As a general guideline, a 10 AWG
wire connected to the grounding lug of the generator
on one end (located on the generator frame as
indicated by the International “GROUND” symbol)
and connected to a copper or brass ground rod
(driven into the ground) on the other end of the wire.
Some locations require generator set or other
grounding. Check with a local electrician to
determine the grounding requirements for your area.
Electrical generators produce electricity; Therefore,
never allow or perform service operations to your
generator set without proper training/certification.
Service operations, without proper precautions can
cause severe shock and even death by
electrocution.
Generators operating on job or construction sites
must be equipped with GFCI (Ground Fault Circuit
Interrupters) on all circuits. Certain generator models
are not equipped with GFCI circuits. Therefore,
customer supplied GFCI’s must be installed in the
power cords connected to the generator. Consult a
local licensed electrician for proper wiring.
Use only 3-Prong extension cords in good condition
and make sure that the wire size within the
extension cords is of sufficient size to safely carry
the surge output of the generator.
Read and understand all the general safety
operational guidelines and rules before operating
this generator.
Always follow National and Local electrical codes.
When moving or transporting this generator, take
proper precautions to avoid fuel spillage. Further,
always use common sense when lifting this
generator. An adequate number of people and
proper lifting procedures must be used.
Do not wire your generator to a home or structure
fed by utility power without proper isolation circuitry.
Consult a local licensed electrician for proper wiring
of your generator to a home, business or any facility
or structure fed by utility power. Failure to properly
isolate utility and generator electrical power could
result in generator damage or electrocution to you or
a
utility worker. The main breaker, which
disconnects from the utility power, must be open
before the generator can safely be connected.
Do not operate this generator unless the generator
is in good mechanical and electrical condition.
Do not overload this generator. Overloading this
generator can cause generator damage, powered
apparatus damage and excessive heat build up.
Always keep hands, body parts, hair and clothing
well away from the rotating or “HOT” parts of the
generator set. Exhaust systems can cause severe
burns.
Do not start this generator with connected devices
turned “ON”. Always make sure that connected
devices are disconnected from the generator or
turned “OFF” before starting the generator.
Do not operate this generator within an enclosed
area. The operation area of the generator must be
completely open. The exhaust gases of this
generator emit “DEADLY” carbon monoxide.
Exposure to carbon monoxide can cause carbon
monoxide poisoning, headaches, nausea, severe
sickness or death.
Never handle extension cords or electrical circuits if
standing in water or if standing in a damp area.
Operate, service or fill with fluids on a level surface
only.
Do not operate this generator in a corrosive or
flammable environment.
Never clean this generator with high-pressure water
or a garden hose. Water can accumulate within the
generator and cause fuel system, ignition system
and or electrical problems or shorts. Cleaning should
be done with a damp rag on a cool generator set.
Do not install this generator in an enclosed area
such as a RV or motorhome. All warranty will be null
and void if installed within an enclosed area.
Always insure that at least 6 feet of clearance on all
sides of the generator are maintained during
operation. Failure to maintain proper clearance
could damage your generator and potentially lead to
fires.
GENERAL MAINTENANCE
ENGINE FUEL: Use Unleaded Fuel - ONLY!
ENGINE OIL:
Refer to the Engine related
documentation.
Never touch a receptacle or bare wire. Electrocution
ENGINE MAINTENANCE:
Refer to the documentation supplied regarding the
engine for all engine maintenance issues.
or shock could result.
Gasoline is highly FLAMMABLE and its vapors
are EXPLOSIVE. Handle gasoline with extreme
care. Failure to properly handle gasoline can result
in explosion or fire. Do not permit smoking within
50ft of this generator set.
GENERATOR CLEANING
NEVER REFILL A HOT GENERATOR WITH FUEL.
NEVER REFILL THE GENERATOR WHILE IT IS
RUNNING. Spillage onto the engine or generator
could result in an explosion or fire. Always allow the
generator set to cool before refilling.
CAUTION!: ALWAYS SHUT OFF THE GENERATOR
AND ALLOW THE GENERATOR TO COMPLETELY
COOL
BEFORE
PERFORMING
CLEANING
OPERATIONS.
WARNING! DO NOT USE HIGH PRESSURE WATER
OR GARDEN HOSE TO CLEAN YOUR
GENERATOR. WATER INTRODUCED INTO THE
Do not store this generator set in any location where
A
gasoline fumes could potentially come into contact
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GENERATOR
GENERATOR DAMAGE OR PERSONAL INJURY.
CAN
CAUSE
ELECTRICAL
SHORTS,
Table 1
Item
GENERAL WATTAGE GUIDE
Running Watts
Air Conditioner (12000 Btu) (*)....................... 1750
Air Compressor (1/2 hp) (*)............................ 1400
Air Compressor (3/4 hp) (*)............................ 1800
Air Compressor (1 hp) (*).............................. 2000
Battery Charger (25A)..................................... 600
Belt Sander (3” belt)..................................... 1000
Circle Saw (6 ½”)................................... 825-1050
Coffee Maker........................................ 900-1100
Edger (lawn)................................................. 550
Furnace Fan (1/3 hp) (*)................................ 1200
Hot Plate (single)......................................... 1500
Impact wrench............................................... 600
Light Bulb............................................Bulb rated
Nail Gun..................................................... 1200
Microwave .................................................... 750
Paint Sprayer (1/3 hp) (*)................................ 650
Paint Sprayer, hand-airless ............................. 175
Radio.......................................................50-200
Refrigerator (*) .............................................. 600
Table Saw (10”) (*)....................................... 2000
Television...............................................250-550
Weed Trimmer .............................................. 500
Note: (*) Items allow 2.5 times the listed wattage
for starting.
Compressed air (max. 25 psi) may be used to blow
loose dirt and dust from your generator. DO NOT
DIRECT COMPRESSED AIR DIRECTLY INTO ANY
OPENING IN THE GENERATOR OR ENGINE.
Use a dampened cloth to wipe clean exterior
surfaces.
Use a soft bristle brush to clean/ loosen heavy dirt, oil
or grease deposits.
NEVER insert rags, tools or any device into the
generator or engine openings.
GENERAL STORAGE GUIDELINES
WARNING: GASOLINE FUMES ARE FLAMMABLE.
DO NOT STORE YOUR GENSET IN ANY AREA
THAT IS INDOORS OR IN POORLY VENTILATED
AREAS. GASOLINE FUMES CAN IGNITE IN THE PRESENCE
OF ANY OPEN FLAME, PILOT LIGHT, CLOTHES DRYER,
WATER HEATER, ETC.
Your generator should be started and operated for
several minutes at least every 30 days.
If the generator cannot be operated every 30 days,
follow the storage recommendations within the engine
documentation.
NOTE: A fuel shut-off valve is positioned at the base
of the fuel tank. The valve should be closed during
storage periods.
GENERATOR DESIGNED
PERFORMANCE GUIDELINES
This electrical generator is designed to produce electrical
energy for the purpose of powering lights, power tools,
appliances and motor loads within the intended design
constraints of the generator. The generator is designed to
produce single-phase electrical power at 120 or 120/ 240
VAC. This generator is not intended for installation in RV
ELECTRICAL LOADS AND GUIDELINES
Your generator set is designed to power electrical
apparatuses within the electrical power output limitations
of the generator. Please note that any generator overload
can cause serious problems/damage to your generator.
Additionally, apparatuses with electrical motors can
require higher wattage requirements at start-up than when
running. Some electric motors require as much as 2.5
times the rated wattage at start-up. Although the start-up
wattage requirements for electric motors lasts only a few
seconds, great care must be taken in connecting loads to
your generator so as not to overload the generator. Refer
to the label on each electrical apparatus to determine the
wattage requirements of that apparatus. THE TOTAL
WATTAGE REQUIREMENTS OF ALL POWERED
APPARATUSES (INCLUDING START-UP LOADS)
MUST NEVER EXCEED THE CONTINUOUS RATING
OF YOUR GENERATOR, CORRECTED TO THE
ACTUAL ENVIRONMENTAL CONDITIONS AT THE
OPERATING SITE.
or
motorhome
applications.
The
Performance
Specifications for your generator are listed in Table 2
Performance Specifications.
Table 2 PERFORMANCE SPECIFICATIONS
38862
38863
120 VAC
2600 Watts
22 Amps @ 120 VAC
3100 Watts
3100 Watts
(Single Phase)
120/240 VAC
(Single Phase)
25.8 Amps @ 120 VAC
3600 Watts
25.8 Amps @ 120 VAC
12.9 Amps @ 240 VAC
3750 Watts
30 Amps @ 120 VAC
15 Amps @ 240 VAC
4500 Watts
39408
39321
120/240 VAC
(Single Phase)
31.2 Amps @ 120 VAC
15.6 Amps @ 240 VAC
4400 Watts
37.5 Amps @ 120 VAC
18.8 Amps @ 240 VAC
5000 Watts
120/240 VAC
(Single Phase)
36 Amps @ 120 VAC
18 Amps @ 240 VAC
41.6 Amps @ 120 VAC
20.8 Amps @ 240 VAC
Table 3 Engine Type
Engine
SKU Number
HP
38862
38863
39408
39321
Honda GX 160
Honda GX 200
Honda GX 240
Honda GX 270
5.5hp
6.5hp
8.0hp
9.0hp
As a reference only, Table 1 below shows some general
wattage requirements for several common electrical
devices. This chart is intended as a guide only. The actual
total wattage should be determined by referring to the
actual labels on each of the powered electrical devices.
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RECEPTACLE DETAILS
The receptacles configurations shown in this section are for reference only. Each receptacle is not available on
all generators.
NEMA 5-20R
125V - 20A
NEMA L5-30R
125V - 30A
NEMA L6-30R
250V - 30A
NEMA L6-20R
250V - 20A
NEMA 14-50R
125/250V - 50A
NEMA L14-20R
125/250V - 20A
NEMA L14-30R
125/250V - 30A
ENGINE LIMITATIONS ON GENERATOR PERFORMANCE
Generator ratings assume 60F (20C) and Sea Level. Operation of your generator at temperatures above 60F (20C) or
above Sea Level will result in lower electrical output. Electrical output must be derated 2% for each 9F above 60F and 3 ½
% for each 1000 feet above mean sea level.
LOADING YOUR GENERATOR SET
WITH REFERENCE TO THE RECEPTACLE DETAILS SECTION, PLEASE REVIEW THE POWER RECEPTACLES FITTED TO YOUR
GENERATOR.
THE ACTUAL LOAD THAT MAY BE PULLED FROM EACH RECEPTACLE IS DRIVEN BY THE CIRCUIT BREAKER
RATING AND THE GENERATOR RATING. ALL GENERATOR UNITS ARE EQUIPPED WITH A “PUSH TO RESET” CIRCUIT BREAKER.
DO NOT EXCEED THE INDIVIDUAL RECEPTACLE RATINGS AS SHOWN IN THE TABLE BELOW. DO NOT EXCEED THE TOTAL
GENERATOR RATING SHOWN IN TABLE 2 PERFORMANCE SPECIFICATIONS.
AMPERAGE RATE TABLE
Model
SKU
38862
38863
39408
39321
Figure 1
120V Duplex 120V Duplex
Figure 2
Figure 3
120V GFCI
20Amps
20Amps
20Amps
Figure 4
Figure 5
125/250V Twistlock 125V/250V Twistlock
20Amps
20Amps
20Amps
20Amps
20Amps
20Amps
20Amps
20Amps
N/A
N/A
N/A
N/A
N/A
15Amps
20Amps
20Amps
20Amps
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS AND
WIRING DIAGRAM(S) IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER
THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR
WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE
ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT; IN FACT THE MANUFACTURER AND/OR
DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS
REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED
TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND
LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR
REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION
OF REPLACEMENT PARTS THERETO. PARTS MAY CHANGE OR VARY FROM THOSE
SHOWN.
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SECTION 2
38862 AND 38863 GENERATOR PARTS AND PART LISTS
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A.C. WIRING SCHEMATIC
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SECTION 3
39408/39321 GENERATOR PARTS AND PART LISTS
Frame and Parts list for
SKU # 39408/39321
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A.C. WIRING SCHEMATIC
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Notes
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