Powermate Portable Generator PM400911 User Manual

OWNERS MANUAL

MODELS: PM401211

AND PM400911

200-2341 - Revision C

Stationary Standby Electric Generator - 11,200 WATTS - MODEL PM401211

Stationary Standby Electric Generator - 9,7 00 WATTS - MODEL PM400911

IMPORTANT SAFETY INSTRUCTIONS – Please make certain that persons who are to install, operate and maintain

this equipment thoroughly read and understand these instructions prior to operation. SAVE THESE INSTRUCTIONS

— This manual contains important instructions that should be followed during installation and maintenance of the

generator and battery.

WARNING:

Read and understand all safety precautions in this manual and other

manuals included with this product before installing, operating and maintaining this

equipment. Failure to comply with instructions in this manual could result in personal

injury, property damage, and/or voiding of your warranty. Coleman Powermate WILL

NOT be liable for any damage because of failure to follow these instructions.

Record the model and serial numbers of your generator below:

Model Number

____________________

Serial Number

____________________

Date Purchased

____________________

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GENERAL SAFETY GUIDELINES

The following information relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To

help you recognize this information, we use the following symbols. Please read the manual and pay attention to these

sections. Also read and follow all safety labels on the engine/generator set. If labels are damaged or unreadable,

contact product service for replacements.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all

safety messages that follow this symbol to avoid possible injury or death.

Ground Location.

– A POTENTIAL HAZARD THAT WILL CAUSE SERIOUS INJURY OR LOSS OF LIFE.

DANGER:

WARNING: ^{– A POTENTIAL HAZARD THAT COULD CAUSE SERIOUS INJURY OR LOSS OF LIFE.}

– A POTENTIAL HAZARD THAT MAY CAUSE MODERATE INJURY OR DAMAGE TO

CAUTION:

EQUIPMENT.

NOTE: Improper installation can damage your electrical system and cause property damage, serious

personal injury or death. Installation MUST be performed by a licensed electrician and licensed

plumber, or gas technician. Installation MUST comply with all applicable building and electrical

codes. Some areas may require building permits and/or detailed sight inspections prior to approving

the unit for operation.

NOTE: The important safety instructions appearing in this manual are not meant to cover all possible

conditions and situations that may occur. It must be understood that common sense, caution, and

care are factors which are not built into a generator, but are supplied by the person(s) installing,

maintaining, and operating it.

circuits at the same time. A properly connected

WARNING:

transfer switch helps to prevent backfeed of

Do not attempt to install the generator yourself.

generator power into commercial lines while the

Extremely high and dangerous electrical voltages

standby generator is operating.

are present in utility power source lines and in

This generator supplies extremely high and

generator load leads when the unit is running.

dangerous power voltages. Any contact with high

Therefore, be sure to turn OFF all power voltage

voltage electrically "hot" components will result in

supplies at their source before attempting to

extremely hazardous, and possibly LETHAL,

complete electrical connections. Only qualified

electrical shock. Use care to avoid contact with live

installation contractors or electrician’s who are

terminals, bare connectors, bare wires, etc.

familiar with applicable codes, standards, regulations

Disconnect all power before performing maintenance

and procedures should install the system. Improper

or service.

or unauthorized installation, operation, or service of

this equipment is extremely hazardous and may

result in serious personal injury or death.

Generator exhaust air contains carbon monoxide, a

deadly odorless, colorless and tasteless gas.

Breathing carbon monoxide causes severe nausea,

fainting or death. Install the generator set outdoors

only. Do not use exhaust air to heat a room. Do not

allow exhaust air to enter a building through

windows, doors, air intakes or other means. Avoid

breathing exhaust air while installing, operating or

servicing generator set. The engine exhaust from

this product contains chemicals known to the State

of California to cause cancer, birth defects, or other

reproductive harm.

It is NOT intended that the information in this manual

be used by any unqualified persons for the purpose

of installing a standby electric power system. This

equipment must be installed, inspected, tested and

adjusted only by qualified personnel. These people

must be familiar with the equipment and installation

requirements.

The installation of this unit must comply with the

regulations of the United States National Electric

Code (NEC) as well as state and local codes and

Occupational Safety and Health Administration

(OSHA) established in the United States.

Short circuits can cause bodily injury and/or

equipment damage. Do not contact electrical

connections with tools or jewelry, make sure

clothing and shoes are dry and stand on a dry

wooden platform while adjustments are made.

Remove wristwatch, rings, and jewelry that can

cause short circuits.

This equipment, when installed as part of a standby

electric power system, must be installed in

conjunction with an approved transfer switch. The

transfer switch serves to prevent both generator

and utility power from being connected to the load

200-2341

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GENERAL SAFETY GUIDELINES (Continued)

CAUTION:

WARNING:

Units with broken or missing parts, without

The National Electrical Code (NEC) requires the

frame and external electrically conductive parts of

the generator to be connected to an approved earth

ground.

protective housing or covers should never be

operated. Contact your service center for

replacement parts.

Inspect the generator regularly, and contact your

nearest Authorized Dealer for parts needing repair

or replacement.

Keep a fire extinguisher near the generator at all

times. Extinguishers rated "ABC" by the National

Fire Protection Association are appropriate for use

on the standby electric system. Keep the

extinguisher properly charged and be familiar with

its use. If you have any question pertaining to fire

extinguishers, consult your local fire department.

Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating

conditions form leaking exhaust gases, fuel

leakage, oil leakage, etc.

Generator/engine noise can cause hearing loss.

Never operate the generator set without a muffler

or with a faulty exhaust system. Always wear

hearing protection when near or operating the

generator.

Thoroughly read the OPERATORS MANUAL

before operating the generator. Safe operation and

top performance can be obtained only when

equipment is operated and maintained properly.

DO NOT permit anyone to operate the standby

electric system without proper instruction.

Ensure that enclosure doors are closed and locked

at all times other than during service.

200-2341

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After inspecting the generator, engine and enclosure

for physical damage, finish reading the Operating and

Maintenance Instructions. These manuals contain

important safety information.

INTRODUCTION

The stationary standby electric generator is

manufactured for our customers to supply reliable

backup power. The generator is a compact unit,

designed to supply the power for your needs when utility

power fails.

WARNING

RISK OF INJURY AND BEING CRUSHED

The standby generator runs on Liquid Propane

Vapor or Natural Gas allowing flexibility for getting the

power you need. Fuel lines should be installed by a

licensed plumber or licensed gas technician.

•

HEAVY EQUIPMENT. Unbalanced weight.

Improper lifting can cause severe injury or

death and equipment damage.

When lifting the generator or using hoisting

equipment, be careful not to touch overhead

power lines. Proper tools and equipment and

qualified personnel should be used in all

phases of handling and unpacking.

WARNING

RISK OF ELECTROCUTION AND/OR INJURY

•

The installation of this equipment must be done

by licensed electricians contractors gas

technicians and plumbers. Installation must be

completed in conformance with NEC and local

electrical and building codes. Some areas may

require building permits and/or detailed sight

inspections prior to approving the unit for

operation.

INSTALLATION PLANNING

DANGER

•

Improper installation can damage your

electrical system and cause property damage,

serious personal injury or death. Installation

MUST be performed by a licensed electrician

and plumber, or gas technician and installation

MUST comply with all applicable building and

electrical codes. Some areas may require

building permits and/or detailed sight

inspections prior to approving the unit for

operation.

•About the Owners Manual

Understanding the operation of the generator is

important when using or maintaining your system. If

there are any questions about the information supplied in

this Owner’s Manuals, call our customer service helpline

number shown on the cover of the manual.

•About Operation or Maintenance

All required safety checks that need to be performed

are the responsibility of the operators. Listed within the

Owners Manual are safety precautions to be followed to

prevent personal injuries to persons around the unit and

to prevent property damage.

Taking a few moments to pre-plan before beginning

installation of the generator can provide significant

savings in materials and labor and lower future

maintenance. Some items to consider in planning

generator installation are safe generator operation, use

of an Automatic Transfer Switch, load requirements,

generator location, fuel supply, environmental conditions

and applicable local, regional or national codes. Some

areas may require building permits and/or detailed site

inspections prior to approving the unit for use. Check

with local authorities before starting installation.

UNPACKING INSTRUCTIONS

Immediately inspect the generator carefully for freight

loss or damage upon arrival. If loss or damage is noted

at the time of delivery, require the person making the

delivery to note the loss or damage on the freight bill, or

affix his signature under the consignor’s memo of the

loss or damage. Contact the carrier for claim

procedures.

When loss or damage is noted after delivery,

segregate the damaged material, and contact the carrier

for claim procedures. Be sure to retain the packaging

material for carrier inspection.

“Concealed Damage” is understood to mean damage

to the contents of a package which is not evident at the

time of delivery by the carrier, but which is discovered

later. The carrier or carriers are responsible for

merchandise lost or damaged in transit. The title to

goods rests with the consignee when generators are

shipped F.O.B. factory, and only the consignee can

legally file a claim.

Installation of a standby engine/generator system is

complex and should not be considered a Do-It-Yourself

project. Safe installation requires the skill and knowledge

of licensed electricians, plumbers, and professional

generator contractors. Contact an authorized dealer for

assistance with installation planning and referral to

properly qualified, licensed installing contractors.

200-2341

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GENERATOR LOCATION

WARNING

Proper location of the generator set is important to

insure safe and reliable operation and can aid in the

installation of the generator. When selecting a site for the

generator, first ensure that the pad is outdoors in a well

ventilated area to allow for proper cooling and proper

removal of deadly exhaust fumes created during

operation. Consider the direction of the engine exhaust

exiting the cabinet and orient the generator on the site

with the exhaust away from any windows, doors,

ventilation intakes or other openings that can allow

engine exhaust fumes to collect in a confined area. In

addition, take into account any prevailing winds or other

air currents that could carry engine exhaust fumes in

unintended directions.

•

For fire safety, the generator must be installed

and maintained properly. Installation always

must comply with applicable codes, standards,

laws and regulations. Adhere strictly to local,

state and national electrical and building codes.

Comply with regulations established by the

Occupational Safety and Health Administration

(OSHA) and National Electrical Code (NEC).

•

This generator is designed to be installed

outside only. Never install this unit inside any

room, enclosure, or basement. The generator

needs adequate cooling and ventilation for

continued proper and safe operation.

For minimum installation costs, plan to locate the

generator outside at a position adjacent to the electrical

service distribution panel and close to the intended fuel

supply.

The exhaust from this product is extremely hot

and remains hot after shutdown. High grass,

weeds, brush, leaves or other combustible

materials, must remain clear of the exhaust.

Such materials may ignite and burn from the

heat of the exhaust system.

To assure adequate cooling air and access for

maintenance, plan to locate the generator so that a

minimum of three (3) feet of clear, unobstructed space is

available on all sides of the cabinet, including above the

lid. If landscaping is used to mask the generator from

view or further control sound, leave enough room so that

the mature plants still allow three feet of clear space

around all sides. If necessary, place a screen style fence

around the site to prevent grass, leaves or other

combustible debris from gathering around the generator,

creating a fire risk.

CAUTION

•

Covering or restricting the air passages on the

generator will cause the unit to overheat and

may create a fire hazard. Do not allow snow or

leaves to cover enclosure openings.

•

Leave a three foot open area around all sides of

the unit. Do not plant trees or plants which may

grow within three feet of the unit.

Unit should be located to prevent combustible

material from accumulating against the

generator set.

DANGER

•

Generator exhaust air contains carbon

The generator MUST be installed outdoors.

monoxide, a deadly odorless, colorless and

tasteless gas. Breathing carbon monoxide

causes severe nausea, fainting or death. Install

the generator outdoors only. Do not use

exhaust air to heat a room. Do not allow exhaust

air to enter a building through windows, doors,

air intakes or other means. Avoid breathing

exhaust air while installing, operating or

servicing the generator. The engine exhaust

from this product contains chemicals known to

the State of California to cause cancer, birth

defects, or other reproductive harm.

•

Considerations for proper rooftop placement

and weight distribution must be designed by a

licensed engineer or architect.

200-2341

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Figure 2

Example of Alternative Transfer

Switch Installation

AUTOMATIC TRANSFER SWITCH

When connecting the generator to a building

electrical distribution system, use of a transfer switch is

recommended to isolate the normal utility source from

the generator supply. By preventing backfeed of the

generator power into the utility lines during a utility power

outage, the switch provides a level of safety for electrical

line workers. An automatic transfer switch listed to

Underwriters Laboratories Standard 1008 performs this

function while also supplying a method to automatically

start and stop the generator set and transfer power to the

building electrical system from an appropriate source.

(Main Panel Load)

When planning for a transfer switch/generator

installation, it is necessary to know the method of

interconnection to the building system. As illustrated, it is

recommended to connect the generator to power only

circuits that are necessary during a power outage. When

following this method, the transfer switch feeds an

electrical sub-panel containing only the necessary

circuits (see figure 1). Another option is to connect the

transfer switch directly to the entire building electrical

distribution system. In this case, all circuits or loads must

be controlled to avoid overloading and possibly

damaging the generator set (see figure 2).

Utility Power

Standby Generator

Main Circuit Panel

Automatic Transfer Switch

Figure 1

Example of Recommended Transfer

Switch Installation

(Essential Sub-panel Load)

Switch selection is based on factors such as the size

of the building distribution system, available generator

power and required generator control system. Due to the

complex nature of electrical distribution systems, the

sizing, selection and installation of a switch is best

handled by a licensed electrician or qualified standby

generator dealer. Any switch installation must be

performed by a licensed electrician to the instructions of

the switch manufacturer and any applicable local,

regional or national codes.

WARNING

•

Hazardous "backfeed" voltage can cause

severe injury or death. Install a transfer switch

in standby power installations to prevent

connection of standby to other sources of

power. Electrical backfeed into a utility

electrical system can cause serious injury or

death to utility personnel working on

transmission lines.

Utility Power

Standby Generator

Main Circuit Panel

Automatic Transfer Switch

Essential Loads Sub-panel

Do not try MANUAL operation of the transfer

switch until all power supplied to the switch has

been positively turned OFF. Failure to remove

power from all sources may result in extremely

dangerous and possibly lethal electrical shock

or arching.

200-2341

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GENERATOR INSTALLATION

Once installation planning is complete and all

necessary local permits are granted, installation of the

generator may begin. Within the following section

general recommendations are given for installing the

generator. However, installations are affected by local

site conditions, regional construction practices, material

availability, local or regional codes and/or other

variables. Therefore, recommendations included in this

manual are provided as a guide only and are not meant

to serve as detailed installation plans. All decisions

regarding installation and materials are at the discretion

of the licensed electricians and licensed plumbers

performing the installation and/or the inspector

performing the final inspection as required by local or

regional code. Additionally, illustrations provided in this

manual are subject to ongoing revisions and shall not be

construed as blueprints.

PLACEMENT AND ANCHORING

The generator is supplied with an integral molded

plastic base for use as an installation pad. Use of this

base is intended to minimize installation cost by

eliminating the need for a poured concrete pad.

A pad of crushed gravel a minimum of three inches

thick is recommended as a base to set the generator on.

Compact the gravel and ensure that the pad is level in all

directions, making sure that the overall pad height is

greater than the surrounding grade with a slope to carry

water away from all sides of the pad. Pad dimensions at

least six inches larger than the base size in all directions

are recommended.

It is possible to use a standard concrete pad if

desired. When using this method, a lightly steel

reinforced pad a minimum of 2 inches thick, poured to

local codes is recommended. Ensure the pad extends

past the generator pallet and is high enough to promote

drainage of water away from the generator.

After preparing the base pad, position the generator

directly on the pad (A), complete with the wooden skids

supplied for shipping. Remove the lag bolts (B)

fastening the wood to the pallet from all six positions.

Using a pry bar with a block of wood as a pivot, carefully

lift one end of the pallet and remove the wooden skids

from both that end and the center of the pallet (C).

Lower the pallet to the pad, then pry the other end up

and remove the skid from that end (D). Check the

generator with a level in all directions, placing material

under the base as required.

Although the weight of the generator is adequate to

prevent movement during normal operation, anchoring of

the generator is recommended. To anchor the generator

on a gravel pad, drive a minimum of four (4) spikes

through the anchoring tabs located on the outside

corners of the pallet. If a concrete pad is used, anchor

the pallet at the same points using appropriate concrete

fasteners.

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INSTALLATION DRAWINGS

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MAIN LINE OUTPUT POWER

ELECTRICAL HOOKUP

The output circuit of the generator is 4-wire, 240V,

rated for the amperage as shown on the generator

nameplate. Connection to the transfer switch requires

two leads, commonly referred to as "hot" leads (L1 & L2),

a neutral (N), and ground lead. Positions of these leads

are labeled on the main line output terminal block, also

shown in Fig. B. Select proper power output wire

sizes according to allowable ampacities given in

Table 310-16 of the latest revision of The National

Electric Code(NFPA 70). To connect the wires, strip

the insulation back approximately ½" from the end of the

wire, insert the stripped end into the terminal block, then

torque the terminal block screw to 35 in-lbs (4.0 N-m).

Once the generator is anchored in its final position, it

is ready for electrical connections. The generator is

supplied with two terminal blocks for connection of three

distinct electrical circuits; main line output power, GFCI

power input and remote start signal. Main line output

power is the electrical output of the generator, GFCI

input powers the battery charger and optional block

heater devices and the remote start signal is the

interface with an Automatic Transfer Switch that allows

the generator to operate automatically upon a utility

power outage.

DANGER

FIG. B

•

Improper installation can damage your

electrical system and cause property damage,

serious personal injury or death. Installation

MUST be performed by a licensed electrician

and plumber, or gas technician and installation

MUST comply with all applicable building and

electrical codes. Some areas may require

building permits and/or detailed sight

inspections prior to approving the unit for

operation.

MAIN

LINE OUTPUT

(CONNECT TO

AUTOMATIC

TRANSFER

SWITCH)

To access the wiring connection terminal blocks,

open the generator lid (A) and place the lid prop rod (B)

into the slot (C) on the underside of the lid. Remove the

three screws (D) from the access panel, then open the

hinged access panel (E) as shown in Fig A. The access

panel is removable by pulling the pins from the panel

hinges. Locate the two terminal blocks (F) on the lower

right corner of the engine partition panel.

NEUTRAL

GROUND

FIG. A

DANGER

•

Hazardous voltage can cause severe injury or

death. Electrocution is possible whenever

electricity is present. Open the main circuit

breaker of all power sources before servicing

the equipment. Configure the installation to

electrically ground the generator set, transfer

switch and related equipment and electrical

circuits to comply with applicable codes and

standards. Never contact electrical leads or

appliances when standing in water or on wet

ground because these conditions increase the

risk of electrocution.

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GFCI CIRCUIT SUPPLY

GENERATOR START SIGNAL

A ground fault circuit interrupting (GFCI) receptacle

is provided with the generator to power the battery

charger for reliable starting. It is also intended to power

an optional block heater if that option is desired.

Connection of this circuit to a power supply that is

only present when normal utility power is supplied is

recommended. By connecting the GFCI in this fashion,

it is possible to insure that neither the battery charger or

block heater are on while the engine is running.

When the control panel mode switch is placed in the

AUTO position, generator starting and stopping is

controlled by the opening or closing of a set of voltage

free contacts. Two wires from those contacts are

connected to the generator through the auxiliary

connection block shown in Fig. D. Use of a twisted pair of

stranded copper wire no smaller than AWG 18 gage is

recommended. To insure proper operation of the auto

start feature, use a transfer switch offering “close-to-run

Precautions are engineered into the generator to prevent control contacts. To connect the wires, strip the

these occurances but connection of the circuit in this

fashion provides an additional fail-safe method of engine

and battery protection.

insulation back approximately ¼" from the end of the

wire, insert the stripped end under the screw and washer

on the terminal block, then torque the terminal block

screw to 20 in-lbs (2.3 N-m).

Input to the GFCI circuit is 3-wire, 120V, 15A.

Connections include a "hot" lead (L1), neutral (N) and

ground lead. Positions of the incoming wire connections

are labeled at the auxiliary connection block, shown in

Fig.C. Select proper GFCI supply wire size

according to allowable ampacities given in Table

310-16 of the latest revision of The National Electric

Code(NFPA 70). To connect the wires, strip the

insulation back approximately ¼" from the end of the

wire, insert the stripped end under the screw and washer

on the terminal block, then torque the terminal block

screw to 20 in-lbs (2.3 N-m).

FIG. D

FIG. C

GENERATOR

START SIGNAL

ATS1

ATS2

(CONNECT TO

AUTOMATIC

TRANSFER

SWITCH)

GFCI

CIRCUIT

SUPPLY

NEUTRAL

(CONNECT TO

120V UTILITY

POWER)

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12KW WIRING DIAGRAM (CP200 CONTROLLER)

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WARNING

FUEL SPECIFICATIONS AND

CONSUMPTION REQUIREMENTS

The engine driving the generator is engineered to

provide reliable power on either Liquefied Propane Vapor

(LPG) or Natural Gas. For proper operation on these

fuels, it is important to deliver gas with adequate energy

content, at sufficient pressure and flow rate. This is

designed to operate on Liquefied Propane Vapor (LPG)

with a minimum energy content of 2500 BTU per cubic

foot or Natural Gas with a minimum energy content of

1000 BTU per cubic foot. This generator is designed to

operate with a fuel pressure at the inlet of the unit

between 7 and 11 inches of water column (4-6

ounces).

•

Natural gas (NG) is highly explosive.

Natural gas (NG) is lighter than air and collects

in high places.

•

Liquid propane vapor (LPG) is highly explosive.

Liquid propane vapor (LPG) is heavier than air

and collects in lower places.

•

Extreme caution should be taken when working

on a new installation or while performing

general maintenance.

•

Do not smoke when near the unit.

Keep flames, sparks, pilot lights, arc-producing

equipment, switches and all other sources of

ignition well away. Keep a type ABC fire

extinguisher handy.

Required fuel flow rates for specific models are given

in the table below. To insure correct sizing of the piping

supplying fuel to the generator set, provide the flow and

pressure requirements of this section to a fuel supplier or

licensed plumber during the installation planning stage. If

the fuel supplier cannot guarantee delivery of fuel with

these properties, the generator may not perform as

advertised.

•

Potential for fire or explosion always exist when

using natural gas (NG) or liquid propane vapor

(LPG) as a fuel source. Install this unit in

compliance with all local fuel codes.

Do Not operate engine if smell of fuel is present

or other explosive conditions exist.

Due to differences in the energy content of fuel used,

it is necessary to derate the output of the generator when

connected to Natural Gas. Additionally, regional and/or

seasonal variations in the makeup of the fuel can further

affect output of the engine/generator system. When

using Natural Gas fuel with minimum properties as

defined, engine output can fall approximately 10% below

that of the same set using Propane Vapor.

FUEL CONSUMPTION TABLE

LP Vapor LP Vapor Natural Gas

(ft 3/hr)

(Gal/hr)

(ft 3/hr)

PM401211

PM409011

2.2

2.1

186

176

All values reflect consumption at 100% rated output.

Per the National Gas Code (NFPA 54 - ANSI

2223.1), a manual shutoff valve in the fuel supply line

to the generator is recommended.

DANGER

•

All fuel system installations MUST BE done by a

licensed plumber or licensed gas technician

and must comply with all applicable codes,

standards and regulations.

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Natural Gas (NG)

When supplying natural gas as the operating fuel,

FUEL HOOKUP

After electrical connections are complete, the next

installation step is to connect a fuel supply to the unit.

The fuel inlet fitting supplied with the generator is male

½" NPT and is located adjacent to a fuel access hole in

the lower engine end panel as illustrated in Fig E. To

accommodate potential settling of the generator relative

to rigid supply pipeline, use of a flexible line to make the

final connection in the supply line is suggested. When

making flexible connections, use only materials rated for

the fuel supplied and approved for use by local, regional

or national codes and/or regulatory agencies.

provide fuel with a minimum of 1000 BTU/ft at inlet

pressures between 7" and 11" of water column (4 - 6

oz). Failure to meet these minimums will cause the

generator to run poorly and/or may limit output to values

below nameplate value. If fuel with these qualities is not

available, a low calorific fuel system kit may be required,

at additional cost. Contact the customer service center

to determine if a kit is required in cases of inadequate

fuel quality.

Refer to the Fuel Consumption Table on page 13 for

fuel flow requirements for the unit installed. Size all

feeding piping to deliver sufficient flow above the

minimum pressure of 7" water column (4 oz).

DANGER

•

All fuel system installations MUST BE done by a

licensed plumber or licensed gas technician

and must comply with all applicable codes,

standards and regulations.

Per the National Gas Code (NFPA 54 - ANSI

2223.1), a manual shutoff valve in the fuel supply line

to the generator is recommended.

Once all external connections are complete, check

the position of the flexible engine supply hose, as shown

in Fig F. When configuring a generator to run on a

specific fuel, it is necessary to verify correct positioning

of the hose on the fuel pressure regulator outlet. The

factory default position is for natural gas (NG), as

indicated in Fig F. If the fuel hose is not in the proper

position, move it to the tee branch labeled NG, making

sure the brass cap is placed securely on the opposite

branch. With fuel supply attached and the flexible engine

supply hose on the proper branch of the regulator output,

the fuel hookup is complete. The generator is supplied

with a fixed orifice tuned to provide proper fuel flow and

no further adjustment of the fuel system is possible or

required.

WARNING

•

Natural Gas and Propane Vapor are highly

explosive gases. Check ALL fuel system

connections for leaks before starting

engine/generator set.

•

DO NOT use a flame to check for leaks.

Use approved equipment and methods to check

for leaks.

FIG. E

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Propane Vapor (LPG)

In cases where liquefied propane vapor is selected

as the fuel of choice, insure fuel delivery in the gaseous

state, with a minimum energy content of 2500 BTU/ft ,

at inlet pressures between 7" and 11" of water

column (4 - 6 oz). Fuel below these specifications may

cause improper engine operation and/or failure to deliver

rated generator output. Size all fuel system plumbing to

provide fuel flow as given in the Fuel Consumption

Table on page 13, at a minimum pressure of 7" water

column (4 oz).

After completing external supply connections, verify

proper positioning of the flexible engine supply hose on

the fuel pressure regulator output, as shown in Fig F.

The factory default position is for natural gas (NG),

requiring a change for liquefied propane vapor (LPG)

operation. If the fuel hose is not in the proper position,

move it to the tee branch labeled LPG, making sure the

brass cap is placed securely on the opposite branch.

With fuel supply attached and the flexible engine supply

hose on the proper branch of the regulator output, the

fuel hookup is complete. The generator is supplied with

a fixed orifice tuned to provide proper fuel flow and no

further adjustment of the fuel system is possible or

required.

FIG. F

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CAUTION

BATTERY REQUIREMENTS

To insure reliable starting in most weather

conditions, it is important to properly match a battery to

the requirements of the generator. The generator uses a

12 Volt, direct current, negative ground control system

Successful engine starting is dependent upon the

cranking speed of the engine, which in turn is affected by

the cranking capacity of the battery. When selecting a

battery, choose the model that provides the highest

available cold cranking amperes (CCA) within a given

size range, as specified by the Battery Council

International (BCI). The battery tray and cables supplied

with the generator are sized to accept either a BCI

Group 26 or 26R battery, with a minimum

A battery presents a risk of electrical shock and a

high short circuit current. The following

precautions are to be observed when working on

batteries:

•

Remove watches, rings or other metal

objects.

Use tools with insulated handles.

Wear rubber gloves.

Do not lay tools or metal parts on top of

batteries.

Disconnect charging source prior to

connecting or disconnecting battery

terminals.

Determine if the battery is inadvertently

grounded. When inadvertently grounded,

remove source of ground. Contact with any

part of a grounded battery is capable of

resulting in electrical shock. The risk of

such shock is reduced when such grounds

are removed during installation and

maintenance.

Failure to connect and disconnect in the

proper sequence can cause equipment

damage. Ensure there is a clean tight fit

from the cables to the post.

•

recommended rating of 450 CCA.

WARNING

Lead-acid batteries present a risk of fire because

lead-acid batteries generate flammable hydrogen

gas.

•

Do not smoke when near batteries.

Do not cause flame or spark in battery area.

Discharge static electricity from body

before touching batteries by first touching a

grounded metal surface.

Do not dispose of batteries in a fire. The

battery is capable of exploding.

Do not open or mutilate the battery or

batteries. Released electrolyte has been

known to be harmful to the skin and eyes

and to be toxic.

•

BATTERY PLACEMENT AND

CONNECTION

The next step in installation of the generator is

placement and connection of the engine cranking

battery. Provided battery cables and battery rack are

sized to accept a BCI Group 26 or 26R automotive style

battery. A battery with a minimum of 450 CCA (cold

cranking amperes) in this size range is recommended to

assure reliable engine starting.

WARNING

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following

procedures are to be observed.

WARNING

•

Wear full eye protection and protective

clothing.

Where electrolyte contacts the skin, wash it

off immediately with water.

Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and

seek medical attention.

•

Make sure the control panel Mode switch is in

the OFF position before connecting the battery

cables. Failure to do so may result in

unexpected engine starting and to personal

injury.

•

Spilled electrolyte is to be washed down

with and acid neutralizing agent. A

common practice is to use a solution of

one pound (500 grams) bicarbonate of soda

to one gallon (4 liters) of water. The

bicarbonate of soda solution is to be added

until the evidence of reaction (foaming) has

ceased. The resulting liquid is to be flushed

with water and the area dried.

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that the charger is connected by checking to see that it is

plugged into a powered GFCI receptacle, and that the

positive (+) and negative (-) charger cables are

connected to their respective battery cables.

BATTERY PLACEMENT AND

CONNECTION (cont.)

To install the battery, begin by placing the battery (A)

into the battery rack as shown in Fig G. Orientation of

the battery terminals is according to installer preference

as the supplied battery cables are of adequate length to

reach terminals regardless of battery direction. Secure

the battery to the rack using the J-bolts (B), nuts (C) and

battery strap (D) packed in the literature bag packed with

the unit, as illustrated by Fig G.

LUBRICATION

Once all connections are made, the final installation

step is verification of proper engine oil level. The engine

is factory filled and shipped with approximately 1.5 qt

(1.4 liters) of SAE 10W-30 weight oil. Begin the level

check by removing the dipstick (K), wiping it clean, then

reinserting it into the engine. Remove the dipstick a

second time, checking that the oil level falls between the

upper and lower limit marks (see Fig A ,page 26) on the

end of the dipstick. Adjust engine oil level as required so

the level is at the upper limit mark on the dipstick, adding

oil to the engine through the oil fill cap (L) as shown in

Fig H.

FIG. G

FIG. H

After the battery is tight in the rack, begin attaching

the battery cables to the battery posts, starting with the

positive (+), or red, cable (E). Loosen the bolt (F) on the

post clamp slightly to allow the clamp to expand, then

firmly push the clamp onto the battery post marked

positive (+) until the top of the post extends past the top

of the clamp. Rotate the clamp around the post as

required to insure the clamp cannot contact any metal

components, then tighten the clamp bolt (F) until snug.

Finally,slide the post boot (G) down the cable and place

it entirely over the clamp.

WARNING

Finish connecting the battery by placing the negative

(-), or black, battery cable (H) to the battery post marked

negative (-). Push the clamp firmly over the post until the

post extends past the top of the clamp, then rotate the

clamp to avoid contact with any metal parts. Tighten the

battery clamp bolt (I) until snug.

•

State and federal agencies have determined

that contact with used engine oil can cause

cancer or reproductive toxicity. Take care to

limit skin contact and breathing of vapors as

much as possible. Use rubber gloves and wash

exposed skin.

The final step of battery installation is to verify proper

connection of all battery charger connections. A battery

charging system (J) is included with the engine/generator

set to maintain the battery charge during extended

periods of generator inactivity, therefore providing

consistent starting. A quick check of charger

CAUTION

Any attempt to crank or start the engine before

it has been properly serviced with the

recommended oil will result in an engine failure

that is not covered by warranty.

•

connections will verify that factory connections are

correct so the charger can function as intended. Insure

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5. Return to the generator and open any manual shutoff

valves in the fuel supply system.

FIRST TIME STARTUP

After completing all installation procedures, read and

understand the operating instructions for the generator

controller. Know how the control panel operates, what to

expect when activating control panel switches and how

to shut the generator off in the event of an emergency.

Before starting the generator for the first time, check off

all items on the following list, then follow the given

procedure to verify correct operation of the generator.

6. Move the control panel mode switch to the RUN

position. The generator should crank and start.

7. Allow the generator to run for approximately three (3)

minutes, then move the main line circuit breaker

handle to the ON position.

DANGER

‰ Is unit level?

‰ Is adequate free air space (3 feet minimum)

available on all sides of the enclosure?

‰ Are all cabinet openings free from blockage?

‰ Is the exhaust directed away from dwellings, dwelling

air intakes, or combustible materials?

‰ Are the fuel supply lines and internal generator fuel

connections leak-free?

‰ Is fuel supply pressure within specifications?

‰ Is the regulator connection properly configured for

the fuel supplied?

•

Generator is now supplying dangerous

voltages. Use extreme caution performing

electrical checks.

8. Check across the terminals of the main line power

output block (Red to Black) for proper frequency and

voltage. Frequency should read approximately 62.5

Hz and voltage between 240 and 245 volts at no load

conditions.

‰ Is an approved transfer switch used to prevent

backfeed into utility lines?

‰ Are electrical connections tight, and properly

connected?

‰ Are electrical conductors sized properly?

‰ Is the engine filled to the proper level with the correct

type of oil?

‰ Is a properly sized engine cranking battery correctly

installed?

9. Adjust no load speed as required to meet

approximately 62.5 Hz.

10. Shut the generator down by moving the mode

switch back to the OFF position.

11. Restore utility power to the transfer switch.

12. Place the control panel mode switch on the

generator set in the AUTO position.

13. Perform a manual exercise cycle following the

instructions provided by the switch manufacturer. If

wiring is connected properly to the switch, the

generator will start and stop under switch control.

While the generator is running, check the voltage

and frequency across the emergency supply

terminals on the transfer switch. Values should

match those found in Steps 8 and 9.

‰ Is the battery maintenance charger plugged in and

operating correctly?

‰ Are all protective covers installed and tightened?

‰ Are all tools clear of moving or electrically live parts?

‰ Is the installation inspected and approved as

required by local or regional code?

Once all items on the checklist are marked off,

complete the initial startup using the listed steps.

14. Allow the transfer switch to shut the generator off by

letting it complete the manual exercise cycle.

DANGER

15. With the generator mode switch still in the AUTO

position, simulate utility power failure by switching

utility power to the transfer switch OFF. Verify

correct function of the automatic transfer switch as

indicated in the switch manual. Restore utility power

to the transfer switch and verify correct automatic

transfer switch function. Allow the switch to shut the

generator down.

•

Contact with high voltages present in

generators and utility systems can cause

severe electric shock or death. Avoid contact

with all live components.

Allow only qualified generator service

technicians or licensed electricians to perform

initial system start-up.

16. Inspect the site to ensure no packaging or installation

materials remain within or against the generator.

1. Place the control panel mode switch on the

generator in the OFF position.

17. Replace all covers on the generator.

18. Place the generator into service by moving the

mode switch to the AUTO position.

2. Move the main line circuit breaker handle on the

generator to the OFF position.

3. Check the utility, or preferred, power supply to the

transfer switch following the instructions provided by

the switch manufacturer.

CAUTION

Failure to set the controller to AUTO before

leaving the generator renders the generator

unavailable for automatic standby service.

•

4. Ensure utility power to the transfer switch is shut off.

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GENERATOR SPECIFICATIONS

PM401211

PM400911

Rated Output

Propane Vapor

Natural Gas

Rated Amperage

11.2 kW

9.5 kW

9.7 kW

8.2 kW

Propane Vapor

Natural Gas

46.7 A

39.6 A

240 V

40.4 A

34.2 A

240 V

Rated Voltage

Frequency

60 Hz

Phase

Single

50 Amp

Single

45 Amp

Circuit Breaker Size

Rated Operating Temperature

Cooling Airflow

Full Load Sound Level

Overall Dimensions

Weight

-20°F to 104°F (-29°C to 40°C)

977 ft³/min

-20°F to 104°F (-29°C to 40°C)

977 ft³/min

69 dB(A)*

68 dB(A)*

42 1/2 in x 32 in x 27 in

478 lb

42 1/2 in x 32 in x 27 in

476 lb

ENGINE SPECIFICATIONS

PM401211

Honda

PM400911

Honda

Manufacturer

Manufacturer Engine Model

Style

VXC-GDACM

Air cooled, V-twin, 2-cylinder

Aluminum

VXC-GDADM

Air cooled, V-twin, 2-cylinder

Aluminum

Block

Displacement

Bore

670 cc (40.9 in³)

3.0 in (77 mm)

2.8 in (72 mm)

8.3:1

614 cc (37.5 in³)

3.0 in (77 mm)

2.6 in (66 mm)

8.3:1

Stroke

Compression Ratio

Exhaust Flow

Exhaust Temperature

Oil capacity

without filter

with filter

102 ft³/min

93 ft³/min

1007 °F

1.2 US qt (1.1 l)

1.5 US qt (1.4 l)

1.2 US qt (1.1 l)

1.5 US qt (1.4 l)

Oil Filter

Honda # 15400-P0H-305PE

Honda # 17210-ZJ1-841

Honda # 15400-P0H-305PE

Honda # 17210-ZJ1-841

Air Filter (paper element)

Spark plugs

Spark plug gap

Valve Clearance

Intake

NGK # ZGR5A or Denso # J16CR-U NGK # ZGR5A or Denso # J16CR-U

0.12 - 0.16 in (0.30 – 0.40 mm)

0.005 - 0.007 in (0.13 - 0.17 mm)

0.007 - 0.009 in (0.18 - 0.22 mm)

0.005 - 0.007 in (0.13 - 0.17 mm)

0.007 - 0.009 in (0.18 - 0.22 mm)

Exhaust

* Average @ 7 m

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ALTERNATOR SPECIFICATIONS

PM401211

2 pole, brushless

3600 RPM

PM400911

2 pole, brushless

3600 RPM

Style

Synchronous Speed

Excitation

Self regulated

12 sKVA^†

Self regulated

12 sKVA^†

Motor Starting Capacity

Winding Resistances

Stator

0.30 – 0.50 W

1.4 – 1.6 W

5.9 – 6.0 W

40mF, 500V

0.30 – 0.50 W

1.4 – 1.6 W

5.9 – 6.0 W

40mF, 500V

Excitation

Rotor

Capacitors

ELECTRICAL SPECIFICATIONS

PM401211

PM400911

Battery

12 VDC, BCI Group 26 or 26R

450

12 VDC, BCI Group 26 or 26R

450

Minimum CCA

Maintenance charger

Fuse

6 Amp, 3 stage

14 Amp, 32 VDC, Type SFE

10 Amp regulated

14 Amp, 32 VDC, Type SFE

10 Amp regulated

Engine Alternator

Fuse

25 Amp, 32 VDC, Type 3AG

Fuel Solenoids

Opening Voltage

Coil Resistance

9.5 VDC

29.1 - 29.8 W

9.5 VDC

29.1 - 29.8 W

14 psi

Oil Pressure Switch

High Temp Switch

Normally open, close on rise

285°F, Normally open, close on rise 285°F, Normally open, close on rise

FUEL SPECIFICATIONS

PM401211

PM400911

Fuel Pressure

7 – 11 inches water (4 – 6 oz)

Fuel Consumption

(100% load)

Propane Vapor

Natural Gas

81 ft³/hr (2.2 Gal/hr)

186 ft³/hr

79 ft³/hr (2.1 Gal/hr)

176 ft³/hr

Min Energy Content

Propane Vapor

Natural Gas

2500 BTU/ft³

1000 BTU/ft³

2500 BTU/ft³

1000 BTU/ft³

^†Measured @ 30% instantaneous voltage dip

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periods of inactivity to insure reliable, consistent

starting.

GENERATOR FEATURE

IDENTIFICATION

Before installing, operating or maintaining the

generator, take a few moments to become familiar with

the features of the generator as illustrated.

6. BATTERY CHARGING CIRCUIT FUSE

Protects engine - mounted battery charging

circuit against damage from electrical faults.

7. FUEL REGULATOR/LOCKOFF SOLENOIDS

1. CONTROL PANEL

Controls fuel flow to engine.

Controls the operation of the generator and

communicates system status.

8. INTERCONNECTION TERMINAL BLOCKS

Provided for quick connection of generator wiring

to transfer switch during generator installation.

2. MAIN LINE CIRCUIT BREAKER

Protects generator and connected loads from

electrical faults. Used to isolate output power

from operating generator.

9. OIL LEVEL DIPSTICK

High visibility yellow dipstick for checking for

proper engine lubricating oil level.

10. OIL FILL PLUG

WARNING

Add fresh engine oil here as required.

11. SPIN ON OIL FILTER

Replaceable, disposable filter to remove

contaminant's from engine oil to prolong engine

life.

•

Place the circuit breaker in the OFF position

when servicing the generator to minimize

electrocution hazards.

12. OIL DRAIN VALVE

Quick turn ball valve with extended drain hose to

speed up maintenance and eliminate mess.

3. GFCI OUTLET

Supplies power to at-rest battery charger and

13. ENGINE AIR FILTER

optional block heater. Standard plug receptacle

also allows convenient location to power a light

or tools during maintenance.

14. LID SUPPORT ROD

15. FRONT SERVICE ACCESS PANEL

Remove to drain oil and change oil filter.

4. CRANKING BATTERY (not included)

Supplies power to start engine and keep control

panel active.

16. CONTROL PANEL CIRCUIT FUSE

Protects control panel against damage from

electrical faults.

5. CRANKING BATTERY CHARGER

Maintains cranking battery at proper level during

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the AUTO position sets the generator for unattended

operation under the control of properly matched

automatic transfer switch.

GENERATOR OPERATION

A standby generator is an engine driven air cooled

system to convert the energy contained in either liquid

propane vapor or natural gas to electrical power. When

coupled with an automatic transfer switch to monitor for

failure of utility power, the unattended system can start,

stop and transfer between sources to insure a nearly

seamless supply of power. The generator is housed in a

weather resistant, sound attenuated enclosure for

outdoor installation only.

B. Main Line Circuit Breaker

A Main Line Circuit Breaker is provided to protect the

generator from damage caused by electrical faults within

the attached electrical distribution system. It is also used

to isolate the output of the generator from the connected

electrical distribution system by moving the breaker

handle to the OFF position. Placing the breaker in this

position does not prevent startup of the generator.

Before installing and starting the generator, become

familiar with the controls and operational features of the

generator. Know how the control panel operates, what to

expect when activating control panel switches and how

to shut the generator off in the event of an emergency.

C. Status Indicator Lights

Status indicator lights are provided to communicate

the status of the generator to the user. Under normal

running conditions, only the green Generator On light is

lit. Function of all other lights are described on page 24.

CONTROL PANEL FEATURES

A. MODE SWITCH

D. Generator Hour Meter

B. CIRCUIT BREAKER

C. STATUS INDICATOR LIGHTS

D. HOUR METER

The Generator Hour Meter is provided to track the

total numbers of hours of operation. The hour meter

runs whenever the engine is running and the alternator is

producing electricity. Placing the main line circuit

breaker in the OFF position while the engine is running

does not stop the meter from counting hours.

E. LAMP TEST SWITCH

E. Lamp Test Switch

A lamp test switch is provided to check for function of

all indicator lights. Press the lamp test switch while the

engine is at rest, with the control panel mode switch in

the OFF position to illuminate all status lights.

F. Engine Charging Circuit Fuse

The Engine Charging Circuit Fuse provides

protection to the engine mounted alternator in the event

of electrical faults in the positive (+) battery circuit.

Failure of this fuse prevents charge from reaching the

battery when the generator is running, leading to early

battery failure. Replace the fuse only with an equivalent

size and style of fuse to prevent damage to the generator

electrical control system.

CONTROL PANEL SWITCHES

A. Mode Switch

The Mode switch is used to set the operating state of

the generator. Placing the switch in the OFF position

prevents engine operation or stops the engine if it is

already running. Moving the switch to the RUN position

immediately starts the generator. Putting the switch in

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fault is declared or until the mode switch is moved to the

OFF position. Once the switch is shifted to the OFF

position, the engine is shut off.

STARTING THE GENERATOR

Two methods are available to start the generator.

The automatic, or AUTO mode is for use with an

automatic transfer switch. With the control panel mode

switch set to this position, the generator waits for an

external signal to start. This signal is supplied by the

transfer switch when utility power is of unacceptable

quality. Since utility power can fail at any time, be aware

the generator can start unexpectedly whenever in the

AUTO position. Keep away from moving parts at all

times. Once utility power is once again acceptable, the

signal from the transfer switch is removed, the generator

shuts off, then returns to waiting for another signal to

start.

When operating with the control panel switch in the

AUTO position, the generator continues to run until a

fault light is declared or the run signal is removed. Once

the signal is removed, the engine shuts down and the

controller returns to waiting for a start signal.

WARNING

•

With the Mode switch in the Auto position, the

unit starts and stops without notice.

Keep clear of all moving parts at all times.

The other method for starting the generating is to

place the mode switch into the RUN position. This mode

is intended for generator control during maintenance or if

an automatic transfer switch is not used. With the control

panel switch shifted to this position, the generator will

immediately attempt to start after a brief pause. Upon

starting, the generator runs until the switch is moved

from the RUN position, at which time the generator will

shut off.

CYCLIC CRANK

To insure the generator starts without damaging the

starter motor, cranking of the engine is performed in a

cyclic manner. When the generator is started from either

the AUTO or RUN positions, the controller alternates

between 10 seconds of engine cranking, followed by 10

seconds of engine rest. If the engine starts during any of

the cranking periods, crank attempts are halted and the

controller begins monitoring for proper function of the

generator. In the event that three 10 second start

attempts occur without the engine starting, cranking

attempts are halted and the Overcrank light is lit.

RUN STATE

After the engine is started and the generator is

producing electrical power, the controller begins

operation in a monitoring state. In this state, several

generator functions are continuously checked to ensure

proper operation of the generator. If functions are

determined unacceptable, a fault is declared, the engine

is shut down and a status light is lit to communicate the

reason for the shutdown.

SHUTDOWN

When operating with the control panel switch in the

RUN position, the generator will continue to run until a

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the engine. Once the light is on, the generator

does not attempt to start until the fault is reset.

When the Overcrank light is on , verify fuel is

available at the inlet to the unit, then check the

condition of the cranking battery.

STATUS INDICATORS

Status indicator lights relay conditions of generator

function for user or service technician convenience.

Illumination of these indicator lights communicate

conditions that require generator service but are not

severe enough to cause damage if the generator is

allowed to operate. Contact a qualified service technician

immediately for service if any of the listed lights are lit,

even if the generator appears to function normally.

D. LOW OIL

The Low Oil light turns on and the engine is shut

off if the engine oil level falls too low. To avoid

engine damage, engine oil pressure is monitored

to determine the amount of oil in the engine.

When pressure falls below a preset level, a Low

Oil fault occurs. Check for proper oil level if the

generator shuts down due to a Low Oil alarm.

A. LOW BATTERY

The Low Battery light is lit when the cranking

battery voltage falls below 11.0 volts. At this

level, the battery begins to lose the ability to

consistently start the engine. Causes of low

battery voltage may include a failing battery,

failed battery charger or failed engine alternator.

E. HIGH TEMPERATURE

The High Temperature light illuminates if the

temperature of the engine becomes too high.

Engine oil temperature is monitored while the

engine is active and the engine is shut off to

avoid damage if the oil temperature becomes too

high. When operating the generator in

temperatures above the maximum listed on the

nameplate, it is necessary to reduce the load

connected to the generator to avoid overheating.

If high ambient temperatures or excessive loads

are eliminated as possible causes of High

Temperature shutdown, check to insure cabinet

openings are not restricted by debris.

B. NOT IN AUTO

The Not In Auto light is lit whenever the control

panel mode switch is not placed in the AUTO

position. This light is provided to call attention to

this condition since the generator cannot start

automatically during a power outage without the

switch in the AUTO position. It is normal for this

lamp to light when the generator is running with

the mode switch in the RUN position, or if the

switch is in the OFF position. To turn the light off,

move the mode switch to the AUTO position.

H. GENERATOR ON

F. OVERSPEED

The Generator On light illuminates when the

generators engine is running. This is the only

light lit when the generator is supplying power as

intended.

The Overspeed light is turned on if the generator

engine is running too fast. Electrical output of the

generator at high speeds may damage loads

connected to the generator output and/or engine

failure may occur at excessive speeds. If the

generator shuts down on an Overspeed error,

seek assistance from a qualified generator

service technician.

FAULTS

Fault lights relay conditions that may cause damage

to the generator and/or loads connected to the output of

the generator. When any of the listed situations occur

while the generator is running, the generator is shut

down and the fault light associated with the shutdown

cause is lit. Once the light is lit, it remains on until it is

cleared by moving the control panel mode switch to the

OFF position. If a fault light is lit, determine and correct

the cause of the problem before restarting the generator.

During generator starting, the controller ignores fault

conditions until 15 seconds after the generator starts,

then uncleared faults will once again cause the generator

to shut off. To determine possible fault causes, refer to

the troubleshooting section of this manual or contact a

qualified service technician for assistance.

G. UNDERSPEED

The Underspeed light is turned on if the

generator engine is running too slow. Electrical

output of the generator at low speeds can

damage loads connected to the generator output

and/or generator failure may occur due to

excessive heating in the generator head. If the

generator turns off due to an Underspeed error,

check to see that the connected loads do not

exceed the nameplate rating of the generator.

C. OVERCRANK

The Overcrank light is lit if all three 10 second

cyclic crank attempts are unsuccessful in starting

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MAINTENANCE

To ensure reliable generator operation, it is critical to

periodically inspect all components. The following chart

is provided as a guide for service check intervals. When

procedures listed in the following sections. A qualified

generator service technician should perform inspections

or adjustments requiring specialized tools or training.

the generator is operated under excessively hot, or dusty Users unfamiliar with any of the listed procedures should

conditions, shorten service intervals according to the

severity of the conditions encountered. To perform

periodic inspections or maintenance, refer to the

contact an authorized dealer for servicing assistance.

Every month Every 6 months Every year or Every 2 years

Maintenance Item

or 15 hours or 100 hours

300 hours

or 500 hours

Engine Oil

Check

X ¹

Change

Engine Oil Filter

Oil Cooler

Change

Check and Clean

Check

Engine Air Filter

Change

Battery

Check and Clean

Check

Battery Charger

Spark Arrestor

Spark Plugs

Check and Clean

Check

Replace

Valve Clearance

Check and Adjust

Check

Generator Output Frequency

Fuel System

Cooling Air Openings

Check

1. Perform first change at 25 hours.

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MAINTENANCE (cont.)

ENGINE OIL LEVEL CHECK

Prior to checking the oil level, start the generator by

moving the Mode switch on the control panel to the RUN

position. Allow the generator to run for one or two

minutes, then shut it down by returning the switch to the

OFF position. After the engine comes to a stop let the

engine set for a couple of minutes before checking the oil

level. Begin the level check by removing the dipstick (A),

wiping it clean, then reinserting it into the engine.

Remove the dipstick a second time, checking that the oil

level falls between the upper and lower limit marks on

the end of the dipstick, as shown in Fig. A. Adjust engine

oil level as required so the level is at the upper limit mark

on the dipstick, adding oil to the engine through the oil fill

cap (B) as shown in Fig B. Add only oil of the same

specification as the oil already in the engine.

WARNING

•

Before performing any maintenance, make sure

the Mode switch is in the OFF position, the

circuit breaker is in the OFF position and the

positive (red) battery cable is disconnected.

Generator/engine components are hot to the

touch when operating. To prevent burns to the

skin allow unit to cool before touching internal

generator or engine components.

Crankcase pressure can blow hot engine oil out

the fill opening causing severe burns. Always

stop the generator before removing the oil fill

cap.

Fig. A

Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts.

Never remove any drive belt or fan guard while

the unit is operating.

Engine block heater can cause electrical shock.

Remove engine block heater plug from

electrical outlet before working on block heater

connections.

UPPER LIMIT

Improper service or replacement of parts can

lead to severe personal injury or death and to

damage to equipment and property. Service

personnel must be qualified to perform

electrical and mechanical service.

LOWER LIMIT

•

Use caution when working on live electrical

equipment. Remove jewelry, make sure clothing

and shoes are dry and stand on a dry wooden

platform.

Fig. B

Do not smoke around the generator. Wipe up

any fuel or oil spills immediately. Ensure that no

combustible materials are left in the generator

compartment, or on or near the generator, as

FIRE or EXPLOSION may result. Keep the area

surrounding the generator clean and free from

debris.

•

When performing maintenance on this

equipment, nothing should be done that might

render the equipment or its installation in non-

compliance with applicable codes, standards,

and regulations.

Eye protection should be used.

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2. Place an oil drain pan capable of holding three (3)

ENGINE OIL AND OIL FILTER

CHANGE

quarts under the end of the oil drain hose (A).

3. Remove the oil fill cap (B) and place in a convenient

location. While holding the end of the oil drain hose

(A) in the drain pan, slowly open the oil drain valve

fully open. Allow the engine oil to completely drain

into the drain pan.

Selection of the correct grade and type of engine oil

greatly affects the performance of the generator,

especially when starting. Before selecting replacement

oil for an oil change, consider the anticipated operating

conditions the generator may be exposed to. Choose the

appropriate weight of oil for anticipated temperatures

from Chart C. If temperatures are expected to fluctuate

between extremes prior to the next oil change interval,

use of synthetic oil is recommended. Use of oil meeting a

minimum American Petroleum Institute (API)

4. When the engine oil is completely drained, close the

valve (C) by turning the handle fully counterclockwise.

5. Place the drain pan underneath the spin on oil filter

(D), then remove the filter by turning it

classification of SJ is advised.

counterclockwise. Once loose, drain all of the oil

from the filter into the drain pan.

Chart C

6. Apply a light film of oil to the gasket on the new oil

filter, then screw the filter onto the adaptor until the

gasket lightly touches the adaptor face. Tighten the

filter an additional ¾ to 1 turn.

10W-30

5W-30

7. Refill the engine with 1.5 qt (1.4 liters) of new engine

oil through the engine oil fill cap (B). Refer to the

engine oil recommendations on chart C for the

proper grade of oil. Replace the oil fill cap (B),

then start the engine and check for leaks.

^oF

-20

100

8. Stop the engine and check the engine oil level as

outlined on page 26. Add oil as required to bring

the oil to the proper level on the dipstick.

^oC

-30 -20

-10

WARNING

•

State and federal agencies have determined

that contact with used engine oil can cause

cancer or reproductive toxicity. Take care to

limit skin contact and breathing of vapors as

much as possible. Use rubber gloves and wash

exposed skin.

CAUTION

Any attempt to crank or start the engine before

it has been properly serviced with the

recommended oil will result in an engine failure

that is not covered by warranty.

•

Engine oil changes are recommended at the

maximum intervals given in the Periodic Maintance

Table. When operating in hot or dusty conditions shorter

change intervals may be necessary. To change the

engine oil and oil filter, the listed procedure is

recommended.

ENGINE OIL COOLER INSPECTION

AND CLEANING

At the intervals given in the maintenance schedule

table, check the oil cooler and lines for leaks. If leaks are

detected, replace clamps, fittings or hoses as necessary.

Also visually inspect the oil cooler for debris clogging the

cooler fins. If the cooler is blocked, use low pressure air

or water to dislodge the blocking material.

1. Warm up the engine oil by running a cold engine for

a few minutes, then shutting it off. Start and stop the

engine by moving the control panel mode switch

between the RUN and OFF positions. Insure the

mode switch is in the OFF position before continuing

the oil change.

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ENGINE AIR FILTER CHANGE

BATTERY MAINTENANCE

The generator engine is equipped with a dry element

air filter to block particles in the combustion air from

getting into the engine and causing excessive engine

wear. Over time this dirt builds-up on the filter, restricting

the amount of combustion air available to the engine, in

turn leading to a loss of generator power output. To

avoid these problems, periodic replacement of the

engine air filter is recommended at the intervals outline in

the service schedule table on page 25. To change the

air filter, follow the listed steps.

WARNING

•

Read and understand all warnings and cautions

on page 16 of this manual before preceding with

any battery maintenance.

Correctly maintaining the battery at regular intervals

is vital to ensure consistent engine starting. Poorly

maintained batteries loose charge over time and may not

provide enough power to crank the engine fast enough

for reliable starts. The steps below are suggested to

care for the battery and charger.

CAUTION

Never run this equipment without the complete

air cleaner system installed on the engine.

Failure to do so will result in premature engine

wear and significantly reduced engine life.

•

1. Access the battery (A) by removing the 3 access

panel screws (B) shown in Fig E using a 5/16"

wrench. The hinge panel (C) is then rotated to

expose the battery.

1. Locate the air filter cover snaps as shown in

Fig. D and pull them upward to release the

cleaner cover.

2. Keep the battery cable clamps at the battery posts

tight and free of corrosion. Replace the battery

cables if cracks are found in the clamps.

2. Remove the air cleaner cover to access the filter

elements, then remove the dirty paper filter element

and foam element.

3. Check and adjust the level of battery electrolyte

according to the battery manufacturer’s instructions if

not using a “maintenance-free” battery. If electrolyte

is low, add only distilled water to the battery. Do not

add tap water to the battery.

3. Carefully wipe the inside of the air cleaner housing

and lid clean with a clean, lint-free rag, taking care

not to knock dirt into the engine intake opening.

4. Wash the foam element in warm soapy water, rinse,

and allow to dry completely. DO NOT oil the foam

element.

4. Use a battery hydrometer to check the condition of

the electrolyte in each of the battery cells. Follow

the instructions provided by the hydrometer

5. Place the new paper filter element into the air

cleaner housing, then re-install the foam filter.

manufacturer to assess the quality of the battery.

6. Complete the replacement by putting the air cleaner

cover back in position and snapping the cover snap

closed.

Fig. E

Fig. D

AIR CLEANER COVER

FOAM FILTER ELEMENT

PAPER FILTER

ELEMENT

FILTER COVER

SNAPS

AIR CLEANER

BASE

FILTER COVER

SNAPS

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Fig. F

BATTERY MAINTENANCE (cont.)

5. Insure the the battery charger is powered and

functioning properly. A correctly operating battery

charger displays lights on the face of the charger to

relay the state of the charger. To locate the battery

charger (A) and check the lights (B) (see note below)

refer to Fig F. Refer to Table A to assess the mode

the charger is operating in.

Note: For easy viewing of the battery charger

lights, use a small handheld mirror held

under the charger.

Table A

Display

Operating Condition

•When the red LED is on, it indicates that your battery is discharged and the charger is recharging

at the "BULK" rate of 6 Amps. •While the red LED is on, the voltage measured will be 11.8 to 14

volts. •If the red LED stays on for more than 24 hours, refer to the troubleshooting section of this

manual.

Red

Green

Red

•When both the green and the red LED's are on, the charger is charging at an "ABSORPTION"

rate of between 1.5 and 5 Amps. This mode of charging gradually "tops off" the battery, and

reduces harmful sulfating. •While both LED's are on, the voltage measured should be approx.

14.0 to 14.5VDC. •If both LED's stay on longer than 24 hours, refer to the troubleshooting section

in this manual.

Green

Red

•When the green LED is on, the charger is charging at a "FLOAT" rate of less than 1.5 Amps.

•This "float" charging current will gradually decrease to as low as 0.1 Amps as the battery reaches

100% charge. It will now be kept at full charge without over-charging. •If the green LED stays on

when the battery is known to be low, refer to the troubleshooting section of this manual.

Green

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spark plugs. If a torque wrench is available, tighten

all plugs to 13 in-lbs (18 N-m).

SPARK PLUG CHECK

Engine spark plugs are an important part of the

engine ignition system. Worn or incorrectly adjusted

spark plugs can negatively affect engine starting and

operation. Therefore, it is important to inspect and regap,

or replace the engine spark plugs as indicated in the

service interval table. The listed steps are recommended

to access and service the engine spark plugs.

9. Finish the procedure by reassembling the enclosure

front panel (I), spark plug access cover (F), exhaust

chamber (D) and enclosure lid (B).

Fig. G

WARNING

•

Before performing any maintenance, make sure

the Mode switch is in the OFF position, the

circuit breaker is in the OFF position and the

positive (red) battery cable is disconnected.

1. To gain access to the spark plug on the rear side of

the engine, some disassembly of the generator

cabinet is required. Begin the disassembly by

carefully removing the lid from the enclosure. First

remove the ground strap by removing the screw

holding it to the lid. Push in the hinge retaining stop

(A), then slide the lid (B) to the left to free it from the

rest of the enclosure as shown in Fig G. Set the lid

aside on a soft surface to avoid scratching the paint.

2. Open the battery access panel by removing the 3

screws and rotating the panel outward (see Fig. E on

page 28).

Fig. H

3. Remove the 2 screws (C) fastening the exhaust

chamber to the rear engine firewall (see Fig H).

Slide the exhaust chamber panel (D) upward to free

it from the enclosure and carefully set it aside.

4. Locate and remove the screws (E) retaining the

spark plug access cover (F). Remove the cover to

gain access to the rear spark plug (G) as shown in

Fig H.

5. Remove the enclosure inlet fasteners (H) and front

panel (I) as indicated in Fig I to access the front

engine spark plug (J).

6. Pull the spark plug boots loose, then clean any dirt

from the area around the spark plugs. Remove the

spark plugs with a 13/16" spark plug wrench.

Fig. I

7. Inspect the spark plugs for fouling or abnormal wear

like excessively worn electrodes or cracked or

chipped insulator material. If abnormal wear is

indicated, replace the spark plugs. Fouled plugs

indicate the need for engine service by a qualified

engine service technician.

New spark plugs or plugs that do not display any

abnormal characteristics should be checked for

proper gap using a suitable spark plug gauge.

Adjust the gap to 0.012 - 0.016 inches (0.30 - 0.40

mm) by carefully bending the grounding electrode.

8. Reinstall the spark plugs by hand until they begin to

seat to avoid cross-threading. After the plugs begin

to seat, tighten used plugs an additional ¼ turn or

13/16" spark plug wrench to avoid damage to the

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SPARK ARRESTOR CLEANING

Fig. GG

In some areas of the United States, a USDA Forest

Service approved exhaust spark arrestor is legally

required. This optional accessory is added to the

generator during initial installation. To identify whether

the generator is equipped with a spark arrestor, inspect

the exhaust tailpipe opening for a screen. If a screen is

present in the tailpipe, the spark arrestor option is

installed.

Spark arrestors require periodic inspection and

cleaning as indicated in the recommended service

interval table on page 25. To maintain the spark

arrestor, the following steps are recommended.

1. To gain access to the spark arrestor assembly inside

the exhaust chamber, some disassembly of the

generator cabinet is required. Begin the disassembly

by carefully removing the lid from the enclosure.

First push in the hinge retaining stop (A), then slide

the lid (B) to the left to free it from the rest of the

enclosure as shown in Fig GG. Set the lid aside on a

soft surface to avoid scratching the lid paint.

Fig. HH

2. Open the battery access panel by removing the 3

screws and rotating the panel outward (see Fig. E on

page 28).

3. Remove the 2 screws (C) fastening the exhaust

chamber panel (D) to the rear engine firewall (see

Fig HH). Slide the exhaust chamber panel (D)

upward to free it from the enclosure and carefully set

it aside.

4. Remove the spark arrestor assembly by loosening

the screw holding the arrestor to the muffler.

5. Use a low pressure stream of compressed air or

water to blow particles from the spark arrestor

screen. Ensure that all particles are completely

flushed from the tailpipe.

6. Visually inspect the spark arrestor screen to for holes

or breaks in the screen. If any are found, replace the

spark arrestor assembly.

7. Reinstall the spark arrestor on the muffler outlet and

replace the clamp.

8. Slide the exhaust chamber panel (D) back into place

and install the screws (C) holding it to the rear

engine firewall.

9. Slide the lid (B) back onto the hinges and reinstall

the retaining clip to secure the lid place.

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ENCLOSURE AND SITE

CAUTION

Proper cooling of the generator is vital to maintain

performance and prevent equipment failure. Blocked

cabinet openings or other airflow obstructions are

potential fire hazards and can cause failures.

Periodically inspect generator cabinet openings and the

engine oil cooler for blockages. Do not allow leaves,

grass, dirt, snow or other objects to build up around the

cabinet. Keep plants and other landscaping groomed to

allow a minimum of three (3) feet of open space around

all sides of the generator. Do not place a cover over the

generator.

•

This adjustment should only be performed by

trained personnel. If incorrect adjustments are

made, the unit may fail to operate or operate

inefficiently.

1. Start the engine by moving the control panel Mode

switch to the RUN position and let the generator run

for a minimum of five minutes with no electrical loads

connected.

2. Once the generator is warmed up, check the

generator output frequency with a suitable meter.

Normal unloaded frequency is approximately 62.5

Hz.

DANGER

3. Adjust engine speed to 62.5 as required by turning

the engine governor screw, shown in Fig K. Turn

the screw clockwise to increase frequency and

counterclockwise to decrease frequency.

•

Generator exhaust air contains carbon

monoxide, a deadly odorless, colorless and

tasteless gas. Breathing carbon monoxide

causes severe nausea, fainting or death. Do not

allow exhaust air to enter a building through

windows, doors, air intakes or other means.

Avoid breathing exhaust air while operating or

servicing the generator set. The engine exhaust

from this product contains chemicals known to

the State of California to cause cancer, birth

defects, or other reproductive harm.

4. Turn the engine off by moving the control panel

Mode switch back to the OFF position.

Fig. K

CAUTION

•

Covering or restricting the air passages on the

generator will cause the unit to overheat and

may create a fire hazard. Do not allow snow or

leaves to cover enclosure openings.

•

Leave a three foot open area around all sides of

the unit. Do not plant trees or plants which may

grow within three feet of the unit.

Unit should be located to prevent combustible

material from accumulating against the

generator.

The generator MUST be installed outdoors.

GOVERNOR SPEED ADJUSTMENT

The engine governor is set at the factory to maintain

generator output frequency within specifications and is

readjusted if required during installation. However,

engine wear may cause frequency to vary as the

generator accumulates hours. Periodic checking and

adjustment of generator frequency by a qualified

generator technician is recommended as outlined in the

table on page 25. If speed adjustment is necessary,

follow the listed procedure to set the correct engine

speed.

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VALVE CLEARANCE CHECK AND

ADJUSTMENT

Over time, normal engine operation leads to wear in

the engine valve train which decreases generator output.

To restore generator output, it is necessary to check and

adjust the engine valve lash at regular intervals

throughout the life of the engine. However, proper valve

lash adjustments require specialized training and tools.

Adjustment by persons unfamiliar with the procedure can

cause damage to the engine not covered under warranty.

Contact an authorized generator dealer for assistance in

locating qualified service personnel.

CAUTION

•

This adjustment should only be performed by

trained personnel. If incorrect adjustments are

made, the unit may fail to operate or operate

inefficiently.

FUEL SYSTEM INSPECTION

Avoid explosive and potentially lethal fuel leaks by

inspecting the complete generator fuel supply system at

intervals no greater than those listed in the Maintenance

Table on page 25. Visually inspect all hoses for cracks,

splits, or brittleness and replace hoses that show these

or other signs of wear. Check all connections for

tightness and cracks, replacing any broken fittings or

clamps. Check all connections for leaks, while the

generator is running, using approved equipment and

methods. DO NOT use a flame to check for leaks.

WARNING

•

Extreme caution should be taken while

performing general maintenance.

•

Do not smoke when near the unit.

Keep flames, sparks, pilot lights, arc-producing

equipment, switches and all other sources of

ignition well away. Keep a type ABC fire

extinguisher handy.

•

Do Not operate engine if smell of fuel is present

or other explosive conditions exist.

Do Not use a flame to check for leaks.

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TROUBLESHOOTING

SYMPTOM

POSSIBLE CAUSE

CORRECTIVE ACTION

Engine does not crank

Loose battery cables

Defective battery

• Check all battery cable connections

• Test battery. Replace as necessary.

• Check battery charger inline fuse

Improper battery charger function • Ensure charger is plugged into GFCI

receptacle

• Check for tripped GFCI receptacle. Reset if

required.

• Check for tripped breaker in branch circuit

supplying GFCI. Reset if required.

• Check all charger cable connections for

cleanness and tightness.

• Check charger lights to verify correct

operation. See Table A, Page 29.

Fault in starter signal circuit

Blown control circuit fuse

• Contact a qualified generator dealer for service

assistance.

• Check control circuit fuse.

Engine cranks without starting Low battery

• Test battery. Replace as necessary.

• Ensure charger is plugged into GFCI

receptacle

• Check for tripped GFCI receptacle. Reset if

required.

• Check for tripped breaker in branch circuit

supplying GFCI. Reset if required.

• Check all charger cable connections for

cleanness and tightness.

• Check charger lights to verify correct

operation. See Table A, Page 29.

• Ensure all manual shutoff valves are open

• Check for proper fuel supply pressure

• Verify size and fill level of propane tank (LPG

only)

Poor fuel supply

• Check fuel solenoid voltage during cranking

• Check engine oil level

Engine starts then

Low oil pressure

immediately shuts down

• Check switch for proper function

• Allow engine to cool, then restart

• Decrease loads on generator

• Check enclosure openings for blockage

• Check oil cooler for blockage

• Check breaker. Clear faults, then reclose

breaker.

• Check for tripped breaker in circuit between

generator output and transfer switch. Clear

fault, then reclose breaker.

High engine temperature

No generator output

Main line circuit breaker tripped

Disconnect breaker tripped

Generator loss of excitation

Excitation capacitor failure

• Contact a qualified generator dealer for service

assistance.

• Contact a qualified generator dealer for service

assistance.

Generator diode or varistor failure • Contact a qualified generator dealer for service

assistance.

Generator head fault

• Contact a qualified generator dealer for service

assistance.

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TROUBLESHOOTING

SYMPTOM

POSSIBLE CAUSE

CORRECTIVE ACTION

Low generator output voltage Low engine speed

• Verify correct engine speed. Remove excess

loads or adjust speed as required.

• Contact a qualified generator dealer for service

assistance.

Excitation capacitor failure

Generator diode or varistor failure • Contact a qualified generator dealer for service

assistance.

Overspeed light stays lit

Underspeed light stays lit

Shutdown due to high engine

speed

• Verify correct engine speed setting. Adjust

engine speed as required.

Shutdown due to low engine

speed

• Reduce loads connected to generator

• Check engine speed setting at no load.

Adjust as required.

Overcrank light stays lit

Not In Auto light stays lit

Failure to start

• See "Engine cranks without starting"

Generator not set for unattended • Place mode switch into AUTO position if

operation

automatic function is required

• Check engine oil level.

Low oil pressure light stays lit Shutdown due to low engine oil

pressure

• Verify correct type of engine oil for ambient

temperature conditions

Low battery light stays lit

Low battery

• Test battery. Replace as necessary.

• Ensure charger is plugged into GFCI

receptacle

• Check for tripped GFCI receptacle. Reset if

required.

• Check for tripped breaker in branch circuit

supplying GFCI. Reset if required.

• Check all charger cable connections for

cleanness and tightness.

• Check battery charger inline fuse

• Check charger lights to verify correct

operation. See Table A, Page 29.

• Check engine alternator fuse

• Allow engine to cool, then restart

Blown charger circuit fuse

High engine temperature light Shutdown due to high engine

stays lit

temperature

• Decrease loads on generator

• Check enclosure openings for blockage

• Check oil cooler for blockage

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PARTS DRAWING - EXHAUST SYSTEM

Torque to 8.5 lbs-ft

Torque to 15 lbs-in

Torque to 16 lbs-ft

Torque to 17 lbs-ft

Torque to 20 lbs-ft

PARTS LIST

Item

Part No

N/A

Qty Description

Item

Part No

N/A

094-0070

094-0072

094-0071

115-0263

Qty Description

Screw, 10-16 x .50” lg

Star washer, #10

Rivet

Label, hot, stamped steel

Cover, muffler (includes items 3,

4, 6 & 7)

Screw, m8 x 13 mm lg

Nut (see Honda manual)

Insulation

N/A

Not replaceable

115-0262

Muffler box (includes items 17,

18, 19 & 22)

094-0069

094-0073

N/A

Insulation

Nut, 5/16-18

Clamp, saddle (includes (2) item

#8)

N/A

094-0094

Bolt, 1/4-20 x 1.25” lg

Insulation

0056767

019-0214

N/A

094-0093

145-0418

N/A

Exhaust manifold muffler, Honda

Nut, 1/4-20, Nylon stop

Isolator, muffler bracket to panel

Tail pipe

*N/A -

These are standard parts available at your local

hardware store.

Lock washer, 5/16”

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PARTS DRAWING - ENCLOSURE

Torque to 15 lbs-in

PARTS LIST

Item

Part No

N/A

Qty Description

Item

Part No

Qty Description

Screw, 10-16 x .50” lg

Star washer, #10

Side panel, left side (includes

item 16)

103-0121

098-2758

094-0084

094-0076

094-0083

098-2856

098-2759

094-0078

Clip, hood rod

Warning label

Insulation (not shown)

Warning label

Fuel label

Insulation, exhaust top (not . . . . .

shown)

115-0264

S115-0242

S115-0240

Prop arm, lid

Lid assembly, complete (see

page 38 for separate parts)

Panel, back (includes items 11 & .

19)

Access panel, top portion

(includes items 13, 14 & 17)

Hinge, swivel

Access panel, bottom portion

(includes item 15 & 18)

Door assembly, (includes inner

door panel)

115-0265

115-0266

Not shown 094-0108

Weather seal (3/16” h x

1/2” w x 12’ lg)

Weather seal (1/8” h x

1/2” w x 12’ lg)

107-0061

115-0267

Not shown 094-0107

S115-0218

094-0075

*N/A - These are standard parts available at your local

hardware store.

Insulation (not shown)

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PARTS DRAWING - LID ASSEMBLY

Torque to 7 lbs-ft

Torque to 15-20 lbs-in

Torque to 24 lbs-in

PARTS LIST

Item

Part No

0056765

146-0023

Order item # 1

Order item #1

0056761

Qty Description

Item

Part No

026-0535

107-0062

N/A

Qty Description

Lock (includes 1A, 1B, 1C & 1D)

Key

Washer

Bolt

Nut

Handle

Lid weldment (order S115-0240

for complete lid assembly)

Nut, 10-32

Ground strap, 17” lg

Hinge (includes (4) item #7)

Rivet

Weather seal (1/4 h x 3/4 w x

12’ lg)

094-0106

094-0077

S115-0240

Insulation

S115-0251

Lid assembly, complete

(includes all of the items listed

above)

N/A

0056766

114-0571

0058221

N/A

Lock, hooked pawl

Bracket, lid stop

Screw, M5-.8 x 8MM

Nut, 1/4-20 Nylon stop

*N/A-

These are standard parts available at your local

hardware store.

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PARTS DRAWING - GENERATOR

Torque to 15 lbs-ft

ITEM 10

ITEM 11

PARTS LIST

Item

Part No

Qty Description

Item

Part No

026-0515

Qty Description

0056629

0056623

160-0311

100-0003

059-0348

160-0312

166-0133

077-0168

098-2827

Discharge louvered cover

Engine adapter

Wiring harness, generator

neutral

Rotor assembly

Diode/varistor assembly

Rotor bolt

Stator assembly

Capacitor, 40F, 500V

Terminal box cover

Warning label

026-0514

160-0309

Wiring harness, generator power

Complete generator assembly

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PARTS DRAWING -H2X BREAKDOWN

Torque to 8.5 lbs-ft

Torque to 15 lbs-in

Torque to 40 lbs-ft

Detail A

See

detail A

For Oil Filter and Air Filter part

numbers, see page 19 of this manual.

PARTS LIST

Item

Part No

Qty Description

Item

Part No

109-0100

071-0031

N/A

S108-0160

094-0068

115-0271

Qty Description

094-0091

115-0268

N/A

160-0309

N/A

Insulation

Base, plastic

Hose clamp

Screw, 10-14 x .63” lg

Engine pan

Vibration isolator

Crossbrace assembly (includes

items 27, 28, 35, 35A & 36)

Warning label

Panel, left side (includes item 1)

Screw, 10-32 x .50” lg

Bolt, 5/16 NC x 1.25” lg

Lock washer, 5/16”

Washer, 5/16”

Generator assembly

Bolt, 3/8-16 x .75” lg

Bolt, 5/16 NC x 1.50” lg

Lock washer, 5/16”

Engine, Honda, GX620 (muffler ...

not incl. - see page 36 for details)

Engine, Honda, GX670 (muffler ...

not incl. - see page 36 for details)

Lag screw, 5/16 x 2” lg w/washer

Insulation

35A

098-2828

098-2821

068-0084

012-0094

012-0098

0057747

0057746

063-0042

026-0309

026-0518

026-0547

S0049224

Warning label

Fitting, hose barb 1/8 x 3/8

Hose, oil drain

025-0063

Hose clamp, .50-1.2

Fitting, barb 3/8 x 1/2

Valve ball, 3/8 M/F

Adapter, oil drain

025-0059

N/A

094-0074

115-0269

Fuse holder

Exhaust access panel (includes

item 15)

Fuse, type 3AG, 25 Amp 32V

Relay DC, 12V, COIL

Ground strap, 12GA, 5.50” lg

094-0081

094-0080

115-0270

Insulation

Back panel (includes items 13 & .

16)

*N/A -

These are standard parts available at your local

hardware store.

115-0245

Engine panel assembly (see

pages 41, 42 & 43 for details)

Spacer

094-0095

N/A

Screw, #10 x 1/2” sheet metal

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PARTS DRAWING - ENGINE PANEL END ASSEMBLY

Torque to 8.5 lbs-ft

Torque to 15 lbs-in

ITEM 37

NOTE: Seal all connections with gas tape. Use 2½ wraps

minimum. Check all connections under pressure using

a soap and water solution.

PARTS LIST

Item

Part No

094-0096

N/A

S012-0106

N/A

026-0338

See page 42

N/A

094-0095

N/A

Qty Description

Item

Part No

019-0211

Qty Description

Insulation

Regulator assy, GX670

Hose clamp, 23/32” I.D.

Hose, high temp oil, 3/8” x 26.5” lg

Nut, 1/4-20, Nylon stop

GFCI Receptacle

Control panel assy, CP200

Screw, 10-16 x .50” lg

Spacer, .75 O.D.

Screw, 1/4-20 x .75” lg

Control box frame

Panel, right hand (includes items

1 & 22)

(PM401211)

019-0213

Regulator assy, GX620

(PM400911)

N/A

0057079

N/A

Bolt, 1/4-20 x 1.75” lg

Oil cooler

Bolt, 1/4-20 x .63” lg

Bracket, oil cooler

Hose, high temp oil, 3/8” x 3” lg

Tee, adapter oil temp

Hose, high temp oil, 3/8” x 13” lg

Switch, oil temp

Bushing, snap .875 ID

Rubber grommet

Wire harness, engine control

Vapor hose assembly

Wire harness, terminal block

power

S114-0564

Order S012-0106

069-0022

Order S012-0106

034-0162

051-0091

093-0053

026-0512

012-0120

026-0516

S115-0238

115-0272

N/A

Screw, 6-32 x .50” lg

Terminal block, ground lug

Terminal block

Screw, torx 8-32 x 1.25” lg

Screw, 8-32 x 1.25” lg

Nut, #8-32 (not shown - for items

15, 16 and 20)

026-0460

026-0472

N/A

093-0054

N/A

098-2826

026-0309

N/A

Fuel grommet, .84 ID x 1.875 OD

Nipple, 3” lg, 1/2 NPT

Warning label

Fuse holder

Fuse, 5A Type 3AG

Fuse label

N/A

Rectifier shipped with engine

(Contact Honda Service Center)

Bolt, 1/4-20 x 1

Screw, 8-32 x .75” lg

Terminal block, 2 row 20A 4-pole

Warning label

N/A

026-0539

098-2800

N/A

098-2850

Elbow, 1/2 NPT x 1/2 NPT

*N/A -

These are standard parts available at your local hardware .

store.

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PARTS DRAWING - CONTROL PANEL BREAKDOWN

Torque to 10 lbs-in

Torque to 15 lbs-in

PARTS LIST

Item

Part No

N/A

034-0161

032-0067

(see #8)

N/A

Qty Description

Item

Part No

002-0060

Qty Description

Screw #8-32 x .75 phillips hd

Switch, toggle

Hourmeter, 120V AC 60HZ

Not available separately

Screw, 6-32 x .38”lg

Lock washer #6

Control box top (includes item 14)

Switch, momentary

Standoff, 6-32 x .75”lg

Controller board, CP200

Nut #6-32, Nylon stop

Circuit breaker, 50 Amp,

120/240V (PM401211)

Circuit breaker, 45 Amp,

120/240V (PM400911)

Circuit breaker mount

Control panel label, CP200

Wire harness

002-0061

0058069

098-2820

026-0537

N/A

115-0273

0056884

060-0175

026-0534

N/A

*N/A -

These are standard parts available at your local

hardware store.

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PARTS DRAWING - BATTERY HOLD DOWN

Torque to 7 lbs-ft

Torque to 8.5 lbs-ft

PARTS LIST

Item

Part No

N/A

Qty

Description

Nut, 1/4-20

11A

S114-0563

026-0480

026-0481

N/A

059-0344

S115-0229

0057024

N/A

026-0696

N/A

Bracket, battery hold down

Battery cable, positive

Battery cable, negative

Battery, BCI Group 26 or 26R

J-bolt, 1/4-20

Battery shelf

Battery standoff, rubber

Bolt, 1/4-20 x .625” lg

Screw, 1/4-20 x 1” lg

Battery charger

Fuse, type 3AG, 25 Amp, 32V

Nut, nylon stop 1/4-20

Nut, 1/4-20 nyloc

*N/A -

These are standard parts available at your local

hardware store.

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NOTES

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NOTES

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Coleman PowerStation™ Stationary Standby

3-Year or 1500 Hour Limited Warranty

Your Coleman PowerStation™ emergency back up power system generator has been manufactured to stringent guidelines &

standards for years of dependable operation & service. Coleman Powermate warrants this product to the original consumer

against defects in material and workmanship for a period of 3-Years or 1500 hours, whichever occurs first, from the date of

purchase and is not transferable.

Coverage:

Replacement parts & labor, including travel time & mileage, for defects in product found to be properly installed, maintained &

operated in accordance with Coleman Powermate & supplied component operator's manuals are eligible for warranty

coverage. A Coleman Powermate Authorized Master Representative, their dealer or their agent must perform warranty

service. Items not covered under the warranty are:

Normal engine wear, tune-ups, and routine service.

Damage caused by shipping, accidents, improper installation

or handling, improper storage, or repairs not performed by a

Coleman Powermate authorized Master Representative, their

dealer or their agent.

Damage caused by operation with improper fuel or at speeds,

loads, conditions, modifications, or installation contrary to

published specifications or recommendations.

Damage caused by negligent maintenance such as:

- Failing to provide the specified type and sufficient quantity of

lubricating oil.

Parts purchased for a replacement of a failed Coleman

Powermate part with a non-Coleman Powermate part voids

warranty on that part.

Fuel injection pumps not repaired locally by an authorized

servicing dealer.

Non-Coleman Powermate-authorized repair shop labor without

prior approval from Coleman Powermate Warranty

Department.

Engine fluids such as fuel, oil, or coolant/antifreeze.

Expenses incurred investigating performance complaints

unless defective Coleman Powermate materials or

workmanship is the cause of the problem.

Maintenance items such as fuses lamps, filters, spark plugs

and adjustments.

- Failing to keep the air intake and cooling areas clean.

- Failing to service the air cleaner.

- Failing to provide sufficient coolant.

- Failing to perform scheduled maintenance as recommended

by Coleman Powermate or by supplied component

manufacturers.

Sales outside the U.S. or Canada

Telephone charges or transportation charges in connection

with the repair of defective parts.

- Failing to regularly exercise the generator set.

Original installation charges and startup costs.

Starting batteries, travel & labor associated with battery failure.

Rental of equipment during performance of warranty repairs.

Engines, or other components, which are covered exclusively

by the warranty of their manufacturer.

Overtime labor charges incurred at the request of owner unless

prior approval is obtained by Coleman Powermate.

Air freight charges or shipping charges outside of Coleman

Powermate shipping practices

Any other expense including consequential damages,

incidental damages, or incidental expenses, including damage

to property. Some states do not allow the exclusion or

limitation of incidental damages, so the limitation may not apply

to you.

Altered, tampered or improperly maintained emission control

system components.

Implied Warranties:

Any implied warranties, including the Implied Warranties of Merchantability and Fitness For A Particular Purpose, are limited

in duration to 3-Years or 1500 Hours from the date of consumer purchase. Some states do not allow limitations on how long

an implied warranty lasts, so the limitation may or may not apply to you.

How To Obtain Warranty Performance:

Replacement parts & service are available from Coleman Powermate's Master Representative service network. Locate the

nearest service location by calling 1-800-445-1805, or write: Coleman Powermate Inc., 4970 Airport Road, PO Box 6001,

Kearney NE 68848.

To the extent any provision of this warranty is prohibited by federal, state, or municipal law, and cannot be preempted, it shall

not be applicable. This warranty gives you specific rights, and you may have other rights which may vary from state to state.

Coleman® is a registered trademark of the

Coleman Company, Inc. used under license.

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CONTACT THE COLEMAN POWERMATE PRODUCT SERVICE DEPARTMENT AT

1-800-445-1805

to obtain warranty service information or to order replacement parts or accessories.

HOW TO ORDER REPLACEMENT PARTS

Even quality built equipment such as the Coleman Powermate standby generator you have

purchased, might need occasional replacement parts to maintain it in good condition over the

years. To order replacement parts, please give the following information:

1. Model No. and Serial No. and all specifications shown on the Model No./Serial No. plate.

2. A brief description of the trouble with the generator.

APPELER LE SERVICE DES PRODUITS COLEMAN POWERMATE AU 1-800-445-1805 pour obtenir

des informations sur le service de garantie ou pour commander des pièces ou des accessoires.

COMMENT COMMANDER DES PIÈCES DE RECHANGE

Même l'équipement de première qualité, comme la génératrice de réserve Coleman Powermate que

vous avez achetée, peut nécessiter occasionnellement des pièces de rechange pour demeurer en

parfait état de marche au fil des années. Pour commander des pièces, veuillez indiquer les

renseignements suivants :

1. Le n° de modèle et le n° de série ainsi que toutes spécifications figurant sur la plaque

signalétique des numéros de modèle et de série.

2. Une brève description du problème de la génératrice.

COMUNÍQUESE CON EL DEPARTAMENTO DE SERVICIO DE PRODUCTOS COLEMAN

POWERMATE EN EL TELÉFONO

1-800-445-1805

para obtener información sobre servicios de garantía o para pedir piezas de repuesto o

accesorios.

CÓMO PEDIR PIEZAS DE REPUESTO

Incluso los equipos de calidad como el generador de emergencia Coleman Powermate que ha

comprado necesitan ocasionalmente piezas de repuesto para mantenerlos en buenas condiciones a

través de los años. Para pedir piezas de repuesto, sírvase entregar la información siguiente:

1. N.º de modelo y de serie y todas las especificaciones que se muestran en la placa de N.º de

Modelo/N.º de Serie.

2. Una descripción breve del problema con el generador.

Coleman Powermate, Inc.

4970 Airport Road

P. O. Box 6001

Kearney, NE 68848

1-800-445-1805

1-308-237-2181

Fax 1-308-234-4187

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