GENERATOR USER
MANUAL
Model Numbers
39461 42723
39982 42724
39984 42725
40423 42726
40814 42727
40827 42728
MODEL & SERIAL NUMBER
Enter the Model and Serial numbers of your generator in
the spaces provided below. Retain these numbers for
future reference. The Model and Serial numbers are
located on the generator data plate on the alternator
case or generator frame, along with other important
information.
Model Number
Serial Number
DOCCHI0011
6/14/00 Rev. 1
1
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Contents
LIMITED 1 YEAR WARRANTY STATEMENT .................................................................................................2
SECTION 1........................................................................................................................................................4
GENERAL INFORMATION .............................................................................................................................4
SAFETY RULES..............................................................................................................................................4
BATTERY SAFETY.........................................................................................................................................4
GENERAL SAFETY OPERATIONAL GUIDELINES..........................................................................................5
GENERAL MAINTENANCE ............................................................................................................................6
GENERATOR CLEANING...............................................................................................................................6
GENERAL STORAGE GUIDELINES ................................................................................................................6
GENERAL BATTERY INSTALLATION ...........................................................................................................6
ELECTRICAL LOADS AND GUIDELINES .......................................................................................................7
GENERATOR DESIGNED PERFORMANCE GUIDELINES ...............................................................................7
ENGINE LIMITATIONS ON GENERATOR PERFORMANCE ............................................................................7
RECEPTACLE DETAILS .................................................................................................................................8
LOADING YOUR GENERATOR SET ...............................................................................................................8
AMPERAGE RATE TABLE..............................................................................................................................8
SECTION 2........................................................................................................................................................9
40814/42723/42724 GENERATOR PARTS AND PART LISTS.............................................................................9
A.C. Wiring Schematics................................................................................................................................ 12
SECTION 3...................................................................................................................................................... 14
39461/39982/40423/42725/42726/42727/39984/40827/42728 GENERATOR PARTS AND PART LIST................... 14
A.C. Wiring Schematics................................................................................................................................ 16
SECTION 4...................................................................................................................................................... 21
CONTROL PANELS ...................................................................................................................................... 21
3
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SECTION 1
SERVICE OR REPAIR THIS GENERATOR UNLESS FULLY
QUALIFIED TO DO SO.
GENERAL INFORMATION
This manual is provided for you so that your
generator may be properly, safely and effectively
applied and operated. Please read and understand
all aspects of this manual before operating your
generator set. Please also read and understand the
documentation supplied with this generator
regarding the engine. Keep this documentation in a
safe and accessible place so that reference can be
made as needed. All operators, users and
subsequent owners of this generator must read and
understand all aspects of this documentation before
operation.
DANGER:
DO NOT OPERATE THIS GENERATOR
AMBIENT TEMPATURE EXCEEDS
IF
THE
104ºF/40ºC.
SAFETY RULES
DANGER: This generator set is designed to be
operated in dry conditions and for outdoor areas
only. Never operate this generator indoors.
Never operate this generator in rain, snow, sleet or
generally wet conditions. Damage to the generator, bodily
injury, or death could result from electrocution.
SPARK ARRESTING MUFFLER
DANGER: If this generator is connected to a
building, home, business, or any other electrical
circuit normally fed by utility power, steps must
be taken to insure the generator output and the utility
power are positively isolated. Failure to isolate the utility
and generator electrical systems will result in generator
damage and could result in injury or death to utility
workers due to the backfeed of electricity.
Certain States and Jurisdictions require that engine
driven equipment be fitted with spark arresting mufflers.
Depending on the generator model, spark arresting
mufflers may or may not be fitted. If spark arresting
mufflers are required for your specific local and the
generator muffler is not spark arresting, contact your
local dealer for instructions for a retrofit.
CAUTION: Do not exceed the rated capacity of
the generator. The total electrical loads at each
outlet must be added to determine the total
electrical load. The total load must not exceed the rated
capacity of the generator. If the driven apparatus does not
list wattage, but only amperage, wattage may be
determined by multiplying amperage times voltage (watts
= amps X volts).
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system for this generator
complies to the standards set forth by the California Air
Resources Board (CARB) and the Environmental
Protection Agency (EPA). Warranties for the exhaust
emission system are administered by the respective
engine manufacturers. Refer to the engine
documentation for warranty information.
CAUTION: Do not tamper with the engine-
governed speed. The generator operates at a
nominal speed of 3600 rpm. Increases in speed
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
over the 3600 rpm nominal will increase the chance of
personal injury due to rotational stresses on the rotating
members. Operation of the generator at speeds below the
nominal 3600 rpm could cause damage to the generator
or driven apparatus due to low voltage output.
THIS SYMBOL IS USED THROUGHOUT YOUR
OWNER’S MANUAL TO BRING ATTENTION TO
IMPORTANT SAFETY INSTRUCTIONS. FAILURE TO
CAUTION: Do not modify or misapply your
generator set. Operation of the generator other
than intended, could result in generator set
damage, bodily injury or even death from electrocution.
FOLLOW SAFETY INSTRUCTIONS COULD ENDANGER YOU
OR OTHERS AND RESULT IN PERSONAL INJURY OR
DEATH.
READ
AND
UNDERSTAND
ALL
SAFETY
INSTRUCTIONS BEFORE OPERATION.
DO NOT OPERATE THIS GENERATOR WITHIN AN
ENCLOSED AREA. THE EXHAUST GASES OF THIS
BATTERY SAFETY
GENERATOR
EMIT
“DEADLY”
CARBON
WARNING: STORAGE BATTERIES PRODUCE
AND RELEASE EXPLOSIVE HYDROGEN GAS
WHEN CHARGING. THE SLIGHTEST SPARK,
FLAME OR BURNING ASH CAN IGNITE THESE
GASES CAUSING A SERIOUS EXPLOSION THAT
COULD RESULT IN BLINDNESS OR OTHER SERIOUS
INJURIES.
MONOXIDE. EXPOSURE TO CARBON MONOXIDE CAN
CAUSE CARBON MONOXIDE POISONING, HEADACHES,
NAUSEA, SEVERE SICKNESS OR DEATH.
DANGER: THIS GENERATOR SET PRODUCES
ELECTRICAL
GUIDELINES MUST BE FOLLOWED. IMPROPER
OF THIS GENERATOR CAN RESULT IN
ELECTROCUTION, INJURY OR DEATH. DO NOT OPERATE,
CURRENT.
THEREFORE, SAFETY
USE
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WARNING: WEAR EYE PROTECTION,
RUBBER APRON AND RUBBER GLOVES
could damage your generator and potentially lead to
fires.
WHEN WORKING AROUND A BATTERY OR
Never touch a receptacle or bare wire. Electrocution
PERFORMING BATTERY SERVICE. BATTERY FLUID
IS AN EXTREMELY CAUSTIC SULFURIC ACID,
WHICH CAN CAUSE SEVERE BURNS. DO NOT
PERMIT THE BATTERY FLUID TO COME IN
CONTACT WITH YOUR CLOTHES OR SKIN.
or shock could result.
Gasoline is highly FLAMMABLE and its vapors
are EXPLOSIVE. Handle gasoline with extreme
care. Failure to properly handle gasoline can result
in explosion or fire. Do not permit smoking within
50ft of this generator set.
WARNING: ALWAYS DISCONNECT THE
NEGATIVE (-) BATTERY CABLE FROM THE
BATTERY BEFORE PERFORMING BATTERY
NEVER REFILL A HOT GENERATOR WITH FUEL.
NEVER REFILL THE GENERATOR WHILE IT IS
RUNNING. Spillage onto the engine or generator
could result in an explosion or fire. Always allow the
generator set to cool before refilling.
Do not store this generator set in any location where
gasoline fumes could potentially come into contact
with sparks, a pilot light or an open flame. Improper
storage of this generator could result in an explosion
or fire.
SERVICE
OR
BEFORE
PERFORMING
ANY
ELECTRICAL SERVICE ON THE GENERATOR OR
ENGINE.
GENERAL SAFETY OPERATIONAL
GUIDELINES
GROUNDING: The NATIONAL ELECTRICAL
CODE requires that the generator frame be properly
grounded to earth. A ground lug is provided on the
generator frame. As a general guideline, a 10 AWG
wire connected to the grounding lug of the generator
on one end (located on the generator frame as
indicated by the International “GROUND” symbol)
and connected to a copper or brass ground rod
(driven into the ground) on the other end of the wire.
Some locations require generator set or other
grounding. Check with a local electrician to
determine the grounding requirements for your area.
Electrical generators produce electricity. Therefore,
never allow or perform service operations to your
generator set without proper training/certification.
Service operations, without proper precautions can
cause severe shock and even death by
electrocution.
Generators operating on job or construction sites
must be equipped with GFCI (Ground Fault Circuit
Interrupters) on all circuits. Certain generator models
are not equipped with GFCI circuits. Therefore,
customer supplied GFCI’s must be installed in the
power cords connected to the generator. Consult a
local licensed electrician for proper wiring.
Use only 3-Prong extension cords in good condition
and make sure that the wire size within the
extension cords is of sufficient size to safely carry
the surge output of the generator.
Read and understand all the general safety
operational guidelines and rules before operating
this generator.
Always follow National and Local electrical codes.
When moving or transporting this generator, take
proper precautions to avoid fuel spillage. Further,
always use common sense when lifting this
generator. An adequate number of people and
proper lifting procedures must be used.
Do not wire your generator to a home or structure
fed by utility power without proper isolation circuitry.
Consult a local licensed electrician for proper wiring
of your generator to a home, business or any facility
or structure fed by utility power. Failure to properly
isolate utility and generator electrical power could
result in generator damage or electrocution to you or
a
utility worker. The main breaker, which
disconnects from the utility power, must be open
before the generator can safely be connected.
Do not operate this generator unless the generator
is in good mechanical and electrical condition.
Do not overload this generator. Overloading this
generator can cause generator damage, powered
apparatus damage and excessive heat build up.
Always keep hands, body parts, hair and clothing
well away from the rotating or “HOT” parts of the
generator set. Exhaust systems can cause severe
burns.
Do not start this generator with connected devices
turned “ON”. Always make sure that connected
devices are disconnected from the generator or
turned “OFF” before starting the generator.
Never handle extension cords or electrical circuits if
standing in water or if standing in a damp area.
Operate, service or fill with fluids on a level surface
only.
Do not operate this generator within an enclosed
area. The operation area of the generator must be
completely open. The exhaust gases of this
generator emit “DEADLY” carbon monoxide.
Exposure to carbon monoxide can cause carbon
monoxide poisoning, headaches, nausea, severe
sickness or death.
Do not operate this generator in a corrosive or
flammable environment.
Never clean this generator with high-pressure water
or a garden hose. Water can accumulate within the
generator and cause fuel system, ignition system
and or electrical problems or shorts. Cleaning should
be done with a damp rag on a cool generator set.
Do not install this generator in an enclosed area
such as a RV or motorhome. All warranty will be null
and void if installed within an enclosed area.
Always insure that at least 6 feet of clearance on all
sides of the generator are maintained during
operation. Failure to maintain proper clearance
5
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GENERAL MAINTENANCE
GENERAL BATTERY INSTALLATION
ENGINE FUEL: Use Unleaded Fuel - ONLY!
WARNING: DO NOT ATTEMPT TO OPERATE
THE GENERATOR WITHOUT THE BATTERY
INSTALLED UNLESS BOTH THE RED(+) AND
BLACK(-) CABLE ENDS ARE COMPLETELY
INSULATED OR THE CABLES ARE REMOVED
ENTIRELY.
ENGINE OIL:
Refer to the Engine related
documentation.
ENGINE MAINTENANCE:
Refer to the documentation supplied regarding the
engine for all engine maintenance issues.
BATTERY SPECIFICATION: 145 CCA; INTERSTATE
BATTERY Model SP-18 or Equivalent
GENERATOR CLEANING
With reference to the diagram below and to the safety
guidelines that must be respected for handling batteries,
install the battery as follows:
CAUTION!:
GENERATOR AND ALLOW THE GENERATOR
TO COMPLETELY COOL BEFORE
PERFORMING CLEANING OPERATIONS.
ALWAYS SHUT OFF THE
1. Place the battery into the battery tray.
2. Place the battery hold down bar (oriented as shown)
on top of the battery.
3. Install qty (2) battery hold down bolts and washers as
shown.
NOTE: Some versions require lock washers and nuts
on lower side of battery tray.
4. Gently and evenly tighten the battery hold down bolts.
Do not crush and or deform the battery case in the
tightening process.
5. Insure that the engine key switch is in the “off”
position.
6. Connect the red (+) cable to the battery (+) terminal
using the supplied bolt, washers and nut. Tighten the
bolt.
7. Connect the black (-) cable to the battery (-) terminal
using the supplied bolt, washers and nut. Tighten the
bolt.
WARNING! DO NOT USE HIGH PRESSURE
WATER OR A GARDEN HOSE TO CLEAN
YOUR GENERATOR. WATER INTRODUCED
INTO THE GENERATOR CAN CAUSE ELECTRICAL
SHORTS, GENERATOR DAMAGE OR PERSONAL
INJURY.
Compressed air (max. 25 psi) may be used to blow
loose dirt and dust from your generator. DO NOT
DIRECT COMPRESSED AIR DIRECTLY INTO ANY
OPENING IN THE GENERATOR OR ENGINE.
Use a dampened cloth to wipe clean exterior
surfaces.
Use a soft bristle brush to clean/ loosen heavy dirt, oil
or grease deposits.
NEVER insert rags, tools or any device into the
generator or engine openings.
GENERAL STORAGE GUIDELINES
WARNING:
GASOLINE FUMES ARE
FLAMMABLE. DO NOT STORE YOUR
GENSET IN ANY AREA THAT IS INDOORS OR
IN POORLY VENTILATED AREAS. GASOLINE FUMES
CAN IGNITE IN THE PRESENCE OF ANY OPEN
FLAME, PILOT LIGHT, CLOTHES DRYER, WATER
HEATER, ETC.
Your generator should be started and operated for
several minutes at least every 30 days.
If the generator cannot be operated every 30 days,
follow the storage recommendations within the engine
documentation.
NOTE: A fuel shut-off valve is positioned at the base
of the fuel tank. The valve should be closed during
storage periods.
Battery Installation Diagram
6
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GENERATOR DESIGNED
PERFORMANCE GUIDELINES
ELECTRICAL LOADS AND GUIDELINES
This electrical generator is designed to produce electrical
energy for the purpose of powering lights, power tools,
appliances and motor loads within the intended design
constraints of the generator. The generator is designed to
produce single-phase electrical power at 120 or 120/ 240
VAC. This generator is not intended for installation in RV
Your generator set is designed to power electrical
apparatuses within the electrical power output limitations
of the generator. Please note that any generator overload
can cause serious problems/damage to your generator.
Additionally, apparatuses with electrical motors can
require higher wattage requirements at start-up than when
running. Some electric motors require as much as 2.5
times the rated wattage at start-up. Although the start-up
wattage requirements for electric motors lasts only a few
seconds, great care must be taken in connecting loads to
your generator so as not to overload the generator. Refer
to the label on each electrical apparatus to determine the
wattage requirements of that apparatus. THE TOTAL
WATTAGE REQUIREMENTS OF ALL POWERED
APPARATUSES (INCLUDING START-UP LOADS)
MUST NEVER EXCEED THE CONTINUOUS RATING
OF YOUR GENERATOR, CORRECTED TO THE
ACTUAL ENVIRONMENTAL CONDITIONS AT THE
OPERATING SITE.
or
motorhome
applications.
The
Performance
Specifications for your generator are listed in Table 2
Performance Specifications.
Table 2 PERFORMANCE SPECIFICATIONS
SKU Number
40814
42723
42724
39461
Voltage
Cont. Watts
Surge Watts
5000 Watts
42 Amps @ 120 VAC
21 Amps @ 240 VAC
8000 Watts
120/240 VAC
4400 Watts
(Single Phase) 37.5 Amps @ 120 VAC
18.5 Amps @ 240 VAC
120/240 VAC
(Single Phase)
6100 Watts
51 Amps @ 120 VAC
26 Amps @ 240 VAC
40423
42725
67 Amps @ 120 VAC
33 Amps @ 240 VAC
42726
39982
42727
120/240 VAC
(Single Phase)
9350 Watts
10000 Watts
83 Amps @ 120 VAC
41.5 Amps @ 240 VAC
12000 Watts
100 Amps @ 120 VAC
50 Amps @ 240 VAC
78 Amps @ 120 VAC
39 Amps @ 240 VAC
10500 Watts
88 Amps @ 120 VAC
44 Amps @ 240 VAC
39984
40827
42728
120/240 VAC
(Single Phase)
As a reference only, Table 1 below shows some general
wattage requirements for several common electrical
devices. This chart is intended as a guide only. The actual
total wattage should be determined by referring to the
actual labels on each of the powered electrical devices.
Table 3 Engine Type
Engine
SKU Number
40814
42723
42724
39461
40423
42725
42726
39982
42727
39984
40827
42728
HP
9.0hp
9.0hp
9.0hp
13.0hp
13.0hp
13.0hp
13.0hp
16.0hp
16.0hp
18.0hp
20.0hp
20.0hp
Honda GX 270
Honda GX 270
Honda GX 270
Honda GX 390
Honda GX 390
Honda GX 390
Honda GX 390
Vanguard
Vanguard
Vanguard
Honda GX 620
Honda GX 620
Table 1
Item
GENERAL WATTAGE GUIDE
Running Watts
Air Conditioner (12000 Btu) (*)........................1750
Air Compressor (1/2 hp) (*)............................1400
Air Compressor (3/4 hp) (*)............................1800
Air Compressor (1 hp) (*)...............................2000
Battery Charger (25A).....................................600
Belt Sander (3” belt)......................................1000
Circle Saw (6 ½”) ...................................825-1050
Coffee Maker.........................................900-1100
Edger (lawn)..................................................550
Furnace Fan (1/3 hp) (*)................................1200
Hot Plate (single)..........................................1500
Impact wrench...............................................600
Light Bulb............................................ Bulb rated
Nail Gun.....................................................1200
Microwave.....................................................750
Paint Sprayer (1/3 hp) (*).................................650
Paint Sprayer, hand-airless..............................175
Radio ...................................................... 50-200
Refrigerator (*)...............................................600
Table Saw (10”) (*).......................................2000
Television............................................... 250-550
Weed Trimmer...............................................500
Note: (*) Items allow 2.5 times the listed wattage
for starting.
ENGINE LIMITATIONS ON GENERATOR
PERFORMANCE
Generator ratings assume 60F (20C) and Sea Level.
Operation of your generator at temperatures above 60F
(20C) or above Sea Level will result in lower electrical
output. Electrical output must be derated 2% for each 9F
above 60F and 3 ½ % for each 1000 feet above mean
sea level.
7
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RECEPTACLE DETAILS
The following receptacle details are to aid in identifying mating plugs. Use this chart and compare to your genset
to determine which receptacle(s) you have. Note the NEMA configuration and use this to purchase the correct
mating plug.
NEMA 5-20R
125V - 20A
NEMA L5-30R
125V - 30A
NEMA L6-30R
250V - 30A
NEMA L6-20R
250V - 20A
NEMA 14-50R
125/250V - 50A
NEMA L14-20R
125/250V - 20A
NEMA L14-30R
125/250V - 30A
LOADING YOUR GENERATOR SET
With reference to the Receptacle details section, please review the power receptacles fitted to your generator. The actual
load that may be pulled from each receptacle is driven by the circuit breaker rating and the generator rating. DO NOT
EXCEED THE INDIVIDUAL RECEPTACLE RATINGS AS SHOWN IN THE AMPERAGE RATE TABLE. DO NOT EXCEED
THE TOTAL GENERATOR RATING SHOWN IN TABLE 2 PERFORMANCE SPECIFICATIONS. All generator units are
equipped with a “PUSH TO RESET” Circuit Breaker.
AMPERAGE RATE TABLE
Model/
SKU
NEMA 5-20R
NEMA L5-30R NEMA L14-30R
NEMA L6-30R
250V Twistlock
NEMA 14-50R
125V/250V
Straight Blade
N/A
NEMA L6-20R
250V
Twistlock
N/A
NEMA L14-20R
125V/250V
Twistlock
N/A
120V – Duplex 120V Twistlock
125V/250V
Twistlock
30Amps
30Amps
30Amps
30Amps
N/A
30Amps
20Amps
N/A
39461
39982
39984
40423
40814
40827
42723
42724
42725
42726
42727
42728
20Amps
15Amps
20Amps
20Amps
20Amps
20Amps
20Amps
20Amps
20Amps
20Amps
15Amps
20Amps
30Amps
30Amps
30Amps
30Amps
20Amps
30Amps
N/A
20Amps
N/A
30Amps
30Amps
30Amps
30Amps
25Amps
30Amps
30Amps
20Amps
30Amps
N/A
35Amps
40Amps
N/A
N/A
45Amps
N/A
N/A
N/A
N/A
20Amps
N/A
N/A
20Amps
N/A
N/A
N/A
N/A
N/A
N/A
20Amps
N/A
20Amps
20Amps
20Amps
N/A
N/A
N/A
20Amps
N/A
N/A
N/A
20Amps
30Amps
30Amps
30Amps
30Amps
25Amps
30Amps
N/A
35Amps
40Amps
N/A
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS AND WIRING
DIAGRAM(S) IN THIS MANUAL AS A REFERENCE TOOL ONLY. NIETHER THE MANUFACTURER
NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE
BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT
HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT; IN FACT THE
MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND
PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED
TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT
PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS
THERETO. PARTS MY CHANGE OR VARY FROM THOSE SHOWN.
8
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SECTION 2
40814/42723/42724 GENERATOR PARTS AND PART LISTS
Frame and Parts list for
SKU # 40814/42723/42724
9
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10
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11
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A.C. WIRING SCHEMATICS
12
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13
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SECTION 3
39461/39982/40423/42725/42726/42727/39984/40827/42728 GENERATOR PARTS AND
PART LIST
Frame and Parts list for
SKU # 39461/39982/40423/
42725/42726/42727/39984/40827/
42728
For Items 9, 12, and 13 please refer to Section 2 of this manual.
14
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A.C. WIRING SCHEMATICS
16
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SECTION 4
CONTROL PANELS
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NOTES
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