Contractor GEN4000/03237 User manual

4000 Watt Generator
Stock No GEN4000/03237
INSTRUCTION MANUAL
Please read this manual BEFORE using this tool

ITEM DESCRIPTION
Electrical Requirements 6.5hp 3000 watt w/ peak surge wattage of 4000w
Engine Type Electronic ignition system, recoil start 4 Cycle
Alternator Two Pole / Single Phase / 60 Hz
DC voltage DC Output 12v @ 8.3amps
Fuel Tank 4 gallon tank capacity
Estimated Run Time 7.8h continuous run time
Overall Dimensions 24.25x17.25x18 in
Weight 101 Lbs.
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, operating, inspection,
maintenance and cleaning procedures, parts list and assembly diagram. Keep your invoice
with this manual. Write the invoice number on the inside of the front cover. Keep this manual
and invoice in a safe and dry place for future reference.
WARNING!
The warnings, cautions and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be
understood by the operator that COMMON SENSE AND CAUTION ARE FACTORS
WHICH CANNOT BE BUILT INTO THIS PRODUCT, BUT MUST BE SUPPLIED BY
THE OPERATOR.
GENERAL SAFETY RULES
WORK AREA
1. Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
2. Do not operate generators in explosive atmospheres, such as in the presence of flammable
liquids, gases, or dust. Generators create sparks, which may ignite the dust or fumes.
3. Keep bystanders, children, and visitors away while operating a generator. Provide barriers or
shields as needed.
4. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair,
clothing, and gloves away from moving parts. Loose clothes, jewelry, and long hair can be caught in
moving parts.
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GENERATOR SAFETY
1. Do not overload the generator. Use the correct generator for your application. The correct generator
will do the job better and safer at the rate for which it is designed.
2. Do not expose to rain or wet conditions. Water entering a generator will increase the risk of electric shock.
3. Stay alert. Watch what you are doing, and use common sense when operating a generator. Do not
use a generator while tired or under the influence of drugs, alcohol, or medication. A moment of
inattention while operating the generator may result in serious personal injury.
4. When operating a power tool outside, use an outdoor extension cord marked "W-A" or "W". These
extension cords are rated for outdoor use, and reduce the risk of electric shock.
5. CAUTION! Never run the generator in an enclosed garage or any other type of enclosed
structure without a proper, leak-free ventilation shaft. Carbon Monoxide, an odorless, colorless
deadly gas may accumulate and cause serious injury or death.
6. Do not use the generator if the Power Switch does not turn it on or off. Any generator that cannot be
controlled with the Power Switch is dangerous and must be repaired.
7. Make sure the Power Switch is in its "OFF" position and disconnect the spark plug wire before
making any adjustments, changing accessories, or storing the generator. Such preventive safety
measures reduce the risk of starting the generator accidentally.
8. Maintain generators with care. Do not use a damaged generator. Tag damaged generators "Do not use"
until repaired.
9. Only qualified repair personnel should perform generator service. Service or maintenance
performed by unqualified personnel could result in injury.
10. Use the right generator for the job. Do not attempt to force a small generator to do the work of a
larger industrial generator. There are certain applications for which this generator was designed. It
will do the job better and more safely at the rate for which it was intended. Do not modify this
generator, and do not use this generator for a purpose for which it was not intended.
INSTALLATION PROCEDURES
1. WARNING! Before using the Generator, read and understand the Engine manufacturer's Operation,
Maintenance, and Parts manual. Also, read the safety precautions in this manual. These should
always be followed to reduce the risk of personal injury and damage to equipment.
2. Ensure installation meets all applicable safety, and local and national electrical codes. Have installation
performed by a qualified, licensed electrician and building contractor.
3. If the generator is installed indoors, exhaust fumes must be piped out of the building using leak-free, heat-
resistant piping. Pipes and silencer should not be made of any flammable materials, nor should they be
installed near any flammable materials. Generator exhaust fumes must be within legal limits, including all
local codes and ordinances.
4. If the generator is installed outdoors, it must be weatherproofed and should be soundproofed. It should not
be run outdoors without protection to the Generator and wiring conduit.
5. Never lift the Generator using the engine or alternator lifting lugs. Connect lifting equipment to the Frame of
the Generator. Before lifting the Generator, ensure the lift rigging and supporting structure are in good
condition, and are rated to lift such a load.
6. The supporting floor/ground surface should be level, and strong enough to safely hold the weight of the
Generator. If the floor/ground surface is not level, strong cross members should be placed under the full
length of the Generator Frame at its low side.
7. For trailer installation, the Generator should be mounted on the center point of the trailer, over the
wheels.
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FIRE AND EXPLOSION PRECAUTIONS:
1. Gasoline fuel and fumes are flammable, and potentially explosive. Use proper fuel storage and
handling procedures. Always have multiple ABC class fire extinguishers nearby.
2. Keep the Generator and surrounding area clean at all times.
3. When spills of fuel or oil occur, they must be cleaned up immediately. Dispose of fluids and
cleaning materials as per any local, state, or federal codes and regulations. Store oil rags in a
covered metal container.
4. Never store fuel or other flammable materials near the Generator.
5. Do not smoke, or allow sparks, flames or other sources of ignition around the Engine and Fuel
Tank. Fuel vapors are explosive.
6. Do not refill the Fuel Tank while the Engine is running or while the Engine is still hot. Do not operate
the Generator with known leaks in the fuel system.
7. Excessive buildup of unburned fuel gases in the exhaust system can create a potentially explosive
condition. This buildup can occur after repeated failed start attempts, valve testing, or hot engine
shutdown. If this occurs, open exhaust system drain plugs, if equipped, and allow the gases to
dissipate before attempting to restart the Generator.
8. Use only engine manufacturer recommended fuel and oil.
CHEMICAL PRECAUTIONS:
1. Avoid contact with fuel, oil, and exhaust fumes.
2. Avoid body contact with fuels, oils, and lubricants used in the Generator. If swallowed, seek
medical treatment immediately. Do not induce vomiting if fuel is swallowed. For skin contact,
immediately wash with soap and water. For eye contact, immediately flush eyes with clean water.
-3-

ELECTRICAL PRECAUTIONS:
1. All connections and conduits from the Generator to the load must only be installed in compliance with all
relevant local, state, and federal electrical codes and standards, and other regulations where applicable.
2. The Generator must be properly earth-grounded by a licensed electrician in accordance with all
relevant electrical codes and standards before operation.
3. If an extension cord is used to provide power to a tool, make sure to use only UL® approved cords
having the correct gauge and length. (See Figure A.)
FIGURE A REQUIRED MINIMUM EXTENSION CORD GAUGE -
120 VOLT
AMPS (At
Full Load) EXTENSION CORD LENGTH
0-25
Feet 25-50 Feet 50-100 Feet 100-150 Feet 150-200 Feet
0-5 16 16 16 12 12
5.1 -8 16 16 14 10 -
8.1 -12 14 14 12 --
12.1 -15 12 12 10 --
15.1 -20 10 10 10 --
4. Do not attempt to connect or disconnect load connections while standing in water, or on wet or
soggy ground.
5. Do not touch electrically energized parts of the Generator and interconnecting cables or conductors
with any part of the body, or with any non-insulated conductive object.
6. Connect the generator only to a load or electrical system that is compatible with the electrical
characteristics and rated capacities of the Generator.
7. Keep all electrical equipment clean and dry. Replace any wiring where the insulation is racked, cut,
abraded or otherwise degraded. Replace terminals that are worn, discolored, or corroded. Keep
terminals clean and tight.
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GROUNDING THE GENERATOR
NOTE: It is recommended that only a trained and licensed electrician perform this procedure.
(Generators without a permanent installation may not need to be grounded, check local codes and
ordinances. Local codes and ordinances may vary. Always check local codes and install in
accordance with all laws).
Connect a #6 AWG grounding wire (not included) from the Generator Grounding Lug
(shown at left) on the front of the generator to a grounding rod (not included) that has
been driven at least 24 inches deep into the earth. The grounding rod must be an
earth-driven copper or brass rod (electrode), which can adequately ground the
Generator.
OPERATING INSTRUCTIONS
PRE-START CHECKS:
NOTE: During operation, it may be necessary to refer to the Engine manufacturer's operation,
Maintenance, and Parts manual (included) for detailed information about starting, running, and
stopping the Engine.
1. Check to make sure the Engine's "ON/OFF" Switch is in its
"OFF" position.
2. Unscrew and remove the Engine's Oil Fill Cap located at the
bottom of the Engine Crankcase. Check to make sure the oil
level is even with the top of the Oil Fill Hole. If necessary,
add oil until its level is even with the Oil Fill Hole. Then,
screw the Oil Fill Cap back into the Oil Fill Hole.
NOTE: Check with the Engine manufacturer's manual for the
proper type of engine oil required for use.
3. Remove Fuel Tank Cap, and fill the Fuel Tank with unleaded
gasoline. Then, replace the Fuel Tank Cap.
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TO START THE GENERATOR:
1. Turn the Fuel Valve to its "OPEN" position.
2. Turn the Engine's "ON/OFF" Switch to its "ON"
position.
3. Move the Engine’s Fuel Choke Lever to its
"START" position (in the direction of the arrow
above it).DC output is protected by an inboard
10 amp fuse.
4. Grasp the Handle of the Engine's Starter Pulley
and rapidly pull the Starter Pulley to start the
Engine. NOTE: It may take one or more pulls on
the Starter Pulley to start the Engine.
Allow the Engine to run for several seconds, and
then move the Engine's Fuel Choke all the way to
the left to its "RUN" position.
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POWERING TOOLS AND EQUIPMENT:
1. Prior to powering tools and equipment, make
sure the Generator's rated voltage, wattage, and
amperage capacity (120V/25 AMP) is adequate to
supply all electrical loads that the unit will power.
If powering exceeds the Generator's capacity, it
may be necessary to group one or more of the
tools and/or equipment for connection to a separate
Generator.
2. Once the Generator is running, simplyconnect the
Power Cords of 120 volt powered tools and
equipment into the 120 volt Dual Outlets.
3. DC voltage 12V
DC output terminal (red) "+"
DC output terminal (black) "-"
4. Should an overload occur the breaker will "trip",
interrupting the circuit (disconnecting power to the
connected tools and/or equipment). You will notice
that the switch labeled "circuit breaker" has been
switched to the OFF position. Reset the circuit
breaker by flipping the breaker switch to the ON
position and continue powering the remaining tools
and equipment.
5. When finished using the Generator, turn the
ON/OFF Switch (46) to its "OFF" position to stop
the Generator.
After the Engine and Generator have completely
cooled, disconnect the spark plug wire and store the
Generator in a safe, clean, dry location (if not already
installed in one).
INSPECTION, MAINTENANCE, AND CLEANING
NOTE: Preventative maintenance procedures and frequency will vary depending on the amount
of Generator use. Refer to the Engine manufacturer's Operation, Maintenance, and Parts manual
for detailed information regarding maintenance of the Engine.
CAUTION! Always make sure the ON/OFF Switch Is In Its OFF position. Disconnect the
spark plugwire from the engine. And allow sufficient time for the Engine andGenerator to
completely cool before performing any Inspection, maintenance, or cleaning.
BEFORE EACH USE, inspect the general condition of the Generator. Check for loose screws,
misalignment or binding of moving parts, cracked or broken parts, damaged electrical wiring, and
any other condition that may affect its safe operation. If abnormal noise or vibration occurs, have
the problem corrected before further use. Do not use damaged equipment. BEFORE EACH
USE, check to make sure the Engine's oil level is adequate. Refer to the Engine manufacturer's
Operation, Maintenance, and Parts Manual for specific information.