Dyna DP4500 User manual

OWNERS MANUAL
, MODELS DP4500 DP4500E DP6000E
CORPORATION
225 South Cardova Avenue
Le Center, Minnesota
56057

READ AND UNDERSTAND ALL INSTRUCTIONSIN
THE MANUAL BEFORE STARTING AND OPERATING
THE GENERATOR SET.
USING THIS MANUAL
Congratulations on your choice of an ENERGX gener-
ator set. You have selected a high-quality, precision-
engineered generator set designed and tested to give
you years of satisfactory portable service.
To get the best performance from your new engine
generator set, it is important that you carefully readand
follow the operating instruction in this manual.
Should you experience a problem please follow the
"Things To Check" near the end of this manual. The
warranty inthe back of this manual describes what you
can expect from ENERGX should you need service
assistance in the future.
There is noother expresswarranty.To the extent permitted
by law, any and all warranties, including those of merchan.
tability and fitness for a particular purpose, are limited to
one year from date of shipment, and liability for incidental
or consequentialdamages or expenses is excluded. Some
states do not allow limitations on the durationof an implied
warranty, and some states do not allow the exclusion or
limitation of incidental or consequential damages, so the
above limitationor exclusion may not apply to you. This war.
ranty gives you specific legal rights; you may have other
rights which vary from state to state.
ENEROX does not warrant engines or certain other com-
ponent parts of the product since such items are warranted
by their manufacturers.
ENERGX does no1warrant alterationsor repairswhich were
not made by the
ENEROX factory or a factory-authorized
service station and which affect the stability or reliability
of the product.
TABLE OF CONTENTS
PAGE
INTRO ...................................... I
ENERGX WARRANTY ......................... I
GUIDE TO PRODUCT SAFETY ................ A1 L
BASIC INFORMATION ....................... B1
Specifications ........................... B1
Intended Uses ........................... B1
Restricted Uses ......................... B1
Unit Capabilities. ........................ B1
Where is Everything Located .............. B2
PREPARING THE UNIT ...................... C1
Unpacking the unit ...................... C1
Oil Requirements ........................ C2
Fuel Requirements
....................... C2
Battery Installation.
...................... C2
......................... BASIC OPERATION Dl
Initial Start Up .......................... Dl
Starting and Stopping .................... Dl
Connecting the Loads .................... D2
INSTALLATION
............................. El
.................................
Wiring El
OPERATOR MAINTENANCE
.................. F1
Engine Care ............................ F1
Generator Care ........................... F1
Unit Cleaning ..... : ..................... F2
Things to Check before you call for Service
. F2
Wiring Diagram.
......................... F2
PROPER USE AND INSTALLATION
You must be sure your new engine generator set is:
* Properly serviced before starting
* Operated in a well ventilated area
*
Exhaust gases are dispersed safely
* Wired by a qualified electrician
* Operated only for its designed purposes
*
Used only by operators who understand its
operation
* Properly maintained
COPY YOUR MODEL AND SERIAL
NUMBER HERE
Noother ENERGX generator hasthe same serial num-
ber as yours. It is important that you record the number
and other vital information here, if you should ever need
to contact us on this unit it will help us to respond to
your needs faster.
1
1
................
MODEL
J
.......... SERIAL NBR..
DATE PURCHASED ...... -
............... DEALER.

GUIDE TO PRODUCT SAFETY
This engine generator set has been designed and
manufactured to insure your personal safety. Improper
- use can result in potential deadly hazards; from elec-
trical shock, exhaust gas asphyxiation, or fire. Please
read all safety instructionscarefully before installation
or use. Keep these instructions handy for future refer-
ence. Take special note and follow all warnings on the
unit and in the manuals.
CAUTION: ~ossibleDamage to Equip-
ment.CAUTION notes indicateany con-
dition or practice, which if not strictly
observed or remedied, could result in
damage or destruction of the equip-
ment.
WARNING: Personal Danger. WARN-
ING notes indicate any condition or
practice, which if not strictly observed,
that could result in personal injury or
possible loss of life.
a
1. ELECTRIC SHOCK - The output voltage pres-
ent in this equipment can cause a fatal electric
shock. This equipment must be operated by a
responsible person.
A. Do not allow anyone to operate the genera-
tor without proper instruction.
-
B. Guard against electric shock.
C. Avoid contact with live terminals or receptacles.
D. Use extreme care if operating this unit in rain or
snow.
E. Use only three-pronggrounded receptacles and
extension cords.
F. Be sure the unit is properly grounded to an ex-
ternal ground rod driven into the earth.
FIREHAZARD - Gasolineand other fuels always pre-
sent a hazard of possible explosion andlor fire.
A. Do not refuel when the engine is running or hot.
Allow the engine to cool at least two minutes
before refueling.
B. Keep fuel containers out of reach of children.
C. Do not smoke or use open flame near the
generator set or fuel tank.
D. Keepa fire-extinguishernearby and know its pro-
per use. Fire extinguishers rated ABC by NFPA
are appropriate.
E. Store fuel only in an approvedcontainer, and on-
ly in a well-ventilated area.
3. DEADLY EXHAUST GAS - Exhaust fumes from any
gasoline engine contain carbon monoxide, an odor-
less and deadly gas that must be mixed with fresh
air.
A. Operate only in well ventilated areas.
B. Never operate indoors without a sealed exhaust
system to the outside.
C.Never operate the unit in such a way as to allow
exhaust gases to seep back intoclosed rooms(i.e.
through windows, walls or floors).
4. NOISE HAZARD - Excessive noise is not only
tiring, but continual exposure can lead to loss of
hearing.
A.Use hearing protection equipment when working
around this equipment for long periods of time.
B. Keep your neighbors in mind when permanently
installing this equipment.
5. CLEANLINESS - Keepthe generator and surrounding
area clean.
A.Remove all grease, ice, snow or materials that
create slippery conditions around the unit.
B .Remove any rags or other material that could
create potential fire hazards.
C.Carefully wipe up any gas or oil spills before start-
ing the unit.
D.Never allow leaves or other flammable material to
build up around the engine exhaust area.
6. SERVICING EQUIPMENT - All service, including the
installation or replacement of service parts, should
be performed only by a qualified technician.
A.Use only factory approved repair parts.
B .Do not work on this equipment when fatigued.
C.Never remove the protective guards, cover or
receptacle panels while the engine is running.
D.Use extreme caution when working on electrical
components. Highoutput voltages from this equip-
ment can cause serious injury or death.
E. When servicing this unit always avoid hot mufflers,
exhaust manifolds, and engine parts. They all can
cause severe burns instantly.
F. Installing andwiring a home-standbygenerator is
not a "do it yourself" project. Consult a qualified,
licensed electrician or contractor. The installation
must comply with all national, state, and local
codes.

SPECIFICATIONS
*Cranking performance at 80 Degree. F. 190 CCA
MODEL
Generator
Surge Watts
Continuous Watts
Volts
AMPs
Receptacles
NEMA 5-15 (120V)
NEMA 6-20 (240V)
Engine
Size
Model
TYpe
Fuel Capacity
Fuel Consumption
full load
Starting System
Stop System
Muffler
Complete Unit
Weight (dry)
Dimensions LxWxH
Owner Must Provide
Fuel
Oil Type
Oil Capacity
Battery Type
INTENDED USES
1. These engine generator sets have been designed
primarily for portable use. Receptacles are provided
in the "end cover" of the generator for you to plug
in your loads (portable appliance and tool). These
units are dual wound generators, therefor the 120
Volt loads must beequally split with 112 of the rated
capacity available on each of the two 120 Volt cir-
cuits. See unit capabilities for further explanation.
2. These units require large quantities of fresh air for
coolingof both the engine and the generator. Fresh
air is drawn from both the engine end and the gen-
erator end and isexhausted at the center of the unit.
For safety, long life and adequate performance,
these units should never be run in small compart-
ments without positive fresh air flow.
DP4500 DP4500E DP6000E
4500 4500 6500
4000 4000 6000
1201240 1201240 1201240
16.7 16.7 22.9
4 4 4
1 1 1
8HP 8HP 11HP
190412 190417 252417
See Engine Shroud Above
Recoil for Type
1 Gal 1 GAL 11/2 Gal
.87glhr .87glhr 1.09glhr
Recoil ----RecoillElectric----
------MechanicalGround------
--------------- Low Tone ----------------
120 LBS 120 LBS 199 LBS
24x19~2024x19~2028x22~20
--------- Unleaded Gasoline-------
----10W-30SF, SE, SD, SC----
See engine manual
for additional info
---2 3h pints------ 3 pints
nla U1 Ul*
RESTRICTED USES
1. DO NOT remove from the cradle assembly. Remov-
al of the generator from the cradle assembly may
cause excessivevibration and damage tothe engine
generator set.
2. DO NOT install and operate these portable gener-
ators insmall compartment.(i.e. generator compart-
ment of vehicles, motor homes or travel trailers)
These compartmentswill not allow enough free flow
fresh air to reach the engine generator set for cool-
ingand will allow the unitto overheatdamaging both
the engine and the generator. Small compartments
will also develop hot spots where there isvery little
air flow and may cause a fire.
L
3. DO NOT attempt to operate this unit at 50 cycles.
These units are designed and governed to operate
at 60 Cycles only. Special units are available for 50
cycle operation.
UNIT CAPABILITIES
1. Generator Connections - The diagram below repre-
sents atypical 4000 watt generator. Up to2000 watts
at 120 volts (16.7 Amps) can be taken from the
generator at receptacle A and up to 2000 watts at
120volts from receptacle B, or 4000 watts at 240 volt
from receptacle C. MIXED COMBINATION of 120
and 240 volt loads upto 4000 watts are also possi-
ble. CAUTION MUST BE EXERCISEDTO PREVENT
OVERLOADING EITHER OF THE 120 VOLT CIR-
CUITS(A OR B). Check the appliance or tool name-
platesfor the current and voltage to insure compat-
ibility. Rememberthat power taken from receptacle
C reduces the power available at both A and B. Any
remaining 120 volt loads should be equally divided
between A and B. Failureto split the loadwill cause
permanentdamageto brushesandlor armature.This
type of damage constitutes abuse and will not be
warranted.
SLIP RINGS BRUSHES
ARMATURE
WINDINGS
I
240 VOLTS
-. -. -. -. -. -. - -
/. \ I V
Figure B-1
Typical 4000 watt generator
The following currents (measuredinamps)are pro-
duced at 120volts and 240 volts for typical wattages
shown.
AMPS AT 120 VOLT 120 VOLT 240 VOLTS
MODEL RECEPTACLE ID
A B C
DP4500 16.7 16.7 16.7
DP4500E 16.7 16.7 16.7
DP6000E 22.9 22.9 22.9
V
Table B-1

SPECIFICATIONS (continued)
2. Starting Electric Motors - Electric motors require
much more current (amps)to start them than to run
L
them. Some motors, particularlylow costsplit-phase
motors arevery hard tostart and require5to 7 times
as much current to start them as to run them. Ca-
pacitor motors are easier to start and usually require
2 to 4 time as much current to start then as to run
them. Repulsion Inductionmotorsare the easiest to
start and usually require
I1/z to 2% time as much
to start them as to run them.
Most fractional horsepower motors take about the
same amount of current to run them whether they
are of Repulsion-Induction (RI), Capacitor (Cap), or
Split-Phase(SP)type. The chart below shows the ap-
proximate current required to start and run various
types of sizes of 120 volt 60 cycle electric motors
under average load conditions.
RUNNING STARTING AMPS
HP AMPS SP CAP R I
116 3.2 16TO22 6TO13 5T0 8
114 4.5 22TO32 9TO18 7TO12
113 5.2 26 TO 35 10 TO 21
8 TO 17
112
7.2
NOT MADE 14 TO 29 11 TO 18
1 13.0 NOT MADE 26 TO 52 20 TO 33
The figures given above are for average load such
as a blower or fan. If the electric motor isconnected
to a hard starting load such as an air compressor,
it will require morestarting current. If it isconnected
to a light load, or no load such as a power saw, it
will require less starting current. The exact require-
ment will also vary with the brand or design of the
motor.
For 240 volt motor, the "running" current is half
as much as shown for the 120 volt motors of the
same size. Some dual voltage 1201240 volt motors
are difficult to start on 240 volts when driven by
enginelgenerators and can be started more easily
when connected to operate on 120volts. This is par-
ticularly true of "capacitor start-induction run"
motors. Sometimes a 240 volt motor which cannot
be started on the 240 volt circuit of a 1201240 volt
generator can be started on a 120 volt circuit and
then quickly switched to the 240 volt circuit after is
is started. This can be done in applications where
the motor is manuallycontrolledand is started under
" no load" conditions.
A self-excited generator responds differently to
severe overloading than a transformer connected to
a power line. To illustrate, suppose that a 240 volt
5 H.P. "capacitor start-InductionRun" motor iscon-
nected to a small transformer that would not be able
to supply enough power to bring the motor up to
operating speed.lt would bevery severelyoverloaded
and probably would burn out in a short time. The
motor might also be damaged. When this motor is
connected to a self-excited4000 watt generator, its
output voltage dropstopractically zero.Thus, there
is virtually no load on the generator or the engine,
and no harm isdone to it either. Underthese condi-
tions the motor may revolve a few times when it is
first turned on, and then stop.
On the other hand,suppose an electric motor that
requiresjust a littlemore output then the generator
can produce is connected to it. It will run out will not
reach a highenough speed for the centrifugal switch
to disconnect the starting winding. The generator
output voltage, instead of being 120,may drop to 70
or 80 volts. RUNNING THE GENERATOR UNDER
THESE CONDITIONS MAY RESULT IN BURNING
OUT THE GENERATOR ARMATURE AS WELL AS
THE MOTOR WINDING.
Because the heavy surge of current required for
starting motors is required for only an instant, the
generator will not be damaged if it can bring the
motor up to speed in a few seconds of time. If dif-
ficulty is experienced in starting motors, turn all
other electrical loads off and if possible reduce the
load on the electric motor.
3. Motor Starting Capacity - listed below you will find
the motor starting capability of your engine gener-
ator set.
Generator Motor Size
Model (code "G" capacitor start)
D
P4500
DP4500E
DP6000E
Trying to start a larger motor or a higher code (ie.
J or K) motor may result in damage to both the
generator and the electric motor especially 120volt
motors.
WHERE IS EVERYTHING LOCATED
1. Start Switch (DP4500E & DP6000E).
2. Battery Negative Connection (DP4500E & DP6000E).
3. Battery Positive Connection (DP4500E & DP6000E).
4. Oil Drain.
5. Battery Charger Connection (DP4500E
& DP6000E).
6. Fuel Shut-off Valve.

SPECIFICATIONS (continued)
L
\ I B
0 @ @
L
1. Fuel filter (DP6000E)
9. Needle valve (load adjustment)
2. Extended oil fill and dipstick (DP6000E) 10. Oil drain plug
3. Fuel fill 11. Oil fill (DP4500 and DP4500E)
4. Spark plug 12. Ground lug
5. Grounding Clip for stopping. 13. 120 volt duplex (reference receptacle 'A')*
6. Air filter 14. 240 volt receptacle (reference receptacle 'C')*
7. Rewind start grip 15. 120 volt duplex (reference receptacle 'B')*
8. Choke
*See Table B-1 for amperage available at each receptacle.
PREPARATION INSTRUCTIONS
THIS UNIT HAS BEEN SHIPPED WITH-
[-] OUT OIL. Failureto maintainthe engine
oil at the proper level will result in
If damage is noted, notify the transportation com-
pany immediately; request proper procedures for fil-
ing a "concealed damage" claim.Title to the equip-
ment and responsibility for filing claim rests with you
when a generator is sent F.O.B. shipping point. Only
UNPACKING - When you unpack you new ENGINE you the customer, can legally file a claim.
GENERATOR be sure to removed all the information 2. Before proceedingwith the preparation of your new
sheets and manuals from the carton. Also be sure that engine generator set for operation, take a few
any accessories (suchas battery rack)orderedwith the minutes to insure that the unit you have received is
generators have also been received. the correct modeland reviewthe specification pages
1. This power plant was in good order when shipped. inthis manualto insurethat this unit meets your job
-
Inspect the power plant promptly after receiving it. requirements.

PREPARATION INSTRUCTIONS
3. After removingthe engine generator from the carton
locate and remove the shipping strap attached the
-
generator shock mount. See the tag attached for re-
moval instructions. FigC-1shows the location of the
tag and the shipping strap.
SHIPPING : GENERATOR
STRAP MOUNTING
Fig C-1 BRACKET
UNIT PREPARATION - Before your engine generator
was shipped from our factory it was fully checked for
performance. The generator was load tested to its full
capacity, and the voltage and frequency were careful-
ly checked and adjusted.
1. Lubrication
- Before startingtheengine, fill the crank-
case to the proper level with a good quality oil. The
recommendedgradeof oil and quantity of oil required
L
is listed in boththe engine operators manual and in
the specifications section (page B1)of this manual.
The importanceof using the correct oil, and keep-
ing the crankcase full cannot be overemphasized.
Enginefailures resulting from inadequate or improper
lubricant are considered abuse and are not covered
by Energx or the engine manufacturer's warranty.
2.Gasoline fuel - When using gasoline always use a
good grade of unleaded fuel. Leaded gasoline may
be use if unleadedisnot available. Gasolinecontain-
ing alcohol, such as gasohol is not recommended.
However if gasoline with alcohol is used, it must not
contain more than 10 percent Ethanol and must be
removed from the engine during storage. DO NOT use
gasoline containing methanol. Always insure that the
fuel is clean and free of all impurities.
FIRE DANGER
Gasoline and its fumes are VERY ex-
plosive when proper precautions are
not taken.
a
Never usegasoline that has been stored for an ex-
tended period of time as the fuel will lose it volatile
properties and you will be left with only the varnish
residue. This varnish like substance will clogthe car-
buretor and will not burn properly. The use of a fuel
additive, such a STA-BIL,or an equivalent, will mini-
mizethe formation of fuel gum deposits. If a unit has
L
been out of operation for an extended period of time
itsbesttodrain oldfuel from the engine and replace
with fresh fuel before attempting to start.
3. Battery Installationand Care - All electric start engine
generator sets are shipped with a battery rack kitfor
customer installation. This kit consists of a battery
rack, battery tie down, battery cables and instruction
sheet for installation.After installingthe battery rack,
file the instruction sheet in the back of this manual
for future reference.
If you intend touse the power plant's electric start
system, you will need to purchase and install a bat-
tery tooperate it. Unitsequippedwith a recoil or rope
start will operate satisfactorily without a battery. A
twelve volt battery group U1 rated at 190 CCA or
larger is recommended for this electric start engine
generator set. Follow the battery manufacturers rec-
ommendations for servicing and charging prior to
use.Connect the battery tothe electric start systems
using the cables provided.
These electric start engines are NEGA-
TIVE GROUND. Use extreme caution
/ when connecting the battery to connect
the NEGATIVE battery terminal to
GROUND.
For your safety always connect the positive bat-
tery terminal to the ''batS"terminal first. Then con-
nect the negativebattery terminal tothe "bat
- " ter-
minal. Makesureall connections are clean and tight.
Reverse the sequence when disconnecting, discon-
nect the negative cable first. These engine produce
enough direct current to keep batteries charged
under normal operating conditions, but they are not
intended to be used as battery charger.
PERSONNEL DANGER
Lead acid batteries produce explosive
hydrogen gas when charging. Keep
sparks, flames, and burning cigarettes
A
away from the battery. Ventilate the
area when charging or using the battery
inan enclosed space. Lead acid batter-
ies contain sulfuric acid, which causes
severe burns. If acid contacts eyes, skin
or clothing, flush well with water. For
contact with eyes, get immediate med-
ical attention.
Generators, when installed for standby purposes,
must be run periodically (at least once a month) for
a minimum of 30 minutes to keep the battery
charged. A trickle charger can also be use to keep
the battery fully charged. The trickle charger should
be a taper charger (usually
2 amps max). With an
taper style charge as the battery reaches ismaximum
charge capacity, the charger current tapers to near
zero and maintainsthe battery ina fully charged con-
dition. Manual type charges with fixed or constant
charging rates are not recommended,since the bat-
tery will be overcharge, permanently damaging the
battery.

BASIC OPERATIQN
INITIAL START UP - Usethe following checklist to verify
the correct preparation of your engine generator before
starting.
On All Units Check:
1. Engine oil, fill as required with correct grade and
quantity.
2. Check fuel level and fill as required with clean fresh
fuel.
3. Visually check unit for loose parts.
4. Battery connections clean and tight on the electric
start units.
5. Proper battery voltage and CCA rating.
6. Battery fully charged.
STARTING AND STOPPING - The throttle control on
these generators is preset and lockedto operate at 3600
RPM (nominal)with no load speed set at 3690 RPM. On-
ly a trained service technician,should be allowed toad-
just this speed setting. See "Operating Speed" section
for additional information.
1. Manual starting - Refertothe engine manual for addi-
tional starting, operating, and stopping instructions.
A. Turn on the fuel supply.
B. Move the choke to the full on position. A warm
engine will require lesschokingthan a cold engine.
C. Grasp starter grip and pull slowly until starter
engages, then pull cord rapidly to overcome com-
pression, prevent kickback and start the engine.
Repeat if necessary.
D.When the engine starts, open the choke gradually.
E. The engine should promptly come up to operating
speed.
the engine when it iswarm. Avoid over-
2. Electric Starting - If engine is cold and stiff or if bat-
tery is not fully charged, starting can be made easier
by slowly hand cranking the engine through the com-
pression stroke before pushing the starter button.
This permits the starter to gain momentum before the
heavy load of the compression stroke occurs,
minimizingdrain on the battery and ensuring starting
under suchadverse conditions. Keepthe battery ful-
ly charged, especially during cold weather operation
A. Turn on the fuel supply.
B.Move the choke to the full on position. A warm
engine will require lesschoking than acoldengine.
C.Depress the starter switch. The best starter life is
provided by using short starting cycles of several
seconds. Do not operate the starter more than 15
seconds each minute.
D. When the engine starts, open the choke gradually.
E .Theengine should promptly come uptooperatin!
speed. -
3. Starting Hints
A. Cold weather
1. Be sure to use the proper oil for the temperature
expected.
2 .A warm battery has muchmore starting capaci-
ty than a cold battery.
3.Use fresh winter grade fuel. Winter grade
gasoline has higher volatility to improve start-
ing. Do not use gasoline left over from summer.
4. A slightly richer fuel mixture will usually improve
cold starting.
B. Hot weather
1. Be sure to use the proper oil for the tempera-
ture expected.
2. Use only summer blended gasoline. Using
gasoline left over from winter may cause the
unit tovapor lock, because of the higher volatili-
ty of the winter fuel.
3. DO not over choke the unit.
4. Stopping and Storage
A. For gasoline units depress the stop switch. On
units fueled with NGlLPturn off the fuel to stop
the unit.
B.Close the fuel shut-off value. Always shut the
fuel off when ever the engine is stopped to pre-
vent fuel leakage from carburetor.
-.-
C.Before extended storage (over 30 days) certain
precautions must be take to ensure the fuel
doesn't deteriorate and clog the fuel system.
Note: The use of a fuel additive, such as STA-
BIL, or an equivalent, will minimize the forma-
tion of fuel gum deposits during storage. Such
an additive rnay be added to gasoline in the fuel
tank of the engine, or to gasoline in a storage
container.
1. Remove the remaining fuel from the fuel
tank.
2. Start the engine and allow it to run until all
the fuel in the carburetor and the fuel lines
has been used up and the engine stops.
3. While the engine is warm drain oil and refill
with fresh oil.
4. Remove the spark plug, pour approximately
112 ounce (15cc)of engine oil into the cylinder
and crank slowly to distribute oil. Replace
spark plug.
5. Clean dirt and chaff from cylinder, cylinder
head fins, blower housing, rotatingscreen and
mufflerareas.
f. Store in a clean anddry area.

BASIC 0 PERATI0 N (continued)
OPERATINGSPEED - The engine-generatormust be run
?t the correct speed inorderto producethe properelec-
, .rical voltage and frequency.
The output voltage should be checked
A
to insurethe generator isworking prop-
erly prior to connecting a load to the
generator. Failuretodo so could result
in damage to equipment plugged into
the unit and possible injury to the indi-
vidual.
1. All engines have a tendency to slow down when a
load is applied.The governoron the engine isdesigned
to holdthe speed nearly constant.When the electrical
load connected to the generator is increased, the
engine is more heavily loaded, and as a result the
speed drops slightly. This slight decrease in speed,
together with the voltage drop within the generator
itself, results in aslightly lowervoltage when the gen-
erator is loaded to its full capacity than when run-
ning no load.The slight variation inspeed also affects
the frequency of the output current. This frequency
variation has no appreciableeffect inthe operation of
motors, lights and most appliances. However, elec-
tronic equipment and clocks will be affected ifcorrect
RPM is not maintained. See load vs. Output chart.
Although individual units and models may vary
slightly, the normal voltage and frequency of the
engine-generatorsdescribed inthis book are approx-
-
imately as follows, under varying loads:
LOAD vs. OUTPUT
Generator Frequency Generator voltage
Load Speed (Hz) 120V 240V
Amlied* (RPM) Rec~t. Rec~t.
None 3690 61.5 129V 258V
Half 3600 60.0 120V 240V
Full 3510 58.5 115V 230V
*Portion of plant's rated output current.
2. The speed of the engine was carefully adjusted at
the factory so that the generator producesthe prop-
er voltage and frequency. For normal usage, the
speed setting should not be changed. If the generator
is being run continuously on a very light load, it is
often advisable to lower the operating speed slight-
ly. Whenever making any speed adjustments check
the unit with a voltmeter or tachometer and be sure
the speed is neither too high nor too low.
Unlessthe engine isequipped with the automatic
conserver assembly the engine must be run at the
specified speed at all times. Lowervoltagemay dam-
age both the generator and any load connecting to
it. Running the engine at excessively high speeds
results in high voltage, which may significantly
shorten the life of appliances being used.
3. Output voltage should be checked periodically to
ensure continued proper operation of the gener-
ating plant and appliances. If the generator is not
equippedwith a voltmeter, it can be checked with
a portable meter. Frequencycan be checked by us-
ing an electric clock with a sweep second hand.
Timed against a wrist watch or a stop watch the
clock should be correct within
+ 1 - 2 seconds.
CONNECTING THE LOADS
1 .ApplyingThe Load - Allow theengine towarm up for
two or three minutes before applying any load. This
will allow the engine to reach normaloperatingtemp-
erature and oil to circulate throughout the engine.A
short warm-up time will permit the engine to work
more efficiently when the load is applied and will
reduce the wear in the engine, extending its life.
A. Receptacles have been provided on the control
panel to connect the loads to. The loads should
be applied gradually. If a large motor is being
started or multiple motors are being started, they
should be started individually and the largest
should be started first.
I] erator and receptaclenameplaterating.
Overloading may cause damageto the
B. Most electric tools and appliances will have the
voltage and amperage requirements on their in-
dividual nameplates. When in doubt consult the
manufactureror a local electrician.The nameplate
amperage rating for electric motors can be mis-
leading,see Starting Electric Motors insection
B.
C. These engine generator sets are inherently self
regulating based on engine speed. The engine
governor will automatically adjust itself to the
load. No harm to the generator will result if it is
run with no load connected.
D. Proper utilization of the receptacleslocatedon the
control panel is necessary to prevent damage to
either the receptacles or the generator. The gen-
erator is a limited source of electrical power,there-
fore pay special attention to the receptacle and
generator ratings.The nameplate ratingcan be ob-
tained through a combination of receptacles or a
single receptacle as long as the receptacle amp-
erage rating is notexceeded. Boththe
120 and 240
volt receptacles can be utilized at the same time.
See section
B for proper load separation.
2. Grounding - All units must be grounded.
A. Drivea 314 or 1" copper pipeor rod into the ground
close to the engine-generatorset. The pipe must
penetrate moist earth. Connect an approved
ground clamp, to the pipe. Run a no.
10 Awg wire
from clamp to the generatorground lugor the bat-
tery negative terminal. Do not connect to a water
pipe or to a ground used by a radio system.

WIRING INSTALLATION
WIRING - Wiring this unit intda homeor business elec-
trical system is NOT A SIMPLE DO-IT-YOURSELFJOB.
For your safety all wiring must be done by a qualified
electrician and must conform to the National Electric
Code and comply with all state and local codes and
regulations. Check with local authorities before
proceeding.
The engine-generatormodelscovered inthis manual B. Connect generator to house wiring circuits only
were designed for portable use.The manufacturerdoes through a fully isolated manual transfer switch.
The
not recommend installing or operating this generator transfer switch prevents damage to the generato,,
indoors. The unit should be stored in a warm dry loca- and other circuit components if main line power is
tion. Duringa power outage move the unit outdoors to restoredwhile the generator isconnected. Installing
a flat dry location such as a driveway or a sidewalk. atransfer switch also permitsthe use of normal fus-
A fully isolated, double pole double
throw manual transfer switch .must be
installed any time a generator is being
connected to an existing distribution
If your home wiring has not been modified and a
manualtransfer switch installed(Fig. E-1)you will have
to plug your appliances such as furnace blower, sump
pump and other items to be powered directly into the
generator receptacles.
Before beginning the wiring installationrecheck the
ratingof the generator set. Be certain it can handle the
intended load and is compatible with the entrance
voltage, phaseand current ratings.These suggestions
are not intended to constitute recommendations or
guarantee of satisfaction or performance.
A. These engine generatorset are designed for portable
use. Therefore the receptacle on the units are de-
signed to have the 120 and 240 volt portable ap-
pliance and tools pluggeddirectly intothem. Please
note that the 3 wire 240 volt receptacle(s)on these
units are designed to provideonly 240 volt as there
is no neutralconnection inthe receptacle.Split serv-
ice 1201240 volts requires a 4 wire receptacle be in-
stalled. Consult a service center or your dealer for
installation.
To connect one of these units directly an emergency
distribution panel select of the following methods.
1.Wire the distribution panel directly to the gener-
ator output brushholders using afine strand (flex-
ible) motor lead wire.
2.Replace the 240 volt receptacle on the unit with
a 1201240 four wire twist-lock receptacle. (Nema
Spec L14-30R)The use of locking receptacles and
locking plugs will prevent the plug from being ac-
cidentally removedby bumping or vibration, caus-
ing a voltage imbalance or interruption.
When installing the L14-30Rreceptacle in place
of the current 240 volt receptacle the neutral wire
will have to be routed to the 120 volt receptacle
currently in the unit. The "hot" leads (GI and G3)
and the ground are already connected to the ex-
isting receptacle.
ing. See figure El for typical wiring examples.
C.Since most homes today are wired with at least a
100amp service, when a operating the generator to
powerthe homeasecondaryemergencydistribution
panel must be installed.The circuits to be powered
during the outage are move to that panel. Keep in
mind that only have a limited amount of amperage
available. Some breaks will have to shut off to pre-
vent and overloadon the generatorduring initialstart
up of the unit. See the specification page for the
amperage available on your generator.
To Power Llne Master Sw~tch
To
Range
TO
Water
neater
To
Lights
To
Lights
To
Lights
Figure E-1 Typical Generator To House Wiring
Equipment Damage
Failureto properly limit and balancethe
loadappliedtothe generator will cause
the generator to produce low voltage
and may damage theengine generator
set. It may also cause severe damage
tothe loadsconnectedtothe generator
at that time. Improper loading of the
generator set constitutes abuse and
will not be covered by warranty.
--

OPERATOR CARE AND MAINTENANCE
ENGINECARE - If major engine service or repair is re-
quired contact a Authorized engine service center. The
" manufacturer of these engines hasestablished an ex-
cellent world-wideengine service organization. Engine
service isvery likely available from a nearbyauthorized
dealer of distributor. Check the yellow pages of your
local telephone directory under "Engines-Gasoline" for
the closest engine repair center or ask the dealer from
whom you purchased the power.plant.
1. Oil Changes
Change to oil after the first five hours of operation
andevery 50 hoursthereafter under normal operating
conditions. Change engine oil every 25 hours of op-
eration if the engine is operated under heavy load,
or in high ambient temperatures.
A. Remove oil drain plug at base of the engine and
and drain the oil with the engine warm.
B.Replace oil drain plug.
C.Remove oilfiller plugand refill with new oil. Refer
tothe table below for the proper grade of oil base
on your operating temperature.
D.Replace filler plug.
2.Checking the Oil Level. The oil level must always be
check before the engine is started. Take care to re-
move any dirt or debris from around the oil fill plug
before removing. Be sure the oil level is maintained.
FILLTO POINT OF OVERFLOWINGor on units with
the extended oil fill to the "FULL" mark on the
- dipstick.
If the engine generator should fail to start and run,
check to be sure that the low oil protection system
has not been activated by a low oil condition.
3. Servicing Air Cleaners
A.Cartridge Air Cleaner - Remove and cleancartridge
yearly or after every 25 hours, whichever occurs
first. Service moreoften if necessary.Clean by tap-
pinggently on flat surface. If very dirty, replacethe
cartridge using only original equipment parts avail-
able at any engine service center.
Do not us petroleumsolvents,such as kerosene,
to attempt to clean the cartridge. They may cause
deterioration of the cartridge. DO NOT OIL CART-
RIDGE, DO NOT USE PRESSURIZED AIR TO
CLEAN OR DRY CARTRIDGE.
B.Dual Element Air Cleaner - Clean and re-oilfoam
pre-cleaner at three month intervals or every 25
hours, whichever occurs first. Service More often
under dusty conditions.
1. Remove knob and cover.
2. Remove foam pre-cleaner by sliding it off the
paper cartridge.
3. Wash foam pre-cleanerin keroseneor liquidde-
tergent and water
4. Wrap foam pre-cleaner in cloth and squeeze
dry.
5. Saturate foam pre-cleaner in engine oil.
Squeeze to remove excess oil.
6.Install foam pre-cleaner over paper cartridge.
Reassemble cover and screw down tight. Re-
placethe cartridge included with Dual Element
Air Cleaner yearly or every 100 hours. Service
more often if necessary.
4. Spark Plug - Clean and reset gap at .030" every 100
hours of operation. Do not blast clean spark plug.
Clean by scraping or wire brushing and washing with
a commercial solvent. Poor spark will occur if ter-
minal does not fit firmly on spark plug. If this hap-
pens reform the terminal to fit firmly on spark plug
tip.
GENERATOR CARE - Proper care and maintenance of
the generator is necessary to insure a long trouble free
life.
1 . ExercisingThe Generator - The generator should be
operated every three to four weeks. It should be op-
erate for a period of timesufficient to warm the unit
up and to dry out any moisture that has accumulated
in the winds. If left this moisture can cause corro-
sion in the winding and on the slip rings. Frequent
operation of the engine generator set will also insure
that the set is operating properly should it be need
in an emergency.
2. Generator Maintenance - Any major generator ser-
vice including the installation or replacement of
parts should be reformed only by a qualified elec-
trical service man. USE ONLY FACTORYAPPROVED
REPAIR PARTS.
A. Bearing
- The bearing when used in these gener-
ators are heavy duty double sealed ball bearing.
They require no maintenance or lubrication.
B. Brushes - Underordinary circumstances brushes
will operate for long periods without requiring re-
placement. They should be inspected after 1000
hoursof operation andevery 100hours there after.
When operating in dusty conditions check more
often to insure the slip ring and brush contact
area is clean and not wearing excessively.
C. Receptacles
- Quality receptacles have been util-
ized. If a receptacle should becomecrack or other-
wise damaged, replace it. Using damaged or
cracked receptaclescan be dangerous both to the
operator and to the equipment.

OPERATOR CARE AND MAINTENANCE (continued)
CLEANING - Remove dirt and debris with a cloth or
brush. DO NOT use high pressure spray to clean
eitherthe engine or the generator.This highpressure
spray could contaminate the fuel system and the
generator components.
1. Keep the air inlet screen on both the engine and
generator free of any dirt or debris to insure prop-
er cooling.At least yearly removethe blower hous-
ing on the engine and clean the chaff and dirt out
of the engine cooling fins andflywheel. Clean more
often if necessary,failure to keepthese areas clean
may cause overheating and permanent damage to
the unit.
2. Periodically clean mufflerarea to removeall grass,
dirt and combustible debris to prevent a fire.
3. On engine mufflersequippedwith spark arresters,
I Problem Possible Causes I
Won't Start *Check and clean spark plug -
*Check fuel level
*Fuel turned on.
*Dead battery
*Defective start switch.
Voltage too low 'Check for proper engine
speed
*Generator overloaded .
*Defective rectifier
*Defective Armature
*Defective Field Coil
Voltage too high *Engine speed is too high
Generator *Overloaded
overheatina *Insufficient ventilation
THINGS TO CHECK -
Sometimes problems can be easily solved by check-
ing a few basic things. Check below before you call
or take your unit to aservicecenter. Itcouldsave you
time and money.
the spark arrester must be removed every 50 hours
for cleaning and inspection. Replace if damaged. generator
*Defective armature
Defective field coil
Defective Brushes
*Shorted condenser
*Shorted rectifier
"
No output voltage *Short in load (disconnect)
*No residual magnetisim in
Battery not *Defective charging circuit
re-charging on engine
I
excitation circuit power circuit output
excitation
rectifier
+
field armature
coils windings
- 1
-
I capacitor
DP450016000 SCH EMATlCWIRING DIAGRAM
~ -
Printed in U.S.A. (3-88)