Dyna Pro-X DX3200 User manual

OWNERS MANUAL
MODELS DX3200, CSADX3200
225 South Cardova Avenue
Le Center, Minnesota
56057

READ AND UNDERSTANDALL INSTRUCTIONS IN
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-
engineeredgenerator set designed and tested to give
you years of satisfactory portable service.
To get the best performance from your new engine
generatorset, it is importantthat you carefully read and
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 backof this manualdescribeswhat you
can expect from ENERGX should you need service
assistance in the future.
TABLE OF CONTENTS
PAGE
INTRO ...................................... I
ENERGX WARRANTY ......................... I
GUIDE TO PRODUCT SAFETY ................ A1
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 ........................ C1
..................... Fuel Requirements.. C1
...................... Battery Installation. C1
.........................BASIC OPERATION Dl
.......................... Initial Start Up Dl
Starting and Stopping .................... Dl
.................. Connecting the Loads.. D2
.................. OPERATOR MAINTENANCE El
............................ Engine Care El
.......................... Generator Care El
........................... Unit Cleaning El
Things to Check before you call for Service . E2
........................ Wiring Diagram.. E3
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 has the same serial num-
ber as yours. It is important that you recordthe number
and othervital information here, if you shouldever need
to contact us on this unit it will help us to respond to
your needs faster.
MODEL ................
SERIAL NUMBER.. ......
DATE PURCHASED ......
DEALER. ...............
\

GUIDE TO PRODUCT SAFETY
This engine generator set has been designed and
manufactured to insureyour personalsafety. Improper
use can result in potential deadly hazards; from elec-
trical shock, exhaust gas asphyxiation, or fire. Please
readall safety instructionscarefully before installation
or use. Keep these instructions handy for future refer-
ence. Take special noteand follow all warnings on the
unit and in the manuals.
CAUTION: Possible Damage 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: ~e'rsonalDanger. WARN-
ING notes indicate any condition or
practice, which if not strictly observed,
could result in personal injury or possi-
ble 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 liveterminals or receptacles.
D. Useextremecare 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.
2. 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. Keepafireextinguishernearby and know itspro-
per use. Fire extinguishers rated ABC by NFPA
are appropriate.
E. Storefuel only inan approved container,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.
C.Never operate the unit in such a way as to allow
exhaust gasestoseep 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 upany gasor oil spills beforestart-
ing the unit.
D.Never allow leavesor 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 servicingthis unit always avoid hot mufflers,
exhaust manifolds, and engine parts.They all can
cause severe burns instantly.
F. Installing and wiring ahome-standbygenerator is
not a "do it yourself" project. Consult aqualified,
licensedelectrician or contractor. The installation
must comply with all national, state, and local
codes.

SPECIFICATIONS
INTENDED USES
1. These engine generator sets have been designedfor
portable use. Receptacles are provided in the con-
trol panel on the generator for you to plug in your
loads (portable appliances and tools). These gener-
ators are designed with full powercapabilities. See
unit capabilities for further explanation.
2. These units require large quantities of fresh air for
cooling of boththe engine and the generator. Fresh
air is drawn from both the engine end and the gen-
eratorend and isexhausted at the centerof the unit.
For safety, long life and adequate performance,
these units should never be run in small compart-
ments without positive fresh air flow.
MODEL
Generator
Surge Watts
Continuous Watts
AC Volts
AC AMPS
DC Volts
DC AMPS
Receptacles
NEMA 5-15 (120V)
NEMA 5-30 (120V)
12 Volt DC
Engine
Size
Model
TYpe
Fuel Capacity
Fuel Consumption
full Load
Starting System
Stop System
Low Oil Shutdown
Muffler
Complete Unit
Weight (dry)
Dimensions LxWxH
Owner Must
Provide
Fuel
Oil Type
Oil Capacity
RESTRICTED USES
1. DO NOT removefrom the cradle assembly. Remov-
al of the generator from the cradle assembly. may
causeexcessivevibration and damagetothe 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 reachthe engine generator set for cool-
ingandwill allow the unit tooverheat damagingboth
DX3200 CSADX3200
3200 3200
2800 2800
120 120
23.3 23.3
12 12
10 10
4 2
1
1 1
5HP 5HP
FA210 FA210
See Engine For Type
3/4 GAL 3/4 GAL
0.75 glhr 0.75 glhr
Recoil
Switch on Engine Shroud
Standard
Standard Muffler with Spark
Arrestor
99 LBS 99 LBS
24x15~14 24x15x1 4
Unleaded Gasoline
SAE30 SC Class. See engine
manual for additional info.
.64 US qt. .64 US qt.
the engine and the generator. Small compartments
will also develophot spots where there is very little
air flow and may cause a fire.
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 - These generatorsare equip-
pedwith asingle output powerwinding. This design
will give the owner full rated generator output from
a SINGLE 120 volt outlet.
The battery charging circuit on the DX3200 is a
center tapped off the standard 120volt winding. On
the CSADX3200 the battery charging circuit is
separate winding on the armature. This output is
then run through a half wave bridge rectifier where
the current is changed from AC to pulsing DC cur-
rent.The open circuit chargingvoltage as measured
with a DC meter or a volt-ohm meter will read ap-
proximatelyseven
(7) volts. The peakvoltage will be
over 16 volts in order to charge the battery. When
the generator is connected to a 12volt battery, the
battery levelvoltagewill immediately increaseabout
0.5 volts showing that the battery is being charged.
A DC ammeter in series with the generator output
will indicate a current reading approximately equal
to the DC nameplate rating if the battery is dis-
charged.
FIG B1
The following currents(measuredin amps)are pro-
duced at 120volts and 240 volts for models shown.
AMPS @ 120 VOLT 12 VOLT
RECEPTACLE ID
MODEL
DX3200
CSADX3200 23.3

SPECIFICATlONS (continued)
2. Starting Electric Motors - Electric motors require
much more current (amps)to start them than to run
--
them. Some motors,particularly low cost split-phase
motors arevery hardto start and require5to 7times
as much current to start them as to run them. Ca-
pacitor motors are easier tostart and usually require
2to4 times as muchcurrent to start them as to run
them. RepulsionInduction motorsare the easiest to
start and usually require
11/2 to 2% times as much
current to start them as to run them.
Mostfractional horsepowermotors 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 RI
116 3.2 16 TO 22 6 TO 13 5 TO 8
114 4.5 22 TO 32 9 TO 18 7 TO 12
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 NOTMADE26TO52 20TO33
WHERE IS EV
L
The figuresgiven above are for average loadssuch
as a bloweror fan. If the electric motor isconnected
to a hard starting load such as an air compressor,
it will require more starting 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.
3. Motor Starting Capacity - listed below you will find
the motor starting capability of your engine gener-
ator set.
Model (code "G" capacitor start)
CSADX1000 HP
Trying to start a larger motor or a higher code (ie.
J or K) motor may result indamageto boththe gen-
erator and the electric motor especially 120 volt
motors.
'ERYTHING LOCATED
0
1. Rewind Start Grip
2. Fuel Fill
3. Choke Lever
4. Air Filter
5. Stop Switch
- 6. Muffler
7. Spark Plug
8. 120 Volt Duplex Receptacle
9. Ground Lug
10. Circuit Breaker
11. Battery Charging Receptacle
12. Low Oil Sensor
*Oil Fill Same Location
Opposite Side
13. Oil Drain Plug
14. Low Oil Control Module

PREPARATION INSTRUCTIONS
[-] OUT OIL. Failureto maintainthe engine
UNPACKING - When you unpack your new ENGINE
GENERATOR be sure to remove all the information
sheets and manuals fromthecarton. Also be sure that
any accessories(suchas battery rack)orderedwith the
generators have also been received.
1. This power plant was in good order when shipped.
Inspect the power plant promptly after receiving it.
If damage is noted, notify the transportation com-
pany immediately; request proper proceduresfor fil-
ing a "concealed damage" claim.Title to the equip-
mentand responsibilityforfiling claim restswith you
when a generator issent F:O.B. shipping point. Only
you the customer, can legally file a claim.
2. Beforeproceedingwith the preparation of your new
engine generator set for operation, take a few
minutesto insure that the unit you have received is
the correct model and reviewthe specification pages
inthis manualto insurethat this unit meetsyour job
requirements.
3. After removingthe enginegenerator from thecarton
locateand install the four rubber feet shipped loose.
The cradle has been predrilled for the installation of
these rubber feet.
UNlT 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 - Beforestarting theengine, fill thecrank-
case to the proper level with a good quality oil. The
recommendedgrade of oiland quantity of oil required
islisted in both the 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 resultingfrom inadequateor 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 unleadedfuel. Leaded gasoline may
be use if unleadedis notavailable.Gasoline contain-
-
ing alcohol, such as gasohol is not recommended.
However if gasolinewith alcohol is used, itmust 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 use gasoline that has been stored for an
extended period of time as the fuel will lose its
volatile properties and you will be left with only the
varnish residue.This varnish like substance will clog
the carburetor and will not burn properly. The use
of a fuel additive,such as STA-BIL,or an equivalent,
will minimize the formation of fuel gum deposits. If
a unit has been out of operation for an extended
period of time its best to drain old fuel from the
engine and replacewith fresh fuel beforeattempting
to start.

BASIC OPERATION
INITIALSTART UP - Usethe following checklist toverify
the correct preparationof your engine generator before
- starting.
On All Units Check:
1. Engine oil, fill as required with correct grade and
quantity.
2. Checkfuel level and fill as requiredwith clean fresh
fuel.
3. Visually check unit for loose parts.
STARTING AND STOPPING - The throttle control on
thesegenerators ispresetand lockedto operateat 3600
RPM (nominal)with no loadspeed set at 3690 RPM. On-
ly atrained service technician should be allowed to ad-
just this speed setting. See "Operating Speed" section
for additional information.
1. Manualstarting - Referto the engine manualfor addi-
tional starting, operating, and stopping instructions.
A. Turn the stop switch to run.
B. Move the choke to the full on position. A warm
enginewill requirelesschokingthan acold engine.
C. Grasp starter grip and pull slowly until starter
engages,then pull cord rapidly toovercomecom-
pression, prevent kickback and start the engine.
Repeat if necessary.
D. When the engine starts, open the chokegradually.
E. The engineshould promptly come uptooperating
speed.
2. Starting Hints
A. Cold weather
1. Besureto usethe properoilfor thetemperature
expected.
2.A warm battery has much morestarting capaci-
ty than a cold battery.
3.Use fresh winter grade fuel. Winter grade
gasoline has higher volatility to improve start-
ing. Do not usegasoline left over from summer.
4. A slightly richerfuel mixturewill usually improve
cold starting.
B. Hot weather
1. Be sure to use the proper oil for the tempera-
ture expected.
2. Useonly summer blended gasoline. Using gas-
oline left over from winter may cause the unit
to vapor lock, because of the highervolatility of
the winter fuel.
3. Do not over-chokethe unit.
3. Stopping and Storage
A. For gasoline units turn the stop switch to stop.
B. Before extended storage (over 30 days) certain
precautions must be taken to ensure the fuel
doesn't deteriorateand clog the fuel system. Note:
-
The use of fuel additive, such as STA-BIL, or an
equivalent,will minimizethe formation of fuel gum
depositsduring storage.Such an additive may 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 inthe carburetor and thefuel 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 (15 cc) of engine oil into the cylinder and
crank slowly to distribute oil. Replacespark plug.
5. Cleandirt and chaff from cylinder, cylinder head
fins, blower housing, rotatingscreenand muffler
areas. Store in a clean and dry area.
OPERATING SPEED -Theengine-generatormust be run
at the correct speed inorderto producethe properelec-
trical voltage and frequency.
The output voltage should be checked
A
to insurethe generatorisworking prop-
erly prior to connecting a load to the
generator. Failure todo 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 governor on the engine is de-
signed to holdthe speed nearlyconstant. When the
electrical loadconnectedtothe generatoris increas-
ed, the engine is moreheavily loaded,andas aresult
the speed drops slightly. This slight decrease in
speed, togetherwith thevoltagedrop within the gen-
erator itself, results in a slightly lowervoltage when
the generatoris loadedto itsfull capacitythan when
runningno load.The slight variation in speed also af-
fects the frequency of the output current. This fre-
quency variation has no appreciable effect in the
operation of motors, lights and most appliances.
However, electronic equipment and clocks will be af-
fected if correct RPM is not maintained.See loadvs.
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:
I LOAD vs. OUTPUT
Generator Frequency Voltage
Speed
Applied* Recpt.
Half 3600 60.0 120V
I Full 3510 58.5 115V
*Portion of plant's rated output current.
2. The speed of the engine was carefully adjusted at
the factory so that the generatorproducesthe prop-
er voltage and frequency. For normal usage, the
speed setting should not be changed. If the gener-
ator is being run continuously on a very light load,
it is often advisable to lower the operating speed
Dl

BASIC OPERATlON (continued)
slightly. Whenever making any speed adjustments
check the unit with avoltmeter or tachometer and be
sure the speed is neither too high or low.
The engine must be run at the specified speed at
all times. Lower voltage may damage both the
generatorand any load connecting to it. Runningthe
engine at excessively high speeds results in high
voltage, which may significantly shorten the life of
appliances being used.
3.Output voltage should bechecked periodically to en-
sure continued proper operation of the generating
plant and appliances. If the generator is not equip-
ped with a voltmeter, it can be checked with a por-
table meter. Frequency can be checked by using an
electric clock with a sweep second hand. Timed
againstawrist watch or astop watch the clock should
be correct within
+ 1- 2 seconds.
CONNECTING THE LOADS
1. ApplyingThe Load -Allowthe enginetowarm up for
two or three minutes before applying any load.This
will allow the engineto reachnormaloperatingtemp-
erature and oil to circulate throughout the engine.
A short warm-uptime will permit the enginetowork
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 for your load connections. 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.
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 localelectrician.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 necessaryto prevent damage to
either the receptacles or the generator. The gen-
erator isa limited sourceof electrical power, there-
fore pay special attention to the receptacle and
generator ratings.The nameplaterating can be ob-
tained through a combination of receptacles or a
single receptacle as long as the receptacle
amperage rating isnotexceeded. Boththe 120and
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.Drive a 3/4 or 1'' copper pipeor rod intothe ground
close to the engine-generatorset. The pipe must
penetrate moist earth. Connect an approved
ground clamp, tothe pipe. Runa no. 10Awg wire
from clamp tothe generatorground lugor the bat-
tery negativeterminal. Do not connect to a water
pipe or to a ground used by a radio system.
3. Connecting the Battery - Enclosed with your new
generator set you will find a 12V DC connector, lead-
wire and battery clip assembly. This lead wire set
is providedfor your use incharging 12volt batteries.
Located on the front panel is a 12 volt receptacle.
To chargeyour batteriesplugthe lead wire assembly
into this receptacle and attach the battery clips to
the battery.The redclip ispositive and the black clip
isnegative. If the positive and negativeleadsare ac-
cidentally shorted, or are incorrectly connected to
the battery, the automatic resetting DC circuit
breaker inthe generator will trip to protect the gener-
ator and your battery. Oncethe short is removed the
circuit breaker will reset itself in about 5 seconds.
A
PERSONAL DANGER
Lead acid batteries produce explosive
hydrogen gas when charging. Keep
sparks, flames, and burning cigarettes
away from the battery. Ventilate the
area when chargingor usingthe 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.
LOW OIL SHUTDOWN SYSTEM
KAWASAKI Powered Generators - These engine gen-
erator sets come equipped with a standard Kawasaki
low oil shut-down system.
A.This low oil shut-down system will automatically
stop the engine well before the oil level reaches a
danger point. This feature is designed to prevent
costly repairs and downtime.
B.The low oil shut-down system consists of a float
switch and a low oil moduleto monitor the oil level
inthe crank case. The float switch is mounted inthe
engine crank case between the engine and the
generator end bracket. The module is mounted on
the engine.The module monitorsthe oil levelviathe
float switch; ifthe oil level islow itwill short out the
engine ignition andshut the engine off. If the oil level
is low when the engine is started, the engine will
start and run for about three
(3) seconds and shut-
down. This indicates that the oil level is low and
must be completely refilled before starting.
C.Useof this low oil shut-downsystem on applications
that are subject to shock, bumping or severe angles
of operation (in excess of 15 degrees) should be
avoided. This is especially true if an unexpected
shutdown would cause a safety hazard or serious
inconveniencefor the operator.To disablethe shut-
down system disconnect the wire running from
under the engine shroud to the control module
mounted on the engine.

OPERATOR CARE AND MAINTENANCE
ENGINECARE - If major engine service or repair is re-
quired contact an Authorized Engine Service Center.
-
The manufacturer of these engines hasestablished an
excellent world-wide engine service organization. En-
gineservice isvery likelyavailablefrom a nearbyauthor-
ized dealer or distributor. Check the yellow pages of
your local telephone directory under "Engines-
Gasoline" for the closest engine repair center or ask
the dealerfrom whom you purchased the power plant.
1. Oil Changes
Change the oil after the first 20 hours of operation
and every 100 hours thereafter under normal oper-
ating conditions. Change engine oil every 50 hours
of operation if the engine is operated under heavy
load, or in high ambient temperatures.
A. Remove oil drain plug at base of the engine and
drain the oil with the engine warm.
B.Replace oil drain plug.
C.Remove oilfiller plug and refillwith new oil. Refer
to the table in the engine manual for the proper
gradeof oil basedonyour operating temperature.
D. Replace filler plug.
2.Checking the Oil Level. The oil level must always be
checked before the engine is started. Take care to
remove any dirt or debris from around the oil fill plug
before removing. Be surethe oil level is maintained.
FILLTO POINT OFOVERFLOWINGor on unitswith
the extended oil fill to the "FULL" mark on the
dipstick.
- If the enginegeneratorshould fail tostart 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 .Cleaning Air Cleaner Element - clean and re-oil
foam air cleaner at three month intervals or every
50 hours, which ever occurs first. Service more
often under dusty conditions.
1. Removeair cleanercover and take the element
out.
2. Wash element in keroseneor liquid detergent
and water.
3. Wrap foam pre-cleaner in cloth and squeeze
dry-
4. Saturate in engine oil. Squeeze to remove ex-
cess oil.
5. Installelement inthe air cleaner body. Be sure
to installwith the surface marked "inside" fac-
ing toward the carburetor.
4. Spark Plug - Clean and reset gap at .030" every 100
hours of operation. Do not blast clean spark plug.
Cleanbyscrapingor wire brushingandwashing with
a commercial solvent. Poor spark will occur if ter-
minal does not fit firmly on spark plug. If this hap-
pens re-formthe terminal to fit firmly on spark plug
tip.
GENERATOR CARE - Proper care and maintenance of
the generatoris necessaryto insurea longtroublefree
life.
1. ExercisingThe Generator - The generator should be
operated every three to four weeks. Itshould be op-
erated for a periodof time sufficient towarm the unit
upandtodry out any moisturethat hasaccumulated
in the winds. If left this moisture can cause corro-
sion in the winding and on the slip rings. Frequent
operationof theenginegeneratorset will also insure
that the set isoperatingproperlyshould it be needed
in an emergency.
2. Generator Maintenance - Any major generator ser-
vice including the installation or replacement of
parts should be performed only by a qualified elec-
trical serviceman. USEONLY FACTORY APPROVED
REPAIR PARTS.
A. Bearing - The bearing when used in these gener-
ators isheavy duty double sealed ball bearing. It
requires 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 100hoursthereafter.
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 havebeen util-
ized. If a receptacle should become cracked or
otherwisedamaged, replaceit. Usingdamagedor
cracked receptaclescan be dangerous bothtothe
operator and to the equipment.
CLEANING - Remove dirt and debris with a cloth or
brush. DO NOT usehigh pressurespraytoclean either
the engine or the generator. This high pressure 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 proper
cooling. At least yearly remove the blower housing
on the engineand clean the chaff and dirt out of the
engine cooling fins and flywheel. Clean more often
if necessary, failure to keep these areas clean may
cause overheating and permanent damage to the
unit.
2. Periodically clean muffler area to remove all grass,
dirt and combustible debris to prevent a fire.
3. Onengine mufflersequippedwith spark arresters, the
spark arrester must be removed every 50 hours for
cleaning and inspection. Replace if damaged.

OPERATOR CARE AND MAINTENANCE (continued)
THINGS TO CHECK -
Sometimes problemscan be easily solved by check-
ing a few basic things. Check the chart below before
you call ortakeyour unittoa service center. Itcould
save you time and money.
Problem Possible Causes
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
Problem Possible Causes
Generator *Overloaded
overheating *Insufficient ventilation
No output voltage *Short in load (disconnect)
*No residual magnetisim in
generator
*Defective armature
*Defective field coil
*Defective Brushes
*Shorted condenser
*Shorted rectifier
Defective receptacle
Battery not *Defective charging circuit
re-charging on engine

EXCITATION CIRCUIT
POWER CIRCUIT "BOOST" CIRCUIT
BATTERY CHARGE
'FULL POWER
ARMATURE
WINDINGS RECEPTACLES
ARMATURE
WINDINGS
EXCITATION ClRCUlT
CAYS I - I I","
RECTIFIER
SHUNT
FIELD
COILS
POWER CIRCUIT d
"tluuti I '. ciln
'FULL POWER
WINDING
SLIP RINGS
\ YRUSHES
BATTERY CHARGE
BAnERY CHARGE
-.?& "ECTIFIER
CIRCUIT
+
"BOOST"
7
OUTPUT
mnn,, AC
BATTERY
CHARGING AUTO RESET
WINDING CIRCUIT BREAKER
120 VOLT 4'
25 AMP 120 VOLT
CIRCUIT BREAKER 9 9 CIRCUIT BREAKER
A A
-
I
NEUTRAL N
i
NOT USED