GENPOWER GENPTL40IGPRACAB User manual

Generators (open frame type)
User manual
WARNING! Read and follow all safety
warnings and instructions carefully before
using this machine. Failure to follow the
warnings and instructions may result in
electric shock, fire and/or serious injury.
Save this manual for future reference.
ATTENTION! Products covered by this
manual will vary in appearance, assembly,
inclusions, description and packaging.
NOTE! This manual covers multiple styles
of generators as well as options /
accessories that may not be suitable for
the machine you have purchased.
IMPORTANT! A UPS or power filter is
recommended for powering expensive
equipment (all models).

Index
Index..........................................................................................................................................................1
Safety Warnings.........................................................................................................................................2
Parts Diagram ............................................................................................................................................4
Before use..................................................................................................................................................5
Starting the engine.....................................................................................................................................7
Stopping the Engine...................................................................................................................................9
Using your Generator...............................................................................................................................10
Balancing power on a 3-Phase generator.................................................................................................12
Maintenance.............................................................................................................................................13
Transporting/Storage................................................................................................................................17
Troubleshooting........................................................................................................................................18
Specifications...........................................................................................................................................19
Appendix..................................................................................................................................................21

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Safety Warnings
General Safety Warnings
It is important you read
and understand the
instruction manual
before use and keep the
manual in a safe place
for future reference.
Safety precautions must
be observed to reduce
the risk of personal
injury when operating
this generator.
The Generator is a
potential source of
electric shock if
misused. DO NOT
expose the generator to moisture,
rain or snow. Do not let the generator
get wet. Do not operate the generator
with wet hands.
It is strongly
recommended that a
comprehensive training
course on machine use,
fuel handling safetyand engine
operation be completed before
attempting to use this machine.
Like all power equipment this unit must
be handled carefully:
Do not expose yourself or others to
danger. Do not permit others to use this
generator unless they have read this
manual and are trained in its operation.
Do not operate if the generator is
damaged or is in an excessively worn
state. To reduce fire hazards keep the
engine and silencer free of debris,
leaves, or excessive lubricant. Do not
use any attachments or accessories with
the generator other than the ones
recommended by the supplier. Serious
injury to the operator or bystanders can
result as well as cause damage to the
generator. Always use proper handles
when moving the generator. Keep the
generator in a horizontal position on a
firm flat surface. Do not tilt. Do not use
the unit if it is damaged or poorly
adjusted. Never remove the generator’s
coverings. Serious injury to the operator
or bystanders could result as well as
damage to the generator. Do not use
this unit for any job other than those for
which it is intended as described in this
manual. In start-up or during or after
operation of the engine, never touch hot
parts such as the muffler, the high
voltage wire or the spark plug. Do not
operate the generator in the rain or
under wet conditions. Always ensure all
handles, guards and covers are fitted
when using the generator. Always keep
the generator away from naked flame or
sparks. Always stop the engine or
disconnect from mains before cleaning /
clearing a blockage or checking,
maintaining or working on the generator.
Connections to a building’s electrical
system must be made by a qualified
electrician and must comply with all
applicable laws and electrical codes.
Improper connections can allow an
electrical current from the generator to
back feed into power lines. Such back
feed may electrocute utility company
workers or others who contact the lines
during a power outage. Improper
connections may cause the generator to
explode, burn or cause fires in the
building’s electrical system.
Transporting the Generator
The engine should be turned off when
the generator is moved between areas
and when transporting or storing the
generator. Always turn off the engine.
When transporting in a vehicle: properly
secure your generator to prevent
turnover, fuel spillage and damage.
Fuelling Petrol is an extremely
flammable fuel. Keep
clear of naked flames.
Do not spill any fuel –
do not smoke near
fuel or the generator.
Always shut off the engine before
refuelling. Do not fuel a hot engine –fuel
may spill and cause a fire. Open the fuel
cap carefully to allow any pressure
build-up in the tank to release slowly
and avoid fuel spillage. Fuel your
generator only in well ventilated areas. If
you spill fuel, wipe the generator
immediately –if fuel gets on your
clothing, change immediately. To reduce
the risk of serious or fatal burn injuries,
check for fuel leakage. If fuel leakage is
found, do not start or run the engine until
leak is fixed.
During Operation
Make sure you always have good
balance and secure footing. Always be
aware of your surroundings and stay
alert for possible hazards that you may
not hear due to the noise of the
generator.
Never allow children to access
the generator.
Avoid operating while people, especially
children or pets are nearby. To reduce
the risk of injury or damage, do not allow
any other persons within a radius of 1
metre of the product. To reduce the risk
of damage to property, also maintain
this distance from other objects
(vehicles, windows).
After Use
Always clean dust and dirt off the
generator –do not use any grease
solvents. Always keep the generator
clean, especially, the fuel tank, its
surroundings, and the air cleaner. After
the engine has stopped, the engine and
exhaust components will still be hot.
Never place the generator in any places
where there are flammable materials
such as dry grass, combustible gases or
combustible liquids etc. Let the engine
cool before storing the generator
indoors.
Maintenance and Repairs
Service the generator regularly. Do not
attempt any maintenance or repair work
not described in this instruction manual.
Have all other work performed by a
servicing dealer. We recommend that
you have servicing and repair work
carried out exclusively by an authorised
service person. Before proceeding to
adjust or repair the generator, be sure to
stop the engine and detach the spark
plug. Never attempt to make engine
adjustments while the unit is running.
Always make engine adjustments with
the unit resting on a flat, clear surface.
Replace any worn, damaged or
removed warning labels immediately.

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IMPORTANT! - Machine, Fuel handling or Electrical Safety
If you are not familiar with safe operation / handling of this machine, or are in any way unsure of any
object of this products suitability or correct use for your application you should complete training
conducted by a person or organisation qualified in safe use and training related to this product.

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Parts Diagram
ATTENTION! Products covered by this manual will vary in appearance, assembly, inclusions,
description and packaging.
1. AC socket
2. Circuit Breaker reset button
3. Voltmeter*
4. AC Circuit Breaker*
5. 3-Phase AC socket*
6. Battery*
7. Oil filler cap (7 & 20)
8. Starter motor*
9. Ignition key*
10. Choke lever (10 & 19)
11. Air filter*
12. Pull Start chord & grip
13. Fuel On/Off switch
14. Frame stand*
15. Exhaust outlet
16. Wheels*
17. Fuel filler cap
18. Fuel gauge*
19. Choke Lever (10 & 19)
20. Oil filler cap (7 & 20)
21. AC Socket
22. Voltmeter*
23. AC Circuit Breaker*
24. 3-Phase AC socket*
25. Ground
26. DC output
27. DC 10A fuse
28. Spark plug & lead
*(if equipped)

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Before Use
Connecting the Battery (if equipped)
For safety the connection plugs were disconnected from battery before shipping. Please
follow the below steps to connect your battery.
1. Bolt the RED wire to the POSITIVE terminal and the BLACK wire to the NEGATIVE terminal on the
battery.
2. Replace the battery cover plate.
NOTE! The battery is self-charging through general use however there may be need on occasion
to remove the battery and charge it with an appropriate charger or jump start (selected 4-Stroke
petrol and Diesel versions only).
Fitting the Wheels (applicable models)
Installing one side at a time simply slide one wheel onto the axle followed by one washer, pass the split
pin through the axle and bend the legs out and around the axle.
Adding Oil (4-Stroke and Diesel engines only)
WARNING! Using the
wrong oil can damage
your engine and void
warranty.
Acceptable Oil Grades:
10W-30 / 10W-40 /
15W-30 / 15W-40.
WARNING! Do not overfill
or tilt while filling.
With the engine perfectly level:
1. Remove the small engine oil filler cap on the side of the engine.
2. Fill with engine oil until oil starts to run back out of the filler hole.
3. Replace the filler cap.

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Adding Fuel
CAUTION!Use only
clean, fresh non-ethanol
unleaded (4-stroke
petrol models) or clean,
fresh commercially
available pump diesel
(diesel models). Be sure
to confirm the engine
type before adding fuel.
WARNING! Do not use
fuel substitutes such as
ethanol, methanol or
biofuel.Using such fuel
will cause damage and
void any applicable
warranty.
CAUTION! Before
refuelling ensure the
engine is switched off
and is cool.
NOTE! It is normal for
smoke to be emitted
from a new engine for
the first 5 hours of use
while running in.
1. Clean surface around fuel cap to prevent contamination.
2. Loosen fuel cap slowly. Rest the cap on a clean surface.
3. Carefully pour fuel into the tank. Avoid spillage.
4. Prior to replacing the fuel cap, clean and inspect the gasket.
5. Immediately replace fuel cap and hand tighten. Wipe up any fuel
spillage.

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Starting the engine
CAUTION! The starter
grip can be drawn back
very quickly before you
can release it. This may
pull your hand forcefully
toward the engine and
cause an injury.
CAUTION! Do not allow
the starter grip to snap
back. Return it slowly by
hand.
ATTENTION! Disconnect
all appliances before
starting engine.
4-Stroke Petrol Engines
1. Turn the “fuel cap vent” (twist knob on fuel cap) to “ON” (if equipped).
2. Turn the “fuel valve” to “ON”.
3. Set the Choke (if equipped); move the “choke lever” to the left (“Cold Start” position).
4. Turn the “ignition key” to "ON" (if equipped) otherwise turn the engine switch to “ON”.
5. Start the engine:
Electric Start (if equipped): If the battery has enough charge, use the ignition key or switch to
start the engine by placing it in the “Start” position for a few seconds (new batteries can have
no/little charge; use pull-start, jump start or change battery if needed).
Pull Start (if equipped): Pull the “start cord” until the engine starts (see example image below).
6. Move the "choke lever” to the right (“Run” position).
7. Turn on any protective switches / circuit breakers.
8. Connect your appliance(s).
9. Turn on your appliance(s).
IF ENGINE WILL NOT START:
1. Repeat the process above but place and leave the “choke lever” to the right ("Run" position).
2. Check engine oil level and ensure level is at or just under "maximum".
3. Charge battery or jump-start if needed.
4. See section "Troubleshooting".
Diesel Engines
ATTENTION! Disconnect all appliances before starting engine.
1. Turn the “fuel valve” to “ON”.
2. Turn the “ignition key” to “ON” (if equipped) otherwise turn the engine switch to “ON”.
3. Start the engine:
If the battery has enough charge, use the ignition key or switch to start the engine by placing it in
the “Start” position for a few seconds (new batteries can have no/little charge; jump start or
change battery if needed).
4. Turn on any protective switches / circuit breakers.
5. Connect your appliance(s).
6. Turn on your appliance(s).
IF ENGINE WILL NOT START:
1. Check engine oil level and ensure level is at or just under "maximum".
2. Charge battery or jump-start if needed.
3. See section “Troubleshooting”.

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Remote control start (if equipped)
Applicable generators may be fitted with an isolator switch; you must have this switch turned on to
be able to use the remote control to start / stop the engine. Some model generators must have the
ignition key or engine switch in the “ON” position to allow the remote to work.
IMPORTANT! If you leave the ignition on without the engine running for extended periods it will
drain the battery.
1. Keys
2. Stop Button
3. Start Button
To turn ON - Press the "Start" button once to activate,then press and hold until unit starts.
To turn OFF - Press the "Stop" button.
6. Once the engine starts, allow it to run continuously and warm up for a short time.
7. Once warm, slide the choke lever (if equipped) to the “RUN” position.
Note - Choosing the correct choke position is important for engine starting. You may have
to practice a few times to use the choke correctly.

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Stopping the Engine
To stop the engine in an emergency, turn the engine switch to the OFF position. In normal use:
1. Switch OFF all connected equipment and pull the inserted plug out.
2. Switch OFF the “AC Circuit Breaker”.
3. Turn the “engine switch”to the OFF position.
4. Turn “fuel valve”to the OFF position.

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Using your Generator
Fuel
WARNING! Fuel is
extremely flammable and is
explosive under certain
conditions.
WARNING! Refuel in a well-
ventilated area with the
engine stopped. Do not
smoke or allow flames or
sparks in the area where the
engine is refuelled or where
fuel is stored.
WARNING! Do not
overfill the fuel tank.
After refuelling, make
sure the fuel filter cap is
closed properly and
securely.
CAUTION! Use only
clean, fresh non-ethanol
unleaded (4-stroke petrol
models) or clean, fresh
commercially available
pump diesel (diesel
models). Be sure to
confirm the engine type
before adding fuel.
WARNING! Be careful
not to spill fuel when
refuelling. Spilled fuel or
fuel vapour may ignite. If
any fuel is spilled, make
sure the area is dry
before starting the
engine.
WARNING! Avoid
repeated or prolonged
contact with skin or
breathing in of vapour.
WARNING! Keep out of
reach of children.
1. Fill the fuel tank until you can see the fuel rise up into the strainer tube or reach the upper limit mark.
2. After refuelling, tighten the fuel filler cap securely.
Checking the Air Filter
1. Unclip the air cleaner cover and remove.
2. Remove the air cleaner and clean or replace.
(Refer to section “Cleaning the filter”)
3. Re-assemble in the reverse order.
Cleaning the air filter
NOTICE! It is normal for a small amount of oil may leak under the air filter box if the generator is
running for a long period of time. Wipe excess oil after each 10 hours of use.
NOTE! Never run the engine without the air cleaner. Rapid engine wear will result from
contaminants, such as dust and dirt, being drawn through the carburettor into the engine.
See section “Cleaning the Air filter” for more information.
Checking the Oil Level
Visually inspect the oil level by opening the “oil filler cap”. Oil should be just touching the outer most brim of the
oil filler hole, See section “adding oil” for more information.

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Oil alert system (if equipped)
ATTENTION! Generators
must operate on a level
surface or engine
damage may occur.
WARNING! This is a
backup feature only;
warranty is void if run
with low oil.
ATTENTION! Check Oil
level before each use or
every 3 hours of
continuous running.
The oil alert system is designed to reduce the chance of engine damage caused by an
insufficient amount of oil in the crankcase. Before the oil level in the crankcase falls below a safe
limit, the oil alert system will automatically shut down the engine (the engine switch will remain in
the ON position).
If the oil alert system shuts down the engine, the oil alert indicator light (red) will come on when
you operate the starter, and the engine will not run. If this occurs, add engine oil. Always check
the oil before starting the engine.
AC applications
1. Ensure all appliances have been disconnected from the generator.
2. Start the engine. Turn on all circuit breakers.
3. Make sure the output indicator light stays on or the Voltmeter indicates steady power output.
(indicators vary between models)
4. Connect appliances one-by-one (spread the load over all 240V outlets if you purchased a 3-Phase).
5. Switch all circuit breakers to “ON”.
6. Switch on your appliances one-by-one taking care not to overload the generator.
DC applications
Charging 12V automotive batteries:
The DC receptacle may be used while the AC power is in use.
An overloaded DC circuit will trip the DC circuit protector. If this happens, unload the DC
load before pushing in the circuit protector to resume operation.
3-Phase applications (selected models only)
If you have purchased a 3-Phase type generator you will see that it has a
large industrial 415V outlet in addition to the standard 240V household style
outlets.
The generator may feature a display panel that shows you various
information. Press MODE to switch between the following displays:
•The current AC voltage being produced (eg: "240V").
•The current AC voltage frequency being produced (eg: 50Hz").
•The total time that the generator engine has been running in hours and
minutes. This is for maintenance purposes as it helps you to keep track
of when maintenance is required (eg: "12:20").
Generator Display Panel (selected models only)

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Balancing power on a 3-Phase generator
IMPORTANT! This section only applied to 3-Phase capable generators.
WARNING! Failure to balance output on a 3-Phase generator can cause damage and void warranty.
IMPORTANT! Only one third of the total generator capacity is available from any single phase 240v outlet.
WARNING! 3-Phase generators are not suitable for running power-hungry appliances from 240v Single
Phase outlets.
WARNING! Appliances that draw surges of power should not be run from the 240v single phase outlets on
3-phase generators.

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Maintenance
Cleaning the air filter
NOTICE! It is normal for a small amount of oil may leak under the air filter box if the generator is running for a
long period of time. Wipe excess oil after each 10 hours of use.
1. Blow out with compressed air.
2. Wipe dirt from the air cleaner body and cover, using a moist rag. Be careful to prevent dirt from
entering the carburettor.
NOTE! Never run the engine without the air cleaner. Rapid engine wear will result from contaminants, such
as dust and dirt, being drawn through the carburettor into the engine.
Changing the oil
NOTE! Drain the oil while the engine is still warm but not hot to assure rapid and complete draining.
IMPORTANT! Make sure to turn the engine switch OFF before draining.
NOTE! When the oil is drained it is an optimal time to clean the oil filter strainer.
1. Drain the oil while the engine is still warm but not hot to assure rapid and complete draining.
2. Make sure to turn the engine switch OFF before draining.
3. Tilt the generator to one side to drain out the oil.
4. Fasten an oil lead pipe onto the oil filler, then tilt the generator to one side to drain out the oil.
5. Refill with new oil and check the oil level (see section “checking the oil”).
6. After refilling with new oil, rock the generator left to right to make sure the internal oil alarm sensor
detects the new oil.
7. Wash your hands with soap and water after handling oil.
Please dispose of used motor oil in a manner that is compatible with the environment. We
suggest you take it in a sealed container to your local waste disposal station for free
reclamation. Do not throw it in the trash or pour it on the ground.
Residual Current Device (RCD) Circuit Breaker (if equipped)
WARNING! If the RCD is tripped due to earth leakage of a connected device or appliance,
have the device inspected and repaired by a qualified technician. If the device is faulty, do
not use it until it is safe to do so.
The RCD circuit breaker is designed to protect users from electric shock or
electrocution in the event of a device/appliance malfunction or short-circuit. If
the RCD is tripped, all power outlets are automatically switched off, however,
the generator will continue to run.
To reset the RCD, ensure that the faulty device is no longer connected to the
generator or the cause for the earth leakage is removed, then unscrew the
RCD cover screw, lift the cover and place the RCD switch in the "ON" position.

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Spark Plug Service
CAUTION! The Spark plug must be securely
tightened. An improperly tightened plug can
become very hot and possibly damage the
generator.
CAUTION! Never use a spark plug with an
improper heat range.
To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.
1. Remove the spark plug cap.
2. Clean any dirt form around the spark plug base.
3. Use a spark plug wrench to remove the spark plug
4. Visually inspect the spark plug. Discard it if the insulator is cracked, chipped or fouled. Clean the
spark plug with a wire brush if it is to be reused.
5. Measure the plug gap with a feeler gauge. Correct as necessary by carefully bending the side
electrode.
6. Install the spark plug carefully by hand to avoid cross-threading.
7. After a new spark plug has been seated by hand, it should be tightened ½ turn with a wrench to
compress its washer. If a used plug is being reinstalled, it should only require 1/8 to ¼ turn after
being seated.
8. Reinstall the spark plug cap on the spark plug securely.
9. Reinstall the spark plug maintenenace cover.

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Transporting/Storage
To prevent fuel spillage when transporting or during temporary storage, the generator should be
secured upright in its normal operating position, with the engine switch and fuel switch OFF and the
fuel cap vent closed. It is also reocmmmended the remote control switch be turned off to avoid
accidental starting.
WARNING! Before storing
the unit for an extended
period be sure the storage
area is free from excessive
humidity and dust.
WARNING! Do not operate
the generator while it is on a
vehicle. Take the generator
off the vehicle and use it in a
well ventilated place.
WARNING! Do not drive on
a rough road for an extended
period with the generator on
board. If you must transport
the generator on a rough
road, drain the fuel from the
generator beforehand.
WARNING! Do not overfill
the tank (there should be no
fuel in the filler neck).
WARNING! Avoid a place
exposed to direct sunlight
when putting the generator
on a vehicle. If the generator
is left in an enclosed vehicle
for many hours, high
temperature inside the
vehicle could cause fuel to
vapourise resulting in a
possible explosion.
NOTE! In the case of storing
the product for a long period
of time, clean the fuel tank
after running it empty. Next,
activate the engine and
empty the carburettor of any
remaining fuel.
Draining the fuel
WARNING! Fuel is extremely flammable and is explosive under certain conditions. Perform this task in a well-ventilated
area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure.
1. Remove the fuel cap.
2. Drain all fuel from the fuel tank into an approved fuel container. We recommend using a
commercially available fuel hand pump.
3. Reinstall the fuel filter and the fuel filler cap.
Draining the oil
(see section –checking the oil level)

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Troubleshooting
Is there fuel in the
tank? Refill the fuel tank
Is the engine switch
ON?
Turn the engine
switch on
Add the
recommended oil
Is there enough oil
in the engine?
If the engine still
does not start, take
the generator to an
authorised service
center.
Clean, re-adjust the
gap and dry the
spark plug. Replace
it if necessary
The Engine Will Not Start
Is the output
indicator ON?
Disconnect the
electrical
appliances. Stop
and re-start the
engine.
Are all circuit
breakers ON?
Check the electrical
appliance or
equipment for any
defects.
Plug in your
appliances
(spread the load
over all 240V outlets
if your purchased a
3-Phase)
Switch all circuit
breakers to “ON”
Take the generator
to an authorised
service center.
Turn all circuit
breakers ON.
- Replace the electrical appliance or equipment.
- Take the electrical appliance or equipment to an
electrical repair shop for repair.
Take the generator
to an authorised
service center.
No power from outlet socket
If ‘yes’
If ‘yes’
If ‘yes’ If ‘yes’
If ‘yes’
If ‘no’
If ‘no’
If ‘no’
If ‘no’
If ‘no’
If ‘no’
If ‘no’
If ‘no’ fault
Is the output
indicator ON?
If ‘yes’
Is the engine
running?
Start Engine
If ‘yes’
If ‘no’
fault
Switch on your
appliances one-by-
one taking care not
to overload the
generator
Is it a Diesel
Engine?
If ‘yes’
Is the spark plug in
good condition?
If ‘no’
If ‘yes’
Could there be an
air lock or bubbles
in the fuel line?
If ‘no’
Re-Prime the Fuel
line system.
See section in
manual.
If ‘yes’
Determine if
“overloaded” If ‘yes’
If ‘no’
Reduce the load on
your generator by
removing some of
your appliances

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Specifications
OSE or Other Seller Equivalent! We provide this specification to enable buyers to compare
generators where @cos0.8 is used as the output measurement. We strongly recommend you only
refer to the Continuous Rated Output when considering whether a product is right for your needs.
NOTE! Power produced by generators can fluctuate.
IMPORTANT! UPS or power filter recommended for powering expensive equipment (all models).
GENPTL40IGPRACAB
Manufacturer: GenPower
Engine Type: 4-Stroke
Engine Displacement: 208CC
Engine Output: 8hp
Fuel Type: 95+ Non Ethanol Petrol
AC Voltage: 240/415V 50Hz
Continuous Rated Output: 2.7kW(2700W)
OSE Max output: 4.5kVA @ 0.8 cos
(Other Seller Equivalent)
DC Output: 12V - 8.3A
Starting Method: Recoil
Engine Oil Type: 10W30 / 10W40 / 15W30 / 15W40.
Noise Level at 7m: 74db
Other Specifications: Refer to brochure or
advertisement
GENPTL40IGPRACAB
Manufacturer: GenPower
Engine Type: 4-Stroke
Engine Displacement: 242cc
Engine Output: 8hp/3600rpm
Fuel Type: 95+ Non Ethanol Petrol
AC Voltage: 240/415V 50Hz
Continuous Rated Output: 2.5kW (2500W)
OSE Max output: 4.5kVA @ 0.8 cos
(Other Seller Equivalent)
DC Output: 12V - 8.3A
Starting Method: Recoil
Engine Oil Type: 10W30 / 10W40 / 15W30 / 15W40.
Noise Level at 7m: 69db
Other Specifications: Refer to brochure or
advertisement
4-Stroke
4-Stroke