Kohler N.A.M.P 6000 Technical manual

GASOLINE GENERATOR OPERATION
INSTRUCTION
THIS MANUAL CONTAINS IMPORTANT INFORMATION REGARDING SAFETY, OPERATION, MAINTENANCE
AND STORAGE OF THIS PRODUCT. BEFORE USE, READ CAREFULLY AND UNDERSTAND ALL CAUTIONS,
WARNINGS, INSTRUCTIONS AND PRODUCT LABELS. FAILURE TO DO SO COULD RESULT IN SERIOUS
PERSONAL INJURY AND/OR PROPERTY DAMAGE

ENGINE SAFETY............................................................................................................. 1
Safety Label Location.................................................................................................... 1
Safety Information...........................................................................................................2
II. INTRODUCTION...................................................................................................... 4
1. Component identification..................................................................................... 4
2. Specification............................................................................................................... 5
III.OPRETION.................................................................................................................. 6
1. Generator Use ........................................................................................................... 7
2. Pre-Operation Check ................................................................................................8
1) Engine oil..................................................................................................................... 8
2) Fuel................................................................................................................................ 9
3. Operation.................................................................................................................. 10
1) Starting the engine.................................................................................................11
2) Stopping the engine ..............................................................................................12
IV.STORAGE...................................................................................................................13
V. SERVICE......................................................................................................................14
1. Maintenance ............................................................................................................ 14
1) Maintenance schedule ......................................................................................... 14
2) Engine oil change.................................................................................................... 14
3) Air Filter Element Maintenance......................................................................... 16
4) Fuel sediment cup cleaning................................................................................ 17
5) Spark plug service...................................................................................................18
2. Troubleshooting...................................................................................................... 19
3. Warranty Service......................................................................................................20
CONTENT

Thank you for purchasing our generator. .
This manual covers the operation and maintenance of our series generator. All
the information in this publication is based on the latest product information
provided at the time of printing.
Our generator reserves the right to make changes at any time without notice and
without incurring any obligation.
No part of this publication may be reproduced without written permission.
This manual should be considered a permanent part of the engine and should re-
main with the engine if it is resold.
READ THIS OWNER'S MANUAL CAREFULLY. Pay special attention to these symbols
and any instructions that follow:
NOTE: Gives helpful information.
If a problem should arise, or if you have any questions about your engine, consult your
engine dealer.
WARNING SYMBOLS
Indicates serious injury or death will result if in-
structions are not followed.
Indicates a strong possibility that serious injury or
death could result if instructions are not followed.
Indicates a strong possibility that serious injury or
death could result if instructions are not followed.
Indicates that equipment or property damage can
result if instructions are not followed.

1
ENGINE SAFETY
Safety Label Location
These labels warn you of potential hazards that can cause serious injury.
Read them carefully.
If a label comes off or becomes hard to read, contact your Generator dealer for a
replacement.

2
1) Operator Responsibility
•Know how to stop the generator quickly in case of emergency.
•Understand the use of all generator controls, output receptacles, and connec-
tions.
•Be sure that anyone who operates the generator receives proper instruction. Do
not let children operate the generator without parental supervision.
2.Carbon Monoxide Hazards
•Exhaust contains poisonous carbon monoxide, a colorless and odorless gas.
Breathing exhaust can cause loss of consciousness and may lead to death.
•If you run the generator in an area that is confined, or even partially enclosed,
the air you breathe could contain a dangerous amount of exhaust gas. To keep exhaust
gas from building up, provide adequate ventilation.
3.Electric Shock Hazards
•The generator produces enough electric power to cause a serious shock or elec-
trocution if misused.
•Using a generator or electrical appliance in wet conditions, such as rain or snow,
or near a pool or sprinkler system, or when your hands are wet, could result in electro-
cution. Keep the generator dry.
•Do not connect to a building's electrical system unless an isolation switch has
been installed by a qualified electrician.
ENGINE SAFETY
Safety Information
Our generators are designed to give safe and dependable service if operated ac-
cording to instructions. Read and understand this owner's manual before operating
your generator. You can help prevent accidents by being familiar with your generator's
controls, and by observing safe operating procedures.

3
Safety Information
4.Fire and Burn Hazards
•The exhaust system gets hot enough to ignite some materials.
Keep the generator at least 1 meter away from buildings and other equipment during
operation.
Do not enclose the generator in any structure.
Keep flammable materials away from the generator.
•The muffler becomes very hot during operation and remains hot for a while
after stopping the engine. Be careful not to touch the muffler while it is hot. Let the en-
gine cool before storing the generator indoors.
•Gasoline is extremely flammable and is explosive under certain conditions. Do
not smoke or allow flames or sparks where the generator is refueled or where
gasoline is stored. Refuel in a well- ventilated area with the engine stopped.
•Fuel vapors are extremely flammable and may ignite after the engine has start-
ed. Make sure that any spilled fuel has been wiped up before starting the gen-
erator.
ENGINE SAFETY

4
Component Identification
INTRODUCTION
DC TERMINAL POSTS
AC CIRCUIT BREAKER
GENERATOR SWITCH
AIR FILTER
FUEL VALVE
RECOIL STARTER
VFT METER
AC RECEPTACLES
MUFFLER
FUEL METER
FUEL TANK CAP

6
INTRODUCTION
Specification
Model 6000(E) 7000(E) 10000(E)
Frequency(Hz) 60 60 60
Rated Output(Kw) 5.5 6.5 7
Max Output(Kw) 677.5
Rated Voltage(V) 120/240 120/240
Fuel tank Capacity(L) 25 25 25
Running Time 50% Loading(H) 12 10 8.5
Running Time 100% Loading(H) 9 8 5
DC Output(V/A) 12/8.3 12/8.3 12/8.3
Phase Single/Three Single/Three Single/Three
Noise dB(7M) ≤76 ≤76 ≤78
Engine model 390(E) 420(E) CH440
Engine type Forced air-cooling,4-stroke,OHV
Displacement(CC) 389 420 429
Starting sysetem Recoil/Electric Start
N.W(Kg) 83/87 88/92 98/102
Dimension(L×W×H MM) 665x540x545 665x540x545 665x540x545

7
OPERATIONS
Generator Use
1.Before starting the engine:
a.Follow the Instructions to prepare the Generator.
b.Unplug all loads from the Generator.
c.Inspect the Generator and engine.
d.Fill the engine with the proper amount and type of both stabilizer-treated fuel
and oil.
2.Basic Generator Use Procedure - See following pages for specific instructions
1.Check that the Generator can handle the wattage needed to power your products.
2.Start the Engine, and allow the Engine and Generator to run and warm up for five
minutes after starting with no electrical load.
3. Plug in products.
4. When finished using the Generator, disconnect all electrical loads.
Note: Do not allow Generator to run out of fuel with loads attached.
6. Turn off the Engine.
7. Allow the Generator and its Engine to completely cool. Then store the unit in a clean,
dry, safe location out of reach of children and other unauthorized people.
3.Break-in Period :
A.Breaking-in the engine will help to ensure proper equipment and engine operation.
B.The operational break-in period will last about 3 hours of use .During this period:
Do not apply a heavy load to the equipment .
C.The maintenance break-in period will last about 20 hours of use. After this period:
•
NOTICE
After starting the engine, allow it to run at no load for five minutes with no load after
each start‑up so that the engine can stabilize.
Under normal operating conditions subsequent maintenance follows the schedule
explained in the SERVICE section .

8
1. Engine Oil
NOTICE
Engine oil is a major factor affecting engine performance and service life. Non-
detergent and 2-stroke engine oils will damage the engine and are not recommend-
ed.
!
OPERATIONS
Pre-operation Check
Check the oil level BEFORE EACH USE with the
generator on a level surface and the engine
stopped. Use 4-stroke motor oil that meets or
exceeds the requirements for API service classifi-
cation SF or SG. Always check the API SERVICE
label on the oil container to be sure it includes
the letters SF or SG.
SAE 10W-30 is recommended for general, all-temperature use. Other viscosities shown
in the chart may be used when the average temperature in your area is within the indi-
cated range.
1. Remove the oil filler cap and wipe the dipstick clean.
2. Check the oil level by inserting the dipstick into the filler neck without screwing it in.
3. If the level is low,add the recommended oil to the upper mark on the dipstick.

9
2.Fuel
1. Check the fuel level gauge.
2. Refill the tank if the fuel level is low. Do not fill above the shoulder of the fuel
strainer.
WARNING
Gasoline is extremely flammale and is explosive under certain conditions.
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 refueled or where gasoline is
stored.
Do not overfill the fuel tank (there should be no fuel in the filler neck). After refuel-
ing, make sure the tank cap is closed properly and securely.
Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any
fuel is spilled, make sure the area is dry before starting the engine.
Avoid repeated or prolonged contact with skin or breathing of vapor.
KEEP OUT OF REACH OF CHILDREN.
OPERATIONS
Fuel Tank capacity
2200
12 L
3000
15 L
3800
15 L
5500
25 L
6500
25 L
10000
25 L

10
OPERATIONS
Use unleaded gasoline with a pump octane rating of 86 or higher. This engine is certi-
fied to operate on unleaded gasoline.
Unleaded gasoline produces fewer engine and spark plug deposits and extends ex-
haust system life.
Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt
or water in the fuel tank.
Occasionally you may hear light "spark knock" or "pinging" (metallic rapping noise)
while operating under heavy loads. This is no cause for concern.
If spark knock or pinging occurs at a steady engine speed, under normal load, change
brands of gasoline. If spark knock or pinging persists, see an authorized gen-erator
dealer.
Running the engine with persistent spark knock or pinging is misuse, and the Distrib-
utor's Limited Warranty does not cover parts damaged by misuse.

11
OPERATIONS
Start The Engine
Make sure that the AC circuit breaker is in the OFF
position. The generator may be hard to start if a
load is connected.
NOTICE
Do not allow the starter grip to snap back. Return it slowly by hand.
Turn the fuel valve to the ON position.
Turn the choke lever to the CLOSE position.
Turn the engine switch to the ON position.
Pull the starter grip lightly until resistance is felt,
then pull briskly.

12
OPERATIONS
Stop The Engine
In an emergency:
To stop the engine in an emergency, move the engine
switch to the OFF position.
In normal use:
2. Move the engine switch to the OFF position.
1. Turn the AC circuit breaker to the OFF position.
3. Turn the fuel valve to the OFF position.

13
TRANSPORTING&STORAGE
When the equipment is to remain idle for longer than 20 days, prepare the
Engine for storage as follows:
When the equipment is to remain idle for longer than 20 days, prepare the Engine for
storage as follows:
1. CLEANING:
Wait for Engine to cool, and then clean Engine with dry cloth. NOTICE: Do not clean
using water. The water will gradually enter the Engine and cause rust damage. Apply a
thin coat of rust preventive oil to all metal parts.
2. FUEL:
To protect the fuel tank during storage, fill the tank with gasoline that has been treated
with a fuel stabilizer additive. Follow fuel stabilizer manufacturer’s recommendations
for use.
Fill tank in a well-ventilated area away from ignition sources. If the engine is hot from
use, shut the engine off and wait for it to cool before adding fuel. Do not smoke.
3. LUBRICATION:
A. Change engine oil.
b. Clean out area around spark plug. Remove spark plug and pour one tablespoon of
engine oil into cylinder through spark plug hole.
C.Replace spark plug, but leave spark plug cap disconnected.
D.Pull Starter Handle to distribute oil in cylinder. Stop after one or two revolutions
when you feel the piston start the compression stroke (when you start to feel re-
sistance).
4. STORAGE AREA:
Cover and store in a dry, level, well-ventilated area out of reach of children. Storage
area should also be away from ignition sources, such as water heaters, clothes dryers,
and furnaces
5. AFTER STORAGE:
Before starting the Engine during or after storage, keep in mind that untreated gasoline
will deteriorate quickly. Drain the fuel tank and change to fresh fuel if untreated gaso-
line has been sitting for a month, if treated gasoline has been sitting beyond the fuel
stabilizer’s recommended time period, or if the Engine does not start.
WARNING
During extended storage periods the Engine must be started every 3 months and
allowed to run for 15 –20 minutes or the Warranty is VOID.

14
SERVICE
1)Maintenance schedule
Follow the maintenance schedule. Remember that this schedule is based on the as-
sumption that your machine will be used for its designed purpose. Sustained high-
load or high-temperature operation, or use in unusually wet or dusty conditions, will
require more frequent service.
Maintenance
2)Engine oil change
Tips:Drain the oil while the engine is warm to assure rapid and complete draining.
Step 1: Remove the drain plug and sealing washer, remove the oil filler cap, and drain
the oil.
Step 2: Reinstall the drain plug and sealing washer. Tighten the plug securely.
Step 3: Refill with the recommended oil and check the oil level.

15
SERVICE
NOTICE
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely, unless you handle used oil on a daily ba-
sis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
Please dispose of used motor oil and containers in a manner that is compatible with
the environment. We suggest you take it in a sealed container to your local service sta-
tion or recycling center for reclamation. Do not throw it in the trash, pour it on the
ground or down a drain.
2200
0.6 L
3000
0.6 L
3500
0.6 L
5500
1.1 L
6500
1.1 L
10000
1.1 L
Engine Oil capacity

16
SERVICE
3).Air Filter Element Maintenance
A dirty air cleaner will restrict air flow to the carburetor. To prevent carbu-
retor malfunction, service the air cleaner regularly. Service more frequently when
operating the engine in extremely dusty areas.
WARNING
Using gasoline or flammable solvent to clean the filter element can
cause a fire or explosion. Use only soapy water or nonflammable solvent.
!
1.Unsnap the air cleaner cover clips, re-
move the air cleaner cover, and remove
the element.
2. Wash the element in a solution of
household detergent and warm water,
then rinse thoroughly, or
wash in nonflammable or high flash
point solvent. Allow the element to dry
thoroughly.
3. Soak the element in clean engine oil
and squeeze out the excess oil. The en-
gine will smoke
during initial start-up if too much oil is
left in the element.
4. Reinstall the air cleaner element and
the cover.

17
SERVICE
4).Sediment Cup Cleaning
The sediment cup prevents dirt or water which may be in the fuel tank from enter-
ing the carburetor. If the engine has not been run for a long time, the sediment cup
should be cleaned.
a) Turn the fuel valve to OFF. Remove the sediment cup and O-ring.
b) Clean the sediment cup and O-ring in nonflammable or high flash point solvent.
c) Reinstall the O-ring and sediment cup.
d) Turn the fuel valve ON and check for leaks.