maxwatt MX2000iS User manual

Generator Operator’s Manual

1 – 5ABOUT YOUR GENERATOR
6 - 11GENERAL SAFETY RULES
12 - 20GENERATOR SET UP AND OPERATION GUIDELINES
21 - 25CONTROLS FUNCTIONS, AND FEATURES AND DIAGRAMS
26 - 29PRE-OPERATINGCHECKS
30 - 33STARTINGTHEENGINE
34 - 35STOPPING THE ENGINE
36 - 42TROUBLESHOOTING AND SPECIFICATIONS
43 - 49MAINTENANCE
50 - 54STORAGE
55WIRING DIAGRAM
56LABELS
57 – 64WARRANTY INFORMATION
TABLE OF CONTENTS

ABOUT YOUR GENERATOR
Thank you for purchasing a MAXWATT generator (hereina er referred to as
“the generator”).
This generator is suitable for use on various trade worksites, recrea onal
such as camping and for use as backup power whether residen l or
commercial.
With built-in Pure Sine Wave technology (THD<5%), its perfect for
powering tools, domes c appliances as well as sensi ve electronics.
Please read and understand this manual for instruc ons on start-up, shut
down, opera ons, adjustments, maintenance as well as safety guidelines
before using this product. Please take all possible precau ons to protect
your own safety and that of the people in the immediate vicinity. This
manual is the latest version. Save this manual for future reference.
As this product is con nuously improved and upgraded, the manufacturer
reserves the right to modify this manual without no e. The manufacturer
shall not assume any liability for incorrect informa on contained in this
manual.
This manual is an essen l and important tool for the use of the
generator. When the generator is transferred to new owners, the
manual must be given to the new owners as well.
Some important informa on in this manual will be indicated in the
following way. The owner/ user must pay special a en on to these
instruc ons.
MAXWATT is constantly improving its products. All informa on supplied
in this manual is based on the latest product informa on available at the
me of prin ng. The specifica ons outlined herein are subject to change
without no e or obliga on. The purchaser and/or user shall assume
liability for any modifica on and/or altera ons of this equipment from
original design or manufacture.

HAZARD SIGNAL WORD DEFINITIONS
For any queries on the above, please contact Gentech Industries, the official
service agent for all MAXWATT generators and water pumps.
The range of MAXWATT generators is safe and reliable, but incorrect usage
of these products may cause personal injury and damage to the machine.
In order to operate the generator safely, strictly adhere to the operator’s
manual and please read it through carefully and thoroughly before using
the generator.
BEFORE STARTING
UNPACKING AND DELIVERY INSPECTION
You should inspect the generator immediately after you receive delivery
thereof. If you have any missing parts, please contact your place of
purchase. DO NOT attempt to operate the generator if there are any
missing parts. The generator is shipped without oil. You must add an
adequate amount of engine oil before using it for the first time. The
engine will be damaged beyond repair if it is started without oil. For oil
type, please see “Recommended Oil Type”section of this manual on page
9. Fresh regular RON 91 fuel must be used in this unit.
DO NOT use Premium or Ethanol based fuels.
SAFETY SIGNS
Comply with the instructions provided by the safety signs and symbols fitted
to the generator and in this manual. The generator and manual only feature
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the symbols relevant to the model purchased. Check that the symbols and
signs affixed to the unit are always present and legible, otherwise fit
replacements in the original positions.
GENERAL WARNINGS & DISCLAIMER
READ and UNDERSTAND this manual completely before using the engine.
Failure to properly set up, operate and maintain this engine could result in
serious injury or death from carbon monoxide poisoning, electric shock,
fire/explosions or burns. In particular be aware of the following hazards:
CD POISONING
Engines give off carbon monoxide, an odorless, colorless poisonous gas
that can kill you. You CANNOT smell it, see it or taste it. ONLY run an
engine OUTDOORS and AWAY from building air intakes.
NEVER run an engine inside any enclosed or semi-enclosed spaces,
including homes, basements, garages, sheds, boxes, RV’s, boats or pick-up
truck beds. These spaces can trap poisonous gases, EVEN if you run a fan or
open windows.
ELECTRIC SHOCK / ELECTROCUTION
High voltage electricity from the generator can kill. DO NOT operate in
wet locations or conditions. Be sure the generator is properly grounded.
Use only outdoor rated grounded extension cords of proper size.
NEVER plug the generator directly into a wall plug outlet. ANY connection
to a building’s electrical system MUST ISOLATE THE GENERATOR FROM
UTILITY POWER via a transfer switch installed by a licensed electrician.
Otherwise, back-feed from the generator into the power grid could kill
utility workers. See “Set up as a building back-up”on page 13 for additional
information.
BEFORE performing any maintenance on the generator, disconnect the
engine starting battery (if equipped) to prevent accidental start-up.
Disconnect the cable from the battery post indicated by a NEGATIVE,
NEG or (-) first. Reconnect the cable last.
HEAT
Unintentional spark can result in fire or electric shock.
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FIRE/EXPLOSION
DO NOT overload the engine (per rate capacity) and OPERATE ONLY in an
area with adequate cooling ventilation so the engine does not overheat.
The exhaust can be extremely hot. Keep the muffler at least 3 meters from
all combustible objects.
All fuels are flammable. Never fuel a running or hot engine. Never pump
fuel directly into the engine at a petrol station –use an approved
container to transfer the fuel. Ensure that there are no fuel leaks and keep
sources of sparks and flames away. Wait for the engine to be cool before
fueling. ALWAYS keep a fire extinguisher rated “ABC”nearby.
STOP!
CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS.
See the Power Load Planning and Management section to determine your
power load requirements and then compare to the generator’s rate
capacity.
INSPECT COMPONENTS
Closely inspect to make sure that there are not any components missing or
damaged.
ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you
will be connecting the generator to your building’s system.
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GENERAL SAFETY RULES FOR OPERATION
Save all warnings and instructions for future reference.
This equipment is to be used for the purpose for which it is designed
and intended.
Seek assistance if required when moving or lifting the generator.
WORK AREA SAFETY
Intended for outdoor use only. DO NOT operate in confined spaces
or indoors as carbon monoxide released from the exhaust can kill.
DO NOT operate in explosive atmospheres such as in the presence
of flammable liquids, gases or dust.
Keep children and bystanders away while operating a generator.
Distractions can cause you to lose control.
Keep your work area clean and well lit. Cluttered benches and dark
areas invite accidents.
This generator is not weatherproof. Exposure to rain, damp
conditions or extreme temperatures can cause damage or serious
injury.
PERSONAL SAFETY
Stay alert, watch what you are doing and use common sense when
operating a generator.
DO NOT use a generator while you are tired or under the influence
of drugs, alcohol or medication. A moment of inattention may
result in serious personal injury. Use personal protection
equipment. Always wear eye protection. Wear approved safety
impact eye goggles, dust mask, non-skid safety shoes, hard hat and
hearing protection for appropriate conditions.
DO NOT overreach. Keep proper footing and balance at all times.
This enables better control of the generator in unexpected
situations.
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Dress properly. DO NOT wear loose clothing, gloves, neckties or
jewelry. Keep your hair and clothing away from moving parts.
Loose clothes, jewelry or long hair can be caught in moving parts.
DO NOT let familiarity gained from frequent use of the generator
allow you to become complacent and ignore safety principles and
rules. A careless action can cause severe injury within a fraction of
a second.
For your own safety, do not operate your generator until it is
completely assembled and installed according to the instructions
and until you have read and understood all of the instructions.
GENERATOR SAFETY RULES
 DO NOT force the generator. Use the correct generator for your
application. The correct generator will do the job better and safer
at the rate for which it was designed.
DO NOT use the generator if the engine switch does not turn it on
and off. Any generator that cannot be controlled with the switch is
dangerous and must be repaired.
Know how to stop the generator without hesitation. Be
thoroughly familiar with proper use of the equipment and all
engine controls, output receptables and connections. Know how
to stop the engine quickly (see “Stopping the Generator”).
The engine owner must instruct all operators in safe
engine set-up and operation. Only trained adults should set up
and operate the engine. DO NOT let children operate it.
Carefully read about and understand the intended use of this
engine. DO NOT use for other purposes as unforeseen hazards or
equipment damage may result.
NEVER operate or let anyone else operate the engine
while under the influence of alcohol, drugs or medication.
DO NOT operate the engine unless all safety covers, guards and
barriers are in place and in good working order –and that all
controls are properly adjusted for safe operation.
DO NOT operate the generator with damaged, missing or
broken parts.
DO NOT modify the generator in any way. Modifications can
create hazards and will also void the warranty.
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NEVER attempt to modify the generator speed setting. The
generator speed is present for safe and optimal performance
of the generator. If speed needs adjusting, it must be done by
factory personnel.
NEVER attempt to connect external fuel sources in order to
increase generator run time. A larger tank at pressure or
higher elevation will cause a leak from the carburetor
during operation. A fire or an explosion could result.
Always turn off the generator and remove the spark plug(s) or
spark plug wire(s) b e fo re w o rk in g on the generator to prevent
accidental starting.
Always discharge the capacitor before working on the
generator head to prevent electrical shock. (See Maintenance &
Repair section of this manual for instructions on how to do this.)
The running generator gives off carbon monoxide, a
poisonous gas that can kill you. You CANNOT smell it, see it, or
taste it. Follow all instructions for site selection and positioning of
the generator and avoid inhaling the exhaust. If you start to feel
sick, dizzy or weak while using the generator, shut off the
generator and get to fresh air RIGHT AWAY. See a doctor. You may
have carbon monoxide poisoning.
Immediately turn off the generator if any of t h e following conditions
arise during operation:
1. Excessive change in generator speed, slow or
fast;
2. Sparking or arcs from generator;
3. Loss of electrical output;
4. Receptacle damage;
5. Generator misfire;
6. Excessive vibration;
7. Flame or smoke or Abnormal noise.
This product contains or emits chemical k no w n t o the
Commonwealth of Australia to cause cancer, birth defects or other
reproductive harm. Avoid inhalation of exhaust.
DO NOT operate the engine or handle any electrical equipment
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while standing in water, while barefoot, while hands are wet or
while in the rain or snow. An electric shock may result.
Avoid contact with bare wires, terminals, connections, etc. while
the generator is running.
If an electric shock accident occurs, immediately shut down the
source of electrical power. If this is not possible, attempt to free
the victim from the live conductor. Avoid direct contact with the
victim. Use a non- conducting implement, such as a dry rope or
board, to free the victim from the live conductor. Administer/apply
applicable first aid and get immediate medical help.
Never smoke near the running engine and never operate near
sources of sparks or flames.
SERVICE
Have your generator serviced by a qualified repair person using only factory
approved replacement parts. This will ensure that the safety of the
generator is maintained. Incorrectly fitted parts will void your warranty.
The equipment may only be used, maintained or repaired by those persons
who understand and have been instructed about the potential dangers.
Independent changes in the equipment cancel any manufacturer’s liability
for any damages that result from these changes.
APPROPRIATE USE
Use the equipment only when it is in technically perfect condition and only
for appropriate jobs, with an awareness of safety and possible dangers,
based on observation of the operating instructions. In particular, problems
which could influence the operational safety must be dealt with
immediately.
All of the manufacture’s safety, work and maintenance regulations as well
as the given norms in the Technical Data must be observed.
STATIC ELECTRICITY AND FILLING THE PETROL TANK
Static electricity can initiate from un-grounded petrol tanks or containers
from flowing petrol and persons carrying a static electric charge. Static
electricity can explosively ignite petrol vapours that are present during the
8

fueling process, resulting in serious burns to nearby persons.
Many objects can accumulate and retain a static electric charge. Objects
made of non-conductive materials (eg. plastics) easily accumulate and
retain static electrical charge, as can objects made of conductive material
(eg. metal, water) if they are not electrically grounded.
To avoid static electricity while fueling, certain steps must be followed
before and during the fueling process in order to minimize and safely
dissipate static charge build-up:
Touch a grounded metal object before starting.
Always dissipate static charge from your body before beginning
the fueling process by touching a grounded metal object at a safe
distance away from the fuel source.
Use a portable container to fill the tank. NEVER fill the engine’s
petrol tank directly from the fuel pump –the engine’s tank is not
grounded and the high velocity flow of petrol from a fuel pump
can cause static electric build-up. Use an approved portable
container to transfer to the engine’s tank.
TYPICAL SOURCES OF STATIC ELECTRIC HAZARDS DURING
FUELING
The following objects can accumulate a static electric charge and cause
an ignition spark in typical fueling situations:
Ungrounded tanks/containers.
Any ungrounded fuel tank or container can accumulate a static electric
charge as a result of contact with other objects or friction during
transportation. This static electricity can discharge as a spark to the
grounded petrol dispenser nozzle as the nozzle is first brought close to
the tank/container at the beginning of the fueling process.
Flowing petrol. Most people are not aware that petrol accumulates
static electric charge while flowing through a hose or pipe. This charge
then transfers to and accumulates in the gas tank or container that is
being filled. The total amount of charge accumulation depends on the
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amount of gas pumped into the container, the speed with which it is
pumped, and whether or not the tank/ container is grounded. If
sufficient static electric charge accumulates in the fuel tank or
container during the fueling process, the tank/container may discharge
a spark to the grounded petrol dispenser nozzle.
A person dispensing the petrol can carry a static electric charge on their
body, typically resulting from contact with their car seat or electronics.
The static electricity can discharge a spark between that person’s hand
and either the grounded dispenser nozzle or the fuel tank opening.
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GENERATOR SET UP
PLANNING THE POWER LOAD
Plan your power load so that you do not exceed the generator’s rate
capacity. To calculate the running and start wattage requirements for
the devices you will be powering, follow the steps on page 18.
SET UP THE PORTABLE POWER SOURCE
This generator is designed to provide up to its maximum power (in was)
of electrical power. When using the generator as a portable power source,
you can plug electric devices and appliances directly into the generator’s
electrical outlets. This generator is equipped with two SAA approved IP66
rate socket outlets. Make sure you plug each electrical device/appliance
into the correct generator outlet based on the device’s plug configuration
and voltage/amperage rating. NEVER exceed the amperage rating of an
outlet.
Note: You must NOT overload the generator.
Overloading may cause serious damage to the generator and aached
electrical devices.
SET UP AS BUILDING BACK UP
To set up as a building backup, you must arrange for a licensed electrician to
connect the generator to your building’s electrical system via the installation
of an approved transfer switch. The transfer switch must be installed in
accordance with the building’s electrical code and guidelines supplied by
the power company.
A transfer switch does the following:
Safely connects the generator to your building’s electrical system
by isolating your generator from your utility company’s power
lines.
Connects your generator to a critical subset of your building’s
circuits that are needed for emergency power needs.

Note:
Regardless of whether you use your generator as a back-up power
source connected to a building or as a portable power source, you
MUST NOT overload the generator. Overloading may cause serious
damage to the generator and attached electrical devices.
If your generator will be connected to your building’s system, it MUST
ALWAYS BE isolated from the utility power grid with an approved transfer
switch installed by a licensed electrician, in compliance with all applicable
building and electrical codes and in accordance with the guidelines
supplied by the power company.
There may be Federal or State Occupational Safety and Health
Administration (OSHA) regulations, local codes or ordinances that apply to
the intended use of the generator.
Please consult a qualified electrician, electrical inspection or the
local agency having jurisdiction.
In some areas, generators are required to be registered with local
utility companies. If the generator is used at a construction site,
there may be additional requirements that must be observed.
GROUNDING THE GENERATOR
Standard generators are protected by electrical separators. This equipment
has a thermic protection device and/or magnet-to-thermic device to
protect against a surge of current, overloading and short-circuiting. In these
cases, the generator should under NO circumstances, be earthed using the
terminal “PE” or with any other part of the generator.
12

If a licensed electrician installs the generator with a connection to your
building’s electrical circuit for use as a back-up power system, grounding
may alternatively be completed through the building’s grounding system.
Ask your electrician.
If the generator is not grounded through your building’s system, follow the
procedure below. This procedure can only be carried out by a licensed
electrician.
1. Drive a ¾ ”or 1”copper pipe or rod into the
Ground close to the generator. The pipe/rod
must penetrate moist earth –the depth required
will be dictated by local soil conditions.
2. Connect an approved ground clamp
to the pipe.
3. Run a 10-gauge wire from the clamp to the
generator grounding post located on the rear
of the generator head.
4. Do not connect the generator grounding post
to a water pipe or a ground used by the radio system.
EXTENSION CORDS
Extension cords may be used to power devices that are located at a
distance from the generator. However, use only Australian approved
outdoor-rated, grounded extension cords.
Locate the generator in a convenient place and where possible, avoid
long extension leads and possible damage to leads by pedestrian or
vehicular traffic.
Extension leads should be heavy duty with at least 1mm of appropriate
current rating and in any case, not less that 1mm cross-section of
conductor and must incorporate an earthing conductor to ensure that
there is not any voltage difference between the generator set and any
equipment powered by the generator.
13

The electrical continuity of the “earthing”core should be checked
periodically from pin to socket to ensure continued electrical safety.
SELECT A SUITABLE SITE
Before using the generator, you must select a suitable OUTDOOR location
for installation and operation that meets the following criteria:
DRY, LEVEL SURFACE
The generator should be positioned on a dry, firm and level surface. Ensure
that the generator sits level and will not slide or shift during operation. If
applicable, block the generator’s wheels to prevent sliding and shifting.
OUTDOORS ONLY
Follow the directions below for choosing a location to operate your
generator in order to avoid carbon monoxide poisoning:
The location you choose to operate the generator must be
OUTDOORS and away from all building air intakes.
14

Never run the generator inside any closed or semi-enclosed
spaces (even if outdoors), including homes, garages,
basements, sheds or boxes. These spaces can trap poisonous
gases, even if you run a fan or open windows.
Ensure that working, battery-operated or battery back-up
carbon monoxide alarms are used in any dwelling/structure
that is in close proximity to the running operator.
Note: This generator is NOT designed or approved for use in vehicles or
marine applications. Never run the generator inside RVs or other
vehicles such as boats or on pick-up truck beds.
ADEQUATE COOLING AND VENTILATION
The generator needs adequate unobstructed flow of air to allow
for proper cooling of the engIne and generator.
Never place the generator immediately adjacent to a building
or other structure –allow at least 2 metres clearance.
Do not run the generator in close proximity to other heat-
generating equipment, such as another generator.
The combined heat that is generated may raise air temperature
in the immediate area and there will not be adequate cooling
ventilation.
Do not allow debris to accumulate and block airflow. Do not
operate with a tarp, blanket, or cover surrounding the generator.
HOT EXHAUST CLEARANCE
Make sure your generator’s exhaust system is at least 2 meters
from all combustible materials and buildings/ structures.
Equip the engine with a spark arrestor if the generator will be used
near any ignitable forest, brush, or grassy land. (see the
“Specifications”section of this manual to determine if your
generator is already equipped).
Make sure you comply with applicable local, state and federal
codes.
15

Keep a fire extinguisher rated “ABC”nearby. Keep it properly
charged and be familiar with its use.
NO WET CONDITIONS
Choose a location where the generator will NOT be exposed to rain, snow or
direct sunlight. Exposure to water can cause an electric shock. You may
operate the generator under an outdoor canopy-like structure of heat-
resistant material that is open on all sides.
Make sure that all parts of the canopy are at least 2m from the exhaust and
allow for adequate clearance above the generator so that heat does not
build up.
OPERATE AWAY FROM DUST/DIRT
Do not use the generator in extremely dusty or dirty conditions. Excessive
dust and dirt can cause premature failure of the machine.
HEARING PROTECTION
Generators can product noise levels >70dB in close proximity, which can be
dangerous to human hearing with prolonged exposure to the running
generator for an extended period of time.
An Important Message about Temperatures
Your generator is designed and rated for continuous operation at ambient
temperatures up to 40 degrees Celsius. When your generator is needed, it
may be operated at temperatures ranging from -15 degrees Celsius to 50
degrees Celsius for short periods. If the generator is exposed to
temperatures outside this range during storage, it should be brought back
within this range before operation.
In any event, the generator must always be operated outdoors, in a well-
ventilated area and away from doors, windows and other vents.
When operated above 25 degrees Celsius, there may be a decrease in
power.
16

Maximum wattage and current area subject to and limited by such factors
as fuel BTU content, ambient temperatures, altitude, engine condition etc.
Maximum power decreases about 3.5% for each 1000 feet above sea level,
and will also decrease about 1% for each -12.2 degrees Celsius above16
degrees Celsius ambient temperature.
POWER LOADING MANAGEMENT
Your generator MUST be sized properly to provide both the running and
starting (surge) wattage of the devices you will be powering. Before using
your generator, determine the running and starting wattage requirements
of all the electrical devices you will be powering simultaneously.
Following below are 4 simple steps and an example on the right:
Step 1 Determine the tools and appliances you want to power at the same
time.
Step 2 List the start up and running power usage
(watts) for each product.
Step 3 Add the total power usage and add 10% as a safety net.
Step 4 Choose a generator with a rated maximum power than equals or
exceeds your total requirements. In this case, a generator with a
rated power of at least 3108W and a maximum power output
greater than 7233W would be required.
Use the following formula to convert voltage and amperage to
watts: Volts x Amps = Watts
To prolong the life of your generator and attached devices, follow
these steps to add electrical load:
1. Start the generator without any electrical load attached.
2. Allow the generator to run for several minutes to stabilize.
3. Plug in and turn on the first item. It is advised to attached
17

the item that requires the largest load first.
4. Allow the generator to stabilize.
5. Plug in and turn on the next item.
6. Allow the generator to stabilize.
7. Repeat 5 and 6 for each additional item.
CONNECTING ELECTRICAL LOADS
1. Let the engine stabilize and warm up for a few minutes after
starting.
2. Prior to powering tools and equipment, make sure the generator’s
rate voltage and amperage capacity (120V AC @ 7 AMPs, 12V DC @
8 AMPs) is adequate to supply all electrical loads that the unit will
power. If powering exceeds the generator’s capacity, it may be
necessary to group one or more of the tools and/or equipment for
connection to a separate generator.
3. Once the generator is running, simply connect the power cords of
120V AC dual outlets and/or the power cord of a 12V DC tool to the
DC terminals.
4. DO NOT connect 3-phase loads to the generator.
5. DO NOT connect 50Hz loads to the generator.
6. DO NOT overload the generator.
STARTING POWER CONSUMPTION
Electronic appliances and brushed motors generally will not draw more
than running watts at start up.
Induction motors in equipment like air conditioners, welders, water pumps
and compressors can draw 2 to 5 times their running power to start.
Please consult your equipment’s rating label, manual or the manufacturer
to confirm specific requirements.
If only the running wattage is given on the nameplate for a device with an
electric motor, the starting wattage can approximate to be three to five
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