Navigator NG2500 User manual

P/N:323745451 Rev:01
OWNER’S MANUAL
Read all safety precautions and instructions carefully
before operating equipment.
Ensure engine is stopped and level before performing
any maintenance or service.
IMPORTANT:
Record product information to reference when ordering parts or
obtaining warranty coverage.
Serial Number:
PORTABLE
GENERATOR
MODEL NUMBER
NG2500
NG3500
N
N
G3500E2
G8500E2
NG9500E2
Purchase Date:

Table of Contents
. . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Precautions . . . . . . . . . . . . . . . . . . . . .2
Unpacking the Generator. . . . . . . . . . . . . . . .6
Parts Included. . . . . . . . . . . . . . . . . . . . . . . .6
. . . . . . . . . .7
Assembly . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 8
Install the Wheel Kit . . . . . . . . . . . . . . . . . . 8
Install the Support Leg. . . . . . . . . . . . . . . . 8
Install the Handle. . . . . .. . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . .9
Controls and Features. . . . . . . . . . . . . . . . . 10
Generator. . . . . . . . . . . . .. . . . . . . . . . . . . .10
Control Panel. . . . . . . . . . . . . . . . . . . . . . . 11
Specifications. . . . . . . . . . . . . . . . . . . . . . . . 12
Add Engine Oil . . . . . . . . . . . . . . . . . . . . . .13
Low Oil Shutdown . . . . . . . . . . . . . . . . . . .13
Add Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Grounding. . . . .. . . . . . . . . . . . . . . .. . . . . .15
System.. . . . . . . . . . . . . . . . . . . . . . .. . . . . .15
Operation . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 16
Generator Location . . . . . . . . . . . . . . . . . . 16
Surge Protection . . . . . . . . . . . . .. . . . . . . .16
Starting the Generator (Recoil Start) . . 17
Starting the Generator (Electric Start) .. 18
Connecting Electrical Loads . . . . . . . .. . . 19
Stopping the Engine . . . . . . . . . . . . . . . . . 20
Low Oil Shutdown . . . . . . . . . . . . . . . . . . 20
Do Not Overload Generator . . . . . . . . . . . 20
Introduction
Removal Of Shipping Supports
Battery Cable Connection
Connecting to a Building’s Electrical
Maintenance And Storage. . . . . . . . . . . . . . 21
Maintenance Schedule . . . . . . . . . . . . . 21
Engine Maintenance .. . . . . . . . . . . .. . . . 22
Change Engine Oil . . .. . . . . . . . . . . . . . . 22
Air Filter Maintenance. . . . . . . . . . . . . . .22
Spark Plug Maintenance. . . . . . . . . . . . . 23
Cleaning Fuel Strainer . . . . . . . . . . . . . 23
. . . . 23
Generator Maintenance . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . .24
Service and Storage . . . . . . . . . . . . . . . .. 25
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . .27
Inspect Muffler . . . . . . . . . . . . . . .
Battery Replacement
English

Thank you for purchasing a Navigator generator.
This manual covers operation and maintenance of the Navigator generators. All information in this
publication is based on the latest production information available at the time of approval for printing.
The manufacturer reserves the right to change, alter or other wise improve the generator and this
documentation at any time without prior change.
Page 01
This manual contains safety information to make you aware of the hazards and risks associated
with generator products and how to avoid them. This generator is designed and intended only
for supplying electrical power for operating compatible electrical lighting, appliances, tools and
motor loads, and is not intended for any other purpose. It is important that you read and
understand these instructions thoroughly before attempting to start or operate this equipment.
Save these original instructions for future reference.
Important Safety Information
The manufacturer cannot possibly anticipate every possible circumstance that might involve a
hazard. The warnings in this manual and the tags and decals affixed to the unit are therefore not
all-inclusive. If you use a procedure, work method or operating technique that the manufacturer
does not specifically recommend you must satisfy yourself that it is safe for you and others. You
must also make sure that the procedure work method or operating technique that you choose
does not render the generator unsafe.
SAFETY INFORMATION
DANGER WARNING CAUTION
DANGER indicates a
potentially hazardous
situation which, if not
avoided. WILL result in
death or serious injury.
WARNING indicates a
potentially hazardous
situation which, if not
avoided, could result in
death or serious injury.
CAUTION indicates a
potentially hazardous
situation which, if not
avoided, may result in minor
or moderate personal injury,
or property damage.
Toxic Fumes
Fire Hazard
Hot Surface.
Do Not Touch the Surface.
Kickback
Risk of Electric Shock
Explosion Hazard
Rotating Parts Entanglement
Hazard
Operator’s Manual
INTRODUCTION
English

SAFETY PRECAUTIONS
Page 02
WARNING
POISONOUS GAS HAZARD.
•
•
•
•
WARNING
WARNING
•
English
The engine exhaust from this product contains
chemicals to cause cancer, birth defects, or
other reproductive harm.

Page 03
CORRECT USAGE
Example location to reduce risk of carbon monoxide poisoning
•ONLY use outside and downwind, far away from windows, doors and vents.
•Direct exhaust away from occupied spaces.
INCORRECT USAGE
Do not operate in any of the following locations:
Near any door, window or vent
Garage
Basement
Crawl Space
Living Area
Attic
Entry Way
Porch
Mudroom
English

Page 04
WHEN OPERATING EQUIPMENT
•
DO NOT tip engine or equipment at angle
which causes fuel to spill.
DO NOT stop engine by moving choke
control to “Start” position.
•
•
WHEN TRANSPORTING, MOVING
OR REPAIRING EQUIPMENT
Transport/move/repair with fuel tank
EMPTY or with fuel shutoff valve OFF.
•
•DO NOT tip engine or equipment at angle
which causes fuel to spill.
Disconnect spark plug wire.
•
WHEN STORING FUEL OR EQUIPMENT
WITH FUEL IN TANK
•
WARNING
Generator voltage could cause
electrical shock or burn resulting
in death or serious injury.
•
WARNING
•
•NEVER start or stop engine with electrical
devices plugged in and turned on.
WARNING
Fuel and its vapors are extremely flammable
and explosive which could cause burns, fire,
or explosion resulting in death or serious
injury and/or property damage.
WHEN ADDING OR DRAINING FUEL
Turn generator engine OFF and let it cool at
least 2 minutes before removing fuel cap.
Loosen cap slowly to relieve pressure in tank.
Fill or drain fuel tank outdoors.
•
•DO NOT overfill tank. Allow space for fuel
expansion.
If fuel spills, wait until it evaporates before
starting engine.
•
Keep fuel away from sparks, open flames,
pilot lights, heat, and other ignition sources.
Check fuel lines, tank, cap, and fittings
frequently for cracks or leaks. Replace if
necessary.
DO NOT light a cigarette or smoke.
•
•
•
•
WHEN STARTING EQUIPMENT
Ensure spark plug, muffler, fuel cap, and air
cleaner are in place.
•
DO NOT crank engine with spark plug
removed.
•
Use approved transfer equipment, suitable
for the intended use, to prevent backfeed by
isolating generator from electric utility
workers.
English
When using generator for backup power,
notify utility company.
Use a ground fault circuit interrupter (GFCI)
in any damp or highly conductive area,
such as metal decking or steel work.
DO NOT touch bare wires or receptacles.
•
•
•
•
•
•
DO NOT use generator with electrical cords
which are worn, frayed, bare or otherwise
damaged.
DO NOT operate generator in the rain or
wet weather.
DO NOT handle generator or electrical
cords while standing in water, while
barefoot, or while hands or feet are wet.

Page 05
WARNING
Unintentional sparking
could cause fire or
electric shock resulting
in death or serious
injury.
WHEN ADJUSTING OR MAKING REPAIRS TO
YOUR GENERATOR
Disconnect the spark plug wire from the
spark plug and place the wire where it cannot
contact spark plug.
•
WHEN TESTING FOR ENGINE SPARK
Use approved spark plug tester.
•DO NOT check for spark with spark plug
removed.
•
WARNING
NEVER operate generator without protective
housing or covers.
DO NOT wear loose clothing, jewelry or
anything that could be caught in the starter
or other rotating parts.
Tie up long hair and remove jewelry.
•
•
•
•
•
DO NOT exceed the generator’s wattage
amperage capacity.
Start generator and let engine stabilize
before connecting electrical loads.
NOTE:
•
•
•
•
CAUTION
Exceeding generators wattage/amperage capacity
could damage generator and/or electrical devices
connected to it.
Connect electrical loads in OFF position,
then turn ON for operation.
Turn electrical loads OFF and disconnect
from generator before stopping generator.
WARNING
Exhaust heat/gases could ignite combustibles,
structures or damage fuel tank causing a fire,
resulting in death or serious injury and/or
property damage.
Contact with muffler area could cause burns
resulting in serious injury.
DO NOT touch hot parts and AVOID hot
exhaust gases.
Allow equipment to cool before touching.
It is a violation of California Public Resource
Code, Section 4442, to use or operate the
engine on any forest-covered, brush-covered,
or grass-covered land unless the exhaust
system is equipped with a spark arrester, as
defined in Section 4442, maintained in
effective working order. Other states or
federal jurisdictions may have similar laws.
Contact the original equipment manufacturer,
retailer, or dealer to obtain a spark arrester
designed for the exhaust system installed on
this engine.
Replacement parts must be the same and
installed in the same position as the original
parts.
•
•
•
•
English
•DO NOT allow unqualified persons or
children to operate or service generator.
•
•
•
•
•
Use generator only for intended uses.
If you have questions about intended use,
ask dealer or contact local service center.
Operate generator only on level surfaces.
DO NOT expose generator to excessive
moisture, dust, dirt, or corrosive vapors.
DO NOT insert any objects through cooling
slots.
If connected devices overheat, turn them off
and disconnect them from generator.
•
NOTE:
Improper treatment of generator could damage
it and shorten its life.

Page 06
WARNING
M edical and Life S upport U ses.
NEVER use this product to power life support
devices or life support appliances.
NEVER use this product to power medical
devices or medical appliances.
Inform your electricity provider immediately
if you or anyone in your household depends
on electrical equipment to live.
Inform your electrical provider immediately
if a loss of power would cause you or anyone
in your household to experience a medical
emergency.
•
•
•
•
UNPACKING THE GENERATOR
•
•
Parts Included
Your gasoline powered generator ships with
the following parts:
1. Axle pin . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2. Wheel . . . ... . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Flat Washer. . . . . . . . . . . . . . . .. . . . . . . . . . . . . .2
4. Cotter pin. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .2
5. Wrench for Spark plug . . . . . . . . . . . . . . . . . . . .1
6. Double Open wrench (10mm & 12mm). . . . 1
7. Handle Pin
8. Cotter Pin
10. Support Leg with Vibration Mounts . . . . . . 1
11. Flange Bolt (M8x16 for Support Leg) . . . . . 2
12. Flange Lock Nut (M8) . . . . . . . . . . . . . . . . . . . 4
13. Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14. Quick Reference Guide . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .1
. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .1
9. Handle . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 1
English
Shut off generator if:
-Electrical output is lost.
-Equipment sparks, smokes, or emits flames.
-Unit vibrates excessively.
•
Open carton and Remove packaging materials.
Remove generator, accessories boxes, and
literature from carton. If any items are missing
or damaged, contact our product service
department at 0098625 84531706.
12
13

REMOVAL OF SHIPPING SUPPORTS
Before you can run your new generator, follow
these simple instructions:
CAUTION
Failure to remove these items can result
in damage to your generator, possible
Personal injury and void your warranty.
Refer to the following instructions and pictures
to remove the attached engine support brackets
(red) under the engine.
3. You may discard these brackets, as it is no longer
required for normal operation of your generator.
Your generator is now ready for use. Refer to
your owner's manual for proper oil fill and
startup instructions.
Red Engine Support Brackets
Remove These Nuts &
Bolts as Indicated.
Supplied Wrenches
Page 07
English

Page 08
English
Install the Wheel Kit
The wheel kit is not intended for over-the-road
use.
Install the Support Leg
ASSEMBLY Install the Handle
1. Place the handle Kover the mounting channel
on the frame.
2. Slide the handle pin Fthrough the mount
point on the frame.
3. Secure the handle and handle pin with the
cotter pin H.
4. Replace the step 2 and 3 to attach another
handle.
A
B
C
F
The generator requires some assembly prior to
usage. If problems arise when assembling the
generator, call
F
E
G
H
K
1. Before adding wheels, tip the generator on
its side.
2. Slide the axle pin Athrough the wheel B.
3. Slide the axle pin Athrough the mount point
on the frame and flat washer D.
4. Secure the wheel and axle pin with the cotter
pin C.
5. Repeat steps 2-4 to attach another wheel.
1. Attach the support leg Gto the generator
frame with flange bolts E(M8x16) and flange
lock nuts F(M8).
2. Tip the generator slowly so that it rests
on the wheels and support leg.
3.Tighten bolt Eand nut Fwith provide
wrenches.
CAUTION
D

Page 09
English
Battery Cable Connection
You will need to use 8mm box wrenches to connect the battery cables to battery.
NOTE:
The generator comes equiped with the positive red cable(red cable) already attached.
1. Verify the positive (+) battery cable (red boot) is securely tightened to the positive (+) battery
post. Make sure boot is over battery post.
2. Remove bolt M5X10 and M5 nut from black cable ring.
3. Remove vinyl cap from the negative(-) battery post. Locate negative (-) black cable and route
to the negative(-) battery post. Tight the cable with bolt M5X10 and M5 nut. Cover the post with
black boot.
M5X10
M5
Black Cable
Ring
Black Boot
Red Cable(+)
Black Cable(-)

Page 10
CONTROLS AND FEATURES
Generator
1- Fuel Gauge
2- Fuel Tank
3- Fuel Cap
4- Choke Lever(behind air filter box)
5- Fuel Valve
6- Air Filter
7- NAVIGATOR OHV Engine
8- Recoil Starter
9- Flat Free Wheel
10- Oil Filler Cap
11- Control Panel
12-
13-
Battery
Handle
English
*We are always working to improve our products. Therefore, the enclosed product may differ
slightly from the image on this page.
1
2⑴
⑵
⑶
⑷
⑸
⑹
⑺
⑻
⑼
⑽⑿⑾
⒀

1
2Time Switch – Time your generator.
3
4
5
Ground Terminal – Consult an electrician
for local grounding regulations.
Volt-Meter – Show the voltage.
Page 11
NOTE: Total power drawn from all receptacles must not exceed the name plate rating.
Engine Switch – Used to start engine
from the starter motor(Electric start model
only). To start engine, press and hold the
switch in the “START”(ll) position, the
engine will crank and attempt to start. When
the engine starts, release the switch to the
“RUN”(l) position.
Control Panel
English
2345
6
1
6
230V, 30A Lock Receptacle
Maximum full load current may be drawn from this
230 Volt, 30 Amp receptacle.
V
Time switch tech enables you to embrace quality
sleep.
Say No to off the gen outside every night and
don’t worry the risk of robbery and kidnapping
meantime.

Page 12
SPECIFICATIONS
AN IMPORTANT MESSAGE ABOUT TEMPERATURE:
When operated above 77°F(25°C) there may be a decrease in power.
Maximum wattage and current are subject to and limited by such factors as fuel BTU content
ambient temperature, altitude, engine condition and etc. Maximum power decreases about
3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 10°F(-12.2°C)
above 60°F(16°C) ambient temperature.
•
•
English
Model
Rated AC Voltage
Phase
Power Factor
Voltage Regulator
Alternator Type
Running Watts
Starting Watts
Engine
Engine Type
Displacement
Low Oil Shutdown
Ignition System
Starting System
Fuel
Capacity Fuel Tank
Lubricating Oil Capacity
Carburetor Type
Air Cleaner
P.T.O. Shaft Rotation
230V
NG2500
3200
AVR
Single
1
Single Cylinder, 4-Stroke OHV Air Cooled
196cc 439cc
Breakless Ignition Type, Flywheel Magneto
Unleaded Automotive Gasoline
23L
0.6L
35L
1.1L
Counter Clockwise (Facing P.T.O.)
Float
Brushed
Polyurethane Type
Yes
2600
NAVIGATOR
Rated Fequency 50Hz
Oil Type
See “Add Engine Oil” Section
Spark Plug
LD F6TC
Recoil
NG3500 NG3500E2 NG8500E2 NG9500E2
2300 2900
5500
5000
6500
6000
Recoil/Electric Start

ADD ENGINE OIL
Page 13
1.Place generator on a flat, level surface.
2.Clean area around oil fill and remove yellow
oil fill cap/dipstick.
3.Wipe dipstick clean.
NOTE:
The engine is equipped with a low oil shut-off and
will stop when the oil level in the crankcase falls
below the threshold level.
NOTE:
We consider the first 5 hours of run time to be
the break-in period for the unit. During the break
in period stay at or below 50% of the running
watt rating and vary the load occasionally to allow
stator windings to heat and cool. Adjusting the
load will also cause engine speed to vary and help
seat piston rings.
CAUTION
The unit is equipped with a low oil shutdown.If
the oil level becomes lower than required,the
sensor will activate a warning device or stop the
engine.
If generator shuts off and the oil level is within
specifications, check to see if generator is sitting
at an angle that forces oil to shift. Place on an
even surface to correct this. If engine fails to
start, the oil level may not be sufficient to
deactivate low oil level switch. Make sure the
sump is completely full of oil.
(H)
DRAIN PLUG
(L)
5.Replace oil fill cap/dipstick and fully tighten.
6.Oil level should be checked prior to each use
or at least every 8 hours of operation. Keep oil
level maintained.
4.Using oil funnel, slowly pour contents of
provided oil bottle into oil fill opening to the
"H" mark on dipstick. Be careful do not
overfill. Overfilling with oil could cause the
engine to not start or hard starting.
Low Oil Shutdown
Degrees Celsiusº(Outside)
Full Synthetic 5W-30
Degrees Fahrenheitº(Outside)
5W-30 20W-50
10W-40
CAUTION
H
L
English
The recommended oil type is 20W-50 automotive
oil. However

ADD FUEL
Page 14
Fuel must meet these requirements:
•Clean, fresh, unleaded gasoline.
Use regular UNLEADED gasoline with the
generator engine with a minimum 87 octane
/ 87 AKI (91 RON).
For high altitude use, see "Operation at High
Altitude".
Do not use gasoline with more than 10%
alcohol such as E85 or ethanol.
•
•
Failure to follow Operator's Manual for fuel
recommendations voids warranty.
Avoid generator damage.
DO NOT use unapproved gasoline such as E85.
DO NOT mix oil in gasoline.
DO NOT modify engine to run on alternate fuels.
•
•
•
WARNING
Fuel and its vapors are extremely flammable
and explosive which could cause burns, fire or
explosion resulting in death, serious injury
and/or property damage.
WHEN ADDING FUEL
Fill fuel tank outdoors.
DO NOT overfill tank. Allow space for fuel
expansion. If the tank is overfilled, fuel
can overflow onto a hot engine and cause fire
or explosion. Wipe up any spilled fuel
immediately.
If fuel spills, wait until it evaporates before
starting engine.
Keep fuel away from sparks, open flames,
pilot lights, heat, and other ignition sources.
Check fuel lines, tank, cap and fittings
frequently for cracks or leaks. Replace if
necessary.
DO NOT light a cigarette or smoke when
filling the fuel tank.
•
•
•
•
1.Clean area around fuel fill cap, remove cap.
2.Slowly add unleaded fuel to fuel tank. Be
careful not to fill above the red fuel level
indicator . This allows adequate space for
fuel expansion.
3.Install fuel cap and let any spilled fuel
evaporate before starting engine or wipe up
any spilled gasoline.
CAUTION
Slowly add unleaded gasoline to fuel tank.
Do not overfill tank.
Do not fill above top of fuel screen. This
will all expansion in hot weather and
prevent overflow.
•
•
•
English
Grounding
The National Electric Code requires your generator
must be properly connected to an appropriate
ground to help prevent electric shock.
Failure to properly ground the
generator can result in electric
shock.
WARNING

Page 15
THERE IS A PERMANENT CONDUCTOR BETWEEN
THE GENERATOR (STATOR WINDING) AND THE
FRAME.
Use approved transfer equipment to prevent
backfeed by isolating generator from electric
utility workers.
When using generator for backup power, notify
utility company.
Use a ground fault circuit interrupter (GFCI) in
any damp or highly conductive area, such as
metal decking or steel work.
DO NOT touch bare wires or receptacles.
DO NOT use generator with electrical cords
which are worn,frayed, bare or otherwise
damaged.
DO NOT operate generator in the rain or wet
weather.
DO NOT handle generator or electrical cords
while standing in water, while barefoot, or
while hands or feet are wet.
DO NOT allow unqualified persons or children
to operate or service generator.
Connecting to a Building's Electrical System
WARNING
Generator voltage could cause
electrical shock or burn resulting
in death or serious injury.
•
•
•
•
•
•
•
•
English

5. OPERATION
Page 16
Generator Location
Make sure you review each warning in order to
prevent fire hazard.
Keep area clear of inflammables or other
hazardous materials.
Select a site that is dry, well ventilated and
protected from the weather.
Keep exhaust pipe clear of foreign objects.
Keep generator away from open flame.
Keep generator on a stable and level surface.
WARNING
Surge Protection
Voltage fluctuation may impair the proper
functioning of sensitive electronic equipment.
WARNING
POISONOUS GAS HAZARD.
•
•
•
•
Do not block generator air vents with paper or
other material.
CAUTION
Tilting can cause fuel spillage.
CAUTION
English

Page 17
Starting the Generator (Recoil Start)
1. Before starting the generator, check for loose
or missing parts and for any damage which
may have occurred during shipment.
2. Check oil level and fuel.
6. Move the choke lever to the “START” position.
5. Flip the engine switch to the “ON(l)” position.
8. Do not over-choke. As soon as engine starts
and warms up, move the choke lever to the
“RUN” position.
9. Allow generator to run at no load for few
minutes upon each initial start-up to permit
engine and generator to stablize.
WARNING
When starting engine, pull cord slowly until
resistance is felt and then pull rapidly to avoid
kickback.
4. Turn the fuel valve to the “ON” (l)position.
7. Pull the starter cord slowly until resistance is
felt and then pull rapidly.
3. Disconnect all electrical loads from the
generator. Never start or stop the generator
with electrical devices plugged in or turned
on.
English
Keep choke lever in “START” position for only 1
pull of the recoil starter. After first pull, move
choke lever to the “RUN ” position for up to the
next 3 pulls of the recoil starter. Too much
choke leads to sparkplug fouling/engine
flooding due to the lack of incoming air. This
will cause the engine not to start.
NG2500
NG3500
NG3500E2
NG8500E2
NG9500E2