Pal Manufacturing 8251498 User manual

10001280
1 OF 15 REV. 03 JAN/09
481 Panet Road Winnipeg, MB R3C 2W7
5.5 Kw Portable Generator
INSTRUCTION MANUAL
ITEM # 8251498
TABLE OF CONTENTS
SECTION PAGE
1 GENERAL INFORMATION 2
2 SAFETY GUIDELINES 2
2.1 Battery Safety 4
2.2 Additional Safety/Operational Guidelines 4
3 OPERATION 5
3.1 Generator Performance Specifications 5
3.2 Electrical Loads 6
3.3 Warning on Sensitive Equipment 6
3.4 Engine Limitations on Generator Performance 6
3.5 Power Receptacles 7
3.6 Circuit Breaker 8
3.7 Automatic Idle Control 8
3.8 LCD Amperage/Hour Readout 9
3.9 12VDC Battery 9
3.10 Starting the Generator 10
4 MAINTENANCE 10
5 PARTS LIST 12

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1. GENERAL INFORMATION
The purpose of this manual is to assist you in operating and maintaining your portable generator.
Please read it carefully as it contains information which will help you achieve years of dependable,
trouble-free operation.
WARRANTY-PARTS-SERVICE
To obtain prompt, efficient service, always remember to give the item number and serial number.
Whenever you need parts or repair service, contact Princess Auto Ltd. at:
Telephone # [phone] Fax # [phone]
The generator is shipped on a pallet and requires no assembly before it can be used. The battery
must be prepared for it’s initial use. Please refer to the battery instruction sheet included for details.
2. SAFETY GUIDELINES
DEFINITIONS
Safety symbols identify important safety messages that alert to the possibility of personal injury or
death. Review them carefully before operating this unit and before performing maintenance or
repairs. Check the rules and regulations, at your operating site and Province or Territory, and identify
possible hazards. The appropriate signal word for each message has been selected using the
following guidelines:
- Danger indicates an immediate and specific hazard, which will result in severe
personal injury or death if the proper precautions are not taken.
- Warning indicates a specific hazard or unsafe practice, which could result in
severe personal injury or death if proper precautions are not taken.
- Caution indicates potentially hazardous situation, which may result in minor or
moderate injury or damage to unit if proper practices are not taken.
IMPORTANT SAFETY INSTRUCTIONS
Read and understand the operator’s manuals and all safety alerts before operating or
maintaining your portable generator. Be certain that everyone operating this equipment is familiar
with the recommended operating and maintenance procedures and follows all the safety precautions.
Never let children or untrained adults operate this equipment.
This generator set produces electrical current. As such, safety guidelines must be followed. Improper
use of this generator can result in electrocution, injury or death. Do not operate, service or repair this
generator unless fully qualified to do so.
This generator set is designed to be operated in dry conditions and in outdoor areas only. NEVER
operate this generator in rain, snow, sleet or generally wet conditions. Damage to the generator,
bodily injury, or death could result from electrocution.
If this generator is connected to a building, home, business, or any other electrical circuit normally fed
by utility power, steps must be taken to ensure the generator output and the utility power are
positively isolated. Failure to isolate the utility and generator electrical systems will result in generator
damage and could result in injury or death to utility workers due to the back-feed of electricity.

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2. SAFETY GUIDELINES(cont’d)
NEVER operate this generator unless all original guards, shields, covers, etc. are undamaged and in
good working condition. Operating this generator with damaged or inoperable guards, shields,
covers, etc. could result in damage to the generator, fire, electrocution, injury or death.
RISK OF CARBON MONOXIDE POISONING
Operate and fuel equipment in well ventilated areas free from obstructions. Engine exhaust contains
carbon monoxide, an odorless, colorless, deadly poison. Exposure to Carbon Monoxide can cause
headaches, nausea, severe sickness or death.
RISK OF EXPLOSION OR FIRE
Spilled gasoline and its vapors can become ignited from cigarette sparks, electrical arcing, exhaust
gases, and hot engine components such as the muffler. Never refuel the engine while hot or running.
Move unit away from refueling area before starting engine. Equip areas with fire extinguishers
suitable for gasoline fires.
Heat will expand gas vapours in the tank, which could result in spillage possibly causing a fire or an
explosion.
Lubricating oil conforming to the engine manufacturer’s specifications must be added to the proper
level before operation. Failure to fill the crankcase with lubricating oil will void all engine warranties.
Do not exceed the rated capacity of the generator. The total electrical loads at each outlet must be
added to determine the total electrical load. The total load must not exceed the rated capacity of the
generator. If the driven apparatus does not list wattage, but only amperage, wattage may be
determined by multiplying amperage by voltage (watts = amps x volts).
Do not tamper with the engine-governed speed. the generator operates at a nominal speed of 3600
rpm. Increases in speed over the nominal 3600 rpm will increase the chance of personal injury due to
rotational stresses on the rotating members. Operation of the generator at speeds below the nominal
3600 rpm could cause damage to the generator or driven apparatus due to low voltage output.
Do not modify or misapply the generator set in any way. Operation of the generator other than
intended, could result in generator set damage, bodily injury or even death from electrocution.

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2. SAFETY GUIDELINES(cont’d)
2.1 BATTERY SAFETY
New batteries and batteries that have been stored for a long period have little to no charge remaining.
These batteries, when charged, produce and release explosive Hydrogen gas. The slightest spark,
flame or burning ash can ignite these gases causing a serious explosion that could result in blindness
or other injury.
Completely drained batteries MUST be brought back up to full charge using a battery charger before
installing into the generator. The trickle charger built into the generator is designed to maintain the
charge of the battery during normal operation under normal operating conditions.
CHARGING A FULLY DISCHARGED BATTERY WITH THE BUILT IN BATTERY TRICKLE
CHARGER MAY CAUSE DAMAGE TO UNIT AND/OR BATTERY.
Wear eye protection, rubber apron, and rubber gloves when working around a battery or performing
battery service. Battery fluid is an extremely caustic sulfuric acid, which can cause severe burns. Do
not permit the battery fluid to come in contact with your clothes or skin.
ALWAYS disconnect the negative (-) battery cable from the battery before performing battery service
or before performing any electrical service on the generator or engine.
2.2 ADDITIONAL SAFETY/OPERATIONAL GUIDELINES
• Always follow National and Local electrical codes.
• When moving or transporting this generator, take proper precautions to avoid fuel spillage.
Further, always use common sense when lifting this generator. An adequate number of
people and proper lifting procedures must be used.
• Do not operate this generator unless the generator is in good mechanical and electrical
condition.
• Do not overload this generator. Overloading this generator can cause generator damage,
powered apparatus damage and excessive heat build up.
• Always keep hands, body parts, hair and clothing well away from the rotating or “HOT” parts
of the generator set. Exhaust systems can cause severe burns.
• Do not start this generator with connected devices turned “ON”. Always make sure that
all devices are disconnected from the generator or are turned “OFF” before starting the
generator.
• Do not operate this generator in an enclosed area. The operation area of the generator
must be completely open. The exhaust gases of this generator emit “DEADLY” carbon
monoxide. Exposure to carbon monoxide can cause carbon monoxide poisoning, headaches,
nausea, severe sickness or death.
• Do not install this generator in an enclosed area such as a RV or motor home. All
warranty will be null and void if installed within an enclosed area.
• Ensure that at least 2 feet of clearance on all sides of the generator are maintained
during operation. Failure to maintain proper clearance could damage your generator and
potentially lead to fires.
• Never touch a receptacle or bare wire. Electrocution or shock could result.
• Gasoline is flammable. Handle gasoline with extreme care. Failure to properly handle
gasoline can result in explosion or fire. Do not smoke within 50 feet of the generator.
• Never refill a hot generator with fuel. Never refill the generator while it is running.
Spillage onto the engine or generator could result in an explosion or fire. Always allow the
generator set to cool before refilling.
• Do not store the generator where gasoline fumes could potentially come into contact
with spark, pilot light or an open flame. Improper storage of this generator could result in
an explosion or fire.

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2. SAFETY GUIDELINES(cont’d)
2.2 ADDITIONAL SAFETY/OPERATIONAL GUIDELINES (cont’d)
• GROUNDING: The National Electrical code requires that the generator frame be properly
grounded to earth. A ground location is located on the front cross member on the bottom of
the frame. As a general guideline, a 10 AWG wire connected to the ground bolt on the
generator frame on one end (located on the bottom front cross-member of the frame as
indicated by the International “GROUND” symbol.) and connected to a copper or brass
ground rod (driven into the ground) on the other end of the wire. Some locations require
generator set or other grounding. Check with a local electrician to determine the grounding
requirements for your area.
• Electrical generators produce electricity. Therefore, never allow or perform service
operations to your generator set without proper training/certification. Service
operations, without proper precautions can cause severe shock and even death by
electrocution.
• Use only 3-Prong extension cords in good condition. Ensure that the extension cord’s wire
gauge is of sufficient size to minimize voltage drop.
• Never handle extension cords or electrical circuits if standing in water or a damp area.
• Operate, service or fill with fluids on a level surface only.
• Do not operate this generator in a corrosive or flammable environment.
• Never clean this generator with high-pressure water or a garden hose. Water can
accumulate within the generator and cause fuel system, ignition system and or
electrical problems or shorts. Cleaning should be done with a damp rag on a cool generator
set.
3. OPERATION
3.1 GENERATOR PERFORMANCE SPECIFICATIONS
The generator is designed to produce electrical energy for the purpose of powering lights, power
tools, appliances and motor loads within the intended design constraints of the generator. The
generator is designed to produce single-phase electrical power at 120 VAC or 120/240 VAC. This
generator is not intended for installation in RV or motor home applications. The performance
specifications of the generator are shown in Table 1.
VOLTAGE CONTINUOUS
WATTS/AMPS SURGE WATTS/AMPS
120/240 VAC
(Single Phase) 5,500 Watts 45.8 Amps @ 120 VAC
22.9 Amps @ 240 VAC
6000 Watts
50 Amps @ 120 VAC
25 Amps @240 VAC
Table 1 –Generator Performance Specifications

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3.2 ELECTRICAL LOADS
Your generator set is designed to power electrical tools/appliances within the electrical power output
limitations of the generator. Please note that any generator overload can cause serious
problems/damage to your generator.
Additionally, products with electric motors can have higher wattage requirements at start-up than
when running. Some electric motors require as much as 4 to 5 times the rated wattage at start-up.
Although the start-up wattage requirements for electric motors lasts only a few seconds, great care
must be taken in connecting loads to your generator so as not to overload the generator.
Refer to the label on electrical products to determine the wattage requirements. The total wattage
requirements of all powered products must never exceed the continuous rating of your
generator.
As a reference only, Table 2 below shows typical wattage requirements for common electrical
devices. Table 2 is intended as a guide only. Always refer to the electrical ratings label on an
electrical product for the actual rating.
ITEM RUNNING
WATTS I
TEM RUNNING
WATTS
Air Conditioner (12,000 Btu) (*) 1750 Impact wrench 500
Air Compressor (1/2 hp) (*) 1400 Light Bulb Bulb rated
Air Compressor (3/4 hp) (*) 1800 Nail Gun 1200
Air Compressor (1 hp) (*) 2000 Microwave 750
Battery Charger (25A) 600 Paint Sprayer (1/3 hp) (*) 650
Belt Sander (3” Belt) 1000 Paint Sprayer, hand air-less 175
Circular Saw (6 ½”) 825-1050 Radio 50-200
Coffee Maker 900-1100 Refrigerator (*) 600
Lawn Edger 550 Table Saw (10”) (*) 2000 (*)
Furnace Fan (1/3 hp) (*) 1200 Television 250-550
Hot Plate (single) 1500 Weed Trimmer 500
* Allow 2 to 5 times the listed wattage for starting.
Table 2 – Common Electrical Tools and Their Power Requirements
3.3 WARNING ON SENSITIVE EQUIPMENT
Do not use the generator to power sensitive electrical products such as laptops or personal
computers. These products are extremely vulnerable to fluctuations in power supply. The frequency
of the power output from the generator is dependent on the consistency of the engine speed, which
can vary as much 300 RPM from the nominal speeds. Electrically sensitive products can become
damaged as a result of fluctuating voltage.
3.4 ENGINE LIMITATIONS ON GENERATOR PERFORMANCE
Generator ratings assume an ambient air temperature of 20°C (68°F) and at sea level. Operation of
your generator at temperatures above 20°C (68°F) or above sea level will result in lower electrical
output. Electrical output must be de-rated 2% for each 5°C (9°F) above 20°C (68°F) and 3.5% for
each 1000 feet above mean sea level.

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3.5 POWER RECEPTACLES
Table 3 and Figure 1 below show the receptacle layout and their corresponding voltage/amperage
ratings. The electrical load that may be drawn from each receptacle is a function of the receptacle
rating and the generator rating.
Do not exceed the individual receptacle ratings as shown in Table 3 below. Do not exceed the
total generator ratings shown in Table 1 on page 5.
RECEPTACLE 1 RECEPTACLE 2
20A / 120V 20A / 120-240V
Table 3 – Maximum Allowable Receptacle Current Draw
RECEPTACLE 1
RECEPTACLE 2
BLACK FILLED LEADS ARE LIVE TERMINALS
GREY LEADS ARE GROUND TERMINALS
WHITE LEADS ARE NEUTRAL TERMINALS
Figure 1 – Receptacle Lead Location Detail

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3.6 CIRCUIT BREAKER
A circuit breaker is present on the receptacle panel to prevent overloading of the generator. The
circuit breaker is rated for a current of 20 amps. See Figure 2 below for the circuit breaker location.
CIRCUIT BREAKER
Figure 2 – Circuit Breaker
The circuit breaker will “trip” when it is overloaded cutting off power to all of the receptacles. How
quickly the circuit breaker trips depends on the severity of the current overload. Stay within the
recommended power ratings described in Sections 3.1, 3.2 and 3.5. If the circuit breaker trips, the
switch will automatically move to the “OFF” position. To resume using the generator, reset the circuit
breaker by pushing the switch to the “ON” position.
NOTE: ensure that it is safe to reset the switch after power has been cut off. The tool/appliance
being used will operate immediately after the circuit breaker has been reset. Use caution.
3.7 AUTOMATIC IDLE CONTROL
The generator is equipped with an automatic-idle feature. When activated this feature allows the
engine to idle down when there is no power being drawn from the unit, conserving fuel.
See Figure 3 below. When no appliances are being used, the unit initiates a time delay, which can be
selected using the time delay knob. If there is still no power demand after the time delay duration, the
unit idles down the engine. The engine will stay at idle speed until there is a power demand, at which
time it will resume full throttle operation instantaneously.
TIME DELAY
KNOB
ACTIVATION
LIGHT
Figure 3 – Automatic Idle Control

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3.8 LCD AMPERAGE/HOUR READOUT
The generator is equipped with an LCD directly above the auto-idle dial setting (see Figure 4 below).
The LCD shows the user the current being drawn from the generator while a tool or appliance is
being used. When there is no power demand, the display automatically switches to “hours used”,
meaning the total time in hours the generator has been running.
The hour meter is useful when scheduling maintenance (i.e. oil changes, air filter changes, refueling,
etc.). “Hours-used” can be displayed anytime while the generator is running by pressing the black
button labeled “Amps/Hrs Switch” directly below the LCD. Press the black button again to go back to
reading amperage.
LCD
AMP/HOURS
SWITCH
LOW BATTERY
WARNING LIGHT
Figure 4 – Amp/Hour Readout
3.9 12VDC BATTERY
Please refer to the battery instruction manual provided for battery installation and maintenance
information. The battery should already be installed and secured onto your generator frame.
The battery will need to be fully charged prior to generator operation. Please refer to the wiring
diagram for proper battery hook-up. The generator features a warning light when the battery charge
is low (see Figure 4 above).

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3.10 STARTING THE GENERATOR
a) When preparing your generator for operation, ensure that the engine fluids are at normal levels
and the battery is connected and charged.
b) Start engine using ignition key. Note that you will not be able to use the engine’s electric
start if the battery’s charge is depleted. Use the recoil start if the electric start is unavailable.
Allow engine to warm up at idle.
c) Ensure the engine throttle control lever is at full throttle. This ensures the alternator is
running at the proper frequency to produce 120/240V.
d) Check that the circuit breaker switch is in the “ON” position.
e) Plug in an electric appliance/tool into one of the available receptacles.
f) Begin using the appliance/tool. Note that the LCD should display the amperage being drawn from
the generator.
4. MAINTENANCE
Engine Fuel:
Use Unleaded Gasoline ONLY!
Engine Oil:
Refer to the Engine’s Operators Manual.
Engine Maintenance:
Refer to the Engine’s Operators Manual regarding all engine maintenance issues.
Generator Cleaning:
ALWAYS shut off the generator and allow the generator to completely cool before
performing cleaning operations.
DO NOT use high pressure water or a garden hose to clean your generator. Water
introduced into the generator can cause electrical shorts, generator damage or personal
injury.
• Compressed air (max. 25 PSI) may be used to blow loose dirt and dust from your generator.
However, do not direct compressed air directly into any openings into the alternator or
engine.
• Use a damp cloth to wipe clean exterior surfaces.
• Use a soft bristle brush to clean/loosen heavy dirt, oil or grease deposits.
• Never insert rags, tools or any device into the generator or engine openings.

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4. MAINTENANCE (cont’d)
General Storage:
Gasoline fumes are flammable. Do not store your generator indoors or in poorly ventilated
areas. Gasoline fumes can ignite in the presence of any open flame, pilot light, lit cigarette,
water heater, static discharge, etc.
• It is recommended that your generator be started and operated for several minutes at least
every 30 days.
• If the generator cannot be operated every 30 days, follow the storage recommendations
within the engine documentation.
• NOTE: A fuel shut-off valve is positioned at the base of the fuel tank. The valve should be
closed during storage periods.

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5. PARTS LIST

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No. Item No. Description Qty
1 10001670-1 FRAME ENGINE ASSY 1
2 10001670-5 FRAME GENERATOR ASSY 1
3 10001670-14SIDE RAIL EXHAUST 1
4 10001672 HANDLE ASSY 1
5 2020060 WHEEL 4.10/3.50-4 2
6 10001113 ENGINE 11 HP HONDA ELEC. START 1
7 ** ADAPTOR FLANGE ALTERNATOR 1
8 10000553 ALTERNATOR 60 HZ 5.5KW 1
9 9232109 BATTERY 12 VOLT 1
10 ** END COVER GENERATOR 1
11 * ISOLATOR VIBRATION 2
12 * ISOLATOR VIBRATION 1
13 10001671 BRACKET STAND 1
14 10001670-13PLATE RECEPTACLE FACE ASSY 1
15 10001193 TANK FUEL 22L 1
16 10001673 AXLE ASSY 1
17 10001670-15SIDE RAIL 1
18 10001670-16HEAT SHEILD 1
19 * NUT HEX SER FLANGE .250-20 UNC 3
20 10001670-17BATTERY HOLD DOWN 1
21 10001195 DECAL POWERFIST GEN. 5.5KW ELEC. ST. 2
22 10001300 DECAL WARNING GENERATOR 1
23 * BOLT HEX .250-20 UNC X .75 LG 2
24 * NUT SPRING #10-24 U TYPE .045-.062 6
25 * BOLT HEX .250-20 UNC X 1.75 LG GR 5 PTD 2
26 * NUT LOCK NYLON .25-20 UNC 5
27 * BOLT HEX SRD FLANGE .250-20 X .50 LG 8
28 * BOLT HEX SRD FLANGE #10-24 X .50 LG 6
29 * SCREW HEX WASHER #10-24 X .50 LG THREAD CUTTING 7
30 * NUT SPRING .250-20 U TYPE 11
31 * WASHER EXTERNAL TOOTH LOCK .313 2
32 * BOLT HEX SER. .312-18UNC X .75 LG 2
33 * NUT HEX SERRATED FLANGE .312-18 UNC 2
34 * BOLT HEX SERRATED FLANGE .250-20 UNC 3
35 * COTTER PIN 3.2MM X 32MM PLATED 2
36 * WASHER EXTERNAL TOOTH LOCK #10 1
37 9803271 BOLT HEX .250-20 UNC X .75 LG 2
38 * WASHER FLAT 313 x 061 THK 3
39 9212044 NUT LOCK NYLON .313-18 UNC 2
40 * WASHER LOCK SPLIT REG .313 PTD 4
41 * BOLT HEX .312-18 UNC X .50 LG GR 5 PTD 2
42 * WASHER FLAT 313 x 125 THK 2
43 * BOLT HEX .312-18 UNC X 1.50 LG GR 5 PTD 2
44 * SCREW HEX UNSLOTTED MS #10-24 X .50 .LG 2
45 * WASHER FLAT #10 2
46 * NUT LOCK NYLON #10-24 UNC GR2 2
47 * WASHER FLAT .188 x .058 THK 2
48 * WASHER FENDER #10 2
49 * SCREW UNSLOTTED HEX #10-24 X .75 LG 2
50 10001294 LEVER THROTTLE CONTROL 1

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51 10001295 SPRING CHOKE RETURN THROTTLE CONTROL 1
52 10001279 SOLENOID THROTTLE CONTROL 1
53 * SCREW HEX #8-28 X .50 LG THREAD CUTTING 1
54 * SCREW PHILIPS M5 X 0.8 X 8MM LG RAISED CHEESE HEAD 2
55 ** HARNESS POWER 1
56 *** HARNESS 12V 1
57 *** WIRE POWER UNIT GROUND 1
58 * WASHER PTD .687 ID X 1.75 OD 2
59 * GROMMET RUBBER .44 ID X .94 OD X .38 2
60 9224916 SCREW ALLAN HEAD M6 X 19 LG 4
61 * SCREW M/C #6-32 UNC X .375 LG 4
62 9232125 CABLE BATTERY 24" BLACK 1
63 9232133 CABLE BATTERY 33" RED 1
64 ** NSM DECAL 1
65 2460048 FILTER FUEL INLINE 3/16 1
66 10001276 LINE FUEL 3/16" ASSY 1
67 * NUT SPRING #10-24 U TYPE .025-.040 2
68 8004211 BOLT J M5 X 216 ASSY 2
69 9161274 DECAL - WARNING REFUEL 1
70 9160813 DECAL PAL SERIAL # 1
71 * BOLT HEX SRD .375-16 UNC 1" LG 4
72 ** ALTERNATOR ANCHOR ROD 1
73 * WASHER PTD .281 ID X .625 OD 1
74 ** WASHER LOCK SPLIT REG .312 PTD 4
75 * NUT HEX .250-20 UNC 1
76 * BOLT HEX SERRATED FLANGE .250-20 UNCX 1.00 LG 1
77 10002336 DECAL GROUND SYMBOL 1
78 ** DECAL ALTERNATOR RATING 1
ITEMS MARKED AS * ARE INCLUDED IN HARDWARE KIT 10001205
ITEMS MARKED AS ** ARE INCLUDED WITH ALTERNATOR 10000553
ITEMS MARKED AS *** ARE INCLUDED WITH PLATE RECEPTACLE S\ASSY 10001196