PENTAGON TORNADO PT6500E User manual

INSTRUCTIONMANUAL
ThankyouforyourpurchaseoftheTornadoPT6500EorGale ForcePT8500Emodel
generator.Withpropercareandmaintenancethisgeneratorwillgiveyouareliable
sourceofelectricalpowerincaseofpublicutilityoutageand inareaswhere
electricalpowerisnot available.
IMPORTANT-All personsthatwilloperatethisequipmentmustread
andbecomethoroughlycompetentwithalloperatingproceduresand
safetyprecautions.
ELECTRIC
GENERATOR
IMPORTANT
ReadUnpacking
InstructionsFirst
(SeparateSheet)
GALE FORCEPT8500E
Copyright2010DTXInternational
TORNADO PT6500E
TM
TM
TM TM

QuietRunningOHV
4Stroke Engine*,69dBA
EasyStartingElectric
LowOilShutoff
6.6GallonAllSteelFuel
Tank, 8-10HourRunTime
(PT6500E),10HourRun
Time(PT8500E)**
FullyIsolated
SteelRoll Cage
Full PowerPanelwithCircuit
BreakerProtection
HourMeter
DC12vOutput
AC120v,&AC240vOutput
(4)20Amp120v3-ProngSockets
(1)30Amp120v/240VTwist-LockSocket
3-in-1DigitalMeter(Voltage,Frequency,
Run Time)
**TornadoPT6500Ehas13HP, GaleForcePT8500E has16HP.
*Runningtime basedonmedium duty draw,running timesmay varywithheavy usage.
CUSTOMERSERVICE
Customerserviceand productsupportareavailable onlineat www.pentagontool.com.
WARRANTYANDRETURNPOLICY
All PentagonToolgeneratorsarewarrantiedagainstdefectsinmaterialandworkmanshipforaperiod
ofoneyearforresidentialand personaluseundernormalconditions.Warrantyislimited to
replacementparts.
All shipping damagesmustbeclaimed withthedesignated shipper.Checktheshipping cartonfor
damagebeforesigning thebilloflading.
Ifanitemisopenedanddeemedto bedefectivewithin30daysfromthedateofdelivery, please
contactusat www.pentagontool.com forreturninstructions. APentagonToolRMAisrequired when
returningdefectivemerchandise. Pentagon
Ourreturnpolicyallows30daysfromthedateofdeliveryto returnproducts,provideditisnew,
unused and intheoriginalpackaging asreceived. Wehighlyrecommendthatthebuyerthoroughly
inspectthepurchasedproductbeforeusing it.Wechargea20%restockingchargeonall returned
items. Returnshippingistheresponsibilityofthebuyer.Wecannot acceptreturnsforanyreason
after30daysfromthedateofdelivery. Acreditwill beissued aftertheitemisinspectedand
accepted.
Whenreturning yourorderpleaseincludeacopyofyourorder
numberwithdatepurchased, yourToolRMAandthereasonforthereturn.
Warrantyshall not apply to:productswhichareusedforapurposeotherthanwhichthey were
designedfororwhichhavebeenaltered inanywaythatwouldbedetrimentalto theperformanceor
lifeoftheproduct.Misapplication,misuseornegligencewill revokethewarranty.
2
Copyright2010DTXInternational

IMPORTANT-All personsthatwilloperatethisequipmentmustread
andbecomethoroughlycompetentwithalloperatingproceduresand
safetyprecautions.Misuseofthisequipmentmayresultindeath,
personalinjuryorpropertydamage.
1.Youwillneedthismanualforthesafetywarnings
andprecautions,operating, inspection,mainte-
nanceand cleaningprocedures,partslistand
assemblydiagram. Keepyour invoicewiththis
manual.Writetheinvoicenumberontheinsideof
thefrontcover.
2.Thewarnings,cautionsandinstructionsdis-
cussedinthisinstructionmanualcannotcoverall
possibleconditionsand situationsthat mayoccur.
Itmustbeunderstoodbytheoperatorthat
commonsenseandcautionarefactorswhich
cannotbebuiltintothisproduct,butmustbe
suppliedbytheoperator.
3.
Keepthismanualandinvoicein
asafeanddryplaceforfuturereference.
DANGER! run thegeneratorinan
enclosedgarage, cellar, excavation,boat, RV
compartmentoranyothertypeof enclosed
structure.Carbonmonoxide,anodorless,
colorless,deadlygasmayaccumulateandcause
seriousinjuryordeath. Ifyoustarttofeeldizzy or
nauseouswhileusing yourgenerator,shut itoff
immediatelyandmovetofreshair.Callforhelp,
youmayhavecarbonmonoxidepoisoning.Use
inawell-ventilatedoutdoorarea.Allowat
least4feetclearanceonallsidesof thegenera-
tor.
4Yourgeneratorisaircooled. Itisimportantthe
youoperateitinawell ventilatedarea.
Temperatureshouldnotexceed104 F. ambient
(40 C).
5.Do
notletthegeneratorgetwetduringoperation.
Protectgeneratorfromrain, snow,runningor
standingwater.Donotapproachawetrunning
generator, seriousinjuryfromelectricalshockcan
occur.
6.Whenoperating powertoolsoutside, usean
outdoorextensioncordmarked"W-A" or"W".
Theseextensioncordsareratedforoutdooruse,
andreducetheriskof electricshock.
7.Stayalert. Watchwhatyouaredoing,anduse
commonsensewhenoperatingagenerator.
A
moment ofinattentionwhileoperatingthe
generatormayresultinseriouspersonalinjury.
8Donot
refuelnearopenflames , pilotlights, welders,
grindersorsparkingelectrictools.Allowengine
tocoolbeforerefueling.Avoidspills, cleanupif
NEVER
ONLY
Donot operategeneratorinwetconditions.
Do
not useageneratorwhiletiredorunder the
influenceofdrugs,alcohol, ormedication.
Neverrefuelwhilegeneratorisrunning.
.
.
SAFETYPRECAUTIONS
necessary.
9. Donotattempt
toforceasmallgeneratortodotheworkof a
largerindustrialgenerator. Choosingtheright
generatorfortheright jobwillimproveefficiency
andensuretheoverallsafetysituation. Best
resultsareensuredwhenthegeneratoris
operatingattherateforwhichitwasdesigned.
10Donotuse this
generatorforapurposeforwhichitwasnot
intended.
11. Anygeneratorthat
cannotbecontrolledwiththePowerSwitchis
dangerousand mustberepaired.
12.
Such
preventivesafetymeasuresreducetheriskof
startingthegeneratoraccidentally.
13Donotusea
damagedgenerator.Tag damagedgenerators
“Dangerdonotuseuntilrepaired”.
14 Serviceormaintenance
performedbyunqualifiedpersonnelcouldresult
ininjury.
Donot smokenearrefuelingarea.
Donot overload thegenerator. Usethecorrect
generatorforyourapplication.
Donot modifythisgenerator.
Donot usethegeneratorif thePowerSwitch
doesnotturnitonoroff.
MakesurethePowerSwitchisinits"OFF"
positionanddisconnectthesparkplugwire
beforemakinganyadjustments,changing
accessories,orstoringthegenerator.
Maintaingeneratorswithcare.
Only qualifiedrepairpersonnelshould perform
generatorservice.
.
.
.
15
Generatorscreatesparkswhichmayignitedust
orfumes.
16 Providebarriersorshieldsasneeded
fortheirprotection.
17
Looseclothes, jewelry, andlong haircanbe
caught inmovingparts.
18
.
.
.
.
.
Donot operategeneratorsinexplosive
atmospheres, suchasinthepresenceof
flammableliquids, gases,ordust.
Keepchildrenandpetsaway whileoperatinga
generator.
Dress properly;donot wearlooseclothingor
jewelry.Containlonghair;keephair,clothing,
andglovesaway frommovingparts.
WARNING: Theexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,orother
reproductiveharm
Copyright2010DTXInternational
3

IMPORTANT-All personsthatwilloperatethisequipmentmustread
andbecomethoroughlycompetentwithalloperatingproceduresand
safetyprecautions.Misuseofthisequipmentmayresultindeath,
personalinjuryorpropertydamage.
SAFETYPRECAUTIONS, WARNINGS & DANGERNOTICES
Copyright2010DTXInternational
Besuretoreadandheedthefollowingprecautionsandwarningslocatedonyourgenerator.
Failuretoheedthesewarningsmayresult inseriousinjury ordeath.NEVERoperateyour
generatorindoors;operateonly inwell-ventilatedoutdoorLEVELlocations. ALWAYS ensure
generatoris properly groundedbeforeuse.DO NOTrungeneratorinrainy orwetconditions.
Keepoutofreachofchildrenorunqualifiedindividuals.touch barewires,receptacles
oroutlets. DONOT
WARNING:
Avoidall open
flameswhichmaycausevaporstoignite.
During operation,generatormay
dischargehighly flammableand explosivegasesthat
maycausesevereburnsordeath.
4

GENERATORSPECIFICATIONS
Copyright2010DTXInternational
5
Model StartType FuelTank OilCapacity Ignition Displacement Noise Engine RunTime*
4-strokeOHVsingle
cylinderwithforced
aircoolingsystem
4-strokeOHVsingle
cylinderwithforced
aircoolingsystem
12hrs.
10hrs.<69dB
<69dB37fl.oz.
(1.1liters)
37fl.oz.
(1.1liters)
389cc
419cc
non-contact
transistor
non-contact
transistor
PT6500E
PT8500E
Electric
Electric
6.6 gal.
(25liters)
6.6 gal.
(25liters)
*Basedon50%load
Model RatedWattage SurgeWattage Voltage Frequency Phase DCVoltage DCAmps
12V 8.3
8.3
Single
60Hz
120V/240V
PT6500E
PT8500E
5500W
Dimensions:Height=21.3”, Width=20”,Length=28”
12V
7000W
6500W
8500W 120V/240V 60Hz
PentagonToolmodelsTornadoPT6500EandPT8500EmeetfederalEPA
standards.
Single

1.
3.
4.
5.
7.
9.
WARNING!
Ifthegeneratorisinstalledindoors
DONOTINSTALL
INDOORS.
Ifthegeneratorisinstalledoutdoors
Neverlift thegeneratorusingtheengine
oralternatorliftinglugs.
Beforeusingthe generator,read
and understand the enginemanufacturer's
Operation,Maintenance,and Partsmanual.
Also,read the safetyprecautionsinthis
manual. Theseshould always be followed to
reducetheriskofpersonalinjury and
damage toequipment.
Ensureinstallation meetsallapplicable
safety,localand national electrical codes.
Haveinstallationperformed byaqualified,
licensedelectrician and building contractor.
,
exhaustfumesmustbepiped outof the
buildingusingleak-free, heat-resistant
piping.Pipesandsilencershould notbe
made ofanyflammable materials,norshould
theybeinstalled nearanyflammable
materials.Generatorexhaustfumesmustbe
within legal limits, including all localcodes
and ordinances.
,it
mustbe weatherproofed and shouldbe
soundproofed.It should notberunoutdoors
withoutprotection forboththegeneratorand
wiringconduit.
Connectlifting
equipmenttothe frameofthe generator.
Beforeliftingthe generator,ensurethelift
rigging and supporting structureareingood
condition,and areratedtoliftsuchaload.
Thesupporting floor/groundsurface
,and strongenough tosafelyhold
theweightofthegenerator.If the
floor/ground surfaceisnotlevel,strong cross
members shouldbeplaced underthefull
lengthofthe generatorframeatitslow side.
Fortrailerinstallation,thegeneratorshould
be mounted on the centerpointof thetrailer,
overthe wheels.
All connectionsand conduitsfromthe
generatortothe load mustonlybe installed
in compliancewithallrelevantlocal,state,
and federal electrical codesand standards,
and otherregulationswhereapplicable.
Check withaqualified electrician.
Thegeneratormustbe properlyearth-
grounded byaqualified electrician in
accordancewithall relevant electrical codes
2.
6.
8.
MUST
BELEVEL
IMPORTANT-All personsthatwilloperatethisequipmentmustread
andbecomethoroughlycompetentwithalloperatingproceduresand
safetyprecautions.Misuseofthisequipmentmayresultindeath,
personalinjuryorpropertydamage.
OPERATINGPRECAUTIONS and standardsbeforeoperation.
If an extension cordisused toprovidepowertoa
tool,makesuretouseonlyUL approvedcords
havingthe correctgaugeandlength.
Do notattempttoconnect ordisconnectload
connectionswhilestanding inwater,oron wetor
soggyground.
Do nottouchelectricallyenergizedpartsofthe
generatorand interconnectingcablesorconduc-
torswithanypartofthe body,orwithanynon-
insulatedconductiveobject.
Connectthegeneratoronlytoaload orelectrical
systemthat iscompatiblewiththeelectrical
characteristicsand ratedcapacitiesof the genera-
tor.
Keep all electrical equipmentcleanand dry.
Replaceanywiring wherethe insulation isracked,
cut, abradedorotherwisedegraded.Replace
terminalsthat areworn,discolored,orcorroded.
Keep terminalsclean and tight.
10.
11.
12.
13.
14.
(See page
12)
15.Ensure that thegeneratorisproperlygrounded
beforeuse
16.
17.
18.
.connectdirectlytoahouseor
buildingelectricalsystemwithoutanelectrician
qualified toinstallthe generator.Makesurethatall
connectionscomplywithlocalcodes.
Failingtocomplywiththiswarning
couldresult in apowerbackflow whichcould
seriouslyinjureorkillelectricalorutilitypersonnel.
If youareusingthisgeneratorin highlyconductive
work areassuchasaround metalplating orasteel
deck,be suretouse
Generatorcanreachtemperaturesas
highas150 degreesF(65 degreesC).Heed
temperaturewarning labelson machine.Allow to
cool beforetouching.
Becomefamiliarwiththismanualand all safety
precautionsand warnings.Do notoverload.
Disconnect malfunctioning devicesand do not
exceed wattagecapacity.
NEVER
DANGER!
CAUTION!
Misuse canshortenthelifeofyourgenerator.
agroundfaultcircuitinter-
rupter (GFCI),availablewithsomeextension
cords.
Copyright2010DTXInternational
6

GENERATORCOMPONENTS ANDPACKAGECONTENTS
Copyright2010DTXInternational
Thefollowingtoolsshouldbeincludedinyourgeneratorpackage:
(1)Phillips-headscrewdriver(A)
(1)Hex-headwrench(B)
(1)Sparkplugwrench(C)
7
COMPONENTS
Beforeoperatingyourgenerator, besureto
becomefamiliarwithallusageinstructionsand
thecomponentslistedbelow:
1.Aircleaner-
2.Chokelever-
3.Fuelgauge-
4.Fuelcap-
5.
6.
7.Voltage Selector
8.
canbe removed andcleanedtohelpkeep
yourgeneratorrunningatpeakefficiencybypreventingdirt
fromgettingintotheengine.
Regulatesengineairintake.
Gasolinelevelindicator.
Fueltankcap.
-switchbetween120Vonlyand
120V/240V.
Voltage meter-
120VoltACreceptacle-
120/240VoltACreceptacle-
9.Circuitbreaker
10.Groundterminal-
11. IdleControlSwitch-
12.12VDCbatteries.
13.l2VDCreceptacle-
Readscurrentvoltageoutput.
Usetoconnectelectrical
devicesthatrun120 Volt,60 Hz, singlephase,ACcurrent
(2¡ÁduplexGFCI).
Receptacletoconnect
electricaldevicesrunning120/240Volt,60Hz, singlephase,
ACcurrent(NEMAL14-30).
-Resetswitchprotectinggeneratorfrom
overload.
Groundingwiresconnectionpointto
ensureproper groundingofgenerator.
Idlecontrolwillallow fuelsavings
whenON(usewhenthere isnoloadongenerator),when
devicesare attached leaveinOFFposition.
Receptacleonlyforcharging12
Voltautomotive-type batteries.
14. Oilfillercap-
Oilfillanddipstick-
Recoilstarter-
Fuelfiltercup-
Fuelvalve-Spark
plug-
Muffler-Quiets engine.
Accessforcheckingoillevelsand
addingoil.
Locationforcheckingandfilling
engineoil.
Pull-cord forstartingengine.
Filtersfuel.
Controlsflow offueltoengine.
Necessaryforengineignition.
21.
15.
Engine Switch 16.
17.
18.
19.
ABC

.Whilenotrequired,youmayelecttoinstallthewheelkitthat isincluded
withyourgenerator.Todothis,followtheinstructions below:
1.Onalevelsurface, elevateyourgenerator’scageonwoodorcement
blockstomakeiteasier toassembleyourwheelkit.
2.Attachthesupportleg tothecageusingthecapscrewsandlocknuts
provided(SeeFigureaa).
3.Attachtheaxletothecageusingthecapscrewsandlocknuts provided
(See Figure bb).
4.Place (See Figure cc,
Figure dd, Figure ee).Makesure thewheel’sairvalveis
accessible.Installthewheelwiththevalvefacingout.
5.Attachthehandlestothecage usingthecapscrewsandlocknuts
provided(SeeFigureff,Figure gg).
6.Doublecheckthatallscrews,locknutsandpinsare secure.
Note:
awheelover theaxle, thenslide aflatwasherover theaxle.
Tightendownthewheelwiththeretainingpinprovided
GENERATORWHEELKITASSEMBLY
Copyright2010DTXInternational
8
Note:Inflate yourtires tobetween 15-30PSI
Figureaa
Figurebb Figurecc Figuredd
Figureee Figureff Figuregg

RECOMMENDEDOILUSAGEATSTARTINGTEMPS
30
10W-30
SYNTHETICOIL
40 60 80 10032200-20
F
C-30 -20 -10 0 10 80 30 40
5W-30 or10W-30
Enginesshipped fromPentagonToolhaveoil in
crankcase.Donot
over-fill.Useahighqualitydetergentoilclassified "For
ServiceSF,SG,SH,SJ"orhigher.Donotusespecial
additives.
ChoosetheSAEviscositygrade ofoilfromthe
“Recommended OilUsageAtStartingTemps”chartbelow.
Choosetheoilthatmatchesthestartingtemperature
anticipated before thenextoilchange.
DONOT
Before startingengine, fillwithoil.
Do notmixoilwith gasoline, donotuse2-
stroke gasolineengine oil.
OILRECOMMENDATIONS
Note:SyntheticoilmeetingILSACGF-2,APIcertification
markandAPIservice symbol(shownhere)with"SJ/CF
ENERGYCONSERVING"orhigher,isanacceptableoilat
all temperatures.Useofsyntheticoildoesnotalter
required 0ilchange Intervals.
CHECKENGINEOIL- EACH USE- BEFORE
STARTINGENGINE
(Oilcapacityis 37fluidoz. or1.1liter.)
.
SAE
5W-30
FOR
GASOLINE
ENGINES
Aircooledenginesrunhotterthanautomotiveengines.The
useofnon-syntheticmulti-viscosilyoils(5W-30,10W-30,
etc.)intemperaturesabove40 F (4 C)willresultinhigher
thannormaloil consumption.Whenusingamulti-viscosity
oil,checkoillevelmore frequently.SAE300il,ifused below
40 F(4 C),willresultinhardstartingandpossibleengine
bore damageduetoinadequatelubrication.
CHECKOILFREQUENTLY
IMPORTANTSTEPS BEFOREUSE
5W-30
RecommendedOil:
SAE10W-30
1.Tankcapacityis6.6U.S. gallons.
2.Useclean, fresh,lead-free,regulargasolinewitha
minimumof87 octane.
3.Purchasefuel inquantitythatcanbeusedwithin30
days.Donotuseoldgas.
4.Avoidgettingwater,oilordirtmixedwiththegasoline.
5.Donotfilltotopoftank.Leaveroomforgasolineto
expand. Checkfuelgauge ontopoftankforcurrent
fuel level.
6.Donotstoregasolineinthetankforextendedperiods
oftime.
7.Besure towipe upanygasolinespillsbefore starting
theengine.
8.makesurethatthegeneratorisonalevel
surface whenfueling.
ALWAYS
FUELRECOMMENDATIONS
WARNING;Gasolinefumes are
extremelyflammable.
DONOTSMOKE
Under certain
conditionsfumescantravel many
feetandtakesome time todissipate.These
fumescanbeignitedbymanysourcessuchas;
openflame,pilotlights, cookingstoves, sparks
fromelectricandbatteryoperated tools, sparks
frommetalhittingahardsurface,static
electricityfromcarpetorcurtains,frictionfrom
shoesrubbingahard surface, heatandsparks
fromothergasolineenginesandmanyothers.
nearthegeneratorwhile
refuelingistakingplace. Afewminutesof
commonsenseandprecautioncanhelpavoid
unfortunateincidents.
1.Place engineonlevelsurfaceandcleanaroundoil fill
cap.
2.Removedipstick/cap,(see figure C)wipewithclean
cloth,checkoillevelondipstickasshown.
3.OilshouldbeatFULL mark.(seefigure B)Ifadditional
oilisrequired,addslowly.
4.Replace andtightendipstick/capfirmlybefore starting
engine.
DONOTOVERFILL. Overfillingwithoilmay cause:
1.Smokingexhaust.
2.Hard starting.
3.Sparkplugfouling.
4.Oilsaturationofairfiller
INITIALOILFILL
Copyright2010DTXInternational
9

Togroundthegenerator,first:
1.Tightenthegroundingwingnutontoagroundingwire
(seefigure D).
2.Attachtheother endofthegroundingwire toa
groundingrod(brassorcopper)thatisdrivenintothe
earth.
3.Sincegroundingcodesmayvarydependingonlocation,
pleaseconsultalocalelectriciantofindoutaboutcodesfor
GROUNDINGTHEGENERATOR
Whetherthisisthefirst time youwill be usingyour
generatorornot,followthechecklistbelow before EACH
usetoensurebest maintenance andsafetypractices.
1.Place engineonlevelsurfaceandcleanaroundoil fill
cap.
2.Removedipstick/cap,(see figure C)wipewithclean
cloth,checkoillevelondipstickasshown.
3.OilshouldbeatFULL mark.(seefigure B)Ifadditional
oilisrequired,addslowly.
4.Replace andtightendipstick/capfirmlybefore starting
engine.
1.Useclean, fresh,lead-free,regulargasolinewitha
minimumof87 octane.
2.Donotfilltotopoftank.Leaveroomforgasolineto
expand.Checkfuelgauge ontopoftankforcurrent
fuellevel.
3.makesurethatthegeneratorisonalevel
surfacewhenfueling.
4.Besuretowipeupanygasolinespillsbeforestarting
theengine.
1.T
2.Donotfilltotopoftank.Leaveroomforgasolineto
expand.Checkfuelgauge ontopoftankforcurrent
fuellevel.
3.
Checktheoil:
Checkthegas:
Ground thegenerator:
ALWAYS
ightenthegroundingwingnutontoagroundingwire.
Attachtheother endofthegroundingwire toa
groundingrod(brassorcopper)thatisdrivenintothe
earth.
IMPORTANTSTEPS BEFOREUSE
Copyright2010DTXInternational
10
DANGER!Failure togroundyourgenerator
properlycan resultin serious injury, shockor
electrocution!Please followtherecommended
groundingguidelines foryourlocality. Check
withacertifiedelectrician.
PRE-STARTCHECKLIST
WARNING:
Thegeneratormustbeproperly
grounded. Failuretoproperlyground
thegeneratorcanresultinelectrocution.
Groundthegeneratorbyattachingastranded
copperNo.12AWGwire tothegroundingnut
locatedonthecontrolpanel.(figure D)The
groundingwireshouldbeconnected witha
clamptoabrass orcopper rodthatisdriven
intotheearth. Consultaqualifiedelectricianto
insure asafeandproper grounding.
WARNING:Toavoidbackfeedingintoutilitysystems,
isolationoftheresidence electricalsystemis
required.Before temporaryconnectionofthe
generatortotheresidence electrical system,turnoff
themainservice disconnect. Consultaqualified
electricianbefore use.
Grounding
WingNut
FigureD

STARTINGTHEENGINE
1. Follow theguidelinesonpage 10
(GroundingtheGenerator).
2.
(located ontopof
gastank)for
adequateamountof
fuelfortask.Inspect
tankforleaks.Ifthe
tankisevenseeping
asmallamountofgas discontinueuseuntilrepaired.
Wipeupallspilled gasbefore startingengine.Ifgas
spillsdowninenginearea,allow adequatetime
gasolinetoevaporation.
3.
Thevalveislocated nearthepull
startchord.
4.
Unpluganydeviceorfeedfromthecontrol
panel. SwitchthecircuitbreakertoOFF.
5. When
enginefires,youcanadjust
thechokeforrunning.
First, besurethatyourgeneratorisproperly
grounded.
Checkfuelgage
Nextturn thefuelvalvetotheON
position.
Make sure therearenoelectrical
devices pullingpowerfromthe
generator.
Movethechoketothe
CLOSEDposition.
6. Whenenginefires,youcanadjust
thechokeforrunning.
7.
8.Whenusingtherecoilstart,
pullthecordslowlyuntil
youfeeltensionor
resistance,thenpullthe
cord quicklytostartthe
generator.
once enginestarts;
togetthelongestlifefromyourrecoilstart,treatcord
gingerlyandrefrainfromallowingittosnapbackinto
place.Youmayneedtorepeatthisstepafew timesto
initiateenginestart.(Ifyoustillcannotstartyour
generator,pleaseseetheTroubleshootingGuide on
page25).
Movethechoketothe
CLOSEDposition.
Movetheengineswitchtothe ONorSTART
position.
Note:Donotrelease cord
quickly
Allowthe engine torun for1-2minutes andthen
move the choke leverhalfwaybetween OPENand
CLOSED.Wait 20seconds andmovethechoke
levertothe OPENposition.
1.Checkanddoublecheckyourelectricaldevicesto
ensure thattheyareOFF.
2.
Refertothechart(FigureE)foraverage wattage
reported fromdevicesyoumayencounter.Most
electricaldeviceswillhavethewattagerequirements
imprintedsomewhereontheappliance. Ifthe
requirementsare reported involtsandampsyoumay
calculatethewattsbythisformula.
Besure thatthetotalrunningwattage ofyour
appliancesdoesnotexceed therunningwattage of
yourgenerator.
It isbetter
tocombinetotalsthatare less thantherunningrated
wattage thantoriskoverload.
Before connectingelectricaldevicestoyour
generatoryoumustcalculate the wattage drawthe
devices willpull.Yourelectricaldevicesmustnot
adduptomore thantherunningwattage.
NOTE:The generatorisdesignedtorun at
maximumsurge forashortperiodoftime.That
will allowamotortostartupwithoutstallingthe
generator. Someappliances requireshortbursts
ofsurge wattage tostartorrun theirmotors.
Watts=AmpsxVolts
DONOTCOMBINERUNNING
WATTAGESTHAT TOTALTHESURGEWATTAGE
OF YOURGENERATORANDATTEMPTTO
OPERATE.
Ifyoufindthat yourcombined loadwillexceedthe
ratingofyourgenerator,youmayneedtogroupone
ormoredevicesonaseparateGenerator.
Tornado:
RunningWattage:5500
Surge Wattage:6500
PT6500E
USINGTHEGENERATOR(AC)
6
Copyright2010DTXInternational
9.Th
Incasethebatteryisdeador
weak, theenginecanbe started
withthepullstartchord.Follow
thesame procedure asabove.
urnte keytotheright untilthe
electricstartmotorengages.
When the engine fires letthe
keyreturntothe run position.
Allowengine towarmupbefore pullingcurrent
fromthegenerator.
11
Gale Force PT8500E:
RunningWattage:7000
Surge Wattage:8500

3.Plugthe
devicesintotheproper receptacles. Standard120volt,
singlephase,60 Hzloadsonlyinthe120 Volt
receptacles.
All 120/240 Volt,singlephase, 60 HZloadswithNEMA
L14-30 maleplugtothe120/240 Voltreceptacle(See
Figure Fbelow).
4.
Makesureelectricaldevices are turnedoff.
Switchthecircuitbreaker intotheposition
5.
ON.
Introduceelectricaldevices accordingtoload.
Heaviestwattage first, then add in lowerwattage
devices.
CAUTION:Donotattach50Hzor 3-phase
loadstoyourgenerator.
USINGTHEGENERATOR
Copyright2010DTXInternational
ToolorApplianceRatedWattsSurgeWatts
ElectricWaterHeater(40gal)40000
HotPlate25000
Saw-RadialArm20002000
ElectricStove15000
Saw-Circular15001500
AirCompressor (1HP)15003000
WindowAirConditioner12001800
Saw12001200
Microwave10000
WellWaterPump10001000
ReciprocatingSaw9601040
SumpPump8001200
RefrigeratorFreezer8001200
FurnaceBlower8001300
Computer8000
ElectricDrill600900
Television5000
DeepFreezer500500
Garage Door Opener4800
Stereo4000
BoxFan300600
ClockRadio3000
SecuritySystem1800
DVDPlayer1000
CommonLightBulb750
(running)
Miter-
FigureE
Note: Thistableshowsestimatedusagerequirements, check
yourdevice’swattageinformationforactualrequirements.
POWERCORDINFORMATION
WARNING!
Toavoiddamagetoyourmachine, be sureto
switchthe circuitbreakerOFF beforechanging
the Voltage SelectorSwitch.
Thevoltageselectorswitchswitchesthemain
power ofthegeneratorintoan120Vonlymodeor
a120V/240Vmode.
Inordertousea240Vappliance,youmusthave
theselectorsetto120V/240Vmode.
120Vappliancesmaybe operated ineither mode.
Youmayuseboth240Vand120Vdevices
simultaneouslywhileinthe120V/240Vmode,.but
donotusea240Vdevice in the 120Vmode
VOLTAGESELECTORSWITCH
INFORMATION
MINIMUM EXTENSIONCORDGAUGE-120 VOLT
EXTENSIONCORDLENGTH
(AtFullLoad) 0-25
16
16
14
12
10
25 -50
16
16
14
12
10
50 -100
16
14
12
10
10
100-150
12
10
-
-
-
150 -200
12
-
-
-
-
0-5
5.1-8
8.1-12
12.1-15
15.1-20
AMPS
Figure A
When usingextension cordsmake surethatthe cord
is ratedslightlyhigherthan is recommendedforthe
deviceyou wanttorun.
Cords thataretoo thinorthataretoo longcan
diminishthe powerflowingfromyourgenerator.
Followthetablebelow(Figure A)forsomebasic
recommendationsforextension cordlength.
12
3.Plugthe
devicesintotheproper receptacles. Standard120volt,
singlephase,60 Hzloadsonlyinthe120 Volt
receptacles.
All 120/240 Volt,singlephase, 60 HZloadswithNEMA
L14-30 maleplugtothe120/240 Voltreceptacle(See
Figure Fbelow).
4.
Makesureelectricaldevices are turnedoff.
Switchthecircuitbreaker intotheONposition
5.
.
Introduceelectricaldevices accordingtoload.
Heaviestwattage first, then add in lowerwattage
devices.
CAUTION:Donotattach50Hzor 3-phase
loadstoyourgenerator.
120VACReceptacles 120/240VACRecptacles
12VDC Receptacles
Disconnectelectrical
load before
moving switch
SZB-T-F-V
GNAJ
HOURMETER
ULSOCKET
MAIN
BREAKER
CAUTION
AC 120V20A
DC12V
OFF
120V 120V/240V
AC
ON
OFF
ON
OFF
ON
ON
OFF
DCPROTECTOR
AC 120V20A
ON OFF
AC 120/240V30A
OFF
RUN
STAR
FigureF

Intheeventofanoverload,thecircuitbreakerwill
be tripped andthepowerrunningtoanyequipment
ordevices willbe disrupted.
OFF ON
When this occursthe circuitbreakerswitch will be in
the position…toreset, flipthe switch tothe
position.
USINGTHEGENERATOR(DC)
Copyright2010DTXInternational
WARNING:
WARNING:
CAUTION:
DonotusetheDCreceptaclestocharge
anythingotherthana12Vautomotivetype
battery.
NEVERattempttojumpstartacarwiththe
generator.
Batteriescontainacidandcanbecomehighly
explosivewhencharged. Refrainfrom
smokingorexposingbatteriestoopen
flames.ALWAYSwearprotectiveclothing,
safetygogglesandgloveswhenrecharging
batteries.Flush skinwithwaterthat comes
intocontactwithbatteryacid;flush eyeswith
waterandconsultaphysicianimmediately.If
youswallowbatteryacid,drinksomemilk
andconsultaphysicianimmediately.
Toattach a12Vbatterytothe DCreceptacle:
1.Connectthe positive endof
thechargingcable orwire
tothe positive endofthe
batterytobe charged.
Connectthe negative end
ofthe chargingcable or
wire tothe negative endofthe batterytobe charged.
2.Next, connectthe otherendofthe positive cable or
wire tothe positive receptacle ofthe generator. Start
yourgenerator.
3.Gentlyconnectthe free endofthe negative charging
cable orwire tothe negative receptacle on the
generator.
4. Take care todisconnectthe chargingcablesorwires
fromthe generatorfirstwhen done toavoidpotential
sparking.
DCoutputterminal (red) “+”, positive
DCoutputterminal (black) “-“, negative
SHUTTINGDOWNTHEGENERATOR
Toturnoffthe generator:
.
.
1.Turn off, then disconnectall devicesandextension
cordsconnectedtothe generator
2.Turn the circuitbreakertobutrun the
generatorforafew more minuteswith nodevices
connectedsothatthe generator’stemperaturewill
cool slowlyandevenly
3.Turn the engineswitch tothe position, then
turn the fuel valve tothe position.
4.Turn the engineswitch tothe position, then
turn the fuel valve tothe position.
OFF
OFF
OFF
OFF
OFF
THECIRCUITBREAKER
WARNING:
CAUTION:
Donottouchthegeneratoruntilyouhave
allowed ittocool.Touchingthegenerator
soonaftershutoff canresultinburns or
otherinjuries.
Neverstore yourgeneratorinareasofhigh
heat orwithfuel inthetankforlongperiods
oftime.Older gasoline,especiallygasoline
withethanol, canbecomeunstablequickly
andmakeitmore difficulttostartyour
generator.
Alwaysdisconnectthesparkplugwire
whenstoring.
Storeinacool, dryplace.
TRANSPORTATIONANDSTORAGE
Ifyouanticipatestoringyourgeneratorforlong
periods oftime, orifyouneed tomoveyour
generatortoanotherlocation,use thefollowing
procedures andrecommendations:
Allowthegeneratortocoolcompletelybefore
handlingit ortransportingit
Removethegas
Disconnectyoursparkplug
1.Turn off, then disconnectall devicesandextension
cordsconnectedtothe generator
2.
3.fromthe gas tank(see Empty
Fuel Tankin the followingMaintenance section)
4.
5.Store in acool, dryplaceandensure thatthe
generatorhas atleast4feetofclearance on all
sides
.
.
.
Makesure your
generatorisOFF.
.Donotcoverwith
anything untilcool!
.
13

GENERATORMAINTENANCEAND
THEHOURMETER
Copyright2010DTXInternational
Performingregularmaintenance,especiallyoilchanges,is
Importanttolongtroublefreegeneratorlife.During
prolongedpower outagesitiseasytolosetrackofexactly
howmanyhoursthegeneratorhasbeeninoperation
betweenoilchanges.Wehaveinstalledanhourmeterto
assist youinrememberingtoperform routinemaintenance
atrecommended manufacturer’sguidelines.
AlwaysmakesuretheON/OFF Switchisinits
position.Disconnectthesparkplugwire fromthe
engineandallow sufficienttimefortheengineand
generatortocompletelycool before performingany
inspection,maintenance,orcleaning.Never carryoutany
maintenanceprocedurewhilethemachineisrunning.
CAUTION!
OFF
Be suretochecktheoverallcondition ofyour
generator.
Neveruse damagedequipment.
Remembertochecktheoillevelin the generator's
engine.
Makesure that there are nopartsthatare
cracked,brokenormisaligned.Besurethat moving
parts arenotimpactedorboundinanyway.Inspectthe
electricalwiringforobvioussignsofwearordamage.If
abnormalnoiseorvibrationoccursyoushoulddiagnose
andresolvetheproblem before further use.
Refertotheenginemanufacturer'sOperation,
Maintenance,andParts Manualforspecificinformation.
Theamountofpreventativeupkeep and
maintenanceforanygeneratorwill dependuponthe
amountofuse.
NOTE:
BEFOREEACHUSE
Task
MAINTENANCERECORD
Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
Task Hours Date Initials
RecommendedMaintenance Schedule
AirFilter:Checkoneachuse,cleanevery50hrs/3months
EngineOil:Checkoneachuse,changeandreplaceevery20hrs/1month
FuelTank:Checkleveloneachuse,cleanevery20hrs/1monthandat1yr
SparkPlug:Checkandcleanevery100hrs/6months
FuelFilter Cup: Checkandcleanevery100hrs/6months
14

You shouldcheckthe oil inyourgeneratorbefore every
use. Todothis:
1.Aswith anymaintenance or operatingprocedure,
make sure yourmachine ison an even, level
surface
2.Remove the oil dipstick(see Figure G)
3.Wipe offanyoil on the dipstickwith aclean drycloth
andreinsertthe dipstickintothe oil fillerhole.
Remove again andcheckthe level ofthe oil onthe
dipstick. Ifthe oil level islowon the stick, ordoes
notappear, you will needtofill the oil crankcase
(see nextsection below).
4.Replace theoildipstickandscrew tightwhen done.
.
.
CHECKTHEGENERATOROIL
Ifwaterorcontaminantshave enteredyouroil
crankcase, orifitis time forascheduledoil change,
follow the stepsbelow todrain youroil:
1.First, place apanbeneath the generatortocatch
theoilas itdrains.
2.Remove the oil drain pluglocatedbeneaththe
oil fillerhole (see Figure I)andallow the oil to
drain
3.Onceoilhas drainedcompletelyreplace the oil
drain plugwith the wrench.
4.Torefill the oil, first, make sure yourmachine is
on an even, level surface
.Usea10mm hex-head wrench.
.
Copyright2010DTXInternational
FigureG
You shouldcheckthe
oil in yourgenerator
before everyuse.
Follow the maintenance
schedule forchanging
youroil asshown on
page 14. The
generatoris equipped
with alow oil automatic
shutoffwhich will not
allow the generatorto
run on insufficientoillevels. Ifyouroil level is toolow
butitis still nottime foran oil change, bringthe oil level
in the crankcase tothe full level.
Note:Theoilcapacityofyourgeneratoris37 fl.
ounces.
CHANGINGORADDINGOIL
FigureH
5.Remove the oil dipstick(see Figure G)
6.Onceoilhas drainedcompletelyreplace the oil
drain plugwith the wrench.
7.With the aidof
(see Figure H).
8. Pleasedispose ofoilproperly.Neverpour
downdrainsorstormdrains.
.
afunnel,addhighdetergentmotor
oiltothegenerator.Seepage 9for
recommendations(formostuses,SAE10W-30).
Checktosee thatthelevelsare nearthetopofthe
crankcase
CLEANINGTHEGENERATOR
You maycleanthe outside of yourgeneratorwitha
cleancloth, pressurizedair, asoftbristlebrushor
vaccuum.
NEVERcleanwithwater,asthis mayenterengine
parts andcompromise thelifeofyourgenerator.
15
FigureI
FILLER CAP
DRAIN PLUG

Aircleanermaintenanceis importanttoensure proper
airflow intothe generator’scarburetor. Follow the
maintenance schedule forcheckingandcleaningyour
aircleanerasshown on page 14.
When checkingthe aircleaner, visuallyinspectthe
cleanertobesurethatitisfree fromdirtandparticles.
1.First, unclaspthe springson the bottomandtopof
thecleaner’scover(see Figure J).
2.Remove the meshycomponentsinside the air
cleanercase
3.Wash with soapywarmwaterandletdry. Thencoat
andsoakin engine oilandsqueezeoutanyexcess
before returningtothe aircleanercase.
4.Replace thecoverandspringclasps.
.
MAINTAININGTHEAIRCLEANER
Copyright2010DTXInternational
FigureK
DRAININGTHEFUELTANK
FigureJ
Toinspectthe sparkplug, first:
1.Remove the sparkplugcapandunscrew the spark
plugusingthesparkplugwrench (See Figure K).
2.Lookatthe sparkplugandcheckfordefectssuch
as cracksorchips.Ifanyofthese defectsare
visible, replace with anewsparkplug
3.Next, measure the sparkpluggap, which
4.Ifyou are notreplacingthe sparkplug, cleanaround
thebase ofthe one tobe reusedandthen resetthe
gap. Screw the plugbackin, usingthe sparkplug
wrench andreplace the plugcap.
.Usea F6RTC
sparkplugsuchasNGKBPR5ES.
shouldbe
0.7-0.8nun (0.028-0.031 in).See FigureK.
MAINTAININGTHESPARKPLUG
CLEANINGTHEFUELFILTERCUP
The fuel filtercuphelpstostrain outdirtandimpurities
thatare attemptingtogetintothe engine. Toclean this
cup:
1.First, move the fuel valveto
2.Use awrench toremove thecupfromthe fuel
valve (see Figure L, below).
3.Clean the cupofdebrisusingaclean cloth, q-tip
orbrush andthen replace.
OFF.
FigureL
Ifyou arestoringyourgeneratorforlongperiodsof
timeyou shoulddrain the gastanktoavoidstarting
trouble the nexttimeyou attempttouse it. Todothis:
1.First, move the fuel valvetoandremovethe
fuel filtercup(see above andFigure L). Emptythe
cupofanyfuel present.
2.Place adrain pan orcontainerunderneaththe
generatortocontain the gas tobe drained, then
turn the fuel valve to
3.Onceall gashas drained, turn the fuelvalve back
tothe position. Wipe anyexcessgas fromthe
bodyofyourgeneratorandreplace the fuel filter
cup.
OFF
ON.
OFF
16
0.7-0.8mm
(0.026-0.031in)
PLUGCAP
PLUG WRENCH
COVER
SPRING
COVER
SPRING AIRCLEANER
COVER ELEMENT
FUELVALVE
FUELFILTER CUP

CHANGINGTHECARBONBRUSH
Copyright2010DTXInternational
17
12 3
4 5 6
Dismantle the2bolts(M5x12)
ofelectricmachineback-cover. Takedowntheinstalledbolts
(M5x16)ofcarbon-brush. Takedownthecarbon-brush
fromDCwireofexcitation.
Installtheelectricmachineback
-coverwith2bolts(M5x12).
Insertand connecttheDC
wireofexcitationaccording
to anode-cathode.
Installthenew carbon-brush
withbolts(M5x16).

CHANGINGTHEAUTOMATICVOLTAGEREGULATOR
Copyright2010DTXInternational
18
12 3
4 5 6
87
Dismantle the2bolts(M5x12)
ofelectricmachineback-cover. Takedownthe2installed bolts(M5x16)ofAVR. Disconnectthesample wire hindered.
Connectthesamplewire
hindered.
Installthenew AVRwith2
bolts(M5x16)
TakedowntheAVRfrom
carbon-brush
Insertand connecttheDC
wireofexcitationaccording
to anode-cathode.
Installtheelectricmachine
back-coverwith2bolts(M5
x12)

TORNADOPT6500E/GALEFORCEPT8500EWIRINGDIAGRAM
Copyright2010DTXInternational
19

PT6500E/PT8500EDETAILVIEW ANDPARTS LIST
Copyright2010DTXInternational
20