Porter-Cable A02871-043-0 User manual

Instruction
manual
IMPORTANT
Please make certain that the person who is
to use this equipment carefully reads and
understands these instructions before
starting operations.
Part No. A02871-043-0
ESPAÑOL: PÁGINA 25
FRANÇAIS: PAGE 49
To learn more about Porter-Cable
visit our website at:
http://www.porter-cable.com
Model
BSV550-W
Copyright © 2004 Porter-Cable Corporation
The Model and Serial No. plate is located on the frame.
Record these numbers in the spaces below and retain for
future reference.
Model No.
Type
Serial No.
Generator

2- ENG
A02871
Read Operators Manual. Do not operate equipment until you have read
operators Manual for Safety, Assembly, Operation, and Maintenance
Instructions.
This product may not be equipped with a spark arresting muffler. If the
product is not equipped and will be used around flammable materials, or
on land covered with materials such as agricultural crops, forest, brush, grass, or other similar
items, then an approved spark arrester must be installed and is legally required in the state of
California. It is a violation of California statutes section 130050 and/or sections 4442 and 4443
of the California Public Resources Code, unless the engine is equipped with a spark arrester, as
defined in section 4442, and maintained in effective working order. Spark arrester are also
required on some U.S. Forest Service land and may also be legally required under other
statutes and ordinances.
Engine exhaust contains chemicals known, in certain quantities, to cause
cancer, birth defects or other reproductive harm.
CONSUMER GENERAL AND SERVICE INFORMATION
• Please read and follow these instructions for proper use and maintenance.
• If you experience any problems and need assistance, please call us at our toll
free number 1-888-559-8550, Monday through Saturday, 8:00 a.m. To 6:00
p.m. C.S.T.
• If repair or service part purchase is required, our many Authorized Warranty
Service Centers are conveniently located and equipped to handle all in-
warranty and out-of-warranty service.
• For the location of the nearest Authorized Warranty Service Center call
1-888-559-8550, 24 hours a day, 7 days a week.
• Retain sales receipt as proof of purchase for warranty service.
•Read and understand all safety warnings.
• Do not operate this unit until you have read and understand this Owners
Manual for Safety, Operation, and Maintenance Instructions.
• Do not operate this unit until you have read and understand the Engine
Owners Manual for Safety, Operation, and Maintenance Instructions.
Note: Photographs and line drawings used in this manual are for reference only and
do not represent a specific model.
CONSUMER SAFETY INFORMATION

3- ENG A02871
indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
indicates a potentially hazardous situation which, if not avoided,may result in
minor or moderate injury
used without the safety alert symbol indicates potentially hazardous situation
which, if not avoided, may result in property damage.
This manual contains information that is important for you to know and understand. This infor-
mation relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To
help you recognize this information, we use the symbols below. Please read the manual and
pay attention to these sections.
SAFETY GUIDELINES / DEFINITIONS
IMPORTANT SAFETY INSTRUCTIONS
Improper operation or maintenance of this product could result in serious
injury and property damage. Read and understand all warnings and
operating instructions before using.
RISK OF ELECTROCUTION AND FIRE
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Attempting to
connect generator
directly to the
electrical system
of any building
structure.
Back feeding electricity through
a building's electrical system to
the outside utility feed lines
could endanger repair persons
attempting to restore service.
Never backfeed electricity
through a structure's electrical
system.
Attempting to connect to the in-
coming utility service could result
in electrocution.
Restoration of electrical service
while the generator is connected
to the incoming utility could
result in a fire or serious damage
if an isolator switch is not
installed.
Failure to use a double throw
transfer switch when connecting
to a structure's electrical system
can damage appliances and
WILL VOID the manufacturer's
warranty.
To connect to a structure's electri-
cal system in a safe manner,
always have a Double-Throw
Transfer Switch installed by a
qualified electrician and in compli-
ance with local ordinances.
(When installing a Double-
Throw Transfer Switch, a mini-
mum of 10 gauge wiring must
be used.)

4- ENG
A02871
Operation of unit
when damaged,
or with guards or
panels removed.
Removal of guarding could
expose electrically charged
components and result in
electrocution.
Do not operate generator with
protective guarding removed.
Improper
connection of
items to
generator.
Exceeding the load capacity of
the generator by attaching too
many items, or items with very
high load ratings to it could
result in overheating of some
items or their attachment wiring
resulting in fire or electrical
shock.
Attempting to use the unit
when it has been damaged, or
when it is not functioning
normally could result in fire or
electrocution.
Read the load rating chart and
instructions in the Wattage Cal-
culation section. Make sure that
the summation of electrical
loads for all attachments does
not exceed the load rating of the
generator.
Do not operate generator with
mechanical or electrical
problem. Have unit repaired by
an Authorized Service Center.
Operation of
generator in rain,
wet, icy, or
flooded
conditions.
Water is an excellent conductor
of electricity! Water which comes
in contact with electrically
charged components can
transmit electricity to the frame
and other surfaces, resulting in
electrical shock to anyone con-
tacting them.
Operate generator in a clean, dry,
well ventilated area. Make sure
hands are dry before touching
unit.
Use of worn,
damaged, under-
sized or un-
grounded exten-
sion cords.
Use of ungrounded cordsets
could prevent operation of
circuit breakers and result in
electrical shock.
Always use a cordset having a
grounding wire with an
appropriate grounding plug. DO
NOT use an ungrounded plug.
Use proper size (wire gauge)
cordset for application see chart
in the Assembly section of this
manual.
Contact with worn or damaged
extension cords could result in
electrocution.
Use of undersize extension
cords could result in overheating
of the wires or attached items,
resulting in fire.
Inspect extension cords before
use and replace with new cord if
required.
Placing generator
on or against
highly conductive
surface, such as a
steel walkway or
metal roof.
Place generator on low conduc-
tivity surface such as a concrete
slab.
Accidental leakage of electrical
current could charge conductive
surfaces in contact with the
generator.
RISK OF ELECTROCUTION AND FIRE
(Continued)
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
ALWAYS operate generator a
minimum of six feet from any
conductive surface.

5- ENG A02871
RISK OF FIRE
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Improper storage
of fuel Improperly stored fuel could
lead to accidental ignition. Fuel
improperly secured could get
into the hands of children or
other unqualified persons.
Store fuel in a OSHA approved
container designed to hold
gasoline. Store container in se-
cure location to prevent use by
others.
Attempting to
fill the fuel tank
while the engine
is running.
Gasoline and gasoline vapors
can become ignited by coming
in contact with hot components
such as the muffler, engine
exhaust gases, or from an
electrical spark.
Cigarettes, sparks, fires, or
other hot objects can cause
gasoline or gasoline vapors to
ignite.
Turn engine off and allow it to
cool before adding fuel to the
tank. Equip area of operation
with a fire extinguisher certified
to handle gasoline or fuel fires.
Add fuel to tank in well
ventilated area. Make sure there
are no sources of ignition near
the generator.
Operate generator in a clean, dry,
well ventilated area a minimum of
four feet from any building, object
or wall. DO NOT OPERATE
UNIT INDOORS OR IN ANY
CONFINED AREA.
Materials placed against or near
the generator or operating the
generator in areas where the
temperature exceeds 104° F. am-
bient (such as storage rooms or
garages) can interfere with its
proper ventilation features caus-
ing overheating and possible ig-
nition of the materials or build-
ings.
Sparks, fire, hot
objects
Inadequate
ventilation for
generator
Tampering with
factory set
engine speed
settings.
Engine speed has been factory
set to provide safe operation.
Tampering with the engine speed
adjustment could result in
overheating of attachments and
could cause a fire.
Spilled fuel and its vapors can
become ignited from hot
surfaces or sparks.
Never attempt to “speed-up”
the engine to obtain more per-
formance. Both the output
voltage and frequency will be
thrown out of standard by this
practice, endangering
attachments and the user.
Use care in filling the tank to
avoid spilling fuel. Make sure
fuel cap is secured tightly and
check engine for fuel leaks
before starting engine. Move
generator away from refueling
area or any spillage before
starting engine. Allow for fuel
expansion. Keep maximum fuel
level ¼ inch below the tip of the
fuel tank. Never refuel with the
engine running.
Overfilling the fuel
tank – fuel
spillage.

6- ENG
A02871
RISK OF UNSAFE OPERATION
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Operation of
generator in
careless manner
All sources of energy include the
potential for injury. Unsafe
operation or maintenance of your
generator could lead to serious
injury or death to you or others.
• Review and understand all of
the operating instructions and
warnings in this manual.
• Become familiar with the oper-
ation and controls of the
generator. Know how to shut it
off quickly.
• Equip area of operation with a
fire extinguisher certified to
handle gasoline or fuel fires.
• Keep children or others away
from the generator at all times.
RISK OF BREATHING - INHALATION
HAZARD
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Breathing exhaust fumes will
cause serious injury or death. Operate generator in clean, dry,
well ventilated area. Never
operate unit in enclosed areas
such as garages, basements,
storage, sheds, or in any
location occupied by humans or
animals. Keep children, pets and
others away from area of operat-
ing unit.
Gasoline
engines produce
toxic carbon
monoxide
exhaust fumes.
RISK OF INJURY AND PROPERTY
DAMAGE WHEN TRANSPORTING
GENERATOR
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Fire, Inhalation,
Damage to
Vehicle Surfaces
Fuel or oil can leak or spill and
could result in fire or breathing
hazard, serious injury or death
can result. Fuel or oil leaks will
damage carpet, paint or other
surfaces in vehicles or trailers.
If generator is equipped with a
fuel shut-off valve, turn the valve
to the off position before
transporting to avoid fuel leaks.
If generator is not equipped with
a fuel shut-off valve, drain the
fuel from tank before transport-
ing. Transport fuel only in an
OSHA approved container.
Always place generator on a
protective mat when transport-
ing to protect against damage to
vehicle from leaks. Remove
generator from vehicle immedi-
ately upon arrival at your desti-
nation.

7- ENG A02871
RISK OF UNSAFE OPERATION
(Continued)
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Improper raising or suspending
can cause damage to the
generator.
Always use cables, chains, or
straps rated at 2000 lbs working
load or more to raise or suspend
generator.
Operation of
voltage
sensitive appli-
ances without a
voltage surge
protector
Any gasoline operated
household generator will incur
voltage variations causing
damage to voltage sensitive ap-
pliances or could result in fire.
Always use a U.L. listed voltage
sensitive surge protector to
connect voltage sensitive
appliances (TV, computer, ste-
reo, etc.). Failure to use a U.L.
listed voltage surge protector
will void the warranty on your
generator.
Notice: A multiple outlet strip is
not a surge protector. Make sure
you use a U.L. listed voltage
surge protector
Raising or
suspending
generators
equipped with
lift rings
improperly
Generator could fall causing
serious injury or death to you or
others.
Always use proper connecting
procedures as described in this
manual when connecting cables,
chains, or straps for raising or
suspending generators equipped
with lift rings.
Operating
generator while
suspended
Generator will not operate
properly while suspended,
cause damage to the generator,
and could cause serious injury
or death to you or others.
Never operate generator while
suspended or in an unlevel
position. Always operate
generate on a flat, level surface.
Contact with hot surfaces, such
as engines exhaust components,
could result in serious burns.
RISK OF HOT SURFACES
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Contact with hot
engine and
generator
components.
During operation, touch only the
control surfaces of the
generator. Keep children away
from the generator at all times.
They may not be able to recog-
nize the hazards of this
product.

8- ENG
A02871
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
RISK OF MOVING PARTS
Never operate generator with
guarding or cover plates
removed. Avoid wearing loose
fitting clothing or jewelry which
could be caught by moving parts.
The generator contains parts
which rotate at high speed during
operation. These parts are
covered by guarding to prevent
injury.
Contact with
moving parts
can result in
serious injury.
RISK FROM LIFTING
The generator is too heavy to be
lifted by one person. Obtain as-
sistance from others before you
try to move it.
Serious injury can result from at-
tempting to lift too heavy an
object.
Lifting a very
heavy object.
SPECIFICATIONS
MODEL BSV550-W
HORSE POWER 9.0
RATED/SURGE WATTS 5500/8850
VOLTAGE 120/240
AMPERAGE 45.8/22.9 A
PHASE SINGLE
FREQUENCY 60 Hz
ENGINE SPEED 3600 RPM
MAX. AMBIENT TEMP. 104° F
FUEL CAPACITY 7 GALLONS
RUN TIME @ 50%/100% 10.4/7.0 HRS

9- ENG A02871
NOTE: Left and right describes the location of a part with the operator
facing the outlet panel.
UNPACKING
1. Open carton from top.
2. Cut carton along dotted lines.
3. Remove all carton inserts.
4. See portability Kit instructions to assemble the portability kit.
ASSEMBLY
Read this manual. Do not attempt to operate equipment
until you have read this Manual for Safety, Operation, and
Maintenance Instructions.
ASSEMBLE PORTABLILITY KIT
Tools needed:
1 - 1/2" socket
1 - 1/2" open end wrench
1 - 3/8" socket
1 - 3/8" open end wrench
1 - 7/8" socket
Kit Contains:
2 - Handles (1)
2 - Wheels (2)
1 - Foot Bracket (3)
1 - Rubber Bumper (4)
Parts bag contains:
2 - Handle Grips (5)
2 - Handle Brackets (6)
6 - Screws, 5/16-18 x 2.00 (7)
7 - Flange Nuts (8)
2 - Snap Buttons (9)
1 - Screw 5/16-18 x .75 (10)
2 - Bolt, 3/8-16 x 2.25 (11)
2 - Locknut, 3/8-16 (12)
1 - Screw 1/4-20 X .75 (13)
1 - Kep Nuts, 1/4-20 (14)
11
2
6
12
14
13
4
38
10
5
1
9
7
8
NOTE: The key numbers in
this figure are referenced
throughout the instructions.

10- ENG
A02871
1. With the help of another person, tilt the generator
and rest on frame as shown. DO NOT remove the
shipping block until portability kit has been
assembled.
The generator is too heavy to be
lifted by one person. Obtain
assistance from others before lifting.
2. Assemble wheels to wheel brackets using shoulder
bolts (11) and locknuts (12). NOTE: Valve stem
should be to the outside. Tighten securely.
3. Attach rubber bumper (4) to foot bracket (3) using
screw (13) and keps nut (14). Tighten securely.
4. Remove the ground lug. Save grounding lug, screw,
and flange nut to assemble foot bracket.
5. Attach foot bracket assembly (3) and ground lug to
generator frame as shown. Tighten screws securely.
NOTE: Make sure grounding lug is oriented as
shown.
6. To make installation easier, submerge handle grips into warm soapy water.
Remove handle grips from soapy water and slide onto handles .
7. Squeeze snap button (9), slide into handle, and
release snap button through second hole.
NOTE: V of snap button is inserted first. Repeat
step on other handle.
8. Depress snap button (9), slide into handle
bracket, and release through first slot in handle bracket as shown. Secure
handle to handle bracket with screw (7) and flange nut (8).
9
1111
vvaallvveesstteemm
ggrroouunnddiinngglluugg
sshhiippppiinnggbblloocckk
1100
88
33
44
ggrroouunnddiinngglluugg

11- ENG A02871
9. On other handle depress snap button (9), slide into handle bracket, and
release through first slot in handle bracket as shown. Secure handle to
handle bracket with screw (7) and flange nut (8).
10. Attach handle bracket assemblies to frame with screws (7) and flange nuts
(8). Tighten securely.
NOTE: Orientation of handle assemblies to frame will depend on how the
operator wishes to operate snap button (9). If snap button is assembled
to outside of the generator frame the fingers will operate it. If snap button
is assembled to inside of the generator frame the thumbs will operate it.
The figure shows the snap button assembled to inside of generator frame
11. Remove shipping block from under the gen head. Unscrew bolt and remove
the shipping block. It is very important that this is removed before starting
your generator.
12. Carefully tilt the generator to operating position.
13. The portability kit is now ready for use.
14. To lower handle, depress snap button and fold handles down.
15. Raise handles and allow snap button to snap into place.
Risk of moving parts. Keep fingers away from
all moving parts. Contact with moving parts
can result in serious injury. Keep children away from the
generator at all times. They may not be able to recognize the
hazards of this product.
7
97
9
9
8
OTHER LOOSE PARTS
1. Oil is supplied, see engine operators manual for correct procedure to add
oil and fuel to engine.
2. The locking plugs may be used when needed or required.
The locking plugs are to be installed and/or used in
accordance with appropriate local electrical code
regulations. Refer to instructions enclosed with each plug for proper
installation.
IMPORTANT: Before any attempt to start your generator be sure to check
engine oil (See Engine Operator's manual)

12- ENG
A02871
DOUBLE THROW TRANSFER SWITCH
Potential hazards exist when a portable electric generator is
connected to the main electrical supply coming into the house.
It is at that point that the electrical generator could feed back into the utility
company's system causing possible electrocution of workers who are repairing
the electrical lines.
To avoid back feeding of electricity into utility systems, a double-throw transfer
switch must be installed between the generator and utility power. The Double-
Throw Transfer Switch should be installed by a licensed electrician and in com-
pliance with all state and local electrical codes. (When installing a Double-
Throw Transfer Switch, a minimum of 10 gauge wiring must be used.)
The electrician should also install a sub-panel to isolate the circuits you would
want to use during an emergency or electrical power outage. Your generator will
not be large enough to handle the load of all the lights, appliances, TV, etc. at
one time. To select which items to run during the electrical power outage, see
Wattage Calculation section in this manual.
GROUNDING THE GENERATOR
A grounding lug is supplied with the generator for
use when required by local electrical ordinances.
Refer to article 250 of the National Electrical Code
to clarify any needed grounding information. Your
local electric company or a certified electrician
should be able to help you with this information.
Grounding Lug
OBTAINING ELECTRICITY FROM THE GENERATOR
There are basically 2 ways to obtain electricity from a generator:
1. Use of extension cords directly from the generator to the appliance, lights,
tools, etc.
2. Use of a double-throw transfer switch installed directly to the main electrical
supply outside of house.
EXTENSION CORDS
When using an appliance or tool at a considerable distance from the generator, a
3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle
that accepts the tool's plug MUST be used in order to reduce the risk of
electrical shock. A cord of adequate size must be used. Using the following chart
to determine the minimum wire size required.
*NOTE: When amperage exceeds 20 amp; a 12 gauge extension cord should
not be used for long distances.
Extension Cord Wire Gauge Chart
Amperage
*Up to 20 amp draw
Up to 30 amp draw
Cord
Length
0 to 100 ft.
0 to 100 ft.
Wire Gauge
Size
12 ga.
10 ga.
An extension cord that is hot to the touch is overloaded.
Repair or replace damaged extension cords immediately.

13- ENG A02871
OPERATION
KNOW YOUR GENERATOR
Read this General Manual and Safety Rules before operation of your Generator.
Compare the illustration in your parts manual with your generator to familiarize yourself with
the location of various controls and adjustments. Save all manuals for future references.
GENERATOR CAPACITY
IMPORTANT: Exceeding the rated capacity of your generator can result in serious damage
to your generator and connected electrical devices. See the Wattage Calculation section in
this manual to assist you in determining the appliances and tools that can be run with the
wattage capacity of your generator.
CIRCUIT BREAKERS
Each receptacle has a circuit breaker to protect the generator from overloading. If the circuit
breaker trips, unplug all electrical loads from the generator. Let the circuit breaker cool
down. Push circuit breaker button to reset.
LOW OIL PROTECTION
Your generator engine is equipped with Low Oil Shutdown. Low Oil Shutdown is
a safety device designed to protect your engine from damage in the event the oil
level in the crankcase is low.
If while the engine is running, the oil gets low, it will automatically shut itself
down and will not restart until the oil is added. If the oil is low before start-up,
the generator will not start until oil is added.
NOTE: The Low Oil Shutdown mechanism is very sensitive. You must fill the
engine to the full mark on the dipstick to inactivate this safety device.
BEFORE START UP
This generator has been shipped from the factory without oil in the
crankcase. Operating the unit without oil can damage the engine.
Always check engine oil level before every start. Running engine low
of oil or out of oil could result in serious damage to the engine.
Follow the steps listed below before starting generator:
1. Check engine oil. Refer to the Engine Operator's Manual for
correct grade and quantity of oil.
2. Check fuel level, fill as required. Make sure generator is turned
off and has been allowed time to cool down. Use clean, fresh,
regular unleaded gasoline with a minimum of 87 octane. Do
not mix oil with gasoline.
Never fill fuel tank completely. Fill tank to
1/2" below the bottom of the filler neck to
provide space for fuel expansion. Wipe any fuel spillage from engine and equipment
before starting engine.
Never fill fuel tank indoors. Never fill fuel tank when engine is
running or hot. Do not smoke when filling fuel tank.
Never run engine indoors or in enclosed, poor ventilated areas, engine
exhaust contains carbon monoxide, an odorless and deadly gas.
3. Make sure generator is grounded in accordance with local requirements.
4. All electrical loads MUST be disconnected.

14- ENG
A02871
Engine speed has been factory set to provide safe operation.
Tampering with the engine speed adjustment could result in over-
heating of attachments and could cause a fire. Never attempt to “speed-up” the en-
gine to obtain more performance. Both the output voltage and frequency will be
thrown out of standard by this practice, endangering attachments and the user.
You MUST unplug any load from the generator before starting to
prevent permanent damage to any appliances.
TO START THE ENGINE
Never run engine indoors or in enclosed, poor ventilated
areas. Engine exhaust contains carbon monoxide, an
odorless and deadly gas.
1. Open the fuel shut-off valve.
2. Move the choke control located on the engine to the “Choke” position.
NOTE: No choke is required on warm engines. make sure choke is in the
“RUN” position on warm engine starts.
3. On the engine there is a ON/OFF switch located on the front
panel of the engine. Place this switch to the "ON" position.
4. Grasp handle on rope starter and pull slowly until resistance
is felt. Let the rope rewind slowly. Pull rope with a rapid full
arm stroke. Let rope rewind slowly. Repeat if necessary.
5. When engine starts, gradually move the choke to the “RUN” position.
IMPORTANT: Allow generator to run at no load for 5 minutes upon each initial
start-up to allow engine and generator to stabilize.

15- ENG A02871
CONNECTING ELECTRICAL LOADS
1. Let engine run and warm up for five minutes after starting with no electrical
load.
Connect loads in the following manner to prevent damage to equipment:
2. Connect inductive load equipment first, inductive loads consist of
refrigerators, freezers, water pumps, air conditioners, or small hand tools.
Connect the items that require the most wattage first. See Wattage Calcu-
lation Section in this manual.
3. Connect the lights next.
4. Voltage sensitive equipment should be the last equipment connected to the
generator. Plug voltage sensitive appliances such at TV's, VCR's, micro-
waves, ovens, computers, and cordless telephones into a UL listed voltage
surge protector, then connect the UL listed voltage surge protector to the
generator.
Failure to connect and operate equipment in this sequence
can cause damage to equipment and will void the warranty
on your generator.
Follow the wattage calculation table in the Wattage Calculation section of
this manual. Overloading the generator will cause power fluctuations and
can damage equipment and appliances.
Porter-Cable Corporation will only be responsible for damage to
customer's equipment when the generator is determined to be defective.
This determination will only be made by an authorized representative of
Porter-Cable Corporation and this decision will be final. Porter-Cable
Corporation reserves the right to inspect the electrical connections at the
customer's site of operation and test the generator for proper operation
before any determination of liability is made. Failure to maintain the
equipment or wiring for inspection will void any claim for damages by the
customer. Porter-Cable Corporation will not be responsible for equipment
damaged as a result of voltage surges, improper operation or improper
installation of the generator.
STOPPING ENGINE
1. Disconnect all electrical loads.
2. Turn ON/OFF switch to "OFF" position.
3. Close fuel shut-off valve.

16- ENG
A02871
Note 1: Change oil after first two (2) operating hours and every 50 operating
hours thereafter, more often if operated in extreme dusty or dirty conditions.
Note 2: Check oil after 5 hours of operation.
CUSTOMER RESPONSIBILITIES TABLE
MAINTENANCE TASK
Before
each
use
Every 25
Hours of
Every
Season
Every 50
Hours of
Every
Season
Every 100
Hours of
Every
Season
Check Spark Plug
Prepare unit for storage if it is to remain
idle for more than 30 days.
MAINTENANCE
Check oil level
Change oil
Clean Air Filter Assembly
Prepare Unit for Storage
See Note 2
X
See Note 1
X
XX
GENERAL RECOMMENDATIONS
The warranty of the generator does not cover items that have been subjected to
operator abuse or negligence. To receive full value from the warranty, operator
must maintain the generator as instructed in this manual.
ENGINE MAINTENANCE
Refer to the Engine Operator's manual for service and maintenance of the
engine.
GENERATOR MAINTENANCE
Your generator should be kept clean and dry at all times. The generator should
not be stored or operated in environments that includes excessive moisture,
dust or any corrosive vapors. If these substances are on the generator, clean
with a cloth or soft bristle brush. Do not use a garden hose or anything with
water pressure to clean the generator. Water may enter the cooling air slots and
could possibly damage the rotor, stator and the internal windings of the gen
head.

17- ENG A02871
If you are going to store your generator for more than 30 days, use the
following information as a guide to prepare the generator for storage.
Never store generator with fuel in the tank, indoors or in
enclosed, poorly ventilated areas, where fumes can reach
an open flame, spark or pilot light as on a furnace, water heater, clothes
dryer or other gas appliances.
ENGINE PREPARATION
1. Add fuel stabilizer to fuel tank to minimize the formation of fuel gum
deposits during storage.
2. Run engine at least 10 minutes after adding stabilizer to allow it to enter the
fuel system.
3. Next shut off engine.
4. Disconnect the spark plug wire and remove the spark plug.
5. Add one teaspoon of oil through the spark plug hole.
6. Place rag over spark plug hole and pull the recoil a few times to lubricate
the combustion chamber.
7. Replace the spark plug, but do not connect the spark plug wire.
NOTE: If a fuel stabilizer is not used, all gasoline must be drained from the tank
and carburetor to prevent gum deposits from forming on these parts and causing
possible malfunction of the engine.
GENERATOR
• Clean the generator as outlined in the Maintenance Section on this manual.
• Check that cooling air slots and openings on generator are open and
unobstructed.
STORAGE

18- ENG
A02871
WATTAGE CALCULATIONS
Never exceed the rated capacity of your generator. Serious damage to the
generator or appliance could result from an overload.
1. Starting and running wattage requirements should always be calculated
when matching a generators wattage capacity to the appliance or tool.
2. There are two types of electrical appliances that can be powered by
your generator:
A. Items such as radios, light bulbs, television sets, and microwaves
have a "resistive load". Starting wattage and running wattage are
the same.
B. Items such as refrigerators, air compressors, washer, dryer, and
hand tools that use an electrical motor have an "inductive load".
Inductive load appliances and tools require approximately 2 to 4
times the listed wattage for starting the equipment. This initial load
only lasts for a few seconds on start-up but is very important when
figuring your total wattage to be used.
C. Always start your largest electric motor first, and then plug in other
items, one at a time.
NOTE: On 120-volt loads the maximum starting wattage should NOT
exceed one half of the rated generator wattage. Example: a 5000 rated
wattage generator = 2500 maximum starting wattage.
IMPORTANT
DETERMINING WATTAGE REQUIREMENTS
Before operating this generator list all of the appliances and/or tools that are
going to operate at the same time. Then determine the starting wattage
requirements and the running wattage requirements by following example
and/or refer to household wattage calculator.
1. First total the running wattage of all appliances and/or tools that will be
operated at the same time.
Running Watts Starting Watts
Example 1:
Lights = 100 Watts 0
Television = 300 Watts 0
Slow Cooker = 250 Watts 0
TOTAL =650 Watts 0
2. Next the starting wattages of any appliances and/or tools that will start and
stop during operation.
Running Watts Starting Watts
Example 2:
Small Refrigerator 500 Watts 2000 Watts
TOTAL =500 Watts 2000 Watts
3. The running wattage of examples 1 & 2 totals 1150 watts. The starting
wattage of the small refrigerator is 2000 watts which is 1500 watts more
than the running watts. Take this difference of 1500 starting watts from the
refrigerator and add to the total running watts of 1150.
Example 3: 1500 Starting Watts
1150 Running Watts
TOTAL =2650 Total Watts
Generator must have a maximum capacity of at least 2650 watts.

19- ENG A02871
STARTING WATTAGE REQUIREMENTS
1. Some appliances and tools will list on the motor nameplate the starting
and running voltage and amperage requirements. Use the following
formula to convert voltage and amperage to wattage:
Volts X Amp = Watts
Example: 120 volts x 10 amps = 1200 watts
2. To determine the approximate starting wattage requirement for most
appliances and tools with inductive type motors, multiply the wattage that
was calculated by 2 to 4 times to assure adequate generator capacity. If
the nameplate information is not available use the values on the following
chart as a guide.
3. Remember that the starting and running wattage for resistive loads are the
same. (Example: a 100 watt light bulb requires only 100 watts to start.)
Most resistive loads will be listed in wattage.
The wattage ratings shown are averages. Wattage requirements may vary
with different brands of appliances.
Application Guide
To select the right generator for your needs, total the wattage
of the items to be run at the same time.
Run
Electric Appliance
Wattage
ContractorEmergency ReliefRecreational
3/8" Hand Drill
Jigsaw
1/3 HP Airless Sprayer
6" Bench Grinder
Belt Sander
Demolition Hammer
7 1/4" Circular Saw
Light Bulb
Home Security
Television
Microwave
Toaster Oven
Portable Heater (5,000 BTU)
Furnace Fan
Refrigerator/Freezer
Sump Pump
Clothes Washer
Water Heater
Air Conditioner (20,000 BTU)
12V DC Battery Charger
Radio
Slow Cooker
Electric Blanket
Electric Skillet
Coffee Maker
Small Refrigerator
100 250 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500
Start

20- ENG
A02871
APPLIANCE OR
LOAD DEVICE*
REFRIGERATOR/
FREEZER
800
SMALL REFRIGERATOR
AIR COND.(ROOM)
SUMP PUMP 1/2 HP
600
TELEVISION
CAUTION !!
HOT PLATE
MICROWAVE
SPACE HEATER
2400
1000
3
2
LIGHTING
60 WATT BULBS
75 WATT BULBS
100 WATT BULBS
300 WATT BULBS
ELECTRIC LOAD GRAND TOTAL
THIS TOTAL MUST BE LESS THAN YOUR GENERATOR RATING
WATTAGE RATING OF YOUR GENERATOR
TOTAL
THIS TOTAL MUST BE GREATER THAN YOUR HOUSEHOLD WATTAGE LOAD
TYPICAL DEVICE
WATTAGE**
2400
1800
7200
2000
300
1500
800
1500
WATER HEATER 4000
TIMES NUMBER
OF BULBS
60
75
100
300
CAUTION !!
WATTS
DEVICES WITH HIGH STARTING (INDUCTIVE)LOADS
RUN WATTS TIMES (X) START FACTOR
DO NOT CONNECT VOLTAGE SENSITIVE
ELECTRONIC EQUIPMENT (TV SET, COMPUTER,
ETC.) DIRECTLY TO YOUR GENERATOR. IF YOU USE
THE GENERATOR TO POWER SENSITIVE EQUIPMENT
YOU MUST USE A U.L. LISTED VOLTAGE SURGE
PROTECTOR.
NOTICE: FAILURE TO USE A U.L. LISTED VOLTAGE
SURGE PROTECTOR WILL DAMAGE YOUR
EQUIPMENT AND VOID YOUR WARRANTY.
3
3
THE IDLE CONTROL MUST BE IN THE
OFF POSITION WHEN OPERATING
LARGE MOTOR LOADS (FREEZERS,
REFRIGERATORS,ETC.) OR VOLTAGE
SENSITIVE ELECTRONIC EQUIPMENT
(TV, COMPUTERS, ETC.)
FURNACE FAN 1/3 HP
800 32400
WELL PUMP 1/2 HP
1000 22000
*FOR PRODUCTS NOT
LISTED REFER TO
CALCULATION
INSTRUCTIONS
**AVERAGE VALUES -
ACTUAL INDIVIDUAL
DEVICE VOLTAGES MAY
BE HIGHER OR LOWER
x
x
x
x
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
x
x
x
x
x
x
=
=
=
=
=
=
=
=
=
=
=
HOUSEHOLD WATTAGE CALCULATOR