Porter-Cable BSV550-W 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. A16596 03-22-06 Rev.0
®
FRANÇAIS: PAGE 23
ESPAÑOL: PÁGINA 47
To learn more about Porter-Cable
visit our website at:
http://www.porter-cable.com
Model
BSV550-W
Copyright © 2006 Porter-Cable
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
A16596
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 SAFETY INFORMATION
This manual contains information that is important for you to know and understand.
This information relates to protecting YOUR SAFETY and PREVENTING EQUIP-
MENT PROBLEMS. To help you recognize this information, we use the symbols
below. Please read the manual and pay attention to these sections.
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.
SAFETY GUIDELINES / DEFINITIONS
TABLE OF CONTENTS
CONSUMER SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SAFETY GUIDELINES/DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
WATTAGE CALCULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
FRANÇAIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46
ESPAÑOL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-56

3- ENG A16596
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 sys-
tem 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
incoming 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 elec-
trical system in a safe manner,
always have a Double-Throw
Transfer Switch installed by
a qualified electrician and in
compliance with local ordinanc-
es. (When installing a Double-
Throw Transfer Switch, a mini-
mum of 10 gauge wiring must
be used.)
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, undersized
or ungrounded exten-
sion cords.
Contact with worn or damaged
extension cords could result in
electrocution.
Inspect extension cords before
use and replace with new cord if
required.
Use of undersize extension
cords could result in overheating
of the wires or attached items,
resulting in fire.
Use proper size (wire gauge)
cordset for application see chart
in the Assembly section of this
manual.
Use of ungrounded cord sets
could prevent operation of circuit
breakers and result in electrical
shock.
Always use a cord set having
a grounding wire with an
appropriate grounding plug.
DO NOT use an ungrounded
plug. Use only outdoor rated
extension cords

4- ENG
A16596
RISK OF ELECTROCUTION
AND FIRE (Continued)
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Placing generator
on or against highly
conductive surface,
such as a steel walk-
way or metal roof.
Accidental leakage of electrical
current could charge conductive
surfaces in contact with the
generator.
Place generator on low conduc-
tivity surface such as a concrete
slab.
ALWAYS operate generator a
minimum of six feet from any
conductive surface.
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.
Read the load rating chart and
instructions in the Wattage
Calculation section. Make sure
that the summation of electrical
loads for all attachments does
not exceed the load rating of the
generator.
Operation of unit
when damaged, or
with guards or panels
removed.
Attempting to use the unit when
it has been damaged, or when it
is not functioning normally could
result in fire or electrocution.
Do not operate generator with
mechanical or electrical problem.
Have unit repaired by an Autho-
rized Service Center.
Removal of guarding could
expose electrically charged
components and result in
electrocution.
Do not operate generator with
protective guarding removed.
RISK OF FIRE
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
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.
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.
Sparks, fire, hot
objects Smoking material, sparks, fires,
or other hot objects can cause
gasoline or gasoline vapors to
ignite.
Add fuel to tank in well ventilated
area. Make sure there are no
sources of ignition near the
generator.
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
secure location to prevent use
by others.
Inadequate ventilation
for generator Materials placed against or near
the generator or operating the
generator in areas where the
temperature exceeds 104° F.
ambient (such as storage rooms
or garages) can interfere with its
proper ventilation features caus-
ing overheating and possible igni-
tion of the materials or buildings.
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.

5- ENG A16596
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.
Never attempt to "speed-up"
the engine to obtain more perfor-
mance. Both the output voltage
and frequency will be thrown
out of standard by this practice,
endangering attachments and
the user.
Overfilling the fuel tank
– fuel spillage. Spilled fuel and its vapors
can become ignited from hot
surfaces or sparks.
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 1/2 inch (12.7 ml) below the
top of the fuel tank. Never refuel
with the engine running.
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 transporting. Transport
fuel only in an OSHA approved
container. Always place
generator on a protective mat
when transporting to protect
against damage to vehicle from
leaks. Keep generator level at
all times to prevent fuel spillage.
Remove generator from vehicle
immediately upon arrival at your
destination.
RISK OF BREATHING -
INHALATION HAZARD
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Gasoline engines
produce toxic carbon
monoxide exhaust
fumes.
Breathing exhaust fumes will
cause serious injury or death. Operate generator in clean, dry, well ventilated area. Never oper-
ate unit in enclosed areas such
as garages, basements, stor-
age, sheds, or in any location
occupied by humans or animals.
Keep children, pets and others
away from area of operating
unit. DO NOT OPERATE
GENERATOR INDOORS OR IN
ANY CONFINED AREA.

6- ENG
A16596
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
operation 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.
Operation of voltage
sensitive appliances
without a voltage
surge protector
Any gasoline operated
household generator will incur
voltage variations causing
damage to voltage sensitive
appliances 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.
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.
Operating generator
while suspended Generator will not operate
properly and will 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
generator on a flat, level surface.

7- ENG A16596
RISK OF HOT SURFACES
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Contact with hot
engine and generator
components.
Contact with hot surfaces, such
as engines exhaust components,
could result in serious burns.
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.
RISK OF MOVING PARTS
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Contact with moving
parts can result in
serious injury.
The generator contains parts
which rotate at high speed
during operation. These parts are
covered by guarding to prevent
injury.
Never operate generator
with guarding or cover plates
removed. Avoid wearing loose
fitting clothing or jewelry and
contain long hair which could be
caught by moving parts.
RISK FROM LIFTING
HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT
Lifting a very heavy
object. Serious injury can result from
attempting to lift too heavy an
object.
The generator is too heavy to
be lifted by one person. Obtain
assistance from others before
you try to move it.
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
Note: Photographs and line drawings used in this manual are for reference only and
do not represent a specific model.

8- ENG
A16596
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.
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
438
10
5
1
9
7
8
NOTE: The key numbers
in this figure are referenced
throughout the instructions.
ASSEMBLY

9- ENG A16596
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).
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
11
grounding lug
shipping block
10
8
3
4
grounding lug

10- ENG
A16596
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.
OTHER LOOSE PARTS
1. Oil is supplied, see engine operators manual for correct procedure to add oil
and fuel to engine.
IMPORTANT: Before any attempt to start your generator be sure to check engine
oil (See Engine Operator's 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.
Risk of fire. Do not use metal
pipe that is being used to carry
combustible materials or gases for the grounding point.
7
97
9
9
8
Grounding Lug

11- ENG A16596
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 deter-
mine the minimum wire size required.
*NOTE: When amperage exceeds 20 amp; a 12 gauge extension cord should
not be used for long distances.
An extension cord that is hot to the touch is overloaded.
Repair or replace damaged extension cords immediately.
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 compli-
ance 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.
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 Cord Wire Gauge Chart
Cord
Length Wire Gauge Size Amperage
0 to 100 ft. 12 ga. *Up to 20 amp draw
0 to 100 ft. 10 ga. Up to 30 amp draw

12- ENG
A16596
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 Watt-
age 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.
Keep fuel out of the reach of children.
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, and
make sure area is dry before starting engine.
Never fill fuel tank indoors. Fill generator in well ventilated area.
Never fill fuel tank when engine is running or hot. Do not smoke
when filling fuel tank. Never allow open flames or sparks in area.
Store fuel in an approved container. Store fuel in a well
ventilated area free of open flames or sparks.

13- ENG A16596
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.
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. Never attempt to "speed-up" the
TO START THE ENGINE
Never run engine indoors or in enclosed, poor ventilat-
ed 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.

14- ENG
A16596
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 Calcula-
tion 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.

15- ENG A16596
CUSTOMER RESPONSIBILITIES TABLE
MAINTENANCE
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 generator head.
MAINTENANCE TASK Before
each
use
Every 25
Hours
of Every
Season
Every 50
Hours
of Every
Season
Every 100
Hours
of Every
Season
Check oil level X See Note 2
Change oil See Note 1
Clean Air Filter Assembly XX
Check Spark Plug X
Check fuel line, hose
clamps and fuel tank X
Prepare Unit for Storage Prepare unit for storage if it is to remain idle
for more than 30 days.
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 condition
Note 2: Check oil after 5 hours of operation.

16- ENG
A16596
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.
• Make sure that the generator storage area is free of excessive humidity and
dust.
• Store the generator in dry, well ventilated areas.”
STORAGE

17- ENG A16596
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 list-
ed 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.

18- ENG
A16596
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. Use wattage values specified on
appliance nameplate.
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

19- ENG A16596
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 3 2400
WELL PUMP 1/2 HP
1000 2 2000
*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

20- ENG
A16596
TROUBLESHOOTING GUIDE
PROBLEM CAUSE CORRECTION
Engine will
not start 1. Low on fuel or oil. 1. Add fuel or oil.
2. Ignition switch in "Off"
position. 2. Turn to "ON" position
3. Faulty spark plug. 3. Replace spark plug.
4. Choke in wrong position. 4. Adjust choke accordingly.
5. Fuel shut-off valve in
closed position 5. Open fuel shut-off valve.
6. Unit loaded during start-up. 6. Remove load from unit.
7. Spark plug wire loose. 7. Attach wire to spark plug.
No electrical
output 1. Faulty receptacle. 1. Have Service Center
replace.
2. Circuit breaker kicked out. 2. Depress and reset.
3. Defective capacitor. 3. Have Service Center
replace capacitor.
4. Faulty power cord. 4. Repair or replace cord.
5. GFCI switch breaker kicked
out (if equipped) 5. Depress and reset
Repeated
circuit
breaker
tripping
1. Overload 1. Reduce load.
2. Faulty cords or equipment 2. Check for damaged,
bare, or frayed wires on
equipment. Replace.
Generator
overheating 1. Generator overloaded. 1. Reduce load.
2. Insufficient ventilation. 2. Move to adequate supply
of fresh air.