Porter-Cable PCG2200 User manual

Instruction manual
Manual de instrucciones
Manual de instruções
PCG2200
PCG4000
PCG6500
GENERATOR
AND ENGINE
Generador y Motor
Gerador e Motor
www.deltaportercable.com
INSTRUCTIVO DE OPERACIÓN, CENTROS
DE SERVICIO Y PÓLIZA DE GARANTÍA.
LÉASE ESTE INSTRUCTIVO
ANTES DE USAR EL PRODUCTO.
196

2- ENG
SAFETY GUIDELINES -
DEFINITIONS
This manual contains information that is
important for you to know and under-
stand.Thisinformationrelatestoprotect-
ing 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 symbols.
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.
Indicates a practice not
related to personal injury which, if
not avoided, may result in property
damage.
IMPORTANT SAFETY
INSTRUCTIONS
Carbon Monoxide.
Using an engine indoors can kill you
in minutes. Engine exhaust contains
high levels of carbon monoxide (CO), a
poisonous gas you cannot see or smell.
You may be breathing CO even if you
do not smell engine exhaust.
This product and its
exhaust contain chemicals known to
the State of California to cause cancer,
and birth defects or other reproductive
harm.
• NEVER use an engine inside
homes, garages, crawlspaces or
other partly enclosed areas. Deadly
levels of carbon monoxide can
build up in these areas. Using a
fan or opening windows and doors
does NOT supply enough fresh
air.
• ONLY use outdoors and far away
from open windows, doors and
vents. These openings can pull in
engine exhaust.
• Even when the engine is used cor-
rectly, CO may leak into your home.
ALWAYS use a battery-powered or
battery backup CO alarm in the
home. Read and follow all direc-
tions for CO alarm before using.
If you start to feel sick, dizzy or
weak at anytime, move to fresh
air immediately. See a doctor. You
could have carbon monoxide poi-
soning.
Do not operate this unit
until you read this instruction manu-
al and the engine instruction manual
for safety, operation and maintenance
instructions.
SAVE THESE
INSTRUCTIONS

3- ENG
  RISK OF ELECTROCUTION AND FIRE
WHAT CAN HAPPEN HOW TO PREVENT IT
     
building’s electrical system to the out-
side utility feed lines could endanger
repair persons attempting to restore
service.
    
a structure's electrical system.
 
utility service could result in electrocu-
tion.
 
the generator is connected to the
incoming utility could result in a fire
or serious damage if a double throw
transfer switch is not installed.
 
switch when connecting to a struc-
ture's electrical system can damage
appliances and WILL VOID the manu-
facturer's warranty.
   -
cal system in a safe manner, always
have a double-throw transfer switch
installed by a qualified electrician
and in compliance with local ordi-
nances. (When installing a double-
throw transfer switch, a minimum of
10 gauge wiring must be used.)
     
which comes in contact with electri-
cally charged components can trans-
mit electricity to the frame and other
surfaces, resulting in electrical shock
to anyone contacting them.
      
well ventilated area. Make sure
hands are dry before touching unit.
 -
sion cords could result in electrocu-
tion.
    
use and replace with new cord if
required.
     
could result in overheating of the wires
or attached items, resulting in fire.
 -
sion cord(s) for application; see
Use of Extension Cords under
Assembly.
     
could prevent operation of cir-
cuit breakers and result in electrical
shock.
     
having a grounding wire with an
appropriate grounding plug. DO
NOT use an ungrounded plug.
 
could charge conductive surfaces in
contact with the generator.
 
surface such as a concrete slab.
ALWAYS operate generator a mini-
mum of 6' (1.8 m) from any conduc-
tive surface.
      
generator by attaching too many
items, or items with very high load rat-
ings to it could result in overheating of
some items or their attachment wiring
resulting in fire or electrical shock.
 Operating Heavy Loads under
Operation. Make sure that the
summation of electrical loads for all
attachments does not exceed the
load rating of the generator.

4- ENG
 
been damaged, or when it is not func-
tioning normally could result in fire or
electrocution.
     
mechanical or electrical problem.
Contact a Customer Care Center at
1-(888)-848-5175.
     
electrically charged components and
result in electrocution.
 -
tective guarding removed.
• Unattended operation of this prod-
uct could result in personal injury
or property damage. To reduce the
risk of fire, do not allow the engine
to operate unattended.
     
the engine when it is operating.
 RISK OF EXPLOSION OR FIRE
WHAT CAN HAPPEN HOW TO PREVENT IT
      
become ignited from sparks from
smoking products, electrical arcing,
exhaust, flame, gases and hot engine
components such as the muffler.
 
before removing cap and adding
fuel to the tank.
       
spilling fuel. Make sure the cap is
secure and move unit away from
fueling area before starting engine.
 
could result in spillage and possible
fire or explosion.
 
shoulders on the debris screen to
allow for expansion.
• Combustiblematerialswhichcome
into contact with hot generator
parts can become ignited.
       -
tilated area. Make sure there are
no sources of ignition, such as
smoking products near refueling
location.
      
well ventilated area a minimum of
48" (1.2 m) from any building, object
or wall. Do not operate unit indoors
or in any confined area.
 
away from dry brush, weeds or
other combustible materials.
      
accidental ignition. Fuel improperly
secured could get into the hands of
children or other unqualified persons.
     
container, in a secure location away
from work area.
      
to provide safe operation. Tampering
with the engine speed adjustment
could result in overheating of attach-
ments and could cause a fire.
     
engine to obtain more performance.
Both the output voltage and fre-
quency will be thrown out of stan-
dard by this practice, endangering
attachments and the user.

5- ENG
RISK TO BREATHING (Asphyxiation)
WHAT CAN HAPPEN HOW TO PREVENT IT
     

contains high levels of carbon monox-
ide (CO), a poisonous gas you cannot
see or smell. You may be breathing
CO even if you do not smell engine
exhaust.
 NEVER use an engine inside
homes, garages, crawlspaces, or
other partly enclosed areas. Deadly
levels of carbon monoxide can build
up in these areas. Using a fan or
opening windows and doors does
NOT supply enough fresh air.
• Only use outdoors and far away
from open windows, doors and
vents. These openings can pull in
engine exhaust.
     
away from area of operation.
 
of foreign objects.
RISK OF INJURY OR PROPERTY DAMAGE WHEN
TRANSPORTING OR STORING
WHAT CAN HAPPEN HOW TO PREVENT IT
 
result in fire or breathing hazard; seri-
ous injury or death can result. Oil leaks
will damage carpet, paint or other sur-
faces in vehicles or trailers.
 
in the fuel system, fuel valve open
or while generator is in operation.
      -
tective mat when transporting to
protect against damage to vehicle
from leaks. Remove generator from
vehicle immediately upon arrival
at your destination. Always keep
generator level and never lie on its
side.
      
approved container.
 RISK OF HOT SURFACES
WHAT CAN HAPPEN HOW TO PREVENT IT
     
other engine parts) can result in seri-
ous burns.
     
parts on generator during or imme-
diately after operation. The gen-
erator will remain hot for several
minutes after operation.
     
shrouds or attempt maintenance
until generator has been allowed to
cool.

6- ENG
RISK FROM MOVING PARTS
WHAT CAN HAPPEN HOW TO PREVENT IT
 
flywheel is turned by hand or moved
by pulling on the pull starter.
     
before performing maintenance.
       -
wheel and belt can cause serious
injury if they come into contact with
you or your clothing.
      
guards or covers which are dam-
aged or removed.
 
away from moving parts. Loose
clothes, jewelry or long hair can be
caught in moving parts.
      
and should be avoided as well.
     
damaged or missing parts or attempt-
ing to repair generator with protective
shrouds removed can expose you to
moving parts and can result in serious
injury.
 
should be performed by authorized
service center personnel.
 RISK OF UNSAFE OPERATION
WHAT CAN HAPPEN HOW TO PREVENT IT
     
could lead to serious injury or death to
you or others.
 -
tions and warnings in this manual.
 

how to shut it off quickly.
 -
sons, pets and obstacles.
      -
erator at all times.
 
fatigued or under the influence of
alcohol or drugs. Stay alert at all
times.
 
this product.
       
extinguisher.
 -
ing, broken or unauthorized parts.
 

7- ENG
 -
erator can produce voltage variations
causing damage to voltage sensitive
appliances or could result in fire.
      
sensitive surge protector to con-
nect voltage sensitive appliances
(TV, computer, stereo, 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 an U.L. listed
voltage surge protector
RISK FROM NOISE
WHAT CAN HAPPEN HOW TO PREVENT IT
 Under some conditions, applications
and duration of use, noise from this
product may contribute to hearing
loss.
 -
ment: ANSI S12.6 (S3.19) hearing
protection.
RISK FROM LIFTING
WHAT CAN HAPPEN HOW TO PREVENT IT
 -
ing to lift too heavy an object.         lifted by one person. Obtain assis-
tance from others before you try to
move it.
SAVE THESE INSTRUCTIONS

8- ENG
GENERATOR COMPONENTS
(FIG 1)
A. Engine
B. Alternator
C. Control Panel
D. Fuel Cap
E. Fuel Tank
F. Fuel Gauge
G. Fuel Shut Off Valve
ENGINE COMPONENTS (FIG 1, 2)
 
I. Air Filter
J. Recoil Pull Start
 
L. Oil Fill Dip Stick
M. Carburetor Bowl Drain
N. Set Throttle Control
O. Low Oil Shut Down
P. Carburetor Bowl
Q. Choke
HOT SURFACES (FIG 2)
R. Valve Cover
S. Exhaust
T. Spark Plug
U. Muffler (not shown)
 
I
J
A
G
D
F
C
B
E
1
Q

9- ENG
CONTROL PANEL LAYOUT
(FIG 3)
W. Twistlock Receptacle
X. Ground Nut
Y. Voltage Selector Switch
Z. Engine On/Off Switch
AA. Main Breaker
BB. Duplex Receptacle
P
M
V
N
L
O
K
J
Q
I
T
S
H
R
2
3Z
BB
AA X
PCG2200

10- ENG
Z
BB
W
AA
X
Z
BB
W
Y
X
3a
PCG4000
3b
PCG6500
Y
AA

11- ENG
PRODUCT SPECIFICATIONS
Model PCG2200
Alternator
Type 110V, 2 Pole AVR
Excitation Brushed
Max AC Output (Watts) 2200
Rated AC Output (Watts) continuous 2000
Rated Current (A) 18 A
Phase Single
 60
Engine
 
Displacement (CC) 196
Fuel Tank Capacity gal (L) 4.8 (18)
Oil Capacity (L) 0.6
Recommended Oil See Oil Recommendations
Low Oil Shutdown Yes
Starting system Recoil
Type Air cooled, 4 cycle single cyl-
inder, spark ignited
Fuel Regular, unleaded gasoline (minimum
86 octane)
DO NOT use E85 fuel.
Air cleaner type Foam element or paper
Spark plug type BPR6ES, BPR6ES/
AUTOLITE: 63/AC DELCO: R41XL,
R42XLS, R43FS, R43XL, R43XLS,
R44XLS, R45XLS or equivalent
Spark plug gap 0.028-0.031" (0.70-0.80 mm)
Fuel shut off solenoid Without
Idle control Without
Electric starter Without
Max. recommended tilt angle < 25°
Receptacles
110V 18 Amp Duplex + Yes (2)
General
Dimensions  23.2 x 18.7 x 18.1/59.0 x 47.5 x 46.0
Dry Weight 99 lbs. (45 kg)

         
under laboratory conditions at 3600 RPM in accordance with SAE (Society of
Automotive Engineers) J1995 and should be used for comparison purposes only.
Actual engine output will be lower and will vary depending on the application, speed
and other variables including altitude and temperature.

+ When using the receptacles, you must connect through a GFCI protected spider box or
use an in-line GFCI adapter.

12- ENG
Model PCG4000
Alternator
Type 120V/240V AC 2 Pole AVR
Excitation Brushed
Max AC Output (Watts) 4000
Rated AC Output (Watts) continuous 3700
Rated Current (A) 31/15A
Phase Single
 60
Engine
 
Displacement (CC) 242
Fuel Tank Capacity gal (L) 6.6 (25)
Oil Capacity (L) 1.1
Recommended Oil See Oil Recommendations
Low Oil Shutdown Yes
Starting system Recoil
Type Air cooled, 4 cycle single
cylinder, spark ignited
Fuel Regular, unleaded gasoline (mini-
mum 86 octane)
DO NOT use E85 fuel.
Air cleaner type Foam element or paper
Spark plug type BPR6ES, BPR6ES/
AUTOLITE: 63/AC DELCO: R41XL,
R42XLS, R43FS, R43XL, R43XLS,
R44XLS, R45XLS or equivalent
Spark plug gap 0.028-0.031" (0.70-0.80 mm)
Fuel shut off solenoid Yes
Idle control Without
Electric starter Without
Max. recommended tilt angle < 25°
Receptacles
120V 20 Amp Duplex + Yes (2)
120/240V 30 A Twist-Locking + Yes (1)
General
Dimensions  27 x 21 x 22/68 x 54 x 55
Dry Weight 150 lbs. (68 kg)


under laboratory conditions at 3600 RPM in accordance with SAE (Society of
Automotive Engineers) J1995 and should be used for comparison purposes only.
Actual engine output will be lower and will vary depending on the application,
speed and other variables including altitude and temperature.

+ When using the receptacles, you must connect through a GFCI protected spider
box or use an in-line GFCI adapter.

13- ENG
Model PCG6500
Alternator
Type 120V/240V AC 2 Pole AVR
Excitation Brushed
Max AC Output (Watts) 6500
Rated AC Output (Watts) continuous 5200
Rated Current (A) 42/21 A
Phase Single
 60
Engine
 
Displacement (CC) 389
Fuel Tank Capacity gal (L) 6.6 (25)
Oil Capacity (L) 1.1
Recommended Oil See Oil Recommendations
Low Oil Shutdown Yes
Starting system Recoil
Type Air cooled, 4 cycle single
cylinder, spark ignited
Fuel Regular, unleaded gasoline (mini-
mum 86 octane)
DO NOT use E85 fuel.
Air cleaner type Foam element or paper
Spark plug type BPR6ES, BPR6ES/
AUTOLITE: 63/AC DELCO: R41XL,
R42XLS, R43FS, R43XL, R43XLS,
R44XLS, R45XLS or equivalent
Spark plug gap 0.028-0.031" (0.70-0.80 mm)
Fuel shut off solenoid Yes
Idle control Without
Electric starter Without
Max. recommended tilt angle < 25 °
Receptacles
120V 20 Amp Duplex + Yes (2)
120/240V 30 A Twist-Locking + Yes (1)
General
Dimensions  27 x 21 x 22/68 x54 x 55
Dry Weight 190 lbs. (86 kg)


under laboratory conditions at 3600 RPM in accordance with SAE (Society of
Automotive Engineers) J1995 and should be used for comparison purposes only.
Actual engine output will be lower and will vary depending on the application,
speed and other variables including altitude and temperature.

+ When using the receptacles, you must connect through a GFCI protected spider
box or use an in-line GFCI adapter.

14- ENG
ASSEMBLY
GROUNDING THE GENERATOR
A grounding nut (X, Fig. 3) is supplied
with the generator for use when required
by local electrical ordinances. Your
local electric company or a certified
electrician should be able to help you
with this information.
USE OF EXTENSION CORDS
Risk of unsafe
operation. Use only grounded extension
cords. Use only three wire or double-
insulated power tools.
Only use grounded extension cords
that are rated for outdoor use and
equipment with a third-wire ground. It
is recommended that GFCI protected
spider box or inline GFCI adapter are
used when connecting to any of the
generator’s receptacles.
When a long extension cord is used
to connect an appliance or tool to the
Minimum gauge for Extension Cord Sets
Volts Total Length of Cord in Feet
120V 0–25
(0–6.7 m)
26–50
(7.9–15.2 m)
51–100
(15.5–30.5 m)
101–150
(30.8–45.7 m)
240V 0–50
(0–15.2 m)
51–100
(15.5–30.5 m)
101–200
(30.8–60.9 m)
201–300
(61.2–91.4 m)
Ampere
Rating AWG
0–10 16 16 14 14
10–13 16 16 14 12
13–16 14 14 12 12
16–25 12 12 12 10
25–30 10 10 10 Not Recommended
Extension Cord
Length Amp Load Voltage Drop 16 AWG 14 AWG 12 AWG 10 AWG
25 Foot
7.6 m
10 A 2.0 1.3 0.8 0.5
15 A 3.0 1.9 1.2 0.8
20 A 4.0 2.5 1.6 1.1
30 A 6.0 3.8 2.3 1.6
50 Foot
15.2 m
10 A 4.0 2.5 1.6 1.1
15 A 6.0 3.8 2.3 1.6
20 A 8.0 5.0 3.1 2.1
30 A 12.0 7.5 4.7 3.2
100 Foot
30.5 m
10 A 8.0 5.0 3.1 2.1
15 A 12.0 7.5 4.7 3.2
20 A 16.0 10.0 6.2 4.2
30 A 24.0 15.0 9.3 6.3
150 Foot
45.7 m
10 A 12.0 7.5 4.7 3.2
15 A 18.0 11.3 7.0 4.7
20 A 24.0 15.0 9.3 6.3
30 A 36.0 22.5 14.0 9.5
generator, a voltage drop occurs. The
longer the cord, the greater the voltage
drop. This results in less voltage being
supplied to the appliance or tool and
increases the amount of current (amp)
draw or reduces performance. A heavier
cord with a larger wire size will reduce
the voltage drop. Be sure to choose a
cord that will supply enough voltage
to operate your tool or appliance. The
tables indicate appropriate gauge for
extension cords and the voltage drop
caused by the use of extension cords,
given different electrical loads.
Risk of unsafe
operation. Operating equipment at low
voltage can cause it to overheat. Using
an excessively long extension cord can
cause the cord to overheat.
Risk of unsafe

condition. Do not use worn, bare or
frayed cords because they can cause
electrical shock.

15- ENG
DOUBLE THROW TRANSFER
SWITCH
  
CUTION. To connect to a structure's
electrical system in a safe manner,
always have a double-throw transfer
switch installed by a qualified elec-
trician and in compliance with local
ordinances. (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 out-
age, see WattageCalculation section
in this manual.
ACCESSORIES ASSEMBLY
Accessories available for generators
include content shown in Fig 4.
NOTE: Two people are needed for these
installations. Install the wheel kit before
adding gasoline or engine oil to prevent
damage to the engine. If accessories
are being installed after running the
generator, make sure the gas tank is
empty, the fuel shut-off valve is turned
to the OFF position (horizontal to the
ground) and the oil is drained from the
engine
NOTE: After approximately 20 hours of
operation, accessory bolts may loosen.
Tighten them as needed.
Wheel Kit Assembly
(PCG4000, PCG6500)
Risk from Lifting. The
generator may be too heavy to be lifted
by one person. Obtain assistance from
others before lifting.
1. Carefully tilt the generator so it
rests on the engine side.
       
lower chassis. Use Bolts (MM) and
nuts (LL) for this step.
HH
(2)
GG
(2)
EE
(2)
QQ)
KK
(2)
MM (4)
LL (4)
DD (2)
FF (2)
NN (4)
PP OO (4)
II (6)
JJ (6)
4

16- ENG
3. Install the axle (QQ) to the lower
chassis. Use bolts (OO), nuts (NN)
and axle strap (PP) for this step.
4. Slide the wheels (EE) on the axle.
Then slide the two washers (DD)
on each end of the axle and secure
with cotter pins (FF), bending one
side of cotter pins.
5. Place the generator upright so it is
resting on the wheels and stands.
Handle Kit Assembly
1. Install handles on the engine side
of the generator by securing each
bracket (GG) with bolts (II) and lock
nuts (JJ).
     
each bracket (GG) and secure
each with remaining bolts (II) and
lock nuts (JJ)
3. Tighten the bolts until the assembly
is snug.
ADD ENGINE OIL AND FUEL
Risk of property
damage.
The engine IS NOT filled with
oil from the factory. Oil must be added to
the engine before operating or damage
to engine may occur.
Oil Recommendations
SAE10W-30isrecommendedforgeneral
use. Refer to the Viscosity-Ambient
Temperature Chart for recommended
oil within your local area’s average
temperature range. NOTE: Synthetic oil
is NOT recommended.
˚F -20 0 20 40 60 80 100
˚C -28.8-17.7-6.6 4.4 15.5 26.6 37.7
5W-30
10W-30
30
Viscosity-Ambient
Temperature Chart
0W-10 or 0W-30
To add oil (Fig. 2)
1. Refer to Viscosity-Ambient
Temperature Chart for correct
viscosity.
2. Remove dipstick (L).
3. Slowly add recommended oil,
see specifications for oil capacity.
NOTE: If the oil is added too
quickly, it will overflow and appear
to be full.
See Oil under Maintenance for
instructions.
Add fuel to generator (FIG. 1, 5)
Risk of explosion or
fire. Gasoline vapor is highly flammable.
Refuel outdoors preferably or only in
well-ventilated areas. Do not refuel or
check gasoline level while the engine
is running. Do not store, spill or use
gasoline near an open flame, a source
of sparks (such as welding), or near
operating electrical equipment. Do not
smoke when filling fuel tank.
1. Remove fuel cap (D).
2. Add fresh, clean, regular unleaded
gasoline with a minimum of
86 octane to the fuel tank (E).
NOTE: Do not mix oil with
gasoline.
Risk of explosion or
fire. Never fill fuel
QQ 5
tank completely. Do
not fill above the
shoulders on the
debris screen (QQ)
as shown to provide
space for fuel expansion. Wipe any fuel
spillage from engine and equipment
before starting engine.
3. Replace the fuel cap on the tank.
Turn the cap clockwise until it
stops.
Oxygenated Fuels
Some conventional gasolines are
blended with alcohol or an ether
compound. These gasolines are
collectively referred to as oxygenated
fuels. To meet clean air standards,
some areas use oxygenated fuels to
help reduce emissions.
If you use an oxygenated fuel, be sure it
is unleaded and meets the 86 minimum
octane rating requirements. Before
using an oxygenated fuel, try to confirm
the fuel’s contents. Some areas require
this information to be posted on the
pump.

17- ENG
Ethanol (ethyl or grain alcohol) 10%
by volume. You may use gasoline
containing up to 10% ethanol by volume.
Gasoline containing ethanol may be
marketed under the name gasohol.
Risk of property damage.
DO NOT use E85 fuel.
MTBE (methyl tertiary butyl ether)
15% by volume. You may use gasoline
containing up to 15% MTBE by
volume.
Methanol (methyl or wood alcohol)
5% by volume. You may use gasoline
containingup to5%methanolby volume
as long as it also contains solvents and
corrosion inhibitors to protect the fuel
system. Gasoline containing more than
5% methanol by volume may cause
starting and/or performance problems.
It may also damage metal, rubber and
plastic parts of the engine or your fuel
system.
If you notice any undesirable operating
symptoms, try another service station
or switch to another brand of gasoline.
NOTE: Fuel system damage or
performance problems resulting
from the use of an oxygenated fuel
containing more than the percentages
of oxygenates mentioned above are not
covered under warranty.
LOCATION
Risk to breathing.
Exhaust from the gasoline engine
contains deadly carbon monoxide,
which is odorless and toxic. Operate
engine only outside in clean, dry, well-
ventilated areas.
Noise Considerations
Consult local officials for information
regarding acceptable noise levels in
your area.
FEATURES (FIG. 1–3)
Engine On/Off Switch
The engine On/Off switch (Z) must be in
the ON position to start the generator.
To stop the generator, place switch in
the OFF position. See Starting and
Stopping Generator under Operation
for complete starting and stopping
instructions.
Main Breaker
The main breaker (AA) protects the
alternator. Overloading the generator
will trip the main breaker. A short circuit
in an electrical device being powered
can also trip the main breaker. If the
main breaker trips:
1. Disconnect the electrical loads
from all receptacles.
2. Place the main breaker (AA) in the
OFF position and then back into
the ON position to reset.
IMPORTANT: If the main breaker
turns to the OFF position when no
electrical loads are connected, contact
a C
u stomer Care Center.
Voltage Selector Switch
PCG4000, PCG6500
This switch (Y) allows the generator to
operate in either single voltage (120V)
or dual voltage (120/240V) mode. When
placed in the 120V position it allows
you to receive the full capacity of the
generator by using all the receptacles.
When placed in the 120/240 position,
you will only be able to receive half the
available watts when using the 120 volt
receptacles and the full available watts
when using the 240V 4-prong twist-lock
receptacle.
NOTE: Do not move the voltage selec-
tor switch (Y) while powering electrical
devices. Disconnect all electrical loads
before moving the switch. Failure to
disconnect electrical loads could dam-
age the switch.
Receptacles (Fig. 3)
The receptacles are protected by the
main breaker. (AA)
NOTE: The receptacles (BB, W) are
not protected by a GFCI. Use a GFCI
protected spider box or GFCI adapter
to connect loads to the receptacle.
LOW OIL PROTECTION
Low oil shutdown is a device designed
to protect the engine from damage in
the event the oil level in the crankcase
is low.

18- ENG
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.
OPERATION
PRE-START CHECKLIST (FIG. 3)
Do not operate this
unit until you read and understand
this instruction manual and the engine
instruction manual for safety, operation
and maintenance instructions.
Risk ofpropertydamage.
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. Place unit on level surface.
2. Check engine oil. Refer to Oil
Recommendations under
Assembly and Product
Specifications for correct grade
and quantity of oil.
Risk of property damage.
Do not operate engine without oil or
with inadequate oil. PORTER-CABLE
is not responsible for engine failure
caused by inadequate oil.
3. Check fuel level, fill as required.
See Add Engine Oil and Fuel
under Assembly.
4. Make sure generator is grounded in
accordancewithlocalrequirements.
See Grounding the Generator
under Assembly.
5. All electrical loads MUST be
disconnected and main breaker
(AA) in the OFF position.
Risk of explosion or fire.
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
performance. Both the output voltage
and frequency will be thrown out of
standard by this practice, endangering
attachments and the user. Tampering
may cause damage to the generator
and voids the warranty.
Riskofpropertydamage.
Unplug any load from the generator
before starting to prevent permanent
damage to any appliances.
STARTING GENERATOR —
(FIG. 1–3, 6–9)
Do not operate this unit
until you read this instruction manual
for safety, operation and maintenance
instructions.
1. Disconnect all electrical loads from
the generator and place the main
breaker (AA) in the OFF position.
2. Turn the fuel
G
6
shut-off valve (G)
on the gas tank
to the vertical
(OPEN) position
as shown.
3. If the engine
is cold, move
the choke
(Q) to the CLOSED position
shown. If the engine is hot,
move the choke to OPEN
position.
CLOSED
Q
7
CLOSED
OR Q
4. Turn engine On/Off switch (Z) to
the ON position.

19- ENG
5. Pull the starter grip (J) slowly until
you feel compression then pull
briskly.
NOTE: Do not allow the starter grip to
snap back. Return it slowly by hand.
NOTE: If the oil level in the engine is
low, the engine will not start. If the
engine does not start, check the oil level
and add oil as needed.
NOTE: To ensure maximum oil
lubrication, place the generator on a
level surface.
6. As the engine warms up, move the
choke (Q) to the OPEN position.
Q
OPEN
8
OPEN
Q
OR
7. Allow the engine to warm up for
five minutes. Then place the main
breaker (AA) in the ON position.
Connect electrical loads, see
Connecting Electrical Loads
under Operation.
NOTE: If any unusual noise or vibration
is noticed, stop the engine and refer to
the troubleshooting section.
STOPPING GENERATOR
(FIG. 3, 9)
To stop the engine in an emergency,
move the engine On/Off switch (Z) to
the OFF position.
To Stop Generator During Normal
Operation:
1. Disconnect all electrical loads
attached to the generator.
2. Move the engine On/Off switch (Z)
in the OFF position.
3. Turn the fuel
G
9
shut-off valve (G)
on the gas tank
to the horizontal
(CLOSED)
position as
shown.
CONNECTING ELECTRICAL
LOADS (FIG. 3)
1. Allow the engine to warm up for
five minutes. Then place the main
breaker (AA, Fig. 3) in the ON
position.
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.
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, microwaves,
ovens, computers and cordless
telephones into a UL listed voltage
surge protector, then connect the
UL listed voltage surge protector
to the generator.
Risk of unsafe
operation. 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.
OPERATING HEAVY LOADS
DO NOT exceed the current limit
specified on the control panel for any
receptacle.
HIGH ALTITUDE OPERATING
At high altitude, the standard carburetor
air-fuel mixture will be too rich.
Performance will decrease and fuel
consumption will increase. A very rich
mixture will also foul the spark plug and
cause hard starting.

20- ENG
    
improved by specific modifications to
the carburetor. If you always operate
your engine at altitudes above 1,524
meters(5,000feet),haveyourauthorized
service center perform a carburetor
modification.
Even with a carburetor modification,
engine horsepower will decrease about
3.5% for each 300 meter (1,000 feet)
increase in altitude. The effect of altitude
on horsepower will be greater than this
if no carburetor modification is made.
A decrease in engine horsepower will
decrease the power output of the
generator.
NOTE: When the carburetor has been
modified for high altitude operation,
the air-fuel mixture will be too lean for
low altitude use. If the generator is
used at low altitudes after a carburetor
modification, the carburetor may cause
the engine to overheat and result in
serious engine damage. For use at low
altitudes, have your authorized service
center return the carburetor to original
factory specifications.
HIGH AND LOW TEMPERATURE
OPERATION
Air temperature affects generator
output. Output drops 1% for each 10ºF
temperature rise above 60º F. Very low
temperature may cause the engine to
be hard to start.
MAINTENANCE
IMPORTANCE OF
MAINTENANCE
Good maintenance is essential for safe,
economical and trouble-free operation.
It will also help reduce air pollution.
Riskofunsafeoperation.
Improper maintenance or failure to
correct a problem before operation
can cause malfunction, serious injury
or death. Always follow the inspection
and maintenance recommendation and
schedules in this manual.
The following pages include a
maintenance schedule, routine
inspection procedures and simple
maintenance procedures using basic
hand tools to help you properly care
for your generator. If you are not
comfortable with any maintenance
procedure, contact a Customer Care
Center.
Maintenance, replacement or repair of
the emission control devices and system
may be performed by any engine repair
establishment or individual using parts
that are certified to EPA standards.
MAINTENANCE SAFETY
Do not operate this
unit until you read and understand
this instruction manual and the engine
instruction manual for safety, operation
and maintenance instructions.
SAFETY PRECAUTIONS
Risk of unsafe
operation. Make sure the engine is
off before beginning any maintenance
or repairs. This will eliminate several
potential hazards, including:
 
engine exhaust. Be sure there
is adequate ventilation whenever
you operate the engine.
      
engine and exhaust system cool
before you touch it to prevent
burns.
     
appropriate clothing, tie back
long hair, and stay alert around
the generator to prevent injury
from moving parts.
To reduce the possibility
of fire or explosion, be careful when
working around gasoline. Use only a
nonflammable solvent, not gasoline, to
    
sparks and flames away from all fuel
related parts.
Read all instructions before beginning
and make sure you have the tools
and skills required. A PORTER-CABLE
factory service center or a PORTER-
CABLE authorized service center knows
your generator best and is fully equipped
to do maintenance and repair. To ensure
the best quality and reliability, use only
new genuine parts or their equivalents
for repair or replacement.