Powerhorse M750139B.2 User manual

Owner’s Manual
Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
750139 –3,100 Watt Continuous (4,000 Watt Surge) Capacity
Can be used to power individual appliances plugged directly into the generator’s outlets, or as a back-up
connection to a building’s power supply (via a professionally installed UL-listed transfer switch).
WARNING
READ and UNDERSTAND this manual completely before using the generator! Failure to properly set up, operate, and
maintain this generator could result in serious injury or death from carbon monoxide poisoning, electric shock,
fire/explosion, or burns. In particular, be aware of the following hazards:
CO Poisoning
Generators give off carbon monoxide, a poisonous gas that can kill you. You CANNOT smell it, see it, or taste it.
•ONLY run generator OUTDOORS and AWAY from building air intakes. NEVER run generator inside any enclosed or semi-enclosed
spaces, including homes, basements, garages, sheds, boxes, RVs, boats or pick-up truck beds. These spaces can trap poisonous
gases, EVEN if you run a fan or open windows.
•Install carbon monoxide alarms inside nearby structures/buildings (battery-operated, or plug-in with battery backup).
Electric shock / Electrocution
•High voltage electricity from generator can kill. DO NOT operate in wet locations. Be sure generator is properly grounded. Use only
UL-listed, outdoor-rated grounded extension cords of proper size.
•NEVER plug the generator directly into a wall outlet. ANY connection to a building’s electrical system MUST ISOLATE THE
GENERATOR FROM UTILITY POWER via a UL-listed transfer switch installed by a licensed electrician. Otherwise, back feed from
the generator into the power grid could kill utility workers.
Fire / Explosion
•DO NOT overload generator (per rated capacity), and OPERATE ONLY in an area with adequate cooling ventilation so engine does
not overheat. Exhaust can be extremely hot. Keep muffler at least 7 feet from all combustible objects.
•All fuels are flammable. Never fuel a running or hot engine. Never pump fuel directly into generator at gas station –use approved
container to transfer fuel. Ensure there are no fuel leaks, and keep sources of sparks and flames away.
•ALWAYS keep a fire extinguisher rated “ABC” nearby.
STOP!
CHOOSE THE RIGHT GENERATOR FOR YOUR NEEDS. See the “Power Load Planning & Management” section of this manual to
determine your power load requirements and then compare to the generator’s rated capacity.
INSPECT COMPONENTS: Closely inspect to make sure no components are missing or damaged. See the “Unpacking & Delivery
Inspection” section for instructions on whom to contact to report missing or damaged parts.
ARRANGE FOR PROFESSIONAL INSTALLATION of a transfer switch if you will be connecting the generator to your building’s
electrical system. See the “Installation/Initial Set-Up” section for more information about this requirement.
ADD ENGINE OIL: Engine is shipped without oil. See engine section of this manual for instructions on capacity and viscosity
recommendations.
Any Questions, Comments, Problems, or Parts Orders
Call Powerhorse Product Support 1-866-443-2576
M750139B.2
ITEM NUMBER: 750139
SERIAL NUMBER: _______________

Hazard Signal Word Definitions
2

Table of Contents
3
Hazard Signal Word Definitions .................................................................................................................2
About Your Generator .................................................................................................................................4
Specifications...............................................................................................................................................6
Safety Label Locations ................................................................................................................................7
Machine Component Identification.............................................................................................................9
Installation / Initial Set-Up:
1. Unpacking & Delivery Inspection..........................................................................................................11
2. Planning the Power Load.....................................................................................................................12
3. Set-up as a BUILDING BACK-UP or PORTABLE Power Source ........................................................14
4. Selecting a Suitable Site ......................................................................................................................16
5. Grounding the Generator .....................................................................................................................18
6. Battery Installation................................................................................................................................19
7. Wheel Kit Assembly .............................................................................................................................20
Operation:
1. General Safety Rules for Operation .....................................................................................................23
2. Preparing for Operation........................................................................................................................26
3. Starting the Engine...............................................................................................................................29
4. Checking Generator Output .................................................................................................................30
5. Connecting Loads ................................................................................................................................31
6. Stopping the Engine.............................................................................................................................31
7. Storage & Exercise ..............................................................................................................................32
Maintenance & Repair.................................................................................................................................33
Troubleshooting..........................................................................................................................................35
Summary of Important Safety Information for Operation ........................................................................36
Engine Operation ........................................................................................................................................40
Exploded Views...........................................................................................................................................46
Warranty.......................................................................................................................................................52

About Your Generator
4
Thank you for purchasing your Powerhorse portable generator!
About Your Generator
This engine-driven, portable generator is designed to provide up to 4,000 Watts of electrical
power (3,100 watts continuous, 4,000 watts surge).
It can supply power:
1. As a portable power source. You can plug appliances directly into the generator’s electrical
outlets.
2. As a back-up, standby power source for a building. A licensed electrician can connect the
generator to your building’s electrical system via the installation of an UL-listed transfer switch.
(See the “Installation & Initial Set-up” section of this manual to learn more about specific
requirements and precautions relating to wiring the generator to your building’s electrical system.)
You must select a generator adequately sized for your power needs. You need to determine the
power needs of all the appliances/tools you wish to power at the same time and choose a generator
rated to provide at least that power level. See the “Planning the Power Load” section of this manual to
determine your specific power load requirements and then compare them to this generator’s rated
capacity. You must not overload the generator. Overloading will cause damage to the generator and
attached electrical devices, and may also result in fire.
Be sure to read about site selection and grounding requirements for running this generator. More
detailed information can be found in the “Installation & Initial Set-up, Steps 4 & 5” of this manual.
Contact Powerhorse Product Support at 1-866-443-2576 with questions about optional
accessories or to order parts.
Read this Manual
WARNING
Improper use or maintenance of this generator can result in serious injury or death from carbon
monoxide poisoning, electric shock/electrocution, fire/explosion, or burns.
Read this manual completely before using the generator and follow all instructions and safety
rules.
You must follow all instructions and safety precautions presented throughout this manual. A summary of
important safety information can be found at the end of the manual. Keep this manual for reference and
review.

About Your Generator (cont’d)
5
Proper preparation, operation, and maintenance will result in operator safety, as well as best
performance and long life of the generator. For detailed engine operation and maintenance information,
always refer to the engine section of this manual.
Powerhorse is constantly improving its products. The specifications outlined herein are subject to
change without prior notice or obligation. The purchaser and/or user shall assume liability for any
modification and/or alterations of this equipment from original design and manufacture.
Before using, the user shall determine the suitability of this product for its intended use and assumes
liability therein.
Contact Powerhorse Product Support at 1-866-443-2576 for any questions about the appropriate
use of this generator.
Warranty Registration
Please fill in the warranty registration information and have it on hand when you call in on a warranty
claim or replacement parts.
ATTENTION:
All Rental Companies and Private Owners who loan this equipment to
others!
All persons to whom you rent/loan this generator must have access to and read this manual. Keep this
owner’s manual with the generator at all times and advise all persons who will operate the machine to
read it. You must also provide personal instruction on how to safely operate the generator and remain
available to answer any questions a renter/borrower might have.

Specifications
6
Item Number
#750139
Maximum Output
4,000 Watts (W)
Continuous Output
3,100 Watts (W)
Voltage
120/240 Volt (V)
Phase
Single phase (4-wire)
Frequency
56.5 - 63.3 Hertz (Hz)
Power Factor
1.0 p.f.
Total Harmonic Distortion
less than 5%
Run Time at 50% Load
10.6 Hours
Engine
212cc
Engine Speed
3600 RPM
Fuel Type
Unleaded gasoline
Fuel Capacity
4 gallons (15 L)
Oil Capacity
0.63 US quarts (0.6 L)
Starting Method
Recoil Start/Electric Start
120/240 Volt Receptacles
4 - 20 Amp 120V duplex
(NEMA 5-20R)
1 –30 Amp 120/240V locking
(NEMA L14-30R)
12 Volt DC Receptacle
1 –8 Amp 12V
AC Circuit Breakers
2 –13.5 Amp (A) thermal, push to reset
DC Circuit Breaker
1 –8 Amp (A) thermal, push to reset
Dimensions
Length
24.75 in.
Width
23.00 in.
Height
21.25 in.
Battery Specs
(Battery Not Included)
12 Volt DC
Sealed Lead Acid
9.0Ah or greater rating
Terminal Type –Nut and Bolt
5.94” (L) x 2.56” (W) x 3.66” (H) or 4.18” (H w/terminals)

Safety Label Locations
7
Always make sure safety labels are in place and in good condition. If a safety label is missing or
not legible, order new labels or unsafe operation could result.
To order replacement safety labels, call Powerhorse Product Support at 1-866-443-2576.
Ref. #
Part #
Description
Qty.
1
795289
Recoil Decal
1
2
793048
Air Filter Decal
1
3
795119
Choke Decal
1
4
795120
Starting Instruction Decal
1
5
795136
Handle Decal
1
6
795126
Shock/Fire Decal
1
7
795124
Ethanol Decal
1
8
795127
CPSC Decal
1
9
795123
Fire & Overheating Warning
1
10
782633
Low Oil Decal
1
11
795321
4000W-ES Nameplate
1
12
790852
Burn Warning Decal
2
13
795125
Battery Warning Decal
1
14
795314
Powerhorse Tank Decal
1
15
782629
Oil Level Decal
1
16
795328
Control Panel Decal
1
17
N/A
EPA Decal
1
18
782628
Fuel On/Off Decal
1
3
2
1
12
14
15
16
4
5
12
10
6
8
7
9
17
11
18
13

Safety Label Locations
8
18
15
1
2
5
3
4
6
7
8
9
10
11
12
17
14
16
13

Machine Component Identification
9
Reference
Description
Reference
Description
1
Handle
9
Muffler
2
Air Cleaner
10
Generator Head
3
Recoil Starter Grip
11
Control Panel
4
Fuel Valve
12
Battery Location (Battery Not Included)
5
Gas Tank
13
Oil Fill
6
Fuel Gauge
14
Oil Drain Plug
7
Gas Cap
15
ON / OFF / START Switch
8
Vibration Isolation Mount
16
Roll Cage Frame
REFERENCE GUIDE
Reference 1 - Handle
Provides a means for moving the generator. To move generator, pivot handle up
and secure using the handle pin.
Reference 2 –Air Cleaner
Filter element that removes particles from incoming air. See the engine section of
this manual for maintenance and replacement.
Reference 3 –Recoil Starter Grip
Grasp firmly when manually starting engine to engage the engine cranking.
Reference 4 –Fuel Valve
ON / OFF valve to control the fuel flow into the engine. Located on the left side of
the recoil. ALWAYS keep valve closed when the generator is not in use.
Reference 5 –Gas Tank
A large tank that allows for extended run capabilities. ALWAYS allow room for
gasoline expansion by not filling the gas tank completely.
Reference 6 –Fuel Gauge
Fuel level indicator for gas tank.
Reference 7 –Gas Cap
The gas cap is extra-large, creating a large hole for refilling and has a comfortable
grip.
Reference 8 –Vibration Isolation Mount
The engine and generator head are mounted on rubber mounts that absorb most of
the engine vibration. This feature eliminates the tendency of the machine to “walk”
while engine is running.
Reference 9 - Muffler
An acoustic device installed onto the exhaust system that is designed to reduce
noise. The outlet also includes a spark arrester.
Reference 10 - Generator Head
The electricity producing part of the generator.
Reference 11 –Control Panel
An electrical device that contains receptacles, switches and other electrical devices.
Reference 12 –Battery Location
Storage location for the battery (battery not included).
Reference 13 –Oil Fill
Cap with dipstick for checking oil level. Also provides access port to fill oil.
Reference 14 –Oil Drain Plug
Bolt located on the engine crankcase that allows oil to be drained.
Reference 15 –Engine Switch
ON / OFF / START switch for power to engine for starting.
Reference 16 –Roll Cage Frame
Provides protection for the generator
3
2
1
9
13
11
4
5
15
10
7
6
14
8
16
12

Machine Component Identification
10
Ref. #
Description
Qty.
1
120/240V, 30A Locking Receptacle (NEMA L14-30R)
1
2
120V, 20A Duplex Receptacle (NEMA 5-20R)
8
3
Grounding Post
1
4
Circuit Breaker, 13.5A
2
5
Volt Meter
1
6
12V DC, 8A Receptacle
1
7
Circuit Breaker, 8A, 12V DC
1
8
Engine Switch
1
9
Low Oil Warning Light
1
2
4
5
6
9
7
3
8
2
1

Installation / Initial Set-Up (cont’d)
11
There are a number of important steps required to set up your generator for initial use. These steps are:
Steps for Installation / Initial Set-Up
1. Unpacking & delivery inspection.
2. Planning the power load to stay within the generator’s rated capacity.
3. Setting up generator for the type of power generation you need:
a. portable power source, or
b. connect to a building as a back-up power source.
4. Selecting a site for using the generator.
5. Grounding the generator.
6. Battery installation (electric start models only).
7. Wheel kit assembly.
Each of these steps is discussed in detail below:
1. Unpacking & Delivery Inspection
You should inspect the generator immediately after you receive delivery.
See the “Machine Component Identification” section of this manual for a diagram of the generator and
its components.
•If you are missing or have damaged components, contact Product Support at 1-866-443-2576.

Installation / Initial Set-Up (cont’d)
12
WARNING
NEVER exceed the rated wattage capacity of your generator.
OVERLOADING may cause SERIOUS DAMAGE to the generator and attached
electrical devices, and may result in fire.
Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of
the devices you will be powering. Before using your generator, determine the running and starting
wattage requirements of all the electrical devices you will be powering simultaneously. The sum of the
running and starting wattages of the devices being powered must not exceed the continuous output
rating of your generator. (The continuous output rating of your generator is listed in the “Specifications”
section of this manual.) Note that:
•Devices without electric motors such as light bulbs, radios, and televisions have the same running
and starting wattage.
•Devices with electric motors such as refrigerators, compressors, and hand tools typically require a
starting wattage that is 3 to 5 times greater than the running wattage.
The running and starting wattage requirements are often listed on a device’s nameplate. If wattage is
not given on the device’s nameplate, the wattage may be calculated by multiplying the nameplate
voltage by nameplate amperage, Watts = Volts X Amps.
Example conversion to watts:
120 Volts X 5 Amps = 600 Watts
If only the running voltage is given on the nameplate for a device with an electric motor, the starting
wattage can be approximated to be three to five times the running wattage.
Estimates for the running wattage requirements for common devices are listed in Table 1 below.
Guidance for starting wattages is provided in the table’s footnotes.
Table 1
Device
Running
Watts
Device
Running
Watts
Air conditioner (12.000 BTU)
1700 (a,b)
Jet pump
800 (a)
Battery charger (20 Amp)
500
Lawn mower
1200
Belt sander (3”)
1000
Light bulb (100 Watt)
100
Chain saw
1200
Microwave oven
700
Circular saw (6½”)
2000 (a,b)
Milk cooler
1100 (a)
Coffee maker
1800 (a,b)
Oil burner on furnace
300
Compressor (1 HP)
1400 (a,b)
Oil-fired space heater (140,000 Btu)
400
Compressor (3/4 HP)
1800 (a)
Oil-fired space heater (85,000 Btu)
225
Compressor (1/2 HP)
1400 (a)
Oil-fired space heater (30,000 Btu)
150
Curling iron
700
Oven
4500
Dishwasher
1200
Paint sprayer, airless (1/3 HP)
600 (a)
Edge trimmer
500
Paint sprayer, airless (handheld)
150
2. Planning the Power Load
Plan your power load so that you do not exceed the generator’s rated capacity.

Installation / Initial Set-Up (cont’d)
13
Device
Running
Watts
Device
Running
Watts
Electric nail gun
1200
Radio
200
Electric range (1 element)
1500
Refrigerator
600 (b)
Electric skillet
1250
Slow cooker
200
Furnace fan (1/3 HP)
1200 (a)
Submersible pump (1-1/2 HP)
2800 (a)
Freezer
800 (b)
Submersible pump (1 HP)
2000 (a)
Hair dryer
1200
Submersible pump (1/2 HP)
1500 (a)
Hand drill (1”)
1100
Sump pump
600 (a)
Hand drill (1/2”)
875
Table saw
2000 (a)
Hand drill (3/8”)
500
Television
500
Hand drill (1/4”)
250
Toaster
1000
Hedge trimmer
450
Vacuum cleaner
250
Home computer
150
VCR
70
Impact wrench
500
Water heater
3000
Weed trimmer
500
(a) Hard-starting motors require 3-5 times the rated running watts
(b) For extremely hard to start loads such as air conditioners and air compressors, consult the equipment dealer to
determine maximum wattage
To calculate the running and starting wattage requirements for the devices you will be powering,
follow these steps:
1. Make a list of all electrical devices you will be powering at the same time with the generator.
2. List the greater of the running or starting wattage next to each device as obtained from the
devices’ nameplate or Table 1. If only the running wattage for a device with an electric motor is
known, the starting wattage can be estimated to be at least 3 times the running wattage.
3. Add the wattages for all devices on your list. This total must be lower than the continuous output
rating of your generator.
Example:
Device to be Powered
Greater of Starting/Running
Wattage
Light bulb
75 W
Refrigerator –18 cu. ft.
1600 W
Microwave
700 W
Window AC
1800 W
Sump pump (1/3 hp)
2100 W
Total
6275W
In this example, the generator must have a continuous output of at least 6275 W in order to power
all of the devices simultaneously.
You can increase the number of devices your generator can power by staggering the load on the
generator. For example, you could alternately power your refrigerator and air conditioner for limited
periods of time -- powering only one of the devices at a time and never powering both at the same time.
STAGGERING LOADS

Installation / Initial Set-Up (cont’d)
14
3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source
This generator is designed to provide up to 4,000 watts of electrical power. It can supply electricity in two
ways:
1. As a back-up, standby power source for a building. For this application, you must arrange for a
licensed electrician to connect the generator to your building’s electrical system via the installation of an
UL-listed transfer switch. The transfer switch must be installed in accordance with building electrical
code and guidelines supplied by your power company.
2. As a portable power source. You can plug appliances or tools directly into the generator’s electrical
outlets.
Specific requirements for each are given below.
Note: Regardless of whether you use your generator as a back-up power source connected to a building
or as a portable power source, you must not overload the generator. Overloading may cause serious
damage to the generator and attached electrical devices.
Using as a
back-up power
source for a
building
Contact a licensed electrician to install a UL-listed transfer switch if you want to
use your generator as a back-up power source for a building.
What does a transfer switch do? It:
a) Safely connects the generator to your building’s electrical system by isolating
your generator from your utility company’s power lines, AND
b) Connects your generator to a critical subset of your building’s circuits that are
needed for emergency power needs.
If your generator will be connected to your building’s electrical system, it MUST
ALWAYS be isolated from the utility power grid with a UL-listed transfer switch
installed by a licensed electrician in compliance with all applicable building and
electrical codes, and in accordance with guidelines supplied by your power company.
DANGER:
A transfer switch must be installed in order to isolate your generator from the
utility power grid. If your generator is NOT properly isolated from the utility
system, serious hazards will arise:
•When your generator is running, its output will back feed into the utility
power line and transformer that are normally used to provide you with
power. The transformer will step up the current to the normal line voltage.
An unsuspecting utility line worker working on what he thinks is a
deactivated line could be electrocuted.
•If your generator is connected (running or not) when utility power is restored,
your generator will be destroyed. It could also explode or cause fire.
In addition to isolating your generator from the utility system, the transfer switch
connects your generator to a limited set of circuits in your building that have been
chosen as critical to operate during a power outage.
The generator cannot power your entire home -- you must work with the installing
electrician to determine which devices/appliances you wish to power during an
outage. The electrician can help you determine which circuits and devices can be
powered simultaneously without overloading the generator.
(See the previous section of this manual entitled “Planning the Power Load”for
more information on load application and selection.)

Installation / Initial Set-Up (cont’d)
15
Using as a portable
power source
When using the generator as a portable power source, you can plug electric
devices and appliances directly into the generator’s electrical outlets.
There are ten different electrical outlets on the generator:
1. One 120/240 Volt, 30 Amp Locking receptacle (NEMA L14-30R compatible
with NEMA L14-30P mating plugs).
2. Eight 120 Volt, 20 Amp Duplex Straight-Blade receptacles (NEMA 5-20R
duplex receptacles compatible with NEMA 5-20P or 5-15P mating plugs).
3. One 12 Volt DC receptacle.
•Make sure you plug each electrical device/appliance into the correct generator
outlet based on the device’s plug configuration and voltage/amperage rating.
Never exceed the amperage rating of an outlet.
•Extension cords may be used to power devices that are located at a distance from
the generator. However, use only UL-listed, outdoor-rated, grounded extension
cords of the proper size. Use Table 2 below to choose an adequately sized
extension cord according to the amperage of the device being used and the length
of the cord.
Table 2
Current/Power
Maximum Extension Cord Length
Amps at
240V
Load
(watts)
#10 Ga.
Cord
#12 Ga.
Cord
#14 Ga.
Cord
#16 Ga.
Cord
10
2400
250’
150’
100’
75’
20
4800
125’
75’
50’
25’
30
7200
60’
35’
25’
10’
40
9600
30’
15’
10’
*
50
12000
15’
*
*
*
WARNING: Use of undersized extension cords can cause electric shock,
fire, or damage to connected devices.
•All extension and appliance cords must be in good condition and not worn, bare,
frayed, or otherwise damaged.
WARNING: Use of damaged electric cords can cause electric shock or fire.
Note: If an extension cord becomes hot to the touch, it is overloaded or damaged and
must be replaced. Northern Tool is NOT responsible for damage or injury resulting from
customer use of inadequate extension cords.
2
2
1
3

Installation / Initial Set-Up (cont’d)
16
4. Select a Suitable Site
Before using the generator, you must select a suitable OUTDOOR location for installation and operation. This
location should meet all of the criteria listed below.
WARNING:
You must choose a suitable site for operating your generator to avoid equipment damage and/or injury
and possible death from carbon monoxide poisoning, electric shock, or fire. Choose a site that meets
all of the criteria specified.
Dry, level surface
The generator should be positioned on a dry, firm, level surface.
Ensure that the generator sits level and will not slide or shift during operation. If
applicable, block the generator’s wheels to prevent sliding and shifting.
Outdoors only –
dangerous carbon
monoxide exhaust
WARNING: Carbon monoxide poisoning hazard
The exhaust from your generator contains carbon monoxide (CO), a poisonous
gas that can kill. You cannot smell it, see it, or taste it. Carbon monoxide
exhaust is given off whether you are using gasoline, natural gas, or propane as
the fuel source to power the generator. Follow the directions below for
choosing a location to operate your generator in order to avoid carbon
monoxide poisoning.
The location you choose to operate the generator must be OUTDOORS and away
from all air intakes:
•Never run the generator inside any closed or semi-enclosed spaces (even if
outdoors), including homes, garages, basements, sheds, or boxes. These spaces
can trap poisonous gases, even if you run a fan or open windows.
•Place the generator so that the exhaust fumes will not be directed towards people
or building air intakes.
•Ensure that working, battery-operated or battery back-up carbon monoxide alarms
are used in any dwelling/structure that is in close proximity to the running generator.
•Note that this generator is NOT designed or approved for use in vehicles or marine
applications. Never run the generator inside RVs or other vehicles, on boats, or on
pick-up truck beds.
WARNING:
Never attempt to attach ductwork to the muffler system to allow for installation
inside an enclosure. This could cause hot air deflection, heat build-up, and
increased exhaust back-pressure, resulting in possible exhaust leakage or
damage to the generator.
Adequate cooling
ventilation
The generator needs adequate, unobstructed flow of air to allow for proper
cooling of engine and generator head.
WARNING:
Heat build-up from inadequate ventilation can result in fire, posing a serious
risk to nearby persons and structures.
•Situate so there is adequate clearance around generator to allow for cooling airflow
so that heat does not build up.
•Never place the generator immediately adjacent to a building or other structure –
allow at least 7 feet clearance.

Installation / Initial Set-Up (cont’d)
17
•DO NOT run the generator in close proximity to other heat-generating equipment,
such as another generator. The combined heat that is generated may raise air
temperature in the immediate area and there will not be adequate cooling
ventilation.
•DO NOT allow debris to accumulate and block airflow.
•DO NOT operate with a tarp, blanket, or cover surrounding the generator.
No wet conditions
Choose a location where the generator will NOT be exposed to rain, snow, or
direct sunlight. Exposure to water can cause electric shock.
You may operate the generator under an outdoor, canopy-like structure of heat-
resistant material that is open on all sides. Make sure that all parts of canopy are at
least 7 feet from exhaust, and allow for adequate clearance above generator so that
heat does not build up.
Hot exhaust
clearance
The exhaust gas from your generator is extremely hot and can cause
combustible materials to catch on fire.
•Make sure your generator’s exhaust system is at least 7 feet from all combustible
materials and buildings/structures.
•The engine is equipped with a spark arrester if the generator will be used near any
ignitable forest, brush, or grassy land. Make sure you comply with applicable local,
state, and federal codes.
•Keep a fire extinguisher rated “ABC” nearby. Keep it properly charged and be
familiar with its use.
Away from
dust/dirt
DO NOT use the generator in extremely dusty or dirty conditions. Excessive dust
and dirt can cause premature failure of the machine.
Hearing protection
Generators can produce noise levels in excess of 95 dB in close proximity,
which can be dangerous to human hearing with prolonged exposure.
Hearing protection may be required for persons working within 15-20 feet of the
running generator for an extended period of time.
WARNING:
Never attempt to attach ductwork to the muffler system to lower noise levels.
This could cause hot air deflection, heat build-up, and increased exhaust back-
pressure, resulting in possible exhaust leakage or damage to the generator.

Installation / Initial Set-Up (cont’d)
18
5. Grounding the generator
Always ensure the generator is properly grounded to prevent electrical shock.
You must always ground the generator by the following method when using the generator as a portable
electrical source:
1. Drive a ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must
penetrate moist earth –the depth required will be dictated by local soil conditions. Consult with an
electrician.
2. Connect an approved ground clamp to the pipe.
3. Run a 10 gauge wire from the clamp to the generator grounding post which is located on the base of
the generator frame to the right of the battery location.
4. DO NOT connect the generator grounding post to a water pipe or a ground used by a radio system.
If a licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a
back-up power system, grounding may alternatively be completed through the building’s grounding system.
Ask your electrician. If the generator is not grounded through your building’s electrical system, follow the
procedure above.
WARNING:
Operating the generator when it is not properly grounded can result in electrical shock.
Grounding Post
10 Ga. wire
Copper
Pipe/Rod
Ground
Control Panel Face

Installation / Initial Set-Up (cont’d)
19
6. Battery Installation
Your generator’s engine is equipped with an electric starter which requires the installation of a 12 volt DC battery.
See the “Specifications” section of this manual for more specific battery requirements for this generator model,
such as minimum amperage or CCA rating.
The battery is to be supplied by the customer and should be installed in the protective battery tray located near
the engine. The orientation of the battery should be with the tabs to the front. Follow the instructions detailed
below for connecting and disconnecting the battery.
See Specification section of the manual for battery information.
WARNING: Battery hazards
Batteries are hazardous because they contain caustic acid, can emit explosive gases, and can cause
electric shock. Caution must be exercised when making connections to a battery to avoid shock and
contact with the acid, and to prevent any sparking that could lead to an explosion.
ALWAYS follow the general battery safety rules and instructions listed below.
General battery safety
rules
•ALWAYS use eye protection when handling batteries.
•NEVER smoke or work near sparks or other sources of ignition.
•NEVER touch both battery terminals at the same time with your hand or any non-
insulated tools.
•If battery acid contacts skin or clothing, flush immediately with water and
neutralize with baking soda.
Connecting the
battery
Always connect the cables in the following sequence to avoid possible shock:
1. Find the battery cables located near the battery tray.
2. Connect the red cable to the positive(+) terminal of the battery.
3. Then connect the black cable to the negative(-) terminal of the battery.
Disconnecting the
battery
Always disconnect cables in the following sequence to avoid possible shock.
1. First, disconnect the black cable from the negative(-) terminal of the battery.
2. Next, disconnect the red cable from the positive(+) terminal of the battery.
Battery tabs
Battery tray

Installation / Initial Set-Up (cont’d)
20
7. Wheel Kit Assembly
Your generator is equipped with a free wheel kit to provide easy portability.
Secure the generator on blocks at least 7” off the ground or work table. Make sure the holes in the base of the
generator are not obstructed to allow for installation of axle and vibration brackets.
Installing the axle
and wheels
1. Slide (1) Axle into the end of the Wheel (1).
2. Slide (1) Axle Washer onto the axle.
3. Slide the Axle, Wheel, and Washer assembly into the Frame.
4. Insert (1) Hairpin in the holes on that end of the Axle to secure the Wheel.
5. Repeat for the opposite Wheel.
Installing the legs
1. Attach (1) Rubber Foot to (1) Leg Bracket. Secure using (1) M6 x 20mm Flange Bolt
and (1) M6 Flange Nut.
2. Repeat Step 1 to assemble the second Leg Bracket assembly.
3. Align (1) Leg Bracket assembly to the holes in the generator base. Attach using (4)
M8 X 12 Bolts and (4) M6 Flange Nuts.
4. Repeat Step 3 to attach the remaining Leg Bracket assembly to the generator base.
Axle
Washer
Wheel
Hairpin
Leg Bracket
Rubber Foot
M6 x 25mm Flange Bolt
M6 Flange Nut
M6 Flange Nut
Generator Base
M6 x 12mm Flange Bolt