Powermate PM0645500 User manual

Thank you for selecting a Coleman@ Powermate® Generator. The Coleman®
Powermate® generator has been made to supply reliable, portable electrical
power when utility power is not available. We hope you will enjoy your new
generator. Welcome to our worldwide family of Coleman® Powermate®
generator users.
Merci d'avoir choisi le groupe electrogene Coleman® Powermate®. Ce
groupe electrogene Coleman® Powermate® a et6 con_u pour fournir le
pouvoir electrique, portatif et fiable quand le pouvoir d'utilite n'est pas
disponible. Nous esperons que votre groupe electrogene vous donnera
entiere satisfaction. Bienvenue dans la famille mondiale des utilisateurs de
groupes electrogenes Coleman® Powermate®.
Gracias por seleccionar un generador Coleman® Powermate®. El generador
Coleman® Powermate® ha sido diseSado para proporcionar energia electrica
confiable y portatil cuando no hay servicio disponible de energia pQblica.
Esperamos que disfrute de su nuevo generador. Bienvenido a nuestra familia
de usuarios de generadores Coleman® Powermate® a nivel mundial.
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CALL US FIRSTt
CUSTOMER HOTLINE
1-800-445-1805
or 1-308-237-2181
FOR QUESTIONS OR
SERVICE INFORMATION
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ou 1-308-237-2181
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QUESTIONS OU SERVICE
3
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AL CLIENTE
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o 1-308-237-2181
PARA la INFORMACION de
PREGUNTAS O SERVICIO
www.powermate.com Customer Hottine 1-800-445-1805

Safety and operation rules ...................... 5
Spark arresting muffler ......................... 6
Determining total wattage ....................... 6
Operating voltage ............................. 7
Installation ................................... 7
Before operation .............................. 8
Grounding the generator .................... 8
Lubrication ............................... 8
Low oil sensor ............................ 8
Fuel .................................... 8
Cord-set wiring ............................... 8
Major generator features ....................... 9
Starting the unit.............................. 10
Pre-start preparation ...................... 10
Starting the engine ........................ 10
Applying load ............................ 10
Shutting the generator off .................. 10
Break-in procedure ........................ 11
Maintenance ................................ 11
Brushes ................................ 11
Inspecting the brushes ..................... 11
Exciting the generator ..................... 11
Heat shield .............................. 11
Engine carburetor icing .................... 11
Quick starting tips ......................... 11
Service and storage .......................... 12
Infrequent service ......................... 12
Long term storage ........................ 12
Service information ........................... 12
Limited warranty ............................. 13
Parts drawing ............................... 32
Parts list ................................. 33-34
Maintenance record .......................... 35
R6gles d'op6ration et de s6curit6 ................ 14
Silencieux pare-6tincelles ...................... 15
Determination de la puissance totale n6cessaire .... 15
V6rifler la tension ............................ 16
Installation .................................. 16
Avant de mettre en marche .................... 17
Mise en place de I'appareil .................. 17
Lubrification .............................. 17
Le d6tecteur de bas niveau d'huile ........... 17
Carburant ................................ 17
C&ble d'installation de I'appareil ................. 17
Caract6ristiques principales du groupe electrogene . 18
D6marrage de I'appareil ....................... 19
Pr6paratifs au d6marrage ................... 19
D6marrage du moteur ...................... 19
Branchement des appareils .................. 19
Arret de I'appareil ......................... 20
Rodage ................................. 20
Entretien ................................... 20
Les balais ............................... 20
Inspection des balais ....................... 20
Excitation de I'appareil ...................... 20
€:crans de chaleur ......................... 20
Givrage du carburateur ..................... 20
Trucs de d6marrage rapide .................. 21
Usage et entreposage ........................ 21
Usage peu fr6quent ........................ 21
Entreposage a long terme ................... 21
Service clientele ............................. 21
Garantie limit6e ............................. 22
Schema des pieces .......................... 32
Liste des pieces ........................... 33-34
Rapport d'entretien ........................... 35
Reglas de seguridad y de funcionamiento ......... 23
Silenciador apagachispas ...................... 24
Como determinar el vataje total ................. 24
Requerimiento de voltaje ...................... 25
Instalacion .................................. 25
Antes de la operacion ......................... 26
Puesta a tierra del generador ................ 26
Lubricacion .............................. 26
El sensor del nivel bajo de aceite ............. 26
Combustible .............................. 26
Alambrado del juego de cordones ............... 26
Caracteristicas principales del generador ......... 27
Arranque de la unidad ........................ 28
Preparacion antes de arrancar ............... 28
Arranque del motor ........................ 28
Como aplicar una carga .................... 28
Apagado del generador ..................... 29
Procedimiento de arranque inicial ............. 29
Mantenimiento .............................. 29
Escobillas ............................... 29
Revisi6n de las escobillas ................... 29
Excitacion del generador .................... 29
Escudo contra el calor ...................... 29
Congelamiento del carburador del motor ....... 29
Instrucciones rapidas para el arranque ......... 30
Servicio y almacenamiento ..................... 30
Servicio poco frecuente ..................... 30
Almacenamiento a largo plazo ............... 30
Informacion de servicio al cliente ................ 30
Garantia limitada ............................. 31
Diagrama de piezas .......................... 32
Lista de piezas ........................... 33-34
Registro de mantenimiento ..................... 35
www.powermate.com 4Customer Hottine 1-800-445-1805

SAFETY INFORMATION
DANGER indicates a potentially
hazardous situation which, if not
avoided, WILL result in death or
serious injury.
WARNING indicates a
potentially hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION indicates a potentially
hazardous situation which, if not
avoided, may result in minor or
moderate personal iniury, or
property damage.
WARNING - Failure to follow these instructions
and warnings may result in death, personal
injury, or property damage.
11. Store the generator in a well ventilated area with
the fuel tank empty. Fuel should not be stored near
the generator.
1. Read carefully and understand operator manual
prior to operation of this product. Read and
understand engine manual prior to operation.
Follow all warnings and instructions.
2. Know your equipment. Consider the applications,
limitations, and the potential hazards specific to
your unit.
3. Equipment must be placed on a firm, supporting
surface.
4. Load must be kept within rating stated on
generator nameplate. Overloading will damage
the unit or shorten its life.
5. Engine must not be run at excessive speeds.
Operating an engine at excessive speeds increases
the hazard of personal injury.
Do not tamper with parts which may increase
or decrease the governed speed.
6. To prevent accidental starting, always remove the
spark plug or cable from the spark plug before
maintaining the generator or engine.
7. Units with broken or missing parts, or without
protective housing or covers, should never be
operated. Contact your service center for
replacement parts.
8. Units should not be operated or stored in wet or
damp conditions or on highly conductive
locations such as metal decking and steel work.
9. Keep the generator clean and free of oil, mud and
other foreign matter.
10.Extension cords, power cords, and all electrical
equipment must be in good condition. Never
operate electrical equipment with damaged or
defective cords.
www.powermate.com 5
12.Your generator should never be operated under
these conditions:
a. Uncontrolled change in engine speed.
b. Electrical output loss.
c. Overheating in connected equipment.
d. Sparking.
e. Damaged receptacles.
f. Engine misfire.
g. Excessive vibration.
h. Flame or smoke.
i. Enclosed colnpartment.
j. Rain or inclement weather. Do not let the unit
get wet when operating.
13. Check the fuel system periodically for leaks or
signs of deterioration such as chafed or spongy
hose, loose or missing clamps, or damaged tank or
cap. All defects should be corrected before
operation.
14. The generator should be operated, serviced, and
refueled only under the following conditions:
a. Start and run the generator outdoors. Do
not run the generator in an enclosed area,
even if doors or windows are open; avoid
areas where vapors may be trapped, such as
pits, garages, cellars, excavations and boat
bilges. DANGER - CARBON MONOXIDE
HAZARD: The engine exhaust contains
carbon monoxide, a poisonous, odorless,
invisible gas which, if breathed, may cause
death or serious personal injury. If you start
to feel sick, dizzy or weak while using the
generator, shut it off and get to fresh air
right away; you may have carbon monoxide
poisoning.
b. Good ventilation for cooling. Air flow and
temperatures are important for air cooled
units. Temperatures should not exceed 104° F
ambient (40° C).
c. Refuel the generator in a well lighted area.
Avoid fuel spills and never refuel while the
generator is running. Allow engine to cool for
two minutes prior to refueling.
Customer Hottine 1-800-445-1805

d. Do not refuel near open flames, pilot lights, or
sparking electrical equipment such as power
tools, welders, and grinders.
e. The muffler and air cleaner must be installed
and in good condition at all times as they
function as flame arresters if backfiring occurs.
f. Do not smoke near the generator.
15.Ensure that generator is properly grounded. (See
"Grounding the generator" section in this
manual.)
16.Do not wear loose clothing, jewelry, or anything
that may be caught in the starter or other rotating
parts.
17.Unit must reach operating speed before electrical
loads are connected. Disconnect loads before
turning off engine.
18.To prevent surging that may possibly damage
equipment, do not allow engine to run out of fuel
when electrical loads are applied.
19.When powering solid state equipment, a Power
Line Conditioner should be used to avoid possible
damage to equipment.
20. Do not stick anything through ventilating slots,
even when the generator is not operating. This can
damage the generator or cause personal injury.
21. Before transporting the generator in a vehicle,
drain all fuel to prevent leakage that may occur.
22. Use proper lifting techniques when transporting
the generator from site to site. hnproper lifting
techniques may result in personal injury.
23. To avoid burns, do not touch engine muffler or
other engine or generator surfaces which became
hot during operation.
24. Do not alter or modify the heat shield.
SPARK ARRESTING MUFFLER
YOUR PRODUCT MAY NOT BE EQUIPPED WITH A
SPARK ARRESTING MUFFLER. If the product will be used
around flannnable materials, such as agricultural crops,
forests, brush, grass, or other similar items, then an approved
spark arrester should be installed and is legally required in the
State of California. The California statutes requiring a spark
arrester are Sections 13005(b), 4442 and 4443. Spark
Arresters are also required on some U.S. Forest Service land
and may also be legally required under other statutes and
ordinances. An approved spark arrester is available from your
Coleman(R)Powerlnate(R) product dealer, or may be ordered
from Powennate Corporation, RO. Box 6001, Kearney,
Nebraska 68848. 1-800-445-1805. Spark arresters can also
be ordered from our website, www.powerlnate.coln.
iii_ii_! _! _iiii _ _ _ _ii _!_ J_i_ _ 2_ _ _ _ i! _ _ iii_!!!_!!!
In order to prevent overloading and possible damage to
your generator it is necessary to know the total wattage of the
connected load. To determine which tools and/or appliances
your generator will run follow these steps:
1. Determine if you want to run one item or multiple items
simultaneously.
2. Check wattage requirements for the items you will be
running by referring to the load's nameplate or by
calculating it (lnultiply amps x volts = watts).
3. Total the watts for each item. If the nameplate only gives
volts and amps, multiply volts x amps = watts.
1KW =1,000 watts.
4. Motorized appliances or tools require more than their
rated wattage for start up.
NOTE: Allow 2 1/2 to 4 times the listed wattage for
starting equipment powered by electric motors.
5. The generator's rated watts should match or exceed the
total number of watts required for the equipment you
want to run.
6. Always connect the heaviest load to the generator first,
then add other items one at a time.
NOTE: Additional information on determining wattage
requirements can be found on our website:
www.powermate.com.
www.powermate.com 6Customer Hottine 1-800-445-1805

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CAUTION: Operating voltage and frequency
requirement of all electronic equipment should be
checked prior to plugging them into this generator.
Damage may result if the equipment is not designed
to operate within a +/- 10% voltage variation, and +/-
3 hz frequency variation from the generator name
plate ratings. To avoid damage, always have an
additional load plugged into the generator if solid
state equipment (such as a television set) is used. A
power line conditioner is recommended for some solid
state applications.
To avoid backfeeding into utility systems, isolation of the
residence electrical system is required.
Before temporary connection of the generator to the
residence electrical system, turn off the main
service/disconnect.
If your generator is to be used as a stand-by power source
in case of utility power failure, it should be installed by a
registered electrician and in compliance with all applicable
local electrical codes.
Proper use requires that a double throw transfer switch be
installed by a licensed qualified electrician so that the
building's electrical circuits may be safely switched between
utility power and the generator's output, thereby preventing
backfeed into the power utility's electrical system.
A power line conditioner should be used when running
one or more of the following solid state items:
Garage door openers
Kitchen appliances with digital displays
Televisions
Stereos
Personal computers
Quartz clocks
Copy machines
Telephone equipment
Other solid state equipment may require a power line
conditioner. For more information, contact our Customer
Service Department at 1-800-445-1805 or
www.powerlnate.coin.
To avoid backfeeding into utility systems, isolation of
the residence electrical system is required. Before
temporary connection of a generator to the residence
electrical system turn off the main switch. Before
making permanent connections a double throw
transfer switch must be installed. To avoid
electrocution or property damage, only a trained
electrician should connect generator to residence
electrical system. California law requires isolation of
the residence electrical system before connecting a
generator to residence electrical systems. Temporary
connection not recommended due to backfeeding.
To avoid possible personal injury or equipment
damage, a registered electrician or an authorized
service representative should perform installation and
all service. Under no circumstances should an
unqualified person attempt to wire into a utility
circuit.
Always follow local codes and regulations that apply to
the installation of any item that concerns this product.
1. NFPA 70 -National Electrical Code.
2. NFPA 37 - Standard for Installation and Use of
Stationary Combustible Engines.
3. Agricultural Wiring handbook of Farm Standby
Electric Power.
www.powermate.com 7Customer Hottine 1-800-445-1805

GROUNDING THE GENERATOR
The National Electric Code requires that this product be
properly connected to an appropriate earth ground to help
prevent electric shock. A ground terminal connected to the
frame of the generator has been provided for this purpose.
Connecting alength of heavy gauge (12 AWG rain.) copper
wire between the generator Ground Terminal and a copper rod
driven into the ground should provide a suitable ground
connection. However, consult with a local electrician to insure
that local codes are being adhered to.
GROUND TERMINAL LOCATION:
GROUND LUG jr
LOW OIL SENSOR
The unit is equipped with a low oil sensor. If the oil level
becomes lower than required, the sensor will activate a
warning device or stop the engine. (See the accompanying
engine manual for more information.)
If generator shuts off and the oil level is within
specifications, check to see if generator is sitting at an angle
that forces oil to shift. Place on an even surface to correct this.
If engine fails to start, the oil level may not be sufficient to
deactivate low oil level switch. Make sure the sulnp is
completely full of oil.
FUEL
Fill the tank with clean, fresh unleaded automotive
gasoline. Regular grade gasoline may be used provided a high
octane rating is obtained (at least 85 pump octane). We
recommend always using a fuel stabilizer. A fuel stabilizer
will minimize the formulation of fuel gum deposits during
storage. The fuel stabilizer can be added to the gasoline in the
fuel tank, or into the gasoline in a storage container.
Do not overfill the tank. Keep maximum fuel level 1/4
inch below the top of the fuel tank. This will allow
expansion in hot weather and prevent overflow.
Do not use apipe carrying combustible material as
the ground source.
LUBRICATION
DO NOT attempt to start this engine without filling the
crank case with the proper amount and type of oil. (See the
accompanying engine manual for this information.) Your
generator has been shipped from the factory without oil in the
crankcase. Operating the unit without oil can damage the
engine.
Fill the engine with oil according to the engine manual.
For units with a dipstick, fill oil to the proper level. Units
without a dipstick should be filled to the top of the opening of
the oil fill.
i ii i i
If your generator is supplied with a 4-wire 120/240V
twistlock receptacle, ground and neutral may be connected
together at the load side.
Y(HF1T)
X (HOT) (GRDUND)
NEUTRAL
HRT
HST GROUND
www.powermate.com 8 Customer Hottine 1-800-445-1805

/
A. Control Panel
B. 120 V, 20 Ampere Duplex Receptacle
20 amps of current may be drawn from each half of the
receptacle. However, total power drawn must be kept within
nameplate ratings. These receptacles may be used along with the
twistlock receptacle provided the generator is not overloaded.
C. 120 Volt GFCI Receptacle
Ground Fault Circuit Interrupter duplex receptacle is rated so
that a total of 20 amps may be drawn regardless of whether both
halves or just one receptacle is used. This receptacle may be used
along with other receptacles provided the generator is not overloaded
and total power drawn is kept within nameplate ratings.
Ground Fault Circuit Interrupter
(Conforms to U.L 943, Class A and NEC requirements)
This device protects you against hazardous electrical shock that may
be caused if your body becomes a path through which electricity
travels to reach ground. This could happen when you touch an
appliance or cord that is " live " through faulty mechanism, damp or
worn insulation, etc.
D. 120/240 V, 30 Ampere Twistlock Receptacle
A maximum of 30 amps may be drawn from the 120/240 volt
receptacle, provided it is the only receptacle used. However, current
must be limited to the nameplate rating. If the 120/240 volt
receptacle is used along with the 120 volt receptacle, the total load
drawn must not exceed the nameplate ratings.
E. Circuit Breakers
The receptacles are protected by an AC circuit breaker. If the
generator is overloaded or an external short circuit occurs, the circuit
breaker will trip. If this occurs, disconnect all electrical loads and try
to determine the cause of the problem before attempting to use the
generator again. If overloading causes the circuit breaker to trip,
reduce the load. NOTE: Continuous tripping of the circuit
breaker may cause damage to generator or equipment. The
circuit breaker may be reset by pushing the button of the breaker.
F. Panel Light
The panel light comes on automatically when the engine is
started. The light goes off automatically when the engine is shut off.
G. DIGITECH TM DigitalInformation Center
The DIGITECH TM Digital Information Center is a patented
feature available only on select Coleman_,R) Powermate_,R) Brand
generators.
At a glance, the user can instantly see how much of the
generator's output capacity is being used and how much power
remains available. The display also indicates the time since last user
reset and the total accumulated runtime of the generator.
Power Bar - This bargraph provides a quick visual indication of
the percentage of rated output currently being supplied.
% Load Indicator - This is a numeric version of the Power Bar.
Hour Meter - This indicates the total number of hours the
generator has run since manufacture.
Maintenance Timer - This indicates the number of hours the
generator has run since the last user reset. This timer should be reset
after evm 7 oil change or any other maintenance task. Follow the
instructions in the engine owners manual for proper engine
maintenance intervals.
Reset Button - Pressing and holding this button will reset the
Maintenance Timer to 0 HRS.
H. Fuel Shut-Off
I. Engine On/Off Switch
J. Engine Choke Lever
K. Yamaha 10HP OHV Engine with:
Cast-Iron Cylinder Sleeve
Low Oil Sensor
L. 7 Gallon Plastic Fuel Tank
M. Fuel Gauge
N. Generator Head
O. Storage Bin
EOil Drain
Q. Pneumatic Tires
R. Retractable Handles
S. Handle Release Buttons
To extend the handles, press the handle release buttons on the
wheel end of the unit. Pull the handles out until the handle release
buttons lock in place on the engine end of the unit.
To retract the handles, press the handle release buttons on the
engine end of the unit. Push the handles in until the
handle release buttons lock in place on the wheel end of the unit.
www.powermate.com 9Customer Hottine 1-800-445-1805

Gasoline is very dangerous.
Serious injury or death may result from fire caused
by gasoline contacting hot surfaces.
1. Do not fill fuel tank with engine running.
2. Do not spill fuel while refilling tank.
3. Do not mix oil with gasoline.
4. Follow all instructions and warnings in the engine
manual.
PRE-START PREPARATION
Before starting the generator, check for loose or missing
parts and for any damage which may have occurred during
shipment.
• Provide adequate ventilation for toxic exhaust
gases and cooling air flow.
• Do not start or run the generator in an enclosed
area, even if door or windows are open.
• Engines give off carbon monoxide, an odorless,
colorless, poison gas.
• Breathing carbon monoxide can cause nausea,
fainting or death.
APPLYING LOAD
This unit has been pretested and adjusted to handle its full
capacity. When starting the generator, disconnect all load.
Apply load only after generator is running. Voltage is
regulated via the engine speed adjusted at the factory for correct
output. Readjusting will void warranty.
This generator must not be operated without all
factory installed heat shields in place. Failure to
comply may cause the fuel tank to overheat and result
in personal injury from fire.
When applying a load, do not exceed the maximum
wattage rating of the generator when using one or
more receptacles. Also, do not exceed the amperage
rating of any one receptacle.
STARTING THE ENGINE
1. Check oil level and fuel.
2. Disconnect all electrical loads from the unit.
3. Open fuel shut off valve.
4. Adjust choke as necessary.
5. Set the engine switch to the "ON" position.
6. Pull on the starter rope with fast steady pull. As the
engine warms up, readjust the choke. On electric start
models, turn the key switch to "START". Release key
switch after the engine starts.
SHUTTING THE GENERATOR OFF
1. Remove entire electrical load.
2. Let the engine run for two minutes without load.
3. Move the engine switch to the "OFF" position. (Turn
the key switch to "OFF" on the electric start models).
4. Do not leave the generator until it has completely
stopped.
5. Close the fuel shut off valve if the engine is to be put in
storage or transported.
6. If a cover is used, do not install until unit has cooled.
Allow generator to run at no load for five minutes
upon each initial start-up to permit engine and
generator to stabilize.
www.powermate.com 10 Customer Hottine 1-800-445-1805

BREAK-IN PROCEDURE
Controlled break-in helps insure proper engine and gener-
ator operation. Follow engine procedure outlined in engine
inanual.
4. Plug a lamp or light into the generator before starting the
engine. The light source will illuminate when voltage has
returned.
5. Start the engine with no load connected to the generator.
6. Attach the "-" lead of the battery to the negative brush.
Very briefly, touch the "+" lead of the battery to the
positive brush as shown. Remove as soon as voltage
builds up. To measure voltage, use a plug-in voltmeter.
Do not apply heavy electrical load during break-in
period (the first two to three hours of operations).
GENERATOR: Brushes
The brushes in the generator should be inspected once
every year for chips and cracks. Brushes should be replaced
when they are worn to 1/4 inch (71nln).
NOTE: Replace brushes in sets only, never separately.
INSPECTING THE BRUSHES:
1. Remove cover plate (R).
2. Remove 4 stator bolts (U) and endbell.
3. Remove screws holding the protective plate on the inside
of the endbell.
4. Disconnect the green (-) or blue (+) brush wires from
the tab.
5. Remove brush mounting screws (S).
6. Slide brushes (T) from holders.
7. Replace if worn to 1/4 inch (71nln).
8. Do not over tighten screws.
NOTE: Replace only with brushes specified in parts
list. Other brushes may appear to be identical but may
have completely different mechanical and electrical
characteristics.
EXCITING THE GENERATOR:
If there is a loss of residual magnetism (voltage will not
build up), it may be necessary to re-excite the unit.
1. Use a 6-volt lantern battery (dry cell) or a 12-volt
automotive battery.
2. Disconnect all loads from generator.
3. Remove the brush cover.
HEAT SHIELD:
Inspect to ensure that all heat shields and heat deflectors
are intact and in place. Do not remove any parts or modify
parts. Removing or modifying parts could cause serious
damage to the unit.
ENGINE: Carburetor Icing
During the winter months, rare atmospheric conditions
may develop which will cause an icing condition in the
carburetor. If this develops, the engine may run rough, loose
power, and may stall. Call Product Service for more
information.
NOTE: Refer to the engine manufacturer's manual
for service and maintenance of the engine.
QUICK STARTING TIPS FOR UNITS THAT HAVE
BEEN SITTING FOR AWHILE:
If your unit has been sitting around for a long time period
and is hard to start, try doing some of these easy steps before
calling the Customer Hotline.
1. Check the oil level.
2. Replace the old fuel.
3. Change the spark plug.
4. Check the fuel lines. Make sure the fuel valve is open.
5. Check all generator parts for integrity.
6. Clean the Carburetor. (See engine manual for service
centers)
www.powermate.com 11 Customer Hottine 1-800-445-1805