Powermate PM1200i User manual

PM1200i Inverter
Owner’s Manual
SAVE THIS MANUAL FOR FUTURE REFERENCE
(000209b)
WARNING
Loss of life. This product is not intended to
be used in a critical life support application.
Failure to adhere to this warning could result
in death or serious injury.
MODEL:________________________
SERIAL:________________________
DATE PURCHASED:______________
Register your Powermate product at:
http://www.powermate.com/register.php
US: 1-888-922-8482
Non-US: 1-262-953-5155
010378

Table of Contents
Section 1 Introduction and Safety 1
Introduction ..................................... 1
Safety Rules .................................... 1
Safety Symbols and Meanings ........ 1
Exhaust and Location Hazards ....... 2
Electrical Hazards ........................... 3
Fire Hazards .................................... 3
Standards Index .............................. 3
Section 2 General Information and
Setup .............................................. 4
Know Your Generator ..................... 5
Emissions ........................................ 5
Connection Plugs ............................ 6
Run/Choke Lever ............................ 6
RPM+ .............................................. 6
Generator Status Lights .................. 6
Circuit Protectors ............................. 6
Remove Contents from Carton ....... 7
Add Engine Oil ................................ 7
Fuel ................................................. 7
Section 3 Operation .......................9
Operation and Use Questions .........9
Before Starting Engine ....................9
Prepare Generator for Use ..............9
Grounding the Generator When In Use
9
Know Generator Limits ....................9
Transporting/Tipping of the Unit ....10
Starting Pull Start Engines .............10
Starting Hot Engines ......................11
Low Oil Level Shutdown System ...11
Section 4 Maintenance and
Troubleshooting ..........................12
Maintenance ..................................12
Maintenance Schedule ..................12
Preventive Maintenance ................12
Engine Maintenance ......................12
Storage ..........................................15
Troubleshooting .............................17
(000393a)
WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.

Owner’s Manual for Portable Generator 1
Section 1 Introduction and Safety
Introduction
Read This Manual Thoroughly
If any section of this manual is not understood,
contact the nearest Independent Authorized
Service Dealer (IASD) or Powermate Cus-
tomer Service at 1-800-445-1805, or
www.powermate.com for starting, operating,
and servicing procedures. The owner is
responsible for proper maintenance and safe
use of the unit.
SAVE THESE INSTRUCTIONS for future ref-
erence. This manual contains important
instructions that must be followed during
placement, operation, and maintenance of the
unit and its components. Always supply this
manual to any individual that will use this unit.
The information in this manual is accurate
based on products produced at the time of
publication. The manufacturer reserves the
right to make technical updates, corrections,
and product revisions at any time without
notice.
Safety Rules
The manufacturer cannot anticipate every
possible circumstance that might involve a
hazard. The alerts in this manual, and on tags
and decals affixed to the unit, are not all inclu-
sive. If using a procedure, work method, or
operating technique that the manufacturer
does not specifically recommend, verify that it
is safe for others and does not render the
equipment unsafe.
Throughout this publication, and on tags and
decals affixed to the unit, DANGER, WARN-
ING, CAUTION, and NOTE blocks are used to
alert personnel to special instructions about a
particular operation that may be hazardous if
performed incorrectly or carelessly. Observe
them carefully. Alert definitions are as follows:
NOTE: Notes contain additional information
important to a procedure and will be found
within the regular text of this manual.
These safety alerts cannot eliminate the haz-
ards that they indicate. Common sense and
strict compliance with the special instructions
while performing the action or service are
essential to preventing accidents.
Safety Symbols and Meanings
• If you start to feel sick, dizzy, or weak after
the generator has been running, move to
fresh air IMMEDIATELY. See a doctor, as
you could have carbon monoxide poison-
ing.
(000100a)
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
WARNING
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
DANGER
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is
a poison you cannot see or smell.
NEVER use inside a home
or garage, EVEN IF doors
and windows are open.
Only use OUTSIDE and
far away from windows,
doors, and vents.
000657
(000103)
DANGER
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous gas.
Carbon monoxide, if not avoided,
will result in death or serious injury.
Asphyxiation. The exhaust system must be properly
maintained. Do not alter or modify the exhaust system
as to render it unsafe or make it noncompliant with
local codes and/or standards. Failure to do so will
result in death or serious injury.
(000179b)
DANGER

2 Owner’s Manual for Portable Generator
• For safety reasons, it is recommended that
the maintenance of this equipment be per-
formed by an IASD. Inspect the generator
regularly, and contact the nearest IASD for
parts needing repair or replacement.
Exhaust and Location Hazards
• If you start to feel sick, dizzy, or weak after
the generator has been running, move to
fresh air IMMEDIATELY. See a doctor, as
you could have carbon monoxide poison-
ing.
• NEVER run a generator indoors or in a
partly enclosed area such as garages.
• ONLY use outdoors and far away from win-
dows, doors, vents, crawl spaces and in an
area where adequate ventilation is avail-
able and will not accumulate deadly
exhaust gas.
• Point muffler exhaust away from people
and occupied buildings.
(000104)
DANGER
Electrocution. Water contact with a power source,
if not avoided, will result in death or serious injury.
(000116)
DANGER
Electrocution. Turn utility and emergency
power supplies to OFF before connecting power
source and load lines. Failure to do so will result
in death or serious injury.
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.
(000178a)
WARNING
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
WARNING
Equipment and property damage. Do not operate unit on
uneven surfaces, or areas of excessive moisture, dirt, dust
or corrosive vapors. Doing so could result in death, serious
injury, property and equipment damage. (000250)
(000111)
WARNING
Moving Parts. Keep clothing, hair, and appendages
away from moving parts. Failure to do so could
result in death or serious injury.
(000108)
WARNING
Hot Surfaces. When operting machine, do not
touch hot surfaces. Keep machine away from
combustables during use. Hot surfaces
could result in severe burns or fire.
(000142a)
WARNING
Personal injury. Do not insert any object through the
air cooling slots. Generator can start at any time and
could result in death, serious injury, and unit damage.
WARNING
Risk of injury. Do not operate or service this machine
if not fully alert. Fatigue can impair the ability to
service this equipment and could result in death or
serious injury. (000215)
(000216)
WARNING
Injury and equipment damage. Do not use generator
as a step. Doing so could result in falling, damaged
parts, unsafe equipment operation, and could result
in death or serious injury.
WARNING
Equipment damage. Do not attempt to start or operate
a unit in need of repair or scheduled maintenance.
Doing so could result in serious injury, death, or
equipment failure or damage. (000291)
000406
(000103)
DANGER
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous gas.
Carbon monoxide, if not avoided,
will result in death or serious injury.
Asphyxiation. The exhaust system must be properly
maintained. Do not alter or modify the exhaust system
as to render it unsafe or make it noncompliant with
local codes and/or standards. Failure to do so will
result in death or serious injury. (000179b)
DANGER
(000178a)
WARNING
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so
could result in death or serious injury.
(000146)
WARNING
Equipment and property damage. Do not alter
construction of, installation, or block ventilation for
generator. Failure to do so could result in unsafe
operation or damage to the generator.

Owner’s Manual for Portable Generator 3
• Using a fan or opening a door will not pro-
vide sufficient ventilation.
Electrical Hazards
• The National Electric Code (NEC) requires
the frame and external electrically conduc-
tive parts of the generator be properly con-
nected to an approved earth ground. Local
electrical codes may also require proper
grounding of the generator. Consult with a
local electrician for grounding requirements
in the area.
• Use a ground fault circuit interrupter in any
damp or highly conductive area (such as
metal decking or steel work).
• Once generator has been started outside,
connect electrical loads to extension
cord(s) inside.
Fire Hazards
• Allow at least 5 feet of clearance on all
sides of the generator when operating to
prevent overheating and fire.
• Do not operate the generator if connected
electrical devices overheat, if electrical out-
put is lost, if engine or generator sparks, or
if flames or smoke are observed while unit
is running.
• Keep a fire extinguisher near the generator
at all times.
Standards Index
1. National Fire Protection Association
(NFPA) 70: The NATIONAL ELECTRIC
CODE (NEC) available from www.nfpa.org
2. National Fire Protection Association
(NFPA) 5000: BUILDING CONSTRUC-
TION AND SAFETY CODE available from
www.nfpa.org
3. International Building Code available from
www.iccsafe.org
4. Agricultural Wiring Handbook available
from www.rerc.org, Rural Electricity
Resource Council P.O. Box 309 Wilming-
ton, OH 45177-0309
5. ASAE EP-364.2 Installation and Mainte-
nance of Farm Standby Electric Power
available from www.asabe.org, American
Society of Agricultural & Biological Engi-
neers 2950 Niles Road, St. Joseph, MI
49085
6. CSA C22.2 100-14 Electric motors and
generators for installation and use, in
accordance with the Rules of the Cana-
dian Electrical Code
7. ANSI/PGMA G300 Safety and Perfor-
mance of Portable Generators. Portable
Generator Manufacturer’s Association,
www.pgmaonline.com
IMPORTANT NOTE: This list is not all inclu-
sive. Check with the Authority Having
Jurisdiction (AHJ) for any local codes or
standards which may be applicable to your
jurisdiction.
(000144)
DANGER
Electrocution. Contact with bare wires,
terminals, and connections while generator
is running will result in death or serious injury.
(000104)
DANGER
Electrocution. Water contact with a power source,
if not avoided, will result in death or serious injury.
(000145)
DANGER
Electrocution. In the event of electrical accident,
immediately shut power OFF. Use non-conductive
implements to free victim from live conductor. Apply
first aid and get medical help. Failure to do so will
result in death or serious injury.
(000105)
DANGER
Explosion and Fire. Fuel and vapors are extremely
flammable and explosive. Add fuel in a well
ventilated area. Keep fire and spark away. Failure to
do so will result in death or serious injury.
(000166b)
DANGER
Explosion and Fire. Do not overfill fuel tank. Fill to
1/2 inch from top of tank to allow for fuel expansion.
Overfilling may cause fuel to spill onto engine causing
fire or explosion, which will result in death or serious
injury.
(000174)
DANGER
Risk of fire. Allow fuel spills to completely dry
before starting engine. Failure to do so will
result in death or serious injury.
WARNING
(000281)
Fire risk. Fuel and vapors are extremely
flammable. Do not operate indoors. Doing
so could result in death, serious injury, or
property or equipment damage.
(000282)
WARNING
Explosion and fire risk. Do not smoke near unit.
Keep fire and spark away. Failure to do so could
result in death, serious injury, or property or
equipment damage.
WARNING
Explosion and Fire. Do not smoke while
refueling unit. Failure to do so could result in
death, serious injury, or property or equipment
damage. (000284a)

4 Owner’s Manual for Portable Generator
Section 2 General Information and Setup
Figure 2-1. Features and Controls
Generator Components
Figure 2-2. Control Panel
1
52
3
4
6
7
010381
010380010378
8
1 Control Panel
2 Spark Plug Access Cover
3 Recoil Handle
4 Engine Control Switch / Fuel Valve
5 Fuel Cap and Vent
6 Engine Service Panel
7 Muffler and Spark Arrestor
8 Choke Lever
9 120V Receptacle
10 Neutral Floating Grounding Location
11 Low Oil LED (Yellow)
12 Overload LED (Red)
13 Output ready LED (Green)
14 AC 9 Amp Circuit Breaker
9
10
1112 13
14
010233

Owner’s Manual for Portable Generator 5
Know Your Generator
Replacement owner’s manuals are available
at www.powermate.com.
Emissions
The United States Environmental Protection
Agency (US EPA) (and California Air
Resources Board (CARB), for engines/equip-
ment certified to California standards) requires
this engine/equipment to comply with exhaust
and evaporative emissions standards. Locate
the emissions compliance decal on the engine
to determine applicable standards. See the
included emissions warranty for emissions
warranty information. Follow the maintenance
specifications in this manual to ensure the
engine complies with applicable emissions
standards for the duration of the product’s life.
(000100a)
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
WARNING
Product Specifications
Generator Specifications
Rated Power 1000 W**
Surge Power 1200 VA
Rated AC Voltage 120V
Rated AC Load at 120V 8.33 Amps**
Rated Frequency 60 Hz
Dimensions L x W x H (in/mm) 18.5 x 10.2 x 7.9 (470 x 260 x 200)
Weight (dry) 33 lb. (15 kg)
** Operating Temperature Range: -6.7° C (20° F) to 40° C (104° F). When operated above 25° C (77°
F) there may be a decrease in power.
** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content,
ambient temperature, altitude, engine condition, etc. Maximum power decreases about 3.5% for
each 1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16°
C (60° F) ambient temperature.
Engine Specifications
Engine Type Single Cylinder, 4-stroke
Displacement 54 cc
Spark Plug Part Number 10000031505
Spark Plug Type Torch A5RTC, Champion RZ10YC, Bosch
U4BC, Autolite 2795 or equivalent
Spark Plug Gap (in/mm) 0.032 (0.8)
Fuel Capacity / Type 3.0 L (0.8 U.S. gallons) / Unleaded
Oil Type 10W30
Oil Capacity 0.25 L (0.26 qt.)
Run Time at 25% Load 7 Hours
Run Time at 50% Load 5.5 Hours
* Go to www.powermate.com or contact an IASD for replacement parts.

6 Owner’s Manual for Portable Generator
Connection Plugs
120 VAC, Duplex Receptacle
The 120 Volt outlet is overload protected by
the 9 Amp push button circuit protector. See
Figure 2-3.
Figure 2-3. 120 VAC, Duplex Receptacle
Run/Choke Lever
This controls the choke operation. See Figure
2-4.
• The RUN position (1) is for normal opera-
tion and to gradually reduce the use of the
choke.
• The CHOKE position (2) closes the choke
in the carburetor to start the engine.
NOTE: The CHOKE is not required to start a
warm engine.
Figure 2-4. Run/Choke Lever (example)
RPM+
RPM+ automatically adjusts engine RPM to
decrease fuel usage and reduce noise.
Generator Status Lights
See Figure 2-5.
•Output Ready LED (green): Indicates out-
put from generator (1) (unless there is a low
oil or overload condition).
•Overload LED (red): Indicates system
overload (2). During motor starting it is nor-
mal for the overload LED to illuminate for a
few seconds. If LED stays illuminated and
the ready LED turns off, the engine will con-
tinue to run without output power. Remove
all applied loads and determine if attached
devices exceed recommended output
power. Check for faulty or shorted connec-
tions. To restore electrical output, turn dial
OFF to reset. Start engine. If condition was
corrected, the LED will not illuminate and
electrical output will be restored. Loads can
be applied once the green LED illuminates.
If the LED returns, contact an IASD.
•Low Oil Level LED (yellow): Illuminates
when oil level is below safe operating level.
Engine shuts down (3).
Figure 2-5. Status Indicators
Circuit Protectors
The AC receptacles are protected by an AC
circuit protector. If the generator is overloaded
or an external short circuit occurs, the circuit
protector will trip. If this occurs, disconnect all
electrical loads to determine the cause of the
problem before using the generator again.
Reduce the load if the circuit protector is
tripped.
NOTE: Continuous tripping of the circuit pro-
tector may cause damage to generator or
equipment.
Push the button of the protector to reset the
circuit protector.
001630
2
1
006676
1
2
3
010382

Owner’s Manual for Portable Generator 7
Remove Contents from Carton
1. Open carton completely by cutting each
corner from top to bottom.
2. Remove and verify carton contents prior to
assembly. Carton contents should contain
the following:
Accessories
3. Call Powermate Customer Service at 1-
800-445-1805 with the unit model and
serial number for any missing carton con-
tents.
4. Record model, serial number, and date of
purchase on front cover of this manual.
Add Engine Oil
NOTE: The generator is shipped without oil
and must be purchased separately. Add oil
slowly and verify oil level often during filling
process to ensure overfilling does not occur.
1. Place generator on a level surface.
2. Remove screw and engine service panel.
3. Clean area around oil fill.
4. Remove oil fill cap and wipe dipstick clean.
See Figure 2-6.
Figure 2-6. Remove Dipstick
5. Insert funnel into oil fill opening. Add rec-
ommended engine oil as necessary. Cli-
mate determines proper engine oil
viscosity. See chart to select correct vis-
cosity.
NOTE: Use petroleum based oil for engine
break-in before using synthetic oil.
6. To check oil level, remove funnel and
insert dipstick into oil filler neck. See Fig-
ure 2-7.
Figure 2-7. Safe Operating Range
7. Remove dipstick and verify oil level is
within safe operating range.
NOTE: Verify oil level often during filling pro-
cess to ensure overfilling does not occur.
8. Install oil fill cap/dipstick and hand-tighten.
9. Install engine service panel.
Fuel
Fuel requirements are as follows:
• Clean, fresh, unleaded gasoline.
• Minimum rating of 87 octane/87 AKI (91
RON).
• Up to 10% ethanol (gasohol) is acceptable
(where available; non-ethanol fuel is rec-
ommended).
• DO NOT use E85.
Item Qty.
Main Unit 1
Owner’s Manual 1
Quick Start Guide 1
Oil Funnel 1
Spark Plug Wrench 1
Service Warranty 1
Emissions Warranty 1
(000135)
Engine damage. Verify proper type and quantity of
engine oil prior to starting engine. Failure to do so
could result in engine damage.
CAUTION
000115
SAE 15W-40
10W-30
Synthetic 5W-30
011240
001792
(000105)
Explosion and Fire. Fuel and vapors are extremely
flammable and explosive. Add fuel in a well
ventilated area. Keep fire and spark away. Failure
to do so will result in death or serious injury.
DANGER
(000214)
DANGER
Explosion and Fire. Do not fill fuel tank past full line.
Allow for fuel expansion. Overfilling may cause fuel
to spill onto engine causing fire or explosion, which
will result in death or serious injury.

8 Owner’s Manual for Portable Generator
• DO NOT use a gas oil mix.
• DO NOT modify engine to run on alternate
fuels. Stabilize fuel prior to storage.
1. Verify unit is OFF and cooled entirely prior
to fueling.
2. Place unit on level ground in a well venti-
lated area.
3. Clean area around fuel cap.
4. Turn cap slowly to remove.
5. Slowly add recommended fuel. Do not
overfill.
6. Install fuel cap.
NOTE: Allow spilled fuel to evaporate before
starting unit.
IMPORTANT NOTE: It is important to pre-
vent gum deposits from forming in fuel
system parts such as the carburetor, fuel
hose or tank during storage. Alcohol-
blended fuels (called gasohol, ethanol or
methanol) can attract moisture, which
leads to separation and formation of acids
during storage. Acidic gas can damage the
fuel system of an engine while in storage.
To avoid engine problems, the fuel system
should be emptied or treated before stor-
age of 30 days or longer. See the Storage
section. Never use engine or carburetor
cleaner products in the fuel tank as perma-
nent damage may occur.
(000362)
WARNING
Explosion and Fire. Verify fuel cap vent is set to
ON for operation, and OFF for transportation and
storage. Failure to do so could result in poor unit
performance, death, or serious injury.

Owner’s Manual for Portable Generator 9
Section 3 Operation
Operation and Use Questions
Call Powermate Customer Service at 1-800-
445-1805 with questions or concerns about
equipment operation and maintenance.
Before Starting Engine
1. Verify engine oil level is correct.
2. Verify fuel level is correct.
3. Verify unit is secure on level ground, with
proper clearance and is in a well ventilated
area.
Prepare Generator for Use
Grounding the Generator When
In Use
The generator is equipped with an equipment
ground connecting the generator frame and
the ground terminals on the AC output recep-
tacles (see NEC 250.34 (A). This allows the
generator to be used as a portable without
grounding the frame of the generator as spec-
ified in NEC 250.34. See Figure 2-2 for
grounding location.
The generator (stator winding) is isolated from
the frame and from the AC receptacle ground
pin. Electrical devices that require a grounded
receptacle pin connection will not function if
the receptacle ground pin is not functional.
• Floating Neutral
Know Generator Limits
Overloading a generator can result in damage
to the generator and connected electrical
devices. Observe the following to prevent
overload:
• Add the total wattage of all electrical
devices to be connected at one time. This
total should NOT be greater than the gener-
ator's wattage capacity.
• The rated wattage of lights can be taken
from light bulbs. The rated wattage of tools,
appliances, and motors can be found on a
data label or decal affixed to the device.
• If the appliance, tool, or motor does not
give wattage, multiply volts times ampere
rating to determine watts (volts x amps =
watts).
• Some electric motors, such as induction
types, require approximately three times
more watts of power for starting than for
running. This surge of power lasts only a
few seconds when starting such motors.
Make sure to allow for high starting wattage
when selecting electrical devices to con-
nect to the generator:
1. Calculate the watts needed to start the
largest motor.
2. Add to that figure the running watts of all
other connected loads.
The Wattage Reference Guide is provided to
assist in determining how many items the gen-
erator can operate at one time.
NOTE: All figures are approximate. See data
label on appliance for wattage requirements.
Wattage Reference Guide
(000103)
Asphyxiation. Running engines produce carbon
monoxide, a colorless, odorless, poisonous
gas. Carbon monoxide, if not avoided, will
result in death or serious injury.
DANGER
Asphyxiation. The exhaust system must be properly
maintained. Do not alter or modify the exhaust system
as to render it unsafe or make it noncompliant with
local codes and/or standards. Failure to do so will
result in death or serious injury.
(000179b)
DANGER
WARNING
(000118a)
Risk of fire. Do not use generator without
spark arrestor installed. Failure to do so
could result in death or serious injury.
(000178a)
Asphyxiation. Always use a battery operated carbon
monoxide alarm indoors and installed according to
the manufacturer’s instructions. Failure to do so could
result in death or serious injury.
WARNING
(000110)
WARNING
Risk of Fire. Hot surfaces could ignite
combustibles, resulting in fire. Fire could
result in death or serious injury.
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.
(000136)
CAUTION
Equipment and property damage. Disconnect
electrical loads prior to starting or stopping unit.
Failure to do so could result in equipment and
property damage.
Device Running
Watts
*Air Conditioner (12,000 Btu) 1700
*Air Conditioner (24,000 Btu) 3800
*Air Conditioner (40,000 Btu) 6000

10 Owner’s Manual for Portable Generator
Transporting/Tipping of the Unit
Do not store or transport the unit at an angle
greater than 15 degrees. Turn fuel vent OFF
for transport or storage of unit.
Starting Pull Start Engines
1. See Figure 3-1. Turn fuel vent ON.
Figure 3-1.Turn Fuel Vent ON
2. See Figure 3-2. Turn engine control switch/
fuel valve ON.
Figure 3-2.Turn Engine Switch/Fuel Valve ON
3. See Figure 3-3. Move the Run/Choke lever
to CHOKE (2).
Battery Charger (20 Amp) 500
Belt Sander (3") 1000
Chain Saw 1200
Circular Saw (7-1/4") 1250 to 1400
*Clothes Dryer (Electric) 5750
*Clothes Dryer (Gas) 700
*Clothes Washer 1150
Coffee Maker 1750
*Compressor (1 HP) 2000
*Compressor (3/4 HP) 1800
*Compressor (1/2 HP) 1400
Curling Iron 700
*Dehumidifier 650
Disc Sander (9") 1200
Edge Trimmer 500
Electric Blanket 400
Electric Nail Gun 1200
Electric Range (per element) 1500
Electric Skillet 1250
*Freezer 700
*Furnace Fan (3/5 HP) 875
*Garage Door Opener 500 to 750
Hair Dryer 1200
Hand Drill 250 to 1100
Hedge Trimmer 450
Impact Wrench 500
Iron 1200
*Jet Pump 800
Lawn Mower 1200
Light Bulb 100
Microwave Oven 700 to 1000
*Milk Cooler 1100
Oil Burner on Furnace 300
Oil Fired Space Heater (140,000
Btu)
400
Oil Fired Space Heater (85,000 Btu) 225
Oil Fired Space Heater (30,000 Btu) 150
*Paint Sprayer, Airless (1/3 HP) 600
Paint Sprayer, Airless (hand-held) 150
Radio 50 to 200
*Refrigerator 700
Slow Cooker 200
*Submersible Pump (1-1/2 HP) 2800
*Submersible Pump (1 HP) 2000
*Submersible Pump (1/2 HP) 1500
*Sump Pump 800 to 1050
*Table Saw (10") 1750 to 2000
Television 200 to 500
Toaster 1000 to 1650
Weed Trimmer 500
* Allow 3 times the listed watts for starting these
devices.
(000183)
WARNING
Recoil Hazard. Recoil could retract unexpectedly.
Kickback could result in death or serious injury.
(000136)
CAUTION
Equipment and property damage. Disconnect
electrical loads prior to starting or stopping unit.
Failure to do so could result in equipment and
property damage.
006677
ON
OFF
010383

Owner’s Manual for Portable Generator 11
Figure 3-3.Run/Choke Positions
4. Firmly grasp recoil handle and pull slowly
until increased resistance is felt. Pull rap-
idly up and away.
5. See Figure 3-3. When engine starts, move
Run/Choke lever to RUN (1).
NOTE: If engine fires, but does not continue to
run, move Run/Choke lever to CHOKE (2) and
repeat starting instructions.
IMPORTANT NOTE: Do not overload gener-
ator or individual panel receptacles. See
Figure 3-4. If an overload occurs, the over-
load LED (A) will illuminate and AC output
ceases. To correct, see Generator Status
Lights. Read Know Generator Limits care-
fully.
Figure 3-4.Shutdown Fault
Generator Shut Down
1. Shut off all loads and unplug electrical
loads from generator panel receptacles.
2. Let engine run at no-load for several min-
utes to stabilize internal temperatures of
engine and generator.
3. See Figure 3-2. Turn engine control switch
OFF.
4. See Figure 3-1. Turn fuel vent OFF.
Starting Hot Engines
1. See Figure 3-3. Move Run/Choke lever to
RUN. Turn ON engine switch/fuel valve to
permit starting.
2. Firmly grasp recoil handle and pull slowly
until increased resistance is felt. Pull rap-
idly up and away.
Low Oil Level Shutdown System
The engine is equipped with a low oil level
sensor that shuts down the engine automati-
cally when the oil level drops below a speci-
fied level to prevent engine damage. See
Figure 3-4 (B). The engine will not run until the
oil has been filled to the proper level.
If the engine shuts down and there is sufficient
fuel, check engine oil level.
2
1
006676
A
B
010382
(000136)
CAUTION
Equipment and property damage. Disconnect
electrical loads prior to starting or stopping unit.
Failure to do so could result in equipment and
property damage.
(000136)
CAUTION
Equipment and property damage. Disconnect
electrical loads prior to starting or stopping unit.
Failure to do so could result in equipment and
property damage.

12 Owner’s Manual for Portable Generator
Section 4 Maintenance and Troubleshooting
Maintenance
Regular maintenance will improve perfor-
mance and extend engine/equipment life. The
manufacturer recommends that all mainte-
nance work be performed by an Independent
Authorized Service Dealer (IASD). Regular
maintenance, replacement or repair of the
emissions control devices and systems may
be performed by any repair shop or person of
the owner’s choosing. However, to obtain
emissions control warranty service free of
charge, the work must be performed by an
IASD. See the emissions warranty.
NOTE: Call Powermate Customer Service at
1-800-445-1805 with questions about compo-
nent replacement.
Maintenance Schedule
Follow maintenance schedule intervals,
whichever occurs first according to use.
NOTE: Adverse conditions will require more
frequent service.
NOTE: All required service and adjustments
should be each season as detailed in the fol-
lowing chart.
Preventive Maintenance
Dirt or debris can cause improper operation
and equipment damage. Clean generator
daily or before each use. Keep area around
and behind muffler free from combustible
debris. Inspect all cooling air openings on
generator.
• Use a damp cloth to wipe exterior surfaces
clean.
• Use a soft bristle brush to loosen caked on
dirt, oil, etc.
• Use a vacuum to pick up loose dirt and
debris.
• Low pressure air (not to exceed 25 psi)
may be used to blow away dirt. Inspect
cooling air slots and openings on generator.
These openings must be kept clean and
unobstructed.
NOTE: DO NOT use a garden hose to clean
generator. Water can enter engine fuel system
and cause problems. If water enters generator
through cooling air slots, some water will be
retained in voids and crevices of rotor and sta-
tor winding insulation. Water and dirt buildup
on generator internal windings will decrease
insulation resistance of windings.
Engine Maintenance
Engine Oil Recommendations
To maintain the product warranty, the engine
oil should be serviced in accordance with the
recommendations of this manual.
Before Each Use
Check engine oil level
Check and clean cooling features
Check air filter
After First 20 Hours or First Month
Change engine oil
After 50 Hours or Every 6 Months
Change engine oil
Clean air filter*
Check and clean spark arrestor
After 100 Hours or Every 6 Months
Check and clean spark plug
After 300 Hours or Every Year
Replace air filter
Replace spark plug
* Service more frequently if operating in dry or
dusty conditions.
(000142a)
WARNING
Personal injury. Do not insert any object through the
air cooling slots. Generator can start at any time and
could result in death, serious injury, and unit damage.
(000141)
WARNING
Accidental start-up. Disconnect spark plug wires when
working on unit. Failure to do so could result in death
or serious injury.
SAE 15W-40
10W-30
Synthetic 5W-30
011240

Owner’s Manual for Portable Generator 13
Inspect Engine Oil Level
Inspect engine oil level prior to each use, or
every 8 hours of operation.
1. Place generator on a level surface.
2. Remove screw and engine service panel.
3. Clean area around oil fill.
4. Remove oil fill cap and wipe dipstick clean.
See Figure 4-1.
Figure 4-1.Engine Oil Fill
5. To check oil level, insert dipstick into oil
filler neck without screwing it in. See Fig-
ure 4-2.
Figure 4-2.Safe Operating Range
6. Remove dipstick and verify oil level is
within safe operating range.
7. Add recommended engine oil as neces-
sary.
NOTE: Verify oil level often during filling pro-
cess to ensure overfilling does not occur.
8. Install oil fill cap/dipstick and hand-tighten.
9. Install engine service panel.
Change Engine Oil
When using generator under extreme, dirty,
dusty conditions, or in extremely hot weather,
change oil more frequently.
NOTE: Don’t pollute. Conserve resources.
Return used oil to collection centers.
Change oil while engine is still warm from run-
ning, as follows:
1. Place generator on a level surface.
2. Remove engine service panel and spark
plug access cover.
3. Disconnect the spark plug wire from the
spark plug and place the wire where it
cannot contact spark plug.
4. Clean area around oil fill and oil drain plug.
5. Remove oil fill cap and wipe dipstick clean.
6. Tip unit and drain oil completely into a suit-
able container.
7. Once oil is sufficiently drained from unit,
install oil drain plug and tighten securely.
8. Insert funnel into oil fill opening. See Fig-
ure 4-3. Add recommended engine oil as
necessary.
Figure 4-3.Oil Fill Opening With Funnel
9. To check oil level, remove funnel and
insert dipstick into oil filler neck without
screwing it in. See Figure 4-2.
10. Remove dipstick and verify oil level is
within safe operating range.
NOTE: Verify oil level often during filling pro-
cess to ensure overfilling does not occur.
11. Install oil fill cap/dipstick and hand-tighten.
12. Install spark plug access cover and service
panel.
13. Wipe up any spilled oil.
14. Properly dispose of oil in accordance with
all applicable regulations.
Air Filter
Engine will not run properly and may be dam-
aged if run with a dirty air filter. Service air fil-
ter more frequently in dirty or dusty conditions.
To service air filter:
1. Remove engine service panel to access
the air filter.
2. Release tab for the air cleaner cover and
tip the cover down.
3. See Figure 4-4. Remove foam element
from air cleaner housing and wash in
soapy water. Squeeze dry in clean cloth
(DO NOT TWIST)
(000139)
WARNING
Risk of burns. Allow engine to cool before
draining oil or coolant. Failure to do so could
result in death or serious injury.
000115
001792
(000141)
WARNING
Accidental start-up. Disconnect spark plug wires when
working on unit. Failure to do so could result in death
or serious injury.
002404

14 Owner’s Manual for Portable Generator
4. Clean air filter cover before installation.
5. Replace engine service panel.
NOTE: To order a new air filter, contact the
nearest authorized service center at 1-800-
445-1805.
Figure 4-4.Air Filter Assembly
Drain Float Bowl
To drain the float bowl:
1. Remove the engine service panel to
access the carburetor.
2. See Figure 4-5. Locate the clear plastic
hose from the float that is exiting out the
bottom of the inverter, and place a suitable
container under it to catch the drained fuel.
Figure 4-5.Float Bowl Hose
3. Loosen the float bowl drain screw until fuel
is seen draining from the float bowl.
4. Allow fuel to drain into the container, and
then tighten the float bowl drain screw.
5. Install the engine service panel.
Service Spark Plug
To service spark plug:
1. Remove spark plug access cover. See Fig-
ure 2-1.
2. Clean area around spark plug.
3. Remove and inspect spark plug.
4. Inspect electrode gap with feeler gauge
and reset spark plug gap to 0.8 mm (0.032
in). See Figure 4-6.
Figure 4-6.Spark Plug
NOTE: Replace spark plug if electrodes are
pitted, burned or porcelain is cracked. Use
ONLY recommended replacement plug. See
Product Specifications.
5. Install spark plug finger tight, and tighten
an additional 3/8 to 1/2 turn using spark
plug wrench.
6. Install spark plug access cover.
Inspect Muffler and Spark Arrestor
NOTE: It is a violation of California Public
Resource Code, Section 4442, to use or oper-
ate the engine on any forest-covered, brush-
covered, or grass-covered land unless the
exhaust system is equipped with a spark
arrestor, as defined in Section 4442, main-
tained in effective working order. Other states
or federal jurisdictions may have similar laws.
Contact original equipment manufacturer,
retailer, or dealer to obtain a spark arrestor
designed for exhaust system installed on this
engine.
NOTE: Use ONLY original equipment replace-
ment parts.
Inspect muffler for cracks, corrosion, or other
damage. Remove spark arrestor, if equipped,
inspect for damage or carbon blockage.
Replace parts as required.
Inspect Spark Arrestor Screen
006673
006680
000211
(000108)
WARNING
Hot Surfaces. When operating machine, do not
touch hot surfaces. Keep machine away from
combustibles during use. Hot surfaces could
result in severe burns or fire.

Owner’s Manual for Portable Generator 15
Clean Spark Arrestor Screen
The engine exhaust muffler has a spark arres-
tor screen. Inspect and clean the screen every
50 hours of operation or every 6 months,
whichever comes first.
To service spark arrestor:
1. Stop the unit and let it cool for several min-
utes.
2. See Figure 4-7. Remove the screws hold-
ing the muffler cover in place.
Figure 4-7.Remove Screws
3. See Figure 4-8. Remove the clamp to
remove retainer.
Figure 4-8.Spark Arrestor Screen
4. Slide spark arrestor screens out from the
muffler outlet tube.
5. Inspect screens and replace if torn, perfo-
rated or otherwise damaged. Do NOT use
a defective screen. If screen is not dam-
aged, clean with a commercial solvent.
6. Replace the screens, and retainer, and
secure with clamp.
7. Replace muffler cover and install screws.
Valve Clearance
Important: Please contact an Independent
Authorized Service Dealer for service assis-
tance. Proper valve clearance is essential for
prolonging the life of the engine.
• Intake — 0.08 ± 0.02 mm (cold), (0.003 ±
0.001 in)
• Exhaust — 0.10 ± 0.02 mm (cold) (0.004 ±
0.001 in)
Storage
General
It is recommended to start and run the genera-
tor for 30 minutes, every 30 days. If this is not
possible, refer to the following list to prepare
unit for storage.
• DO NOT place a storage cover on a hot
generator. Allow unit to cool to room tem-
perature before storage.
• DO NOT store fuel from one season to
another unless properly treated.
• Replace fuel container if rust is present.
Rust in fuel will cause fuel system prob-
lems.
• Cover unit with a suitable protective, mois-
ture resistant cover.
• Store unit in a clean, dry area.
• Always store generator and fuel away from
heat and ignition sources.
Prepare Fuel System/Engine for
Storage
Fuel stored over 30 days can go bad and
damage fuel system components. Keep fuel
fresh, use fuel stabilizer.
If fuel stabilizer is added to the fuel system,
prepare and run engine for long term storage.
Run engine for 10-15 minutes to circulate sta-
bilizer throughout fuel system. Adequately
prepared fuel can be stored up to 24 months.
NOTE: If fuel has not been treated with fuel
stabilizer, it must be drained into an approved
container. Run engine until it stops from lack
of fuel. Use of fuel stabilizer in fuel storage
container is recommended to keep fuel fresh.
1. Change engine oil.
2. Remove spark plug.
3. Pour tablespoon (5-10cc) of clean engine
oil or spray a suitable fogging agent into
cylinder.
4. Pull starter recoil several times to distrib-
ute oil in cylinder.
006672
002352
(000143)
Explosion and Fire. Fuel and vapors are extremely
flammable and explosive. Store fuel in a well
ventilated area. Keep fire and spark away. Failure to
do so will result in death or serious injury.
DANGER
(000109)
WARNING
Risk of Fire. Verify machine has properly
cooled before installing cover and storing
machine. Hot surfaces could result in fire.
(000181)
WARNING
Vision Loss. Eye protection is required to
avoid spray from spark plug hole when
cranking engine. Failure to do so could
result in vision loss.

16 Owner’s Manual for Portable Generator
5. Install spark plug.
6. Pull recoil slowly until resistance is felt.
This will close valves so moisture cannot
enter engine cylinder. Gently release
recoil.
Change Oil
Change engine oil before storage. See,
Change Engine Oil.

Owner’s Manual for Portable Generator 17
Troubleshooting
PROBLEM CAUSE CORRECTION
Engine won't start. 1. Engine switch/fuel valve
turned off.
2. Out of fuel.
3. Defective spark plug.
4. Defective or stuck Dial assem-
bly.
5. Incorrect engine oil level.
6. Defective ignition coil.
7. Fuel cap vent OFF.
8. Carb is flooded.
9. Dirty or gummed up carbure-
tor.
1. Turn engine switch/fuel valve
on.
2. Fill fuel tank.
3. Replace spark plug.
4. Contact IASD.
5. Check/fill engine oil.
6. Contact IASD.
7. Turn fuel cap vent ON.
8. Drain carb.
9. Clean carburetor.
Engine starts, then shuts
down.
1. Out of fuel.
2. Incorrect engine oil level.
3. Contaminated fuel.
4. Defective low oil level switch.
1. Fill fuel tank.
2. Check engine oil level.
3. Contact IASD.
4. Contact IASD.
Engine will not start; or
starts and runs rough.*
1. Choke is stuck or left on.
2. Dirty or clogged air filter.
3. Defective or dirty spark plug.
4. Dirty or gummed up carburet-
tor.
5. Unit not warmed up.
6. Spark arrestor clogged.
7. Fuel cap vent OFF.
1. Turn choke off.
2. Clean or replace air filter.
3. Replace spark plug.
4. Clean carburetor.
5. Gradually adjust Dial and
reduce choke until engine runs
smoothly in RUN position.
6. Clean spark arrestor.
7. Turn fuel cap vent ON.
No AC output. 1. Generator is overloaded.
2. Inverter module is overheated.
3. Short circuit in electrical
device.
4. Defective inverter or alterna-
tor assembly.
1. Disconnect all loads. Shut
down generator to reset mod-
ule. Reduce loads, restart
generator.
2. Verify service door is ON. Let
cool 15 minutes by running
engine without AC output.
Press and hold Reset button
on control panel, restart gener-
ator.
3. Verify condition of extension
cords and items being pow-
ered. Press and hold Reset
button on control panel.
4. Contact IASD.
Fuel leaks from drain
hoses.
1. Carburetor drain in bowl is not
closed.
1. Turn valve clockwise to close.
* Engine speed increases and decreases — This is normal as generator starts up and loads vary.

Part No. A0000136692 Rev. B 07/23/2020
©2020 Powermate, LLC. All rights reserved.
Specifications are subject to change without
notice.
No reproduction allowed in any form without
prior written consent from Powermate, LLC.
Powermate, LLC
S45 W29290 Hwy. 59
Waukesha, WI 53189
1-800-445-1805
www.powermate.com