Powermate PM2000 User manual

Powermate PM2000
Portable Generator
Owner’s Manual
MODEL:________________________
SERIAL:________________________
DATE PURCHASED:______________
SAVE THIS MANUAL FOR FUTURE REFERENCE
009407
(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.
Register your Powermate product at:
www.powermate.com/register.php
1-888-922-8482

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
Replacement Hazard Labels ........... 4
Section 2 General Information and
Setup .............................................. 5
Know Your Generator ..................... 6
Emissions ........................................ 6
Connection Plugs ............................ 6
CO-SENSE™ .................................. 7
Remove Contents from Carton ....... 8
Add Engine Oil ................................ 8
Fuel ................................................. 9
Section 3 Operation .................... 10
Operation and Use Questions ....... 10
Before Starting Engine .................. 10
Prepare Generator for Use ............ 10
Grounding the Portable Generator 10
Know Generator Limits .................. 11
Transporting/Tipping of the Unit .... 12
Starting Pull Start Engines ............ 12
Low Oil Level Shutdown System ... 12
Section 4 Maintenance and
Troubleshooting ..........................13
Maintenance ..................................13
Maintenance Schedule ..................13
Preventive Maintenance ................13
Engine Maintenance ......................13
Inspect Muffler and Spark Arrester 15
Valve Clearance ............................15
Storage ..........................................15
Troubleshooting .............................17
Wiring Diagram - CSA Model ........19
Notes .............................................20
(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.
• Using a fan or opening a door will not pro-
vide sufficient ventilation.
(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.
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
Electrical Hazards
• National Electric Code (NEC) requires the
frame and external electrically conductive
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 (GFCI)
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
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.
(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.

4 Owner’s Manual for Portable Generator
Replacement Hazard Labels
The following replacement hazard labels are
available free from Powermate:
• A0000134026 (Fuel Fill/Warning)
• 0H8251B (Vertical CO Warning Decal)
• A00000129151 - Exhaust Direction
• A00000136284 - User Action Label (if
COsense equipped)
009416
009547
009413

Owner’s Manual for Portable Generator 5
Section 2 General Information and Setup
Figure 2-1. Features and Controls
Generator Components
Figure 2-2. Control Panel
Figure 2-3. Unit Identification Label
12
11
5
4
13
14
910
009407 009408
009412
76
3
15
8
1 120 Volt AC, 20 Amp, Duplex Receptacle
(NEMA 5-20R)
2 Circuit Breakers (AC)
3OilDrain
4 Air Filter
5 Fuel Tank
6 Grounding Lug
7 Off/Run/Cold Start Dial
8 Muffler
9GasCap
10 Fuel Gauge
11 Oil Check/Fill
12 Spark Plug
13 Recoil Starter
14 Fuel Shut Off
15 Spark Arrestor
16 CO-SENSE RED (Hazard) (if equipped)
17 CO-SENSE YELLOW (Fault) (if equipped)
17
1 2
009409
7
16
009447

6 Owner’s Manual for Portable Generator
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.
Connection Plugs
120 VAC, 20 Amp, Duplex
Receptacle
The 120 Volt outlet is overload protected by a
12 Amp push-to-reset circuit breaker. See Fig-
ure 2-4. Each receptacle will power 120 Volt
AC, single phase, 60 Hz electrical loads
requiring up to 1400 watts (1.4 kW) or 12
Amps of current. Use only high quality, well-
insulated, 3-wire grounded cord sets rated for
125 Volts at 20 Amps (or greater). Figure 2-4. 120 VAC, 20 Amp, Duplex
Receptacle NEMA 5-20R
(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 @1.0 Power Factor 1.4 kW**
Surge Power 2.0 KVA**
Rated AC Voltage 120
Rated AC Load
Current @ 120V** 11.67
Rated Frequency 60 Hz @ 3600 RPM
Phase Single Phase
Weight (dry) 61.7 lb (28 kg)
** Operating Temperature Range: -12.2 deg. C (10 deg. F) to 40 Deg. C (104 Deg. F). When operated
above 25 deg. C (77 deg. F) there may be a decrease in power.
** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambi-
ent 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
Displacement 98 cc
Spark Plug Part No. 0K91470141
Spark Plug Type E6RTC or equivalent
Spark Plug Gap 0.028-0.031 inch or (0.70-0.80 mm)
Gasoline Capacity 8.5 L (2.25 gal)
Oil Type See Chart in Add Engine Oil
Oil Capacity 0.4 L (.42 qt.)
Run Time at 25% / 50% Load 14.5 Hours / 10.5 Hours
* Go to www.powermate.com or contact an IASD for replacement parts.
000424

Owner’s Manual for Portable Generator 7
CO-SENSE™
Carbon Monoxide (CO) Detection
and Shut-off System (if equipped)
The CO-SENSE module monitors for the
accumulation of poisonous CO gas found in
engine exhaust when the generator is running.
If CO-SENSE detects increasing levels of CO
gas, it automatically shuts off the engine. CO-
SENSE only monitors when the engine is run-
ning. Generators are intended to be used out-
doors, far from occupied buildings and the
exhaust pointed away from personnel and
buildings. However, if mis-used and operated
in a location that results in the accumulation of
CO, like indoors or in a partially enclosed
area, CO-SENSE shuts off the engine, notifies
the user of what has happened and directs the
user to read the instruction action label for
steps to take. See Figure 2-5. CO-Sense is not
a substitute for an indoor carbon monoxide
alarm.
See Figure 2-6. As the user approaches the
generator to investigate a shut-off, a blinking
RED light in the CO-SENSE badge on the
side of the generator provides notification that
the generator was shut off due to an accumu-
lating CO hazard. The RED light will blink for
at least five minutes after a CO shut-off. Move
the generator to an open, outdoor area and
point the exhaust away from people and occu-
pied buildings. Once relocated to a safe area,
the generator can be restarted and the proper
electrical connections made to supply electri-
cal power. The RED light will stop blinking
automatically upon engine re-start. Introduce
fresh air and ventilate the location where the
generator had shut down.
See Figure 2-6. If a CO-SENSE system fault
has occurred and no longer provides protec-
tion, the portable generator is shut off auto-
matically and the YELLOW light will blink for at
least five minutes in the CO-SENSE badge to
notify the user of the fault. The CO-SENSE
module can only be diagnosed and repaired
by a trained technician at the dealer. The gen-
erator can be re-started, but may continue to
shut-off.
CO-SENSE will detect the accumulation of
Carbon Monoxide from other fuel burning
sources such as engine powered tools or pro-
pane heaters used in the area of operation.
For example, if another generator is used and
the exhaust is pointed at a CO-SENSE
equipped generator, CO-SENSE may initiate
a shut-off due to rising CO levels. This is not
an error. Hazardous Carbon Monoxide has
been detected. The user must take action to
move and re-direct these devices to better dis-
sipate Carbon Monoxide far away from per-
sonnel and occupied buildings.
Figure 2-5. Instruction Action Label
009413
009547

8 Owner’s Manual for Portable Generator
Figure 2-6. Instruction Decal (if equipped)
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. Record model, serial number, and date of
purchase on front cover of this manual.
NOTE:
Add Engine Oil
1. Place generator on a level surface.
2. Verify oil fill area is clean.
3. See Figure 2-7. Remove oil fill cap and
wipe dipstick clean.
Figure 2-7. Remove Dipstick
4. Add recommended engine oil as shown in
the following chart.
NOTE: Use petroleum based oil (supplied) for
engine break-in before using synthetic oil.
.
NOTE: Some units have more than one oil fill
location. It is only necessary to use one oil fill
point.
5. See Figure 2-8. Screw dipstick into filler
neck. Remove dipstick and verify oil level
is within safe operating range.
009414
Item Qty.
Main Unit 1
Owner’s Manual 1
0.4 Liter Oil SAE 10W-30 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 30
10W-30
Synthetic 5W-30
000399

Owner’s Manual for Portable Generator 9
Figure 2-8. Safe Operating Range
6. Install oil fill cap/dipstick and hand-tighten.
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-premium fuel
is recommended).
• DO NOT use E85.
• 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 for a mini-
mum of two minutes prior to fueling.
2. Place unit on level ground in a well venti-
lated area.
3. Clean area around fuel cap and remove
cap slowly.
4. Slowly add recommended fuel (A). Do not
overfill (B). See Figure 2-9.
5. Install fuel cap.
Figure 2-9. Add Recommended Fuel
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 before storage of 30
days or longer. See the Storage section.
Never use engine or carburetor cleaner
products in the fuel tank as permanent
damage may occur.
000116
(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
(000106b)
Fluid Injection. This machine produces
high-pressure fluid streams that can pierce
skin. Fluid injection could result in death or
serious injury.
WARNING
000400
A
B

10 Owner’s Manual for Portable Generator
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 Portable
Generator
See Figure 3-1. The portable generator is
equipped with a terminal for the connection of
a field grounding electrode conductor where a
grounding electrode system is required by
NEC Article 250.34(A). The equipment
grounding conductor terminals of the genera-
tor receptacles are bonded to the generator
frame. Where the generator supplies power to
cord and plug connected equipment, like
power tools, the frame of the generator is not
required by the NEC to be connected to a field
grounding electrode. The generator neutral
conductor is bonded to the generator frame in
accordance with NEC Article 250.34(C).
• CSA model - Neutral Floating
• 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.
• CO Sense model - NEUTRAL BONDED
TO FRAME
• THERE IS A PERMANENT CONDUCTOR
BETWEEN THE GENERATOR (STATOR
WINDING) AND FRAME
See Figure 3-1. Where the generator is con-
nected to a manual transfer switch, the trans-
fer switch must also switch the neutral upon
transfer to be NEC code compliant (3-Pole
switch). A grounding electrode is required to
be connected to the generator frame to prop-
erly ground the generator. The ground wire
connected from the generator terminal/frame
to a field ground electrode shall be of equal or
larger ampacity than the largest conductor
used in the generator. Generac HomeLink
manual transfer switches and kits meet this
requirement and are recommended for use.
Figure 3-1. Grounding the Generator
(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
(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
(000118a)
Risk of fire. Do not use generator without
spark arrestor installed. Failure to do so
could result in death or serious injury.
(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.
000227

Owner’s Manual for Portable Generator 11
Connecting the Generator to a
Building Electrical System
It is recommended to use a manual transfer
switch when connecting directly to a building
electrical system to prevent hazardous back-
feeding and avoid injuring utility line workers.
When connecting a portable generator to a
building electrical system, a transfer switch
must isolate the generator power from the util-
ity power at all times. Failure to comply will
result in a hazardous condition. Installation is
to be made in strict compliance with all
national and local electrical codes and laws,
and be completed by a qualified electrician.
Special Requirements
Review all Federal or State Occupational
Safety and Health Administration (OSHA) reg-
ulations, local codes, or ordinances that apply
to the intended use of the generator.
Consult a qualified electrician, electrical
inspector, or the local agency having jurisdic-
tion:
• In some areas, generators are required to
be registered with local utility companies.
• If the generator is used at a construction
site, there may be additional regulations
which must be observed.
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
Device Running
Watts
*Air Conditioner (12,000 Btu) 1700
*Air Conditioner (24,000 Btu) 3800
*Air Conditioner (40,000 Btu) 6000
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

12 Owner’s Manual for Portable Generator
Transporting/Tipping of the Unit
Do not operate, store or transport the unit at
an angle greater than 15 degrees.
Starting Pull Start Engines
1. Unplug all electrical loads from the unit's
receptacles before starting engine.
2. Place generator on a level surface.
3. See Figure 3-2. Open the fuel shut-off
valve (A).
.
Figure 3-2.Fuel Shut-off Valve
4. Turn OFF/RUN/COLD START dial to
COLD START. See Figure 3-3.
.
Figure 3-3.Power Dial
5. Firmly grasp recoil handle and pull slowly
until increased resistance is felt. Pull rap-
idly up and away.
6. When engine starts, rotate OFF/RUN/
COLD START dial to RUN. COLD START
operation is reduced as OFF/RUN/COLD
START dial is rotated to RUN.
NOTE: If engine fires, but does not continue to
run, rotate OFF/RUN/COLD START dial to
OFF and repeat starting instructions.
IMPORTANT NOTE: Do not overload the
generator. Also, do not overload individual
panel receptacles. These outlets are pro-
tected against overload with push-to-reset-
type circuit breakers. If amperage rating of
any circuit breaker is exceeded, that
breaker opens and electrical output to that
receptacle is lost. Read Know Generator
Limits carefully.
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. Rotate OFF/Run/COLD START dial to
OFF.
4. Close fuel valve.
NOTE: Under normal conditions, close fuel
valve and allow generator to run carburetor
bowl out of fuel. For emergencies, switch to
OFF.
Low Oil Level Shutdown System
The engine is equipped with a low oil level
sensor to shut down the engine automatically
when the oil level drops below a specified
level. The engine will not run until the oil has
been filled to the proper level.
IMPORTANT NOTE: Verify proper engine oil
and fuel levels before use.
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.
OFF
APAGADO
ARRÊT
ON
ENCENDIDO
MARCHE
009493
2
13
RUN
COLD
START
OFF
009415
(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.

Owner’s Manual for Portable Generator 13
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 1-800-445-1805 with questions
about component replacement.
Maintenance Schedule
Follow maintenance schedule intervals,
whichever occurs first according to use.
NOTE: Adverse conditions will require more
frequent service.
NOTE: Go to www.powermate.com or contact
an IASD for replacement parts.
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. For your
convenience, maintenance kits designed and
intended for use on this product are available
from the manufacturer that include engine oil,
oil filter, air filter, spark plug(s), a shop towel
and funnel. These kits can be obtained from
an Independent Authorized Service Dealer
(IASD).
At Each Use
Check engine oil level
Every 100 Hours or Every Year*
Change oil ǂ
Inspect/clean spark arrestor
Every Year
Inspect/Service Spark Plug
Check Valve Clearance***
Every 200 Hours or Every Year
Inspect/clean air cleaner filter**
ǂChange oil after first 30 hours of operation,
then every season.
* Change oil and oil filter (if equipped) every
month when operating under heavy load or
in high temperatures.
** Clean more often under dirty or dusty oper-
ating conditions. Replace air filter parts if
they cannot be adequately cleaned.
*** Check valve clearance and adjust if neces-
sary after first 50 hours of operation and
every 300 hours thereafter.
(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.

14 Owner’s Manual for Portable Generator
.
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. Verify oil fill area is clean.
3. See Figure 4-1. Remove oil fill cap and
wipe dipstick clean.
Figure 4-1. Engine Oil Fill
4. See Figure 4-2. Screw dipstick into filler
neck. Remove dipstick and verify oil level
is within safe operating range.
Figure 4-2. Safe Operating Range
5. Add recommended engine oil as neces-
sary.
NOTE: Some units have more than one oil fill
location. It is only necessary to use one oil fill
point.
6. Install oil fill cap/dipstick and hand-tighten.
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. Disconnect the spark plug wire from the
spark plug and place the wire where it
cannot contact spark plug.
3. Clean area around oil fill, and oil drain
plug.
4. Remove oil fill cap.
5. Remove oil drain plug and drain oil com-
pletely into a suitable container.
6. Install oil drain plug and tighten securely.
7. Slowly pour oil into oil fill opening until oil
level is between L and H marks on dip-
stick. DO NOT overfill.
8. Install oil fill cap/dipstick and hand-tighten.
9. Wipe up any spilled oil.
10. 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. See Figure 4-3. Turn knob (A) and remove
air filter cover.
2. Wash in soapy water. Squeeze filter dry in
clean cloth (DO NOT TWIST).
3. Clean air filter cover before re-installing it.
NOTE: To order a new air filter, contact the
nearest authorized service center at 1-800-
445-1805.
Figure 4-3. Air Filter Assembly
SAE 30
10W-30
Synthetic 5W-30
000399
(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
000116
(000141)
WARNING
Accidental start-up. Disconnect spark plug wires when
working on unit. Failure to do so could result in death
or serious injury.
A
009409

Owner’s Manual for Portable Generator 15
Service Spark Plug
To service spark plug:
1. Clean area around spark plug.
2. Remove and inspect spark plug.
3. Inspect electrode gap with wire feeler
gauge and reset spark plug gap to 0.028 -
0.031 in (0.70 - 0.80 mm). See Figure 4-4.
Figure 4-4. Spark Plug
NOTE: Replace spark plug if electrodes are
pitted, burned or porcelain is cracked. Use
ONLY recommended replacement plug. See
Specifications.
4. Install spark plug finger tight, and tighten
an additional 3/8 to 1/2 turn using spark
plug wrench.
Inspect Muffler and Spark
Arrester
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
arrester, 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 arrester
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 arrester, if equipped,
inspect for damage or carbon blockage.
Replace parts as required.
Inspect Spark Arrester Screen
1. Loosen clamp (A) and remove screw. See
Figure 4-5.
2. Inspect screen (B) and replace if torn, per-
forated or otherwise damaged. If screen is
not damaged, clean with commercial sol-
vent.
3. Replace spark arrestor cone (C) and
screen (B). Secure with clamp and screw.
Figure 4-5. Spark Arrestor Screen
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.
Check valve clearance after the first fifty-hours
of operation. Adjust as necessary.
• Intake — 0.1 ± 0.02mm (cold), (0.004" ±
0.0008" inches)
• Exhaust — 0.15 ± 0.02mm (cold) (0.006" ±
0.0008" inches)
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 and dry area.
• Always store generator and fuel away from
heat and ignition sources.
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.
A
B
C
009411
(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.

16 Owner’s Manual for Portable Generator
Prepare Fuel System 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 fuel system, pre-
pare 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.
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.
(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.

Owner’s Manual for Portable Generator 17
Troubleshooting
PROBLEM CAUSE CORRECTION
Engine is running, but
AC output is not
available.
1. Circuit breaker OPEN.
2. Poor connection or defective
cord set.
3. Connected device is bad.
4. Fault in generator.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is
in good condition.
4. Contact IASD.
Engine runs well at
no-load, but bogs when
load is applied.
1. Short circuit in a connected
load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
5. Clogged spark arrestor.
1. Disconnect shorted electrical
load.
2. See Know Generator Limits.
3. Contact IASD.
4. Contact IASD.
5. Clean spark arrestor screen.
Engine will not start; or
starts and runs rough.
1. Fuel shut-off is OFF.
2. Dirty air filter.
3. Out of fuel.
4. Stale fuel.
5. Spark plug wire not connected
to spark plug.
6. Bad spark plug.
7. Water in fuel.
8. Overchoking.
9. Low oil level.
10. Excessive rich fuel mixture.
11. Intake valve stuck open or
closed.
12. Engine lost compression.
1. Turn fuel shut-off ON.
2. Clean or replace air filter.
3. Fill fuel tank.
4. Drain fuel tank and fill with
fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain fuel tank; fill with fresh
fuel.
8. Set choke to no choke posi-
tion.
9. Fill crankcase to correct level.
10. Contact IASD.
11. Contact IASD.
12. Contact IASD.
Engine shuts down
during operation.
1. Out of fuel.
2. Low oil level.
3. Fault in engine.
4. CO-SENSE shut-off due to
accumulating carbon monox-
ide if a red light blinks on the
side panel badge.
5. CO-SENSE shut-off due to a
system fault if a yellow light
blinks on the side panel
badge.
1. Fill fuel tank.
2. Fill crankcase to correct level.
3. Contact IASD.
4. Follow all safety instructions
and relocate generator to an
open area outside, far away
from windows, doors and
vents.
5. Start to confirm yellow light
blinks when/if generator shuts-
off. If CO-SENSE continues to
fault and shut-off, contact
IASD.
Engine lacks power. 1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
4. Clogged spark arrestor.
1. Reduce load (see Know Gen-
erator Limits).
2. Clean or replace air filter.
3. Contact IASD.
4. Clean spark arrestor screen.
Engine surges or
stumbles.
1. Carburetor is running too rich
or too lean.
1. Contact IASD.

18 Owner’s Manual for Portable Generator
Engine starts and shuts
off right away.
1. CO-SENSE shut-off due to
accumulating carbon monox-
ide if a red light blinks on the
side panel badge.
2. CO-SENSE shut-off due to a
system fault if a yellow light
blinks on the side panel
badge.
1. Follow all safety instructions
and relocate generator to an
open area outside, far away
from windows, doors and
vents.
2. Start to confirm yellow light
blinks when/if generator shuts-
off. If CO-SENSE continues to
fault and shut-off, contact
IASD.
PROBLEM CAUSE CORRECTION