PowerPro Technology 4050 User manual

MODEL 4050
7.0 HP Generator
Item # 56405
Owner’s Manual
DO NOT RETURN TO STORE
Questions? Problems?
Please call our customer help line:
[phone] M-F 8-5 CST
FEATURES
x4050 Starting Watt Output
x3250 Running Watt Output
x2-120 Volt Duplex Receptacles
x1-120 Volt Twist Lock Receptacle
xLow Oil Automatic Shutoff
xCircuit Breaker for Overload Protection
x3.1 Gallon Fuel Tank Capacity
xSpark Arrester
xDigital Hour Meter
xMobility Kit included
xMeets EPA Emission Standards

GENERATOR IDENTIFICATION
For information and questions, please contact the Customer Service Help Line by calling (800) 232-
1195. Certain information will be requested by the Customer Service Representative and to facilitate
that, please fill in the information below.
Refer to the illustration below for the location of Serial Number. Record generator information in the
spaces provided below.
DATE OF PURCHASE: ______________________________________________
PURCHASED FROM: ______________________________________________
GENERATOR MODEL NUMBER: ____________________________________
ENGINE SERIAL NUMBER: _________________________________________
ENGINE SERIAL NUMBER
SERVICE RECORD
Record Service Dates:
Date Date Date Date Date Date
Oil Change
Change spark plug
Clean Fuel Tank
Clean Filter Cup
Clean Air Cleaner
Carburetor Maintenance
i

TABLE OF CONTENTS
GENERATOR IDENTIFICATION ................................................................................................i
SERVICE RECORD .........................................................................................................................i
INTRODUCTION ............................................................................................................................1
SAFETY INFORMATION..............................................................................................................2
GENERAL SAFETY PROCEDURES ...........................................................................................3
IMPORTANT SAFETY INSTRUCTIONS ...................................................................................5
PACKAGE CONTENTS .................................................................................................................7
GENERATOR COMPONENTS.....................................................................................................8
ASSEMBLY………………………………………………………………………………………..9
GENERATOR PREPARATION ....................................................................................................9
Using the Generator for the First Time ..........................................................................................9
Step 1 - Fill Oil .........................................................................................................................10
Step 2- Add Gasoline................................................................................................................11
Step 3- Ground the Generator...................................................................................................12
STARTING THE GENERATOR .................................................................................................13
SUBSEQUENT STARTING OF THE GENERATOR...............................................................14
Step 1- Check the Oil................................................................................................................15
Step 2 – Check the Fuel Level..................................................................................................15
Step 3- Ground the Generator...................................................................................................15
USING THE GENERATOR .........................................................................................................16
STOPPING THE GENERATOR .................................................................................................19
MAINTENANCE / CARE .............................................................................................................20
Cleaning the Generator.................................................................................................................20
Checking the Oil...........................................................................................................................20
Changing/ Adding Oil ..................................................................................................................21
Air Cleaner Maintenance..............................................................................................................22
Fuel Filter Cup Cleaning ..............................................................................................................22
Spark Plug Maintenance...............................................................................................................23
Draining the Fuel Tank.................................................................................................................23
STORAGE / TRANSPORT PROCEDURES ..............................................................................24
SPECIFICATIONS ........................................................................................................................25
TROUBLESHOOTING.................................................................................................................26
EXPLODED VIEW AND PARTS LIST ......................................................................................27
WIRING DIAGRAM .....................................................................................................................32
WARRANTY STATEMENT ........................................................................................................34
ii

INTRODUCTION
Thank You for Purchasing a Powerpro Technology TM Product.
.
This manual provides information regarding the safe operation and maintenance of this product.
Every effort has been made to ensure the accuracy of the information in this manual. Powerpro
Technology TM reserves the right to change this product and specifications at any time without prior
notice.
Please keep this manual available to all users during the entire life of the generator.
Special Messages
This manual contains special messages to bring attention to potential safety concerns, generator
damage as well as helpful operating and servicing information. Please read all the information
carefully to avoid injury and machine damage.
Questions? Problems?
DO NOT RETURN TO STORE
Store personnel where the generator was purchased are not trained to handle technical
questions or problems.
In order to answer questions and solve problems in the most efficient and speedy manner,
contact Customer Service at:
[phone] M-F 8-5 CST
NOTICE REGARDING EMISSIONS
Engines that are certified to comply with U.S. EPA emission regulations for SORE (Small Off
Road Equipment), are certified to operate on regular unleaded gasoline, and may include the
following emission control systems: (EM) Engine Modifications and (TWC) Three-Way Catalyst
(if so equipped).
1

SAFETY INFORMATION
Before operating this generator read and observe all warnings, cautions, and instructions on
this sheet, on the generator, and in the Owner’s Manual.
NOTE: The following safety information is not meant to cover all possible conditions and
situations that may occur. Read the entire Owner’s Manual for safety and operating
instructions. Failure to follow instructions and safety information could result in serious
injury or death.
This safety alert symbol is used to identify safety information about hazards that can result in
personal injury.
A signal word (DANGER,WARNING, or CAUTION) is used
with the alert symbol to indicate the likelihood and the potential severity of injury.
In addition, a hazard symbol may be used to represent the type of hazard.
DANGER indicates a hazard, which, if not avoided, will result in death or serious
injury.
WARNING indicates a hazard, which, if not avoided, could result in death or
serious injury.
CAUTION indicates a hazard, which, if not avoided, might result in minor or
moderate injury.
CAUTION, when used without the alert symbol, indicates a situation that could
result in damage to the engine or generator.
SAFETY SYMBOLS AND MEANINGS
2

GENERAL SAFETY PROCEDURES
For any questions regarding the hazard and safety notices listed in this manual or on the
product, please call [phone] M-F 8-5 CST before using the generator.
DANGER: CARBON MONOXIDE. Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison gas you
cannot see or smell. If you can smell the generator exhaust, you are breathing CO.
But even if you cannot smell the exhaust, you could be breathing CO.
xNEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed
areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh air.
xONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-
powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh
air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
WARNING: The exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects, or other reproductive harm.
WARNING: This generator may emit highly
flammable and explosive gasoline vapors, which can
cause severe burns or even death, if ignited. A nearby open flame can lead to
explosion even if not directly in contact with gasoline.
xDo not operate near open flame.
xDo not smoke near generator.
xAlways operate on a firm, level surface.
xAlways turn generator off before refueling. Allow generator to cool for at least 2
minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.
xDo not overfill fuel tank. Gasoline may expand during operation. Do not fill to the
top of the tank. Allow for expansion.
xAlways check for spilled fuel before operating.
xEmpty fuel tank before storing or transporting the generator.
xBefore transporting, turn fuel valve to off and disconnect spark plug wire.
3

WARNING: This generator produces powerful voltage, which can
result in electrocution.
xALWAYS ground the generator before using it (see the “Ground the Generator”
portion of the “GENERATOR PREPARATION” section).
xGenerator should only be plugged into electrical devices, either directly or with an
extension cord. NEVER connect to a building electrical system without a qualified
electrician. Such connections must comply with local electrical laws and codes.
Failure to comply can create a back-feed, which may result in serious injury or death
to utility workers.
xUse a ground fault circuit interrupter (GFCI) in highly conductive areas such as
metal decking or steel work. GFCIs are available in-line with some extension cords.
xDo not use in rainy conditions.
xDo not touch bare wires or receptacles (outlets).
xDo not allow children or non-qualified persons to operate.
WARNING: This generator produces heat when running. Temperatures
near exhaust can exceed 150º F (65º C).
xDo not touch hot surfaces. Pay attention to warning labels on the generator identifying
hot parts of the machine.
xAllow generator to cool down after use before touching engine or areas of the generator
that become hot during use.
CAUTION: Misuse of this generator can damage it or shorten its life.
xUse generator only for its intended purposes.
xOperate only on dry, level surfaces.
xAllow generator to run for several minutes before connecting electrical devices.
xShut off and disconnect any malfunctioning devices from generator.
xDo not exceed the wattage capacity of the generator by plugging in more electrical devices
than the unit can handle.
xDo not turn on electrical devices until after they are connected to the generator.
xTurn off all connected electrical devices before stopping the generator.
xTurn the switch to “OFF” position when the engine is not running.
4

IMPORTANT SAFETY INSTRUCTIONS
xSAVE THESE INSTRUCTIONS – This manual contains important instructions for
Powerpro Technology 4050 generator that should be followed during installation and
maintenance of the generator.
xGenerators vibrate in normal use. During and after the use of the generator, inspect the
generator as well as extension and power supply cords connected to it for damage resulting
from vibration. Have damaged items repaired or replaced as necessary. Do not use plugs or
cords that show signs of damage such as broken or cracked insulation or damaged blades.
xFor power outages, permanently installed stationary generators are better suited for
providing backup power to the home. Even a properly connected portable generator can
become overloaded. This may result in overheating or stressing the generator components,
possibly leading to a generator failure.
xWARNING: When this generator is used to supply a building wiring system:
Generator must be installed by a qualified electrician and connected to a transfer switch as
a separately derived system in accordance with the National Electrical Code, NFPA 70.
The generator shall be connected to a transfer switch that switches all conductors other than
the equipment grounding conductor. The frame of the generator shall be connected to an
approved grounding electrode.
5

In addition to the previous safety notices, please become familiar with the safety and hazard
markings on the generator.
6

PACKAGE CONTENTS
Your generator comes with the items listed below. Please check to see that all of the following
items are included with your generator.
If there are any damaged or missing items, please call [phone] M-F 8-5 CST for
customer service. DO NOT RETURN TO STORE. Store personnel are not trained to assist
with damaged or missing items.
ITEM LIST
NEMA L5-30 locking plug for 120V devices
Spark plug wrench
Mobility kit
wrenches
7

GENERATOR COMPONENTS
Please familiarize yourself with the locations and functions of the various components and controls
of your generator.
(1)Air Cleaner- A removable, cleanable, sponge-
like element that limits the amount of dirt pulled
into the engine.
(2)Fuel Valve- Allows fuel to enter engine.
(3)Fuel Filter Cup- Traps dirt and water from fuel
before it enters the engine.
(4)Recoil Starter- Pull-cord for starting engine.
(5)Engine Switch- To start/stop engine.
(6)Oil Fill and Dipstick- Location for checking and
filling engine oil.
(7)Circuit Reset Button-Reset button that protect
the generator from electrical overload.
(8)120 Volt AC Duplex Receptacle- To connect
electrical devices that run 120 Volt, 60 Hz, single
phase, AC current, rated 20 amps
(9)120 Volt AC Twist lock Receptacle- To connect
electrical devices that run 120 Volt, 60 Hz, single
phase, AC current, rated 30 amps.
(10) Ground Terminal- Connect grounding wires here
to properly ground unit.
(11) Engine Hourmeter- Tracks hours of operation.
(12) Fuel Gauge- Indicates the amount of fuel in the
tank.
(13) Fuel Cap- Access to the fuel tank for adding fuel.
(14) Choke Lever- Adjusts the amount of air let into
the engine.
(15) Wheel
(16) Muffler with Spark Arrester- Reduces engine
noise.
(17) Spark Plug- Provides proper engine ignition.
(18) Handle
8

ASSEMBLY
Step 1 – Wheel Installation
1. Blocking up the muffler side of the generator, assemble the axle to the frame.
2. Slide the wheel and washer onto the axle, with the offset of the wheel hub against the frame.
3. Secure the wheel to the axle with the cotter pin.
4. Repeat above instructions for the remaining wheel.
Step 2 –Foot Installation
1. Blocking up the engine side of the generator, assemble the rubber foot to the frame.
2. Repeat above instructions for the remaining foot.
Step 3 –Handle Installation
1. Assemble the handle to the frame (align with hole in tubing). Slide the bolt through handle,
frame and washer and secure with the nut. Tighten until handle is securely clamped to the
frame.
2. Repeat above instruction for remaining handle.
GENERATOR PREPARATION
Using the Generator for the First Time
The following section describes steps necessary to prepare the generator for use. If after
reading this section, you are unsure about how to perform any of the steps please call (800)
232-1195 M-F 8-5 CST for customer service. Failure to perform these steps properly can
damage the generator or shorten its life.
9

Step 1 - Fill Oil
The generator is shipped without oil. User must add the proper amount of oil before operating the
generator for the first time. The oil capacity of the engine crankcase is 20 fluid oz.
Select good quality detergent oil bearing the American Petroleum Institute (API) service
classifications SJ, SL, or SM. (Synthetic oils may be used.) Use the SAE viscosity grade
of oil from the following chart that matches the starting temperature anticipated before
the next oil changes.
Figure 1- Engine oil recommendations
To fill oil to the crankcase, follow these steps:
1. Make sure the generator is on a level surface. Tilting the generator to assist in filling will
cause oil to flow into engine areas and will cause damage. Keep generator level!
2. Remove the oil filler/dipstick cap from the engine as shown in figure 2.
3. Using a funnel, add the appropriate type and amount of oil into the crankcase. The
crankcase is full when the oil level has reached the second thread from the lip of the
opening (see figure 3).
4. Check for oil leaks. Reinstall oil filler cap before starting engine.
Figure 2- Unscrewing the oil cap Figure 3- filling oil
10

Step 2- Add Gasoline
WARNING: This generator may emit highly
flammable and explosive gasoline vapors, which can
cause severe burns or even death if ignited. A nearby
open flame can lead to explosion even if not directly in contact with gasoline.
xDo not operate near open flame.
xDo not smoke near generator.
xAlways operate on a firm, level surface.
xAlways turn generator off before refueling. Allow generator to cool for at least 2
minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.
xDo not overfill fuel tank. Gasoline may expand during operation. Do not fill to the
top of the tank. Allow for expansion.
xAlways check for spilled fuel before operating. Clean up any spilled fuel before
starting.
xEmpty fuel tank before storing or transporting the generator.
xBefore transporting, turn fuel valve to off position and disconnect spark plug wire.
Use fresh (within 30 days from purchase), unleaded gasoline with a minimum 87 octane rating. Do
not use gasoline which contains Methanol. Do not mix oil with gasoline.
To add gasoline, follow these steps:
1. Make sure the generator is on a level surface.
2. Unscrew fuel cap and set aside (NOTE: the fuel cap may be tight and hard to unscrew).
3. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. Please refer to the
chart in figure 4 for the fuel capacity. The fuel gauge on the top of the generator indicates
how much gasoline is in the generator fuel tank. NOTE: Do not fill the fuel tank to the
very top. Gasoline will expand and spill over during use even with the fuel cap in place.
4. Reinstall fuel cap and wipe off any spilled gasoline with a dry cloth.
IMPORTANT:
xNever use an oil/gasoline mixture.
xNever use old gasoline.
xAvoid letting dirt or water into the fuel tank.
xGasoline can age in the tank and make it hard to start up the generator in the future. Never
store generator for extended periods of time with fuel in the tank.
Model number 4050
Fuel tank
capacity
12 L (3.1 gallons)
Figure 4- Fuel Tank Capacity
11

Step 3- Ground the Generator
WARNING: Failure to properly ground the generator can result in
electrocution.
Ground the generator by tightening the grounding nut against a grounding wire (see figure 5). A
generally acceptable grounding wire is a No. 12 AWG (American Wire Gauge) stranded copper
wire. This grounding wire should be connected at the other end to a copper or brass grounding rod
that is driven into the earth. Wire and grounding rod are not included in generator contents.
Grounding codes can vary by location. Please contact a local electrician to check the grounding
regulations for your area.
Figure 5- Grounding nut location
NOTE: After completing the 3-step Generator Preparation, the generator is ready to be
started.
12

STARTING THE GENERATOR
Before starting the generator, make sure you have read and performed the steps in the
“GENERATOR PREPARATION” section of this manual. If you are unsure about how to
perform any of the steps in this manual please call [phone] M-F 8-5 CST for
customer service.
DANGER: CARBON MONOXIDE. Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison gas you
cannot see or smell. If you can smell the generator exhaust, you are breathing CO.
But even if you cannot smell the exhaust, you could be breathing CO.
xNEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed
areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh air.
xONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
Even if you use a generator correctly, CO may leak into the home. ALWAYS use a battery-
powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh
air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.
WARNING: This generator produces powerful voltage, which can result in
electrocution.
xALWAYS ground the generator before using it (see the “Ground the Generator”
portion of the “GENERATOR PREPARATION” section).
xGenerator should only be plugged into electrical devices, either directly or with an
extension cord. NEVER connect to a building electrical system without a qualified
electrician. Such connections must comply with local electrical laws and codes.
Failure to comply can create a back-feed, which may result in serious injury or death
to utility workers.
xUse a ground fault circuit interrupter (GFCI) in highly conductive areas such as
metal decking or steel work. GFCIs are available in-line with some extension cords.
xDo not use in rainy or wet conditions.
xDo not touch bare wires or receptacles (outlets).
xDo not allow children or non-qualified persons to operate.
CAUTION: Disconnect all electrical loads from the generator before
attempting to start.
13

To start your generator, perform the following steps:
1. No electrical devices should be connected to the generator during starting. Devices can
make it difficult for the engine to start.
2. Check that the generator is properly grounded (see “Ground the Generator”).
3. Check the oil and fuel levels.
4. Turn the fuel valve to the “ON” position (see figure 6).
5. Move the choke lever to the “CLOSED” position (see figure 7).
6. Set the engine switch to the “ON” position.
7. Pull on the recoil starter grip slowly until a slight resistance is felt (see figure 8). Then pull
quickly to start the engine. Return cord gently into the machine. Never allow the cord to
snap back.
8. If engine fails to start, repeat step 7. NOTE: After repeated failed attempts to start the
engine, please consult the troubleshooting guide before attempting again. If problems
persist please call [phone] M-F 8-5 CST.
9. Once the engine has started, slowly return the choke lever all the way to the “OPEN”
position.
10. Allow the generator to run for several minutes before attempting to connect any electrical
devices. This allows the generator to stabilize its speed and temperature.
Figure 6- Fuel Valve in the “on” position
Figure 8- Pulling the start cord
Figure 7- Push choke left to close. Pull
lever right to open.
SUBSEQUENT STARTING OF THE GENERATOR
If this is not the first time using the generator, user should take the following steps to prepare it for
operation.
IMPORTANT: At this point the user should be familiar with the procedures described in the
section titled “Using the Generator for the First Time.” If the user has not yet read this
section, go back and read it now.
14

Step 1- Check the Oil
Oil consumption is normal during generator usage. The generator is equipped with a low-oil
shutoff to protect it from damage. The oil level in the engine should be checked before each use to
ensure that the engine crankcase contains sufficient lubricant.
To check or add oil, follow these steps:
1. Make sure the generator is on a level surface. Clean around oil fill.
2. Remove the oil filler/dipstick cap and check oil level.
3. If oil level is below the second thread from the lip of the oil fill opening, slowly add oil
until the engine crankcase is filled.
4. Reinstall and tighten oil filler cap before starting the engine. .
Step 2 – Check the Fuel Level
Before starting the generator, check to see that there is sufficient gasoline in the fuel tank. The fuel
gauge on top of the generator will indicate the fuel level in the tank. Add gasoline if necessary but
leave sufficient room in tank for expansion.
WARNING: This generator may emit highly
flammable and explosive gasoline vapors, which can
cause severe burns or even death if ignited. A nearby
open flame can lead to explosion even if not directly in contact with fuel.
xDo not operate near open flame.
xDo not smoke near generator.
xAlways operate on a firm, level surface.
xAlways turn generator off before refueling. Allow generator to cool for at least 2
minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.
xDo not overfill fuel tank. Gasoline may expand during operation. Do not fill to the
top of the tank. Allow for expansion.
xAlways check for spilled fuel before operating. Clean up any spilled fuel before
starting.
xEmpty fuel tank before storing or transporting the generator.
xBefore transporting, turn fuel valve to off and disconnect spark plug wire.
IMPORTANT:
xUse only UNLEADED gasoline with an octane rating of 87 or higher.
xDo not use old gasoline.
xNever use an oil/gasoline mixture.
xAvoid letting dirt or water into the fuel tank.
Step 3- Ground the Generator
WARNING: Failure to properly ground the generator can result in
electrocution.
Ground the generator by tightening the grounding nut on the front control panel against a
grounding wire. (Figure 5) A generally acceptable grounding wire is a No. 12 AWG (American
15

Wire Gauge) stranded copper wire. This grounding wire should be connected at the other end to a
copper, brass, or steel-grounding rod that is driven into the earth. Wire and grounding rod are not
included in generator contents.
Grounding codes can vary by location. Contact a local electrician for area codes.
USING THE GENERATOR
WARNING: When this generator is used to supply a building wiring system:
Generator must be installed by a qualified electrician and connected to a transfer switch
as a separately derived system in accordance with the National Electrical Code, NFPA 70.
The generator shall be connected to a transfer switch that switches all conductors other than the
equipment grounding conductor. The frame of the generator shall be connected to an approved
grounding electrode.
For power outages, permanently installed stationary generators are better suited for providing
backup power to the home. Even a properly connected portable generator can become overloaded.
This may result in overheating or stressing the generator components, possibly leading to a
generator failure.
Before connecting electrical devices, allow the generator to run for a few minutes to stabilize the
speed and voltage output.
CAUTION: Become familiar with the markings on the panel before connecting electrical devices.
Connect electrical devices running on AC current according to their wattage requirements. The
chart in figure 9 shows the running and starting wattage of your generator according to its model
number.
NOTE: Although the overall running wattage of the machine is 3250 Watts, it is not recommended
that you attempt to draw more than 2400 Watts (20 A) from any ONE of the 120 Volt duplex
receptacles. The duplex receptacles are rated 20amps.
The running wattage corresponds to the maximum wattage the generator can output on a
continuous basis.
The starting wattage corresponds to the maximum amount of power the generator can output for a
short period of time. Many electrical devices such as refrigerators require short bursts of extra
power, in addition to the running wattage listed by the device, to stop and start their motors. The
starting wattage ability of the generator covers this extra power requirement.
Model Number Running Wattage Starting Watt
4050 3250 4050
Figure 9- generator wattage by model number.
The total running wattage requirement of the electrical devices connected to the generator should
not exceed the running wattage of the generator itself. To calculate the total wattage requirement
of the electrical devices you wish to connect, find the rated (or running) wattage of each device.
This number should be listed somewhere on the device or in its instruction manual. If you cannot
find this wattage, you may calculate it by multiplying the Voltage requirement by the Amperage
drawn:
Watts= Volts x Amperes
16