Pramac S3100 User manual

G005447 Rev.04 1
GENERATOR MODELS
S3100 –S5000 –S7500 –S10000 –S12000
S3100 S12000
MODEL & SERIAL NUMBER
Enter the Model and Serial numbers of your generator in the spaces provided below. Retain these numbers for future
reference. The Model and Serial numbers are located on the generator data plate on the alternator case or generator
frame, along with other important information. This manual contains important safety information. This manual must be
available to any personnel who operate or maintain this machine. Do not destroy.
Model Number
Serial Number
GENERATOR USER
MANUAL
Power Systems

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CONTACT INFORMATION
For Parts, Service or your nearest distributor call:
U.S. and Canada
[phone]
Latin America
[phone]

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Table of Contents
ENGLISH INSTRUCTIONS.............................................................................................................5
SAFETY....................................................................................................................................................................... 5
GENERAL INFORMATION .................................................................................................................................... 5
SAFETY RULES ...................................................................................................................................................... 5
Limited warranty....................................................................................................................................................... 7
WARRANTY REGISTRATION................................................................................................................................... 8
OPERATION...............................................................................................................................................................11
GENERAL INFORMATION ...................................................................................................................................11
BEFORE START-UP...............................................................................................................................................11
OPERATION...........................................................................................................................................................11
GENERATOR APPLICATION................................................................................................................................13
LOADING YOUR GENERATOR SET....................................................................................................................13
ENGINE LIMITATIONS ON GENERATOR PERFORMANCE..............................................................................13
GENERATOR CLEANING.....................................................................................................................................13
GENERAL STORAGE GUIDELINES.....................................................................................................................14
RECEPTACLE DETAILS........................................................................................................................................14
GENERAL MAINTENANCE......................................................................................................................................14
Engine Specifications and Capacities........................................................................................................................14
Oil Selection.............................................................................................................................................................15
Engine Maintenance Schedule ..................................................................................................................................15
DAILY INSPECTION..............................................................................................................................................16
FAULT FINDING GUIDE.......................................................................................................................................16
PARTS ORDERING....................................................................................................................................................17
GENERATOR PARTS LISTS.........................................................................................................19
S3100 GENERATOR PART LISTS.............................................................................................................................19
S5000 GENERATOR PART LISTS.............................................................................................................................21
S7500 GENERATOR PART LISTS.............................................................................................................................24
WHEEL KIT –S5000 AND S7500 ..............................................................................................................................26
BATTERY INSTALLATION –S7500.........................................................................................................................27
S10000 GENERATOR PART LISTS...........................................................................................................................28
S12000 GENERATOR PART LISTS...........................................................................................................................31
WIRING SCHEMATICS.................................................................................................................34
FRENCH INSTRUCTIONS ............................................................................................................37
SÉCURITÉ..................................................................................................................................................................37
INFORMATION GENERALE.................................................................................................................................37
règles de sécurité......................................................................................................................................................37
ENREGISTREMENT DE LA GARANTIE..................................................................................................................39
GARANTIE LIMITÉE.................................................................................................................................................42
UTILISATION ............................................................................................................................................................43
INFORMATION GÉNÉRALE.................................................................................................................................43
AVANT LE DÉMARRAGE.....................................................................................................................................43
UTILISATION.........................................................................................................................................................43
USAGE DE LA GÉNÉRATRICE.............................................................................................................................45
charger votre génératrice...........................................................................................................................................45
Limite du moteur sur la performance de la génératrice...............................................................................................45
Nettoyage de la génératrice.......................................................................................................................................45
Règles générales d’entretien......................................................................................................................................46

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Détails des réceptacles (prise femelle).......................................................................................................................46
ENTRETIEN GÉNÉRAL.............................................................................................................................................47
spécifications du moteur et capacités.........................................................................................................................47
SÉlection d’huile......................................................................................................................................................47
horaire d’entretien du moteur....................................................................................................................................48
INSPECTION quotidienne........................................................................................................................................48
guide des failles........................................................................................................................................................48
COMMANDE DES PIÈCES........................................................................................................................................49
SPANISH INSTRUCTIONS............................................................................................................51
SEGURIDAD ..............................................................................................................................................................51
informacion GENERAL ...........................................................................................................................................51
reglas de seguridad...................................................................................................................................................51
REGISTRACION DE GARANTIA..............................................................................................................................53
GARANTIA LIMITADA.........................................................................................................................................56
FUNCIONAMIENTO..................................................................................................................................................57
INFORMACIÓN GENERAL...................................................................................................................................57
comenzando.............................................................................................................................................................57
funcionamiento.........................................................................................................................................................57
APLICACIÓN del generador....................................................................................................................................58
Carga DE su generador.............................................................................................................................................59
limitaciones del motor y rendimiento del generador...................................................................................................59
limpieza del generador..............................................................................................................................................59
detalles de receptaculos ............................................................................................................................................60
MANTENIMIENTO GENERAL.................................................................................................................................61
especificaciones y capacidades del motor..................................................................................................................61
Selection de aceite....................................................................................................................................................61
programa de mantenimiento de motor .......................................................................................................................62
inspeccion diaria.......................................................................................................................................................62
Guia para encontrar fallas.........................................................................................................................................62
ORDENANDO PIEZAS...........................................................................................................................................63
All information provided in this manual is believed to be correct at the time of printing. The manufacturer reserves the right to correct any
errors and omissions.

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ENGLISH INSTRUCTIONS
SAFETY
GENERAL INFORMATION
This manual is provided so that your generator may
be properly, safely and effectively applied and
operated. Please read and understand all aspects
of this manual before operating your generator set.
Please also read and understand the
documentation supplied with this generator
regarding the engine and alternator. Keep this
documentation in a safe and accessible place so
that reference can be made as needed. All
operators, users and subsequent owners of this
generator must read and understand all aspects of
this documentation before operating this product.
THIS SYMBOL IS USED THROUGHOUT YOUR
OWNER’S MANUAL TO BRING ATTENTION TO
IMPORTANT SAFETY INSTRUCTIONS. THE WORDS
DANGER, WARNING, AND CAUTION ACCOMPANY THIS
SYMBOL AND REFLECT THE POTENTIAL SEVERITY OF
INJURY OR DAMAGE. FAILURE TO FOLLOW SAFETY
INSTRUCTIONS COULD ENDANGER YOU OR OTHERS AND
RESULT IN PERSONAL INJURY OR DEATH. READ AND
UNDERSTAND ALL SAFETY INSTRUCTIONS BEFORE
OPERATION.
SAFETY RULES
SPARK ARRESTING MUFFLER
Certain States and Jurisdictions require that engine
driven equipment be fitted with spark arresting mufflers.
Depending on the generator model, spark-arresting
mufflers may or may not be fitted. If spark-arresting
mufflers are required for your location and the generator
muffler is not spark arresting, contact your local dealer
for instructions for a retrofit.
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system for this generator
complies with the standards set forth by the California
Air Resources Board (CARB) and the Environmental
Protection Agency (EPA). The respective engine
manufacturers administer warranties for the exhaust
emission system. Refer to the engine documentation for
warranty information.
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
ELECTROCUTION
DANGER:THIS GENERATOR SET PRODUCES
ELECTRICAL CURRENT. THEREFORE, SAFETY
GUIDELINES MUST BE FOLLOWED. IMPROPER
USE OF THIS GENERATOR CAN RESULT IN
ELECTROCUTION, INJURY OR DEATH. DO NOT OPERATE,
SERVICE OR REPAIR THIS GENERATOR UNLESS FULLY
QUALIFIED TO DO SO.
DANGER: THIS GENERATOR SET IS DESIGNED
TO BE OPERATED IN DRY CONDITIONS AND FOR
OUTDOOR AREAS ONLY. NEVER OPERATE THIS
GENERATOR INDOORS. NEVER OPERATE THIS
GENERATOR IN RAIN, SNOW, SLEET OR GENERALLY WET
CONDITIONS. DAMAGE TO THE GENERATOR, BODILY
INJURY, OR DEATH COULD RESULT FROM
ELECTROCUTION.
DANGER: IF THIS GENERATOR IS CONNECTED TO
A BUILDING, HOME, BUSINESS, OR ANY OTHER
ELECTRICAL CIRCUIT NORMALLY FED BY UTILITY
POWER, STEPS MUST BE TAKEN TO INSURE THE
GENERATOR OUTPUT AND THE UTILITY POWER ARE
POSITIVELY ISOLATED. THIS IS TYPICALLY
ACCOMPLISHED THROUGH THE USE OF A PROPERLY
INSTALLED TRANSFER SWITCH. FAILURE TO ISOLATE THE
UTILITY AND GENERATOR ELECTRICAL SYSTEMS WILL
RESULT IN GENERATOR DAMAGE AND COULD RESULT IN
INJURY OR DEATH TO UTILITY WORKERS DUE TO THE
BACKFEED OF ELECTRICITY.
DANGER: DO NOT MODIFY OR MISAPPLY YOUR
GENERATOR SET. OPERATION OF THE
GENERATOR OTHER THAN INTENDED COULD
RESULT IN GENERATOR SET DAMAGE, BODILY INJURY OR
EVEN DEATH FROM ELECTROCUTION.
DANGER: NEVER TOUCH A RECEPTACLE OR
BARE WIRE. ELECTROCUTION OR SHOCK
COULD RESULT.
FIRE
WARNING: ALWAYS INSURE THAT AT LEAST 6
FEET OF CLEARANCE ON ALL SIDES OF THE
GENERATOR ARE MAINTAINED DURING
OPERATION. FAILURE TO MAINTAIN PROPER CLEARANCE
COULD DAMAGE YOUR GENERATOR AND POTENTIALLY
LEAD TO FIRES.
WARNING: GASOLINE IS HIGHLY FLAMMABLE
AND ITS VAPORS ARE EXPLOSIVE. FAILURE TO
PROPERLY HANDLE GASOLINE CAN RESULT IN
EXPLOSION OR FIRE. DO NOT PERMIT SMOKING WITHIN
50FT OF THIS GENERATOR SET.
WARNING: NEVER REFILL A HOT GENERATOR
WITH FUEL. NEVER REFILL THE GENERATOR
WHILE IT IS RUNNING. SPILLAGE ONTO THE
ENGINE OR GENERATOR COULD RESULT IN AN
EXPLOSION OR FIRE. ALWAYS ALLOW THE GENERATOR
SET TO COOL BEFORE REFILLING.

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WARNING: DO NOT STORE THIS GENERATOR
SET IN ANY LOCATION WHERE GASOLINE
FUMES COULD POTENTIALLY COME INTO
CONTACT WITH SPARKS, A PILOT LIGHT OR AN OPEN
FLAME. IMPROPER STORAGE OF THIS GENERATOR
COULD RESULT IN AN EXPLOSION OR FIRE.
EXHAUST GASES
DANGER: DO NOT OPERATE THIS GENERATOR
WITHIN AN ENCLOSED AREA. THE EXHAUST GASES OF
THIS GENERATOR EMIT “DEADLY”CARBON MONOXIDE.
EXPOSURE TO CARBON MONOXIDE CAN CAUSE CARBON
MONOXIDE POISONING, HEADACHES, NAUSEA, SEVERE
SICKNESS OR DEATH.
BURNS AND SCALDS
CAUTION: KEEP HANDS, BODY PARTS, HAIR AND
CLOTHING AWAY FROM THE “HOT”PARTS OF THE
GENERATOR SET DURING AND AFTER OPERATION. THE
EXHAUST SYSTEM, AND THE GENERATOR IN GENERAL,
CAN REMAIN VERY HOT EVEN AFTER BEING SHUT DOWN.
ENVIRONMENTAL PROTECTION
CAUTION: INSPECT THE EXHAUST SYSTEM
REGULARLY TO ENSURE IT IS FUNCTIONING PROPERLY.
LEAKY EXHAUST SYSTEMS WILL INCREASE NOISE
LEVELS.
CAUTION: DIRECT THE “LOUD”SIDES OF THE
GENERATOR INTO OPEN SPACES AVOIDING
REVERBERATION FROM WALLS OR BUILDINGS
THUS AMPLIFYING THE SOUND.
CAUTION: INSPECT THE SPARK ARRESTOR
PERIODICALLY. SPARK ARRESTORS ARE
REQUIRED IN SOME AREAS AND MINIMIZE THE
RISK OF FIRE FROM SPARKS EMMITTED FROM THE
EXHAUST.
CAUTION: NEVER DRAIN OR DISPOSE OF
ENGINE OIL INTO THE GROUND OR DOMESTIC
WASTE WATER SYSTEMS.
GENERAL SAFETY
Always follow National and Local electrical codes
pertaining to generators. All local and national codes
supersede rules or information provided in this manual.
CAUTION: DO NOT OPERATE THIS GENERATOR
IF THE AMBIENT TEMPERATURE EXCEEDS
104ºF/40ºC.
CAUTION: DO NOT EXCEED THE RATED CAPACITY
OF THE GENERATOR. THE TOTAL ELECTRICAL
LOADS AT EACH OUTLET MUST BE ADDED TO
DETERMINE THE TOTAL ELECTRICAL LOAD. THE TOTAL
LOAD MUST NOT EXCEED THE RATED CAPACITY OF THE
GENERATOR. IF THE DRIVEN APPARATUS DOES NOT LIST
WATTAGE, BUT ONLY AMPERAGE, WATTAGE MAY BE
DETERMINED BY MULTIPLYING AMPERAGE TIMES
VOLTAGE (WATTS = AMPS X VOLTS).
CAUTION: DO NOT TAMPER WITH THE ENGINE-GOVERNED
SPEED. THE GENERATOR OPERATES AT A NOMINAL
SPEED OF 3600 RPM. INCREASES IN SPEED OVER THE
3600 RPM NOMINAL WILL INCREASE THE CHANCE OF
PERSONAL INJURY DUE TO ROTATIONAL STRESSES ON
THE ROTATING MEMBERS. OPERATION OF THE
GENERATOR AT SPEEDS BELOW THE NOMINAL 3600 RPM
COULD CAUSE DAMAGE TO THE GENERATOR OR
DRIVEN APPARATUS DUE TO LOW VOLTAGE
OUTPUT.
WARNING: REFER TO LOCAL AND NATIONAL ELECTRICAL
CODES TO DETERMINE GROUNDING REQUIREMENTS AS
THIS CAN VARY PER APPLICATION. THE GENERATOR IS
GROUNDED INTERNALLY NEUTRAL TO FRAME. WHERE
APPLICATIONS REQUIRE EXTERNAL GROUNDING, A
CONNECTION MUST BE MADE FROM THE GENERATOR TO
A SOLID EARTH GROUND. A CONTINUOUS LENGTH OF
SPLICE-FREE COPPER CABLE, NO SMALLER
THAN 6 AWG, SHALL BE USED FOR THE
CONDUCTOR.
When moving or transporting this generator, take
proper precautions to avoid fuel spillage. Further,
always use common sense when lifting this
generator. An adequate number of people and
proper lifting methods must be used.
Do not cover the generator while it is running or
immediately after shutdown. Always allow time to
cool down before covering.
Do not operate this generator unless it is in good
mechanical and electrical condition.
Always keep hands, body parts, hair and clothing
well away from the rotating parts of the generator.
Do not start this generator with connected devices
turned “ON”. Always make sure that connected
devices are disconnected from the generator or
turned “OFF”before starting the generator.
Generators operating on job or construction sites
may be required to have GFCI (Ground Fault Circuit
Interrupters) receptacles.
Use only grounded extension cords in good
condition and make sure that the wire size within the
extension cords is of sufficient size to safely carry
the surge output of the generator.
Never handle extension cords or electrical circuits if
standing in water or if standing in a damp area.
BATTERY SAFETY
WARNING: STORAGE BATTERIES PRODUCE AND
RELEASE EXPLOSIVE HYDROGEN GAS WHEN
CHARGING. THE SLIGHTEST SPARK, FLAME OR
BURNING ASH CAN IGNITE THESE GASES CAUSING A
SERIOUS EXPLOSION THAT COULD RESULT IN BLINDNESS
OR OTHER SERIOUS INJURIES. WEAR EYE PROTECTION,
RUBBER APRON AND RUBBER GLOVES WHEN WORKING
AROUND A BATTERY OR PERFORMING BATTERY SERVICE.
BATTERY FLUID IS AN EXTREMELY CAUSTIC SULFURIC
ACID, WHICH CAN CAUSE SEVERE BURNS. ALWAYS
DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM
THE BATTERY BEFORE PERFORMING BATTERY SERVICE
OR BEFORE PERFORMING ANY ELECTRICAL SERVICE ON
THE GENERATOR OR ENGINE.

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LIMITED WARRANTY
A. PRAMAC electrical generating sets originally sold by PRAMAC Industries, Inc. or an authorized Distributor/ Dealer
thereof, are covered by a limited warranty for a period of 12 months. The Warranty period begins on the date of
purchase by the end user, 2 days after shipment to the end user by the PRAMAC Distributor/ Dealer, or 12 months from
the date of original invoice by PRAMAC Industries, Inc.-whichever occurs first. PRAMAC Industries, Inc. warrants their
PRAMAC products to be free of defects in materials and workmanship for the time period shown above and within the
limitations presented in the following. This PRAMAC Limited Warranty does not cover components or assemblies
manufactured by other organizations, including, but not limited to –engine, alternator, receptacles, etc. Warranties for
items and assemblies not manufactured by PRAMAC Industries, Inc. are covered under the warranties of the respective
manufacturers of those products. Documentation concerning the warranty policies of items not manufactured by
PRAMAC Industries, Inc., but included as part of the PRAMAC electrical generator is included within the generator
documentation.
These warranties are in lieu of and exclude all other warranties of merchantability, fitness, or otherwise, express or
implied. There are no warranties extending beyond the description on the face thereof. The sole obligation of PRAMAC
Industries, Inc. (Seller) shall be to repair or replace any components thereof which are proved to be other than
warranted. PRAMAC Industries, Inc. shall have the sole right to determine whether such goods shall be repaired or
replaced. This remedy of repair or replacement is in lieu of all other remedies, and it is agreed that no other claim may
be made by the Buyer. Buyer and Seller agree that the sole purpose of this remedy is to provide the Buyer a
satisfactory product under the contract. It is further agreed that in no event shall the Seller be liable for incidental or
consequential damages arising from any breach of warranty. If goods are claimed to be other than as warranted, Seller
or Sellers Authorized Agent, upon notice promptly given, will issue shipping instructions for return to the Seller or
Sellers authorized Agent (transportation costs to be born by Buyer) the goods or components, and if goods are proven
to be other than as warranted, replacement or repaired components will be shipped (cheapest way) to the Buyer with
transportation costs borne by the Seller. PRAMAC Industries, Inc. reserves absolute and final decision power regarding
the warrantability of any and all failed components or parts. Some states do not allow limitations on how long an implied
warranty lasts, and some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also
have other rights that vary from state to state.
B. All warranties of merchantability, fitness or otherwise, whether express or implied, shall not extend to any goods or
parts thereof which have been: subject to misuse or neglect, damaged by accident, rendered defective by reason of
improper handling or application, damaged or rendered defective due to tampering of factory set adjustments, damaged
due to shipment, damaged due to lack of maintenance, damaged due to collision, impact or shock loads, damaged due
to corrosion/ rust or damaged due to overload. Further, any modifications to the intended and original designed use of
the PRAMAC electrical generator will negate all warranties. Seller does not accept any liability for normal wear and tear,
nor for charges for repairs or replacements made without authority, nor contingent liability of any kind.
C. YOUR WARRANTY RESPONSIBILITIES: You are responsible for the performance of all maintenance including the
use of approved fluids. Upon first indication of a problem, you are to cease operation of your PRAMACelectrical
generator and report the problem to your Authorized PRAMAC Distributor/ Dealer. Upon request, you will be required to
produce proof of purchase and other pertinent information. Your Authorized PRAMAC Distributor/ Dealer will instruct
you regarding transportation (prepaid by buyer) of your PRAMAC electrical generator to the Authorized Distributor/
Dealer location or arrange for shipment (prepaid by buyer) of the failed components to the Authorized Distributor/
Dealer for warranty inspection. The name, address and telephone number of your local PRAMAC Distributor/ Dealer or
authorized service facility may be obtained by contacting PRAMAC Industries, Inc. at [phone].
JANUARY 01, 2002

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WARRANTY REGISTRATION
Complete Machine Registration
Fill out the Warranty Registration Form in this section, keep a copy for your records
and mail form to:
PRAMAC INDUSTRIES INC.
1100 North Cobb Parkway, Suite C
MARIETTA,GA 30062-2416 - USA
Attn: Warranty Department
Note: Completion of this form within 30 days of purchase validates the warranty.

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Registered To
First Name Last Name
Address
City State Zip Code
Country Telephone Email
User Information
Is this your first purchase of a Pramac product?
Yes
No
Why did you select this product? (check all appropriate boxes)
Salesman
Recommendation
Brand Recognition
Quality Price
Would you like to receive information about other Pramac products? (check all appropriate boxes)
Stationary Generator
Portable Generator Material Handling Pressure Washers
Purchase From Store Internet(list website
below) Other
Purchased From
Address
City State
Zip Date of purchase
Product Details
Model Number
Serial Number
Are you satisfied with the product you purchased? Yes No
When you need to replace your machine will you consider another Pramac product? Yes No
SERVICING DISTRIBUTOR/USER ACKNOWLEDGEMENT
1. The Purchaser has been instructed and/or has read the manual and understands proper preventative
maintenance, general operation and safety precautions.
2. The warranty and limitation of liability has been reviewed and understood by the owner/user.
3. Pramac Industries reserves the right to make design changes or modifications of Pramac products at
anytime without incurring any obligation to make similar changes or modifications on previously sold units.

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-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- fold -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
PRAMAC INDUSTRIES INC.
1100 North Cobb Parkway, Suite C
MARIETTA,GA 30062-2416 - USA
Attn: Warranty Department
Place
Stamp
Here

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OPERATION
GENERAL INFORMATION
This manual has been prepared to acquaint you with the operation and maintenance of this product. Study the
information provided carefully to avoid problems associated with improper application or maintenance. Upon
receipt of your generator, verify that it is complete and in good condition.
The generator is comprised of a 4 stroke, air-cooled engine directly coupled to a 2 pole alternator producing
either 125VAC or 125/250VAC depending on model. The no-load speed is approximately 3750rpm with the
speed under load going to approximately 3600rpm thus producing a frequency of 60Hz.
INITIAL INSPECTION
Upon receiving your generator set, inspect the product to
make sure it is complete and in good condition. Handle
with care and place in a suitable site for storage or
operation.
GROUND CONNECTION
The generator can be grounded to earth to reduce the
chance of electrical shock. To do this you will need a
grounding rod and an appropriately sized copper ground
wire. Drive the ground rod into the earth, connect one end
of the copper wire to the rod and connect the other end to
the external ground connection on the generator set. This
is a general explanation, consult National and Local
electrical codes to ensure compliance.
BEFORE START-UP
ENGINE FUEL
Use Unleaded Gasoline with minimum Octane 86. Check
the fuel gauge beside the fuel fill and add as necessary.
ENGINE OIL
The engine manual or other information provided by the
engine manufacturer supersedes data provided here.
Proper oil grade varies with climate. The grade listed in
the table is typically a good grade but consult the engine
manual to verify proper grade. The oil fill ports are located
on both sides of the engine. The gray filler cap has an
integral dipstick. Add the proper amount of oil and check
the level using the dipstick. NOTE: The dipstick should be
placed into the filler opening but not screwed in to check
the level.
ENGINE HP Capacity Grade
Honda GX160 5.5 0.63 qt API SJ SAE 10W-30
Honda GX270 9 1.16 qt API SJ SAE 10W-30
Honda GX390 13 1.16 qt API SJ SAE 10W-30
Honda GX610 18 1.58 qt API SJ SAE 10W-30
Honda GX620 20 1.58 qt API SJ SAE 10W-30
STARTING BATTERY (Electric Start Models Only)
It is rated at 12V-18AH (35AH for S10000/12000). The
battery is fully charged if a voltage of 13.7VDC is
measured across the terminals using a DC Voltmeter.
POSITIONING
Place the generator set on a flat and solid
surface to prevent it from sinking.
The surface should not be more than 17from
horizontal in any direction for the engine to
lubricate properly.
Keep fuel, oil or other explosives at a safe
distance from the generator set.
Select a site that is well ventilated and protected
from the weather.
When indoor use cannot be avoided, provide
excellent ventilation for exhaust, cooling, and
combustion requirements.
Place the generator set safely away from people
and animals.
OPERATION
Check the engine oil before each use. Never
operate the generator set with insufficient oil.
GENERATOR SET OVERLOAD
Do not exceed the rated load of the generator set when
operating continuously. Before connecting items to the
generator set, determine the total electrical requirements
of the products to be connected. The requirement of each
item is generally given on the manufacturer’s nameplate.
Below is a list of commonly used items and typical
requirements. Use this list as a guideline only if no other
data is available.

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GENERAL WATTAGE GUIDE
Item Running Watts
Air Conditioner (12000 Btu) (*) .........................1750
Air Compressor (1/2 hp) (*) ..............................1400
Air Compressor (3/4 hp) (*) ..............................1800
Air Compressor (1 hp) (*).................................2000
Battery Charger (25A)........................................600
Belt Sander (3”belt).........................................1000
Circular Saw (7 1/4”).................................825-1050
Coffee Maker............................................900-1100
Edger (lawn)......................................................550
Furnace Fan (1/3 hp) (*)...................................1200
Hot Plate (single).............................................1500
Impact wrench...................................................600
Light Bulb............................................... Bulb rating
Nail Gun..........................................................1200
Microwave.........................................................750
Paint Sprayer (1/3 hp) (*) ...................................650
Paint Sprayer, hand-airless................................175
Radio...........................................................50-200
Refrigerator (*)...................................................600
Table Saw (10”) (*) ..........................................2000
Television...................................................250-550
Weed Trimmer...................................................500
Note: (*) Items allow at least 3 times the listed
wattage for starting.
NOTE: Many appliances such as saws or drills draw more
current than indicated on the manufacturer’s nameplate
when under severe load.
STARTING THE GENERATOR SET
Before attempting to start the generator set, ensure that
all instructions given in previous sections have been
followed completely.
Check oil and fuel levels.
Turn the fuel valve under the fuel tank on.
Turn the fuel valve on the front of the engine on.
Move the choke lever on the front of the engine on.
Note: the choke may not be required when the engine
is warm or in high ambient temperatures.
Turn idle-control On/Off switch OFF.
RECOIL START
Move engine On/Off switch to On position.
Slowly pull recoil cord until resistance is felt and then
pull firmly. Let the recoil rewind slowly to avoid
damage.
Return the choke to the original position.
ELECTRIC START
Move engine On/Off switch to On position.
Hold the On/Off switch in the Start position until the
engine starts and release. Note: If the engine does
not start after 5 seconds, stop and wait 10 seconds
and repeat this step.
Return the choke to the original position.
CAUTION: This generator is equipped with an oil
protection system. When oil levels are too low for safe
operation the engine will shut down and/or will not start
until the oil level is corrected.
OPERATING THE GENERATOR SET
Once started, allow the engine to stabilize for
approximately 3 minutes. Check that the circuit breakers
and the GFCI receptacles are not tripped. Turn the idle-
control switch to the On position if this feature is to be
utilized (S5000 & S7500). Set the voltage selector switch
to the appropriate mode, either 120V or 120/240V(S5000
& S7500). See the guides below for more information on
the idle-control and voltage selector features.
IDLE CONTROL GUIDE (applicable models)
The automatic idle control system is available on some
generators. This feature allows the engine to automatically
idle down when there is no load drawn against the
generator thus saving fuel, decreasing wear and lowering
the noise level. There is an on-off switch located on the
control panel that activates or deactivates this feature. In
the on position the engine will idle down after detection of
less than 40Watts. The engine will return to the correct
running speed immediately when a load of 350Watts or
more is applied. For applications with loads less than 50W
or with near constant loads, such as home back up, it is
best to turn the idle control feature off. The feature should
be turned off before starting or stopping the generator and
turned on when there will be extended periods of inactivity
for the generator.
VOLTAGE SELECTOR GUIDE (applicable models)
The voltage selector switch allows the generator set to
produce 120 volts only or to produce 120/240 volts
simultaneously. With the switch in the 120V position only
the 120V receptacles may be used. All of the power from
the generator is available at 120 volts but the 240V output
is not available. In the 120/240V position all receptacles
are operable however only half of the generator output is
available at any one 120V receptacle. Full power may be
pulled from the generator from the 240V receptacle. The
switch should always be left in the 120V position when
240 volts are not needed. This balances the load on the
generator more effectively.
STOPPING THE GENERATOR SET
Unplug all appliances and let the engine run unloaded for
a couple of minutes. Turn the fuel valve on the front of the
engine to the Off position where installed. Turn the engine
On/Off switch to the Off position. Turn the fuel valve on
the fuel tank Off. CAUTION: Never use the choke to stop
the engine.

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GENERATOR APPLICATION
WHAT IS A GENERATOR
A generator is basically a prime mover, typically a
gasoline or diesel engine, coupled to an alternator to
produce electricity. It is very useful as a substitute power
source during power outages or as the primary source in
remote locations where power is not available.
Generators are essential for people such as contractors
or farmers who are always in need of portable power.
They are also very convenient for recreational use.
SELECTING A GENERATOR
Selecting the proper generator is important. A generator
that is too small for your application will not run all of the
equipment needed. A generator that is too large will cost
more and if never used to its potential the money is
wasted. The correct size generator is determined by
totaling the wattage requirements of the items to be used
simultaneously, determine additional starting wattage
requirements and total these numbers. Select a generator
with a continuous rating that exceeds this by about 20%
to allow for expansion. See the table in the section titled
“Generator Set Overload”for some wattage guidelines of
common equipment.
RATED vs. SURGE WATTS
Rated, or continuous, watts are the watts an item needs
as it is running.
Surge, or maximum, watts are the watts an item needs to
start. This is typically 2-4 times the rated watts.
This information is typically provided on the
manufacturer’s nameplate. If watts are not provided, it
can be calculated using the formula: Watts=Amps x Volts.
EXTENSION CORDS
An extension cord should always be in good condition
with no damage to the wires or sheathing. Never run an
extension cord through water. The correct wire size for an
extension cord can be determined from the table that
follows.
Continuous
Load Minimum Cord Gauge (AWG)
Amps 0-50 Feet 50-100 Feet 100-150
Feet
20 12 10 8
25 12 10 6
30 10 8 6
35 10 8 4
40 8 6 2
50 6 4 2
LOADING YOUR GENERATOR SET
With reference to the Receptacle details section, please
review the power receptacles fitted to your generator. The
circuit breaker rating and the generator rating drive the
actual load that may be pulled from each receptacle. The
ratings shown in the table are the maximum available from
each receptacle. DO NOT EXCEED THE INDIVIDUAL
RECEPTACLE RATINGS AS SHOWN IN THE TABLE
BELOW. DO NOT EXCEED THE TOTAL GENERATOR
RATING SHOWN IN TABLE 2 PERFORMANCE
SPECIFICATIONS. All generator units are equipped with
a thermal-magnetic main circuit breaker as well as a
“PUSH TO RESET”breaker on branch circuits.
AMPERAGE RATE TABLE
Model NEMA 5-
20R
125V GFCI
NEMA L5-
30R
125V
Twistlock
NEMA L14-
30R
125/250V
Twistlock
NEMA 14-
50R
125/250V
S3100 20Amps 25Amps NA NA
S5000 20Amps 30Amps* 20Amps NA
S7500 20Amps 30Amps* 30Amps NA
S10000 20Amps NA 30Amps 35Amps
S12000 20Amps NA 30Amps 45Amps
*With voltage selector in 120V mode.
ENGINE LIMITATIONS ON GENERATOR
PERFORMANCE
Generator ratings assume 60F (20C) and Sea
Level. Operation of your generator at temperatures
above 60F (20C) or above Sea Level will result in
lower electrical output. Electrical output must be
derated 1% for each 10F above 60F and 3 ½ %
for each 1000 feet above mean sea level.
GENERATOR CLEANING
CAUTION: ALWAYS SHUT DOWN THE
GENERATOR AND ALLOW IT TO COOL
COMPLETELY BEFORE PERFORMING
CLEANING OPERATIONS.
WARNING: DO NOT USE HIGH PRESSURE
WATER OR A GARDEN HOSE TO CLEAN
YOUR GENERATOR. WATER INTRODUCED
INTO THE GENERATOR CAN CAUSE ELECTRICAL
SHORTS, GENERATOR DAMAGE OR PERSONAL
INJURY.
Compressed air (max. 25 psi) may be used to blow
loose dirt and dust from your generator. DO NOT
DIRECT COMPRESSED AIR DIRECTLY INTO ANY
OPENING IN THE GENERATOR OR ENGINE.
Use a dampened cloth to wipe clean exterior
surfaces.
Use a soft bristle brush to clean/ loosen heavy dirt, oil
or grease deposits.
NEVER insert rags, tools or any device into the
generator or engine openings.

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GENERAL STORAGE GUIDELINES
WARNING: GASOLINE FUMES ARE FLAMMABLE. DO
NOT STORE YOUR GENSET IN ANY AREA THAT IS
INDOOR OR IN POORLY VENTILATED AREAS.
GASOLINE FUMES CAN IGNITE IN THE PRESENCE
OF ANY OPEN FLAME, PILOT LIGHT, CLOTHES
DRYER, WATER HEATER, ETC.
Your generator should be started and operated for
several minutes at least every 30 days.
If the generator cannot be operated every 30 days,
follow the storage recommendations within the engine
documentation.
NOTE: A fuel shut-off valve is positioned at the base
of the fuel tank. The valve should be closed during
storage periods.
RECEPTACLE DETAILS
The receptacles shown in this section are for reference only. Each receptacle is not available on all generators.
NEMA 5-20R
125V - 20A NEMA L5-30R 125V - 30A NEMA L6-30R 250V - 30A NEMA L6-20R 250V - 20A
NEMA 14-50R
125/250V - 50A NEMA L14-30R
125/250V - 30A
NEMA L14-20R
125/250V - 20A
GENERAL MAINTENANCE
Proper maintenance and service are required to achieve maximum engine life and maintain warranty. The following tables
provide engine specifications as well as maintenance schedules for the generator engines. Note that the generator models
are referenced with the engine model. An engine owner’s manual is provided with each machine that also provides basic
maintenance and troubleshooting information. Defer to the engine manufacturers manual if any discrepancies appear
between the data provided in this manual and the engine owner’s manual. Full engine service manuals are available from
American Honda Motor Co., 4900 Marconi Drive, Alpharetta, GA 30005-8847, [phone].
ENGINE SPECIFICATIONS AND CAPACITIES
Model GX160
(S3100) GX270 (S5000) GX390 (S7500) GX610 (S10000) GX620 (S12000)
Type 4-stroke, overhead valve single cylinder,
inclined 254-stroke, overhead valve, V-Twin
Displacement 163cc (9.9 cu
in) 270cc (16.5 cu in) 389cc (23.7 cu in) 614cc (37.5 cu in) 614cc (37.5 cu in)
Bore and
Stroke 68 x 45 mm
(2.7 x 1.8 in) 77 x 58 mm (3.0 x 2.3 in) 88 x 64 mm (3.5 x 2.5 in) 77 x 66 mm (3.0 x 2.6 in) 77 x 66 mm (3.0 x 2.6 in)
Max. HP 5.5 hp 9.0 hp 13.0 hp 18.0 hp 20.0 hp

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@3600rpm @3600rpm @3600rpm @3600rpm @3600rpm
Max. Torque 8ft-lb
@2500rpm 14ft-lb @2500rpm 20ft-lb @2500rpm 31.8 ft-lb @2500rpm 32.5 ft-lb @2500rpm
Compression
Ratio 8.5 : 1 8.2 : 1 8.0 : 1 8.3:1 8.3:1
Cooling
System Forced-air
Ignition System Transistorized magneto
Ignition Timing 25B.T.D.C.
(fixed) 20B.T.D.C. (fixed) 25B.T.D.C. (fixed)
Spark Plug BPR6ES (NGK), W20EPR-U (Nippondenso)
Carburetor Horizontal type, butterfly valve
Air Cleaner Dual element type
Lubricating
System Splash Forced Oil
Oil Capacity 0.6l (0.63 US
qt) 1.1l (1.16 US qt) 1.1l (1.16 US qt) 1.5l (1.58 US qt) 1.5l (1.58 US qt)
Starting
System Recoil Recoil Recoil/Electric Electric Electric
Stopping
System Ignition primary circuit ground
Fuel Type Unleaded gasoline (86 pump octane)
PTO Shaft
Rotation Counterclockwise (from PTO side)
Dry Weight ??.?kg (??.?
lb) 25.4kg (55.1 lb) 31.0kg (68.3 lb) 40.0kg (88.2 lb) 40.0kg (88.2 lb)
OIL SELECTION
Proper oil selection as well as proper oil level is critical to achieve maximum engine life. Use high detergent, premium quality
motor oil certified for service class SJ that should be designated on the container. SAE 10W-30 is recommended for general,
all temperature use. Use the table below to select the proper oil for the temperature in your area.
Viscosity -30C/-22F -20C/-4F -10C/14F 0C/32F 10C/50F 20C/68F 30C/86F 40C/104F
Single 10W
20W
20
30
40
Multi 20W-40,20W-50
15W-40, 15W-50
10W-40
10W-30
ENGINE MAINTENANCE SCHEDULE
ITEM
Each Use First Month
Or
20 Hrs
3 Months
Or
50Hrs
6 Months
Or
100Hrs
Every year
Or
300Hrs
Check XOil Change X X
Check XAir Cleaner Clean X(1)

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Sediment Cup Clean X
Spark Plug Check-Clean X
Spark Arrestor Clean X
Valve Clearance Check-Adjust X(2)
Fuel Tank and Strainer Clean X(2)
Fuel Line Check Replace as necessary.
Notes:
(1) Service more frequently in dusty areas.
(2) Should be serviced by authorized dealer unless owner has proper tools and is mechanically proficient. See engine
Shop Manual for instructions.
DAILY INSPECTION
1. Recoil Starter Cord
2. Engine Oil Level
3. Check for Engine Oil or Fuel Leaks
4. Inspect Spark Plug Cables
5. Inspect Cooling System for Cleanliness
6. Listen for Abnormal Noise
7. Look for Abnormal Vibration
FAULT FINDING GUIDE
SYMPTOMS PROBABLE CAUSES CORRECTION
ENGINE WILL NOT START 1. Oil level too low.
2. No fuel or valve(s) turned off.
3. Start switch turned Off.
4. Blocked or leaking fuel system.
5. Clogged air filter.
6. Genset under load at start-up.
1. Add oil.
2. Add fuel and/or turn valve(s) on.
3. Turn switch On.
4. Repair fuel system.
5. Clean or replace air filter.
6. Disconnect load.
NO POWER OUTPUT 1. Circuit breaker tripped.
2. GFCI receptacle tripped.
3. Faulty circuit breaker.
4. Faulty receptacle.
5. Faulty capacitor in alternator.
6. Faulty diodes in alternator.
7. Failure in alternator windings.
1. Reset circuit breaker.
2. Reset GFCI receptacle.
3. Replace circuit breaker.
4. Replace receptacle.
5. Replace capacitor.
6. Replace diodes.
7. Repair or replace alternator.
NOISY MACHINE 1. Damaged bearing.
2. Damaged exhaust system.
3. Loose or rattling parts.
1. Replace bearing.
2. Repair or replace.
3. Repair loose or rattling parts.
OVERHEATING 1. Ventilation openings blocked.
2. Overload.
3. Ambient temperature too high.
1. Clear ventilation openings.
2. Verify load levels.
3. Provide better ventilation for
cooling.
CIRCUIT BREAKER TRIPS 1. Overloaded circuit.
2. Faulty equipment or cable.
3. Faulty circuit breaker.
1. Reduce load.
2. Check, repair or replace.
3. Replace circuit breaker.

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PARTS ORDERING
GENERAL
This publication, which contains an illustrated parts breakdown, has been prepared as an aid in locating those
parts which may be required in the maintenance of the unit. All of the parts listed in the parts breakdown are
manufactured with the same precision as the original equipment. For the greatest protection always insist on
genuine Pramac Industries parts for your generator.
NOTE: Pramac Industries can bear no responsibility for injury or damages resulting directly from the use of non-
approved repair parts.
Special order parts may not be included in this manual. Contact the local Pramac Parts provider with the unit
serial number for assistance with these special parts.
DESCRIPTION
The parts breakdown illustrates and lists the detailed parts which make up this particular machine. This covers
the standard models and the more popular options that are available. The part number, the description of the
part and the quantity of parts required are shown on each illustration.
The quantities specified are the number of parts used per one assembly and are not necessarily the total
number of parts used in the machine. Where no quantity is specified the quantity is assumed to be one.
Each description of a part is based upon the “noun first”method, i.e., the identifying noun or item name is always
the first part of the description. The noun name is generally followed by a single descriptive modifier. The
descriptive modifier may be followed by words or abbreviations such as upper, lower, inner, outer, front, rear,
RH, LH, etc. when they are essential.
MARKINGS AND DECALS
NOTE: Do not paint over safety warnings or instructional decals. If safety warning decals become illegible,
immediately order replacements from the factory.
Part numbers for original individual decals and their mounting locations are shown within Parts List Section.
These are available as long as a particular model is in production. Afterwards, service sets of exterior decals
and current production safety warning decals are available.
HOW TO USE PARTS LIST
Turn to Parts List Section.
Locate the area of the machine in which the desired part is used and find illustration.
Locate the desired part on the illustration by visual identification and make note of part number and
description.
HOW TO ORDER
The satisfactory ordering of parts by a purchaser is greatly dependent upon the proper use of all available
information. By supplying the nearest sales office, autonomous company or authorized distributor, with
complete information, you will enable them to fill your order correctly and to avoid any unnecessary delays.
In order that all avoidable errors may be eliminated, the following instructions are offered as a guide to the
purchaser when ordering replacement parts:
Always specify the model number of the machine.
Always specify the serial number of the unit. THIS IS IMPORTANT.
Always specify the number of the parts list publication.
Always specify the quantity of parts required.
Always specify the part number, as well as the description of the part, or parts, exactly as it is given on the
parts list illustration.

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In the event parts are being returned to your nearest sales office, autonomous company or authorized
distributor, for inspection or repair, it is important to include the serial number of the unit from which the parts
were removed.
TERMS AND CONDITIONS ON PARTS ORDERS
Acceptance: Acceptance of an offer is expressly limited to the exact terms contained herein. If purchaser’s
order form is used for acceptance of an offer, it is expressly understood and agreed that the terms and
conditions of such order form shall not apply unless expressly agreed to by Pramac Industries (“Company”) in
writing. No additional or contrary terms will be binding upon the Company unless expressly agreed to in writing.
Taxes: Any tax or other governmental charge now or hereafter levied upon the production, sale, use or
shipment of material and equipment ordered or sold is not included in the Company’s price and will be charged
to and paid for by the Purchaser.
Shipping dates shall be extended for delays due to acts of God, acts of Purchaser, acts of Government, fires,
floods, strikes, riot, war, embargo, transportation shortages, delay or default on the part of the Company’s
vendors, or any other cause beyond the Company’s reasonable control.
Should Purchaser request special shipping instruction, such as exclusive use of shipping facilities, including air
freight when common carrier has been quoted and before change order to purchase order can be received by
the Company, the additional charges will be honored by the Purchaser.
Warranty: The Company warrants that parts manufactured by it will be as specified and will be free from
defects in materials and workmanship.
The Company’s liability under this warranty shall be limited to the repair or replacement of any part which was
defective at the time of shipment provided Purchaser notifies the Company of any such defect promptly upon
discovery, but in no event later than three (3) months from the date of shipment of such part by the Company.
The only exception to the previous statement is the extended warranty as it applies to the special airend
exchange program.
Repairs and replacements shall be made by the Company F.O.B. point of shipment. The Company shall not be
responsible for costs of transportation, removal or installation.
Warranties applicable to material and equipment supplied by the Company but wholly manufactured by others
shall be limited to the warranties extended to the Company by the manufacturer which are able to be conveyed
to the Purchaser.
Delivery: Shipping dates are approximate. The Company will use best efforts to ship by the dates specified;
however, the Company shall not be liable for any delay or failure in the estimated delivery or shipment of
material and equipment or for any damages suffered by reason thereof.
This company makes no other warranty or representation of any kind whatsoever, expressed or implied, except
that of title, and all implied warranties, including any warranty of merchantability and fitness for a particular
purpose, are hereby disclaimed.

S3100 GENERATOR PARTS
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GENERATOR PARTS LISTS
S3100 GENERATOR PART LISTS

S3100 GENERATOR PARTS
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