Tomahawk TG5500i User manual

TG5500i
INVERTER GENERATOR Operations Manual
FIND THE HOW TO GUIDE ON

Thank you for choosing a Tomahawk Generator!
Please read this manual carefully before operating. Safely and
correctly operating your generator will ensure you get the best
results.
All information in this publication is based on the latest
product information available at the time of printing. The contents
in this manual may be different from the actual parts due to revision
and other changes.
Tomahawk Power, LLC reserves the right to make changes at
any time without notice and without incurring any obligation. No
part of this publication may be reproduced without written
permission from Tomahawk Power, LLC.
This manual should be considered a permanent part of the
generator and should remain with the generator if it is resold.

SAFETY
Your safety and the safety of others are very important. We have
provided important safety information in this manual and on the
generator. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt
you or others. Each safety message is preceded by a safety alert
symbol and one of three words: DANGER, WARNING, or
CAUTION:
You WILL be KILLED or SERIOUSLY HURT if you do not follow
instructions.
You CAN be KILLED or SERIOUSLY HURT if you do not follow
instructions.
You CAN be SERIOUSLY HURT if you do not follow instructions.
Your generator or other property could be DAMAGED if you do not
follow instructions.

CONTENTS
GENERATOR......................................................................................... 1
SAFETY MESSAGES............................................................................ 3
1. SAFETY NOTICE............................................................................... 5
1. Safety Standard......................................................................... 5
2. Special Requirements................................................................ 6
2.COMPONENT IDENTIFICATION........................................................ 7
1. Component Identification ........................................................... 7
2. Engine Type & Serial Number.................................................... 8
3. CONTROLFUNCTION....................................................................... 9
1. Oil warning light (red)................................................................. 9
2. Overload indicator light (Red) .................................................... 9
4. PREPARATION................................................................................ 11
1. Fuel.......................................................................................... 11
2 Engine oil.................................................................................. 11
3. Recoil Starter........................................................................... 12
4. Fuel Valve................................................................................ 12
5. AC Circuit Breaker/Over current Protector............................... 12
6. Ground Terminal........................................................................ 13
5. GENERATOR OPERATION ............................................................ 14
1. Connection to the Household Power Supply............................ 14
2. Generator Grounding.................................................................. 15
3.ACCurrent................................................................................. 15
4. DC Current............................................................................... 16
5. High Altitude Operation............................................................ 16
6. STARTING THE ENGINE................................................................ 17
1. Recoil Starter........................................................................... 17
2. Electric starting ........................................................................ 18
7. STOPPING THE ENGINE................................................................ 18
8. MAINTENANCE............................................................................... 19
1. Engine Oil Change................................................................... 20
2. Air Cleaner Service.................................................................. 21
3. Fuel Sediment Cup Cleaning................................................... 22
4. Spark Plug Service .................................................................. 23
9. STORAGE........................................................................................ 23
10. TROUBLESHOOTING................................................................... 25
11. WIRING DIAGRAM........................................................................ 26
12. SPECIFICATIONS ......................................................................... 27

1. SAFETY NOTICE
1. Safety Standard
Read and understand this owner’s manual before
operating your generator. You can help prevent accidents
by being familiar with your generator’s controls, and by
observing safe operating procedures.
DO NOT operate indoors
DO NOT operate in the wet
conditions
DO NOT directly connect to a
household power supply
DO NOT smoke when refueling

DO NOT overflow the fuel
when refueling
Stop the engine before refueling
Keep the generator at least 10 feet far away from any
flammable materials
2. Special Requirements
Electrical equipment including lines and plug connections
should not be damaged in any way or have exposed wires.
The circuit breakers that have been installed match with the
provided generator.
If the circuit breakers require replacement, the replacement
must be a circuit breaker with identical ratings and
performance characteristics.
DO NOT operate the generator before grounding.

If using extension cords, be sure to check the electrical needs
of your appliance, as electrical power is lost over distance. Use
this rule: if your extension cord is #16 gauge wire,
you can have a cord up to 50 feet. For the same appliance,
if your cord is #10 gauge, your maximum length is 250 feet.
2.COMPONENT IDENTIFICATION
1. Component Identification
TG5500i

2. Engine Type & Serial Number

3. CONTROL FUNCTION
1. Oil warning light (red)
When the oil level falls below the
required level, the oil warning light
will turn on and the engine will stop
automatically. Unless you refill with
oil, the engine will not start again.
Tip: If the engine stalls or does not
start, turn the engine switch to “ON”
and then pull the recoil starter.
If the oil warning light flickers for a few seconds,
the engine oil is insufficient. Add oil and restart.
2. Overload indicator light (Red)
The overload indicator light comes on
when an overload of a connected
electrical device is detected, the
inverter control unit overheats, or the
AC output voltage rises. Then, the AC
protector will trip, stopping power
generation to protect the generator and any connected
electrical devices. The AC pilot light (Green) will go off and the
overload indicator light (Red) will stay on, but the engine will
not stop running.
When the overload indicator light comes on and power
generation stops, proceed as follows:
1）Turn off any connectedelectrical devices and stop the
engine.
2）Reduce the total wattage of connected electrical
devices within the rated output.
3）Check for blockages in the cooling air inlet and around

the control unit.
If any blockages are found, remove.
4）After checking, restart the engine.
Tip: The overload indicator light may come on for a few
seconds at first when using electrical devices that require a
large starting current, such as a
compressor or a submersible pump.
However, this is not a malfunction.
3. AC pilot light (Green)
The AC pilot light comes on when
the engine starts and produces
power.
4. Engine smart control (ECO)
①“ON”
When the ECO switch is turned to “ON”, the economy control unit
controls the engine speed according to the connected load. The
results are better fuel consumption and less noise.
②“OFF”
When the ECO switch is turned to “OFF”, the
engine runs at the rated/min (3600r/min)
regardless of whether it is connected to a load.
Tip: The ECO switch must be turned to “OFF”
when using electrical devices that require a
large starting current, such as a compressor or a submersible
pump.
5. Ground (Earth) Terminal
The Ground (Earth) terminal connects the ground line for
prevention of electric shock. When the electric devices are
grounded, always ground the generator.

4. PREPARATION
1. Fuel
DANGER!
Fuel is highly flammable and dangerous. Check “SAFETY
INFORMATION” carefully before filling.
Do not overfill the fuel tank, or it may overflow when the fuel
warms up and expands.
After filling the fuel tank, make sure the fuel tank cap is
tightened securely.
Immediately wipe off spilled fuel with a clean, dry, soft cloth.
Fuel may deteriorate painted surfaces or plastic parts.
Use unleaded gasoline only, as leaded gasoline can severely
damage internal parts of the generator.
Remove the fuel tank cap and fillthe tank to the red level.
Recommended fuel: Unleaded gasoline
Fuel tank capacity: 4.5 gallons
2. Engine Oil
The generator has been shipped without engine oil. DO NOT
start the engine until it is filled with sufficient engine oil.

3. Recoil Starter
To start the engine, pull the starter grip lightly until resistance
is felt, then pull quickly.
Do not allow the starter to snap back against the engine.
Return it gently to prevent damage to the starter.
4. Fuel Valve
The fuel valve controls fuel flowing from the fuel tank to the
carburetor. Be sure to return the lever to “OFF” after stopping the
engine.
5. AC Circuit Breaker/Over Current Protector
The overload current will automatically switch off the circuit

breakertoavoid a short circuit of theload or overload. If theindicator
of the AC Over current Protector is raised, the Over current
Protector is now in the “OFF” position. Press the button of the
AC Over current Protector to the “ON” position again 1 min later. If
the circuit
breaker is switched OFF automatically, switch the circuit
breaker ONagain.
6. Ground Terminal
This ground terminal is used to connect the generator.
OVERCURRENT
PROTECTOR
GROUND
TERMINAL

5. GENERATOR OPERATION
Generator operation environment:
· Temperature: 23
°
F ~ 100
°
F (-5
℃ ～40 ℃)
· Humidity
: Below 95%
· Height above sea level:
Power output can be expected to decrease by an
average of 3.5% per 1000ft above sea level. When
operating at extreme altitudes, carburetor
adjustments are recommended to maintain proper
output.
1. Connection to the Household Power Supply
When connecting the generator to the household power
supply, connection must be made by a qualified electrician.
After connecting, carefully check the electric connection for
safety and reliability. Incorrect electrical connections may
cause generator damage and/or a fire hazard.

2. Generator Grounding
To prevent electrical shock or misuse from faulty
appliances, the generator should be grounded with an
insulated lead.
3.AC Current
Before starting the generator, make sure that the total
load (Total resistance, capacitive and inductive) does
not exceed the rated power of the generator.
Overload operation will shorten generator life.
If the generator set is connected to multiple loads or
electric appliances, connect each appliance 1 at a time,
starting with the highest load appliance first. Allow the
generator to adjust to each load before adding more.
The following table is a reference for when connecting to

the electric appliances.
4. DC Current
DC Terminals
The DC terminals are used to provide a DC power supply
for lower power loads such as charging a battery.
The terminals are colored red to identify the positive (+)
terminal and black to identify the negative (-) terminal.
Load connection method: The load must be connected to
DC terminals with the proper polarity (load positive to
positive of DC terminal and load negative to negative of
DC terminal).
5. High Altitude Operation
At high altitude, the standard carburetor air-fuel mixture will
be excessively rich. Output power will decrease, and fuel
consumption will increase.
Engine performance can be improved by installing a smaller
diameter main fuel jet in the carburetor and readjusting the

pilot screw. If you always operate the engine at altitudes
3500 feet above sea level, you should have a Tomahawk
Power authorized dealer perform this carburetor
modification. If not, you should lower the load in the
operating generator.
Even with the right carburetor, engine horsepower will
decrease approximately 3.5% for every 1000-foot increase
in altitude. If no carburetor adjustments are made for high
altitude operation, this will have a major negative effect on
horsepower output.
If a carburetor for high altitude is equipped with an engine
and operated at a lower altitude, the lean air fuel mixture will
cause the engine output power to lower, over-heat and
seriously damage the unit.
6. STARTING THE ENGINE
1. Recoil Starter
(1) Remove all the loads out of the output.
(2) Turn the fuel valve to the “ON” position.
(3) Turn the AC circuit breaker to the “OFF” position.
(4) Turn the choke lever to the “CLOSE” position.
Don’t close the choke when starting a warm engine
(5) Turn the generator switch to the “ON” position.
(6) Pull the starter grip until compression is felt, then pull
briskly.
(7) Turn the choke lever to the “OPEN” position after the
engine is warm.

(8) Don’t use any electric apparatus before setting the
circuit breaker to the “ON” position.
2. Electric starting
(1) Remove all the loads out of the output.
(2) Turn the fuel valve to the “ON” position.
(3) Turn the choke lever to the “CLOSE” position.
Don’t close the choke when starting a warm engine
(4) Turn the generator switch to electric starting position.
(5) After starting engine, immediately release generator
switch and generator switch can automatically return to
open position.
(6) Turn the choke lever to “OPEN” position after the engine
is warm.
Turning the gasoline switch to the electric starting position
for more than 5 seconds can damage the starting motor. If
failing to start, release the switch and wait 10 seconds
before operating it again.
If the speed of the starting motor drops fast after a period of
time, it means that the battery should be recharged.
7. STOPPING THE ENGINE
(1) Turn the AC circuit breaker to the “OFF”position.
(2) Turn the generator switch to the “OFF”position.
(3) Turn the fuel valve to the “OFF”position.

To stop the engine in an emergency, turn the generator
switch to the “OFF”position.
8. MAINTENANCE
The engine must be properly maintained to ensure its
operation is safe, trouble-free, as well as eco-friendly.
In order to keep your gasoline engine in good working
condition, it must be periodically serviced. The following
maintenance schedule and routine inspection
procedures must be carefully followed:
●If the gasoline engine is frequently worked under high
temperature or at a high load, change the oil every 25 hours.
●If the engine is frequently worked under dusty or other
Frequency
Items
Each
time
First 1
month or
first 20hrs
of
operation
Thereafter,
every 3 months
or every 50hrs
of operation
Every year
or every
100 hrs of
operation
Engine oil
Check- Refill
√
Replace
√
√
Air filter
element
Check
√
Clean
√
Replace
√
Deposit Cup(if
equipped)
Clean
√
Spark Plug
Check -
adjust
√*
Spark arrester
Clean
√
Idling (if
equipped) **
Check -
adjust
√
Valve
clearance **
Check-adjust
√
Fuel tank &
fuel filter **
Clean
√
Fuel line
Check
Every 2 years(change if necessary)
Cylinder head,
piston
Clean up
carbon **
＜225cc，Every 125hrs
≧225cc，Every 250hrs
* These items should be replaced if replacement needed.
** These items should be maintained and repaired by our authorized dealer, unless the
owner has appropriate tools and is proficient with mechanical maintenance.