Homelite HG6000 Portable Generator User Manual
Contents
1. Ground G Page 22 Engine switch continuity DC winding JL V E ircui lt oc O lt A O x z Generator symbol Minior winding Capacitor Integrator Engine symbolic c B m J er on Fuel solenoid valve FS Sparkplug IGNITION coil IG ow SENSOR ee Excition winding WARRANTY LIMITED WARRANTY STATEMENT Baja Motorsports warrants to the original retail purchaser that this HOMELITE brand outdoor product is free from defect in material and workmanship and agrees to repair or replace at Baja Motorsports discretion any defective product free of charge within these time periods from the date of purchase E One year if the product is used for personal family or household use m 90 days if used for any other purpose such as commercial or rental This warranty extends to the original retail purchaser only and commences on the date of the original retail purchase Any part of the this product manufactured or supplied by Baja Motorsports and found in the reasonable judgment of Baja Motorsports to be defective in material or workmanship will be repaired or replaced without charge for parts and labor by a Baja authorized service center The product including any defective part must be returned to a Baja authorized service dealer within the warranty period The expense of delivering the product to the dealer for warranty work and the expense2. smoothly and attached device operates properly CAUTION Do not overload the generator s capacity Exceeding the generator s wattage amperage capacity can damage the generator and or electrical devices connected to it Typical Continuous Running Starting Watts Watts a HeatingiGooing mee Typical Tool or Appliance Surge 2350 1800 Electric Stove Single Element 2100 Family Room ay 500 lower SCSSCC d ars C Aness Sprayer VHP oo Reciprocating San oso Eec barvane oo 2350 1200 2300 4 Plug in and turn on the next load Miter Saw 10 in 1800 1800 5 Again permit the generator to stabilize Planer Jointer 6 in 1800 1800 6 Repeat steps 4 and 5 for each additional load Table Saw Radial Arm Saw 10 in 2000 2000 Air Compressor 1 HP 1600 4500 Wattages listed are approximate Check tool or appliance for actual wattage Never add more loads than the generator capacity Take special care to consider surge loads in generator capacity as previously described Page 9 FEATURES PRODUCT SPECIFICATIONS ENGINE GENERATOR Engine Type u eeeeeeeeeeesseeeeeeeeees 4 Stroke Overhead Valve Rated Voltage sol s i 120V 240V Bore x StroOKe ccccccccecccccccceccccecececeucececeeuuues 88 mm x 64 mm Rated Amps E A A A A T 22 9A Cooling System acecwseticeasiuetseseaatee Forced Air pated OUT DU cei tccccesaseccsetrnnecseniessesceeetensesceeviveneecestien 5
3. A WARNING When servicing use only identical Homelite replacement parts Use of any other parts may create a hazard or cause product damage Only the parts shown on the parts list are intended to be repaired or replaced by the customer All other parts should be replaced at a Baja authorized service center GENERAL MAINTENANCE Keep the generator in a clean and dry environment where it is not exposed to dust dirt moisture or corrosive vapors Do not allow the cooling air slots in the generator to become clogged with foreign material such as leaves snow etc Do not use a garden hose to clean the generator Water en tering the fuel system or other internal parts of the unit can cause problems that will decrease the life of the generator To clean the unit E Use a soft bristle brush and or vacuum cleaner to loosen and remove dirt and debris E Clean air vents with low pressure air that does not exceed 25 psi E Wipe the exterior surfaces of the generator with a damp cloth CHECKING CLEANING AIR FILTER See Figure 11 For proper performance and long life keep air filter clean E Rotate the knob counterclockwise to release E Lift the air filter cover toward you and up to remove from the air filter unit E Remove the filter element E Ifthe filter element is dirty clean with warm soapy water Rinse and let dry E Apply a light coat of engine oil to the elements then squeeze it out m Replace the elemen
4. Axle Frame Support with Foot Large Cotter Pin 10W 30 4 Cycle Engine Oil Small Cotter Pin 34 fl oz not shown Registration Card not shown Operator s Manual not shown Page 12 ASSEMBLY UNPACKING This product requires assembly E Remove one end of the box and carefully slide out the generator and any accessories NOTE The generator is heavy If you must lift the unit out of the box get another person to help you and lift with your legs not your back E Inspect the unit carefully to make sure no damage oc curred during shipping E Donotdiscard the packing material until you have carefully inspected and satisfactorily operated the product E f any parts are damaged or missing please call 1 866 260 8280 for assistance A WARNING If any parts are damaged or missing do not operate this product until the parts are replaced Failure to heed this warning could result in serious personal injury A WARNING Do not attempt to modify this tool or create accessories not recommended for use with this tool Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious personal injury A WARNING Do not attempt to operate the generator until assembly is complete Failure to comply could result in possible serious personal injury INSTALLING THE WHEELS See Figure 3 Wheels are provided to assist in moving the generator to the desired location and should be
5. all times The unit operates best in temperatures between 23 F and 104 F with a relative humidity of 90 or less Specific modifications for high altitude performance are needed if the generator will always be operated at altitudes above 5 000 feet Contact your nearest Baja authorized service center for more information and to have these modifications performed Save these instructions Refer to them frequently and use them to instruct others who may use this tool If you loan someone this tool loan them these instructions also SYMBOLS Some of the following symbols may be used on this product Please study them and learn their meaning Proper interpretation of these symbols will allow you to operate the product better and safer SYMBOL NAME DESIGNATION EXPLANATION Time Volume Volume Do not expose to rain or use in damp locations To reduce the risk of injury user must read and understand operator s manual before using this product Always wear safety goggles or safety glasses with side shields and as necessary a full face shield when operating this product Precautions that involve your safety Failure to use in dry conditions and to observe safe practices can result in electric shock Running generator gives off carbon monoxide an odorless color less poison gas Breathing carbon monoxide can cause nausea fainting or death Fuel and its vapors are extremely flammable and explosive Fire or explosion c
6. must add oil before first operating the generator The oil reservoir capacity is 1 2 qt Always check the oil level before each operation The oil level should always register within the hatched area on the dipstick The unit is equipped with an oil sensor which will automatically shut off the engine if ie ground oil level falls below a safe limit This engine is equipped with an oil sensor Fill oil to upper level if failure to start HOT SURFACE WARNING Do not touch the muffler or aluminum cylinder of the engine They are very HOT and will cause severe burns Don t put any flammable or combustible materials in the direct path of the exhaust Page 7 amp DANGER You WILL be KILLED or SERIOUSLY HURT if you do not follow the Operator s Manual instructions Risk of Fire Do not add fuel while the product is operating Generator is a potential source of electric shock Do not expose to moisture rain or snow Do not operate with wet hands or feet Exhaust contains poisonous carbon monoxide gas that can cause unconsciousness or DEATH Operate in well ventilated outdoor areas away from open windows or doors Failure to properly ground generator can result in electrocution especially if the generator is equipped with a wheel kit Do not expose to rain or use in damp locations LA WARNING OO Product does not include ground rod or copper wire National Electric Code requires generator to be properly gro
7. of returning it back to the owner after repair or replacement will be paid by the owner Baja Motorsports responsibility in respect to claims is limited to making the required repairs or replacements and no claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any HOMELITE brand product Proof of purchase will be required by the dealer to substantiate any warranty claim All warranty work must be performed by a Baja authorized service center This warranty is limited to ninety 90 days from the date of original retail purchase for any HOMELITE brand product that is used for rental or commercial purposes or any other income producing purpose This warranty does not cover any HOMELITE brand product that has been subject to misuse neglect negligence or accident or that has been operated in any way contrary to the operating instructions as specified in this operator s manual This warranty does not apply to any damage to the product that is the result of improper maintenance or to any product that has been altered or modified The warranty does not extend to repairs made necessary by normal wear or by the use of parts or accessories which are either incompatible with the HOMELITE brand product or adversely affect its operation performance or durability In addition this warranty does not cover A Tune ups Spark Plugs Carburetor Carburetor Adjustments Ignition Filters Oil Chan
8. 500 W Compression RatiO ccscccccsssseeeessseneeesssseeeeessssnaeees 8 1 MS a UE UT ten Sante a eed Rated Frequency ideiouso tiniest 60 Hz Starting System ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee Recoil Sa T l DIMENSIONS JOOP SyaT i seratina Gil Length sc ecceecdictiee eukean aR EERE 32 67 in Spark PIU ss sssssssssessssiasnisesasnissnaseeseresenneeens TORCH EIRIO XIN n altel asian eas dnd ee a Say oe Sc ea 26 77 in Engine Oil VOLUME eee eee tsetse eee tnaneneneneneees taqt Height iiaeaa aiin 24 6 in Fuel VOUM E iat damit bana a e niet 6 5 gal Net Weight aruna useless ER tacit 202 Ibs AC CIRCUIT 120 VOLT AC FUEL LEVEL BREAKER 20 AMP GFCI GAUGE eee RECEPTACLES FUEL TANK 240 VOLT AC 30 AMP RECEPTACLE GROUND TERMINAL FUEL VALVE RECOIL STARTER AE ENGINE OIL CAP DIPSTICK SWITCH OIL DRAINAGE BOLT Page 10 FEATURES KNOW YOUR GENERATOR See Figure 2 The safe use of this product requires an understanding of the information on the product and in this operator s manual as well as a knowledge of the project you are attempting Before use of this product familiarize yourself with all operating features and safety rules AC CIRCUIT BREAKER The circuit breaker is provided to protect the generator against electrical overload and can be used to turn the generator s electrical power on or off AIR FILTER The air filter helps to limit the amount of dirt and dust drawn int
9. ION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other rights which vary from state to state This warranty applies to all HOMELITE brand products manufactured by or for Baja Motorsports and sold in the United States and Canada To locate your nearest Baja authorized service center dial 1 866 260 8280 or log on to our website at www bajamotorsports net Page 23 OPERATOR S MANUAL PORTABLE GENERATOR SET 6 000 WATT HG6000 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CALIFORNIA PROPOSITION 65 e SERVICE Now that you have purchased your tool should a need ever exist for repair parts or service simply contact your nearest Baja authorized service center Be sure to provide all pertinent facts when you call or visit Please call 1 866 260 8280 for your nearest Baja authorized service center e MODEL NO AND SERIAL NO The model number of this tool will be found on a plate on the side of the generator above the recoil starter housing Please record the model number and serial number in the space provided below e HOW TO ORDER REPAIR PARTS When ordering repair parts always give the following information e MODEL NUMBER HG6000 e SERIAL NUMBER BAJA MOTORSPORTS 2801 Fair Lane So
10. OPERATOR S MANUAL PORTABLE GENERATOR SET 6 000 WATT HG6000 eS EZ Your new generator has been engineered and manufactured to a high standard for dependability ease of operation and operator safety When properly cared for it will give you years of rugged trouble free performance A DANGER You WILL be KILLED or SERIOUSLY HURT if you do not follow the instructions in this operator s manual Thank you for your purchase SAVE THIS MANUAL FOR FUTURE REFERENCE TABLE OF CONTENTS ME MOUCHO Nessin iaei aE EAR EEEa ARENE EK EENE a sieved endings E EEEE aa EENET EERE days cs SEEKER 2 E General Salet RUES iena e en E r a aa tage say a a aE a a E NE 3 M Specific Safety RUl S ssisiniriiaaninan inan erana ndadani ai anana akian aaa taaa ania an Naana id ea aaa dAran kaa Kanani aa radades aaraa Eain 4 E SymBOlS iea aaa a aara er ea eaa dice EERE vest Daaa Naa KEKA Ea Ea Aaea aa aeae aa aE a AE aa eee lees 5 7 M Electmical n gne e a S a e E aE a ere 8 9 M Feature Sean ia naa E aE EAEE A E aS E a a aE a aa S aaa 10 11 E Loose Parts iStore eara EEEE KENEK EKE E de wean a ETa EEA REE a SEEE ENE EE AR ce evens eves 12 MPSS ONY aeien e fete ite eee cen ett ect eatevedcneacaeny nace a a 13 14 MB SACOM ez ava act ehcce cess canta ck TTET ceed coves zc sees E EA A E E A ET RETA 14 16 E Malinite man Ce sireeni anaie sts ba ecg en ed fw 02h be gaia bac ERREA a foal Laona KEAN S au dlc AEAEE Oa AE Eae R a r Ta n AEE 17 20 M T OUDIESNOOUNO ra
11. an cause severe burns or death To reduce the risk of injury or damage avoid contact with any hot surface To reduce the risk of serious injury avoid attempting to lift the generator alone Consult with local electrician to determine grounding requirements before operation Failure to properly ground generator can result in electrocution especially if the generator is equipped with a wheel kit Page 5 SYMBOLS The following signal words and meanings are intended to explain the levels of risk associated with this product SYMBOL SIGNAL MEANING Indicates an imminently hazardous situation which if not avoided will result DANGER in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in CAUTION minor or moderate injury Without Safety Alert Symbol Indicates a situation that may result in property CAUTION Mapes SERVICE Servicing requires extreme care and knowledge and should A DANGER be performed only by a qualified service technician For service contact Baja Motorsports at 1 866 260 8280 When servicing use only identical replacement parts To avoid death or serious personal injury do not attempt to operate this product until you read thoroughly and understand completely the operator s manual If you do not understand the
12. ap dipstick CHECKING ADDING FUEL See Figure 7 E Check the fuel level gauge If fuel is needed continue with the next step E Remove the fuel cap E Fill the fuel tank to 1 in below the top of the fuel neck E Replace and secure the fuel cap NOTE Always use unleaded gasoline with a pump octane rating of 86 or higher Never use old stale or contaminated gasoline and do not use an oil gas mixture Do not allow dirt or water into the fuel tank USING FUEL STABILIZER Fuel gets old oxidizes and breaks down over time Add ing a fuel stabilizer extends the usable life of fuel and helps prevent deposits from forming that can clog the fuel system Follow fuel stabilizer manufacturer s directions for correct ratio of stabilizer to fuel E Add stabilizer to fuel tank then fill with gasoline following previous instructions NOTE Fuel stabilizer and gasoline can be mixed prior to filling the tank by using a gas can or other approved fuel container and shaking gently to combine E Replace and secure the fuel tank cap E Start and run the engine for at least 5 minutes to allow stabilizer to treat the entire fuel system OIL CAP DIPSTICK OIL FILL HOLE FUEL TANK FUEL CAP FUEL LEVEL OXYGENATED FUELS Some conventional gasolines are blended with alcohol or an ether compound These gasolines are collectively referred to as oxygenated fuels To meet clean air standards some areas of the United States an
13. before each use of the generator STARTING THE ENGINE See Figures 8 10 NOTE If location of generator is not level the unit may not start or may shut down during operation E Unplug all loads from the generator E Switch the AC circuit breakers to the OFF O position E Turn the fuel valve to the ON position E Pull the choke lever to the START position NOTE If engine is warm or the temperature is above 50 F push the choke lever in to the RUN position Put the engine switch in the ON 1 position E Pull the recoil starting grip until the engine runs a maxi mum of 6 times NOTE Do not allow the grip to snap back after starting return it gently to its original place E Allow the engine to run for 30 seconds then push the choke lever in to the RUN position E Switch the AC circuit breakers to the ON position ae SS Reco SS eee STARTER ENGINE ae GRIP SWITCH ad PULL CHOKE LEVER OUT TO START PUSH CHOKE LEVER IN TO RUN Fig 10 STOPPING THE ENGINE See Figures 8 9 To stop the engine under normal operating conditions E Remove any load from the generator E Place the voltage selector in the center OFF position Switch the AC circuit breakers to the OFF position E Turn the fuel valve to the OFF position E Put the engine switch in the OFF O position To stop the engine in an emergency situation E Put the engine switch in the OFF O position Page 16 MAINTENANCE
14. d Canada use oxygenated fuels to help reduce emissions Page 15 OPERATION If using an oxygenated fuel make sure it is unleaded and meets the minimum octane rating requirements Before using an oxygenated fuel try to confirm the fuel s contents Some states provinces require this information to be posted on the pump The following are the EPA approved percentages of oxygenates Ethanol ethyl or grain alcohol 10 by volume You may use gasoline containing up to 10 ethanol by volume Gasoline containing ethanol may be marketed under the name Gasohol MTBE methyl tertiary butyl ether 15 by volume You may use gasoline containing up to 15 MTBE by volume Methanol methyl or wood alcohol 5 by volume You may use gasoline containing up to 5 methanol by volume as long as it also contains cosolvents and corrosion inhibi tors to protect the fuel system Gasoline containing more than 5 methanol by volume may cause starting and or performance problems It may also damage metal rubber and plastic parts of the generator or your fuel system Ifyou notice any undesirable operating symptoms try another service station or switch to another brand of gasoline NOTE Fuel system damage or performance problems re sulting from the use of an oxygenated fuel containing more than the percentages of oxygenates stated previously are not covered under warranty CAUTION On a level surface with the engine off check the oil level
15. ed or under the influence of drugs alcohol or medication Keep all parts of your body away from any moving parts and all hot surfaces of the unit Product users on United States Forest Service land and in some states must comply with fire prevention regula tions This product is not equipped with a spark arrestor Check with the federal state or local authorities in your area before use Do not touch bare wire or receptacles Do not use generator with electrical cords which are worn frayed bare or otherwise damaged Before storing allow the engine to cool Do not operate generator in rain snow or wet weather Page 3 Empty fuel tank close fuel valve and restrain the unit from moving before transporting in a vehicle Allow engine to cool for five minutes before refueling To reduce the risk of fire and burn injury handle fuel with care It is highly flammable Do not smoke while handling fuel Store fuel in a container approved for gasoline Position the unit on level ground stop engine and allow to cool before refueling Loosen fuel cap slowly to release pressure and to keep fuel from escaping around the cap Tighten the fuel cap securely after refueling Wipe spilled fuel from the unit Never attempt to burn off spilled fuel under any circum stances Use only authorized replacement parts and accessories and follow instructions in the Maintenance section of this manual Use of unauthorized parts or fa
16. el valve to ON position and check for leaks SPARK PLUG MAINTENANCE SEDIMENT See Figure 14 CUP The spark plug must be properly gapped and free of deposits in order to ensure proper engine operation To check E Remove the spark plug cap E Clean any dirt from around base of spark plug E Remove spark plug using wrench provided E Inspect spark plug for damage and clean with a wire brush before reinstalling If insulator is cracked or chipped spark plug should be replaced NOTE If replacing use the following recommended spark plugs or equivalent Champion RN9YC or NGK BPR5SES E Measure plug gap The correct gap is 0 028 0 031 in 0 7 0 8 mm To widen gap if necessary carefully bend the ground top electrode To lessen gap gently tap ground electrode on a hard surface E Seat spark plug in position thread in by hand to prevent cross threading E Tighten with wrench to compress washer If spark plug is new use 1 2 turn to compress washer appropriate amount If reusing old spark plug use 1 8 to 1 4 turn for proper washer compression NOTE An improperly tightened spark plug will become very hot and could damage the engine Page 18 MAINTENANCE CLEANING THE EXHAUST PORT AND MUFFLER Depending on the type of fuel used the type and amount of oil used and or your operating conditions the exhaust port and muffler may become blocked with carbon deposits If you notice a power loss with your gas powered t
17. ench All electrical tools and appliances operated from this generator must be properly grounded by use of a third wire or be Double Insulated It is recommended to 1 Use electrical devices with 3 prong grounded plugs 2 Use an extension cord with a 3 pole receptacle and a 3 prong plug at opposite ends to ensure continuity of the ground protection from the generator to the appliance M YY S_ 4 14 A C Check and adhere to all applicable federal state and local regulations relating to grounding specifications Consult a quali fied electrician or service personnel if the grounding instructions are not completely understood or if in doubt as to whether the generator is properly grounded Page 2 GENERAL SAFETY RULES A WARNING Read and understand all instructions Failure to follow all instructions listed below may result in electrocution fire and or carbon monoxide poisoning which will cause death or serious injury Do not allow children or untrained individuals to use this unit Never start or run the engine inside a closed or partially enclosed area Breathing exhaust fumes will kill you Wear eye protection which is marked to comply with ANSI Z87 1 as well as hearing protection when operating this equipment Keep all bystanders children and pets at least 10 feet away Wear sturdy and dry shoes or boots Do not operate while barefoot Do not operate generator when you are tir
18. ge B Wear items Recoil Starter Rope Engine Brushes Cotter Pins Tires Baja Motorsports reserves the right to change or improve the design of any HOMELITE brand product without assuming any obligation to modify any product previously manufactured ALL IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE STATED WARRANTY PERIOD ACCORDINGLY ANY SUCH IMPLIED WARRANTIES INCLUDING MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE ARE DISCLAIMED IN THEIR ENTIRETY AFTER THE EXPIRATION OF THE APPROPRIATE ONE YEAR OR NINETY DAY WARRANTY PERIOD BAJA MOTORSPORTS OBLIGATION UNDER THIS WARRANTY IS STRICTLY AND EXCLUSIVELY LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE PARTS AND BAJA MOTORSPORTS DOES NOT ASSUME OR AUTHORIZE ANYONE TO ASSUME FOR THEM ANY OTHER OBLIGATION SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU BAJA MOTORSPORTS ASSUMES NO RESPONSIBILITY FOR INCIDENTAL CONSEQUENTIAL OR OTHER DAMAGES INCLUDING BUT NOT LIMITED TO EXPENSE OF RETURNING THE PRODUCT TO A BAJA AUTHORIZED SERVICE CENTER AND EXPENSE OF DELIVERING IT BACK TO THE OWNER MECHANIC S TRAVEL TIME TELEPHONE OR TELEGRAM CHARGES RENTAL OF A LIKE PRODUCT DURING THE TIME WARRANTY SERVICE IS BEING PERFORMED TRAVEL LOSS OR DAMAGE TO PERSONAL PROPERTY LOSS OF REVENUE LOSS OF USE OF THE PRODUCT LOSS OF TIME OR INCONVENIENCE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITAT
19. hout treating or Drain fuel and carburetor Refuel with draining gasoline or refueled with bad fresh gasoline gasoline AC receptacle does not work Circuit breaker is OFF Turn ON the AC circuit breaker Item plugged in is defective Try a different item Generator makes a spark knock or An occasional light knocking or ping Switch to a different brand of gasoline pinging noise ing under heavy load is not a cause making sure that the octane rating is 86 for concern However if the knocking or higher If problem continues contact or pinging occurs under normal load your nearest Baja authorized service at a steady engine speed the problem center may be with the brand of gasoline be ing used If problem persists after trying the above solutions contact your nearest Baja authorized service center for assistance The following symptoms may indicate problems that will affect the emissions level of the unit Hard starting or stalling after starting Rough idle Misfiring or backfiring under load Afterburning backfiring E Black exhaust smoke or high fuel consumption If you encounter any of these symptoms have the unit inspected and repaired by the nearest Baja authorized service center Page 21 Breaker 23A Control box BI AC 240V Main winding Socket 30A Main winding Breaker 23A IC circu Ground Engine switch E
20. ilure to follow Maintenance instructions may create a risk of shock or injury Maintain the unit per maintenance instructions in this Operator s Manual Inspect the unit before each use for loose fasteners fuel leaks etc Replace damaged parts National Electric Code requires generator to be grounded to an approved earth ground Before using the ground terminal consult a qualified electrician electrical inspec tor or local agency having jurisdiction for local codes or ordinances that apply to the intended use of the generator SPECIFIC SAFETY RULES E Exhaust contains poisonous carbon monoxide a color less odorless gas Breathing exhaust can cause loss of consciousness and can lead to death If running in a confined or partially enclosed area the air may contain a dangerous amount of carbon monoxide To keep ex haust fumes from building up always provide adequate ventilation Always use a battery powered carbon monoxide detec tor when running the generator If you begin to feel sick dizzy or weak while using the generator shut it off and get to fresh air immediately See a doctor You may have carbon monoxide poisoning Place the generator on a flat stable surface with a slope of no more than 4 Operate in a well ventilated well lit area isolated from working areas to avoid noise interference Operating the generator in wet conditions could result in electrocution Keep the unit dry Keep the generator a m
21. inimum of 3 feet away from all types of combustible material Do not operate generator near hazardous material Do not operate generator at a gas or natural gas filling station Do not touch the muffler or cylinder during or immediately after use they are HOT and will cause burn injury Do not connect to a building s electrical system unless a transfer switch has been properly installed by a qualified electrician To connect a generator to your existing wiring notify your utility company that you are installing a generator Page 4 for backup power Then have a licensed electrical contrac tor install a transfer switch The transfer switch isolates your home from the ability to back feed neutral power lines Failure to isolate the generator from power utility can result in death or injury to electric utility workers Do not allow the generator s gas tank to overflow when filling Fill to 1 in below the top neck of the gasoline tank to allow for fuel expansion Check the ventilation hole in side the fuel tank cap for debris Do not block the vent Do not smoke when filling the generator with gasoline Allow the engine to remain in a shut down condition for at least five minutes before adding gasoline or oil Do not remove the oil dipstick or the fuel tank cap when the engine is running Pay close attention to all safety labels located on the generator Keep children a minimum of 10 feet away from the gen erator at
22. installed on the side opposite the recoil starter NOTE Install the wheels before installing the handle Do not put fuel or oil in the generator before installing the wheels E Locate the following items 2 wheel axles 2 wheels 2 small cotter pins 2 large cotter pins E Raise the end of the generator opposite the recoil starter high enough to gain access to the frame bottom securely position props underneath to support E Locate the U bracket on one side of the frame bottom Slide a wheel axle through the bracket so that an end extends from both sides of the bracket E On the end that extends inside the generator frame insert a small cotter pin through the hole in the axle to secure Bend the ends of the cotter pin to prevent the pin from slipping out FRAME SUPPORT WITH FOOT E Place a wheel over the other end of the axle E Insert a large cotter pin through the hole in the axle Bend the ends of the pin to secure E Repeat the process on the other side INSTALLING THE FRAME SUPPORTS See Figure 4 Install the two frame supports provided on the bottom side of the generator frame opposite the wheels E Locate the following items 2 frame supports 6 bolts E Raise the end of the generator where the recoil starter is located high enough to gain access to the frame bottom securely position props underneath to support E Align the holes on the frame support with the holes on the generator frame E Insert a bolt th
23. is ene o EE a a a E EE ER 21 E Wiring Diagram cccccccecccssssecesssecsseeeessseecssaeecssseecssueessasesecaeecseaseeeseueescaseessseeessseeesseeeecseesessenseseeasaessaeeessseeessaeeseaees 22 E Warranty sianie ae na aniani eo expen sna deena devel bec ERENER baie sec ved ne EEEN ayes aAa SERENAT EEA es EVE E OaE eee 23 MY Pans ordenng Sei viCe issn iai e a ar s AE a Back Page This product has many features for making its use more pleasant and enjoyable Safety performance and dependability have been given top priority in the design of this product making it easy to maintain and operate A DANGER GROUNDING THE GENERATOR To avoid the risk of shock or electrocution generator must be properly grounded The nut and ground terminal on the frame must always be used to connect the generator to a suitable ground source The ground path should be made with 8 size wire Connect the terminal of the ground wire between the lock washer and the nut and tighten the nut fully Connect the other end of the wire securely to a suitable ground source The National Electric Code contains several practical ways in which to establish a good ground source If a steel or iron rod is used it should be at least 5 8 in diameter and if a nonferrous rod is used it should be at least 1 2 in diameter and be listed as material for grounding Drive the rod or pipe to a depth of 8 ft If a rock bottom is encountered less than 4 ft down bury the rod or pipe in a tr
24. items This is the amount of power the generator must produce to keep the items running See the wattage reference chart at right Estimate how many surge starting watts you will need Surge wattage is the short burst of power needed to start electric motor driven tools or appliances such as a circular saw or refrigerator Because not all motors start at the same time total surge watts can be estimated by adding only the item s with the highest additional surge watts to the total rated watts from step 2 Example Tool or Appliance Window AC 10 000 BTU Refrigerator 1 3 HP Well Pump 27 in Television Light 75 Watts Continuous Running Watts Surge Starting Watts 3475 Total Running Watts 2200 Highest Surge Watts 3475 2200 5675 Total Continuous Running Watts Plus Highest Additional Surge Watts Equals Total Generator Output Required POWER MANAGEMENT To prolong the life of the generator and attached devices it is important to take care when adding electrical loads to the generator There should be nothing connected to the generator outlets before starting its engine The correct and safe way to manage generator power is to sequentially add loads as follows 1 With nothing connected to the generator start the engine as described later in this manual Plug in and turn on the first load preferably the largest load you have Permit the generator output to stabilize engine runs
25. nded by the manufacturer of this product The use of attachments or accessories not recommended can result in serious personal injury APPLICATIONS This generator is designed to supply electrical power for operating compatible electrical lighting appliances tools and motor loads A WARNING Do not allow familiarity with tools to make you careless Remember that a careless fraction of a second is suf ficient to inflict serious injury Page 14 OPERATION BEFORE OPERATING THE UNIT Position the generator on a flat surface before checking fluid levels or adding fluid CAUTION Attempting to start the engine before it has been properly filled with oil will result in equipment failure CHECKING ADDING OIL See Figure 6 Engine oil has a major influence on engine performance and service life For general all temperature use SAE 10W 30 is recommended Always use a 4 stroke motor oil that meets or exceeds the requirements for API service classification SJ NOTE Non detergent or 2 stroke engine oils will damage the engine and should not be used E Unscrew the oil cap dipstick and remove E Wipe dipstick clean and re seat in hole do not re thread E Remove dipstick again and check oil level Oil level should fall within the hatched area on the dipstick E If level is low add engine oil until the fluid level rises to the upper portion of the hatched area on the dipstick E Replace and secure the oil c
26. o the unit during operation CHOKE LEVER The choke lever is used when starting the engine ENGINE SWITCH The engine switch is used in combination with the recoil starter grip to start the generator It is also used to turn the generator off FUEL LEVEL GAUGE Consult the fuel level gauge to determine the amount of fuel remaining in the generator FUEL TANK The fuel tank has a capacity of 6 5 gallons FUEL VALVE The flow of fuel through the generator is controlled by the position of the fuel valve GROUND TERMINAL The ground terminal is used to assist in properly ground ing the generator to help protect against electrical shock Consult with a local electrician for grounding requirements in your area OIL DRAINAGE BOLT When changing the engine oil the oil drainage bolt is loos ened to allow old engine oil to be drained OIL CAP DIPSTICK Remove the oil fill cap to check and add oil to the generator when necessary RECEPTACLES Your generator has the following single phase 60 Hz outlets four 120 Volt AC 20 Amp GFCI receptacles and one 240 Volt AC 30 Amp receptacle These can be used for operat ing appropriate appliances electrical lighting tools and motor loads RECOIL STARTER GRIP The recoil starter grip is used along with the engine switch to start the generator s engine Page 11 LOOSE PARTS LIST The following items are included with the generator Description Wheels Wheel
27. of operation of operation Check Engine Oit e o y Change Engine Oit Check AirFitter e ooo o e y Clean Air Fitter o o e y Change Air Fitter J o o O C FP Sediment Cup Check Adjust Spark Plug Replace Spark Plug o o O Check Adjust Idle Speed Check Adjust Valve Clearance Clean Fuel Tank and Filter Check Fuel Tube D ee E A These items should only be carried out by a Baja authorized service center NOTE Maintenance should be performed more frequently when generator is used in dusty areas When generator has exceeded the maximum figures specified in the table maintenance should still be cycled according to the intervals of time or hours stated herein Before each use Page 20 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Engine will not start Engine switch is OFF Turn engine switch to ON No fuel Fill fuel tank Oil level is low Check engine oil level and fill if necessary Fuel valve is OFF Turn fuel valve ON Spark plug faulty fouled or improperly Replace spark plug gapped Fuel is not reaching carburetor Clean fuel sediment cup Choke is OPEN Pull choke lever out to CLOSED Engine stored without treating or Drain fuel and carburetor Refuel with draining gasoline or refueled with bad fresh gasoline gasoline Engine lacks power Fuel element clogged Check air filter element Clean or replace as needed Engine stored wit
28. ool you may need to remove these deposits to restore performance We highly recommend that only qualified service technicians perform this service SPARK ARRESTOR Product users on United States Forest Service land and in some states must comply with fire prevention regulations This product is not equipped with a spark arrestor To pur chase a spark arrestor for the generator contact Baja cus tomer service at 1 866 260 8280 and request part number H60 130 DRAINING FUEL TANK CARBURETOR See Figures 15 16 When not using a fuel stabilizer draining the fuel from the tank and carburetor before storage may help prevent gum deposits in the fuel system DRAINING THE FUEL TANK E Turn the engine switch OFF O E Close fuel valve E Remove the fuel line from the petcock by squeezing the ends of the retaining clip and sliding the fuel line off E Install one end of a drain line over the petcock and place the other end in a fuel container large enough to catch the fuel being drained from the tank E Open fuel valve E When the fuel has drained from the tank close the fuel valve and reinstall fuel line on petcock DRAINING THE CARBURETOR E Turn the engine switch OFF O E Close the fuel valve E Position a suitable container under the carburetor drain screw to catch fuel loosen the screw E Allow fuel to drain completely into container E Retighten drain screw CARBURETOR DRAIN SCREW NOTE Consult hazardous wa
29. rough the hole in the generator frame so it extends down through the frame support E Tighten bolt to secure E Repeat with the two remaining screws E Repeat on other side to install second frame support Page 13 ASSEMBLY INSTALLING THE HANDLES See Figure 5 Locate the following items 2 handles 2 small cotter pins With the generator in normal operating position find the holes on the frame above the recoil starter Align the holes in one of the handle brackets with the holes in one side of the generator frame Insert a clevis pin through the handle bracket and frame The head of the pin should be on the outside of the frame Insert the small cotter pin through the hole in the clevis pin Bend the ends of the pin to secure Repeat the above steps to install the second handle 2 clevis pins A CAUTION Do not attempt to lift the unit by the handle assembly If it is necessary to lift the generator always grasp by the frame Use proper lifting techniques to avoid back injury CLEVIS PIN COTTER PIN y GENERATOR FRAME HANDLE OPERATION A DANGER Failure to properly ground generator can result in elec trocution especially if the generator is equipped with a wheel kit National Electric Code requires generator to be properly grounded to an approved earth ground Call an electrician for local grounding requirements A WARNING Do not use any attachments or accessories not recomme
30. ste management guidelines in your area for the proper way to dispose of used fuel TRANSPORTING E Turn engine switch OFF O E Close the fuel valve E Make sure engine and exhaust of unit is cool E Keep unit level to prevent fuel spillage E Do not drop or strike unit or place under heavy objects Page 19 MAINTENANCE STORAGE When preparing the generator for storage follow the guidelines below STORAGE TIME PRIOR TO STORING Less than 1 month No special preparation is required 1 to 2 months E Fill with fresh gasoline and add a gasoline stabilizer 2 months to 1 year Fill with fresh gasoline and add a gasoline stabilizer Drain fuel from carburetor Clean fuel sediment cup 1 year or more Fill with fresh gasoline and add a gasoline stabilizer Drain fuel from the carburetor Clean fuel sediment cup Remove spark plug Put a tablespoon of engine oil into the spark plug cylinder Turn the engine slowly with the pull rope to distribute the oil Reinstall spark plug Change engine oil After removal from storage E Drain and dispose of stored gasoline in a suitable container E Fill with fresh gasoline Use gasoline stabilizers formulated to extend storage life For recommendations contact your nearest Baja authorized service center MAINTENANCE SCHEDULE After 1st month Every 3 months Every 6 months Every year or or 20 hours of or 50 hours of or 100 hours after 300 hours operation operation
31. t in the air filter unit E Replace the air filter cover E Reinstall the knob and rotate clockwise to secure NOTE Do not run the generator without the air filter Rapid engine wear will result CHANGING ENGINE OIL See Figure 12 E Remove the oil cap dipstick E Place a container underneath the oil drainage bolt to collect used oil as it drains AIR FILTER COVER FILTER ELEMENT AIR FILTER UNIT Fig 11 OIL CAP DIPSTICK OIL DRAINAGE BOLT Fig 12 Unscrew the oil drainage bolt and remove Allow oil to drain completely Reinstall the oil drainage bolt and tighten securely Refill with oil following the instructions in the Checking Adding Oil section Reinstall the oil cap dipstick NOTE Used oil should be disposed of at an approved dis posal site See your local oil retailer for more information Page 17 MAINTENANCE CLEANING FUEL SEDIMENT CUP See Figure 13 The sediment cup prevents dirt and water that may have gotten into the fuel tank from entering the carburetor If the engine has not been run for a long time the sediment cup should be cleaned before use E Turn the fuel valve to the OFF position E Remove the sediment cup using a 10 mm wrench not provided E Remove the O ring and filter E Clean each of the parts in carburetor cleaner or any comparable cleaning product FILTER E Reinstall the filter O ring and sediment cup Tighten with wrench to secure E Return the fu
32. unded to an approved earth ground Call an electrician for local grounding requirements VENTILATION WARNING Do not use the generator in an enclosed area or near open windows vents or doors Fumes from the unit can kill 4 amp DANGER Do not use indoors or outside open windows Fumes can kill you ELECTRICAL EXTENSION CORD CABLE SIZE Refer to the table below to ensure the cable size of the extension cords you use are capable of carrying the required load Inadequate size cables can cause a voltage drop which can burn out the appliance and overheat the cord Load in Watts Maximum Allowable Cord Length Amperes ati2ov at2aov 8Wire 10Wire 12Wire 14Wire 16 Wire coo toot eoor azs 50 120 soot soot poo 125 goo aom oot 125f 100f f ason son toon son M ison oon eon o o mse se se O ooo 0 e0 isot toon OO o S o o o0 se s i Sid SSCS E E a a O E ELECTRIC MOTOR LOADS It is characteristic of common electric motors in normal operation to draw up to six times their running current while start ing This table may be used to estimate the watts required to start Code G electric motors however if an electric motor fails to start or reach running speed turn off the appliance or tool immediately to avoid equipment damage Always check the requirements of the tool or appliance being used compared to the rated outp
33. ut of the generator Watts Required to Start Motor Motor Size H P 7 7 Repulsion Induction Split Phase oo o oon mi w pes A tc 05 poe tos oo ps tp pot o o Ts et oo G S GROUND FAULT CIRCUIT INTERRUPTER Perform this test monthly to ensure proper operation of the GFCI If the generator is stored outdoors unprotected from the weather test the GFCI receptacle before each use The 20 amp 120 volt receptacles on the generator are pro tected by a Ground Fault Circuit Interrupter GFCI which guards against the hazards of ground fault currents An example of ground fault current is the current that would flow through a person who is using an appliance with faulty insulation and atthe same time is in contact with an electrical RESET BUTTON qd TEST BUTTON ground such as a plumbing fixture wet floor or earth GFCI receptacles do not protect against short circuits overloads or shocks The GFCI receptacles can be tested with the TEST and RESET buttons To test d E Depress the TEST button This should cause the Reset p button to pop out E To restore power depress the RESET button Page 8 ELECTRICAL GENERATOR CAPACITY Make sure the generator can supply enough continuous run ning and surge starting watts for the items you will power at the same time Follow these simple steps 1 2 Select the items you will power at the same time Total the continuous running watts of these
34. uth 103 Tempe AZ 85282 Phone 1 866 260 8280 987000 012 www bajamotorsports net 7 28 06 REV 00
35. warnings and instructions in the operator s manual do not use this product Call Baja AQ WARNING p R i customer service for assistance Observe all normal safety precautions related to avoid electrical shock A WARNING The operation of any products can result in foreign objects being thrown into your eyes which can result in severe eye damage Before beginning power tool operation always wear safety goggles or safety glasses D with side shields and when needed a full face shield We recommend Wide Vision Safety Mask for use over eyeglasses or standard safety glasses with side shields Always wear eye protection which is marked to comply with ANSI Z87 1 SAVE THESE INSTRUCTIONS Page 6 SYMBOLS SAFETY LABELS The information below can be found on the generator For your safety please study and understand all of the labels before starting the generator If any of the labels come off the unit or become hard to read contact a Baja authorized service center for replacement FUEL WARNING No smoking when filling with gasoline Do not overfill Full level is 1 in below the top of the fuel neck Stop the engine for five minutes before refueling to avoid the heat from the muffler igniting fuel vapors Check for any fuel overflow or leaking Stop the engine before refuelling GROUNDING WARNING National Electric Code requires generator to be grounded to an approved earth ENGINE OIL WARNING You
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