WEN POWER Power Pro 5500 Owner`s manual
Contents
1. 1010 0 0 JJ g01V43N38 16 S E 2 3 3 2 4 5 2 2 3 4 j C 5 5s i u O L J 2 voles 5 9 9 4 d Ji 9 T Tg D 2s 5 JD N 5 T I 52 J 1 3 v Jg Jg D e 1 a 1 0 79 nj 5 1 U 5 D J I E 14 2 11 441411244 Sd n N e 1 a 0 D A ML A C 2 1 71102 KON A E 3x 48 t CO 33 NOTES 34 WARRANTY STATEMENT FOR POWERPRO TECHNOLOGY PRODUCTS PowerPro Technology generators2. 2 4444 uua 15 OM RS 15 Step o Check the Fuel Eevee 00101010101 15 SED 3s Ground The GCA lop 16 USING THE GENERATOR a 17 SIOPPING THE GENERATOR 20 NATNTENANCE7 0101111010107 21 Clednine the GE 2 io 12 2 210100 x AAS da Oa 21 21 Chane mo AGAn Oil makana cts DRAN S 22 Aur Cleaner 0 0 0000000 29 Fuc Palter Cop leant yy u u EA ESS E SEDER 23 Spark Mattenaliee aac a 24 Dramime the FUEL Tank uere bete E ere Edu toda ume 24 Cban me the BAUME SASS T 25 STORAGE TRANSPORT PROCEDURES 25 SPECIFICATIONS caiie 00 2 000 0 0 018 80524261 du au pas amapas i u 26 TROUBLESHOOTING 6 152 22 96 2 6 22016 22 622 2 222000 6602 6 22216 2 8 610 0 22 20 02 00 9 0 22225 27 EXPLODED AND PARTS LIST uy yuyu a 28 WIRING DIAGRAM
3. Figure 17 Air cleaner maintenance Fuel Filter Cup Cleaning The fuel filter cup 1s a small well underneath the fuel valve It helps to trap dirt and water that may be in the fuel tank before it can enter the engine To clean the fuel filter cup 1 Turn the fuel valve to the off position 2 Unscrew the fuel filter cup from the fuel valve using a wrench Turn the valve toward you to unscrew see figure 18 3 Clean the cup of all sediment using a rag or brush 4 Reinstall the fuel filter cup Fuel Valve Fuel Filter Cup Fuel Filter 2 0 RING lt Fuel Filter Cup Z A Figure 18 Removing the Fuel Filter Cup 23 Spark Plug Maintenance The spark plug is important for proper engine operation A good spark plug should be intact free of deposits and properly gapped To inspect the spark plug l Pull on the spark plug cap to remove it 2 Unscrew the spark plug from the generator using the spark plug wrench included with this product see figure 19 3 Visually inspect the spark plug If it is cracked or chipped discard and replace with a new spark plug 4 Measure the plug gap with a gauge see figure 20 The gap should be 0 7 0 8mm 0 028 0 03 lin 5 If you are re using the spark plug use a wire brush to clean any dirt from around the spark plug base and then re gap the spark plug 6 Screw the spark plug back into its place on the ge
4. SPARK PLUG Hal lease ccasll mana Eloy away i 5 balo e runrinn PACKAGE CONTENTS Your generator comes with the items listed below Please check to see that all of the following items are included with your generator 5 8 5 If there any damaged or missing items please call 800 232 1195 8 5 CST for customer service DO NOT RETURN TO STORE Store personnel are not trained to assist with damaged or missing items ITEM LIST L14 30 plug for connecting 240 Volt electrical devices Spark plug wrench Mobility kit Wrenches Please familiarize yourself with the locations and functions of the various components and controls GENERATOR COMPONENTS of your generator 1 2 3 4 5 6 7 8 Choke Lever Adjusts the amount of air let into the engine Air Cleaner A removable cleanable sponge like element that limits the amount of dirt pulled into the engine Fuel Valve Allows fuel to enter engine Fuel Filter Cup Traps dirt and water from fuel before it enters the engine Recoil Starter Pull cord for starting engine Electric start Switch To start stop engine Oil Fill and Dipstick Location for checkin
5. STOPPING THE GENERATOR Procedure to Stop Generator NOTE Stopping the motor or unplugging cords from the generator while it is supplying power to devices will possibly damage the voltage regulator and result in low or no power output until the voltage regulator is replaced Following the stopping procedure will minimize the possibility of damaged voltage regulators l 2 3 Turn off all electrical devices being powered by generator prior to unplugging them from the generator Turn the engine switch to the off position Turn the fuel valve to the off horizontal position Stopping when generator is to be stored for long period of time l 2 3 Turn off all electrical devices being powered by generator prior to unplugging them from the generator Turn the fuel valve to the off horizontal position Allow engine to run until it stops If generator will be stored for more than 60 days remove all fuel from the tank Fuel removal is best accomplished by siphoning as much as 1s possible from the tank and then remove the fuel hose from the fuel cock turn on the fuel valve and drain the remaining fuel from the tank Disconnect the negative battery cable from the battery for storage After disconnecting the cable cover the free end with an insulator such as electrical tape WARNI NG Allow the generator to cool for several minutes before touching areas that become hot during use CAUTION Allowing gasoline to
6. RUBBER PLUG 21 22 GOVERNOR ARM WASHER 2 35 OILSEAL 36 CRANKCASE COVER ASSEMBLY 37 GASKET CRANKCASE 38 CAP COMP OIL FILLER 39 O RING OIL FILLER 35 36 Y 37 38 39 O RING 4 por 42 43 44 2 2 66 CAMSHAFT ASSEMBLY 68 INTAKE VALVE EXHAUST VALVE BBB EXHAUST VALVE VALVE SPRING 2 70 EX VALVE SPRING SEAT 72 72 VALVECAP VALVE SEAL 74 IN VALVE SPRING SEAT VALVE LIFTER 74 75 80 VALVEADJUSTINGNUT 2 86 GP 00005 2 BOLT 42 BEARING 487 GOVERNOR GEAR ASSEMBLY 44 WASHER I 20 89 RETURNING SPRING 90 SPRING 134 WINGSCREW 135 AIRCLEANERCOVER 1 3 a37 Borr 6 _ 141 ATR CLEANER BRACKET 1 _ 2 2 nor 1 143 AIR CLEANER ASSEMBLY _ 144 FLYWHEELNUT 101 145 STARTERPULLEY 5 as ran 0 147 FLYWHEEL 1 151 BOT 108 109 15 110 111 112 113 114 2 108 THROTTLE VALVE 109 CHOKE ASSEMBLY 153 CHARGECOL 110 IDLE SPEEDJET 154 BOT 111 IDLE ADJUSTING SPRING 112 IDLE ADJUSTING BOLT 113 IDLE ADJUSTING SCREW 114 CHOKE SUBASSEMBLY MAIN NOZZLE 116 FLOAT SPRING VALVE FILLING OIL NEEDLE 116 117 121 122 123 124 156 CHARGE COIL CLAMP 157 THROTTLE CONTROL ASSEMBLY 1 0 BOLT 3 BOLT 155 BOLT 156 157 158 BOLT 15 1
7. Spark plug is broken Lau spark plug Generator is not Move generator to a level surface to prevent low oil shutdown level surface from Oil is low Add or Add or replace oil 0000000000000 oil Air cleaner is dirty Clean or replace air cleaner Circuit reset button Wait for 2 minutes and push the circuit reset button to the is OFF ON position Bad connecting wires cables If you are using an extension cord try a different one Bad electrical device connected to generator Try connecting a different device hue the brush Perform these steps 1 Turn off all electrical devices 2 Unplug all electrical devices 3 Turn off generator 4 Wait several minutes Generator is 5 Restart generator overloaded 6 Try connecting fewer electrical loads to the generator Short in one of the connected devices disconnecting any faulty or short circuited electrical loads 21 ENGINE EXPLODED VIEW AND PARTS LIST 6 __ sl 1 sd 8 8 8 ISL 2 EXVALVEGUDE 49 GOVERNOR SLIDER 6 CYLINDER HEAD COVER 1 so JOLSEAL 1 51 8 BREATHERTUBE 11 3 pio WASHER 11 BOLT GASKET 55 CRANKSHAFT ASSEMBLY 1 14 15 CEE 14 Jan BALANCER WEIGHT 15 CYLINDER HEAD BOLT PISTON RING ASSEMBLY EN SPARK PLUG PISTON CYLINDER HEAD ASSEMBLY 17 CYLINDER HEAD ASSEMBLY CRANKCASE ASSEMBLY CRANKCASE OIL SEAL 21 OIL SENSOR
8. THROTTLE HANDLE BLOCK ADJUSTING SPRING SCREW _ 121 DEPOSIIONCUP 12 WASHER 124 DRAINPLUG 126 FLOATGASKET 11 128 WASHER 2 30 GENERATOR EXPLODED VIEW AND PARTS LIST IU y Ld i e Jr 3l Item Description Qty _ MUFFLER SHROUD 1 1 MUFFLER SHROUD 3 4 RUBBERSEAL 1 5 MUFFLERBRACKET 8 pir 1 9 9 MUFFLER GUARD 1 11 2 NUT M8 12 EXHAUST PIPE 1 4 BUSH 18 2 FUELGAUGEPLATE 23 SCREW 24 FUEL FILTER GAS CAP GASCAP 005 31 2 35 BATTERY CLAMP BOLT 2 36 BATTERY CLAMP 1 41 45 AXLE 46 47 AXLE 46 AXLE BRACKET 2 WASHER 2 Description Qty 59 SLEEVE 1 60 SLEEVE 1 61 6 68 WASHER 4 6 scREW o 4 71 STATOR COMP 72 MOTOR HOUSING BOLT WASHER BOLT 7 78 79 81 VOLTAGE REGULATOR BOLT BRUSH ASSEMBLY END COVER EN 79 BOLT 80 81 BOLT 002 TERMINAL TERMINAL 83 BOLT 2 84 CABLE TIE 2 86 A 89 SPARKARRESTOR 90 SCREW 95 HANDLE GRIP 2 1 2 2 2 EE 32 WIRING DIAGRAM 14715 NO 140 WY Lu T 24 49 IZA Cy Ys 018 3N DNJ
9. EORR 32 WARRANTY STA TEMEN ESS SD a a a 35 11 INTRODUCTION Thank You for Purchasing Powerpro Technology Product This manual provides information regarding the safe operation and maintenance of this product Every effort has been made to ensure the accuracy of the information in this manual Powerpro Technology reserves the right to change this product and specifications at any time without prior notice Please keep this manual available to all users during the entire life of the generator Special Messages This manual contains special messages to bring attention to potential safety concerns generator damage as well as helpful operating and servicing information Please read all the information carefully to avoid injury and machine damage Questions Problems DO NOT RETURN TO STORE Store personnel where the generator was purchased are not trained to handle technical questions or problems In order to answer questions and solve problems in the most efficient and speedy manner contact Customer Service at 800 232 1195 M F 8 5 CST NOTICE REGARDING EMISSIONS Engines that are certified to comply with U S EPA emission regulations for SORE Small Off Road Equipment are certified to operate on regular unleaded gasoline and may include the following emission control systems EM Engine Modifications and TWC Three Way Catalyst 1f so equipped SAFETY INFORMATION Before operating this generator read and
10. appropriate type and amount of oil into the crankcase The crankcase 16 full when the oil level has reached the second thread from the lip of the opening see figure 3 4 Check for oil leaks Reinstall oil filler cap before starting engine OIL FILLER CAP OIL FILLER HOLE FILL TO THIS LEVEL Figure 2 Unscrewing the oil cap Figure 3 filling oil Step 2 Add Gasoline AN A 9 69 WARNING This generator may emit highly Riskot MES flammable and explosive gasoline vapors which can cause severe burns or even death if ignited A nearby open flame can lead to explosion even if not directly in contact with gasoline Do not operate near open flame Do not smoke near generator Always operate on a firm level surface Always turn generator off before refueling Allow generator to cool for at least 2 minutes before removing fuel cap Loosen cap slowly to relieve pressure in tank Do not overfill fuel tank Gasoline may expand during operation Do not fill to the top of the tank Allow for expansion e Always check for spilled fuel before operating Clean up any spilled fuel before starting e Empty fuel tank before storing or transporting the generator e Before transporting turn fuel valve to off position and disconnect spark plug wire 10 Use fresh within 30 days from purchase unleaded gasoline with a minimum 97 octane rating Do not use gasoline which contains Methanol Do not mix oil with gasol
11. electrical devices such as refrigerators require short bursts of extra power in addition to the running wattage listed by the device to stop and start their motors The starting wattage ability of the generator covers this extra power requirement Model Number Rated Running Wattage Starting Watt 6800E 5500 6800 Figure 9 generator wattage The total running wattage requirement of the electrical devices connected to the generator should not exceed the running wattage of the generator itself To calculate the total wattage requirement of the electrical devices you wish to connect find the rated or running wattage of each device This number should be listed somewhere on the device or in its instruction manual If you cannot find this wattage you may calculate it by multiplying the Voltage requirement by the Amperage drawn Watts Volts x Amperes If these specifications are not available you may estimate the Watts required by your device using the chart in figure 10 17 When the running wattage requirement of each electrical device has been determined add these numbers to find the total running wattage needed If this number exceeds the running wattage of the generator DO NOT connect all these devices Select a combination of electrical devices which has a total running wattage lower than or equal to the running wattage of the generator CAUTION The generator can run at its starting wattage capacity for only a short time Con
12. observe all warnings cautions and instructions on this sheet on the generator and in the Owner s Manual NOTE The following safety information is not meant to cover all possible conditions and situations that may occur Read the entire Owner s Manual for safety and operating instructions Failure to follow instructions and safety information could result 1n serious injury or death This safety alert symbol is used to identify safety information about hazards that can result in personal injury A signal word DANGER WARNING Or CAUTION is used with the alert symbol to indicate the likelihood and the potential severity of injury In addition a hazard symbol may be used to represent the type of hazard DANGER indicates a hazard which if not avoided will result in death or serious injury WARNING indicates a hazard which if not avoided could result in death or serious injury CAUTION indicates a hazard which if not avoided might result in minor or moderate injury CAUTION when used without the alert symbol indicates a situation that could result in damage to the engine or generator SAFETY SYMBOLS AND MEANINGS Da Not Touch Hot Surface GENERAL SAFETY PROCEDURES For any questions regarding the hazard and safety notices listed 1n this manual or on the product please call 800 232 1195 M F 8 5 CST before using the generator A ems DANGER CARBON MONOXIDE Using a generator indoors CAN KILL
13. sit in the generator tank for long periods of time without use can make it difficult to start the generator in the future Never store generator for extended periods of time with fuel in the tank 20 MAINTENANCE CARE Proper routine maintenance of your generator will help prolong the life of your machine Please perform maintenance checks and operations according the schedule in figure 13 dii If you have questions about any of maintenance procedures listed this manual please call 800 232 1195 M F 8 5CST CAUTION Never perform maintenance operations while the generator is running Recommended Maintenance Schedule first month every every 6 then every months or months or every year 50 hrs 100 hrs or 300 hrs oe level o X j o j ee DE SS M LLLI Air cleaner check clean fuel filter cup clean spark plug pewden x check fuel level x dean oo Figure 13 Recommended maintenance schedule Cleaning the Generator Never clean the generator when it 1s running Never clean with a bucket of water or a hose Water can get inside the working parts of the generator and cause a short circuit or corrosion Always try to use the generator in a cool dry place If the generator becomes dirty clean the exterior with a damp cloth a soft brush vacuum or pressurized air Checking the Oil Check the oil level of the generator according to the Recommended Mainte
14. 2 3 minutes allowing stabilized fuel mixture to circulate through the carburetor When transporting or storing the generator for extended periods of time Drain the fuel tank see Draining the Fuel Tank in the Maintenance section Disconnect the spark plug cap from the spark plug Do not obstruct any ventilation openings Keep the generator in a cool dry area 25 SPECIFICATIONS Generator Running Wattage 5500W Starting Wattage 6800W Rated Voltage 240V 120 V Rated Amperage 23 46 Dimensions in without kit length 27 4 width 21 8 height 21 5 200 Ibs 4 stroke OHV single cylinder with forced air cooling system Ignition system non contact transistor Fuel tank capacity 25 L 6 50 US gal Oil ria 1 1L fl oz Run time on Run time 50 load 11 MS 74 dB idle Noise rating at 22 feet 29 dB full Spark plug NGKBPRES 6 5 26 TROUBLESHOOTING IMPORTANT If trouble persists please call our customer help line at 800 232 1195 M F 8 5 Central Time Problem Cause Solution 0 0 0 0 00 Engine will not start Engine runs but there is no electrical output Generator runs but to OFF Turn fuel valve to ON position position o choke out Engine is out of fuel Add Engine is filled with contaminated or old gasoline y the gasoline in the engine Spark plug is dirty Clean plug
15. Allow generator to cool for at least 2 minutes before removing fuel cap Loosen cap slowly to relieve pressure in tank Do not overfill fuel tank Gasoline may expand during operation Do not fill to the top of the tank Allow for expansion Always check for spilled fuel before operating Clean up any spilled fuel before starting Empty fuel tank before storing or transporting the generator Before transporting turn fuel valve to off and disconnect spark plug wire IMPORTANT Use only UNLEADED gasoline with an octane rating of 87 or higher Do not use old gasoline Never use an oil gasoline mixture Avoid letting dirt or water into the fuel tank Step 3 Ground the Generator WARNING Failure to properly ground the generator can result in electrocution Ground the generator by tightening the grounding nut on the front control panel against a erounding wire Figure 5 A generally acceptable grounding wire is a No 12 AWG American Wire Gauge stranded copper wire This grounding wire should be connected at the other end to a copper brass or steel grounding rod that 1s driven into the earth Wire and grounding rod are not included in generator contents Grounding codes can vary by location Contact a local electrician for area codes 16 USING THE GENERATOR AN WARNI NG When this generator is used to supply a building wiring system Sanger Generator must be installed by a qualified electrician and con
16. L NUMBER SERVICE RECORD Record Service Dates 1 TABLE OF CONTENTS GENERATOR IDENTIFICA TION 506228 i SERVICE RECORD 562201 531599151620681 3940915162 0843535900 16 0084 3 49903502 68 0 8 0 0 5 0 0 00 54 0 00 1885 i INTRODUC HON aa 1 SAFETY INFORMATION 0 1 0 1 1 0 _ 0110101010101010 0 2 GENERAL SAFETY 1 11 31 891 3 IMPORTANT SAFETY INSTRUCTIONS 2 aaa aa 5 PACKAGE CONTENDS 6 GENERATOR COMPONENTS caccini Z 8 ASSEMBLY 1 1 1 1 1 0 000101010101010 ba vies 9 GENERATOR PREPARA DION 5 0 9 Wsine the Generator for ihe First TIME 9 viole E 9 Slop Add Gasolina 0000001 MIU MEE S ELE 10 SE the luu acres N E 11 S p CONNEC Ne Dale Se u D ae sa nud 12 STARTING THE GENERATOR 3 5 5 tissues ini 13 SUBSEQUENT STARTING OF THE
17. POW EAH L L Em LL MODEL 6800E 13 HP Generator Item 56680 Owner s Manual J SS 5 s x 5 p c t lt 9 E b M S lt EN 5 N RASA NN SIMI lt gt WSs SF a N V 5 d E N ONS es x DO NOT RETURN TO STORE a Questions Problems Please call our customer help line 800 232 1195 M F 8 5 CST FEATURES 6800 Starting Watt Output 5500 Running Watt Output 120 and 240 Volt AC Outputs Low Oil Automatic Shutoff Circuit Breaker for Overload Protection 6 5 Gallon Fuel Tank Capacity Spark Arrestor Digital Hour Meter Electric Starter Mobility Kit included Meets EPA Emission Standards 06 09 GENERATOR IDENTIFICATION For information and questions please contact the Customer Service Help Line by calling 800 232 1195 Certain information will be requested by the Customer Service Representative and to facilitate that please fill in the information below Refer to the illustration below for the location of Serial Number Record generator information in the spaces provided below DATE OF PURCHASE PURCHASED FROM GENERATOR MODEL NUMBER ENGINE SERIAL NUMBER 0 ENGINE SERIA
18. YOU IN MINUTES Generator exhaust contains carbon monoxide CO This is a poison gas you cannot see or smell If you can smell the generator exhaust you are breathing CO But even if you cannot smell the exhaust you could be breathing CO NEVER use a generator inside homes garages crawlspaces or other partly enclosed areas Deadly levels of carbon monoxide can build up in these areas Using a fan or opening windows and doors does NOT supply enough fresh air e ONLY use a generator outside and far away from windows doors and vents These openings can pull in generator exhaust Even if you use a generator correctly CO may leak into the home ALWAYS use a battery powered or battery backup CO alarm in the home If you start to feel sick dizzy or weak after the generator has been running move to fresh air RIGHT AWAY See a doctor You may have carbon monoxide poisoning AN WARNI NG The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A A e WARNING This generator may emit highly igt No Em flammable and explosive gasoline vapors which can cause severe burns or even death if ignited A nearby open flame can lead to explosion even if not directly in contact with gasoline Do not operate near open flame Do not smoke near generator Always operate on a firm level surface Always turn generator off before refueling Allow g
19. are warranted to the original purchaser to be free from defects in materials and workmanship for a period of two 2 years from the date of original purchase Generators used for commercial or for rental have a warranty period of 90 days from date of original purchase Please fill out the enclosed warranty card and mail it to Power Pro Technology along with a copy of the receipt The information is required to process warranty claims PowerPro Technology M will repair or replace at its discretion any part that 1s proven to be defective in materials or workmanship under normal use during the two 2 year warranty period Warranty repairs or replacements will be made without charge for parts or labor Parts replaced during warranty repairs will be considered as part of the original product and will have the same warranty period as the original product TO EXERCISE WARRANTY COVERAGE Do not return to retailer For warranty and technical support call the toll free Customer Service Number 800 232 1195 and you will be informed of the nearest authorized service center We will prearrange the repair with the center WARRANTY COVERAGE This warranty 15 conveyed to the original purchaser and is not transferable Generators contain parts that will wear out with usage and parts that need maintenance The warranty does not cover wear or maintenance parts Specifically the warranty does not cover replacement of air filter spark plug brush and recoil s
20. ct battery while generator is running e Service or use battery only in well ventilated areas WARNING Battery contains sulfuric acid Battery acid is poisonous Tilting the generator with the battery installed can cause battery acid to spill Wear protective clothing and eyewear when servicing battery e Keep out of reach of children Donottilt generator with battery installed If your generator will start manually using the recoil starter pull cord but will not start electrically with the key the battery may be drained In this case you can recharge the battery by starting the generator manually and allowing it to run for 20 minutes However if your battery will no longer hold a charge you may need to replace it To replace the battery 1 Disconnect the positive and negative cables from the battery 2 Remove the metal bracket that secures the battery to the generator 3 Install the replacement battery and secure to the generator with the bracket Use a 12V battery that 15 11 Ah or greater Connect the positive and negative cables to the new battery STORAGE TRANSPORT PROCEDURES CAUTION Never place any type of storage cover on the generator while it is still hot If the generator 1s being stored for short periods of time 30 60 days add stabilized fuel to the fuel tank until full NOTE Filling the tank reduces the amount of air in the tank and helps reduce deterioration of fuel Run the engine for
21. d are not included in generator contents Grounding codes can vary by location Please contact a local electrician to check the grounding regulations for your area p Grounding Figure 5 Grounding nut location 11 Step 4 Connect the Battery A WARNING Battery gives off explosive hydrogen gas Keep battery away from spark flame or cigarette e not connect or disconnect battery while generator is running e Service or use battery only in well ventilated areas WARNING Battery contains sulfuric acid Battery acid is poisonous Tilting the generator with the battery installed can cause battery acid to spill Wear protective clothing and eyewear when servicing battery Keep out of reach of children Do not tilt generator with battery installed If battery acid gets on your skin wash with water immediately If battery acid gets in your eyes flush with water for at least 15 minutes and call a doctor immediately If battery acid is swallowed drink a large amount of water or milk Then drink milk of magnesia or vegetable oil Call a doctor immediately The generator comes with the battery disconnected for safety To use the electric start the battery needs to be connected To connect the battery 1 Remove the protective covering from the free end of the negative battery cable This cable is connected to the generator on the other end and 15 located in the vicinity of the battery 2 Attach the free end of t
22. dle is securely clamped to the frame 2 Repeat above instruction for remaining handle GENERATOR PREPARATION Using the Generator for the First Time The following section describes steps necessary to prepare the generator for use If after reading this section you are unsure about how to perform any of the steps please call 800 232 1195 M F 8 5 CST for customer service Failure to perform these steps properly can damage the generator or shorten its life Step 1 Fill Oil The generator 15 shipped without oil User must add the proper amount of oil before operating the generator for the first time The oil capacity of the engine crankcase 15 37 fluid oz Select good quality detergent oil bearing the American Petroleum Institute API service classifications SJ SL or SM Synthetic oils may be used Use the SAE viscosity grade 9 of oil from the following chart that matches the starting temperature anticipated before the next oil changes lt 9W 30 10W 30 5 10 0 10 20 30 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE Figure 1 Engine oil recommendations To fill oil to the crankcase follow these steps 1 Make sure the generator 15 on a level surface Tilting the generator to assist in filling will cause oil to flow into engine areas and will cause damage Keep generator level 2 Remove the oil filler dipstick cap from the engine as shown in figure 2 3 Using a funnel add the
23. enerator to cool for at least 2 minutes before removing fuel cap Loosen cap slowly to relieve pressure in tank Do not overfill fuel tank Gasoline may expand during operation Do not fill to the top of the tank Allow for expansion e Always check for spilled fuel before operating e Empty fuel tank before storing or transporting the generator e Before transporting turn fuel valve to off and disconnect spark plug wire WARNING This generator produces powerful voltage which can me result in electrocution ALWAYS ground the generator before using it see the Ground the Generator portion of the PREPARATION section Generator should only be plugged into electrical devices either directly or with an extension cord NEVER connect to a building electrical system without a qualified electrician Such connections must comply with local electrical laws and codes Failure to comply can create a back feed which may result in serious injury or death to utility workers Use a ground fault circuit interrupter in highly conductive areas such as metal decking or steel work GFCIs are available in line with some extension cords Do not use in rainy conditions Do not touch bare wires or receptacles outlets Do not allow children or non qualified persons to operate WARNING This generator produces heat when running Temperatures near exhaust can exceed 150 F 65 C e Do not touch hot su
24. er outages permanently installed stationary generators are better suited for providing backup power to the home Even a properly connected portable generator can become overloaded This may result in overheating or stressing the generator components possibly leading to a generator failure WARNI NG When this generator is used to supply a building wiring system Generator must be installed by a qualified electrician and connected to a transfer switch as a separately derived system in accordance with the National Electrical Code NFPA 70 The generator shall be connected to a transfer switch that switches all conductors other than the equipment grounding conductor The frame of the generator shall be connected to an approved grounding electrode In addition to the previous safety notices please become familiar with the safety and hazard markings on the generator USE CAS A DANGER Fuel Gauge DO NOT RETURN TO STORE YOU AHF HAVING PRDFI PNS WITH THIS GENERATOR CALL OUR CUSTOMER HELP LINE 800 232 1195 W F 5CT Run Pus 1 Seu i r NI E3251 OIL FILL AND DIPSTICK 37 IQ AD O UNSUR W LAI FILL TO 12W 20 DEL RG NI MOIOR OIL
25. ficult for the engine to start Check that the generator 1s properly grounded see Figure 5 Ground the Generator Check the oil and gas levels Turn the fuel valve to the position see figure 6 Move the choke rod to the Start position see figure 7 Set the engine switch to the ON position Turn the engine switch to the START position for 2 3 seconds or until the engine starts NOTE If the engine does not start after 2 3 seconds release the switch from the start position Keeping the switch the START position too long can damage the starter If engine fails to start wait 10 seconds then repeat step 7 NOTE After repeated attempts to start the engine please consult the troubleshooting guide before attempting again If problems persist please call 800 232 1195 M F 8 5 CST Once the engine has started Slowly move the choke rod all the way to the Run position Allow the generator to run for several minutes before attempting to connect any electrical devices Manual Start To start your generator using the manual start function perform the following steps 1 E 9 No electrical devices should be connected to the generator during starting Devices can make it difficult for the engine to start Check that the generator 1s properly grounded see Ground the Generator Check the oil and fuel levels Turn the fuel valve to the position see figure 6 Move the choke
26. g and filling engine oil Circuit Reset Buttons Reset buttons that protect the generator from electrical overload 9 Ground Terminal Connect grounding wires here to properly ground unit 10 120 Volt AC Duplex Receptacle To connect electrical devices that run 120 Volt 60 Hz single phase AC current rated 20 amps 11 120 240 Volt AC Receptacle To connect electrical devices that run 120 and or 240 Volt 60 Hz single phase AC current twist lock receptacle rated 30 amps 12 Muffler with Spark Arrester Reduces engine noise 13 Spark Plug Provides proper engine ignition 14 Fuel Cap Access to the fuel tank for adding fuel 15 Fuel Gauge Indicates the amount of fuel in the tank 16 Wheel 17 Handle hold up the handle and pull it to walk ASSEMBLY Step 1 Wheel Installation 1 Blocking up the muffler side of the generator assemble the axle to the frame 2 Slide the wheel and washer onto the axle with the offset of the wheel hub against the frame 3 Secure the wheel to the axle with the cotter pin 4 Repeat above instructions for the remaining wheel Step 2 Foot Installation 1 Blocking up the engine side of the generator assemble the rubber foot to the frame 2 Repeat above instructions for the remaining foot Step 3 Handle Installation 1 Assemble the handle to the frame align with hole in tubing Slide the bolt through handle frame and washer and secure with the nut Tighten until han
27. g the Generator for the First Time If the user has not yet read this section go back and read it now Step I Check the Oil Oil consumption is normal during generator usage The generator 1s equipped with a low oil shutoff to protect it from damage The oil level in the engine should be checked before each use to ensure that the engine crankcase contains sufficient lubricant To check or add oil follow these steps 1 Make sure the generator 15 on a level surface Clean around oil fill 2 Remove the oil filler dipstick cap and check oil level 3 11 011 level 1s below the second thread from the lip of the oil fill opening slowly add until the engine crankcase is filled 4 Reinstall and tighten oil filler cap before starting the engine Step 2 Check the Fuel Level Before starting the generator check to see that there 1s sufficient gasoline in the fuel tank The fuel gauge on top of the generator will indicate the fuel level in the tank Add gasoline if necessary but leave sufficient room in tank for expansion A 9 9 WARNING This generator may emit highly mmu flammable and explosive gasoline vapors which can cause severe burns or even death if ignited A nearby 15 open flame can lead to explosion even if not directly in contact with fuel Do not operate near open flame Do not smoke near generator Always operate on a firm level surface Always turn generator off before refueling
28. he negative cable to the battery and secure the connection NOTE If you do not plan to use the generator for a long period of time it 1s a good idea to disconnect the negative battery cable from the battery for storage After disconnecting the cable cover the free end with an insulator such as electrical tape NOTE After completing the 4 step Generator Preparation the generator is ready to be started 12 STARTING THE GENERATOR Before starting the generator make sure you have read and performed the steps in the Generator Preparation section of this manual If you are unsure about how to perform any of the steps in this manual please call 800 232 1195 M F 8 5 CST for customer service A DANGER CARBON MONOXIDE Using a generator indoors CAN KILL TEE YOU IN MINUTES Generator exhaust contains carbon monoxide CO This is a poison gas you cannot see or smell If you can smell the generator exhaust you are breathing CO But even if you cannot smell the exhaust you could be breathing CO NEVER use a generator inside homes garages crawlspaces or other partly enclosed areas Deadly levels of carbon monoxide can build up in these areas Using a fan or opening windows and doors does NOT supply enough fresh air e ONLY use a generator outside and far away from windows doors and vents These openings can pull in generator exhaust Even if you use a generator correctly CO may leak into the home ALWAYS use a battery
29. ine To add gasoline follow these steps 1 Make sure the generator is on a level surface 2 Unscrew fuel cap and set aside NOTE the fuel cap may be tight and hard to unscrew 3 Slowly add unleaded gasoline to the fuel tank Be careful not to overfill Please refer to the chart in figure 4 for fuel capacity The fuel gauge on the top of the generator indicates how much gasoline is in the generator fuel tank NOTE Do not fill the fuel tank to the very top Gasoline will expand and spill over during use even with the fuel cap in place 4 Reinstall fuel cap and wipe off any spilled gasoline with a dry cloth IMPORTANT Never use an oil gasoline mixture Never use old gasoline Avoid letting dirt or water into the fuel tank Gasoline can age in the tank and make it hard to start up the generator in the future Never store generator for extended periods of time with fuel in the tank Model number 6800E Fuel tank 25L 6 50 gallons capacity Figure 4 Fuel Tank Capacity Step 3 Ground the Generator WARNING Failure to properly ground the generator can result in electrocution Ground the generator by tightening the grounding nut against a grounding wire see figure 5 A generally acceptable grounding wire is a No 12 AWG American Wire Gauge stranded copper wire This grounding wire should be connected at the other end to a copper or brass grounding rod that 1s driven into the earth Wire and grounding ro
30. lever to the Start position see figure 7 Set the engine switch to the ON position Pull on the recoil starter grip slowly until a slight resistance 1s felt see figure 8 Then pull quickly to start the engine Return cord gently into the machine Never allow the cord to snap back If engine fails to start repeat step 7 NOTE After repeated failed attempts to start the engine please consult the troubleshooting guide before attempting again If problems persist please call 800 232 1195 M F 8 5 CST Once the engine has started Slowly move the choke rod all the way to the Run position Allow the generator to run for several minutes before attempting to connect any electrical devices This allows the generator to stabilize its speed and temperature 14 Run Push Choke Start Pull Figure 7 Pull choke out for Start position Push in for Run position 1 Gn 1 5 Figure 8 Pulling the start cord SUBSEQUENT STARTING OF THE GENERATOR If this 1s not the first time using the generator user should take the following steps to prepare it for operation IMPORTANT At this point the user should be familiar with the procedures described in the section titled Usin
31. nance Schedule in Figure 13 The generator is equipped with an automatic shutoff to protect it from running with low oil pressure The generator should be checked before each use for proper oil level This is a critical step for proper engine starting To check or add oil follow these steps 1 Make sure the generator 15 on a level surface Clean around oil fill 2 Remove the oil filler dipstick cap and check oil level as shown in figure 14 3 If oil level is below the second thread from the lip of the oil fill opening slowly add until the engine crankcase is filled 4 Reinstall and tighten oil filler cap before starting the engine 21 OIL FILLER CAP OIL FILLER HOLE Figure 14 Checking the oil Changing Adding Oil Change the oil according to the maintenance schedule in figure 13 Change the oil when the engine is warm This will allow for complete drainage Change oil more often if operating under heavy load or high ambient temperatures It 15 also necessary to drain the oil from the crankcase if it has become contaminated with water or dirt The oil capacity of the engine in this generator 15 37 fluid oz Add oil when the oil level 15 low Drain the oil from the generator according to the following steps 1 Placea container underneath the engine to catch oil as it drains 2 Using a 10 mm hex wrench unscrew the oil drain plug see figure 15 Allow all the oil to drain from the engine 3 Reinstall the oil drain
32. nect electrical devices requiring a rated running wattage equal to or less than the running wattage of the generator Never connect devices requiring a running wattage equal to the surge wattage of the generator This can trip the circuit protectors circuit breakers electric water heater 40 gal 4000 i hotplate OD 0 00 electric stove each element 1500280 saw miter microwave 100 _ 2 320 reciprocatingsaw 90 104 4 sump pump furnace blower eleticdil 6O0 deep freezer garage door opener 40 2 stereo jj y o clockradio 7 30 o 0 NOTE The above wattage figures are estimates Try to check the wattage listed on your electrical device before consulting this chart Figure 10 Estimated wattage requirements of common electrical devices Once you have determined what electrical devices you will be powering with the generator connect these devices according to the following procedure 1 Plug in each electrical device with the device turned off NOTE Be sure to attach appliances to the correct receptacles outlets Connect standard 120 Volt single phase 60 Hz loads only to the 120 Volt receptacles Connect 120 240 Volt single phase 60Hz loads with a NEMA L14 30 plug only to the 120 240 Volt receptacle See Figure 11 for a depiction of each of these receptacles 18 2 Push in the circuit reset buttons to the ON position NOTE They may be pushed in already CAUTION Do no
33. nected to a transfer switch as a separately derived system in accordance with the National Electrical Code NFPA 70 The generator shall be connected to a transfer switch that switches all conductors other than the equipment grounding conductor The frame of the generator shall be connected to an approved grounding electrode For power outages permanently installed stationary generators are better suited for providing backup power to the home Even a properly connected portable generator can become overloaded This may result in overheating or stressing the generator components possibly leading to a generator failure Before connecting electrical devices allow the generator to run for a few minutes to stabilize the speed and voltage output CAUTION Become familiar with the markings on the panel before connecting electrical devices Connect electrical devices running on AC current according to their wattage requirements The chart in figure 9 shows the running and starting wattage of your generator according to its model number NOTE Although the overall running wattage of the machine 15 5000 Watts 1t Is not recommended that you attempt to draw more than 2400 Watts 20 A from any ONE of the 120 Volt receptacles The running wattage corresponds to the maximum wattage the generator can output on a continuous basis The starting wattage corresponds to the maximum amount of power the generator can output for a short period of time Many
34. nerator using the spark plug wrench Do not over tighten spark plug Recommended tightening of spark plug is gt to of a turn after spark plug gasket contacts spark plug hole Reinstall the spark plug cap PLUG WRENCH 1 M 0 028 0 031 in PLUGCAP Figure 19 Removing the spark plug Figure 20 Measuring the spark plug gap Spark Plug NGK BPR6ES Draining the Fuel Tank Clean fuel tank each year or before storing the generator for extended periods of time To drain the fuel tank and carburetor 1 Turn the fuel valve to the OFF position 2 Remove the fuel line between the fuel valve and carburetor Caution a small amount of 5 6 7 8 9 1 fuel may leak from the hose during removal 3 Attach a fuel line not included with the generator to exposed end of the fuel valve 4 Position fuel line into an appropriate container and open the valve allowing fuel to flow into the container Once fuel 1s drained shut off the fuel valve Start and run the engine until fuel runs out Remove the fuel filter cup see Fuel Filter Cup Cleaning earlier in this section Empty the fuel filter cup of any fuel and clean Reinstall the fuel filter cup 0 Store the emptied gasoline in a suitable place CAUTION Do not store fuel for more than 3 months 24 Changing the Battery A WARNING Battery gives off explosive hydrogen gas Keep battery away from spark flame or cigarette Do not connect or disconne
35. plug and tighten with a 10 mm hex wrench To fill the crankcase with oil follow these steps 1 Make sure the generator 15 on a level surface Tilting the generator to assist in filling will cause oil to flow into engine areas and will cause damage Keep generator level 2 Remove the oil filler dipstick cap from the engine as shown in figure 14 above 3 Using a funnel add the appropriate type and amount of oil into the crankcase The crankcase 16 full when the oil level has reached the second thread from the lip of the opening see figure 16 4 Check for oil leaks Reinstall oil filler cap before starting engine FILL TO THIS LEVEL FILLER CAP DRAIN PLUG Figure 15 Draining oil Figure 16 Adding oil NOTE Never dispose of used motor oil in the trash or down a drain Please call your local recycling center or auto garage to arrange oil disposal 22 Air Cleaner Maintenance Routine maintenance of the air cleaner helps maintain proper air flow to the carburetor Check that the air cleaner 15 free of excessive dirt Unscrew the four bolts at the top and bottom of the air cleaner cover see figure 17 Remove the sponge like elements from the cover Wipe the dirt from inside the empty air cleaner cover Wash the sponge like elements in household detergent and warm water Allow to dry Reinstall the sponge like elements in the air cleaner casing and reinstall the cover AES
36. powered or battery backup CO alarm in the home If you start to feel sick dizzy or weak after the generator has been running move to fresh air RIGHT AWAY See a doctor You may have carbon monoxide poisoning WARNING This generator produces powerful voltage which can result in electrocution e ALWAYS ground the generator before using it see the Ground the Generator portion of the PREPARATION section e Generator should only be plugged into electrical devices either directly or with an extension cord NEVER connect to a building electrical system without a qualified electrician Such connections must comply with local electrical laws and codes Failure to comply can create a back feed which may result in serious injury or death to utility workers Usea ground fault circuit interrupter GFCT in highly conductive areas such as metal decking or steel work GFCIs are available in line with some extension cords e Do not use in rainy or wet conditions e Do not touch bare wires or receptacles outlets Do not allow children or non qualified persons to operate A CAUTION Disconnect all electrical loads from the generator before attempting to start 13 Electric Start To start the generator using the electric start function perform the following steps l DU e ps 9 Make sure no electrical devices are connected to the generator Such devices can make it dif
37. rfaces Pay attention to warning labels on the generator identifying hot parts of the machine e Allow generator to cool down after use before touching engine or areas of the generator that become hot during use CAUTION Misuse of this generator can damage it or shorten its life Use generator only for its intended purposes Operate only on dry level surfaces Allow generator to run for several minutes before connecting electrical devices Shut off and disconnect any malfunctioning devices from generator Do not exceed the wattage capacity of the generator by plugging in more electrical devices than the unit can handle Do not turn on electrical devices until after they are connected to the generator Turn off all connected electrical devices before stopping the generator Turn the engine switch to OFF position when the engine 15 not running IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for Powerpro Technology 6800E generator that should be followed during installation and maintenance of the generator and battery Generators vibrate in normal use During and after the use of the generator inspect the generator as well as extension and power supply cords connected to it for damage resulting from vibration Have damaged items repaired or replaced as necessary Do not use plugs or cords that show signs of damage such as broken or cracked insulation or damaged blades For pow
38. t connect 50Hz or 3 phase loads to the generator POWERPRO TECHNOLOGY 2 1 20 volt duplex receptacle 800 232 1195 120 240 volt receptacle Figure 11 Receptacles available on the generator CIRCUIT RESET BUTTONS The circuit reset buttons help to prevent the generator from electrical overload If your receptacle short circuits or becomes overloaded by an electrical device or devices with too great a wattage rating the circuit protector may shut off power to the receptacle In the event of such an overload disconnect all electrical devices from the generator and press the circuit reset buttons If power still does not return to the receptacle call our customer service line SOME NOTES ABOUT POWER CORDS Long or thin cords can drain the power provided to an electrical device by the generator When using such cords allow for a slightly higher running wattage requirement by the electrical device See Figure 12 for recommended cords based on the power requirement of the electrical device 25 30 760 1000 600 375 250 5 60 1200 NR EL 9800 1800 NR 350 200 125 100 10 10 20 NR 250 150 100 50 15 100 3600 150 10 6 NR NR 25 8300 600 15 100 6 NR NR 30 360 70 15 65 NR NR 40 40 90 90 NH NR NRz not recommended Figure 12 Maximum Extension Cord Lengths by Power Requirement 19
39. tarter rope Warranty does not extend to generators damaged or affected by accidents neglect misuse contaminated fuel unauthorized alterations use in applications beyond product design and any other modification or abuse PowerPro Technology is not liable for any indirect incidental or consequential damages from the sale or use of this product Any implied warranties are limited to two 2 years as stated this written limited warranty Some states do not allow limitation on the length of an implied warranty Some states do not allow the exclusion or limitation of incidental or consequential damages This warranty gives you the specific legal right and you may have other rights that vary by state 39
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