ltem#6915

GENERATOR 120V AC & 12V DC, 2500W

IMPORTANT: READ THIS MANUAL BEFORE USING!

/

Made Exclusively For . ALDIInc.

Batavia, IL 60510-1477 Visit us at www. ALDI.com

Made in China

.. I

TABLE OF CONTENTS

(I) SAFETY INFORMATION ...................................................................................... 1

(II) PREPARATION .................................................................................................... 1

(Ill) STARTING THE ENGINE ................................................................................... 2

(IV) CONNECTING AN ELECTRICAL DEVICE TO

THE GENERATOR ........................................................................................... 3

(V) STOPPING THE ENGINE ....................................... ; ........................................... 3

(VI) PERIODIC MAINTENANCE .............................................................................. 4

ENGINE OIL REPLACEMENT ......................................................................... 4

AIR FILTER ....................................................................................................... 4

SPARK PLUG ................................................................................................... 5

MUFFLER SCREEN ......................................................................................... 5

FUEL FILTER ................................................................................................... 6

(VII) SPECIFICATIONS ............................................ ; ............................................... 7

DIMENSIONS ................................................................................................... 7

ENGINE ............................................................................................................. 7

GENERATOR .................................................................................................... 7

(VIII) TROUBLESHOOTING ..................................................................................... 7

ENGINE WILL NOT START .............................................................................. 7

(IX) SCHEMATIC ...................................................................................................... 8

(X) EXPLODED VIEW- MAIN UNIT ......................................................................... 9

(XI) PARTS LIST- MAIN UNIT ............................................................................... 10

l .. I

. I

I ..,

5.5!-IP, 3.2-GAL.L..QN, GAS()L..INE PQWERED EL..EGTRI€ GENERATQR

(I) SAFETY INFORMATION

• NEVER operate this power generator indoors or anywhere airflow is restricted.

• To prevent fire or carbon monoxide poisoning, NEVER point the generator's exhaust toward combustible materials or in the direction of open windows or doors.

• NEVER refuel the engine while it is running; stop the engine before refueling .

• To prevent fire, clean any spilled fuel before starting generator.

• NEVER use this power generator near open flames.

• NEVER operate power generator on wet surfaces, rain or snow.

• To prevent electric shock, keep everyone away from the power generator while it is running.

• The sum of the load current used at each outlet should not exceed the nominal maximum current rating printed on the side label.

• The sum of the power used at each outlet should not exceed the total rated power of the generator printed on the side label.

• To prevent electric shock, NEVER touch the generator with wet hands.

(II) PREPARATION NOTE: The following checks should be made each time the generator is used.

Picture 1 - GroEtnding the Generator

1

To prevent electric shock, ALWAYS ground the generator before starting. See Picture 1.

• Before starting, check to make sure there is sufficient fuel in the tank. See Picture 2 .

Picture 2- ®heck ffi'uel in tne lliank

• The fuel tank capacity is 3.2 gallons.

• Do not overfill the fuel tank. Always fill to a level lower than the top of the fuel filter. See Picture 3.

Picture 3 -Avoid Overfilling

• After filling the fuel tank, make sure the cap is tightened securely. Clean any fuel that may have spilled- onto the tank. See Picture 4.

Picture 4- Tighten the ®ap Securely

5.5HP, 3.2-GALL6N, GASOLINE POWERED .ELECT~.IC a"ENE~~T6R

• Before starting the generator, ALWAYS check to make sure the engine oil is near the top of the bottom lip of the oil fill hole. See Picture 5. This generator uses SAE 10W-40 oil. ALWAYS use clean oil when filling.

Add oil as necessary until it reaches the level indicated by CD in Picture 5.

A WARNING: This generator has been shipped without engine oil. Fill the generator with clean SAE 1 OW-40 oil before starting. If the generator is not filled with oil, it will not start.

Picture 5- Checking the IZ:ngine Oil

(Ill) STARTING THE ENGINE • DO NOT plug any device into the generator

before starting the engine. See Picture 6.

Picture 6 - Unplug all Devices

2

1. Turn the fuel petcock to the "ON" position. See Picture 7.

Picture 7 -Turn on the Fuel

ON 2. Turn the choke lever to "0" as shown in Picture 8.

Picture 8- Turn the Choke Lever

3. To start the engine, turn the engine switch to the "ON" position. See Picture 9.

Picture 9- Turn on the Engine . '

ON

4. Grasping the handle, pull slowly on the recoil starter until it is engaged, then pull briskly. See Picture 10.

Picture 1 0·- Pull on the Recoil Starter

I ~

5.5HP, 3.2-GA.l..l..ON, GA.SOI..INE POWERED El..EGillRIG GENERA.illOR

5. Allow the generator's engine to warm up.

6. Now, turn the choke lever back to its normal position as shown in Picture 11.

~icture 11 - murn the Choke l..ever

(IV) CONNECTING AN ELECTRICAL DEVICE TO THE GENERATOR

1. To prevent the power cord of the electrical device being powered from inadvertently becoming unplugged, wind the power cord 2 or 3 turns around the frame of the generator. See Picture 12.

2. ALWAYS check to see that the electrical equipment to be powered is turned off before plugging it into the generator's AC receptacle.

~ieture 12- Secure the ~ower Cord

3. Be sure that the total load of the electrical equipment to be powered is within the generator's rated output.

4. Plug the power cord of the equipm~nt to be powered into the AC receptacle on the generator. See Picture 13.

~ieture 13- ~lug in the ~o~er Cord

3

5. Check to make sure the voltmeter read 120V. See Picture 14.

~ieture 14 - Cheek the "ifoltrneter

~> ·( I\~

v

(V) STOPPING THE ENGINE

1. Before stopping the generator, turn off the electrical device being powered and unplug its power cord from the generator's AC outlet. See Picture 15.

~icture 15- Unplug all Devices

2. Turn the fuel petcock to the "OFF" position as is shown in Picture 16.

~icture 16- murn Off the Fuel

5.5HP, 3.2-GAl..l..ON, GASOI..INE POWERED El..ECTRIC GENERATOR

3. Turn the generator's engine switch to "STOP". See Picture 17.

Picture 17 - Stop the Engine

(VI) PERIODIC MAINTENANCE

e ENGINE OIL REPLACEMENT: Replace after every 20 hours.

1 . Place the generator on a level surface and warm up the engine for several minutes. Now, stop the engine.

2. Remove the oil fill cap. See Picture 18.

Picture 18 - Remove the Oil Fill Cap

3. Place an oil pan under the engine. Carefully, remove the oil drain plug .and allow the oil to drain completely. See Picture 18.

4. Check the drain plug, gasket, oil fill cap, and 0-ring for wear and/or damage. If any of these items are excessively worn or damaged, replace immediately.

CD Oil drain plug ®Gasket ® Oil fill cap with 0-ring

5. Replace oil drain plug. Torque the plug to 12.5 foot pounds-force.

6. Add SAE 1 OW-40 oil until it reaches the top of lower lip. See Picture 19.

4

Picture 19 -Add SAE 1 0\1\l-IJID ®il

ACAUTION: Be sure no foreign material enters the crankcase.

• AIR FILTER: Once per month or every 150 hours.

Picture 20 - Clean the Air Filter

1. Remove the air filter. 2. Wash the air filter gently in cleaning solvent. 3. Add a little motor oil to the filter. 4. Knead the filter to allow the oil to permeate the

sponge. 5. Gently squeeze out excess motor oil.

See Picture 20.

A CAUTION: The engine should never run without the filter element in place.

Be sure the filter element forms a good seal with the air filter to prevent contaminants from bypassing the filter.

- ··- ~

. . 5.51-:iP, 3.2-GAI.d ... ON·, .GAS~liiNE POWERED EliEGTRIG GENERATOR

e SPARK PLUG: Replace after every 50 hours of operation.

1. Remove the spark plug. See Picture21.

~ieture 21 -Remove Spark ~lug

2. Remove carbon deposits with a stiff brush. See Picture 22.

~ieture 22-Remove Carbon Deposits

3. Check for discoloration of the spark plugs tip. Normally, its color should be tan.

4. Check the spark plug gap. It should be set between 0.028- 0.031 inch. See Picture 23.

~ieture 23-Cheeking Spark ~lug Gag

5

e MUFFLER SCREEN: Inspect and clean every 1 00 hours or once every 6 months.

1. Remove the muffler screen. See Picture 24. CD Screw ® Muffler screen

-~icture 24 - Remove l\/luffler Sereen

2. Remove the carbon deposits from the muffler screen by using a wire brush. See Picture 25.

~icture 25- Clean the l\/luffler Sereen

3. Check the muffler screen, and replace it if necessary.

4. Replace the muffler screen and tighten the screw. See Picture 26.

~icture 26- Replace Muffler Sereen

5.5HP, 3.2-GAI.H ... E>N, GASE>Ii.INE P0WEREID Eli.EGTRIC GENERA1"0R

• FUEL FILTER: Inspect and clean every three months or every 150 hours.

Ricture 27- Glean Euel Eilter J:XssembiM

·'OFF''

1. Stop the engine. 2. Turn the fuel petcock to the "OFF" position. 3. Remove the fuel filter assembly with a wrench. 4. Clean with solvent, dry, and replace fuel filter

assembly. Do not overtighten. See Picture 27.

6

!Bieture 28-®lean F"uel Rilter ana ®a~

.

--w-(Q'i> ~

1 . Remove the fuel cap and filter. 2. Wash the fuel filter in solvent. 3. Wipe off and dry. 4. Insert into fuel tank and replace fuel cap.

See Picture 28.

5.5HP, 3.2-GALLON, GASOLINE POWERED ELECTRIC GENERATOR

{VII) SPECIFICATIONS

o DIMENSIONS

Overall Length: 22.83 inch

Overall Height: 17.72 inch

Overall width: 16.34 inch

Net Weight: 95 lbs

o GENERATOR

Rated Output: 2200W

Maximum Output: 2500W

Safety Device: N.F.B.

Rated Frequency: 60Hz

Rated AC Voltage: 120V

Rated AC Current: 18A

Rated DC Voltage: 12V

Rated DC Current: 8.3A

o ENGINE

5.5HP, Air-cooled, 4-stroke, OHV gasoline powered

Displacement: 175 cc

Bore x Stroke: 2.68 x 1.97 inch

Full Fuel Tank Runtime: 9 hours

Fuel Requirements: Unleaded gasoline only

Fuel Tank Capacity: 3.2-gallon

Engine Oil Capacity: 1.25 pints or 20-ounces

Ignition system: TCI

Spark Plug Type: BPR4ES (NGK)

Spark Plug Gap: 0.7-0.8mm or0.028-0.031 inch

Noise Level: 70 dB measured at a distance of 23 feet (7m).

A. CAUTION: This generator can produce two 120V voltages simultaneously: However, when generating two 120V AC, make sure the sum of the output current and/or power do not exceed the rated output of the generator.

{VIII) TROUBLESHOOTING

o ENGINE WILL NOT START

1. No fuel is being supplied to generator's combustion chamber.

• No fuel in tank -7 fill fuel tank.

• Clogged fuel line -7 clean the fuel line.

• Foreign matter in fuel cock -7 clean the fuel

cock.

• Clogged carburetor -7 clean the carburetor.

2. ALWAYS check oil level before starting the generator.

• Oil level is low -7 add engine oil.

3. Electrical system checks.

7

• •

• •

The engine switch should be "ON" .

Spark plug is dirty or wet -7 remove carbon buildup or wipe spark plug dry. Faulty ignition system -7 consult dealer . AC switch trips "OFF" -7 attached electrical device is drawing too much of a load or excessive current. Reduce the load on the generator. If the generator turns off again, consult dealer.

4. Causes for low compression in engine.

• Worn piston and/or cylinder -7 consult dealer.

• Loose cylinder head -7 tighten nuts properly.

• Damaged gasket -7 replace gasket.

SIGNAL

BLK0.75 ¢4 ENGINE IGNITION

YEL/GRN0.75 ill SPARK PLUG

OIL GAUGE

¢4

QO LOW OIL PRESSURE ALAR~

DESCRIPTION MARK

TV/0-INIRE CONNECT ~

ONE-INIRE ---6.3 FLAT FLAKE 6.3 c::J

6.3 FLAT REED 6.3 a </J 4 RECEPTACLE </J4-<

</J 4 PLUG </J4~

</J 6 FLAKE CONNECTOR ¢6 --o 6.3 'L' REED 6.3

IBLK,0.75SECTION,350MMLENGTH BLK0.75/350

II

I I

6.3 4-PIN CONNECTOR

BLU

!BLU

6.3 4-PIN CONNECTOR

->< -(J) (") :I: m :5: ~ -(")

5.5HP, 3.2-GALLON, GASOLINE POWERED ELECTRIC GENERATOR

(X) EXPLODED VIEW- MAIN UNIT

14

rs ~6

I

~: ~4

11 r I

I I

10 I I

j

9

74

35

11

5.5HP, 3.2-GALLON, GASOLINE POWERED ELECTRIC GENERATOR

{XI) PARTS LIST- MAIN UNIT

Item Description Qty Item Description Qty 1 Fuel Tank 1 39 Bracket, Muffler 1 2 Fuel Cap 1 40 Bolt, M6x16 1 3 Seal Gasket 1 41 Bracket, Muffler 1 4 Filter Basket 1 42 Washer 5 2 5 /Screw M6x12 2 43 Spring Washer 5 2 6 Fuel Gauge 1 44 Screw M5x12 2 7 Bolt M6x30 4 45 Nut M6 1

8 Washer 6 4 46 Bolt M6x12 1 9 Grommet, Rubber 4 47 Fuel Signal 1

10 Nut 4 48 Voltmeter 0-150V 1 11 Cradle 1 49 Power Signal 1

12 Bolt M6x16 4 50 Screw M3x35 4 13 Bolt M6x10 4 51 Nut, Circuit Breaker, 120V 2 14 Shield, Muffler 1 52 Nut, DC connector 2 15 Muffler 1 53 Screw M4 x12 2

16 Engine 1 54 Screw M4 x12 6 17 NutM8 4 55 Washer5 2 18 Mount, Vibration 45° 4 56 NutM5 2

19 Nut,M8 4 57 Washer4 6 20 Housing, Engine Adapter 1 58 Bolt M5 x16 1

21 Washer 8 4 59 Assembly, DC connector 2

22 Spring Washer 8 4 60 Nut, Fuel Signal 2

23 Bolt M8x25 4 61 Engine Switch 1

24 Bolt M6x12 4 62 Outlet, 120V/15A 2 25 Spring Washer 6 4 63 Spring Washer 3 4

26 Washer 6 4 64 Nut M3 4 27 Fan 1 65 Circuit Breaker 2

28 Fan Retainer 1 66 Washer 3 2

29 Assemply, Rotor 1 67 Spring Washer 3 2

30 Bearing 6203 with Pin 1 68 NutM3 2 31 Assembly, Stator 1 69 Idle Control Switch 1

32 Carrier, Rear Bearing 1 70 Screw M3 x45 2

33 Washer 6 4 71 Capacitor 20 1.1 F 1

34 Spring Washer 4 72 Screw M5 x16 1

35 Bolt M6x100 4 73 Sleeve, Rubber, Bottom 2

36 Bolt M8x195 1 74 Housing, Panel 1

37 Cover, Bearing Carrier 1 75 Fuel Valve 1

38 Bolt M6x12 2

10

5.5HP, 3.2-GALLON, GASOLINE POWERED ELECTRIC GENERATOR

Alton Industries Group, Ltd. warrants to the original retail purchaser that this product is free from defects in material and workmanship, and agrees to repair or replace, at Alton's option, any defective product within 1 year from the date of purchase. This warranty is not transferable. It only covers damage resulting from defects in material or workmanship, and it does not cover conditions or malfunctions resulting from normal wear, neglect, abuse, accident or repairs attempted or made by other than qualified small engine repair technicians.

THIS WARRANTY IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES. ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE DURATION OF THIS WARRANTY. ALTON SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.

This warranty is limited to sales in the United States and Canada. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights that vary from state to state.

Customer Service is available Monday through Friday between SAM -11 :30AM and 1PM- 4PM. To contact us, please call 630-584-9373 CST.

/ 11