Portable Electric Generator
Owner's Manual
MODEL: PPG 6000
IMPORTANT - Please make certain the person
who uses this generator thoroughly reads these
instructions and all other instructions provided to
ensure proper safety, use, and care of your new
portable electric generator.
420077 04.24.08 CL
Printed in U.S.A.
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SAFETY RULES
DANGER
WARNING
Running generator gives off carbon monoxide,
an odorless, colorless, poison gas.
Fuel and its vapors are extremely flammable and
explosive.
Breathing carbon monoxide will cause nausea,
fainting, or death.
Fire or explosion can cause severe burns or
death.
• Operate generator ONLY outdoors.
WHEN ADDING FUEL:
adequate
• Keep clearance on all sides of generator for
ventilation.
• Turn generator OFF and let it cool at least 2 minutes before
removing gas cap. Loosen cap slowly to relieve pressure in tank.
• DO NOT operate generator inside any building or enclosure,
including the generator compartment of a recreational vehicle (RV).
• Fill fuel tank outdoors.
• DO NOT overfill tank.Allow space for fuel expansion.
• Keep fuel away from sparks, open flames, pilot lights, heat, and
other ignition sources.
DANGER
Failure to properly ground generator can result
in electrocution, especially if the generator is
equipped with a wheel kit.
• DO NOT light a cigarette or smoke.
WHEN OPERATING EQUIPMENT:
• DO NOT tip engine or equipment at angle which causes fuel
to spill.
• National Electric Code requires generator to be properly
grounded to an approved earth ground. Call an electrician for
local grounding requirements.
• This generator is not for use in mobile equipment or marine
applications.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT:
DANGER
Generator produces powerful voltage.
• Transport/repair with fuel tank EMPTY or with fuel shutoff
valve in the OFF position.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
• Disconnect spark plug wire.
WHEN STORING FUEL OR EQUIPMENT WITH FUEL
IN TANK:
• When using generator for backup power, notify utility
company. Use approved transfer equipment to isolate
generator from electric utility.
• Use a ground fault circuit interrupter (GFCI) in any damp or
highly conductive area, such as metal decking or steel work.
• Store away from furnaces, stoves, water heaters, clothes
dryers, or other appliances that have pilot light or other
ignition source because they can ignite fuel vapors.
• DO NOT touch bare wires or receptacles.
• DO NOT use generator with electrical cords which are worn,
frayed, bare, or otherwise damaged.
• DO NOT operate generator in the rain or other forms of
precipitation.
• DO NOT handle generator or electrical cords while standing
in water, while barefoot, or while hands or feet are wet.
• DO NOT allow unqualified persons or children to operate or
service generator.
WARNING
• This generator does not meet U. S. Coast Guard Regulation
33CFR-183 and should not be used on marine applications.
• Failure to use the appropriate U. S. Coast Guard approved
generator could result in bodily injury and/or property
damage.
3
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SAFETY RULES
CAUTION
WARNING
Exceeding generator’s wattage/amperage capacity can
damage generator and/or electrical devices connected
to it.
Unintentional sparking can result in fire or
electric shock.
• See “Don’t Overload Generator” on page 16.
• Start generator and let engine stabilize before connecting
electrical loads.
WHEN ADJUSTING OR MAKING REPAIRS TOYOUR
GENERATOR
• Connect electrical loads in OFF position, then turn ON for
operation.
• Disconnect the spark plug wire from the spark plug and place
the wire where it cannot contact spark plug.
• Turn electrical loads OFF and disconnect from generator
before stopping generator.
WARNING
Running engines produce heat.Temperature of
muffler and nearby areas can reach or exceed
150°F (65°C).
CAUTION
Improper treatment of generator can damage it and
shorten its life.
Severe burns can occur on contact.
• Use generator only for intended uses.
• DO NOT touch hot surfaces.
• If you have questions about intended use, ask your dealer
or contact customer service at 1-866-237-1049.
• Allow equipment to cool before touching.
• Operate generator only on level surfaces.
CAUTION
Excessively high operating speeds increase risk of injury
and damage to generator.
• DO NOT expose generator to excessive moisture, dust, dirt,
or corrosive vapors.
• DO NOT insert any objects through cooling slots.
• If connected devices overheat, turn them off and disconnect
them from generator.
Excessively low speeds impose a heavy load.
• DO NOT tamper with governed speed. Generator supplies
correct rated frequency and voltage when running at governed
speed.
• Shut off generator if:
-electrical output is lost;
-equipment sparks, smokes, or emits flames;
-unit vibrates excessively.
• DO NOT modify generator in any way.
4
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SYMBOLS
Some of the following symbols may be used on this generator. Please study them and learn their meaning. Proper
interpretation of these symbols will allow you to operate the generator better and safer.
SYMBOL
NAME
DESIGNATION/EXPLANATION
V
Volts
Voltage
Current
A
Amperes
Hertz
Hz
W
min
~
Frequency (cycles per second)
Power
Watt
Minutes
Time
Alternating Current
Direct Current
Type of current
Type of current
n
o
No Load Speed
Rotational speed, at no load
Wet Conditions Alert
Read The Operator's Manual
Eye Protection
Safety Alert
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 a full face shield when operating this product.
Precautions that involve your safety.
Failure to properly ground generator can result in electrocution
especially if the generator is equipped with a wheel kit.
Electrocution
Electrical Shock
Electrical Shock
Toxic Fumes
Generator produces powerful voltage. Failure to isolate generator
from power utility can result in death or injury to electrical utility
workers due to backfeed of electrical energy.
Unintentional sparking can result in electric shock.
Running generator gives off carbon monoxide, an odorless
colorless, poison gas. Breathing carbon monoxide can cause
nausea, fainting, or death.
Fuel and its vapors are extremely flammable. Fire can cause
severe burns or death.
Fire
Fuel and its vapors are extremely explosive. Explosions can
cause severe burns or death.
Explosion
To reduce the risk of injury or damage, avoid contact with any hot
surface.
Hot Surface
Consult with local electrician to determine grounding requirements
before operation.
Ground
5
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SYMBOLS
The following signal words and meanings are intended to explain the levels of risk associated with this product.
SYMBOL
SIGNAL
MEANING
DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury
CAUTION: (Without Safety Alert Symbol) indicates a situation that may result in property damage
SERVICE
Servicing requires extreme care and knowledge and
should be performed only by a qualified service technician.
For service we suggest you return the product to your
nearest AUTHORIZED SERVICE DEALER for repair.
When servicing, use only identical replacement parts.
DANGER:
To avoid death or serious personal injury, do not
attempt to operate this product until you thoroughly
read the owner's manual and understand it completely.
Save this operator’s manual and review frequently for
continuing safe operation and instructing others who
may use this product.
WARNING:
Observeallnormalsafetyprecautionsrelatedtoavoiding
electrical shock.
WARNING:
The operation of any product can result in foreign objects being thrown into your eyes, which can result
in severe eye damage. Before beginning operation, always wear safety goggles or safety glasses with
side shields and full face shield when needed. 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
6
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SYMBOLS
SAFETY LABELS
The following labels are found on the generator. For your
safety, please study and understand all of the labels
before starting the generator.
You will be KILLED or SERIOUSLY HURT
if you do not follow the Owner’s Manual
instructions.
If any of the labels come off the unit or become hard to
read,contactanauthorizedservicecenterforreplacement.
Do not expose to rain or use in damp
locations.
FUEL WARNING
DO NOT SMOKE when filling with gasoline. Do not over
fill. Full level is 1 inch below the top of the fuel neck.
Stop the engine two minutes before refueling to avoid
the heat from the muffler igniting fuel vapors.
Risk of Fire. Do not add fuel while the
product is operating.
Exhaust contains poisonous carbon monox-
ide gas that can cause unconsciousness or
DEATH. Operate in well ventilated, outdoor
areas away from open windows or doors.
Generator is a potential source of electric
shock. Do not expose to moisture, rain, or
snow. Ground the system. Do not operate
with wet hands or feet.
$!.'%2
HOT MUFFLER 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.
WARNING
HOT
MUFFLER
DO NOT
TOUCH
#HECKªFORªANYª
FUELªOVERFLOWªOR
LEAKINGꢀ
3TOPªTHEªENGINE
BEFOREªREFUELINGꢀ
VENTILATION WARNING
Do not use the generator in an enclosed area or near
open windows, vents, or doors. Fumes from the unit can
kill.
ENGINE OIL WARNING
You must add oil before the first operation of the generator.
The oil reservoir capacity is 1.2 quarts. Always check the
oil level before each operation. The oil level should always
register on the dipstick.
7
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FEATURES
SPECIFICATIONS
GENERATOR
ENGINE
Rated Voltage..................................................120V/240V
120V/240V Receptacle Plug Type..........................L14-30
Rated Frequency......................................................60 Hz
Rated Maximum Continuous Load Current........50/22.7 A
Maximum Rated Watts.........................................6,200 W
Continuous Wattage Capacity..............................5,800 W
Engine Type..............................4 Stroke, Overhead Valve
Cylinder Discharge Capacity...................................389 cc
Bore x Stroke..................................................3.5 x 2.5 in.
Cooling System...................................Forced Air Cooling
Ignition System........................Transistor Magnet Ignition
Spark Plug................................................NGK or BP6ES
SparkPlugGap..............................................0.28-.031in.
Engine Oil Volume...................................................1.2 qt.
Oil Type (API-SG-SL).....................................SAE 10W30
Fuel Volume...........................................................6.6 gal.
Compression Ratio....................................................8.0:1
DIMENSIONS
Length...................................................................26.7 in.
Width........................................................................20 in.
Height..................................................................21.25 in.
Dry Weight............................................................187 lbs.
FUEL TANK AC CIRCUIT
BREAKER
FUEL LEVEL
GAUGE
FUEL TANK
CAP
120 VOLTS AC
RECEPTACLES
CHOKE LEVER
GROUNDING
TERMINAL
AIR FILTER
FUEL VALVE
120/240 VOLTS AC
RECEPTACLES
RECOIL STARTER
GRIP
ENGINE
SWITCH
OIL FILL CAP/DIPSTICK
OIL DRAINAGE BOLTS
Fig. 1
8
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FEATURES
KNOW YOUR GENERATOR
RECOIL STARTER GRIP
The recoil starter grip is used (along with the engine
switch) to start the generator’s engine.
See Figure 1.
Before attempting to use this product, familiarize yourself
with all operating features and safety rules.
FUEL VALVE
The flow of fuel through the generator is controlled by
the position of the fuel valve.
GROUNDING TERMINAL
The grounding terminal is used to assist in properly
grounding the generator to help protect against electrical
shock. Consult with a local electrician for grounding
requirements in your area.
AIR FILTER
The air filter helps to limit the amount of dirt and dust
drawn into the unit during operation.
RECEPTACLES
Your generator has the following single phase, 60 Hz
outlets: four 120 Volt AC, 20 Amp, and one 120 Volt/240
Volt AC, 30 Amp. The receptacles can be used for
operating appropriate appliances, electrical lighting,
tools, and motor loads.
CHOKE LEVER
Use the choke lever for starting a cold engine.
OIL DRAINAGE BOLT
When changing the engine oil, the oil drainage bolt is
AC CIRCUIT BREAKER
The circuit breaker is provided to protect the generator
against electrical overload and can be used to turn the
generator’s power on or off.
loosened to allow old engine oil to be drained.
FUEL LEVEL GAUGE
Consult the fuel level gauge to determine the amount of
fuel remaining in the generator.
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 TANK
The fuel tank has a capacity of 6.6 gallons.
OIL FILL CAP/DIPSTICK
Remove the oil cap to check and add oil to the generator
when necessary.
9
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ASSEMBLY
The following tools are required for assembly:
10 mm BOX-END WRENCH
12 mm OPEN-END WRENCH
Fig. 2
UNASSEMBLED PARTS
The following assembly hardware items are included with the generator. (See Figure 3.)
Wheel Assembly..............................................................1
Handle Assembly.............................................................1
Foot Assembly.................................................................1
13
6
ITEM NUMBER
QUANTITY
Fig. 3
10
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ASSEMBLY
INSTALLING HANDLE ASSEMBLY
INSTRUCTIONS
See Figure 4.
This product requires assembly.
■
Locate the following items:
■
Carefully remove the generator and any accessories
from the box.
Handle (5)
Left and right handle brackets (2)
4 bolts (3)
NOTE:Thegeneratorisheavy. Toavoidbackinjury, liftwith
your legs, not your back, and get help when needed.
4 square curved washers (14)
4 nuts (6)
■
■
■
Make sure that all items listed in the unassembled
parts list are included. (See Figure 3.)
4 flat washers (4)
Inspect the generator carefully to make sure no
breakage or damage occurred during shipping.
■
Align left handle bracket with hole in left side of
generator frame. Insert bolt through handle bracket
and frame. Slide curved washer on end of bolt,
making sure the cupped side of washer faces the
frame. Assemble nut; finger tighten. _
Do not discard the packing material until you have
carefully inspected and satisfactorily operated the
generator.
■
■
Repeat above step with right handle bracket.
■
If any parts are damaged or missing, please call
1-866-237-1049 for assistance.
Put one side of handle inside left handle bracket.
Slide washer over bolt, then insert bolt through the
bracket handle and bracket. Push bolt through so
that it exits on the other side of the handle, then add
another washer and the nut. Finger tighten.
PACKING LIST
Generator
Wheel Assembly
Handle Assembly
Foot Assembly
Container of Oil
Warranty Card
Owner's Manual
■
■
Repeat above step with other side of the handle and
the right handle bracket.
Return to the first bolt installed. While holding bolt
head steady with 10 mm box-end wrench, use 12 mm
open-end wrench to tighten snugly. (See Figure 2.)
Repeat with remaining bolts.
WARNING:
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.
WARNING:
If any parts are missing, do not operate this generator
until the missing parts are replaced. Failure to do so
could result in possible serious personal injury.
WARNING:
Do not attempt to modify this generator or create
accessories not recommended for use with this
generator. Any such alteration or modification is
misuse and could result in a hazardous condition
leading to possible serious personal injury.
WARNING:
Do not attempt to operate the generator until assembly
is complete. Failure to comply could result in possible
serious personal injury.
Fig. 4
11
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ASSEMBLY
INSTALLING WHEEL ASSEMBLY
See Figure 5.
■
Locate the following items:
2 wheels
2 square curved washers (14)
2 flat washers (4)
2 hex nuts (11)
2 nuts (6)
■
■
■
Slide wheel over axle extension.
Slide flat washer on axle extension.
Install hex nut on axle extension and tighten to
secure.
■
Repeat for second wheel.
NOTE: Block up frame securely with wood blocks to
provide clearance for frame bolts & wheel assembly.
■
Slide square curved washer, curved side down,
on bolt.
■
Place on frame and slide bolt through frame
hole.
■
■
■
Repeat for second bolt.
Fig. 5
Lift axle and align hole with installed frame bolts.
Install nuts on 2 bolts and tighten to secure
INSTALLING FOOT ASSEMBLY
See Figure 6.
■
Locate the following items:
2 foot supports (12)
6 bolts (13)
NOTE: Block up frame securely with wood blocks to
provide clearance for foot support assembly.
■
■
■
■
Align foot support with 3 holes in frame cross member.
Insert 3 bolts into welded nuts on foot support.
Tighten bolts to secure
Repeat for second foot.
Fig. 6
12
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OPERATION
GROUNDING THE GENERATOR
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local
electrical codes may also require proper grounding of
the unit. For that purpose, a GROUNDING FASTENER
is provided on the generator end (Figure 7).
Grounding
Fastener
Fig. 7
Generally, connecting a No. 12 AWG (American Wire
Gauge) stranded copper wire to the grounding fastener
and to an earth-driven copper or brass grounding rod
(electrode) provides adequate protection against elec-
trical shock. Be careful to keep the grounding wire
attached after connecting the stranded copper wire.
However, local codes may vary widely.
WARNING:
Consult with a local electrician for grounding
requirements in your area.
Properly grounding the generator helps prevent electrical
shock if a ground fault condition exists in the generator
or in connected electrical devices, especially when the
unit is equipped with a wheel kit. Proper grounding also
helps dissipate static electricity, which often builds up in
ungrounded devices.
13
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OPERATION
DANGER:
OIL DIPSTICK
Failure to properly ground generator can result in
electrocution,especiallyifthegeneratorisequippedwith
a wheel kit. National Electric Code requires generator
to be properly grounded to an approved earth ground.
Call an electrician for local grounding requirements
OIL FILL HOLE
WARNING:
Do not use any attachments or accessories not
recommended by the manufacturer of this generator.
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.
Fig. 8
BEFORE OPERATING THE UNIT
Position the generator on a flat surface before checking
fluid levels or adding fluid.
RES
CAUTION:
Attempting to start the engine before it has been
properly filled with oil will result in equipment failure.
FUEL
CHECKING/ADDING OIL
See Figure 8.
FUEL TANK
FUEL LEVEL
GAUGE
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.
FUEL TANK CAP
NOTE: Non-detergent or 2-stroke engine oils will dam-
age the engine and should not be used.
■
■
■
Unscrew the oil dipstick and remove.
Wipe dipstick clean and reseat in hole. Do not rethread
Remove dipstick again and check oil level. Oil level
should fall within the hatched area on the dipstick.
Fig. 9
■
■
If level is low, add engine oil until the fluid level rises
to the upper portion of the hatched area on the
dipstick.
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 to enter the fuel tank.
Replace and secure the dipstick.
CHECKING/ADDING FUEL
See Figure 9.
OXYGENATED FUELS
Someconventionalgasolinesareblendedwithalcoholoran
ether compound. These gasolines are collectively referred
to as oxygenated fuels. To meet clean air standards, some
areas of the United States use oxygenated fuels to help
reduce emissions.
■
Check the fuel level gauge. If fuel is needed,
continue with the next step.
■
■
■
Remove the fuel tank cap.
Fill the fuel tank to 1 in. below the tip of the fuel neck.
Replace and secure the fuel tank cap.
14
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OPERATION
If using an oxygenated fuel, make sure it is unleaded
ENGINE
SWITCH
RECOIL
STARTING
GRIP
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.”
CIRCUIT
BREAKER
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 inhibitors 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.
Fig. 10
OFF
If you notice any undesirable operating symptoms, try
another service station or switch to another brand of
gasoline.
ON
NOTE: Fuel system damage or performance problems
resulting from the use of an oxygenated fuel containing
more than the percentages of oxygenates mentioned
above are not covered under warranty.
FUEL
VALVE
WARNING:
Fig. 11
On a level surface with the engine off, check the oil
level before each use of the generator.
MOVE CHOKE
LEVER TO "ON"
POSITION TO
CLOSE
STARTING THE ENGINE
See Figures 10 - 12.
NOTE: If location of generator is not level, the unit may
not start or may shut down during operation.
■
■
■
■
Unplug all loads from the generator.
Switch the circuit breaker to the ON position.
Turn the fuel valve to the ON position.
Move the choke lever to the ON (closed) position.
NOTE: When starting a warm engine, leave the choke in
the OFF (open) position.
■
Put the engine switch in the ON position.
■
Pull the recoil starting grip lightly until you feel a
resistance, then pull it briskly.
Fig. 12
NOTE: Do not allow the grip to snap back after starting;
return it gently to its original place.
■
■
■
Switch the AC circuit breaker to the OFF position.
Put the engine switch in the OFF position.
Turn the fuel valve to the OFF position.
■
As the engine warms, slowly move the choke lever
to the OFF position.
STOPPING THE ENGINE
See Figures 10 - 12.
To stop the engine in an emergency situation:
Put the engine switch in the OFF position.
■
To stop the engine under normal operating conditions:
■
Remove any load from the generator.
15
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ELECTRICAL
DON'T OVERLOAD GENERATOR
WARNING:
CAPACITY
Do not overload generator's capacity. Exceeding
generator's wattage/amperage capacity can damage
generator and/or electrical devices connected to it.
Make sure the generator can supply enough rated
(running) and surge (starting) watts for the items you will
power at the same time. Follow these simple steps:
Additional
Rated*
Surge
1. Select the items you will power at the same time.
Tool or Appliance
(Running)
Watts
(Starting)
Watts
2. Total the rated (running) watts of these items. This is
the amount of power the generator must produce to
keep the items running. See the wattage reference
chart at the right.
3. 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.
Essentials
Light Bulb-75 Watt
Deep Freezer
75
−
500
800
800
100
500
Sump Pump
1200
1600
2000
Refrigerator/Freezer - 18 Cu. Ft.
Water Well Pump - 1/3 HP
Heating/Cooling
Window AC - 10,000 BTU
Window Fan
1200
300
1800
600
Example:
Tool or Appliance
Rated (Running)
Watts
Surge
Furnace Fan Blower - 1/2 HP
Kitchen
800
1300
(Starting) Watts
Window Air
Conditioner
1200
1800
Microwave Oven - 1000 Watt
Coffee Maker
1000
1500
1500
2500
−
−
−
−
Refrigerator
Deep Freezer
Television
800
500
500
75
1600
500
−
Electric Stove - Single Element
Hot Plate
Family Room
Light (75 Watts)
−
DVD/CD Player
100
100
450
500
800
−
−
−
−
−
3075 Total
1800 Highest
Surge Watts
Running Watts
VCR
Stereo Receiver
Maximum
Allowed
5800
Color Television - 27"
PersonalComputerw/17"monitor
Other
Total Rated (Running Watts)
Highest Additional Surge Watts = 1800
Total Generator Output Required = 4875
= 3075
6200
Security System
180
300
−
−
POWER MANAGEMENT
AM/FM Clock Radio
Garage Door Opener - 1/2 HP
Electric Water Heater - 40 Gal.
DIY/Job Site
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 the engine. The
correct and safe way to manage generator power is to
sequentially add loads as follows:
480
520
−
4000
Quartz Halogen Work Light
Airless Sprayer - 1/3 HP
Reciprocating Saw
Electric Drill - 1/2 HP
Circular Saw - 7-1/4"
Miter Saw - 10"
1000
600
−
1200
960
1. With nothing connected to the generator, start
the engine as described earlier in this manual.
2. Plug in and turn on the first load, preferably the
largest load you have.
3. Permit the generator output to stabilize. (engine runs
smoothly and attached device operates properly.)
4. Plug in and turn on the next load.
960
1000
1500
1800
1800
200
1000
1500
1800
1800
2000
2500
Planer/Jointer - 6"
Table Saw/Radial Arm Saw - 10"
Air Compressor - 1-1/2 HP
5. Again, permit the generator to stabilize.
6. Repeat steps 4 and 5 for each additional load.
2500
*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.
16
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MAINTENANCE
WARNING:
When servicing, use only identical Poulan Pro
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 Poulan Pro Authorized Service
Center.
GENERAL MAINTENANCE
Keep the generator in a clean and dry environment
where it is not exposed to dust, dirt, moisture, or cor-
rosive 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
entering the fuel system or other internal parts of the
unit can cause problems that will decrease the life of the
generator.
Fig. 13
To clean the unit:
■
■
■
Use a soft bristle brush and/or vacuum cleaner to
loosen and remove dirt and debris.
Clean air vents with low pressure air that does not
exceed 25 psi.
Wipe the exterior surfaces of the generator with a
damp cloth.
OIL FILL
TUBE
CLEANING/REPLACING AIR FILTERS
See Figure 13.
OIL DRAINAGE
BOLT
For proper performance and long life, keep air filters clean:
■
■
■
■
■
Release the upper and lower retaining clips and
remove the air filter cover.
OIL DIPSTICK
Remove the outer filter element and the inner
precleaner element.
If the filter elements are dirty, clean with warm, soapy
water. Rinse and let dry.
Apply a light coat of engine oil to the elements, then
squeeze it out.
Put the filter elements back together and replace
in the air filter compartment, being careful to place
the outer filter element closest to the air filter cover.
■
Replace the cover and snap retaining clips back in
place to secure.
NOTE: Do not run the generator without the air filters.
Rapid engine wear will result.
Fig. 14
CHANGING ENGINE OIL
See Figure 14
■
■
Reinstall the oil drainage bolt and tighten securely.
Refill with oil following the instructions in the
“Checking/Adding Oil” section on page 14.
■
Remove the oil dipstick.
■
Place a container underneath the oil drainage bolt
to collect used oil as it drains.
NOTE: Disposal of used oil should be at an approved
disposalsite.Seeyourlocaloilretailerformoreinformation.
■
■
Unscrew the oil drainage bolt and remove.
Allow oil to drain completely.
17
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MAINTENANCE
CLEANING FUEL SEDIMENT CUP
See Figure 15.
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.
■
■
■
■
■
Turn the fuel valve to the off position.
Remove the sediment cup using a 10 mm wrench.
Remove the o-ring and filter.
Clean each of the parts in a high flash-point solvent.
Reinstall the filter, o-ring, and sediment cup. Tighten
with 10 mm wrench to secure.
■
Return the fuel valve to the ON position and check
for leaks.
SPARK PLUG MAINTENANCE
See Figure 16.
Fig. 15
The spark plug must be properly gapped and free of
deposits in order to ensure proper engine operation.
SPARK PLUG
To check the spark plug:
■
■
Remove the spark plug cap.
Clean any dirt from around the base of the spark
plug.
■
■
Remove the spark plug.
Inspect the spark plug for damage, and clean with
a wire brush before reinstalling. If the insulator
is cracked or chipped, the spark plug should be
replaced.
NOTE: If replacing, use the following recommended
spark plugs or equivalent: NGK, BP6ES.
■
Measure the plug gap with a feeler gauge. The
correct gap is .028 - .031 in. Correct, if necessary, by
carefully bending the side electrode.
Fig. 16
■
■
Seat spark plug in position; thread in by hand to
prevent cross-threading.
Tighten with spark plug 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.
MAINTENANCE SCHEDULE
After 100 hours
of operation
or annually
Before operating
each time
After 25 hours of
operation
■
Check Engine Oil
■
■
■
Change Engine Oil
■
Check Air Filters
Replace Air Filters
■
■
■
Clean Fuel Sediment Cup
Replace Spark Plug
Clean or Replace Spark Arrester
■
■
18
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MAINTENANCE
CLEANING SPARK ARRESTER
See Figure 17.
■
■
■
■
■
Remove the eight 5 mm screws from the muffler
protector, then remove muffler protector.
Remove the 4 mm screw from the spark arrester and
remove the spark arrester.
Use a brush to remove carbon deposits from the
spark arrester screen.
Inspect the spark arrester for breaks or holes.
Replace if necessary.
Reinstall the spark arrester and muffler protector.
SPARK ARRESTER
DRAINING CARBURETOR
See Figure 18.
■
■
Loosen the carburetor drain screw.
Allow gasoline to drain completely into suitable
container.
Fig. 17
■
Retighten drain screw.
TRANSPORTING
■
■
■
■
Turn the engine switch and fuel valve OFF.
Make sure engine and exhaust system of unit is cool.
Keep the unit level to prevent fuel spillage.
Do not drop or strike the unit or place under heavy
objects.
DRAIN SCREW
Fig. 18
STORAGE
STORAGE
When preparing the generator for storage, follow the guidelines below.
STORAGE TIME
Less than 1 month
1 to 2 months
PRIOR TO STORING
■ No special preparation is required.
■ Fill with fresh gasoline and add a gasoline conditioner*.
2 months to 1 year
■ Fill with fresh gasoline and add a gasoline conditioner*.
■ Drain fuel from carburetor.
■ Clean fuel sediment cup.
1 year or more
■ Drain fuel tank.
■ 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:
■ Fill with fresh gasoline.
*Use gasoline conditioners formulated to extend storage life. For recommendations, contact your nearest authorized
service center.
19
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TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
Engine switch is OFF
No fuel
SOLUTION
Engine will not start
Turn engine switch to ON.
Fill fuel tank.
Oil level is low
Check engine oil level and fill, if necessary
Replace spark plug.
Check spark plug condition
Fuel is not reaching carburetor
Fuel valve is in OFF position
Clean fuel sediment cup.
Move fuel valve to ON position
AC receptacle does not work
Circuit breaker is OFF
Turn ON the AC circuit breaker.
Try a different item.
Item plugged in is defective
Generator makes a “spark knock” or An occasional light “knocking” or
Switch to a different brand of gasoline,
making sure that the octane rating is 86 or
higher. If problem continues, contact your
nearest authorized service center.
“pinging” noise
“pinging” under heavy load is not
a cause for concern. However, if
the knocking or pinging occurs
under normal load at a steady
engine speed, the problem may
be with the brand of gasoline
being used.
If problem persists after trying the above solutions, please call 1-866-237-1049 for your nearest authorized service center.
20
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PORTABLE ELECTRIC GENERATOR- -MODEL NO. PPG6000
WIRING DIAGRAM
21
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PORTABLE ELECTRIC GENERATOR- -MODEL NO. PPG6000
DECALS
10
9
10
8
4
1
7
5
6
2
3
KEY PART
NO. NO.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
419397
Decal, Logo
419938
419939
420413
420820
420821
420822
420823
420824
420825
Decal, Rewind Cover
Decal, Control Panel
Decal, Danger Label
Decal, Fuel Valve
Decal, Air Filter Maintenance
Decal, Choke
Decal, Fuel Level
Decal, Danger
Decal, Hot Surface
22
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PORTABLE ELECTRIC GENERATOR- -MODEL NO. PPG6000
CONTROL PANEL ASSEMBLY
KEY
NO.
PART
NO.
DESCRIPTION
6
Td2000-c03-2000
Td2006-c03-0100
Td9001-c03-0000
Control Panel Assy
Control Panel Comp
Case,control Panel
7
8
14
B057890006002070b Bolt hex m6×20
B061770006000060b Nut hex m6
16
17
Td2310-c03-0000
Circuit Breaker 23a
18
B000970206000000b Washer plain w6
B000930006000000b Washer spring w6
B057890006002070b Bolt m6×20
19
20
61
Td2611-c03-0100
Td2410-c03-0100
Td2410-c03-0200
B06170004000060b Screw M4
Td2016-b92-0000
Td2611-c03-0000
B000930004000000b Washer, Spring, W4
B000970204000000b Washer, Plain, W4
B061770004000060b Nut m4
Td2018-c03-0100
B057890006001470b Bolt m6×14
Harness Assy B., Wire
Socket,120v
Socket,(120v 240v)Plug Type L14-30
204
205
206
213
218
219
220
221
222
223
Switch
Harness Assy A., Wire
Diode Assy
23
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PORTABLE ELECTRIC GENERATOR- -MODEL NO. PPG6000
MUFFLER ASSEMBLY
KEY
NO.
PART
NO.
DESCRIPTION
35
18000-qc03-0000
Td5004-b98-0000
Td5003-b98-0000
Td5002-c03-0000
Td5006-b98-0000
18100-pb52-0000
18066-mb32-0100
18066-mb32-0000
Td5001-b98-0000
Muffler Comp
36
Muffler Side Protector
Muffler Outer Protector Comp.
Muffler Inner Protector Comp.
Protector Muffler Seal
Exhaust Pipe Comp.
Exhaust Pipe Gasket (A)
Exhaust Pipe Gasket (B)
Muffler Stay Comp.
37
38
39
40
41
42
43
44
B000930008000000b Spring Washer W8
B057890008002570b Bolt M8×25
B061700008000060b Nut 8mm
B057890006001270b Bolt M6×12
B057890008001670b Bolt M8×16
45
46
47
48
231
230
241
242
18000-qc03-0100
Spark Arrestor
B057890005002070b Bolt M5×20
Td5006-pb50-0000
Td5007-pb50-0000
Lock Plate 50mm
Lock Plate 60mm
24
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PORTABLE ELECTRIC GENERATOR- -MODEL NO. PPG6000
AIR FILTER ASSEMBLY
KEY
NO.
PART
NO.
DESCRIPTION
21
23
24
25
26
27
28
30
33
31
34
12104-mb32-0000
16101-mb32-0100
16106-mb32-0000
16127-mb32-0000
Td4121-c01-0000
16105-mb32-0200
16109-mb32-0000
16102-mb32-0000
Breather Tube
Air Cleaner Element
Air Cleaner Separator Plastic
Air Cleaner Case Rear
Air Cleaner Stay
Air Cleaner Cover Case Front
Gemel
Air Cleaner Seal
B061700004000060b Nut 4mm
B061770106000060b Nut, M6
B061770106000060b Nut, M6
25
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PORTABLE ELECTRIC GENERATOR- -MODEL NO. PPG6000
FRAME & FUEL TANK ASSEMBLY
KEY
NO.
PART
NO.
KEY
NO.
PART
NO.
DESCRIPTION
DESCRIPTION
49
50
51
52
53
54
55
56
58
59
60
63
65
66
67
68
217
218
Td6110-b98-0400
Td6008-b98-0000
Td6120-b98-0000
Td6130-b93-0000
Td6140-b93-0000
Tank Comp., Fuel
Fuel Tank Seal
Fuel Filler Cap Comp.
Fuel Filter
226
Td4010-c03-1200
Wheel And Handle Assy
Frame Kit
226-1 Td4010-c03-2100
226-2 Td4013-c03-0200
226-2a Td4013-c03-0300
Left Gemel
Right Gemel
Meter Assy.,fuel
226-3 B057890006004070b Bolt,m6×40
B057890006003070b Bolt, Flange, M6×30
226-4 B000970206000000b Flat Washer, W6
Td6003-b93-0000
Td6002-b93-0000
Tank Cushion Washer
Bush
226-5 Td4011-c03-0200
Handle
226-6 B061870006000000b Nut, M6
B090740005001000b Screw, Flat, M5×10
226-7 Td4015-c03-0400
226-8 Td4014-c05-0400
Axle Of Wheel
Wheel
17020-jc79-0200
Tube Clip, (B8)
T2999706300130185 FuelTube, W3.5×W10×165
226-9 91302-91002030000 Flat Washer, W10
226-10 B0009300010000000b Washer, Spring, W10
226-11 B009230006000000b Nut, M10
Td6007-b98-0000
Td4111-b98-0000
Td4112-b98-0000
Fuel Tank MountingRubber
Bottom Rubber l
Bottom Rubber r
226-12 Td4012-c03-0600
Foot
B061770010000060b Nut M10
B061770008000060b Nut M8
Td6040-b98-0400
Td6121-b93-0100
227-13 B094410006001870b Bolt, M6×18
226-14 Td7051-c06-0000
Tile
Fuel Cock Assy.
226-15 B057890006005570b Bolt, M6×40
226-16 B057890006003570b Bolt, M6×35
Fuel Filler Cap Packing
Rubber
226-17 Td4113-b98-0000
Rubber Bumper For Foot
219
Td6122-b93-0100
Fuel Filler Cap Packing
Plastic
226-18 B094410006001870b M6×18
26
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U.S. EPA Emissions Control Warranty Statement
The U.S. Environmental Protection Agency and General Power Products Company are pleased to explain the Emissions
control system warranty on your equipment. In California, new engines must be designed and built to meet the state’s
anti-smog standards. Elsewhere in the U.S., similar standards must be met that are set forth by the U.S. EPA. GPP will
warrant the emissions control system of your engine for the time periods listed below, provided there has been no unap-
proved modification, improper maintenance, abuse, or neglect of your product.
Your emissions control system includes parts such as the air cleaner, ignition system, muffler and carburetor.
Where a warrantable condition exists, GPP will repair your engine at no cost for parts, labor, and diagnosis.
GPP Emissions System Warranty Coverage
Engines are warranted with respect to the emissions control parts set forth by the U.S. EPA for a period of two years. If
any emissions part is found defective during that period, it will be replaced or repaired by GPP.
Owner’s Warranty Responsibility
As an engine and equipment owner, you are responsible for the required maintenance listed in the owner’s manual.
GPP recommends you retain all records associated with the maintenance and repair of your product, but GPP cannot
deny the warranty solely on the lack of receipts or your failure to produce records of the performed maintenance.
You are responsible for presenting your product to an authorized repair and service outlet as soon as a problem arises.
The warranty repairs should be completed in a reasonable amount of time. The time should not exceed 30 days.
You may be denied warranty coverage if your product has failure due to unapproved modification, improper maintenance,
abuse, or neglect.
An authorized GPP service representative can perform warranty or service. For more information on those service rep-
resentatives see your local yellow pages or contact General Power Products at 1-866-237-1049.
GPP Emissions Control Warranty Provisions
The warranty explains your rights and responsibilities under the emissions control warranty which is provided to you by
General Power Products Company. Poulan Pro provides a limited warranty for purchasers of new products on a separate
sheet. The emissions control warranty applies only to the emissions control system of your product. If there is a conflict in
terms between the emissions control warranty and the Poulan Pro Limited Warranty, the emissions control system war-
ranty shall apply.
It must be an authorized service representative that performs warranty work. Evidence of the purchase date to the original
purchaser must be presented to the service representative at the time of request to perform warranty. GPP is not respon-
sible for service calls or transporting the product to the warranty service location. The purchaser is responsible for any loss
or damage in connection with transportation of the product or parts thereof submitted for inspection and warranty work.
This product is not available for sale in California.
The following are provisions related to the Emissions Control Warranty Coverage:
1. GPP warrants the product to the initial owner and any subsequent owner that the parts are free from material
and workmanship defects, which causes failure for a period of two years from the date the product is delivered
to the retail purchaser.
2. Warranted parts are as follows:
a. Fuel System
i. Carburetor
ii. Fuel Pump
b. Air intake system
i. Air cleaner
ii. Intake manifold
c. Ignition System
i. Spark plug
ii. Ignition Module system
d. Muffler System
i. Muffler
ii. Exhaust manifold
e. Other components
i. Crankcase breather tube
ii. Flywheel
3. Warranty coverage shall be excluded where unapproved modifications, improper maintenance, abuse or
neglect exists.
4. Any part that is scheduled for routine maintenance replacement will be covered up to the time for that part to be
replaced or repaired under the scheduled maintenance period. The owner is required to perform all scheduled
maintenance.
5. The owner shall not be charged for any diagnostic labor that leads up to the determination that the part is
defective. An authorized General Power Products representative must perform the work.
6. Repair or replacement of a warranty part shall be at no charge to the owner when done by an authorized
General Power Product representative.
If you have any questions regarding Emissions Control warranty rights and responsibilities, contact General Power
Products Company at 1-866-237-1049.
27
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WARRANTY
EMISSIONS MAINTENANCE SCHEDULE AND WARRANTED PARTS LIST
Emissions Parts
Inspect Before
Each Use
Clean Every
5 Hours
Replace Every
25 Hours or Yearly 25 Hours or Yearly
Clean Every
AIR FILTER ASSY
INCLUDES:
FILTER...................................................................................X.....................................X
SPARK SCREEN.............................................................................................................................................X
CARBURETOR ASSY
INCLUDES:
HEAT DAM
GASKETS
FUEL TANK ASSY
INCLUDES:
FUEL LINES.......................................X
FUEL CAP...........................................X
FUEL FILTER
IGNITION ASSY
INCLUDES
SPARK PLUG................................................................................................................X
ALL EMISSIONS–RELATED PARTS ARE WARRANTED FOR TWO YEARS, OR FOR THE PERIOD OF TIME
PRIOR TO PART'S FIRST SCHEDULED REPLACEMENT—WHICHEVER COMES FIRST.
28
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LIMITED WARRANTY
HOP (The "Manufacturer") warrants to the original consumer purchaser that this product as manufactured is free from
defects in materials and workmanship. For a period of two (2) years from date of purchase by the original consumer
purchaser, we will repair or replace, at our option, without charge for parts or labor incurred in replacing parts, any part which
we find to be defective due to materials or workmanship. This Warranty is subject to the following limitations and exclusions.
1. Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the
purchaser. Transportation charges for any parts submitted for replacement under this warranty must be paid by the
purchaser unless such return is requested by the manufacturer.
2. The Warranty period for any products used for rental or commercial purposes is limited to 90 days from the date of
original purchase.
3. This Warranty applies only to products which have been properly assembled, adjusted, operated, and maintained in
accordance with the instructions furnished. This Warranty does not apply to any product which has been subjected to
alteration, misuse, abuse, improper assembly or installation, delivery damage, or to normal wear of the product.
4. Exclusions: Excluded from this Warranty are normal wear, normal adjustments, standard hardware and normal
maintenance.
5. In the event you have a claim under this Warranty, you must return the product to an authorized service dealer.
Should you have any unanswered questions concerning this Warranty, please contact:
Poulan Pro
HOP Customer Service Dept.
1030 Stevens Creek Road
Augusta, GA 30907 USA
1-866-237-1049
giving the model number, serial number and date of purchase of your product and the name and address of the authorized
dealer from whom it was purchased.
THIS WARRANTY DOES NOT APPLY TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND ANY IMPLIED
WARRANTIES ARE LIMITED TO THE SAME TIME PERIODS STATED HEREIN FOR OUR EXPRESSED WARRANTIES.
Some areas do not allow the limitation of consequential damages or limitations of how long an implied Warranty may last,
so the above limitations or exclusions may not apply to you. This Warranty gives you specific legal rights, and you may have
other rights which vary from locale to locale.
This is a limited Warranty within the meaning of that term as defined in the Magnuson-Moss Act of 1975.
29
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SERVICE NOTES
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SERVICE NOTES
31
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● SERVICE
Now that you have purchased your tool, should a need ever exist for repair parts or service,
simply contact your nearest Poulan Pro Authorized Service Center. Be sure to provide all
pertinent facts when you call or visit. Please call 1-866-237-1049 for your nearest Poulan
complete list of Authorized Service Centers.
● MODEL NO. AND SERIAL NO.
The model number of this generator will be found on a plate attached to the motor housing.
Please record the model number and serial number in the space provided below.
● HOW TO ORDER REPAIR PARTS
When ordering repair parts, always give the following information:
PPG 6000
● MODEL NUMBER
● SERIAL NUMBER
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