DIRTY HAND TOOLS 101091 (01) PDF MANUAL

DIRTY HAND TOOLS 101091 (01) PDF SUMMARY:

What should I do before operating this portable power generator?

Read and thoroughly understand all instructions and safety information before operating this portable power generator. Failure to do so may cause serious injury or death.

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What should I do if I have any questions or concerns about the safe operation of this equipment?

Call customer service at 720-287-5182, 1-877-487-8275, or visit http://www.dirtyhandtools.com.

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What should I wear during the setup of the portable power generator?

Wear ANSI-approved safety goggles and heavy-duty work gloves during set up.

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Should I wear ear protection while using the generator?

While this portable power generator operates at a relatively low noise level, about 70dB, you may want to wear ear plugs or noise deafening headphones.

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Should people with pacemakers use this portable power generator?

People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure.

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What should I do before operating the generator?

Read the operation manual before operation.

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Who should not operate this equipment?

Do not permit children to operate this equipment at any time. Do not permit others that have not read and understood the complete Operation Manual to operate this equipment. Do not operate the portable power generator when under the influence of alcohol, drugs or medication. Do not allow a person who is tired or otherwise impaired or not completely alert to operate the portable power generator.

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Where should I not place my body when the generator is running?

Never place fingers, hands, or body near the generator when it is running. Do not lean or reach over the generator.

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How far away should people be from the generator when it is running?

Keep all people (except the operator) a minimum of six feet from the generator during operation.

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Should I transport the generator with the engine running?

Do not transport the generator with the engine running.

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Should the generator be tilted when the engine is running?

Do not tilt the machine while the engine is running.

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Can I leave the generator unattended when it is running?

Do not leave the generator unattended when it is running. Turn off the engine before leaving the area.

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Where should the engine not be run?

Never run the engine in an enclosed area or without proper ventilation as the exhaust from the engine contains carbon monoxide, which is an odorless, tasteless, and deadly poisonous.

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When should I fill the gasoline tank?

Fill the gasoline tank outdoors with the engine off and allow the engine to cool completely.

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Should the air cleaner or cover over the carburetor air-intake be removed when the engine is running?

Do not operate the engine with the air cleaner or cover over the carburetor air-intake removed, except for adjustment. Removal of such parts could create a fire hazard.

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Can I touch the muffler or engine when it is running?

The muffler and engine become very hot with use and can cause a severe burn; do not touch. Allow the engine to cool before refueling, doing maintenance, or making adjustments.

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Where should the generator be used?

Use only outside away from windows, doors, and vents.

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What could the operation of this equipment create?

Operation of this equipment may create sparks that can start fires around dry vegetation or flammable materials.

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What should I do to prevent serious injury, electric shock, and property damage?

• Keep access doors on enclosures locked.
• Have a licensed electrician do all electric work, including ground connection and maintenance.
• Keep dry.
• Keep all guards in place and in proper working condition.
• Wear ANSI-approved safety goggles during setup and maintenance.
• Turn the switch off and remove the key after use.
• Read the Operator’s Manual before setup or use.
• Add engine oil before starting. Starting without oil will ruin the engine and void the warranty. Read maintenance information in the Operator’s Manual.
• Unconditioned electrical equipment can damage sensitive equipment. Do not use to power sensitive electrical equipment without an appropriate line conditioner sold separately.

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What should I do when adding fuel to the generator?

• Do not add fuel while the engine is running or when the engine is hot.
• Do not smoke while filling with fuel.
• Do not overfill. Use only fresh gasoline. Empty fuel before storage.

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What should I do before shutting off the generator?

Disconnect powered devices from the generator before shutting off. Shutting down with devices powered can damage the generator.

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Where should I set up the portable power generator?

Set up for use outside in a well-ventilated area on a level, stable surface away from doors, windows, vents, etc.

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What should I do before attempting to operate the generator?

Completely read and understand the operator’s manual before attempting to operate the generator.

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What should I do before operating the generator?

Always check the fuel level before operating.

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How long should I wait before removing the fuel cap?

Allow the engine to cool for at least two minutes before removing the fuel cap.

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Where should the generator be set up?

Set up the generator outdoors in a well-ventilated, dry area, away from building air intakes. The generator should be protected from direct exposure to rain and snow. Do not set up the generator on a conductive surface such as a metal deck.

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How much fuel does the fuel tank hold?

The fuel tank holds approximately 4 gallons of fuel.

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What type of gasoline is recommended?

87+ octane unleaded gasoline is recommended.

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How much oil should I add to the generator?

Add engine oil to the upper level of the oil filler hole. The oil capacity is 0.63 quarts (0.6L).

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What type of motor oil is recommended?

SAE 10/30 motor oil is recommended for most environmental conditions.

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Should the dipstick be threaded in when checking the oil level?

Do not thread the dipstick in when checking the oil level.

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What should I do to prevent serious injury and fire when adding fuel?

• Do not add fuel while the engine is hot or running.
• Do not smoke while filling with fuel.
• Do not overfill. Empty fuel before storage.

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What should I check before connecting an appliance or power cord to the generator?

Before connecting an appliance or power cord to the generator make sure that it is in good working order. Faulty appliances or power cords can create a potential for electrical shock.

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What should I do if an appliance starts to operate abnormally?

If an appliance begins to operate abnormally, becomes sluggish, or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is the appliance, or if the rated load capacity of the generator has been exceeded.

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What should I do to make sure that the generator is not overloaded?

Make sure that the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.

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What happens when the generator is substantially overloaded?

Substantial overloading will open the circuit breaker. Exceeding the time limit for maximum power operation or slightly overloading the generator may not switch the circuit breaker OFF, but will shorten the service life of the generator.

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What should the generator be connected to?

Connect the generator only to an electrical system (120V~) that is compatible with the electrical characteristics and rated capacities of the generator.

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How should the generator be set up?

Set up the generator outdoors in a well-ventilated, dry area, away from building air intakes. The generator should be protected from direct exposure to rain and snow. Do not set up the generator on a conductive surface such as a metal deck.

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How do I calculate the total wattage of the devices I want to power?

Before using the generator, calculate the total wattage of all the devices that you want to power at the same time. The total must not exceed the Running Wattage of the generator (3200 watts).

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What are the steps to calculating wattage?

• Add up the Running Watts for all appliances/tools that you want to use at the same time.
• Make sure that the total calculated wattage is less than the Rated Wattage of the generator (3200 watts).
• Find the single highest starting rate wattage product and add that to the total.
• Make sure that this total now is less than the Maximum Wattage of the generator (4000 watts maximum).
• Plug in and turn on appliances/tools from the largest wattage first to the smallest wattage last.

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How do I calculate wattage?

Volts and amps can be multiplied together to get watts. (volts x amps = watts).

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How do I calculate additional start-up watts?

For equipment with a motor use the rated watts amount as an estimate of additional start-up watts. For most lights or heaters there are no additional start-up watts.

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When should I plug in an appliance or tool into the AC outlet?

Only after the generator is running smoothly should an appliance or tool be plugged into the AC outlet of the generator.

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What should I do before each use of the generator?

Prior to each use, connect a #6 AWG grounding wire (not included) from the ground terminal on the control panel to a grounding rod (not included) that has been driven at least 24 inches deep into the earth. The grounding rod must be an earth-driven copper or brass rod (electrode).

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What is the starting procedure for the generator?

• Turn the engine’s fuel valve to the OPEN position.
• Turn the engine’s choke lever to the START position. Set the choke lever to the run position only when the engine has started or upon restarting a warm engine.
• Turn the engine power switch to the ON position.
• Pull the recoil starter handle slowly until you meet some resistance. Pull the recoil starter with a rapid full arm stroke allowing the starter rope to rewind slowly. Repeat as necessary until the engine starts running.
• After the engine warms up and starts running normally, move the choke lever to the RUN position.

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How long should the engine warm up before moving the choke lever to the RUN position?

Allow the engine to warm up for about 3 minutes before moving the choke lever to the RUN position.

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What is the break-in period for the generator?

The first 25 hours of operation is the break-in period. During this time frame, DO NOT exceed 75% of the generator’s load limit. In other words, the maximum load during this break-in period should be no more than 3000 watts. After the first 25 hours of use drain and replace the engine oil.

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What should I do if the AC circuit breaker turns off?

Always reduce the load if the AC circuit breaker turns off. Once the load is reduced, press the breaker to reset the generator and continue operation.

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How do I calculate power draw?

Power draw can be calculated by multiplying volts and amps. The resulting number is wattage. Never exceed the rated maximum wattage (4000 watts) for the generator.

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What is the AC application procedure?

Allow the engine to run at no load until warm (approx. 3 minutes) after each start-up to allow the engine to stabilize.

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What should I do with the power cords of the appliances?

Plug the power cords of the 120 volt appliance(s) into the 120 volt AC outlets on the generator. Use caution to distribute the load evenly over the outlets. Add devices according to the largest wattage usage first.

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What should I not allow to happen with the fuel while devices are attached?

Do not allow the generator to completely run out of fuel with devices attached. A generator’s output may sharply spike as it runs out of fuel, causing damage to attached devices.

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What should I do when finished using the appliance(s)?

When finished using the appliance(s) unplug power cords from the AC outlets on the generator before shutting the generator off.

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What is the generator shut off procedure?

• Remove all electrical load devices from the generator. Allow the engine to run for approximately 3 minutes with no electrical load.
• Turn the generator’s power switch to OFF to stop the engine.
• Turn the fuel valve to the OFF position.
• Allow the generator to completely cool down before storing, at least 20 minutes.
• For any lengthy time of storage, more than 20 days, completely empty the fuel from the generator’s fuel tank and engine’s fuel lines. Cover and store in a well-ventilated area.

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What should I do before performing any maintenance procedure?

Before performing any maintenance procedure stop the engine, wait five (5) minutes to allow all parts to cool. Disconnect the spark plug wire, keeping it away from the spark plug.

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What should I do before performing any inspection, maintenance, or cleaning procedures?

Wait for the engine to cool, and remove the spark plug wire before performing any inspection, maintenance, or cleaning procedures.

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What is the procedure for changing/cleaning the air filter?

• Wipe off the air cleaner cover. Loosen the clips that retain the air filter cover on the top and the bottom.
• Remove the air cleaner filters and deflecting plate.
• Wash the air filters in warm water and mild detergent several times. Rinse. Squeeze out excess water and allow it to dry completely. Soak the filters in lightweight oil briefly, then squeeze out the excess oil.
• Install new air filters or reinstall the cleaned air filters. Secure the air cleaner cover by before use.

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What is the procedure for spark plug maintenance?

• Disconnect the spark plug wire from the end of the plug. Clean out debris from around the spark plug.
• Using the spark plug wrench provided, remove the spark plug. Inspect the spark plug. If the electrode is oily, clean it using a clean, dry rag. If the electrode has deposits on it, polish it using emery paper. If the white insulator is cracked or chipped, replace the spark plug.
• When installing a new spark plug, adjust the plug’s gap to the specification on the technical specification chart. Do not pry against the electrode or the insulator, the spark plug can be damaged.
• Install the new spark plug or the cleaned spark plug into the engine. Gasket style spark plugs should be finger-tightened until the gasket contacts the cylinder head, then turned about 1/2 to 2/3 more rotation. Non-gasket-style spark plugs should be finger-tightened until the plug contacts the head, then about 1/16 turn more.

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What should I do when the oil is changed?

Wait for the engine to cool before changing oil.

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What is the procedure for changing the engine oil?

• Make sure the engine is stopped and is level.
• Close the fuel valve.
• Place a drain pan underneath the crankcase’s drain plug.
• Remove the drain plug and, if possible, tilt the crankcase slightly to help drain the oil out.
• Replace the drain plug and tighten it.
• Clean the top of the dipstick and the area around it. Remove the dipstick by threading it counterclockwise, and wipe it off with a clean lint free rag.
• Add the appropriate type of oil until the oil level is at the full level. SAE 10W-30 oil is recommended for general use for temperatures above 32°F. Use SAE 5W-30 for temperatures consistently below 32°F.
• Thread the dipstick back in clockwise.

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What should I do if the engine will not start?

• No fuel in tank or fuel valve closed: Add fuel and open fuel valve.
• Choke not in start position: Place choke in START position and pull recoil starter.
• Low quality or deteriorated, old gasoline: Drain fuel. Add fresh 87+ octane unleaded gasoline.
• Dirty fuel passageways blocking fuel flow: Clean out fuel passageways using fuel additive.
• Carburetor needle stuck. Smell of fuel in air: Gently tap side of carburetor with screwdriver handle.
• Too much fuel in chamber: Turn choke to RUN position.
• Spark plug wire not connected securely: Connect spark plug wire securely to spark plug.
• Spark plug electrode wet or dirty: Remove and clean spark plug. Reinstall spark plug and restart.
• Incorrect spark plug gap: Reset spark plug gap according to specifications.
• Spark plug wire or spark plug broken: Replace spark plug and/or spark plug wire.
• Cylinder not lubricated after long storage: Remove spark plug. Pour tablespoon of oil into spark plug hole. Replace spark plug. Crank engine a few times and try to start.
• Clogged fuel filter: Replace fuel filter.
• If the engine still will not start, visit our web site at http://www.dirtyhandtools.com or call 1-877-487-8275 for assistance.

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What should I do if the engine misfires, backfires, or knocks?

• Spark plug wire loose: Tighten spark plug wire.
• Incorrect spark plug gap: Reset spark plug gap according to specifications.
• Spark plug wire or spark plug broken: Replace spark plug and/or spark plug wire.
• Low quality or deteriorated, old gasoline: Drain fuel. Add new fresh 87+ octane unleaded gasoline.
• Engine too cold: Use cold weather fuel and oil additives.
• Engine knocks: Engine overloaded, do not exceed recommended load rating.

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What should I do if the engine stops suddenly?

• Low quality or deteriorated, old gasoline: Drain fuel. Add fresh 87+ octane unleaded gasoline.
• Defective fuel cap creates vacuum: Test and replace fuel cap.
• Improper idle speed: Move choke to RUN position.
• Incorrect timing, deposit buildup, worn engine or other mechanical problem: Requires qualified technician.

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What should I do if there is no output from the generator’s AC receptacle?

• Engine speed too slow: Adjust engine speed. Requires qualified technician.
• Open or shorted wiring: Clean and reconnect all wiring.
• Faulty capacitor: Replace capacitor.
• Open/shorted rotor or stator windings: Replace stator windings.
• Open rectifier: Test rectifier and replace if required.

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What should I do if there is low output voltage with no load?

• Engine speed is too slow: Adjust engine speed. Requires qualified technician.
• Open rectifier: Test rectifier and replace if required.
• Faulty capacitor: Replace capacitor.
• Open/shorted rotor or stator windings: Replace stator windings.
• Alternator not magnetized: Re-magnetize the alternator.

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What should I do if there is a high output voltage with no load?

• Faulty capacitor: Replace capacitor.
• Engine speed is too fast: Adjust engine speed. Requires qualified technician.

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What should I do if there is low output voltage under load?

• Open rectifier: Test rectifier and replace if required.
• Engine speed is too low at full load: Adjust engine speed. Requires qualified technician.
• Excessive load applied: Reduce the applied load.
• Engine speed is too fast: Adjust engine speed. Requires qualified technician.

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What should I do if there is erratic output voltage?

• Dirty, corroded, or loose wiring: Clean and reconnect all wiring.
• Unbalanced load applied: Remove all loads, then apply each individually to determine which load is causing the erratic output. Do not reconnect the faulty tool or appliance.

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What should I do if there is noisy operation?

• Loose generator or engine bolt: Tighten all mountings.
• Short circuit in generator field or load: Test winding resistance, replace field winding if required, test load devices for shorts, replace defective load device(s).
• Faulty bearing: Replace bearing.

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What is the storage procedure for the generator?

• Wait for the engine to cool, then clean the engine with a clean cloth.
• When the generator is to be stored for longer than 20 days, prepare the engine for storage by emptying the fuel tank and draining all fuel lines. Clean out area around spark plug and remove. Pour one tablespoon of engine oil into the cylinder through the spark plug hole. Reinstall the spark plug, but leave the spark plug wire disconnected. Pull recoil starter handle to distribute oil in the cylinder. Stop after one or two revolutions when you feel the piston start the compression stroke (when you start to feel resistance).
• Apply a thin coat of rust preventive oil to all uncoated metal parts.
• Cover and store in a dry, well-ventilated area out of reach of children.

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What is the spark plug gap?

The spark plug gap is 0.028”~ 0.031”.