DIRTY HAND TOOLS 101174 (01) PDF MANUAL

DIRTY HAND TOOLS 101174 (01) PDF SUMMARY:

How do I unpack and set up the portable power generator?

Your portable power generator is completely assembled at the factory. Save the packing materials and box for future use as a storage container. Setup for use outside in a well-ventilated area on a level, stable surface away from doors, windows, vents, etc. COMPLETELY READ AND UNDERSTAND THE OPERATOR’S MANUAL BEFORE ATTEMPTING TO OPERATE THE GENERATOR.

How do I fill the generator with gasoline and oil?

FUEL IS HIGHLY FLAMMABLE AND POISONOUS ALWAYS FILL THE TANK WITH ENGINE OFF AND COOL. ALWAYS CHECK THE FUEL LEVEL BEFORE OPERATING. Allow the engine to cool for at least two minutes before removing the fuel cap.

1. Place the portable power generator on a level surface. 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.
2. The fuel tank holds approximately 2.55 gallons of fuel. 87+ octane unleaded gasoline is recommended. Do not fill above the top of the fuel filter. Replace the fuel cap securely and wipe any excess from the fuel tank before starting the generator.
3. Add engine oil to the upper level of the oil filler hole. SAE 10/30 motor oil is recommended for most environmental conditions. The oil capacity is 0.63 quarts (0.6L).

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

What are some operation precautions I should take?

1. Keep all safety guards in place and in proper working order at all times.
2. NEVER place fingers, hands, or body near the generator when it is running. Do not lean or reach over the generator when the machine is running.
3. Keep all people (except the operator) a minimum of six feet from the generator during operation.
4. Do not transport the generator with the engine running.
5. Operate on level ground. Do not tilt the machine while the engine is running.
6. Do not leave the generator unattended when it is running. Turn off the engine before leaving the area.
7. Do not operate in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Gasoline-powered engines may ignite the dust or fumes.
8. Do not use this piece of equipment while tired or under the influence of drugs, alcohol, or medication.
9. Parts, especially exhaust system components, get very hot during use. Stay clear of hot parts.
10. Do not cover the generator during operation.

This generator is not intended to power sensitive electronic equipment* without the addition of an appropriate line conditioner and surge protector (both not included). Sensitive electronic equipment, including but not limited to audio/video equipment, television sets, computers, and printers, should be operated on approved inverter-type generators or pure sine wave generators. If the plugged-in product operates abnormally or unusually slow, immediately stop using the generator as a power source.

1. 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.
2. 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.
3. 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.
4. 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.
5. Connect the generator only to an electrical system (120V~) that is compatible with the electrical characteristics and rated capacities of the generator.
6. 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.

What are the safety information warnings?

• WARNING: 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. Do not allow anyone to operate this portable power generator who has not read this manual. As with all power equipment, a portable power generator can be dangerous if used improperly. Do not operate this portable power generator if you have doubts or questions concerning safe operation. Call our customer service department at 720-287-5182, 1-877-487-8275, or visit http://www.dirtyhandtools.com if you have any questions or concerns about the safe operation of this equipment.
• WARNING: Failure to follow warnings, cautions, assembly, and operation instructions in the Operation Manual may result in serious injury or death.
• DANGER: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES.
  • Exhaust contains carbon monoxide, which is a poison that you cannot see or smell.
  • Never use inside a house or garage even with doors and windows open!
  • Use only outside away from windows, doors, and vents!
• CAUTION: HOT MUFFLER! TO PREVENT BURNS, DO NOT TOUCH MUFFLER OR OTHER EXHAUST COMPONENTS.

What is the intended use of the portable power generator?

Do not use the portable power generator for any purpose other than for which it was designed. Any other use is unauthorized and may result in serious injury or death.

What personal protective equipment should I wear?

Wear ANSI-approved safety goggles and heavy-duty work gloves during setup. While this portable power generator operates at a relatively low noise level, about 70dB, you may want to wear earplugs or noise-deafening headphones. 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. Caution is necessary when near the engine’s magneto or recoil starter.

What are some general safety tips?

• 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.
• NEVER place fingers, hands, or body near the generator when it is running. Do not lean or reach over the generator.
• Keep all safety guards in place and in proper working order.
• Keep all people (except the operator) a minimum of six feet from the generator during operation.
• Do not transport the generator with the engine running.
• Do not tilt the machine while the engine is running.
• Do not leave the generator unattended when it is running. Turn off the engine before leaving the area.
• 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.
• Fill the gasoline tank outdoors with the engine off and allow the engine to cool completely.
• 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.
• 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.
• To prevent serious injury: Operation of this equipment may create sparks that can start fires around dry vegetation or flammable materials. A spark arrestor may be required. The operator should contact local fire agencies for laws and regulations regarding fire prevention requirements.

What are the safety decals?

Safety labels on the portable power generator are to remind you of important information while you are operating the unit. Make sure all safety warning decals are attached and in readable condition. Replace missing or defaced decals. Contact Dirty Hand Tools at 1-877-487-8275 for replacement decals.

To prevent serious injury, electric shock, and property damage:

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

To prevent serious injury and fire:

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

What octane of gasoline is recommended?

87+ octane unleaded gasoline is recommended.

What type of motor oil is recommended?

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

What is the oil capacity?

0.63 quarts (0.6L).

What is the fuel capacity?

The fuel tank holds approximately 2.55 gallons of fuel.

How do you calculate the total wattage?

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 (1000 watts).

1. Add up the Running Watts for all appliances/tools that you want to use at the same time.
2. Make sure that the total calculated wattage is less than the Rated Wattage of the generator (1000 watts).
3. Find the single highest starting rate wattage product and add that to the total.
4. Make sure that this total now is less than the Maximum Wattage of the generator (1200 watts maximum).
5. Plug in and turn on appliances/tools from the largest wattage first to the smallest wattage last.

How do you calculate wattage?

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

How do you 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.

When can you plug in appliances or tools to the generator?

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

What are the steps on how to operate the generator?

1. 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).

2. Turn the engine’s fuel valve to the OPEN position.

3. 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.

4. Turn the engine power switch to the ON position.

5. 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.

6. After the engine warms up and starts running normally, move the choke lever to the RUN position.

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

7. The first 25 hours of operation is the break-in period. Breaking-in the engine will help ensure proper equipment and engine operation, and will extend the engine’s lifespan. 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 900 watts. After the first 25 hours of use drain and replace the engine oil.

   • The warranty is void if the engine is not broken in properly.

8. Load And Circuit Breaker: The total combined load through the outlet on the generator must not exceed the rated maximum power (1200 watts) of the unit. 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.

9. Calculating Power Draw: Power draw can be calculated by multiplying volts and amps. The resulting number is wattage. Never exceed the rated maximum wattage (1200 watts) for the generator. Refer to appliance/tool owner’s manuals to determine the wattage of electrical load devices.

   • Note: Long power cords and extension cords draw additional power. Keep cord length at a minimum.

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

11. 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 useage first.

    • 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.

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

13. Generator Shut Off: Remove all electrical load devices from the generator. Allow the engine to run for approximately 3 minutes with no electrical load.

14. Turn the generator’s power switch to OFF to stop the engine.

15. Turn the fuel valve to the OFF position.

16. Allow the generator to completely cool down before storing, at least 20 minutes.

17. 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.

What is the maintenance checklist?

Procedure	Before Each Use	Monthly/ 20 Hours	Every 6 Mo./ 100 Hours	Annually/ 300 Hours
Check Engine Fuel Level	X	X	X	X
Check General Equipment Condition	X
Check Air Cleaner	X	X	X	X
Check Fuel Strainer	X	X	X	X
Clean/Replace Air Filter*		X	X	X
Check/Clean Spark Plug		X	X
Check/Adjust Idle Speed		X	X
Check/Adjust Valve Clearance		X	X
Clean Fuel Tank, Strainer & Carburetor			X
Clean Combustion Chamber**				X
Replace Fuel Lines**				X

*Change/clean air filter more frequently if in dusty environment.

**Service performed by qualified technician.

What safety precautions should you take before performing any maintenance?

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.

How do you change/clean the air filter?

1. Wipe off the air cleaner cover. Loosen the knob at the bottom of the air cleaner housing.
2. Remove the air cleaner filter and deflecting plate.
3. Wash the air filter in warm water and mild detergent several times. Rinse. Squeeze out excess water and allow it to dry completely. Soak the filter in lightweight oil briefly, then squeeze out the excess oil.
4. Install a new air filter or reinstall the cleaned air filter. Secure the air cleaner cover before use.

What safety precautions should you take before performing spark plug maintenance?

To prevent serious injury from accidental starting turn the power switch of the engine to its “OFF” position. Wait for the engine to cool, and remove the spark plug wire before performing any inspection, maintenance, or cleaning procedures.

How do you perform spark plug maintenance?

1. Disconnect spark plug wire from end of plug. Clean out debris from around the spark plug.
2. 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.
3. 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.
4. 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.

What safety precautions should you take before changing the engine oil?

Oil is very hot during operation and can cause burns. Wait for engine to cool before changing oil. Wait for the engine to cool, and remove the spark plug wire before performing any inspection, maintenance, or cleaning procedures.

How do you change the engine oil?

1. Make sure the engine is stopped and is level.
2. Close the fuel valve.
3. Place a drain pan underneath the crankcase’s drain plug.
4. Remove the drain plug and, if possible, tilt the crankcase slightly to help drain the oil out.
5. Replace the drain plug and tighten it.
6. 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.
   • Note: Do not thread the dipstick in when checking the oil level.
7. 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.
8. Thread the dipstick back in clockwise.
   • DO NOT RUN THE ENGINE WITH TOO LITTLE OIL. THE ENGINE WILL BE PERMANENTLY DAMAGED.

What are the SAE viscosity grades for average outside temperature?

SAE VISCOSITY GRADES	AVERAGE OUTSIDE TEMPERATURE (°F)
30W	-20
10W-30W	0
5W-30W	20
	40
	60
	80
	100

What do you 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.

What do you 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.

What do you 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.

What safety precautions should you take before performing any maintenance to the engine?

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.

What do you do if there is no output from 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.

What do you 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.

What do you do if there is high output voltage with no load?

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

What do you 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.

What do you 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.

What do you 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.

What are the storage instructions?

1. Wait for the engine to cool, then clean the engine with a clean cloth.
2. 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).
3. Apply a thin coat of rust preventive oil to all uncoated metal parts.
4. Cover and store in a dry, well-ventilated area out of reach of children.

What is the important notice about the product and/or specifications?

We, the manufacturer, reserve the right to change the product and/ or specifications in this manual without notification. The manual is for information usage only and the pictures and drawings depicted herein are for reference only.

What are the warranty repair and service instructions?

Do not return this product to the store for warranty issues or repair. Call our customer service department at 720-287-5182, 1-877-487-8275, or visit http://www.dirtyhandtools.com for the location of the nearest service center.

What are the specifications of the product?

SKU/Part No.	101174
Description	1200W Portable Power Generator
	Peak Wattage 1200 Watts Maximum Continuous Wattage 1000 Watts Circuit Breaker 20 Amps Power Receptacles 2 – 120VDC, 60Hz, 1 – DC 12V, 5.3A Engine 2.4 HP
	79.8cc* EPA/CARB Approved
Fuel Type	Unleaded Gasoline, 87+ Octane
Spark Plug Gap	0.028”~ 0.031”
Run Time	@ 50% Load 8 Hours
Sound Rating	70 dB
Dimensions	20”L x 18”W x 17”H Weight 80 Lbs. Accessories Spark Plug Wrench Included

*As rated by engine manufacturer

What is the contact number for service or questions?

1-877-487-8275

What is the contact number for FrictionlessWorld?

720-287-5182