PORTER-CABLE PCI2800-B3 (01) PDF MANUAL

PORTER-CABLE PCI2800-B3 (01) PDF SUMMARY:

What should I do before starting the generator?

Follow the steps listed below before starting the generator:

1. Place unit on level surface.
2. Check engine oil. Refer to Oil Recommendations under Assembly and Product Specifications for correct grade and quantity of oil.
3. Check fuel level, fill as required. See Add Engine Oil and Fuel under Assembly.
4. Make sure generator is grounded in accordance with local requirements. See Grounding the Generator under Assembly.
5. All electrical loads MUST be disconnected and main breaker (AA) in the OFF position.

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What are the steps for starting the generator?

1. Disconnect all electrical loads from the generator and place the main breaker (AA) in the OFF position.
2. Turn the fuel shut-off valve (G) on the gas tank to the vertical (OPEN) position as shown.
3. If the engine is cold, move the choke (Q) to the CLOSED position shown. If the engine is hot, move the choke to OPEN position.
4. Turn engine On/Off switch (Z) to the ON position.
5. Pull the starter grip (J) slowly until you feel compression then pull briskly. NOTE: Do not allow the starter grip to snap back. Return it slowly by hand. NOTE: If the oil level in the engine is low, the engine will not start. If the engine does not start, check the oil level and add oil as needed. NOTE: To ensure maximum oil lubrication, place the generator on a level surface.
6. As the engine warms up, move the choke (Q) to the OPEN position.
7. Allow the engine to warm up for five minutes.

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What should I do to connect electrical loads?

1. Allow the engine to warm up for five minutes. Then place the main breaker (AA, Fig. 3) in the ON position.
2. Connect inductive load equipment first. Inductive loads consist of refrigerators, freezers, water pumps, air conditioners or small hand tools. Connect the items that require the most wattage first.
3. Connect the lights next.
4. Voltage sensitive equipment should be the last equipment connected to the generator. Plug voltage sensitive appliances such at TV’s, VCR’s, microwaves, ovens, computers and cordless telephones into a UL listed voltage surge protector, then connect the UL listed voltage surge protector to the generator.

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How should I stop the generator in an emergency?

To stop the engine in an emergency, move the engine On/Off switch (Z) to the OFF position.

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What are the steps for normal generator operation shutdown?

1. Disconnect all electrical loads attached to the generator.
2. Move the engine On/Off switch (Z) in the OFF position.
3. Turn the fuel shut-off valve (G) on the gas tank to the horizontal (CLOSED) position as shown.

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What should I do if I notice an unusual noise or vibration?

If any unusual noise or vibration is noticed, stop the engine and refer to the troubleshooting section.

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How should I maintain the generator?

• Good maintenance is essential for safe, economical and trouble-free operation.
• Always follow the inspection and maintenance recommendation and schedules in the manual.

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What safety precautions should I take before performing any maintenance or repairs?

Make sure the engine is off before beginning any maintenance or repairs. This will eliminate several potential hazards, including:

• carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you operate the engine.
• burns from hot parts. Let the engine and exhaust system cool before you touch it to prevent burns.
• injury from moving parts. Wear appropriate clothing, tie back long hair, and stay alert around the generator to prevent injury from moving parts.

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What type of solvent should I use to clean parts?

To reduce the possibility of fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep smoking products, sparks and flames away from all fuel related parts.

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What do I need to ensure before beginning repairs?

Read all instructions before beginning and make sure you have the tools and skills required. A PORTER CABLE factory service center or a PORTER CABLE authorized service center knows your generator best and is fully equipped to do maintenance and repair. To ensure the best quality and reliability, use only new genuine parts or their equivalents for repair or replacement.

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What should I do before storing the generator?

Contact with a hot engine or exhaust system can cause serious burns or fires. Let the engine and muffler cool before storing the generator.

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What should I do with used maintenance parts?

All generators contain maintenance parts (e.g. oil, filters, etc.) that are periodically replaced. These used parts may contain substances that are regulated and must be disposed of in accordance with local and national laws and regulations.

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What should I take note of during maintenance?

Take note of the positions and locations of parts during disassembly to make reassembly easier.

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What should I do if a service operation is not included in the maintenance section?

Any service operations not included in this section should be performed by a PORTER CABLE factory service center or a PORTER CABLE authorized service center.

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What should I do before performing maintenance or service?

The following procedures must be followed when maintenance or service is performed on the generator.

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What is the maintenance chart for the generator?

Procedure	Daily	50 hours or weekly	100 hours (whichever comes first)	150 hours or monthly	500 Hours (whichever comes first)
Clean generator’s exterior	X
Check oil level	X
Change oil				X*(1)
Clean air filter				X(1)
Clean spark plugs					X
Check fuel line, hose clamps and fuel tank	X
Oil leak inspection	X
Sediment cup		X
Clean fuel tank and filter					X(2)
Check for unusual noise/vibration	X
Check and adjust valve clearance				X (2)
Prepare unit for Storage

* The engine oil must be changed after the first 20 hours or operation. Thereafter change oil every 150 hours of operation or monthly, whichever comes first. (1) Perform more frequently in dusty or humid conditions (2) Contact a Customer Care Center.

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How should I clean the generator’s exterior?

When cleaning, use only mild soap and a damp cloth on plastic parts. Many household cleaners contain chemicals which could seriously damage plastic. Also, do not use gasoline, turpentine, lacquer, paint thinner, dry cleaning fluids or similar products which may seriously damage plastic parts. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

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How should the generator be stored and operated?

The generator should be kept clean and dry at all times. The generator should not be stored or operated in environments that include excessive moisture, dust or any corrosive vapors. If these substances are on the generator, clean with a cloth or soft bristle brush. Do not use a garden hose or anything with water pressure to clean the generator. Water may enter the cooling air slots and could possibly damage the rotor, stator and the internal windings of the alternator.

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How should I clean the fuel sediment cup?

1. Turn the fuel shut-off valve (G) to the OFF position (horizontal to the ground). Remove the sediment cup (TT), O-ring (UU) and screen (SS) as shown.
2. Clean the sediment cup, O-ring and screen in nonflammable or high flash point solvent.
3. Reinstall O-ring, screen and sediment cup.

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How do I clean the air filter element?

1. Unsnap the air filter cover (I) clips and remove the air cleaner cover.
2. Remove the element from air filter.
3. Wash element(s) (RR) in a solution of household detergent and warm water, then rinse thoroughly, or wash in nonflammable or high flash point solvent. Allow the element(s) to dry thoroughly.
4. Soak the element in clean engine oil and squeeze out the excess oil. NOTE: The engine will smoke during initial start-up if too much oil is left in the element.
5. Reinstall the air filter element and snap air filter cover in place.

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What are the steps for checking the oil?

1. Place unit on a flat level surface.
2. Remove oil fill/dipstick (L) and wipe clean.
3. Reinsert oil fill/dipstick fully into oil fill port and tighten. Allow oil to collect on the dipstick for a few seconds.
4. Remove oil fill dipstick to read oil level. If oil falls below top of pattern on dipstick, add oil. NOTE: Patterns may differ according to engine.
5. Replace dipstick and tighten securely.

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How do I change the oil?

1. Disconnect spark plug wire.
2. Locate a suitable container under oil drain plug (K).
3. Remove the oil fill/dipstick (L) from crankcase.
4. Remove the oil drain plug (K).
5. Allow ample time for all oil to drain out.
6. Install the oil drain plug.
7. Fill with recommended oil, refer to Oil Recommendations under Assembly.
8. Replace dipstick and tighten securely.
9. Reconnect spark plug wire.
10. Dispose of oil according to local or national laws and regulations.

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What are the steps for maintaining the spark plug?

1. Remove the spark plug cap.
2. Clean any dirt from around the spark plug base.
3. Use a spark plug wrench (not supplied) to remove the spark plug.
4. Visually inspect the spark plug. Replace it if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is going to be reused.
5. Measure the plug gap with a feeler gauge (VV). Correct as necessary by carefully bending the side electrode. See Product Specifications for correct gap.
6. Make sure the spark plug washer is in good condition. Thread the spark plug in by hand to prevent cross threading.
7. After the spark plug is seated, tighten with a spark plug wrench to compress the washer. If installing a new spark plug, tighten the spark plug 1/2 turn after it seats to compress the washer. If reinstalling a used spark plug, tighten 1/8-1/4 turn after the spark plug seats to compress the washer. Do not overtighten.
8. Securely replace spark plug cap.

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How do I drain the carburetor bowl?

1. Place the fuel valve lever (G) in the closed position (horizontal to ground).
2. Place an OSHA-approved container suitable for fuel under the carburetor bowl (P). NOTE: Using a funnel will allow the fuel to flow into the container with less spillage.
3. Remove the carburetor bowl drain (M).
4. Fuel will drain from carburetor bowl.
5. When drained, replace carburetor bowl drain.

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How do I clean the debris screen?

1. Remove fuel cap (D).
2. Remove debris screen (QQ).
3. Clean debris screen. Use compressed air to blow off debris.
4. Replace debris screen and fuel cap.

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What should I do before transporting the generator?

1. Place engine On/Off switch in the OFF position.
2. Place the fuel valve lever on gas tank in the CLOSED position.
3. Keep generator level at all times to prevent fuel spillage. Fuel vapor or spilled fuel may ignite.

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What should I do before storing the generator?

1. Clean the generator as outlined under Maintenance.
2. Check that cooling air slots and openings on generator are open and unobstructed.

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What is a proper storage procedure for the engine?

If storing the unit for more than thirty days drain all fuel out of fuel lines, tank and carburetor bowl. Drain oil and refill with fresh, clean oil. Fuel will oxidize and deteriorate in storage. If fuel is allowed to deteriorate during storage the carburetor and fuel related parts will need to be serviced. Fuel stabilizer can be used to lengthen the fuel life, follow the fuel stabilizer’s recommended instructions.

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What might cause the engine to not start?

1, 2, 3, 4, 14, 15, 16, 17, 18, 19, 20, 21, 27

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What might cause there to be no electrical output?

5, 6, 7, 8, 9, 10, 12, 13

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What might cause the generator to repeatedly trip the main breaker?

9, 10

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What might cause the generator to overheat?

9, 11

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What might cause the engine to not continue to run after starting?

1, 2, 3, 14, 16, 18, 19, 20, 21, 27

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What might cause the engine to make knocking noises?

23

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What might cause the engine to over speed or run at a low speed?

24, 25, 26

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What might cause low power output?

16, 19, 22, 23

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What should I do if the engine On/Off switch is in the OFF position?

Turn the switch to the ON position.

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What should I do if the choke is in the wrong position?

Adjust choke accordingly.

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What should I do if the fuel shut-off valve is in the closed position?

Open fuel shut-off valve.

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What should I do if the unit is loaded during start-up?

Remove load from unit.

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What should I do if the receptacle is faulty?

Contact a Customer Care Center.

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What should I do if the receptacle thermal circuit breaker is tripped?

Depress and reset.

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What should I do if the capacitor is defective?

Contact a Customer Care Center.

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What should I do if the power cord is faulty?

Repair or replace cord.

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What should I do if the generator is overloaded?

Reduce load.

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What should I do if the cords or equipment is faulty?

Check for damaged, bare or frayed wires on equipment. Replace.

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What should I do if there is insufficient ventilation?

Move to adequate supply of fresh air.

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What should I do if the windings in the stator are faulty?

Contact a Customer Care Center.

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What should I do if the wire harness is faulty?

Contact a Customer Care Center.

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What should I do if there is low or no fuel?

Add fuel.

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What should I do if the fuel is bad?

Drain fuel tank and replace with fresh, clean, regular unleaded gasoline with a minimum of 86 octane.

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What should I do if the oil is low?

Add oil.

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What should I do if the spark plug is faulty?

Replace spark plug.

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What should I do if the spark plug cap is loose?

Attach spark plug cap securely.

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What should I do if there is no or low compression?

Tighten spark plug. If problem is not corrected, contact a PORTER CABLE factory service center or a PORTER CABLE authorized service center.

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What should I do if there is no spark?

Check spark plug wire. If problem is not corrected, contact a Customer Care Center.

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What should I do if the spark plug is fouling and is sooty or sticky black?

a. Clean spark plug. See Spark Plug under Maintenance. b. Check spark plug gap, adjust if needed. See Spark Plug under Maintenance. c. Replace spark plug. See Specifications. d. If engine still fails to start, contact a Customer Care Center.

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What should I do if the air filter is dirty?

Clean or replace the air filter elements.

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What should I do if the valve clearances are improper?

Reset valve clearances. Contact a Customer Care Center.

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What should I do if the governor linkage is stuck or bent?

Contact a Customer Care Center.

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What should I do if the throttle shaft is stuck?

Contact a Customer Care Center.

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What should I do if the governor spring is bent or lost?

Contact a Customer Care Center.

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What should I do if the carburetor is dirty?

Contact a Customer Care Center.

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How do I ground the generator?

A grounding nut (X, Fig. 3) is supplied with the generator for use when required by local electrical ordinances. Your local electric company or a certified electrician should be able to help you with this information.

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What type of extension cords should I use with the generator?

Use only grounded extension cords. Use only three wire or double-insulated power tools.

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What are the guidelines for use with extension cords?

Only use grounded extension cords that are rated for outdoor use and equipment with a third-wire ground. It is recommended that GFCI protected spider box or inline GFCI adapter are used when connecting to any of the generator’s receptacles.

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What happens when a long extension cord is used?

When a long extension cord is used to connect an appliance or tool to the generator, a voltage drop occurs. The longer the cord, the greater the voltage drop. This results in less voltage being supplied to the appliance or tool and increases the amount of current (amp) draw or reduces performance. A heavier cord with a larger wire size will reduce the voltage drop. Be sure to choose a cord that will supply enough voltage to operate your tool or appliance. The tables indicate appropriate gauge for extension cords and the voltage drop caused by the use of extension cords, given different electrical loads.

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What is the risk of operating equipment at low voltage?

Operating equipment at low voltage can cause it to overheat. Using an excessively long extension cord can cause the cord to overheat.

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What should I do with electrical cords in poor condition?

Keep electrical cords in good condition. Do not use worn, bare or frayed cords because they can cause electrical shock.

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What is the minimum gauge for extension cord sets?

Volts	Total Length of Cord in Feet
120V	0-25 (0-6.7 m) 26-50 (7.9-15.2 m) 51-100 (15.5-30.5 m) 101-150 (30.8-45.7 m)
240V	0-50 (0-15.2 m) 51-100 (15.5-30.5 m) 101-200 (30.8–60.9 m) 201-300 (61.2-91.4 m)
	Ampere AWG
	Rating 0-10 10-13 13-16 16-25 25-30
	16 16 14 12 10
	16 16 14 12 10
	14 14 12 12 Not Recommended

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What is the voltage drop in extension cords?

Extension Cord Length	Amp Load	Voltage Drop
		16 AWG 14 AWG
25 Foot 7.6 m	10 A	2.0 1.3
	15 A	3.0 1.9
	20 A	4.0 2.5
	30 A	6.0 3.8
50 Foot 15.2 m	10 A	4.0 2.5
	15 A	6.0 3.8
	20 A	8.0 5.0
	30 A	12.0 7.5
100 Foot 30.5 m	10 A	8.0 5.0
	15 A	12.0 7.5
	20 A	16.0 10.0
	30 A	24.0 15.0
150 Foot 45.7 m	10 A	12.0 7.5
	15 A	18.0 11.3
	20 A	24.0 15.0
	30 A	36.0 22.5
		12 AWG 10 AWG
	10 A	0.8 0.5
	15 A	1.2 0.8
	20 A	1.6 1.1
	30 A	2.3 1.6
	10 A	1.6 1.1
	15 A	2.3 1.6
	20 A	3.1 2.1
	30 A	4.7 3.2
	10 A	3.1 2.1
	15 A	4.7 3.2
	20 A	6.2 4.2
	30 A	9.3 6.3
	10 A	4.7 3.2
	15 A	7.0 4.7
	20 A	9.3 6.3
	30 A	14.0 9.5

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How do I assemble the wheel kit (PCI5000 only)?

1. Carefully tilt the generator so it rests on the engine side.
2. Install the two stands (KK) at the lower chassis. Use Bolts (MM) and nuts (LL) for this step.
3. Install the axle (QQ) to the lower chassis. Use bolts (OO), nuts (NN) and axle strap (PP) for this step.
4. Slide the wheels (EE) on the axle. Then slide the two washers (DD) on each end of the axle and secure with cotter pins (FF), bend one side of cotter pins.
5. Place the generator upright so it is resting on the wheels and stands.

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How do I install the handle kit?

1. Install handles on the engine side of the generator by securing each bracket (GG) with bolts (II) and nuts (JJ).
2. Place handle assembly (HH) onto each bracket (GG) and secure each with remaining bolts (II) and nuts (JJ)
3. Tighten the bolts until the assembly is snug.

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What is the procedure for using the voltage selector switch?

This switch (Y) allows the generator to operate in either single voltage (120V) or dual voltage (120/240V) mode. When placed in the 120V position it allows you to receive the full capacity of the generator by using all the receptacles. When placed in the 120/240 position, you will only be able to receive half the available watts when using the 120 volt receptacles and the full available watts when using the 240V 4-prong twist-lock receptacle.

NOTE: Do not move the voltage selector switch (Y) while powering electrical devices. Disconnect all electrical loads before moving the switch. Failure to disconnect electrical loads could damage the switch.