John Deere G2500K, G4400K, G5500K, G5500KE Generator OMPS02245 - PDF

Electric Generators

R

Generatrice Electrique Generador Electrico

OMPS 02245

Third Edition

THANK YOU for purchasing a John Deere product.

Read this manual thoroughly. Failure to do so could result in personal injury or equipment damage.

This manual should be considered a permanent part of your unit and should remain with the unit when you sell it.

Measurements in this manual are U.S. customary units and their metric equivalents.

Product warranty is provided as part of John Deere’s support program for customers who operate and maintain their equipment as described in this manual. The product warranty is explained later in this manual.

Record identification numbers below. Be sure to record all the numbers to help in tracing the machine if it is stolen. You also need to give these numbers to your dealer when you order parts.

MERCI d’avoir acheté un produit John Deere.

Veuillez lire ce manuel au complet pour éviter toute blessure personnelle ou dommage à l’équipement.

Le présent manuel doit être considéré comme faisant partie intégrale et permanente de votre appareil et devrait lui être adjoint si vous vendez l’appareil.

Les mesures sont exprimées dans les unités habituelles aux É.-U. et accompagnées de leurs équivalents métriques.

Le produit est garanti, conformément au programme de soutien à la clientèle de John Deere, en autant que les clients opèrent et entretiennent leur équipement comme indiqué dans ce manuel. La garantie est précisée plus loin.

Vous trouverez ci-dessous les numéros d’identification pour l’enregistrement. Notez bien tous les numéros afin de vous aider à retrouver la machine au cas où elle serait volée. Vous devez également fournir ces numéros au détaillant quand vous commandez des pièces.

GRACIAS por comprar un producto John Deere.

Lea completamente este manual. El hecho de no hacerlo podría dar lugar a daños personales o a daños en el equipo.

El presente manual se debería considerar una parte permanente de su unidad y debería permanecer con la unidad cuando usted la venda.

Las medidas existentes en el presente manual se indican en las unidades utilizadas normalmente en los EE.UU. y sus equivalentes en el sistema métrico.

La garantía del producto se proporciona como parte del programa de soporte de John Deere para los clientes que operan y mantienen su equipo de conformidad con lo descrito en este manual. La garantía del producto se explica más adelante en el presente manual.

Anote los números de identificación a continuación. Asegúrese de anotar todos los números para ayudarle a localizar la máquina en caso de que sea robada. Usted debe proporcionar asimismo estos números a su distribuidor cuando efectúe pedidos de piezas.

Date of Purchase / Date d’achat / Fecha de compra:_______________________________________________________________

Dealer Name / Nom du détaillant / Nombre del distribuidor:__________________________________________________________

Dealer Phone / Téléphone du détaillant / Teléfono del distribuidor:____________________________________________________

Serial Number / Numéro de série / Número de serie:_______________________________________________________________

2 © 2000, John Deere Consumer Products, Inc.

SAFETY INSTRUCTIONS.................................................................................................................4 GROUND FAULT CIRCUIT INTERUPTER (GFCI)...................................................................4 GENERATOR GROUNDING.......................................................................................................5 LINE TRANSFER SWITCH...........................................................................................................5 PREPARING FOR USE.....................................................................................................................6 STARTING AND STOPPING.............................................................................................................7 OPERATION ....................................................................................................................................... 8 MAINTENANCE ................................................................................................................................ 11 STORAGE ......................................................................................................................................... 13 TROUBLESHOOTING.....................................................................................................................13 WARRANTY ...................................................................................................................................... 13 EMISSION CONTROL INFORMATION..........................................................................................14 GENERAL SPECIFICATIONS.........................................................................................................15 WIRING DIAGRAM...........................................................................................................................16

INSTRUCTIONS DE SÉCURITÉ.....................................................................................................17 DISJONCTEUR DIFFÉRENTIEL (GFCI)..................................................................................17 MISE À LA TERRE DU LA GÉNÉRATRICE..............................................................................18 COMMUTATEUR DE SÉCURITÉ..............................................................................................18 PRÉPARATION À LA MISE EN MARCHE.......................................................................................19 DÉMARRAGE ET ARRÊT................................................................................................................20 FONCTIONNEMENT ....................................................................................................................... 21 ENTRETIEN ...................................................................................................................................... 24 ENTREPOSAGE ............................................................................................................................... 26 LOCALISATION DES PANNES.......................................................................................................26 GARANTIE LIMITÉE.........................................................................................................................26 INFORMATION SUR LE CONTRÔLE DE LA POLLUTION..........................................................27 GENERAL SPECIFICATIONS.........................................................................................................28 PLAN DE CÂBLAGE.........................................................................................................................29

MEDIDAS DE SEGURIDAD:............................................................................................................30 INTERRUPTOR PARA CORRIENTE DE CORTOCIRCUITO CON TOMA A TIERRA (GFCI)....30 TOMA A TIERRA DEL GENERADOR.......................................................................................31 CONMUTADOR DE TRANSFERENCIA DE LINEA..................................................................31 PREPARACION PARA EL USO.......................................................................................................32 PUESTA EN MARCHA Y PARADA..................................................................................................33 FUNCIONAMIENTO ......................................................................................................................... 34 MANTENIMIENTO ............................................................................................................................ 37 ALMACENAMIENTO ........................................................................................................................ 39 RESOLUCION DE PROBLEMAS....................................................................................................39 GARANTIA ........................................................................................................................................ 39 INFORMACIÓN RELATIVA A CONTROL DE EMISIONES...........................................................40 GENERAL SPECIFICATIONS.........................................................................................................41 DIAGRAMA DE CABLES..................................................................................................................42

Symbols / Définition des symboles / Definiciones de los simbolos Warning, Danger Caution ! Attention Danger (indique un dang er) Advertencia, Peligro, Precaución

Read all Safety, Operating Maitenance instructions.

and

Veillez à lire toutes les instructions de sécurité, de fonctionnement et d’entretien.

Lea todas las instrucciones de Seguridad, Funcionamiento y Mantenimiento.

3

WARNING TO AVOID DAMAGE TO UNIT, remove packing cards before operating generator: 1.Remove nut () and washer () shown from both engine mountA B ing bolts and discard properly.

2.Slide packing card () out from between engine (D) and mountC ing E channel () and discard properly.

WARNING:FOR SAFE OPERATION, READ THESE

INSTRUCTIONS BEFORE USING YOUR FOLLOW ALL INSTRUCTIONS FOR SAFE OPERATION. • If this generator is used for emergency standby service it will be necessary to install a manual transfer switch between the electric utility's meter and the building's distribution panel. The transfer switch isolates the generator and load from the utility power line, thus avoiding any danger of electricity being fed back to the utility lines. The installation should be done by a licensed electrician.

• Never operate the machine in an explosive atmosphere, near combustible materials or where ventilation is not sufficient to carry away exhaust fumes. Exhaust fumes can cause serious injury or death.

• When starting the machine, be sure that nothing is in a position to be hit by the operators hand or arm.

• Be sure the switch on electric power tools is in the “OFF” FOLLOW positionTHESE INSTRUCTIONS TO REDUCE THE RISK OF INJURY. before plugging them into the machine.

• This generator is equipped with a grounding terminal for your protection. Always complete the ground path from the generator to an external ground source as instructed in the section labeled “Grounding the Generator”.

• Keep the immediate area free of all bystanders.

• Be sure each person who operates this machine is properly instructed in its safe operation.

• Do not operate this machine or any electrical tool in any area where water or similar materials constitute an electrical hazard to the operator.Do not operate on wet surfaces or in the • rain.

Always be sure that the machine is on secure footing so that it • cannot slide or shift around, endangering workers.

Avoid contacting the hot exhaust manifold, muffler or cylinder.

• Keep clear of all rotating parts.

Unless the tool or appliance is double insulated, ground it. Tools and appliances which have 3 prong plugs must be plugged into extension cords and electrical receptacles with 3 holes. Before • operating any electrical item, be sure it is in good repair.

Follow instructions in this manual when testing Ground Fault • Circuit Interrupter to insure reliable operation.

BEWARE OF USING THIS EQUIPMENT IN CONFINED SPACES Confined spaces, without sufficient fresh air ventilation, can contain dangerous gases. Running gasoline engines in such environments can lead to deadly explosions and/or asphyxiation.

4

• UseJOHN DEERE® genuine replacement parts. Failure to do so may cause poor fit and injury.

• Never operate machine with any guard removed.

• Shut off the engine and disconnect the spark plug wire before working on any part of this machine.

• Always keep the machine and all associated equipment clean, properly serviced and maintained.

• • • • •

Observe all safety regulations for the safe handling of fuel.

Handle fuel in safety containers.

If container does not have a spout, use a funnel.

Do not refill fuel tank while the engine is running.

Fill the tank only on an area of bare ground. While filling the tank, keep heat, sparks and open flame away. Carefully clean up any spilled fuel before starting engine.

These generators are equipped with a GFCI (Ground Fault Circuit Interrupter) 120V duplex receptacle for protection against the haz- ards of electrical shock from defective attachments such as, tools, cords, and cables.

WARNING The GFCI may not function unless the generator is properly grounded. Follow the correct grounding procedure specified below.

The GFCI is a device that interrupts electricity from either the utility or generator by means of a special type of circuit breaker if a fault current flow to the ground occurs.

WARNING ON THE G4400K, G5500K AND G5500KE MODELS, ONLY THE 120V DUPLEX RECEPTACLES ARE PROTECTED BY THE GFCI. GFCI PROTECTED RECEPTACLES

UNPROTECTED RECEPTACLES

For additional protection against shock hazards due to defective equipment attached to the twist-lock receptacles, consider the use of a GFCI on each of these receptacles as well.

A GFCI can be used only with generators that have the neutral wire internally bonded to the frame, and the frame properly grounded to the earth. A GFCI will not work on generators that do not have the neutral wire bonded to the frame, or on generators which have not been properly grounded.

A GFCI may be required by OSHA regulations, the National Electric Code and/or local and federal codes when operating a generator.

GFCI and GFCI protected cord sets and cables may be purchased from local electrical supply houses.

As with any other safety devices, the GFCI supplied with these generators function- must be checked every month to insure that it is ing properly. To test the GFCI, follow the instructions and then enter the date of the test below.

1.With the generator running and the idle control switch in the "START" position (if so equipped), push the "TEST" button. The "RESET" button should pop out. This should result in the power being off at both outlets of the duplex receptacles. Verify this by plugging a test lamp into each outlet.

WARNING If the "RESET" button does not pop out or the test lamp lights when the "RESET" button does pop out, DO NOT USE ANY OF THE FOUR OUTLETS OF THE DUPLEX RECEPTACLES. Have the units serviced by an authorized John Deere Dealer immediately.

2.If the GFCI tests correctly, restore power by FIRMLY pushing the "RESET" button back in until you hear or feel a distinctive "click."

IF THE GFCI FAILS TO RESET PROPERLY, DO NOT USE EITHER OUTLET OF EITHER DUPLEX RECEPTACLE. Have the unit serviced by an authorized John Deere Dealer immediately.

3.High vibration or severe mechanical shock loads may cause the GFCI to trip. IF THE GFCI TRIPS BY ITSELF AT ANY TIME, reset it and perform test procedures 1. and 2.

The wing nut and ground terminal on the frame must always be used to connect the generator to a suitable ground source. The ground path should be made with #8 size wire. Connect the terminal of the ground wire between the lock washer and the wing nut, and tighten the wing nut fully. Connect the other end of the wire securely to a suitable ground source.

The National Electric Code contains several practical ways in which to establish a good ground source. Examples given below illustrate a few of the ways in which a good ground source may be established. A metal underground water pipe in direct contact with the earth for at least 10 feet can be used as a grounding source. If an under- ground pipe is unavailable, an 8 foot length of pipe or rod may be used as the ground source. The pipe should be 3/4 inch trade size or larger and the outer surface must be noncorrosive. If a steel or iron rod is used it should be at least 5/8 inch diameter and if a nonferrous rod is used it should be at least 1/2 inch diameter and be listed as material for grounding. Drive the rod or pipe to a depth of 8 feet. If a rock bottom is encountered less than 4 feet down, bury the rod or pipe in a trench. All electrical tools and appliances operated from this generator, must be properly grounded by use of a third wire or be “Double Insulated”.

It is recommended to: 1.Use electrical devices with 3 prong power cords.

2.Use an extension cord with a 3 hole receptacle and a 3 prong plug at opposite ends to ensure continuity of the ground protection from the generator to appliance.

We strongly recommend that all applicable federal, state and local regulations relating to grounding specifications be checked and adhered to.

WARNING Although the above test procedures will indicate proper GFCI operation on an ungrounded or improperly grounded generator, the generator MUST still be properly grounded for the GFCI to function properly and protect the user from electrical faults.

Year

Jan. Feb. Mar. Apr. May Jun. Jul.

#8 WIRE GROUND CONNECTION GROUND SOURCE (ROD OR PIPE)

Aug. Sep. Oct. Nov. Dec.

GROUND TERMINAL AND WING NUT

LESS THAN 25 OHMS RESISTANCE

If this generator is used for standby service, it must have a transfer switch between the utility power service and the generator. The transfer switch not only prevents the utility power from feeding into the generator, but it also prevents the generator from feeding out into the utility company's lines. This is intended to protect a serviceman who may be working on a damaged line.

THIS INSTALLATION MUST BE DONE BY A LICENSED ELECTRICIAN AND ALL LOCAL CODES MUST BE FOLLOWED.

NOTE Situations exist where the GFCI will not afford any protection against the hazards of electrical shock. EXAMPLE: if a person touches two or more conductors from a damaged cord set and is not in direct contact with the ground, he may receive a shock.

Since there is no path to ground for a ground fault current to flow through, the GFCI will not operate and serious injury may result.

The GFCI is merely an added safety feature. There are no substitutes for good safety precautions, correct electrical practices and proper maintenance of cords, equipment and connections.

5

Use oil viscosity based on the expected air temperature range during the period between oil changes.

Do not mix oil with gasoline.

John Deere PLUS-4® oil is the preferred oil to use. If John Deere PLUS-4® oil is not available, us a high quality detergent oil with an API classification of SE, SF, SG or SH.

THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A minimum of 87 octane of the antiknock index is recommended. The antiknock index is posted on service station pumps in the U.S.A. For normal use, purchase fuel that can be used in 30 days. This will assure fuel freshness and volatility tailored to the season.

Arctic oils (such as Military Specification MIL-L-46167B) may be used at temperature below -30°C (-22°F).

Check oil level before each operation and ensure that it is maintained.

CAU T IO N This engine crankcase is not filled with oil at the factory, so be sure to fill it before operating the engine.

1.Level the engine to ensure accurate inspection and to prevent overfilling.

2.Unscrew the oil gauge, wipe the dipstick dry. Insert it into the filler hold but DO NOT SCREW IT IN. 3.The oil level should be between the “H” and “L” marks on the dipstick.

-20°C

- 10 °C

0°C

10°C

20°C

30°C

40°C

SAE40

1.Level the engine before filling the tank.

2.Clean area around fuel cap and loosen cap slowly. Rest the cap on a clean surface.

3.Carefully put fuel into the tank, filling to approximately 1/4 inch (5mm) of the top. Avoid spillage.

4.Immediately replace cap and hand tighten. Wipe up any fuel spillage.

DO NOT OPERATE ENGINE IF GASOLINE IS SPILLED. AVOID CREATING ANY IGNITION UNTIL THE GASOLINE HAS EVAPORATED.

The battery is supplied dry and must be serviced before it can be put into use. You can do this yourself or have it done either by an automotive service station or your authorized John Deere Dealer.

Two quarts of electrolyte are required for proper battery fill and can be purchased from your John Deere Dealer.

SAE30 SAE10W-30/SAE10W-40 SAE5-20

NOTE When checking the oil be sure the engine is level.

“H” Mark “L” Mark

This engine is equipped with a “Low Oil” shut-off system for engine protection. If the engine fails to start, check engine crankcase oil.

G2500K..............0.58 qt. (0.55L) G4400K..............1.2 qt. (1.1L) G5500K..............1.4 qt. (1.3L) G5500KE...........1.4 qt. (1.3L)

6

WARNING Always wear protective glasses, gloves, and clothing when handling batteries and sulfuric acid electrolyte.

Avoid contact with the battery electrolyte. It is a strong acid and will cause painful and dangerous injury to eyes or skin. It will damage clothing and other articles if spilled or splattered. Before handling the electrolyte, read all warnings, cautions, etc. on the carton. Study the antidote label on the container for instructions and procedures in case of accidental contact.

The gases issuing from a charging battery are a mixture of hydrogen and oxygen gases and will explode with great violence and spraying of acid if a spark or flame is brought too near them.

A room or compartment in which charging batteries are confined should be ventilated. Do not bring a flame or sparks near vent openings.

In all automotive battery cells small quantities of hydrogen gas are given off at the negative plates even when the cells are not being charged. It must therefore be assumed that explosive mixtures of hydrogen gas are present within the cells at all times.

A torch, match flame, lighted cigarette, or sparks from metal tools accidentally contacting the terminals could cause ignition of the gases.

To avoid sparks, do not disturb connections between batteries while charging; first throw switch “off” at the charger. The possibility of ignition of hydrogen gas by static electricity when working on or near batteries is minimized by grounding one's self and the vehicle to remove any static charge.

For the full PDF version of this manual, Please click on the above download PDF button.

1.Remove filler caps and fill battery with electrolyte to proper level as shown below. Allow battery to sit for 20 minutes before proceeding.

2.Charge battery at 2 amps until the specific gravity reading is 1.265-1.275.

3.Install filler caps and tighten firmly.

CAP

4.A light coat of heavy-duty Mineral Grease or Petrolatum may be applied to the battery terminals and cable ends to prevent corrosion.

FILLER TUBE FILLE R CAPS

PROPER ELECTROLYTE LEVEL 3/16" (+/- 1/8")

NOTE: Check engine oil before starting Always level the engine before starting.

ON 1 Turn ignition switch to “”. . Turn the fuel valve counterclockwise to open (located under fuel 2 tank). . Set choke to the "CHOKE" position.

3 NOTE: If the engine is warm, set choke to "RUN" position. .

4.On G4400K, G5500K and G5500KE : Set idle control switch to

start position.

PILOT LIGHT

IDLE CONTROL SWITCH

5.Grasp starter grip and pull slowly until starter engages, then rapidly to overcome compression and start engine.

CAUTION: DO NOT let the recoil cord snap back by itself. This may damage the cord of the recoil starter assembly.

NOTE: If the engine does not start in three (3) pulls, open the choke and try again.

6.When engine starts, gradually move choke to "RUN" position.

Allow engine to warm up before applying a load.

7.Set idle control to “RUN” position.

1.Put the key into the engine switch.

2.Set choke to the “CHOKE” position.

3.Turn I the key to the “START” () position. The engine usually starts within three (3) seconds.

CAUTION: Do not run the starter continuously more than 5 seconds, otherwise the battery may discharge quickly. If the engine does not start right away, wait 15 seconds and try again.

4.When engine starts, gradually move choke to “RUN” position.

Alow engine to warm up before applying a load.

5.Set idle control to “RUN” position.

Remove load, allow to run for 2 minutes before turning ignition switch to “OFF” (O).

Remove load, allow engine to run at idle speed for 2 minutes before turning ignition switch to “OFF” (O).

Remove load and allow engine to run at idle speed for two (2) minutes before turning ignition switch to “OFF” (O).

7

NOTE: There engines are equipped with a “Low Oil” shut-off system for engine protection. The engine stops and the LED flashes when the oil level gets too low. The engine will not restart without adding oil. If the unit is tilted too much during operation, it may suddenly stop even though the oil level is not low.

Check the engine oil before restarting the engine. If the unit is tilted, level the engine, then check the oil before restarting the engine.

Product users on United States forest service land, and in some states, must comply with fire prevention regulations.

The G2500K is equipped with a spark arrestor. The G4400K, G5500K and the G5500KE uses spark arrestor part number AW26849, which is available from your local John Deere Dealer.

Other user requirements may apply, check with your Federal, State, or local authorities.

ENGINE

Kawasaki, 5.5 H.P.

Kawasaki, 8.0 H.P.

Kawasaki, 11 H.P.

WATTS (AC) CONTINUOUS

2300 WATTS

4000 WATTS

5000 WATTS

WATTS (AC) INTERMITTENT

2500 WATTS

4400 WATTS

5500 WATTS

RATED AMPERAGE

19.2

33.3/16.6

41.6/20.8

RATED VOLTAGE (AC)

120 VOLTS

120/240 VOLTS

120/240 VOLTS

VOLTAGE REG.

ELECTRONIC, 6%

ELECTRONIC, 6%

ELECTRONIC, 6%

FR EQ UE NC Y

60 Hz

60 Hz

60 Hz

7.4 HOURS AT RATED LOAD 3 GALLONS (US) 11 LITERS

12.7 HOURS AT RATED LOAD 8 GALLONS (US) 30 LITERS

9.5 HOURS AT RATED LOAD 8 GALLONS (US) 30 LITERS

RUN TIME HRS./TANK OF FUEL FUEL TANK CAPACITY

NOTE Unit ratings are established based on operation at standard conditions of 60° F and at sea level. The performance of the generator must be de-rated for temperature and altitude by 1% for every 10° F above 60° F and 3.5% for every 1000 feet above sea level. Due to the operational characteristics of the thermal type circuit breaker, the power available from the generator will decrease slightly with a corresponding increase in ambient temperature.

Due to continuing product improvements, specifications are subject to change without notice.

8

The G2500K generator is equipped with the following receptacles: One 120 Volt, 20 Amp, NEMA 5-20R, Duplex (2 outlets), GFCI protected.

One 120 Volt, 20 Amp, NEMA 5-20R, Duplex (2 outlets), GFCI protected by the above receptacle.

Pilot Light.

NEVER EXCEED THE RATING OF A RECEPTACLE. These receptacles are protected against severe overloads by resettable thermal type circuit breakers. If a circuit breaker trips, the cause should be determined and corrected prior to continuing use.

The 120 volt, 20 Amp duplex receptacle (5-20R) is Ground Fault Protected by the 120 volt, 20A duplex GFCI receptacle (5-20R GFCI). Simultaneous loading of these receptacles must not exceed a total of 20 Amps.

PILOT LIGHT

5-20R

The G4400K, G5500K and G5500KE generators are equipped with the following receptacles: One 120/240 Volt, 20 Amp, NEMA L14-20R, Locking type.

One 120 Volt, 30 Amp, NEMA L5-30R, Locking type.

One 120 Volt, 20 Amp, NEMA 5-20R, Duplex (2 outlets), GFCI protected.

One 120Volt, 20 Amp, NEMA 5-20R, Duplex (2 outlets), GFCI protected by the above receptacle.

Hour meter and voltage meter.

NEVER EXCEED THE RATING OF A RECEPTACLE. These receptacles are protected against severe overloads by resettable thermal type circuit breakers. If a circuit breaker trips, the cause should be determined and corrected prior to continuing use.

The 120 volt, 20 Amp duplex receptacle (5-20R) is Ground Fault Protected by the 120 volt, 20A duplex GFCI receptacle (5-20R GFCI).

Simultaneous loading of these receptacles must not exceed a total

5-20R GFCI

of 20 Amps. The 120 volt, 30 Amp (L5-30R) and 120/240 Volt, 20 Amp (L14-20R) locking receptacles ARE NOT GROUND FAULT PROTECTED. If Ground Fault Protection on these receptacles is necessary or desired, external protection devices must be used. Refer to CIRCUIT BREAKER

the IDLE CONTROL HOUR on "Ground VOLT 5section Fault Interrupters" forL5-30R more information.

SWITCH METER METER 5-20R

20R GFCI

L14-20R

CIRCUIT BREAKERS

The G4400K, G5500K and G5500KE generators are equipped with an hour meter that records run time for the unit. This is very useful in scheduling maintenance.

The G4400K, G5500K and G5500KE generators are equipped with a volt meter that indicates output from the voltage regulator.

If there is no voltage at the receptacles and the volt meter is indicating normal output, check and reset the circuit breakers and the GFCI receptacle.

9

The idle control system controls the engine speed in the following manner: 1.With the idle control switch in the "START" position and with no load on the generator, start the engine.

2.After a one to two minute warm up period, move the switch to the "RUN" position. The engine will throttle back to idle speed following a 3 - 5 second delay.

3.When a load is applied to the generator, the electromagnet of the idle control system becomes de-energized and the engine governor is released from the solenoid. The engine then accelerates to normal operating speed, controlled by the governor.

4.When the load is removed. the solenoid becomes re-energized and throttles the engine back to idle speed after a 3 - 5 second delay.

The continuous duty rating should not be exceeded for long periods of time. Always be sure that the voltage, amperage and frequency requirements of the equipment to be used can be satisfied by the generator. To avoid damage, the generator should not be operated at the intermittent rating for more than 10 minutes out of every hour.

For best voltage regulation results, the 120 Volt loads should be balanced between the duplex receptacles and the 120 volt, 30 Amp locking receptacle. 120 Volt and 240 Volt loads applied to the 120/240 Volt, 20 Amp Locking receptacle simultaneously should be balanced for best voltage regulation results.

NOTE:While the engine is idling, the generator voltage is automatically reduced to 85-95 volts to reduce generator temperatures.

The voltage will return to normal levels immediately upon the application of load.

The idle control is factory installed. This electronic device is designed to let the engine run at fuel saving low idle speed when the generator is not loaded, and atfull normal governed speed when a load is applied. The electromagnet overrides the engine governor to provide idle speed. When a load is applied, the electronic circuit reacts to de-energize the electromagnet so that the engine can resume full governed operating speed.

CABLE SIZE Equipment damage can result from low voltage. Therefore, to prevent excessive voltage drop between the generator and the equipment, the cable should be of adequate gauge for the length used. The cable selection chart gives the maximum cable length for various gauges of wire which can adequately carry the loads shown.

CURRENT INLOAD IN WATTS AMPERESAT 120 VOLTSAT 240 VOLTS

#8 WIRE

MAXIMUM ALLOWABLE CABLE LENGTH #10 WIRE#12 WIRE#14 WIRE#16 WIRE

1000ft.

375ft.

250 ft.

300 600 600ft.

500 200 125 600 120 300 350 125 100 900 0 200 250 100 50 120 180 150 150 65 0 0 100 125 50 175ft.

180 240 75 100 150 0 0 60 65 125 240 360 90 0 0 300 480 0 0 360 600 0 0 480 It is characteristic of common electric motors 720 in normal operation to draw up to six times their running current while starting. This table may 0 required to start 0 "CODE G" electric motors, however if an electric motor fails to start or reach running speed, be used to estimate the watts turn off the appliance or tool immediately to avoid 960 equipment damage. Always check the requirements of the tool or appliance being used compared to the rated output of the generator.0 2.5 5 7.5 10 15 20 25 30 40

Motor Size (H.P.) 1/8 1/6 1/4 1/3 1/2 3/4 1

10

Running Watts 275 275 400 450 600 850 1100

Watts Required to Start Motor Repulsion InductionCapacitorSplit Phase 600 850 1200 600 850 2050 850 1050 2400 975 1350 2700 1300 1800 3600 1900 2600 2500 3300 -

Keep all air vents clear.

Keep clean.

Periodically check all fasteners and tighten.

CAUTION Never run the engine without the air filter, serious damage can result.

WARNING Clean the element in a well ventilated area. Ensure that no sparks or flames are near the working area, this includes any appliance with a pilot light. Do not use gasoline or low flash-point solvents to clean the element, a fire or explosion could result.

IDLE CONTROL SPEED ADJUSTMENT G4400K, G5500K and G5500KE only: NOTE The automatic idle speed is set between 2640 and 2940 RPM. Do not set the idle speed lower than recommended range.

A 1.Remove the air cleaner wing bolts ().

The idle speed has been pre-set at the factory and should rarely C require readjustment. We recommend that all adjustments of 2.Remove the air cleaner cover (B), then remove the elements ( & D). this nature be made by a competent serviceman.

3.Separate the foam element (C) from the paper element (D).

Erratic idle operation or "hunting" of the engine usually indicates a 4.Clean the elements: need for carburetor adjustment to provide a smooth idle. The idle Foam Element: Clean the element in warm soapy water. Rinse control will not function properly when the idle speed is below the and let dry completely. Soak the element in SAE30 weight oil for recommended limits or the carburetor is improperly adjusted.

5 minutes; squeeze out excess oil.NOTE:Clean the foam element every 25 hours.

Paper element: Clean by gently tapping the element to remove dust. Replace the element if extremely dirty. NOTE:Clean the The engine for this generator is governed to operate at speeds paper element every 100 hours. Replace the paper element close to 3600 RPM (60 Hz) throughout the operating load range. every 300 hours.

The no load speed (before a load is applied) will be just a bit higher than the load speed and is normally set to 3750 RPM.

WARNING Do not tamper with the governor mechanism, change the setting experimentally, or push the throttle open in an attempt to gener- ate more electrical current; equipment damage may result.

Governor speed adjustment should be made only by an

A C D B

experienced serviceman.

Check oil level before each operation and ensure that it is maintained per "PREPARING FOR USE" section.

Change oil after the first five hours of operation. Thereafter it should be changed every 50 hours.

1.Make sure the unit is on level ground. Run the engine to warm the oil.

2.Stop the engine.

3.Remove the oil drain screw.

4.Drain oil while engine is warm, into a suitable container.

The oil filter should be changed every 200 hours of operation.

1.Rotate the filter (A) counterclockwise to remove it.

2.Coat a film of clean engine oil on the seal of the new oil filter.

3.Install the new filter by rotating it clockwise until the seal contacts the mounting surface (B). Rotate the filter 3/4 of a turn more by hand.

4.Supply engine oil as specified.

WARNING 5.Run the engine for about three (3) minutes, stop engine and Oil being drained may be hot. To reduce the risk of burn injury, check for oil leakage around the filter. handle with care.

6.Check the oil level as per instructions in “PREPARING FOR USE” 5.Install the oil drain screw. section then add additional oil to compensate for oil in the filter.

6.Remove oil gauge and refill with new oil. See "PREPARING FOR USE" section for oil recommendations.

7.Check the oil level as per instructions in "PREPARING FOR USE" section.

B

A

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Check the spark plug gap and reset it if necessary. The Spark Plug Gap should be between 0.7 and 0.8mm (0.028 and 0.032 in.). To change the gap, bend the side-electrode only, using a spark plug tool.

Install and tighten the spark plug to 23 Nm (17 ft-lb), (204 inlb).

Connect the spark plug lead.

Recommended Spark Plug: Spark Plug.......................NGK BPR5ES Spark Plug Gap...............0.7-0.8 mm (0.028-0.032 in.)

Torque.............................23 N-m (17 ft-lb) (204 in-lb) CAUTION Always replace with an NGK BPR5ES, or equivalent plug of the same configuration and heat range. A resistor plug is required by law in some areas.

0.028 - 0.032" (0.7 - 0.8mm)

To ensure satisfactory operation over an extended period of time, an engine requires normal maintenance at regular intervals.The Periodic

Maintenance Chart below shows periodic inspection and maintenance items and suitable intervals. The bullet ma corresponding item should be performed at that interval.

Some adjustments require the use of special tools or other equipment. An electronic tachometer will facilitate setting idle and running speeds.

Daily Check fuel....................................................................

Check and add engine oil...........................................

Check for loose or lost nuts and bolts.........................

Check for fuel leakage................................................

Check for engine oil leakage......................................

Check cylinder and head fins for................................. dust and dirt Check battery electrolyte level....................................

• • • • • •

Every 25 Hr.

Every 50 hr.

Every 100 hr.

Every 200 hr.

Every 300 hr.

• Tighten nuts and bolts (1)....................................................................................................................• Change engine oil (1).................................................................................................• Change oil filter (G5500K & G5500KE)......................................................................................................................• Clean fuel valve...........................................................................................................• Check carburetor adjustment......................................................................................• Clean air cleaner foam element (2)....................................................• Clean air cleaner paper element (2)...................................................................................................• Check engine speed...................................................................................................• Clean and regap spark plug...............................................................................................................• Change air cleaner paper element (2)................................................................................................................................................

Clean dust and dirt from cylinder and................................................................................................................................................. cylinder head fins (2) Clean combustion chamber*...............................................................................................................................................................

Check and adjust valve clearance*....................................................................................................................................................

Valve maintenance*............................................................................................................................................................................

Check fuel line (Replace if necessary)...............................................................................................................................................

(1 ) (2 )*

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• • • • • •

Perform these operations after the first 5 hours of use, then at the recommended interval.

Service more frequently under dusty conditions.

These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service, unless you have the proper equipment and mechanical proficiency.

1.Drain all fuel from tank into a container approved for gasoline.

2.Run engine until it stops.

3.Loosen the carburetor bowl drain plug. Drain remaining fuel into a container approved for gasoline. Retighten the carburetor bowl drain plug 4.Remove the spark plug, pour 1 - 2 teaspoons (5 - 10 cc) of engine oil into the cylinder, slowly pull the starter handle 2 or 3 times, reinstall the spark plug and tighten securely.

NOTE: Servicing generators may require use of specialized tools and electronic equipment. If these solutions do not solve the problem contact your John Deere Dealer.

PROBLEM: Engine will not start: 1.Is the engine switch ON? 2.Is there fuel in the tank?

3.Is there adequate oil in the engine crankcase?

These engines are equipped with a low oil sensor. The engine cannot be started unless the oil level is above the prescribed lower limit.

4.Is there spark at the spark plug?

A)Remove the spark plug cap. Clean any dirt from around the plug base, then remove the spark plug.

B)Install the spark plug in the plug cap.

5.Retighten all bolts and nuts.

6.Clean the exterior surface of the generator and apply a rust inhibitor.

7.Store the generator in a dry, well ventilated place.

WARNING Fuel should be drained in a well ventilated area and stored in a container approved for gasoline.

C)Turn the engine switch on.

D)Grounding the electrode to any engine ground, pull the recoil starter to see if sparks jump across the gap.

E)If there is no spark, replace the plug.

F)With new plug installed repeat “D” above.

G)If okay, reinstall plug and start engine according to instructions.

H)If engine still does not start, take it to a John Deere Dealer.

PROBLEM: Generator has no output.

1.Reset circuit breakers 2.Check cord sets and extension cords.

3.Consult a John Deere Dealer.

The manufacturer warrants to the original retail purchaser that this product is free from defects in material and workmanship and agrees to repair or replace, at manufacturer's discretion, any defective product free of charge within these time periods from the date of purchase: • One year, if the Product is used for personal, family, or household use; • 90 days, if the Product is used for any other purpose, such as commercial or rental use.

This warranty is not transferable and does not cover damage resulting from defects other than in material or workmanship, or damage caused by unreasonable use, including the failure to provide reasonable and necessary maintenance. Also, the warranty obligations do not apply to conditions resulting from misuse, alteration or accident. In addition, this warranty does not cover general check-ups on electrical equipment, tune-ups on gasoline engines, or replacement of non-defective parts (such as electrical brushes, cables, plugs, spark plugs, filters, starter ropes, etc.) that may wear and need to be replaced with reasonable use within the warranty period or which may require replacement in connection with normal maintenance. This warranty applies only to produc sold within the United States of America, the District of Columbia, Canada, Mexico, the Commonwealth of Puerto Rico, the Virgin Islands, Guam, the Canal Zone, or American Samoa.

SAVE YOUR SALES SLIP Proof of purchase in the form of your dated sales receipt, cash register slip, etc. showing the serial number and the model of your product will be required before our dealers can perform warranty service on the product. You must at your own expense, arrange to deliver or ship the product for warranty repairs and arrange for pickup or return of the product after repairs have been made.

This warranty does not apply to any trade accessory, engine, or electric motor which is separately warranted by another manufacturer and not manufactured by the manufacturer.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER EXPRESS WARRANTIES. ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY OR OTHERWISE, APPLICABLE TO THIS PRODUCT, SHALL BE LIMITED IN DURATION TO THE DURATION OF THIS LIMITED WARRANTY. THE MANUFACTURER SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL, OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. HOW TO OBTAIN WARRANTY SERVICE Warranty service can be obtained from a JOHN DEERE dealer authorized to make warranty repairs. If you need warranty service, check first with the dealer from whom you purchased the product. FOR WARRANTY SERVICE INFORMATION OUTSIDE THE USA AND CANADA, PLEASE CONTACT YOUR LOCAL JOHN DEERE DEALER. The manufacturer will not make any reimbursements for warranty service, except to JOHN DEERE dealers authorized to make warranty repairs. You must present your sales receipt when making any claim for warranty service.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

If you have any questions regarding your warranty rights and responsibilities, you should contact your John Deere Retailer, or the John Deere Customer Communications Center, 1-800-537-8233.

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