JEGS 86004 Gas Powered Portable Generator User Guide

JEGS 86004 Gas Powered Portable Generator

Parts List

Introduction

Thank you for purchasing this 5250 watt portable generator from JEGS. This generator is designed to give you years of reliable service when operated and maintained as instructed in this manual.
Product Specifications:
This generator is an engine-driven, revolving field, alternating current (AC) portable generator. It is designed to supply electrical power to operate tools, appliances, camping equipment, lighting, or serve as a backup power source during power outages.

AC Output

| Rated Wattage| 4250W
Rated Voltage| 120V/240V
Rated Frequency| 60Hz
Rated Ampere| 35.4A / 17.7A
Rated Output| 4.25kVA
Maximum Output| 5.25kVa

Engine

| Displacement| 224cc
Engine Type| Single Cylinder,

4-Stroke, OHV Air Cooled

Engine Oil Type| SAE 10w30
Engine Oil Capacity| 20 oz / 0.6 L
Fuel Tank Type| 4 gal / 15L
Fuel Type| Unleaded

The emissions control system for this generator is compliant with all standards set by the US EPA.

How to Contact Customer Service:
If you have questions regarding your purchase please contact customer service at: 1.800.345.4545. Save your original sales receipt and record the following information below for service or warranty assistance.

Date of Purchase:|
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Model Number:|
Serial Number:|

Safety Symbols

Indicates a hazardous situation which could result in serious injury or death if not avoided.

• Toxic Fumes
• Risk of Fire
• Risk of Explosion
• Risk of Electric Shock
• Hot Surface
• Lifting Hazard

Safety Rules

The manufacturer cannot anticipate every possible circumstance that the user may encounter hazards. Therefore, the warnings in this manual, on tags, and on affixed decals are not all-inclusive. To avoid accidents, the user must understand and follow all manual instructions and use good common sense.

WARNING!

Read and understand this manual in its entirety before operating this generator. Improper use of this generator could result in serious injury or death.

Do not operate indoors or in a confined space that prevents dangerous carbon monoxide gas from dissipating.

• Using a generator indoors CAN KILL YOU IN MINUTES!
• Carbon monoxide gas is a poisonous, odorless gas that can cause headache, confusion, fatigue, nausea, fainting, sickness, seizures, or death. If you start to experience any of these symptoms, IMMEDIATELY get fresh air and seek medical attention.
• Never use indoors, in a covered area, or in a confined space, even if the doors and windows are open.
• Install a battery-operated carbon monoxide alarm near bedrooms.
• Keep exhaust this unit produces from entering a confined area through windows, doors, vents, or other openings.
• When working in areas where vapors could be inhaled, use a respirator rated for carbon monoxide protection.

The engine exhaust contains chemicals that can cause cancer and birth defects.

• Always wash hands after handling generator.

To reduce the risk of serious injury, do not attempt to lift the generator alone.

Never exceed the generator’s wattage/ amperage capacity. This may damage the generator and/or connected devices.

• Check operating voltage and frequency of all electrical devices prior to plugging into generator.

Never start or stop the engine with electrical devices plugged into the receptacles. Failure to do so could damage the generator and/or connected devices.

• Always start the engine and let it stabilize before connecting any electrical devices.
• Disconnect all electrical devices before stopping the engine.

Starter recoil and other moving parts can catch on clothing, jewelry, and hair.

• Do not wear loose clothing or loose gloves.
• Remove jewelry or anything else that could be caught in moving parts.
• Tie back hair, or wear protective head covering to contain long hair.

The generator must be properly grounded to prevent electrocution.

• Only operate the generator on a level surface.
• If connected to a structure, connect the ground terminal to an appropriate ground.

Keep away from flammable objects and other hazardous materials.

• The fuel and its vapors used to power this unit are highly flammable and could explode resulting in serious injury or death.
• Never fill or drain fuel tank indoors.
• Never overfill fuel tank. If fuel spills, move the unit at least 30 feet away from the spill and wipe up any remaining fuel on the unit before starting the engine.
• Never smoke while operating or fueling this unit.
• Never operate or store this unit near an open flame, heat, or any other ignition source.
• Generator should be far away from buildings or other equipment during operation.
• Keep engine free of grass, leaves, grease, and other flammable debris.
• When adding or draining fuel, unit should be turned off for at least 2 minutes to cool before removing fuel cap. If unit has been running, the fuel cap may be under pressure, remove slowly.
• To keep fuel from spilling, secure unit so it cannot tip while operating or transporting.
• When transporting unit, disconnect the spark plug wire and make sure the fuel tank is empty with the fuel shutoff valve turned to the off position.

Never modify this unit in any way or modify governed engine speed.

• Increasing the governed engine speed is dangerous and can result in personal injury and/ or damaged equipment.
• Decreasing the governed engine speed adds an excessive load and can damage the equipment.
• This generator will supply the correct rated frequency and voltage only when operating at the preset governed speed.

Avoid touching hot areas of this unit.

• Only operate the generator on a level surface.
• If connected to a structure, connect the ground terminal to an appropriate ground.

This generator produces high voltage which may result in burns/electrocution causing serious injury or death.

• Never handle the generator, electrical devices, or
  any cord while standing in water, while barefoot, or when hands or feet are wet.

• Always keep the generator dry. Never operate a generator in rain or under wet conditions.

• Use a ground fault circuit interrupter (GFCI) in a damp or highly conductive area, such as metal decking or steel work.

• Never plug electrical devices into a generator having frayed, worn, or bare wires. Never touch bare wires or contact receptacles.

• Never permit a child or unqualified person to operate the generator. Always keep children a minimum of 10 feet away from the generator.

• If using the generator for backup power, notify the utility company.

• If connecting a generator to a building’s electrical system for standby power, you must use a qualified electrician to install a transfer switch. Failure to isolate the generator from the power utility could result in serious injury or death to electric utility workers.

Pull cord recoils rapidly and can pull arm towards engine faster than you can let go which could result in injury.

• To avoid recoil, pull starter cord slowly until resistance is felt, then pull rapidly

Only use as intended. Used incorrectly serious injury or death could result.

• Do not bypass any safety device. Moving parts are covered with guards. Make sure all protective covers are in place.
• Never transport or make adjustments to this unit while it is running.
• Never insert objects into cooling slots.

Never operate this unit if there are any broken or missing parts.

• Improper treatment of this generator can shorten it’s life.
• Always repair this unit as specified in this manual.
• Shut generator off if electrical output is missing, unit vibrates excessively or begins to smoke, spark, or emit flames.

Assembly

Unpacking

1. Place box on a level surface.
2. Remove all items from box except the generator. Make sure all items listed on the packing list are included and not damaged.
3. Cut down the sides of the box being careful to avoid hitting the generator.
4. Leave generator on box to install wheel assembly.

Packing List

Check all loose parts to the following list. Contact your dealer if any loose parts are not included.

Attaching the Handle (Figure 1)

1. Parts needed:
   • 1 Handle
   • 1 Handle bracket
   • 1 Handle clip
   • 4 Screws
   • 4 Nuts.
2.  Install handle bracket to generator frame.
3.  Attach handle to the bracket handle.
4.  Install handle clip.

Attaching the Wheels (Figure 2)

1. Parts needed:
   • 2 Wheels
   • 2 Axles
   • 2 Cotter pins
   • 2 Washers
2. Raise or tilt generator so you can slide the wheel axle pin into the wheel, the washer, the wheel mounting hole located on the side of the frame.
3. Secure the wheel assembly by reinserting a hair pin through hole at the end of the wheel axle and pressing until it locks into place.
4. Repeat process on the other side of the generator to install the second wheel.

Installing the Support Legs (Figure 3)

1. Parts needed:
   • 2 Support legs
   • 4 M8 screws
   • 4 M8 nuts
2. Tip the generator 90º on end to gain access to the bottom of the frame. Securely position props underneath to support.
3. Line up holes on the support leg bracket to the holes on the front of the generator frame.
4. Attach the support leg using M8 screws (2) and nuts.

You must add oil before first operating this generator. Check level every use.

• DO NOT use E15 or E85 fuel in this unit. It is a violation of federal law, will damage the generator, and void your warranty.

Adding / Checking Engine Oil (Figure 4)

1. Place generator on a level surface.
2. Insert a funnel into the crankcase dipstick hole and carefully add 4-Cycle engine oil (SAE 10W30) to empty crankcase until oil reaches the outer edge of the oil fill hole (crankcase dipstick hole).
3. Be sure to replace the dipstick before attempting to start the engine.
4. To check oil, set the generator on a level surface, wipe dipstick clean, then reinsert dipstick without rethreading.

Adding Fuel (Figure 5)

1. Set the generator outdoors away from windows and doors.
2. Remove fuel cap.
3. Insert a funnel into the fuel tank and carefully pour gasoline into the tank until fuel level reaches 1 ½ inches below the top of the neck. Be careful not to overfill the tank to provide space for fuel expansion.

Operation

Connecting your Generator to an Electrical System
If connecting the generator to a building’s electrical system for standby power, you must use a qualified electrician to install a transfer switch. The power from the generator must be isolated from the circuit breaker or alternative power source. The connection must comply with all electrical codes and applicable laws.

This generator produces a very high voltage which could result in burn or electrocution causing serious injury or death.

• Never handle the generator, electronic devices, or any cord while standing in water, while barefoot, or when hands or feet are wet.
• Always keep the generator dry. Never operate generator in rain or under wet conditions.
• Use a ground fault circuit interrupter (GFCI) in a damp or highly conductive area, such as metal decking or steel work.
• Never plug electronic devices into generator having frayed, worn, or bare wires. Never touch bare wires or make contact with receptacles.
• Never permit a child or unqualified person to operate the generator. Keep children a minimum of 10 feet away from the generator at all times.
• If using the generator for back up power, notify the utility company.
• Install a transfer switch. Failure to isolate the generator from the power utility could result in serious injury or death to electric utility workers.

Generator must be properly grounded to prevent electrocution.

• Only operate generator on a level surface.
• Always connect the nut and ground terminal on the frame to an appropriate ground source.

How to Start the Engine

• Place the generator on a level surface. All electrical loads must be disconnected from generator.
• Turn fuel valve to the “ON” position. (See fig. 6)
• Slide the choke lever to the “Choke” position. (See fig. 7)
• Skip this step if the engine is hot.
• For a manual start, turn the engine ON/OFF switch to the “ON” position. Pull the recoil handle (starter cord) slowly until resistance is felt, then pull rapidly. (See fig. 8)
• Let engine run for several seconds and then gradually, as engine warms up, slide the choke lever towards the “RUN” position until the choke is fully slid to the “RUN” position. (See fig. 9).

Pull cord recoils rapidly and pulls arm towards engine faster than you can let go which could result in injury.

• To avoid recoil, pull starter cord slowly until resistance is felt, then pull rapidly.

How to Stop the Engine

• All loads must be disconnected from the generator. Never start or stop the engine with any electrical devices plugged in to the receptacles (Fig. 10).
• Turn the fuel valve to the “OFF” position (Fig. 11)
• Turn the engine ON/OFF switch to the “OFF” position (Fig. 12).

Receptacles and Extension Cords
Only use high quality, well-insulated, extension cords in good condition with generator receptacles.

This generator is equipped with the following receptacles:

• Two 120 Volt AC, 20 Amp receptacles.
• One 120 Volt AC,30 Amp RV receptacle
• 120 / 240 Volt AC, 30 Amp twist lock receptacle
  • (NEMA L14-30).
• 12 Volt 8.3 Amp Output
  • (For charging batteries only)

120 Volt AC, 20 Amp receptacle

• This receptacle has a 20 Amp push-to reset circuit breaker to protect against overload.
• Each socket is rated to operate 120 Volt, AC, single phase, 60Hz loads requiring up to 2400 watts (2.4 kW) at 20 Amps.
• Use extension cords having a minimum rating of 125 Volts AC, 20 Amps.

120 / 240 Volt AC, 30 Amp locking receptacle

• This receptacle has a 30 Amp push-to-reset circuit breaker to protect against overload.
• This receptacle is rated to operate 120 Volt, AC, single phase, 60Hz loads requiring up to 3600 watts (3.6 kW) at 30 Amps. It is also rated to operate 240 Volt AC, single phase, 60Hz loads.
• Use a NEMA L14-30 plug with this receptacle.

Voltage selector switch
This switch toggles between 120 volts and 240 volts, AC output; on the respective receptacles.

Do not connect 3-phase loads to the generator.

• Do not move the voltage selector switch with devices connected. Disconnect all electrical loads before moving the switch. Failure to do so could damage the switch or generator.
• 12 Volt 8.3 Amp Output is for batteries only

Extension Cord Selection
Refer to the above table to ensure the extension cord used has the capacity to carry the required load. If the size of the cable is inadequate it can cause a voltage drop, which can damage the electrical device and cord.

Moving the Generator

• Disconnect any electronic devices from generator then turn generator off.
• Turn fuel valve to the “OFF” position.
• Tilt generator until it balances on wheels. Roll machine to desired location.
• If the generator must be carried, fold handle to the down position. Never lift or carry generator by its handle.

WARNING

This product is heavy and requires several people to lift. Lift and lower with your legs by bending at the knees, not your back, to avoid injury.

Don’t Overload the Generator
Make sure you can supply enough rated watts and surge watts for all electrical devices connected to the generator. Rated watts refer to the power a generator must supply to keep a device running. Surge watts refer to the power a generator must supply to start an electrical device. This power surge for starting a device usually lasts between 2-3 seconds but this additional output must be taken into account when selecting the electrical devices you plan to attach to the generator. To prevent overloading the generator take the following steps:

1. Add up the total rated wattage of all electronic devices that will be connected to the generator simultaneously.
2. Estimate surge watts by adding the item(s) with the highest output (it is unnecessary to calculate the surge output for all devices as they should be connected one at a time).
3. Add the Surge Watts to the total Rated Watts in step 1. Keep total load within generator’s power capacity.

Operating Voltage and Frequency
Operating voltage and frequency requirement of all electronic equipment should be checked prior to plugging them into this generator. Damage may result if the equipment is not designed to operate within a +/- 10% voltage variation, and +/- 3 Hz frequency variation from the generator name plate ratings. To reduce the risk of damage, always have an additional load plugged into the generator if solid state equipment (such as television set) is used. A power line conditioner is recommended for some solid state applications.

Wattage Reference Guide
(Wattages listed are approximate. Check electrical devices for actual wattage.)

WARNING

Never exceed the generator’s wattage/amperage capacity. This could damage the generator and / or connected devices.

3-in-1 Meter
The multifunction meter operates whenever the engine is running and keeps track of how many hours, frequency, and voltage is being used on the generator.

Power Management

• Start the engine without anything connected to the generator.
• When the engine has stabilized, plug in and turn on first load. It is strongly recommended to plug in devices with the largest power requirement first and the smallest power requirement last to help prevent overloading the generator.
• Allow generator output to stabilize (engine and attached devices run evenly) before plugging in the next load.

Cold Weather Operation
Under humid conditions where temperatures drop to 40ºF (4ºC) the carburetor and/or crankcase breather system may begin to freeze. To prevent icing take the following steps:

• Replace any old fuel with clean, fresh fuel.
• Use synthetic 5W-30 or SAE 5W-30 engine oil. Check oil daily or after every 8 hours of use.
• Ensure generator is serviced according to the maintenance schedule under “Maintenance” section of manual.
• Shelter unit from elements.

Maintenance

Regular Maintenance
Regular maintenance will extend the life of this unit and improve its performance. The warranty does not cover items that result from operator negligence, misuse, or abuse. To receive full value from the warranty, operator must maintain the generator as instructed in this manual, including proper storage.
Pre-Operation Steps
Before starting the engine, perform the following pre-operation steps:

• Check the level of the engine oil and the fuel gauge level. Add oil or fuel as needed.
• Make sure the air filter is clean.
• Remove any debris that has collected on the generator and around the muffler and controls. Use a vacuum cleaner to pick up loose debris. If dirt is caked on, use a soft bristle brush.
• Inspect the work area for hazards.

After Each Use
Follow the following procedure after each use:

• Shut off engine.
• Store unit in a clean and dry area.

WARNING
Before inspecting or servicing this machine, make sure the engine is off and no parts are moving. Disconnect the spark plug wire and move it away from the spark plug.

Maintenance Schedule

Changing Engine Oil (Figure 13)

• Run the generator until the engine is warm.
• Place generator on a level surface.
• Remove the crankcase dipstick.
• Place an oil pan underneath the oil drainage bolt to collect used oil.
• Remove the oil drainage plug and allow oil to drain completely.
• Reinstall oil drainage plug, tighten securely.
• Carefully add SAE 10W-30 to empty crankcase until the oil reaches the outer edge of the oil fill hole (crankcase dipstick hole).
• Replace crankcase dipstick.

Note:

• Below 40º F (4º C) the use of SAE 30 will result in hard starting.
• Above 80º F (27º C) the use of 10W-30 may cause increased oil consumption. Check oil level more frequently.

WARNING

Used oil should be disposed of at an approved disposal site. See your local oil retailer for more information.

Oil Recommendations (Figure 14)

• Do not use special additives.
• Outdoor temperatures determine the proper oil viscosity for the engine. Use the chart to select the best viscosity for the outdoor temperature range expected.

Air Filter (Figure 15)
A dirty air filter will reduce the life span of the engine, make it difficult to start the engine, and reduce the unit’s performance.

• To clean, remove the air filter cover.
• Carefully pull the air filter out by lifting up along the edges.
• Remove dirt from filter by tapping on it or having it blown out. Replace with new filter annually.
• Reinstall air filter so that it seals and replace air filter cover.

Checking Spark Plugs (Figure 16)

• Disconnect the plug wire from the spark plug.
• Before removing the spark plug, clean the area around its base to prevent debris from entering the engine.
• Clean carbon deposits off the electrode with a wire brush.
• Check the electrode gap and slowly adjust to 0.762 mm – 0.80 mm (.030 – .031”) if necessary
• Reinstall spark plug and tighten to Torque 22.0 – 26.9 Nm (16-20 ft-lbs).
• Reconnect spark plug wire.
• If the spark plug is worn replace it only with an equivalent replacement part.
• Spark plug should be replaced annually.
  • Torch F6TC
  • NGK BP6ES
  • Champion N9YC
  • Or Equivalent

Spark Plug Gap

• 0.030-0.031 in.
• 0.762-0.80 mm

Spark Plug Torque

• 16-20 ft-lbs
• 22.0-26.9 Nm

Spark Arrestor (Figure 17)

• Inspect the spark arrestor for breaks or holes. Replace if necessary.
• Use a brush to remove carbon deposits from the spark arrestor screen as needed.
• To remove the spark arrestor: While the muffler is cool, loosen the locking clamp and slide the spark arrestor out of the muffler. Reverse this process to install it.

Carburetor Adjustment
The carburetor is low emission and is equipped with a non-adjustable idle mixture valve.
Replacing the Fuel Filter (Figure 18)

• Turn the fuel valve to the “OFF” position.
• Remove the fuel line from both sides of the filter by squeezing the retaining clip ends with pliers.
• Slide the fuel line off.
• Replace with new fuel filter.
• Reinstall fuel lines to new fuel filter.
• Turn the fuel valve to the “ON” position.

Prevent Old Fuel Issues
To help prevent gum deposits in the fuel system, drain the fuel from the tank and carburetor before storing the unit for long periods of time. This will help prevent starting problems in the future. If the unit is stored with fuel and the fuel becomes stale or turns gummy or to varnish the warranty does not cover this repair or service.

WARNING

Consult your local hazardous waste management in your area for the proper way to dispose of used fuel.

Draining the Fuel Tank

• Turn the engine OFF.
• Turn the fuel valve to the OFF position.
• Push the fuel valve knob through the valve holder bracket allowing you to access the petcock.
• Remove the fuel line that leads to the carburetor from the petcock by squeezing the ends of the hose clamps and sliding the fuel line off.
• If needed, install a fuel hose that will extend to a suitable fuel container large enough to catch the fuel being drained from the tank.
• Turn the fuel valve to the ON position.
• When the fuel has drained from the tank, close the fuel valve and reinstall fuel line securely on petcock.
• Reinstall the fuel valve knob in the valve bracket. Push forward until knob snaps securely into position.

Draining the Carburetor

• Turn the engine OFF.
• Turn the fuel valve to the OFF position.
• Position a suitable container under the carburetor drain screw to catch fuel; loosen the screw.
• Allow fuel to drain completely into container.
• Re-tighten drain screw.

Storage

• Remove any debris that has collected on the generator and around the muffler and controls. Use a vacuum cleaner to pick up loose debris. If dirt is caked on, use a soft bristle brush.
• Inspect air cooling slots. Remove any debris if obstructed.
• Disconnect negative battery cable from battery.
• For short-term storage, start generator once every 7 days.
• For long-term storage, add fuel stabilizer to prevent stale fuel from causing acid and gum deposits in the fuel system and carburetor.

Troubleshooting

breaker
output is not available.| 2.| Poor connection| 2.| Check and repair
 | 3.| Defective cord set| 3.| See above step (#2)
 | 4.| Connected device is faulty| 4.| Connect a device that is
 | 5.| Fault in generator|  | working properly
 |  |  | 5.| Contact tech sales
Engine runs well without| 1.| Short circuit in connected| 1.| Disconnect device
load, but bogs down when|  | device| 2.| See “Don’t overload generator”
loads are connected| 2.| Generator is overloaded|  | on pg. 12
 | 3.| Clogged fuel filter| 3.| Clean or replace fuel filter
 | 4.| Engine speed is too slow| 4.| Contact tech sales
 | 5.| Short circuit in generator| 5.| See above step (#4)
Engine will not start, shuts| 1.| On/Off switch set to “Off”| 1.| Turn switch to “Choke” then
down during operation,| 2.| Dirty ar filter|  | pull recoil starter.
or starts and runs rough.| 3.| Clogged fuel filter| 2.| Clean or replace air filter
 | 4.| Out of fuel or Stale fuel| 3.| Clean or replace fuel filter
 | 5.| Spark plug wire disconnected| 4.| Replace fuel
 |  | from spark plug| 5.| Reconnect spark plug wire
 | 6.| Bad spark plug| 6.| Clean or replace spark plug
 | 7.| Water in fuel| 7.| Drain fuel tank and replace fuel
 | 8.| Fuel valve in “Off” position| 8.| Turn fuel valve to “On” postion
 | 9.| Over-choking| 9.| Turn off choke
 | 10.| Low oil level| 10.| Check oil level
 | 11.| Engine has flooded| 11.| Wait 5 minutes and re-start
 | 12.| Loss of engine compression| 12.| Contact tech sales
Engine lacks power| 1.| Generator is overloaded| 1.| See “Don’t overload generator”
 | 2.| Clogged fuel filter|  | on pg. 12
 | 3.| Dirty air filter| 2.| Clean or replace fuel filter
 | 4.| Engine needs servicing| 3.| Replace air filter
 |  |  | 4.| Contact tech sales
Engine “hunts” or falters| 1.| Choke was removed too soon| 1.| Adjust choke
 | 2.| Clogged fuel filter| 2.| Clean or replace fuel filter
 | 3.| Carburetor is running too rich| 3.| Contact tech sales
 |  | or too lean|  |

Wiring Diagram

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