The Tool Shed 6KVA Portable Power Generator Instruction Manual

The Tool Shed 6KVA Portable Power Generator

Product Information: – Product Name: 6KVA Generator – Model:TSG9&TSG10 – Manufacturer: Champion Power Equipment – Warranty:
years for residential use, 90 days for commercial

Product Usage Instructions:
Ensure you have all the parts included in the package Follow the assembly instructions provided in the user manual to properly assemble the generator. 2. Safety Rules: – Before operating the generator, read and understand all the safety rules mentioned.

Repair/Replacement Warranty
warrants to the original purchaser that the mechanical and electrical components will be free of defects in material and workmanship for a period of two (1) years from the original date of purchase (90 days for commercial & industrial use). Transmutation charges on product submitted for repair or replacement under this warranty are the sole responsibility of the purchaser. This warranty only applies to the original purchaser and is not transferable.

Warranty Exclusions
This warranty does not cover the following repairs and equipment:

Normal Wear
Generators need periodic parts and service to perform well. This warranty does not cover repair when normal use has exhausted the life of a part or the equipment as a whole.

Installation, Use and Maintenance
This warranty will not apply to parts and/ or labor if this generator is deemed to have been misused, neglected, involved in an accident, abused, loaded beyond the generator’s limits, modified, installed improperly or connected incorrectly to any electrical component. Normal maintenance such as spark plugs, air filters, adjustments, fuel system cleaning and obstruction due to buildup is not covered by this warranty.

Other Exclusions
This warranty excludes:
Cosmetic defects such as paint, decals, etc.
Wear items such as filter elements, o-rings, etc. Accessory pa1ts such as starting batteries, and storage covers.
Failures due to acts of God and other force majeure events beyond the manufacturer’s control.

Problems cause by pa1ts that are not original Champion Power Equipment parts. This warranty does not apply to generators used for prime power in place of a utility.

Limits of Implied Warranty and Consequential Damage
Champion Power Equipment disclaims any obligation to cover any loss of time, use of this product, freight, or any incidental or consequential claim by anyone from using this  generator.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE

A unit provided as an exchange will be subject to the warranty of the original unit. The length of the warranty governing the exchanged unit will remain calculated by reference to the purchase date of the original unit.

This warranty gives you ce1tain legal rights which may change from state to state. Your state may also have other rights you may be entitled to that are not listed within this warranty.

Troubleshooting

Generator will not start

|

Low oil level

| | |
---|---|---|---|---
| Add fuel|
| Replace spark plu|
| Remove load from unit

Fill crankcase to the proper level

Place generator on a flat, level surface

|
Generator will not start; Generator starts but runs roughly|
,osition. __

Spark plug wire loose

| Adjust choke.

Fill crankcase to the proper level. Place generator on a flat, level surface

|
Generator shuts down during             Out of fuel __ operation Low oil level|
Generator cannot supply enough power or overheating| Generator is overloaded| Review load and adjust. See “Power Management”|
Insufficient ventilation| Check for air restriction. Move to a

well ventilated area

|
No AC output| Cable not properly connected| Check all connections|
Connected device is defective| Replace defective device|
Circuit breaker is open| Reset circuit breaker|
Capacitor defective| Replace capacitor (Service Center:|
Faulty brush assembly| Replace brush assembly (Service Center|
Faulty AVR (auto voltage regulator)| Replace AVR (auto voltage

regulator)(Service Center

|
Loose wiring| Inspect and tighten wiring connections|
Other| Contact the help line.|
Generator gallops                            Engine governor defective| Contact the help line|
Repeated circuit breaker tripping| Overload| Review load and adjust. See “Power Management”|
Faulty cords or device| Check for damaged, bare or frayed

wires. Replace defective device

|

Introduction

Congratulations on your purchase of our
designs and builds generators to strict specifications. With proper use and maintenance, this generator will bring years of satisfying service.
This Owner’s Manual contains important safety instructions and information. SA VE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

Portable Power Generator
This unit is an electric-start gasoline engine driven, alternating current (AC) generator. It is designed to supply electrical power for lighting, appliances, tools and similar equipment.

Record the model and serial numbers as well as date and place of purchase for future reference. Have this information available when ordering parts and when making technical or warranty inquiries.

Accessories
our’s manufactures and sells accessories designed to help you get the most from your purchase. To find out more about our covers, power cables and storm kits, please visit our web site

This Booklet
Every effort has been made to ensure the accuracy and completeness of the information in this manual. We reserve the right to change, alter and/or improve the product and this document at any time without prior notice.

Manual Conventions

This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol is used with a key word to alert you to potential hazards in operating and owning power equipment.
Follow all safety messages to avoid or reduce the risk of serious injury or death.

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, wi//result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Fuel

Fuel capacity is 6.6 gallons (251 ). Use
regular unleaded gasoline with a minimum octane rating of 85.

Oil
Oil capacity is 1. 16 qt ( 1. 1 L).

Storage

The generator should be started at least once every 14 days and allowed to run for at least 20 minutes. For longer term storage, please follow these guidelines.

Engine Storage

1. Allow the engine to cool completely before storage.
2. Clean the engine according to the instructions in the Maintenance section.
3. Drain all fuel completely from the fuel line and carburetor to prevent gum from forming.
4. Add a fuel stabilizer into the fuel tank.
5. Change the oil.
6. Remove the spark plug and pour about ½ ounce of oil into the cylinder. Crank the engine slowly to distribute the oil and lubricate the cylinder.
7. Reattach the spark plug.

Generator Storage

1. Allow the generator to cool completely before storage.
2. Turn off the fuel supply at the fuel valve.
3. Clean the generator according to the instructions in the Maintenance section.
4. Store the unit in a clean, dry area.
5. Store in a clean, dry place out of direct sunlight.

Safety Rules

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm.

Generator exhaust contains carbon monoxide, a colorless, odorless, poison gas. Breathing carbon monoxide will cause nausea, dizziness, fainting or death. If you start to feel dizzy or weak, get to fresh air immediately
Operate generator outdoors only in a well ventilated area.

• DO NOT operate the generator inside any building, including garages, basements, crawlspaces and sheds, enclosure or compartment, including the generator compartment of a recreational vehicle.
• DO NOT allow exhaust fumes to enter a confined area through windows, doors, vents or other openings.
• DANGER CARBON MONOXIDE, using a generator indoors CAN KILL YOU IN MINUTES.

DANGER

Rotating parts can entangle hands, feet, hair, clothing and/or accessories.

Traumatic amputation or severe laceration can result.

Keep hands and feet away from rotating parts.

Tie up long hair and remove jewelry. Operate equipment with guards in place.
DO NOT wear loose-fitting clothing, dangling drawstrings or items that could become caught.

• DO NOT touch bare wires or receptacles.
• DO NOT use electrical cords that are worn, damaged or frayed.
• DO NOT operate generator in wet weather. DO NOT allow children or unqualified persons to operate or service the generator
• Use a ground fault circuit interrupter (GFCI) in damp areas and areas containing conductive material such as metal decking.
• Use approved transfer equipment to isolate generator from your electric utility and Notify your utility company before connecting your generator to your power system.

When servicing the generator:
Disconnect the spark plug wire and place it where it cannot contact the plug.
DO NOT check for spark with the plug removed. Use only approved spark plug testers.

Running engines produce heat.
Severe burns can occur on contact. Combustible material can catch fire on contact.

DO NOT touch hot surfaces.
Avoid contact with hot exhaust gases.
Allow equipment to cool before touching. Maintain at least three feet of clearance on all sides to ensure adequate cooling.
Maintain at least five feet of clearance from combustible materials.

A Spark Arrestor May be Required. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements.

DANGER

• Fuel and fuel vapors are highly flammable and extremely explosive.

• Fire or explosion can cause severe burns or death.

• Unintentional startup can result in entanglement, traumatic amputation or laceration.

• When adding or removing fuel

• Turn the generator off and let it cool for at least two minutes before removing the fuel cap. Loosen the cap slowly to relieve pressure in the tank.

• Only fill or drain fuel outdoors in a well-ventilated area.
  DO NOT overfill the fuel tank.

• Always keep fuel away from sparks, open flames, pilot lights, heat and other sources of ignition. DO NOT light or smoke cigarettes.

• When starting the generator

• DO NOT attempt to start a damaged generator. Make certain that the gas cap, air filter, spark plug, fuel lines and exhaust system are properly in place.

• Allow spilled fuel to evaporate fully before attempting to start the engine.

• Make certain that the generator is resting firmly on level ground.

• When operating the generator:

• DO NOT move or tip the generator during operation.

• DO NOT tip the generator or allow fuel or oil to spill.

• When transporting or servicing the generator:

• Make certain that the fuel shutoff valve is in the off position and the fuel tank is empty. Disconnect the spark plug wire.

• When storing the generator:

• Store away from sparks, open flames, pilot lights, heat and other sources of ignition.

Rapid retraction of the starter cord will pull hand and arm towards the engine faster than you can let go.
Unintentional startup can result in entanglement, traumatic amputation or laceration.

Broken bones, fractures, bruises or sprains could result.

When starting engine, pull the starter cord slowly until resistance is felt and then pull rapidly to avoid kickback.
DO NOT start or stop the engine with electrical devices plugged in.

DO NOT overload the generator.

Start the generator and allow the engine to stabilize before connecting electrical loads. Connect electrical equipment in the off position, and then turn them on for operation.

Turn electrical equipment off and disconnect before stopping the generator.

DO NOT tamper with the governed speed.

DO NOT modify the generator in any way.

Improper treatment or use of the generator can damage it, shorten its life and void your warranty.
Use the generator only for intended uses. Operate only on level surfaces.
DO NOT expose generator to excessive moisture, dust, or dirt.

DO NOT allow any material to block the cooling slots.
If connected devices overheat, turn them off and disconnect them from the generator.

DO NOT use the generator if:

Electrical output is lost

Equipment sparks, smokes or emits flames Equipment vibrates excessively

Spark Arrester

1. Allow the engine to cool completely before servicing the spark arrester.
2. Remove the two screws holding the cover plate which retains the end of the spark arrester to the muffler.
3. Remove the spark arrester screen.
4. Carefully remove the carbon deposits from the spark arrester screen with a wire brush.
5. Replace the spark arrester if it is damaged.
6. Position the spark arrester in the muffler and attach with the two screws.

Cleaning

Use a damp cloth to clean exterior surfaces of the engine.
Use a soft bristle brush to remove dirt and oil.
Use an air compressor (25 PSI) to clear dirt and debris from the engine.

Adjustments
The air-fuel mixture is not adjustable. Tampering with the governor can damage your generator and your electrical devices and will void your warranty. CPE recommends that you contact Sun Shine Impex for all other service and/or adjustment needs.

Maintenance Schedule
Follow the service intervals indicated in the schedule below.

Service your generator more frequently when operating in adverse conditions. Contact our help line locate the nearest Champion Power Equipment certified service dealer for your generator or engine maintenance needs.

Every 100 hours or every season

• Change oil
• CleanL Adjust spark plu,
• Chec!5LAdjust valve clearance*
• Clean spark arrester
• Clean fuel tank and filter *

To be performed by knowledgeable, experienced owners or Champion Power Equipment certified service dealers

Generator Maintenance

Make certain that the generator is kept clean and stored properly. Only operate the unit on a flat, level surface in a clean, dry operating environment. DO NOT expose the unit to extreme conditions, excessive dust, dirt, moisture or corrosive vapors.

Water can enter the generator through the cooling slots and damage the generator windings.

Use a damp cloth to clean exterior sauces of the generator.
Use a soft bristle brush to remove dirt and oil.

Use an air compressor (25 PSI) to clear diit and debris from the generator.
Inspect all air vents and cooling slots to ensure that they are clean and unobstructed.

Maintenance

The owner/operator is responsible for all periodic maintenance.

NOTICE

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any non-road engine repair establishment or individual.

Complete all scheduled maintenance in a timely manner. Correct any issue before operating the generator.

Engine Maintenance
To prevent accidental starting, remove and ground spark plug wire before performing any service.

Oil
Change oil when the engine is warm. Refer to the oil specification to select the proper grade of oil for your operating environment.

1. Remove the oil drain plug with a 15 mm socket and extension.
2. Allow the oil to drain completely.
3. Replace the drain plug.
4. Remove oil fill cap/dipstick to add oil.
5. Add 1.16 qt (1.1 L) of oil and replace oil fill cap/dipstick.
6. Dispose of used oil at an approved waste

Spark Plugs

1. Remove the spark plug cable from the spark plug.
2. Remove the spark plug.
3. Inspect the electrode on the plug. It must be clean and not worn to produce the spark required for ignition.
4. Make certain the spark plug gap is 0.7 – 0.8mm (0.028 – 0.031 in.).
5. Refer to the spark plug recommendation chart when replacing the plug.
6. Carefully thread the plug into the engine.
7. Use the spark plug tool to firmly install the plug.
8. Attach the spark plug wire to the plug.

Air Filter

1. Remove the snap on cover holding the air filter to the assembly.
2. Remove the foam element.
3. Wash in liquid detergent and water. Squeeze thoroughly dry in a clean cloth.
4. Saturate in clean engine oil.
5. Squeeze in a clean, absorbent cloth to remove all excess oil.
6. Place the filter in the assembly.
7. Reattach the air filter cover and snap in place.

Controls and Features

Read this owner’s manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference.

Parts Included
Your Model Gasoline Powered Generator ships with the following parts:

Wheel Kit

• 10 in. (25.4 cm) Wheel
• Bushing
• Flange Bolt (Ml0x120 for Wheel)
• Flat Washer ¢10
• Lock Nut (MIO)
• Support Leg w/vibration mounts
• Flange Bolt (M8x16 for Support Leg)
• Flange Lock Nut (M8)

Other

• Oil Funnel
• Spark Plug Socket
• Cap Screw (M5xl0 for Battery Terminals)
• Flange Nut (M5)
• Plug
• Oil
• Automotive style battery charge cables.

Assembly
Your generator requires some assembly. This unit ships from our factory without oil. It must be properly serviced with fuel and oil before operation.

Remove the Generator from the Shipping Carton

1. Set the shipping carton on a solid, flat surface.
2. Remove everything from the carton except the generator.
3. Carefully cut each corner of the box from top to bottom. Fold each side flat on the ground to provide a surface area to install the wheel kit and support leg.

Install the Wheel Kit

You will need the following tools to install the wheel kit:

17 mm wrench OR adjustable wrench (not included) Socket wrench with a 16 mm socket Pliers (not included)

1. Before adding fuel and oil, tip the generator on it’s side.

2. Slide the M1ox120 wheel bolt through the washer, sleeve and wheel.

3. Slide the bolt through the mount point on the frame.

4. Fasten securely with the 10mm nut.

5. Repeat steps 2-4 to attach the second wheel.

6. Attach the rubber vibration mount to the support leg with a cap screw (MSx25) and lock nut (MS).

7. Attach the support leg to the generator frame with cap screws (MSx16) and lock nuts (MS).

8. Tip the generator slowly so that it rests on the wheels and support leg.

Connect the Battery

1. Remove the protective cover from the red battery lead.
2.  Attach the red lead to the red terminal on the battery with the cap screw (M5x12) and secure with the lock washer (M5)
3. Repeat step 2 for the black battery lead.

Wattage Reference Chart
Use the chart to determine approximate wattage requirements for your equipment.

©NOTE
Starting watts can exceed three times the running watts. The values in the following table are approximate. Refer to your tool or appliance for actual wattage consumption.

Item Running   Starting

Watts        Watts

Essentials

Liaht Bulb 100W                              100

__Refriaerator/Freezer                        1200         2400

Freezer                                          500           500

Sumo Pump                                    600         1800

__Well Pumo 1 HP       2000         4000

Water Heater                                4000

Securitv Svstem                              180

AM/FM Radio                                  300

Garaae Door Opener 1/2 HP              500           600

Battery Charger 12V DC                    110

__Heatina/Coolina

Air Conditioner 12000 BTU               1700         2500

__Fan                        300           600

Furnace Fan 1/3 HP                        1200         2000

Home Appliances

|
---|---
Microwave 1000W| 1000|
Electric Range – One Element| 1500|
Electric Skillet| 1250|
Coffee Maker| 1500|
Clothes Washer| 1200|
__     Entertainment

CD/DVD Player VCR

__Stereo Receiver Television 27″

PC with 15″ Monitor   __

Job Site

Belt Sander 3″

Bench Grinder 6″ Circular Saw Comoressor 1 1/2 HP

__Edae Trimmer Hand Drill 1/2″

Lawn Mower Paint Sorayer

__Table Saw

|

100

100

450

500

800

1000         1500

700         1500

1500         1500

2500         2500

500           500

1000         1000

1200         1800

600         1200

2000         2000

|

Operation

©NOTE
Connecting a generator to your electric utility company’s power lines or to another power source may be against the law. In addition this action, if done incorrectly, could damage your generator and appliances and could cause serious injury or even death to you or a utility worker who may be working on nearby power lines. If you plan to run a portable electric generator during an outage, please notify your electric utility company immediately and remember to plug your appliances directly into the generator. Do not plug the generator into any electric outlet in your home. Doing so could create a connection to the utility company power lines. You are responsible for ensuring that your generator’s electricity does not feed back into the electric utility power lines.

If the generator will be connected to a building electrical system, consult your local utility company or a qualified electrician. Connections must isolate generator power from utility power and must comply with all applicable laws and codes.

Stopping the Engine

1. Turn off and unplug all electrical loads. Never start or stop the generator with electrical devices plugged in or turned on.
2. Let the generator run at no-load for several minutes to stabilize internal temperatures of the engine and generator.
3. Turn the ignition switch to the “Off’ position.
4. Turn the fuel valve to the “Off’ position.

Do Not Overload Generator Capacity

1. Follow these simple steps to calculate the 1. Select the electrical devices you plan on running at the same time.
2. Total the running watts of these items. This is the amount of power you need to keep your items running.
3. Identify the highest starting wattage of all devices identified in step 1. Add this number to the number calculated in step 2. Surge wattage is the extra burst of power needed to start some electric driven equipment. Following the steps listed under “Power Management” will guarantee that only one device will be starting at a time.

Power Management
Use the following formula to conve1t voltage and amperage to watts:
Volts x Amps = Watts

To prolong the life of your generator and attached devices, follow these steps to add electrical load:

1. Sta1t the generator with no electrical load attached.
2. Allow the engine to run for several minutes to stabilize.
3. Plug in and turn on the first item. It is best to attach the item with the largest load first.
4. Allow the engine to stabilize.
5. Plug in and turn on the next item.
6. Allow the engine to stabilize.
7. Repeat steps 5-6 for each additional item.

©NOTE
Never exceed the generator capacity when adding loads.

Install the Spark Arrester

Inse1t the spark arrester screen into the muffler outlet. Secure the spark arrester by placing the cover plate over the end of the screen, with the lettering facing outward. Secure the cover plate with the two screws and lock washers provided with the spark arrester kit.

CAUTION
Failure to install the spark arrester may result in an increased risk of fire..

Add Engine Oil

CAUTION
DO NOT attempt to crank or start the engine before it has been properly filled with the recommended type and amount of oil. Damage to the generator as a result of failure to follow these instructions will void your warranty.

1. Place the generator on a flat, level surface.

2. Remove oil fill cap/dipstick to add oil.

3. Add 1.16 qt (1.1 L) of oil and replace oil fill cap/dipstick. See “Specifications” for oil recommendations based on operating conditions.

4. Check engine oil level daily and add as needed.

©NOTE
Check oil often during the break-in period. Refer to the Maintenance section for recommended service intervals.

©NOTE
The generator rotor has a sealed, pre-lubricated ball bearing that requires no additional lubrication for the life of the bearing.

Add Fuel

1. Use clean, fresh, regular unleaded fuel with a minimum octane rating of 85.

2. DO NOT mix oil with fuel.

3. Clean the area around the fuel cap.

4. Remove the fuel cap

5. Slowly add fuel to the tank. DO NOT overfill. Allow approximately ¼ inch of space for fuel expansion.

6. Screw on the fuel cap and wipe away any spilled fuel.

• Do not mix oil and gasoline.
• Fill tank to approximately ¼” below the top of the tank to allow for fuel expansion.
• DO NOT fill fuel tank indoors.
• DO NOT fill fuel tank when the engine is running or hot.
• DO NOT overfill the fuel tank.
• DO NOT light cigarettes or smoke when filling the fuel tank.

Grounding
Your generator must be properly connected to an appropriate ground to help prevent electric shock.

A ground terminal connected to the frame of the generator has been provided on the power panel. For remote grounding, connect of a length of heavy gauge (12 A WG minimum) copper wire between the generator ground terminal and a copper rod driven into the ground. We strongly recommend that you consult with a qualified electrician to ensure compliance with local electrical codes.

Generator Location
Please consult your local authority. In some areas, generators must be registered with the local utility.
Generators used at construction sites may be subject to additional rules and regulations. This generator must have at least five feet of clearance from combustible material. Leave at least three feet of clearance on all sides of the generator to allow for adequate cooling, maintenance and servicing.
Place the generator in a well-ventilated area.
DO NOT place the generator near vents or intakes where exhaust fumes could be drawn into occupied or confined spaces. Carefully consider wind and air currents when positioning generator.

Surge Protection

Electronic devices, including computers and many programmable appliances use components that are designed to operate within a narrow voltage range and may be affected by momentary voltage fluctuations. While there is no way to prevent voltage fluctuations, you can take steps to protect sensitive electronic equipment.

1. Install UL1449, CSA-listed, plug-in surge suppressors on the outlets feeding your sensitive equipment.
2. Surge suppressors come in single- or multi-outlet styles. They’re designed to protect against virtually all shott­duration voltage fluctuations.
3.  Obtain an Uninterruptible Power Supply (UPS) device.
4. Most UPS devices come with a rechargeable battery between the electronic equipment and power supply source. The device buffers the voltage and protects against virtually all short­duration voltage fluctuations.

Starting the Engine

1. Make ce1tain the generator is on a flat, level surface.
2. Disconnect all electrical loads from the generator. Never start or stop the generator with electrical devices plugged in or turned on.
3. Turn the fuel valve to the “On” position.
4. Move the choke lever to the “Choke” position.
5. ELECTRIC START: Press the switch to the “START” position. Release as the engine begins to roll over.
6. RECOIL START: Pull the starter cord slowly until resistance is felt and then pull rapidly.
7. As engine warms up, move the choke lever to “Run”.

©NOTE
If the engine starts but does not run, make certain that the generator is on a flat, level surface. The engine is equipped with a low oil sensor that will prevent the engine from running when the oil level falls below a critical threshold.

Connecting Electrical Loads

1. Let the engine stabilize and warm up for a few minutes after starting
2. Plug in and turn on the desired 220 Volt AC single phase, 50 Hz electrical loads.

• DO NOT connect 3-phase loads to the generator.
• DO NOT connect 60 Hz loads to the generator.
• DO NOT overload the generator.

References

• The ToolShed - NZ | Power Tools | Hand Tools | Air Tools

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