User Manual
Contents
1. 10 WIRING DIAGRAM CIRCUIT BREAKER ie AC OUT Br VOLT METER W m T GROUND TERMINAL f DIODE DC PROTECTER Gr NE DE E WINDING 6 5 B Gr CX Gr 45 3 n E 9 z B gt EXCITER WINDING AVR MAIN WINDING 1 FIELD WINDING CILLEVEL SWITCH IGNITION COIL 11 SPECIFICATIONS Rate irequencyiiz o 12 10 B 12 vc ratedeurrenttay w Air cooled single cylinder 4 stroke Type engine Note specifications subject to change without prior notice Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 11 12 PARTS LIST AND DIAGRAM 12 1 CRANKCASE ASSEMBLY QTY 1 X sor 67 QJ168QDJ 01 04 GUAGE engine oil 16800 01 03 COVER supply oil mouth 6 157 3 8 GUIDE dowel QJ168QDJ 01 02 SPACER crankcase GB T5787 BOLT QU168FJH 3 01 02 Sai ASSY fuel Cm BEARING 2 QJ166QDK 01 07 _ 1 66 DRANPLUS 27 12 2 CYLINDER HEAD ASSY QJ168QDL 02 01 BOLT cylinder head CANAL intake valve QJ168QDJ 0201 03 MATTRESS h 4 02 02 MATTRESS heat 1 insulating 3 N N M Q 92 lt 5 N COO 4 gt gt c QJ168QDJ 02 07 BOLT exhaust2. Call 866 797 27738 NT 12 9 CARBURETOR ASSY CARBURETOR ASSY wswoxo 4 JON PLANK 1 NO 12 10 GENERATOR QJ2300 03 04 10122000301 sitor Asy 9532000302 Rosy 4 QJ2500 03 02 01 01 Impeller Fixing Base 1 1 ge No aad Warranty and Service Questions Missing or Damaged parts Call 866 797 27738 16 12 11 GAS TANK ASSEMBLY PART NO DESCRIPTION 1 5000 01 01 Fuel Tank QJ6000 01 04 Fuel Tank QJ950 01 02 Filtering Net QJ6000 01 03 Sender Unit GB T819 1 2000 Screw M5 10 GB T5789 86 Bolt M6 20 7 GB T96 2 2002 Washer D6 QJ2600 01 02 Fuel Tank Rubber Hose QJ2600 01 01 Fuel Tank Rubber 10 QJ2600 01 02 Fuel Valve 12 12 PANEL KE3500D 02 01B as2600 02 058 Voi meter 7 9 GB T5789 86 Flange Face M6 8 Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 Sud 12 13 MUFFLER PART NO DESCRIPTION QTY 1 0 3200 02 014 Muffler 2 42900 04 01 Muffler Cover 12 14 FRAME 1 5000 06 01 3 GB T5789 86 Flange Face Bolt M610 Left and Right Shockproof 5 GB T6177 1 2000 Flange Face NutM8 8 Hight Shockproof QJ2500 04 02 2 M
3. PRODUCT REGISTRATION CARD For more efficient customer service please fill out the information below and mail to International Merchandis ing Service Inc Model No Engine Serial No Purchase Date Purchased from Retail location Private Consumer Other Name Location Address Telephone w area code Purchase Price Purchased NEW or JUSED Consumer Information Name Telephone w area code Street Address SuiteorApt City State Zip Code Province or Country Are you a Business lResidence Product usage Information How often will you use this product Everyday Periodically JEmergency use only JOther What type of application will you use this product in Commercial Moderate Commercial Commercial 1 Tradeshows Residential Moderate Residential ILight Residential Camping backpacking JOther Mail this page to International Mer Service Inc 1928 West Malvern Avenue Fullerton CA92833 Warranty and Service Questions Missing or Damaged parts Call 866 797 27738 OT x
4. BE RECEIVED AT IMS UST WITHOUT A VALID CASE NUMBER INCLUDED ON THE SHIPPING LABEL No exceptions to this warranty procedure are allowed Failure to follow the steps outlined phone consult return authorization pre paid freight return will result in no parts replaced under the warranty What is not covered by this Warranty Normal Wear and Tear e Problems caused by using dirty or otherwise contaminated fuel Problems caused by not properly maintaining the correct crankcase oil type fluid level This unit is equipped with low oil shutoff sensor Maintaining proper oil volume in the crankcase is critical to the safe and effective use of the motor e 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 E This unit is powered by an air cooled engine Operating this unit in environments where the air temperature and relative humidity are extreme will cause parts to malfunction This warranty does not cover those situations a This warranty will not apply to parts 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 air filters adjustments fuel system cleaning spark plugs and obstruction due to contaminant buildup are no
5. cee nee tee tee cen cee ee 92 cee nee 12 3 INTAKE amp EXHAUST MECHANISM ASSY 55555555 lt lt 12 4 CRANKCASE ASSEMBLY AM 12 5 CENTRIFUGAL ADJUSTMENT ASSY 12 6 IGNITION SYSTEM cee cee cee eee cee see see nes ADF STARTING SET 12 8 AIR CLEANER 5 cee cee cee nee IIR 12 9 CARBURETOR 55 m ce ce cee cee cen see cee cae cee ces 12 10 GENERATOR 0 den wanes 948 cea ines 12 11 GAS TANK III cee tee eee aes 13 PARTS REPLACEMENT LIMITED WARRANTY 14 PRODUCT REGISTRATION CARD s Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 1 SAFETY 1 1 SAFETY LABELS RISK OF ELECTRICAL SH OCK Using a generator Indoors CAN KILL YOU IN MINUTES Utilizar un generador dentro LE MATARA EN MINUTOS This generator produces high voltage Generator exhaust contalns carbon monoxide This Is escape contiene mon xido de carbono un gas ALWAYS ground properly before use poison you cannot see or smell DO NOT connect to any building electrical system NEVER use in wet or rainy conditions NEVER touch bare wires or receptacles NEVER allow children or non qualifi ed persons to operate t xico usted lo puede ver nl oler NEVER u use Inside a home Only use OUT
6. equipment will draw a higher current when starting The following table is provided for your reference when connecting such apparatus to your generator WATTAGE EXAMPLE TYPE STARTING RATED TYPICALAPPARATUS o MA STARTING RATED Incandescentiamp Incandescent lamp 5 is Co m A mJ UP J a 100VA 9g x1 x1 we W FE 80VA 60VA W W Refrigerator X 450 750 300VA W W 150W Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 Motor driven equipment Fluorescent lamp Electric fan 3 When two or more pieces of apparatus are connected to your generator turn them on beginning with the one drawing higher current when starting SIBIRA 24 AC APPLICATION 1 Start the engine 2 Make sure that the needle of the voltmeter indicates the voltage 3 Plug in the appliance 222 Bap Note a Over current will autornatically turn off the AC breaker When that is Fi turned off the generator shall be restarted with load reduced a few minutes thereafter b Generally 5 10 variance of voltage output is an acceptable tolerance of voltage variation Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 26 DC APPLICATION The DC terminals may be used for charging 12V automotive type batteries only 1 Connect the charging cables to the batt
7. pipe QJ168QDJ 02 01 SPACER exhaust pipe 21 QU168QDL 02 01 CYLINDER HEAD N Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 udi 12 3 INTAKE 4 EXHAUST MECHANISMASSY DESCRIPTION ADJUSTING NUT valve clearance QJ182QDP 03 07 BUTTONHEAD arm 3 QJ168QDJ 03 09 ARM CAP exhaust door QJ168QDJ 03 02 1 rod UPPER RETAINER QJ168QDJ 03 10 1 exhaust door spring QJ168QDJ 03 07 SPRING valve QJ168QDJ 03 05 Valve exhaust 1 1 PARTS NO QJ166QDK 03 11 B B n GUIDE PLATE QJ168QDJ 03 03 onnecting stud QJ168QDJ 03 02 ROD connecting UPPER RETAINER QJ168QDJ 03 08 1 intake door spring ADJUSTING STUD valve clearance NO QJ168QDL 03 01 STUD connecting QJ168QDL 03 01 CAMSHAFT QJ1P64 02 01 OILSEAL Valve 1 A 5 C2 12 4 CRANKCASE ASSEMBLY PARTS NO DESCRIPTION QJ168QDJ 04 06 NUT clamp QJ168QDJ 04 10 RATCHET WHEEL NO KEY 1 aui68a0s 00 09 DRVENGEAR 1 a ok y a A OIL RING ASSY BOLT comectng rod COVER comecin rod N QJ168QDJ 04 02 1 ASSY Warranty and Service Questions 2 Missing or Damaged parts Call 866 797 2738 13 O 1 4 12 5 CENTRIFUGALADJUSTMENT A
8. ANER 1 Unsnap the air cleaner cover springs and remove the air cleaner cover 2 Check the air cleaner element to be sure it is clean and in good condition 3 If it is dirty remove and clean 1 Wash in solvent 2 Squeeze 3 Soak oil 4 Squeeze dry the element 4 Reinstall the air cleaner element and secure the cover by setting the cover spring 4 STARTING THE ENGINE 1 Disconnect any load from the 2 Turn the fuel valve to AC receptacle the ON position 4 the engine switch to 3 Move choke lever to the left CLOSED position the ON position Check the air cleaner element to be sure it is clean Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 Ae 5 the starter grip lightly until resistance 15 felt then pull briskly Warning Do not allow the starter grip to snap 6 Move choke lever to the right OPEN position back against the engine Return it gently 5 GENERATOR USE To keep the generator always in top mechanical and electrical condition observe the following A WARNING 1 To prevent electrical shock from faulty appliances the generator N as the engine warms up should be grounded Connect a copper wire to the generator and the other end of wire to a metal stake driven into the ground 2 Combined load of the connected apparatus must not exceed the rated capacity of the generator Electric apparatus particularly motor driven
9. Owner s Manual GG4200 Series 6 asoline Generators Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell home Only use QUTSIDE and or garage EVEN IF doors far away from windows and windows are open doors and vents Utilizar un generador dentro LE MATARA EN MINUTOS El escape contiene mon xido de carbono un gas t xico usted no lo puede ver ni oler NUNCA utilice en el hogar ni SOLAMENTE fuera y en reas en parte encerradas lejos de ventanas abiertas tales como garajes puertas y respiraderos Do Not Return To Store One year or 60 Hours Limited Warranty see page 19 For customer service or warranty information call toll free 866 797 2738 Read carefully before attempting to assemble install operate or maintain the product described Protect yourself and others by observing all safety information Failure to comply with the user s manual could result in personal injury and or property damage retain the user s manual for future reference call toll free number 866 797 2738 for parts and service DISCLAIMER All pictures may not be identical to product inside box Distributed by UST Fullerton CA 92833 SAFETY ALERT SYMBOL Indicates danger warming or caution Attention is required in order to avoicserious personal injury The signal word DANGER WARNING or CAUTION is used with the alert sym
10. SIDE and NUNCA utilice en el hogar ni SOLAMENTE fuera far away from windows en reas en parte encerradas lejos de ventanas abiertas RISK OF EXPLOSION and windows are open doors and vents tales como garajes puertas y respiraderos be aie ed e fueling Avoid other generator hazards Evite otros riesgos del generador DO NOT operate near open flame READ MANUAL BEFORE USE LEA EL MANUAL ANTES DE USARLO RISK OF ELECTRICAL SHOCK RISK OF EXPLOSION This generator produces high voltage STOP generator before fueling ALWAYS ground properly before use CHECK for spilled fuel DO NOT A nect to dm building electrical system PONOT eperstenee open tamg NEVER use in wet or rainy conditions NEVER touch bare wires or receptacles NEVER allow children or non qualified persons to operate Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside a home or garage EVEN IF doors and windows are open Only use OUTSIDE and far away from windows doors and vents Avoid other generator hazards READ MANUAL BEFORE USE BEFORE YOU START GENERATOR rep PUE 1 Please verify the engine oil is full YOU START GENERATOR 1 Please verify the engine oil is full 2 Please add new fuel to gas tank 2 Please add new fuel to gas tank 3 Please turn the fuel valve and engine switch to the ON position 3 Please turn th
11. SSY NO DESCRIPTION 72 Tawe 5 BOLT square 1 10599 sPcER2 1 Fork 1 QJ166QDK 06 03 SPACER 1 6800 05 0 QJ166QDK 01 02 CIRCLIP centrifugal 2 15 0216800 05 08 SPACERS 1 16 16800 05 02 COVER push rod 1 QJ168QDJ 2 02 01 19 QJ168QDJ 20201 HANDLE ASSY GB T5789 BOLT M6X25 12 6 IGNITION SYSTEMASSY PARTS NO DESCRIPTION QTY QJ168FJH 3 0801 SWITCH ASSY Ignition GB T5787 BOLT M6x8 1 3 11 08 WINDING ignition GB T5789 BOLT M6x25 5 CONNECTING 5 CONNECT 6 QJ168FJH 3 08 01 J1 7 ELECTIONIC EN QJ182QDP 01 05 SWITCH Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 14 12 7 STARTING SETASSY L2 omoes 1 5 amsooneo 1 QJ168QDJ 06 01 8 GB T5789 1986 BOLT M6X8 9 QJ168QDJ 06 01 COVER starting QJ168QDJ 06 02 02 I 12 8 AIR CLEANER ASSY am 6 61689640703 SEAL air cleaner e cere NUT wet 9 cemsres BOT 5 GB T823 BOLT M6X12 QJ168FJH 3 05 01 air cleaner ASSY Warranty and Service Questions Missing or Damaged parts
12. TYPE F7RTC 2 5 Reinstall the spark plug and plug cap 4 Measure the gap 3 Clean the deposit 4 FUEL STRAINER 1 Turn the fuel valve 2 Clean the sediment to the OFF position cup and fuel filter rn and remove the screen e sediment cup and 4 filter screen 3 Install the fuel filter screen and sediment S STORAGE 1 Close the fuel valve drain 2 Drain the fuel from the carburetor 3 Remove the oil filler cap the fuel from the fuel tank and drain plug to drain the oil 4 Tighten the oil drain plug 5 the starter grip carefully 6 Store the generator and fill the engine with until resistance is felt in a clean area new oil to the filler neck Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 2 9 SHOOTING ENGINE DOES NOT START 1 Turn on the engine switch 2 Checkfuellever and 3 Check oil fuel ON OFF valve Engine will not start unless oil level is correct 5 Check spark Hold spark plug against metal pull the recoil starter to see spark 4 Remove spark plug Plug in known Check AC circuit breaker working light bulb In case long term storage generator has no output when started please turn off the circuit breaker and prod the ARM to increase the throttle until the volt meter indicates voltage Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 10
13. bol to alert you to special instruction about a particular operation that may be hazardous if pe rformed incorrectly or carelessly Observe them carefully DANGER Failure to obey a safety warning will result in serious personal injuries or deaths WARNING Failure to obey a safety warning can result in serious personal injuries or deaths CAUTION Failure to obey a safety warning may result in minor or moderate injuries CAUTION When used without the alert symbol could result in damage to your engine or other property If you do not understand any portion of this manual about engine please search for your dealer for explanations Warranty and Service Questions Missing or Damaged parts Call 866 797 27738 CONTENTS 1 SAFETY sc ccc HII 2 COMPONENT 3 PRE OPERATION 4 STARTING THE ENGINE cee 5 GENERATOR USE een 6 STOPPING THE 7 RR e 8 STORAGE 9 TROUBLE SHOOTING KK ees 44 SDECTEICAT ION eee eee st 12 PARTS LIST AND DIAGRAM t t 12 1 CRANKCASE n IRI cee cee cee cee cee cee cee nee 12 2 CYLINDER HEAD n e cee
14. e fuel valve and engine switch to p Nee cioe ee SERGE poson th ON iti 5 Disconnect all electrical maiis SUE is too low 4 Place the choke lever to the CHOKE position 5 Disconnect all electrical devices Generator will not start if the OIL LEVEL is too low 1 Remove the oil filler cap dipstick and wipe off any oil 2 Insert the oil filler cap dipstick into oil fitler neck but do not screw it in Let the fillercap dipstick sit above the filler hole then remove it to check the oil level ADD OIL 1 Remove the oil filler cap dipstick and wipe off any oil 2 Insert the oil filler cap dipstick into oil filler neck but do not screw it in Let the fillercap dipstick sit above the filler hole then remove it to check the oil level 3 Add oil if the oil level is low then reinstall the oil filler cap securely before starting BEFORE OPERATING GENERATOR The generator is shipped without M RTANT oil in the crankcase Add oil as indicated in operating and instruction manual Failure to do so Connect ground to earth will void your warranty before operating Replace shipping plug with working oil fill plug Failure to do so may resultin injury DO NOT RETURN TO STORE DO NOT RETURN TO STORE If you are hav ng problems with this generator call our customer service help line 1 866 797 2738 M F 7 30am 4 00pm PST BEFORE OPERATING GENERATOR The generator is shipp
15. ed without oilin the crankcase Add as instruction manual Failure to do so indicated in operating and HOT EXHAUST M CAUSE will void your warranty CONTA CT AY Replace shipping plug with working DO NOT TOUCH oil fill plug to do so may result in injury If you are having problems with this generator call our customer service help line HOT IS 1 866 797 2738 CONTACT MAY N M F 7 30am 4 00pm PST DO NOT W arranty and ServiceQ uestions 2 M issingorD am aged parts Call866 797 2738 542 1 2 GENERATOR SAFETY DO NOT USE INSIDE HOUSE DO NOT USE IN WET DO NOT CONNECT TO SURROUNDING HOUSEHOLD CIRCUIT KEEP FLAMMABLE MATERIAL NO SMOKING DO NOT SPILL STOP ENGINE AT LEAST 1m 3FT AWAY BEFORE REFUELING 2 COMPONENT IDENTIFICATION 1 FUELTANKCAP 2 FUEL TANK 3 FRAME 4 HOUR METER 5 CIRCUITBREAKER 6 VOLT METER T DOUBLESOCKET 8 15 9 DC TERMINALS 10 GROUND TERMINAL 14 11 SWITCH 12 OIL FILLER 1 13 OILDRAINPLUG 14 RECOIL STARTER 15 FUEL VALVE 16 AIR CLEANER 17 CHOKE LEVER 18 NOU m Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 uu 3 PRE OPERATION CHECK 1 01 LEVEL CAUTION Be sure to check the generator engine fluid levels with the generator on a level surface Recommended oil 4 stroke motor oil service classification SJ SL SG or SAE 10W 30 for general t
16. emperature 1 Remove the oil filler cap dipstick and wipe off any oil 2 Insert the oil filler cap dipstick into oil filler neck but do not screw it in Let the filler cap dipstick sit above the oil level 3 Add oil if the oil level is low 2 FUELLEVEL 1 Remove the fuel tank cap 2 Check the fuel level if 3 Add the unleaded gasoline 4 Install the fuel tank cap the fuel level is low to the shoulder of the filter screen CAUTION To avoid damage to engine never use stale or contaminated gasoline or oil gasoline mixture Avoid getting dirt or water in fuel tank NWARNING Fuel and fuel vapors are extremely flammable and explosive under certain conditions Refuel generator only outdoors in a well ventilated area NEVER fill fuel tank while engine is running Turn gen erator OFF and allow to cool before filling with fuel NEVER smoke or allow flames or sparks near genera tor or where gasoline is stored NEVER overfill fuel tank no fuel should be in filler neck After refueling be sure fuel tank cap is closed properly and securely Be careful not to spill fuel when refueling Spilled fuel or fuel vapor may ignite If any fuel is spilled be sure area is dry before starting engine Avoid repeated or prolonged contact with skin or breathing of vapor Maximum Fuel Level Warranty and Service Questions Missing or Damaged parts Call 866 797 27738 E fy 3 AIR CLE
17. ery terminal 2 Start the engine and charge the battery NOTE An overloaded DC circuit will trip the DC circuit breaker push button comes out If this happens check the short circuit or connection and wait a few minutes before pushing the circuit protector 3 Stop the engine then disconnect the charging cables in the reverse order of connection 1 ON 2 OFF 6 STOPPING THE ENGINE 1 Turn off all electrical appliances 3 Disconnect the electrical appliance gt NOTE To stop the engine in emergency turn the engine switch OFF Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 A a 7 MAINTENANCE Spark plug 2 _ These items shoule be serviced by a dealer dne 3 years 1 0IL CHANGE 1 Remove the oil filler cap 2 Remove the drain plug and drain the oil 3 Dispose of oil property 4 Install the drain plug and tighten it securely 9 Refill with the motor oil see 2 page and check the oil level ENGINE OIL CAPACITY 20 oz 0 6 Liter LOW LEVEL 6 Install the oil filler cap icu Recommended oil 4 stroke motor oil service classification SJ SL SG or SAE10W 30 for general temperature 7 Engine will not start level is not correct Warranty and Service Questions 2 Missing or Damaged parts Call 866 797 2738 2 AIR CLEANER See 3 3 SPARK PLUG SPARK PLUG
18. ounting Feet NO Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 248 13 Parts Replacement Limited Warranty IMS UST warrants to the original purchaser that the mechanical and electrical components will be free of defects in material and workmanship for a period of one 1 year or 60 hours from the original date of purchase whichever is first For commercial and industrial use the warranty is applicable for 90 days or 60 hours whichever comes first All costs associated with the transportation diagnosis and replacement of parts determined to be not operable during this warranty period are the sole responsibility of the purchaser This warranty only applies to the original purchaser and is not transferable No claims for warranties will be processed without valid proof of purchase For Help with Your Warranty Do not return the unit to the ace of Contact IMS UST s Technical Service and IMS UST will troubleshoot your purch ase problems with this product via phone or e mail If the problem is not corrected as a result of the phone or email contact IMS UST at its option will evaluate the issue and will authorize a repair or replacement of the defective part of the unit IMS UST will provide you with a case number for warranty service IT IS THE RESPONSIBILITY OF THE PURCHASER TO ARRANGE AND PREPAY ALL TRANSPORTATION CHARGES NO UNITS SENT TO IMS UST WILL
19. t covered by this warranty Limits of Implied Warranty and Consequential Damage issues specifically not covered under the warranty e Cosmetic defects Failures due to acts of God and other forces of natural events beyond the manufacturer s control Problems caused by parts that are not original OEM parts This warranty will not cover any damages that occur from the user s failure to follow the instructions and warnings provided in the manual IMS UST 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 e Parts provided as a replacement will be subject to the warranty of the original unit The length of the warranty will never exceed the total time period of the warranty from the original purchase date THERE IS NO OTHER EXPRESS WARRANTY ALL IMPLIED WARRANTIES ARE EXCLUDED UNLESS PROVIDED BY AN INDEPENDENT RETAILER IN WHICH CASE ANY IMPLIED WARRANTIES ARE THE RESPONSIBILITY OF THE RETAILERS WHO EXTENDED THEM LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW This warranty gives you certain 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 Warranty and Service Questions Missing or Damaged parts Call 866 797 2738 19 lt 1 T TM b
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