Pramac Portable Generator E SERIES GENERATOR User's Manual
Contents
1. E3100 AND E3600 GENERATOR PARTS AND PART 115 5 Winne Schemat C eemi an a aad eo Hd anes dae das de we Me eg na hu we arkene 11 SECTION 3 E4500 AND E5000 GENERATOR PARTS AND PART LISTS 12 A C Wiring SCHEMAIC 14 All information provided in this manual is believed to be correct at the time of printing The manufacturer reserves the right to correct any errors and omissions 22256432 SECTION 1 GENERAL INFORMATION This manual is provided for you so that your generator may be properly safely and effectively applied and operated Please read and understand all aspects of this manual before operating your generator set Please also read and understand the documentation supplied with this generator regarding the engine Keep this documentation in a safe and accessible place so that reference can be made as needed All operators users and subsequent owners of this generator must read and understand all aspects of this documentation before operation SPARK ARRESTING MUFFLER Certain States and Jurisdictions require that engine driven equipment be fitted with spark arresting mufflers Depending on the generator model spark arresting mufflers m2. e Compressed air max 25 psi may be used to blow loose dirt and dust from your generator DO NOT DIRECT COMPRESSED AIR DIRECTLY INTO ANY OPENING IN THE GENERATOR OR ENGINE e Use a dampened cloth to wipe clean exterior surfaces e Use a soft bristle brush to clean loosen heavy dirt oil or grease deposits e NEVER insert rags tools or any device into the generator or engine openings GENERAL STORAGE GUIDELINES WARNING GASOLINE FUMES ARE FLAMMABLE DO NOT STORE YOUR GENSET IN ANY AREA THAT IS INDOORS OR IN POORLY VENTILATED AREAS GASOLINE FUMES CAN IGNITE IN THE PRESENCE OF ANY OPEN FLAME PILOT LIGHT CLOTHES DRYER WATER HEATER ETC e Your generator should be started and operated for several minutes at least every 30 days e f the generator cannot be operated every 30 days follow the storage recommendations within the engine documentation e NOTE A fuel shut off valve is positioned at the base of the fuel tank The valve should be closed during storage periods ELECTRICAL LOADS AND GUIDELINES Your generator set is designed to power electrical apparatuses within the electrical power output limitations of the generator Please note that any generator overload can cause serious problems damage to your generator Additionally apparatuses with electrical motors can require higher wattage requirements at start up than when running Some electric motors require as much as 2 5 times the rated wattage at start up Al
3. ENGINE LIMITATIONS ON GENERATOR PERFORMANCE Generator ratings assume 60 F 20C and Sea Level Operation of your generator at temperatures above 60 F 20C or above Sea Level will result in lower electrical output Electrical output must be derated 2 for each 9 F above 60 F and 3 for each 1000 feet above mean Sea level Au Fa D NEMA L14 30R 125 250V 30A LOADING YOUR GENERATOR SET With reference to the Receptacle details section please review the power receptacles fitted to your generator The actual load that may be pulled from each receptacle is driven by the circuit breaker rating and the generator rating DO NOT EXCEED THE INDIVIDUAL RECEPTACLE RATINGS AS SHOWN IN THE TABLE BELOW DO EXCEED THE TOTAL GENERATOR RATING SHOWN IN TABLE 2 PERFORMANCE SPECIFICATIONS All generator units are equipped with a PUSH TO RESET Circuit Breaker AMPERAGE RATE TABLE Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 120V Duplex 120V Duplex 120V GFCI 125V 250V 125V 250V Twistlock Twistlock PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS AND WIRING DIAGRAM S IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR
4. DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO PARTS MAY CHANGE OR VARY FROM THOSE SHOWN SECTION 2 E3100 AND E3600 GENERATOR PARTS AND PART LISTS Frame and Parts list for E3100 E3600 NUTM080001 S wASMOg0001 Fiatwasher MW tfv130009 Vibro Isolator 30X30 Ground Assenbl 15680301 Bolt 5 16 18 Grade 5 e 1 wAsMogoov2 M8 Lockyosher 3 ft NuTO3t0001 5716 4 1 EG 8 ITEM QTY PART P 21180008 25 Thermal Circuit Breaker E3600 ITEM QTY PART NI DESCRIPTION i 1 RECO0003 30 125 250V Twistlock Receptacle e 2 180003 15 Thermal Circuit Breaker 3 A SCROZ5O001 Bolt 88 32x3 8 Phil Pan HD Z 4 A NUTO 50001 Nut 88 Nylon Insert 5 1 IRECO0001 20A Duplex Receptacle ALL WIRES 12AWG 3100 W GENSETS A C Wiring Schenutic Rating Rating ax isa paw I E4500 Bue E5000 dem des Pesses s4 1 Remove Distribution Bar NOTES A Refer to table For circuit breaker ratings nnd wire sizes 2 Gan 1 tha PRAVAC Lifter alternator Gen 2 S tne Necc A
5. ANGER THIS GENERATOR SET PRODUCES SERVICE OR REPAIR THIS GENERATOR UNLESS FULLY QUALIFIED TO DO SO DANGER DO NOT OPERATE THIS GENERATOR IF THE AMBIENT TEMPATURE EXCEEDS 105 F 41 C SAFETY RULES operated in dry conditions and for outdoor areas only Never operate this generator indoors Never operate this generator in rain snow sleet or generally wet conditions Damage to the generator bodily injury or death could result from electrocution DANGER This generator set is designed to be DANGER If this generator is connected to a building home business or any other electrical circuit normally fed by utility power steps must be taken to insure the generator output and the utility power are positively isolated Failure to isolate the utility and generator electrical systems will result in generator damage and could result in injury or death to utility workers due to the backfeed of electricity CAUTION Do not exceed the rated capacity of A the generator The total electrical loads at each outlet must be added to determine the total electrical load The total load must not exceed the rated capacity of the generator If the driven apparatus does not list wattage but only amperage wattage may be determined by multiplying amperage times voltage watts amps X volts governed speed The generator operates at a nominal speed of 3600 rpm Increases in speed over the 3600 rpm nominal will increase the chance of pe
6. PRAMAC G A O U F Power Systems E SERIES GENERATOR USER MANUAL Model Numbers E3100 E3600 E4500 E5000 E3600 Model Shown MODEL amp SERIAL NUMBER Enter the Model and Serial numbers of your generator in the spaces provided below Retain these numbers for future reference The Model and Serial numbers are located on the generator data plate on the alternator case or generator frame along with other important information Model Number Serial Number DOCPRA0010 1 PRAMAC s A U LIMITED 1 YEAR WARRANTY STATEMENT A PRAMAC Lifter electrical generating sets originally sold by PRAMAC Industries Inc or an authorized Distributor Dealer thereof are covered by a limited warranty for a period of 12 months The Warranty period begins on the date of purchase by the end user 2 days after shipment to the end user by the PRAMAC Lifter Distributor Dealer or 12 months from the date of original invoice by PRAMAC Industries Inc whichever occurs first PRAMAC Industries Inc warrants their PRAMAC Lifter products to be free of defects in materials and workmanship for the time period shown above and within the limitations presented in the following This PRAMAC Lifter Limited Warranty does not cover components or assemblies manufactured by other organizations including but not limited to engine alternator receptacles etc Warranties for items and assemblies not manufactured by PRAMAC Industries Inc
7. S You are responsible for the performance of all maintenance including the use of approved fluids Upon first indication of a problem you are to cease operation of your PRAMAC Lifter electrical generator and report the problem to your Authorized PRAMAC Lifter Distributor Dealer Upon request you will be required to produce proof of purchase and other pertinent information Your Authorized PRAMAC Lifter Distributor Dealer will instruct you regarding transportation prepaid by buyer of your PRAMAC Lifter electrical generator to the Authorized Distributor Dealer location or arrange for shipment prepaid by buyer of the failed components to the Authorized Distributor Dealer for warranty inspection The name address and telephone number of your local PRAMAC Lifter Distributor Dealer or authorized service facility may be obtained by contacting PRAMAC Industries Inc at 770 479 2922 January 01 2002 22256432 2 SECTION 2 Contents
8. anical and electrical condition Do not overload this generator Overloading this generator can cause generator damage powered apparatus damage and excessive heat build up Always keep hands body parts hair and clothing well away from the rotating or HOT parts of the generator set Exhaust systems can cause severe burns Do not start this generator with connected devices turned Always make sure that connected devices are disconnected from the generator or turned OFF before starting the generator Do not operate this generator within an enclosed area The operation area of the generator must be completely open The exhaust gases of this generator emit DEADLY carbon monoxide Exposure to carbon monoxide can cause carbon monoxide poisoning headaches nausea severe sickness or death Do not install this generator in an enclosed area such as a RV or motorhome All warranty will be null and void if installed within an enclosed area Always insure that at least 6 feet of clearance on all sides of the generator are maintained during operation Failure to maintain proper clearance could damage your generator and potentially lead to fires Never touch a receptacle or bare wire Electrocution or shock could result Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE Handle gasoline with extreme care Failure to properly handle gasoline can result in explosion or fire Do not permit smoking within of th
9. are covered under the warranties of the respective manufacturers of those products Documentation concerning the warranty policies of items not manufactured by PRAMAC Industries Inc but included as part of the PRAMAC Lifter electrical generator is included within the generator documentation These warranties are in lieu of and exclude all other warranties of merchantability fitness or otherwise express or implied There are no warranties extending beyond the description on the face thereof The sole obligation of PRAMAC Industries Inc Seller shall be to repair or replace any components thereof which are proved to be other than warranted PRAMAC Industries Inc shall have the sole right to determine whether such goods shall be repaired or replaced This remedy of repair or replacement is in lieu of all other remedies and it is agreed that no other claim may be made by the Buyer Buyer and Seller agree that the sole purpose of this remedy is to provide the Buyer a satisfactory product under the contract It is further agreed that in no event shall the Seller be liable for incidental or consequential damages arising from any breach of warranty If goods are claimed to be other than as warranted Seller or Sellers Authorized Agent upon notice promptly given will issue shipping instructions for return to the Seller or Sellers authorized Agent transportation costs to be born by Buyer the goods or components and if goods are proven to be other tha
10. ay or may not be fitted If spark arresting mufflers are required for your specific local and the generator muffler is not spark arresting contact your local dealer for instructions for a retrofit EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system for this generator complies to the standards set forth by the California Air Resources Board CARB and the Environmental Protection Agency EPA Warranties for the exhaust emission system are administered by the respective engine manufacturers Refer to the engine documentation for warranty information WARNING California Proposition 65 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm OWNER S MANUAL TO BRING ATTENTION TO IMPORTANT SAFETY INSTRUCTIONS FAILURE TO FOLLOW SAFETY INSTRUCTIONS COULD ENDANGER YOU OR OTHERS AND RESULT IN PERSONAL INJURY OR DEATH READ AND UNDERSTAND ALL SAFETY INSTRUCTIONS BEFORE OPERATION THS SYMBOL IS USED THROUGHOUT YOUR ENCLOSED AREA THE EXHAUST GASES OF THIS GENERATOR EMIT DEADLY CARBON MONOXIDE EXPOSURE CARBON MONOXIDE CAN CAUSE CARBON MONOXIDE POISONING HEADACHES NAUSEA SEVERE SICKNESS OR DEATH DO NOT OPERATE THIS GENERATOR WITHIN AN ELECTRICAL CURRENT THEREFORE SAFETY GUIDELINES MUST BE FOLLOWED IMPROPER USE OF THIS GENERATOR CAN RESULT IN ELECTROCUTION INJURY OR DEATH DO NOT OPERATE D
11. he purpose of powering lights power tools appliances and motor loads within the intended design constraints of the generator The generator is designed to produce single phase electrical power at 120 or 120 240 VAC This generator is not intended for installation in RV or motorhome applications The Performance Specifications for your generator are listed in Table 2 Performance Specifications Table 2 PERFORMANCE SPECIFICATIONS Model Voltage Cont Wats SurgeWats Single Phase 22 Amps 120 VAC 25 8 Amps 120 VAC 3100 Watts 3600 Watts Single Phase 25 8 Amps 120 VAC 30 Amps 120 VAC 12 9 Amps 240 VAC 15 Amps 240 VAC 3825 Watts 4500 Watts Single Phase 32 Amps 120 VAC 37 5 Amps 120 VAC 16 Amps 240 VAC 18 8 Amps 240 VAC E5000 120 240 VAC 4250 Watts 5000 Watts 36 120 41 6 Amps 120 VAC 18 Amps 240 VAC 20 8 Amps 240 VAC Table 3 Engine Type SKU Number Engine H k E3600 Honda GX 200 6 5hp E4500 Honda GX 240 8 0hp E5000 Honda GX 270 9 0hp RECEPTACLE DETAILS The following receptacle details are to aid in identifying mating plugs Use this chart and compare to your genset to determine which receptacle s you have Note the NEMA configuration and use this to purchase the correct mating plug NEMA 5 20R NEMA L5 30R NEMA L6 30R NEMA L6 20R 125V 20A 125V 30A 250V 30A 250V 20 10 ar D NEMA 14 50R NEMA L14 20R 125 250V 50A 125 250V 20A
12. is generator set NEVER REFILL A HOT GENERATOR WITH FUEL NEVER REFILL THE GENERATOR WHILE IT IS RUNNING Spillage onto the engine or generator could result in an explosion or fire Always allow the generator set to cool before refilling Do not store this generator set in any location where gasoline fumes could potentially come into contact with sparks a pilot light or an open flame Improper storage of this generator could result in an explosion or fire e GROUNDING The NATIONAL ELECTRICAL CODE requires that the generator frame be properly grounded to earth A ground lug is provided on the generator frame As a general guideline a 10 AWG wire connected to the grounding lug of the generator on one end located on the generator frame as indicated by the International GROUND symbol and connected to a copper or brass ground rod driven into the ground on the other end of the wire Some locations require generator set or other grounding Check with a local electrician to determine the grounding requirements for your area e Electrical generators produce electricity Therefore never allow or perform service operations to your generator set without proper training certification Service operations without proper precautions can cause severe shock and even death by electrocution e Generators operating on job or construction sites must be equipped with GFCI Ground Fault Circuit Interrupters on all circuits Certain generator mode
13. ls are not equipped with GFCI circuits Therefore customer supplied GFCI s must be installed in the power cords connected to the generator Consult a local licensed electrician for proper wiring e Use only 3 Prong extension cords in good condition and make sure that the wire size within the extension cords is of sufficient size to safely carry the surge output of the generator e Never handle extension cords or electrical circuits if standing in water or if standing in a damp area e Operate service or fill with fluids on a level surface only e Do not operate this generator in a corrosive or flammable environment e Never clean this generator with high pressure water or a garden hose Water can accumulate within the generator and cause fuel system ignition system and or electrical problems or shorts Cleaning should be done with a damp rag on a cool generator set GENERAL MAINTENANCE ENGINE FUEL Use Unleaded Fuel ONLY ENGINE OIL Refer to the Engine related documentation ENGINE MAINTENANCE Refer to the documentation supplied regarding the engine for all engine maintenance issues GENERATOR CLEANING CAUTION ALWAYS SHUT OFF THE GENERATOR A AND ALLOW THE GENERATOR TO COMPLETELY COOL BEFORE OPERATIONS WARNING DO NOT USE HIGH PRESSURE WATER PERFORMING CLEANING OR A GARDEN HOSE TO CLEAN YOUR GENERATOR WATER INTRODUCED INTO THE GENERATOR CAUSE ELECTRICAL SHORTS GENERATOR DAMAGE OR PERSONAL INJURY
14. lte alternator SENE EE ete AC Wiring Schematic 11 SECTION 3 E4500 AND E5000 GENERATOR PARTS AND PART LISTS Frame and Parts list for E4500 E5000 TEN QTY 1 1 FRAQOI Frame Assembly E4500 5000 2 1 BRAO044 1 d 1 V1B0009 Vibration Isolator 30 X 30 5 S wAsMosooo Flotyosher M8 6 2 scrMosooo2 Bolt MB X 16 8 1 Sub Frame Assembly Engine Sub Frame Assembly Engine Sub Frome Assembly 1 1 supooot t Engine Sub Frone 4NVASMI0002 Flatwasher M O Z 7 2NutMioooot Nut Mio 2 WASMIOOOOI Lockyosher MD 9 e scrmosoooe Bolt M9 X 16 12 Ground Wire Assembly 1 SCRO31000 5 16 x18x1 Grade 5 5 3 090001 Flatwasher 6 1 0310002 Nut 5716 18 Grade 5 7 1 wiR0004 Wire Ground E3100 5000 e PART NO DESCRIPTION 1 fIREC0003 30 125 250V Twistlock Receptacle 3 4SCF025001 Bolt 8 32x3 8 Phil Pan HD M S Z 4 0250001 Nut 8 Nylon Insert 5 f JRECOQ0 20A Duplex Receptacle 13 A C WIRING SCHEMATIC g 7 6 5 4 3 l E3600 Bue Blue Te dem me dine E4500 12AWG E5000 12AWG Remove Distribution Bar A 1 Refer ta table for crcult breaker ratings and wire sizes 2 Gen is tha PRAMAC Lifter alternator and Gen 2 is the Merc ALte alternator ea adem eis GENSETS A C Wiring Schematic 14 Notes
15. n as warranted replacement or repaired components will be shipped cheapest way to the Buyer with transportation costs borne by the Seller PRAMAC Industries Inc reserves absolute and final decision power regarding the warrantability of any and all failed components or parts Some states do not allow limitations on how long an implied warranty lasts and some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights that vary from state to state B All warranties of merchantability fitness or otherwise whether express or implied shall not extend to any goods or parts thereof which have been subject to misuse or neglect damaged by accident rendered defective by reason of improper handling or application damaged or rendered defective due to tampering of factory set adjustments damaged due to shipment damaged due to lack of maintenance damaged due to collision impact or shock loads damaged due to corrosion rust or damaged due to overload Further any modifications to the intended and original designed use of the PRAMAC Lifter electrical generator will negate all warranties Seller does not accept any liability for normal wear and tear nor for charges for repairs or replacements made without authority nor contingent liability of any kind C YOUR WARRANTY RESPONSIBILITIE
16. rsonal injury due to rotational stresses on the rotating members Operation of the generator at speeds below the nominal 3600 rpm could cause damage to the generator or driven apparatus due to low voltage output CAUTION Do not modify or misapply your generator set Operation of the generator other than intended could result in generator set damage bodily injury or even death from electrocution CAUTION Do not tamper with the engine GENERAL SAFETY OPERATIONAL GUIDELINES Read and understand all the general safety operational guidelines and rules before operating this generator Always follow National and Local electrical codes When moving or transporting this generator take proper precautions to avoid fuel spillage Further always use common sense when lifting this generator An adequate number of people and proper lifting procedures must be used Do not wire your generator to a home or structure fed by utility power without proper isolation circuitry Consult a local licensed electrician for proper wiring of your generator to home business or any facility or structure fed by utility power Failure to properly isolate utility and generator electrical power could result in generator damage or electrocution to you or a utility worker The main breaker which disconnects from the utility power must be open before the generator can safely be connected Do not operate this generator unless the generator is in good mech
17. though the start up wattage requirements for electric motors lasts only a few seconds great care must be taken in connecting loads to your generator so as not to overload the generator Refer to the label on each electrical apparatus to determine the wattage requirements of that apparatus THE TOTAL WATTAGE REQUIREMENTS OF ALL POWERED APPARATUSES INCLUDING START UP LOADS MUST NEVER EXCEED THE CONTINUOUS RATING OF YOUR GENERATOR CORRECTED TO THE ACTUAL ENVIRONMENTAL CONDITIONS AT THE OPERATING SITE As a reference only Table 1 below shows some general wattage requirements for several common electrical devices This chart is intended as a guide only The actual total wattage should be determined by referring to the actual labels on each of the powered electrical devices Table 1 GENERAL WATTAGE GUIDE Item Running Watts Air Conditioner 12000 Btu Air Compressor 1 2 hp Air Compressor 3 4 hp Air Compressor 1 hp Battery Charger 25A Belt Sander 3 belt Circle Saw 6 12 Coffee Maker Edger lawn Furnace Fan 1 3 hp Hot Plate single Impact wrench Light Bulb Nail Gun Microwave Paint Sprayer 1 3 hp Paint Sprayer hand airless Refrigerator Table Saw 10 Television Weed Trimmer Note Items allow 2 5 times the listed wattage for starting GENERATOR DESIGNED PERFORMANCE GUIDELINES This electrical generator is designed to produce electrical energy for t
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