4000 Watt Generator Owner’s Manual WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
™ Thank you very much for choosing an Ironton product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it. This generator is designed for certain applications only.
Table of Contents Intended Use .......................................................................................................................................... 4 Technical Specifications ...................................................................................................................... 4 Important Safety Information ............................................................................................................... 4 Before Each Use ...................................
Intended Use Ironton’s 4000 Watt Generator can be used to power individual appliances plugged directly into the generator’s outlets Wheel kit (item #45719) is available and sold separately. Technical Specifications Property Surge Watts Rated Watts Voltage Phase Frequency Power Factor Total Harmonic Distortion Engine Engine Speed Fuel Type Fuel Capacity Capacity Starting Method Specification 4000 Watts 3200 Watts 120/240 Volts Single 56.5-63.3 Hertz 1.0 Less than 23% 212cc OHV 3750 RPM Unleaded Gasoline 3.
situations that could occur. Exercise common sense and caution when using this tool. Always be aware of the environment and ensure that the tool is used in a safe and responsible manner. Do not allow persons to operate or assemble the product until they have read this manual and have developed a thorough understanding of how it works. Do not modify this product in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the product.
inattention while operating the tool may result in serious personal injury. Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection systems, and hearing protection when appropriate. This applies to all persons in the work area. Do not overreach.
⚠WARNING A transfer switch must be installed in order to isolate your generator from the utility power grid. If your generator is NOT properly isolated from the utility system, serious hazards will arise: When your generator is running, its output will back feed into the utility power line and transformer that are normally used to provide you with power. The transformer will step up the current to the normal line voltage.
Note: Regardless of whether you use your generator as a back-up power source or as a portable power source, you must not overload it. Overloading the generator may cause serious damage to the unit and any attached electrical devices. Extension Cords Extension cords may be used to power devices that are located at a distance from the generator. However, use only outdoor-rated, grounded extension cords of the proper size.
2. Outdoors Only ⚠WARNING The exhaust from your generator contains carbon monoxide (CO), a poisonous gas that can kill. You cannot smell it, see it, or taste it. Carbon monoxide exhaust is given off whether you are using gasoline, natural gas, or propane as the fuel source to power the generator. Follow the directions below for choosing a location to operate your generator in order to avoid carbon monoxide poisoning.
⚠WARNING Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures. Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up. Never place the generator immediately adjacent to a building or other structure. Allow at least 7 feet clearance. Do not run the generator in close proximity to other heat-generating equipment, such as another generator.
⚠WARNING Never attempt to attach ductwork to the muffler system to lower noise levels. This could cause hot air deflection, heat build-up, and increased exhaust back-pressure, resulting in possible exhaust leakage or damage to the generator. Grounding the Generator Always ensure the generator is properly grounded to prevent electrical shock. You must always ground the generator by the following method when using the generator as a portable electrical source: 1.
Operating Instructions Once you have set up the generator for use, it is time to start the unit. The following are the procedures necessary for safe, successful operation of your generator. General Safety Rules for Operation ⚠WARNING Failure to follow safety rules may result in serious injury or death to the operator or bystanders. Before starting the generator, review the following general safety rules for operation: Know proper use/how to stop.
Engine misfire Excessive vibration Flame or smoke Abnormal noise Adjusting / repairing. Always turn off generator and remove spark plug(s) or spark plug wire(s) before working on the generator to prevent accidental starting. Always discharge the capacitor before working on the generator head to prevent electrical shock. (See Maintenance & Repair section of this manual for instructions on how to do this.) Carbon monoxide poisoning.
Use a portable container to fill tank. Never fill the generator's gas tank directly from the fuel pump -the generator's tank is not grounded and the high velocity flow of gasoline from a fuel pump can cause static electric build-up. Use an approved portable container to transfer gasoline to the generator's tank. Fill container on the ground. Never fill the portable gas container while it is sitting inside a vehicle, trailer, trunk, or pick-up truck bed.
⚠WARNING Carbon monoxide poisoning hazard. Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and away from air intakes. NEVER run generator inside any enclosed or semi-enclosed spaces, including homes, garages, basements, sheds, boxes, pick-up truck beds, RVs, or boats. These spaces can trap poisonous gases, EVEN if you run a fan or open windows.
Carefully follow all the instructions in this section to avoid the following conditions which could result in gasoline ignition: • Gas vapor collection inside enclosures • Static electric sparks • Sparks from electric wiring, batteries, or running engines • Sources of heat (such as a hot engine or exhaust) • Open flames, including pilot lights 1.
5. Clean up gasoline spills/splashed immediately. If possible, move the generator away from spilled gasoline on the ground. Wipe up spilled gasoline, and wait 5 minutes for excess gasoline to evaporate before starting engine. Gasoline soaked rags are flammable and should be disposed of properly. If gasoline is spilled on your skin or clothes, change clothes and wash skin immediately. 6. Replace gasoline cap securely before starting engine. 7.
iii. Allow starter cord to return slowly. 5. When engine starts, move choke lever to RUN position. 6. Under long, continuous-run operating conditions, be prepared to: a. Check and refuel the engine on a regular basis. A tank of gas should last about 9.5 hours under 50% load. ⚠WARNING A running engine is hot enough to ignite fuel. Never add fuel or remove gas cap if engine is running or still hot. Let cool at least 2 minutes. b. Check engine oil level each time you refuel. c.
generator cycle on or off. The slight variation has no appreciable effect in the operation of motors, lights, and most appliances. Connecting Electrical Loads (Portable Power Generation) You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. ⚠WARNING Do not overload generator. Make sure that combined starting and running loads do not exceed rated capacity of generator.
2. Turn the engine key switch to the OFF position. 3. Store the generator properly 4. Plan on exercising the engine regularly unless the generator is prepared for long-term storage. Disconnect loads and turn off fuel supply. When you are finished using the generator, disconnect all loads and turn off fuel supply: 1. Make sure all devices that were connected to the generator's outlets have been disconnected. 2. Check to be sure gasoline line shut-off valve is in OFF position. Cool engine before storing.
Read and follow these safety rules whenever you will be servicing the generator: Turn off generator. Always turn off generator and remove spark plug(s) or spark plug wire(s) before working on the engine or generator to prevent accidental starting. Follow safety rules Replace guards. Make sure all guards and shields are replaced after servicing the generator. Repair.
Parts Diagram for Engine Page 22 of 29
Parts List for Engine No. Code Part Description Qty. No. Code Part Description Qty.
No. Code Part Description Qty. No. Code Part Description Qty.
Parts Diagram for Generator Page 25 of 29
Parts List for Generator No. Code Part Description Qty. No. Code Part Description Qty. 1 770168-010 Frame 1 21.1 6080 Switch Assembly 1 1 2 531201 Isolator A 2 21.2 6032 Double Receptacle, America 20A/125V UL 3 531204 Isolator B 2 21.3 6246 Thermal Protector 13.5A UL 2 4 90011 Nut M8 6 21.4 6241 30A/125V/250V UL 1 5 91325 Bolt M6X12 11 21.
No. Code Part Description Qty. No. Code Part Description Qty. 19 96054 Packing Exhaust 1 37 544303 Grounding Wire 1 20 705326 Muffler Comp 1 38 531112 Rubber Damping Bracket 4 21 710185 Panel Comp 1 Replacement Parts For replacement parts and technical questions, please call Customer Service at 1-877-234-6869. Not all product components are available for replacement.
Limited Warranty Northern Tool and Equipment Company, Inc. ("We'' or ''Us'') warrants to the original purchaser only (''You'' or ''Your'') that the Ironton product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of 90 days from date of purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in accordance with product instructions.
Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.
