generator safety refuel with care gasoline is extremely flammable, and gasoline vapor can explode....

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The information and specifications included in this publication were ineffect at the time of approval for printing. Honda Motor Co., Ltd.reserves the right, however, to discontinue or change specifications ordesign at any time without notice and without incurring any obligationwhatever.

Keep this owner’s manual handy so that you can refer to it at any time.This owner’s manual is considered a permanent part of the generatorand should remain with the generator if resold.

Exhaust contains poisonous carbonmonoxide gas that can build up todangerous levels in closed areas.Breathing carbon monoxide cancause unconsciousness or death.

Never run the generator in a closed,or even partly closed area wherepeople may be present.

2004 2008 Honda Motor Co., Ltd. All Rights Reserve

The engine exhaust from this productcontains chemicals known to the State

of California to cause cancer, birthdefects or other reproductive harm.

1

INTRODUCTION

We want to help you get the best results from your new generator andto operate it safely. This manual contains all the information on how todo that; please read it carefully.

As you read this manual, you will find information preceded by asymbol. That information is intended to help you avoid

damage to your generator, other property, or the environment.

We suggest you read the warranty policy to fully understand itscoverage and your responsibilities of ownership. The warranty policyis a separate document that should have been given to you by yourdealer.

Congratulations on your selection of this generator. We are certainyou will be pleased with your purchase of one of the finest generatorson the market.

When your generator needs scheduled maintenance, keep in mindthat your Alphagen servicing dealer is specially trained in servicingthis generator. Please contact your Alphagen dealer to have yourgenerator serviced. Your servicing dealer is dedicated to yoursatisfaction and will be pleased to answer your questions andconcerns.

Best Wishes,

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2

A FEW WORDS ABOUT SAFETY

Safety Labels

Safety Messages

Safety Headings

Safety Section

Instructions

Your safety and the safety of others are very important. And using thisgenerator safely is an important responsibility.

To help you make informed decisions about safety, we have providedoperating procedures and other information on labels and in thismanual. This information alerts you to potential hazards that couldhurt you or others.

Of course, it is not practical or possible to warn you about all thehazards associated with operating or maintaining a generator. Youmust use your own good judgement.

You will find important safety information in a variety of forms,including:

on the generator.

preceded by a safety alert symbol and oneof three signal words, DANGER, WARNING, or CAUTION.

These signal words mean:

be or ifyou don’t follow instructions.

be or ifyou don’t follow instructions.

be if you don’t followinstructions.

such as IMPORTANT SAFETY INFORMATION.

such as

how to use this generator correctly and safely.

This entire book is filled with important safety information pleaseread it carefully.

You WILL KILLED SERIOUSLY HURT

You CAN KILLED SERIOUSLY HURT

You CAN HURT

GENERATOR SAFETY .

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3

CONTENTS

................................................................................GENERATOR SAFETY .6

........................................................................CONTROLS & FEATURES .11

...............................................................................BEFORE OPERATION .20

..................................................IMPORTANT SAFETY INFORMATION .6......................................................................Operator Responsibility .6

.................................................................Carbon Monoxide Hazards .6.......................................................................Electric Shock Hazards .7........................................................................Fire and Burn Hazards .7

.................................................................................Refuel With Care .8.................................................................SAFETY LABEL LOCATIONS .9

...........................................COMPONENT & CONTROL LOCATIONS .11............................................................................................CONTROLS .13

.............................................................DC Voltage Selector Switch .13................................................................................Fuel Valve Lever .13

.......................................................................................Choke Knob .14....................................................................................Engine Switch .14

........................................................................................Starter Grip .15....................................................................................Output Switch .16

.............................................................................................FEATURES .17...............................................................................Ground Terminal .17

............................................................................DC Output Coupler .17...........................................................................................Voltmeter .17

.........................................................................Eco-Throttle System .17................................................................................Output Indicator .18

............................................................................Overload Indicator .18..............................................................................Oil Alert Indicator .19

.........................................................................................Fuel Gauge .19

................................................ARE YOU READY TO GET STARTED ? .20.........................................................................................Knowledge .20

.............................................IS YOUR GENERATOR READY TO GO ? .20...............................................................................Check the Engine .21

4

CONTENTS

..............................................................................................OPERATION .22

.............................................................SERVICING YOUR GENERATOR .30

.....................................................SAFE OPERATING PRECAUTIONS .22..........................................STARTING THE ENGINE/DC OPERATION .23

....................................................................................Forced Output .26......................................................................STOPPING THE ENGINE .28

.............................................THE IMPORTANCE OF MAINTENANCE .30......................................................................MAINTENANCE SAFETY .31

............................................................................Safety Precautions .31................................................................MAINTENANCE SCHEDULE .32

...........................................................................................REFUELING .33...............................................................FUEL RECOMMENDATIONS .34

..................................................................ENGINE OIL LEVEL CHECK .35...........................................................................ENGINE OIL CHANGE .36

....................................................ENGINE OIL RECOMMENDATIONS .37........................................................................AIR CLEANER SERVICE .38

.............................................................FOAM AIR FILTER CLEANING .40.................................................................SEDIMENT CUP CLEANING .41

.........................................................................SPARK PLUG SERVICE .43................................................................SPARK ARRESTER SERVICE .45

5

CONTENTS

..................................................................................................STORAGE .48

......................................................................................TRANSPORTING .53

.......................................TAKING CARE OF UNEXPECTED PROBLEMS .54

..........................................TECHNICAL & CONSUMER INFORMATION .58

........................................................................................................INDEX .67

.............................QUICK REFERENCE INFORMATION .Inside back cover

....................................................................STORAGE PREPARATION .48.............................................................................................Cleaning .48

.....................................................................................................Fuel .48...........................................................................Engine Preparation .51

...................................................................STORAGE PRECAUTIONS .52................................................................REMOVAL FROM STORAGE .52

.............................................................................ENGINE PROBLEMS .54....................................................................GENERATOR PROBLEMS .56

................................................................TECHNICAL INFORMATION .58...................................................................Serial Number Location .58

....................Carburetor Modification for High Altitude Operation .59............................................Emission Control System Information .60

.............................................................................................Air Index .62....................................................................................Specifications .63

.................................................................................Wiring Diagram .64...............................................................CONSUMER INFORMATION .65

.......................................................................................Publications .65.........................................................Customer Service Information .66

6

GENERATOR SAFETY

IMPORTANT SAFETY INFORMATION

Carbon Monoxide Hazards

Operator Responsibility

This generator is designed for use with CATV/Telecommunicationsequipment that has suitable power requirements. Other uses canresult in injury to the operator or damage to the generator and otherproperty.Most mishaps can be prevented if you follow all instructions in thismanual and on the generator. The most common hazards arediscussed below, along with the best way to protect yourself andothers.

Be sure that anyone who operates the generator receives properinstruction. Do not let children operate the generator withoutparental supervision.

Know how to stop the generator quickly in case of emergency.

Understand the use of all generator controls, output receptacles,and connections.

Exhaust contains poisonous carbon monoxide, a colorless andodorless gas. Breathing carbon monoxide can cause loss ofconsciousness and may lead to death.

If you run the generator in a confined or even partly enclosed area,the air you breathe could contain dangerous amount of exhaust gas.

Never run your generator inside a garage, house, or near openwindows or doors.

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7

GENERATOR SAFETY

Electric Shock Hazards

Fire and Burn Hazards

The generator produces enough electric power to cause a seriousshock or electrocution if misused.

If the generator is stored outdoors, unprotected from the weather,check all of the electrical components on the control panel beforeeach use. Moisture or ice can cause a malfunction or short circuit inelectrical components which could result in electrocution.

Using a generator or electrical appliance in wet conditions, such asrain or snow, or near a pool or sprinkler system, or when your handsare wet, could result in electrocution. Keep the generator dry.

Do not touch the uninsulated portion of the output coupler.There is a risk of electrical shock.

The exhaust system gets hot enough to ignite some materials.Keep the generator at least 3 feet (1 meter) away from buildingsand other equipment during operation.Do not enclose the generator in any structure.Keep flammable materials away from the generator.

The muffler becomes very hot during operation and remains hot fora while after stopping the engine. Be careful not to touch the mufflerwhile it is hot. Let the engine cool before storing the generatorindoors.

8

GENERATOR SAFETY

Refuel With Care

Gasoline is extremely flammable, and gasoline vapor can explode.Allow the engine to cool if the generator has been in operation. Refuelonly outdoors in a well-ventilated area with the engine OFF. Do notoverfill the fuel tank. Never smoke near gasoline, and keep otherflames and sparks away. Always store gasoline in an approvedcontainer. Make sure that any spilled fuel has been wiped up beforestarting the engine.

9

GENERATOR SAFETY

SAFETY LABEL LOCATIONS

These labels warn you of potential hazards that can cause seriousinjury. Read them carefully. If a label comes off or becomes hard toread, contact your Alphagen servicing dealer for a replacement.

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10

GENERATOR SAFETY

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11

COMPONENT & CONTROL LOCATIONS

CONTROLS & FEATURES

ENGINE SWITCH

CHOKE KNOB

FUEL VALVE LEVER

OUTPUTINDICATOR

OVERLOADINDICATOR

OUTPUT SWITCH

GROUNDTERMINAL

DC OUTPUTCOUPLER

VOLTMETER

OIL ALERTINDICATOR

Use the illustrations on these pages to locate and identify the mostfrequently used controls.

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12

CONTROL & FEATURES

OIL FILLER CAP/DIPSTICK

MAINTENANCE COVER

OIL MAINTENANCECOVER

OIL DRAINPLUG

MUFFLER

FRONT HANDLE

DC VOLTAGESELECTOR SWITCH

AIR CLEANER

SPARK PLUG CAP

FUEL GAUGE

STARTER GRIP

REAR HANDLE

FUEL TANK CAP

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13

CONTROL & FEATURES

CONTROLS

DC Voltage Selector Switch

Fuel Valve Lever

OOFFFF

OONN

DC VOLTAGE SELECTOR SWITCH

FUEL VALVE LEVER

MAINTENANCE COVER

The DC voltage selector switch isused to select generator DCvoltage; either 36 V or 48 V.

The fuel valve lever is located onthe control panel.

To operate the DC voltageselector switch, make sure theengine is OFF, then open themaintenance cover.After selecting the voltage, closethe maintenance cover.

Select the same voltage as thebattery voltage of the UPS batterystring.

The fuel valve lever must be in theON position for the engine to run.

After stopping the engine, turnthe fuel valve lever to the OFFposition.

08/03/28 11:10:57 31ZS9700_014

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14

CONTROL & FEATURES

Choke Knob

Engine Switch

CHOKE KNOB

OOPPEENN

OOFFFF

OONN

CCLLOOSSEEDD

ENGINE SWITCH

ENGINE SWITCH KEY

The choke knob opens and closesthe choke valve in the carburetor.

The CLOSED position enrichesthe fuel mixture for starting a coldengine.

The OPEN position provides thecorrect fuel mixture for operationafter starting, and for restarting awarm engine.

The engine switch controls theignition system.

OFF Stops the engine. Theengine switch key can beremoved/inserted.

ON Running position, and forstarting with the starter grip.

08/03/28 11:11:06 31ZS9700_015

15

CONTROL & FEATURES

Starter GripSTARTER GRIP

Direction to pull

Pulling the starter grip operatesthe recoil starter to crank theengine for starting.

Do not allow the starter grip tosnap back against the engine.Return it gently to preventdamage to the starter.Do not let the starter rope rubagainst the generator body, orthe rope will wear outprematurely.

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16

CONTROL & FEATURES

Output SwitchOUTPUT SWITCHThe output switch has two functions.

Following the forced outputprocedure, the generator willprovide output to charge thebattery string when thebattery string charge is toolow to activate automaticcharging.

Forced Output

During the output operation,press the output switch tostop output. To reset, stopand restart the engine.

Stop Output

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17

CONTROL & FEATURES

FEATURES

Ground Terminal

DC Output Coupler

Voltmeter

Eco-Throttle System

DC OUTPUT COUPLER

Positiveside

Negativeside

The ground terminal is connectedto the frame of the generator andthe metal non-current-carryingparts of the generator.Before using the ground terminal,consult a qualified electrician,electrical inspector, or localagency having jurisdiction forlocal codes or ordinances thatapply to the intended use of thegenerator.

SYSTEM FLOATING:The system ground is notconnected to the DC circuit.

The DC output coupler may ONLYbe used for charging UPS 36 V or48 V battery strings.When connecting the power cordto the DC output coupler, alwaysuse the correct coupler and powercord.

The voltmeter indicates the voltage of the UPS batteries whenconnected to the DC output coupler.

The Eco-Throttle system automatically reduces engine speed whenthe UPS battery string is fully charged.When the UPS battery string becomes discharged, the engine returnsto the proper speed to recharge the batteries.

TM

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18

CONTROL & FEATURES

Output Indicator

Overload Indicator

OUTPUT INDICATOR(GREEN)

OVERLOAD INDICATOR(RED)

The output indicator (green) is illuminated when the generator isoperating normally. It indicates that the generator is producingelectrical power at the DC output coupler.

The overload indicator (red) will go steady ON if the generator isoverloaded, the converter becomes overheated or there is a shortcircuit in the connected UPS battery string. The overload indicator(red) will stay ON, and after about five seconds, current to theconnected UPS and the output indicator (green) will go OFF. When theUPS battery voltage is too low or too high, the overload indicator (red)will flash.

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19

CONTROL & FEATURES

Fuel Gauge

Oil Alert Indicator

FULL

EMPTY

FUEL TANK CAP

FUEL GAUGE

OIL ALERTINDICATOR

The fuel gauge is a mechanical device that measures the fuel level inthe tank. The red indicator in the window will reference the level inrelation to full or empty. To provide increased operating time, startwith a full tank before beginning operation. Check the fuel level withthe generator on a level surface. Always refuel with the engine OFFand cool.

The Oil Alert system is designed to prevent engine damage causedby an insufficient amount of oil in the crankcase. Before the oil level inthe crankcase can fall below a safe limit, the Oil Alert indicator comeson, and the Oil Alert system automatically will stop the engine (theengine switch will remain in the ON position).If the engine stops or the Oil Alert indicator comes on when you pullthe starter grip, check the engine oil level (see page ) beforetroubleshooting in other areas.

35

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20

BEFORE OPERATION

ARE YOU READY TO GET STARTED?

Knowledge

IS YOUR GENERATOR READY TO GO?

Your safety is your responsibility. A little time spent in preparation willsignificantly reduce your risk of injury.

Read and understand this manual. Know what the controls do andhow to operate them.

Familiarize yourself with the generator and its operation before youbegin using it. Know how to quickly shut off the generator in case ofan emergency.

When the generator is being used, check the voltage requirement ofthe UPS battery strings. This generator is designed to charge 36 V and48 V battery strings.

For your safety, and to maximize the service life of your equipment, itis very important to take a few moments before you operate thegenerator to check its condition. Be sure to take care of any problemyou find, or have your servicing dealer correct it, before you operatethe generator.

Always perform a preoperationinspection before each operation,and correct any problem.

Improperly maintaining thisgenerator, or failing to correct aproblem before operation, couldcause a malfunction in which youcould be seriously injured.

To prevent a possible fire, keep the generator at least 3 feet (1 meter)away from building walls and other equipment during operation. Donot place flammable objects close to the engine.

Before beginning your preoperation checks, be sure the generator ison a level surface and the engine switch is in the OFF position.

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21

BEFORE OPERATION

Check the Engine

Check the oil level (see page ). A low oil level will cause the Oil Alertsystem to shut down the engine.

Check the air filter (see page ). A dirty air filter will restrict air flow tothe carburetor, reducing engine and generator performance.

Check the fuel level (see page ). Starting with a full tank will help toeliminate or reduce operating interruptions for refueling.

35

38

33

06/12/22 17:00:41 31ZS9700_022

22

SAFE OPERATING PRECAUTIONS

OPERATION

Before operating the generator for the first time, please review theGENERATOR SAFETY section and the chapter titled BEFOREOPERATION.

For your safety, do not operate the generator in an enclosed area suchas a garage. Your generator’s exhaust contains poisonous carbonmonoxide gas that can collect rapidly in an enclosed area and causeillness or death.

Exhaust contains poisonous carbonmonoxide gas that can build up todangerous levels in closed areas.Breathing carbon monoxide cancause unconsciousness or death.

Never run the generator in a closed,or even partly closed area wherepeople may be present.

Do not operate the generator in an enclosed structure.

Operate the generator at least 3 feet (1 meter) away from buildingsand other equipment.

Inspect the power cord and coupler, and replace if damaged. Faultypower cords and coupler can create a potential for electric shock.

Mark sure the positive terminal of the UPS battery string isconnected to generator positive side of the DC output coupler.

This generator is a DC only generator which connects to the UPSand is made to charge the UPS battery strings. When connecting thepower cord to the DC output coupler, always use the correct couplerand power cord.

Before connecting a power cord to the generator:

07/06/26 13:03:32 31ZS9700_023

23

OPERATION

STARTING THE ENGINE/DC OPERATION

DC OUTPUT COUPLER

POWER CORD COUPLER

DC VOLTAGE SELECTOR SWITCH

VOLTMETER

MAINTENANCE COVER

No gap

Select the same voltage as thebattery voltage of UPS.

Connect the power cord of the UPS to the DC output coupler.

When the UPS battery string is connected to the generator, the backlight in the voltmeter is turned on and indicates the battery stringvoltage.

Select the DC voltage selectorswitch, either 36 V or 48 V.

Open the maintenance cover.

Close the maintenance cover.

1.

a.b.

c.

2.

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24

OPERATION

FUEL VALVE LEVER

OONN

CHOKE KNOB

CLOSED

OOPPEENN

OOFFFF

Turn the fuel valve lever to theON position.

Leave the choke knob in theOPEN position to restart awarm engine.

Pull the choke knob to theCLOSED position to start a coldengine.

3.

4.

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25

OPERATION

ENGINE SWITCH

OOFFFF

OONN

STARTER GRIP

CHOKE KNOB

OPEN

Direction to pull

Turn the engine switch to theON position.

When the engine starts, DC output will begin charging the UPS batterystring automatically and the output indicator (green) will go ON. If theUPS battery string voltage is too low, the DC output will be turned off.At this time, the output indicator (green) will go OFF and the overloadindicator (red) will go ON. See Forced Output, page for additionalinformation.

Pull the starter grip lightly untilyou feel resistance, then pullbriskly in the direction of thearrow as shown in the picture atthe right.

Do not allow the starter gripto snap back against theengine. Return it gently toprevent damage to the starter.Do not let the starter rope rubagainst the generator body orthe rope will wear outprematurely.

If the choke knob was pulled tothe CLOSED position to startthe engine, gradually move it tothe OPEN position as theengine warms up.

5.

6.

7.

26

06/12/22 17:01:16 31ZS9700_026

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26

OPERATION

Forced Output

The forced output function should only be used by personnel who areknowledgeable regarding UPS battery string operation. Follow theinstructions in the UPS battery owner’s manual.

The DC voltage selector switch must be set equal to the voltage of theUPS battery string. Incorrectly setting the voltage selector switch maycause damage or fire to the UPS battery string. The engine must bestopped whenever you change the DC voltage selector switch.

Forced output can only be initiated if the DC output does not initiateautomatically when following the ‘‘STARTING THE ENGINE/DCOPERATION’’ procedure (see pages ).

Applicable conditions:Output voltage depends on the DC voltage selector switch position.Forced output is allowed under the following conditions.

In addition, the forced output function is dependant on the UPSbattery string voltage. Forced output can only be initiated if theconditions shown in the following table are met.

Output indicator(Green)

OFFOFF

Overload indicator(red)

FLASHFLASH

UPS batteryVoltage2 27 V2 42 V

23 25

DC Voltageselector switch

36 V48 V

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27

OPERATION

OUTPUT SWITCH

Operation:Verify that the overload indicator (red) is flashing.Press the output switch for 5 seconds, the overload indicator (red)will go OFF.Release your finger from the switch.If step 3 is not carried out within 5 seconds, the overload indicator(red) will start to flash again.Press the output switch for 5 seconds once again.The output indicator (green) will go ON and forced output starts towork.

You cannot use forced output with protection function after using thestop output function in normal operation. Stop and restart the engineto reset the generator.

1.2.

3.

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28

OPERATION

STOPPING THE ENGINE

OONN

OOFFFF

OUTPUT SWITCH

ENGINE SWITCH

To stop the engine in an emergency, simply turn the engine switch tothe OFF position. Under normal conditions, use the followingprocedure.

Push the output switch.

Output is off, but engine isoperating.

Turn the engine switch to theOFF position.

1.

2.

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29

OPERATION

FUEL VALVE LEVER

DC OUTPUT COUPLER

POWER CORD COUPLER

OFF

ON

Turn the fuel valve lever to theOFF position.

Remove the power cord coupler from the DC output coupler.

3.

4.

04/10/12 11:50:34 31ZS9700_030

30

THE IMPORTANCE OF MAINTENANCE

Maintenance, replacement, or repair of the emission control devicesand systems may be performed by any engine repair establishment orindividual, using parts that are ‘‘certified’’ to EPA standards.

SERVICING YOUR GENERATOR

Good maintenance is essential for safe, economical, and trouble-freeoperation. It will also help reduce air pollution.

To help you properly care for your generator, the following pagesinclude a maintenance schedule, routine inspection procedures, andsimple maintenance procedures using basic hand tools. Other servicetasks that are more difficult, or require special tools, are best handledby professionals and are normally performed by an Alphagentechnician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. Ifyou operate your generator under unusual conditions, such assustained high-load or high-temperature operation, or use it in dustyconditions, consult your servicing dealer for recommendationsapplicable to your individual needs and use.

Improper maintenance, or failure tocorrect a problem before operation,can cause a malfunction in whichyou can be seriously hurt or killed.

Always follow the inspection andmaintenance recommendations andschedules in this owner’s manual.

Remember that your servicing dealer knows your generator best andis fully equipped to maintain and repair it.

To ensure the best quality and reliability, use only new, genuineHonda parts or their equivalents for repair and replacement.

04/10/12 11:50:42 31ZS9700_031

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31


MAINTENANCE SAFETY

Safety Precautions

Carbon monoxide poisoning from engine exhaust.

Burns from hot parts.

Injury from moving parts.

Some of the most important safety precautions follow. However, wecannot warn you of every conceivable hazard that can arise inperforming maintenance. Only you can decide whether or not youshould perform a given task.

Failure to properly followmaintenance instructions andprecautions can cause you to beseriously hurt or killed.

Always follow the procedures andprecautions in the owner’s manual.

Make sure the engine is off before you begin any maintenance orrepairs. This will eliminate several potential hazards:

Operate outside away from open windows or doors.

Let the engine and exhaust system cool before touching.

Do not run the engine unless instructed to do so.

Read the instructions before you begin, and make sure you have thetools and skills required.

To reduce the possibility of fire or explosion, be careful whenworking around gasoline. Use only a nonflammable solvent, notgasoline, to clean parts. Keep cigarettes, sparks, and flames awayfrom all fuel-related parts.

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32


MAINTENANCE SCHEDULE

REGULAR SERVICE PERIOD (3)ITEM Each

usePerform at every indicated month oroperating hour interval, whichever comesfirst.

These items should be serviced by an authorized Alphagen generator dealer, unless theowner has the proper tools and is mechanically proficient. See the Shop Manual.

Service more frequently when used in dusty areas.Replace the paper air filter element only.

Every 2 years (Replace if necessary) (2)

Every 2 years (Replace if necessary) (2)Every 2 years (Replace if necessary) (2)Every 2 years (Replace if necessary) (2)

Check levelChangeCheckCleanReplaceCheckCheckCheckCleanCheck-adjustReplaceCleanCheck-adjustClean

CleanCheck

(1)

(2)

(2)

3536384038

4143

45

For commercial use, log hours of operation to determine proper maintenance intervals.

Failure to follow this maintenance schedule could result in non-warrantable failures.

After every 500 hrs. (2)

Engine oil

Air cleaner

CanisterPurge tubeCharge tubeSediment cupSpark plug

Spark arresterValve clearanceCombustionchamberFuel tank and filterFuel tube

(1)(2)

(3)

Firstmonth

or20 hrs.

Every3

monthsor

50 hrs.

Every6

monthsor

100 hrs.

Everyyearor

300 hrs.Page

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33


REFUELING

With the engine stopped, check the fuel level gauge. Refill the tank ifthe fuel level is low. Refuel carefully to avoid spilling fuel. Do not fillabove the maximum fuel level.

Gasoline is highly flammable andexplosive.

You can be burned or seriouslyinjured when handling fuel.

Stop the engine and keep heat,sparks, and flame away.Handle fuel only outdoors.Wipe up spills immediately.

Refuel in a well-ventilated area with the engine stopped. If the enginehas been running, allow it to cool first. Refuel carefully to avoidspilling fuel. Do not fill the fuel tank above the upper level mark (red)on the fuel strainer.

Never refuel the engine inside a building where gasoline fumes mayreach flames or sparks. Keep gasoline away from appliance pilot lights,barbecues, electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental damage.Wipe up spills immediately.

Fuel can damage paint and plastic. Be careful not to spill fuel whenfilling your fuel tank. Damage caused by spilled fuel is not coveredunder warranty.

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34


FUEL RECOMMENDATIONS

FUEL TANK CAP

EMPTY TETHER

FUEL STRAINER

UPPER LEVELMARK (RED)

FULL

UPPER LEVELMARK

FUEL LEVEL GAUGE

After refueling, reinstall the fuel tank cap securely.

Never use stale or contaminated gasoline or an oil/gasoline mixture.Avoid getting dirt or water in the fuel tank.

This engine is certified to operate on regular unleaded gasoline with apump octane rating of 86 or higher.

You may use regular unleaded gasoline containing no more than 10%ethanol (E10) or 5% methanol by volume. In addition, methanol mustcontain cosolvents and corrosion inhibitors.

Use of fuels with content of ethanol or methanol greater than shownabove may cause starting and/or performance problems. It may alsodamage metal, rubber, and plastic parts of the fuel system.

Engine damage or performance problems that result from using a fuelwith percentages of ethanol or methanol greater than shown aboveare not covered under warranty.

If your equipment will be used on an infrequent or intermittent basis,please refer to the fuel section of the STORAGE chapter (page ) foradditional information regarding fuel deterioration.

48

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35


ENGINE OIL LEVEL CHECK

DIPSTICK

OIL FILLER CAP

UPPER LIMIT

OIL MAINTENANCE COVER

Check the engine oil level with the generator on a level surface and theengine stopped.

Remove the oil filler cap/dipstick and wipe it clean.

Open the oil maintenance cover.

Close and latch the oil maintenance cover.

Insert and remove the dipstick without screwing it into the filler neck.Check the oil level shown on the dipstick.

If the oil level is low, fill to the top of the oil filler neck with therecommended oil (see page ).

Screw in the oil filler cap/dipstick securely.

The Oil Alert system will automatically stop the engine before the oillevel falls below safe limits. However, to avoid the inconvenience of anunexpected shutdown, check the oil level regularly.

1.

2.

3.

4.

5.

6.

37

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36


ENGINE OIL CHANGE

OIL FILLER CAP

UPPER LIMITOIL DRAIN PLUG

OIL MAINTENANCECOVER

DIPSTICK

Drain the oil while the engine is warm to assure rapid and completedraining.

Allow the used oil to drain completely, then reinstall the drain plugand sealing washer. Tighten the plug securely.

Place a suitable container below the engine to catch the used oil,then remove the oil filler cap/dipstick, drain plug and sealing washer.

Open and remove the oil maintenance cover.

Improper disposal of engine oil can be harmful to the environment.If you change your own oil, please dispose of the used oil properly.Put it in a sealed container and take it to a recycling center. Do notdiscard it in a trash bin, dump it on the ground or pour it down thedrain.

Wash your hands with soap and water after handling used oil.

Reinstall, close and latch the oil maintenance cover.

Screw in the oil filler cap/dipstick securely.

With the generator in a level position, fill to the outer edge of the oilfilter hole with the recommended oil (see page ).

1.

2.

3.

4.

5.

6.

37

04/10/12 11:51:48 31ZS9700_037

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37


ENGINE OIL RECOMMENDATIONS

AMBIENT TEMPERATURE

Oil is a major factor affecting performance and service life. Use4-stroke automotive detergent oil.

SAE 10W 30 is recommended for general use. Other viscositiesshown in the chart may be used when the average temperature inyour area is within the recommended range.

The SAE oil viscosity and service category are in the API label on theoil container. We recommend that you use API SERVICE category SJor later (or equivalent) oil.

08/03/28 11:12:19 31ZS9700_038

38


AIR CLEANER SERVICE

AIR CLEANERCOVER

CLIPS

FOAM AIR FILTER

AIR CLEANER COVER

CLIPS

MANTENANCE COVER


Reinstall the foam air filter in the aircleaner cover.

Check the foam air filter to be sure itis clean and in good condition. If thefoam air filter is dirty, clean it asdescribed on page . Replace thefoam air filter if it is damaged.

Remove the foam air filter from theair cleaner cover.

Foam air filter:

Unsnap the air cleaner cover clips;remove the air cleaner cover.

3.

2.

1.

a.

b.

c.

40

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39


AIR CLEANER COVER

PAPER AIR FILTERPaper air filter:If the paper air filter is dirty,replace it with a new one. Donot clean the paper air filter.

Reinstall the air cleaner cover.

Close and latch themaintenance cover.

Operating the engine without an air filter, or with a damaged air filter,will allow dirt to enter the engine, causing rapid engine wear. This typeof damage is not covered by the Distributor’s Limited Warranty.

5.

6.

4.

04/10/12 11:52:13 31ZS9700_040

40


FOAM AIR FILTER CLEANING

FOAM AIR FILTER

A dirty foam air filter will restrict air flow to the carburetor, reducingengine performance. If you operate the generator in very dusty areas,clean the foam air filter more frequently than specified in theMaintenance Schedule.

Clean the foam air filter in warmsoapy water, rinse, and allow todry thoroughly, or clean innonflammable solvent andallow to dry.

Dip the foam air filter in cleanengine oil, then squeeze out allexcess oil. The engine willsmoke when started if too muchoil is left in the filter.

Wipe dirt from the air cleaner housing and cover using a moist rag.Be careful to prevent dirt from entering the air duct that leads to thecarburetor.

1.

2.

3.

2.Squeeze1.Soak 3.Oil 4.SqueezeDo not twist. Do not twist.

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41


SEDIMENT CUP CLEANING

BREATHER HOSE

AIR CLEANER BASE

6 mm BOLT

6 mm NUTS

Turn the fuel valve lever to the OFF position.

Remove the air cleaner cover, foam and paper air filter (see page ).

Disconnect the breather hose from the air cleaner base.

Remove the 6 mm bolt and two 6 mm nuts, and remove the aircleaner base.


1.

2.

3.

4.

5.

38

04/10/12 11:52:29 31ZS9700_042

42


SEDIMENT CUP

SEDIMENT CUP

O-RING(replace)

FILTER



Wash the sediment cup, O-ring and filter in nonflammable solvent,and dry them thoroughly.


Unscrew the sediment cup by turning it counterclockwise.

Reinstall the air cleaner base, and connect the breather hose withthe air cleaner base.

Reinstall the filter, new O-ring, and sediment cup.

Turn the fuel valve ON and check for leaks.

Close and latch the maintenance cover.

Reinstall the paper air filter and air cleaner cover.

6.

7.

8.

9.

10.

11.

12.

06/12/22 17:03:58 31ZS9700_043

43


Recommended spark plugs:

SPARK PLUG SERVICE

SPARK PLUGINSPECTION COVER

COVER SCREW

SPARK PLUG WRENCH

BPR5ES (NGK)W16EPR-U (DENSO)

Incorrect spark plugs can cause engine damage.

Remove the spark plug with a 13/16-inch spark plug wrench(commercially available).

Disconnect the spark plug cap, and remove any dirt from around thespark plug area.

Loosen the cover screw and remove the spark plug inspection cover.


If the engine is hot, allow it to cool before servicing the spark plug.

1.

2.

3.

4.

06/12/22 17:04:09 31ZS9700_044

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－－

－－

44


SEALING WASHER

0.028 0.031 in(0.7 0.8 mm)

Inspect the spark plug. Replaceit if the electrodes are worn or ifthe insulator is cracked,chipped, or fouled.

Measure the spark plugelectrode gap with a wire-typefeeler gauge. Correct the gap, ifnecessary, by carefully bendingthe side electrode.

The gap should be:

Make sure that the spark plug sealing washer is in good condition,and thread the spark plug in by hand to prevent cross-threading.

After the spark plug seats, tighten with a 13/16-inch spark plugwrench to compress the washer.

If reinstalling a used spark plug, tighten 1/8 1/4 turn after the sparkplug seats.If installing a new spark plug, tighten 1/2 turn after the spark plugseats.

A loose spark plug can overheat and damage the engine.Overtightening the spark plug can damage the threads in thecylinder head.

Attach the spark plug cap.

Reinstall the spark plug inspection cover and tighten the coverscrew.

Close and latch the maintenance cover.

0.028 0.031 in (0.7 0.8 mm)

7.

5.

6.

9.

8.

10.

11.

08/03/28 11:12:31 31ZS9700_045

45


SPARK ARRESTER SERVICE

6 mm BOLTS

REAR COVER

6 mm CAP NUTS

REAR HANDLE

6 mm BOLTS

8 mm BOLTS

UPPER MUFFLERPROTECTOR

REAR UNDER PLATE

WASHER

WASHER

6 mm BOLTS

LOWER MUFFLERPROTECTOR

The spark arrester must be serviced every 100 hours to keep itfunctioning as designed.

If the engine has been running, the muffler will be very hot. Allow themuffler to cool before servicing the spark arrester.

Remove the four 6 mm cap nuts, and remove the rear cover.

Remove the four 6 mm bolts, and remove the upper mufflerprotector.

Remove the lower muffler protector.

Remove the four 6 mm bolts, and remove the rear under plate.

Remove the four 8 mm bolts, and remove the rear handle.

1.

2.

3.

5.

4.

06/12/22 17:04:32 31ZS9700_046

46


5 mm BOLTS

EXHAUST TAIL PIPE

SPARK ARRESTER

Use a brush to remove carbon deposits from the spark arresterscreen.

Remove the three 5 mm bolts, and remove the exhaust tail pipe andthe spark arrester.

Be careful to avoid damaging the screen.

Install the spark arrester and the exhaust tail pipe in the reverseorder of removal.

Inspect the spark arrester screen for breaks, holes or tears. Replace itif necessary.

6.

7.

8.

9.

04/10/12 11:53:20 31ZS9700_047

47


LOWER MUFFLER PROTECTOR

HOOK

LOWERMUFFLERPROTECTOR

REAR COVER

OIL FILLER NECK

REAR HANDLE

RUBBER DRIPGUARD

OIL DRAIN NECK

REAR UNDER PLATEHOOK

UPPER MUFFLER PROTECTOR

Install the lower muffler protector, the rear under plate, and the rearhandle in the reverse order of removal.

Install the lower muffler protector inside the hook securely.

Install the upper muffler protector and the rear cover in the reverseorder of removal.When installing the rear cover, carefully fit the rubber drip guardaround the oil filler neck and oil drain neck.

10.

11.

08/03/28 11:19:50 31ZS9700_048

48

STORAGE

STORAGE PREPARATION

Cleaning

Fuel

Proper storage preparation is essential for keeping your generatortrouble-free and looking good. The following steps will help to keeprust and corrosion from impairing your generator’s function andappearance, and will make the engine easier to start when you use thegenerator again.

Wipe the generator with a moist cloth. After the generator has dried,touch up any damaged paint, and coat other areas that may rust with alight film of oil.

Gasoline will oxidize and deteriorate in storage. Old gasoline willcause hard starting, and it leaves gum deposits that clog the fuelsystem. If the gasoline in your generator deteriorates during storage,you may need to have the carburetor and other fuel systemcomponents serviced or replaced.

The length of time that gasoline can be left in your fuel tank andcarburetor without causing functional problems will vary with suchfactors as gasoline blend, your storage temperatures, and whether thefuel tank is partially or completely filled. The air in a partially filled fueltank promotes fuel deterioration. Very warm storage temperaturesaccelerate fuel deterioration. Fuel deterioration problems may occurwithin a few months, or even less if the gasoline was not fresh whenyou filled the fuel tank.

The does not cover fuel system damage orengine performance problems resulting from neglected storagepreparation.

You can extend fuel storage life by adding a gasoline stabilizer that isformulated for that purpose, or you can avoid fuel deteriorationproblems by draining the fuel tank and carburetor.

Distributor’s Limited Warranty

04/10/12 11:53:36 31ZS9700_049

49

STORAGE

Adding a Gasoline Stabilizer to Extend Fuel Storage Life

When adding a gasoline stabilizer, fill the fuel tank with fresh gasoline.If only partially filled, air in the tank will promote fuel deteriorationduring storage. If you keep a container of gasoline for refueling, besure that it contains only fresh gasoline.

Add gasoline stabilizer following the manufacturer’s instructions.

After adding a gasoline stabilizer, run the engine outdoors for 10minutes to be sure that treated gasoline has replaced the untreatedgasoline in the carburetor.

Stop the engine, and turn the fuel valve lever to the OFF position.

1.

2.

3.

07/06/26 13:03:45 31ZS9700_050

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50

STORAGE

Draining the Fuel Tank and Carburetor

DRAIN SCREW



Place an approved gasoline container below the sediment cup, anduse a funnel to avoid spilling fuel.

After all the fuel has drained into thecontainer, tighten the drain screwsecurely.

Loosen the carburetor drain screwand drain the gasoline from thecarburetor.

Place a suitable gasoline containerbelow the carburetor drain hose.



Close the maintenance cover.

Remove the sediment cup, then move the fuel valve lever to the ONposition (see pages ).

Allow the fuel to drain completely, then reinstall the sediment cup(see pages ).

1.

2.

3.

4.

5.

6.

7.

41 42

41 42

06/12/22 17:05:17 31ZS9700_051

－

51

STORAGE

Engine Preparation

Change the engine oil (see page ).

Pour a tablespoon (5 10 cc) of clean engine oil into the cylinder.

Remove the spark plug (see page ).

Reinstall the spark plug.

Slowly pull the starter grip until resistance is felt. At this point, thepiston is coming up on its compression stroke and both the intakeand exhaust valves are closed. Storing the engine in this positionwill help to protect it from internal corrosion. Return the starter gripgently.

Pull the starter grip several times to distribute the oil in the cylinder.

1.

2.

3.

6.

5.

4.

36

43

06/12/22 17:05:26 31ZS9700_052

52

STORAGE

STORAGE PRECAUTIONS

REMOVAL FROM STORAGE

If your generator will be stored with gasoline in the fuel tank andcarburetor, it is important to reduce the hazard of gasoline vaporignition.

If the cylinder was coated with oil during storage preparation, theengine may smoke briefly at startup. This is normal.

If the fuel was drained during storage preparation, fill the tank withfresh gasoline. If you keep a container of gasoline for refueling, besure that it contains only fresh gasoline. Gasoline oxidizes anddeteriorates over time, causing hard starting.

Check your generator as described in the BEFORE OPERATION chapterof this manual.

Do not use sheet plastic as a dust cover. A nonporous cover will trapmoisture around the generator, promoting rust and corrosion.

With the engine and exhaust system cool, cover the generator to keepout dust. A hot engine and exhaust system can ignite or melt somematerials.

Place the generator on a level surface. Tilting can cause fuel or oilleakage.

If possible, avoid storage areas with high humidity, because thatpromotes rust and corrosion.

Also avoid any area with a spark-producing electric motor, or wherepower tools are operated.

Select a well-ventilated storage area away from any appliance thatoperates with a flame, such as a furnace, water heater, or clothes dryer.

Unless all fuel has been drained from the fuel tank, leave the fuel valvelever in the OFF position to reduce the possibility of leakage.

04/10/12 11:54:12 31ZS9700_053

53

TRANSPORTING

If the generator has been running, allow the engine to cool for at least15 minutes before loading the generator on the transport vehicle. Ahot engine and exhaust system can burn you and can ignite somematerials.

Keep the generator level when transporting to reduce the possibility offuel leakage. Move the fuel valve lever to the OFF position.

04/10/12 11:54:16 31ZS9700_054

54

ENGINE PROBLEMS

Engine Will NotStart

Possible Cause Correction

TAKING CARE OF UNEXPECTED PROBLEMS

Check controlpositions.

Check fuel.

Check engine oillevel.

Remove andinspectspark plug.

Take generator toan authorizedAlphagenservicing dealer, orrefer to shopmanual.

Fuel valve leverOFF.Choke knob OPEN.

Engine switch OFF.

Out of fuel.Bad fuel; generatorstored withouttreating ordraining gasoline,or refueled withbad gasoline.Low oil levelcaused Oil Alert tostop engine.Spark plug faulty,fouled, orimproperly gapped.Spark plug wetwith fuel (floodedengine).Fuel filter clogged,carburetormalfunction,ignitionmalfunction,valves stuck, etc.

Turn lever ON.

Move to CLOSEDunless engine iswarm.Turn engine switchto ON.Refuel (p. 33).Drain fuel tank andcarburetor (p. 50).Refuel with freshgasoline (p. 33).

Add oil (p. 35).

Gap or replacespark plug (p. 43).

Dry and reinstallspark plug.

Replace or repairfaulty componentsas necessary.

2.

1.

3.

4.

5.

07/06/26 13:03:52 31ZS9700_055

55


Engine LacksPower

CorrectionPossible Cause

Air filter clogged.

Bad fuel; generatorstored withouttreating ordraining gasoline,or refueled withbad gasoline.Fuel filter clogged,carburetormalfunction,ignitionmalfunction,valves stuck, etc.

Check air filter.

Check fuel.

Take generator toan authorizedAlphagenservicing dealer, orrefer to shopmanual.

Clean or replaceair filter (p. 38).Drain fuel tank andcarburetor (p. 50).Refuel with freshgasoline (p. 33).


1.

2.

3.

04/10/12 11:54:30 31ZS9700_056

56


GENERATOR PROBLEMS

Possible Cause CorrectionNo Power at theDC Output Coupler

Output indicator isOFF, and overloadindicator is ON.

Setting differentvoltage connectedto the UPS.

Power cordconnected to UPSbattery string inreverse polarity.

Faulty generator.

Check outputand overloadindicator.

Check UPSbattery stringvoltagerequirement.

Check the powercord.

Take generatorto an authorizedAlphagenservicing dealer,or refer to shopmanual.

Check DC load.Stop and restartthe engine.Check the coolingair inlet. Stop andrestart the engine.Turn OFF theengine switch andset the voltageselector switch tothe same batterystring voltage ofthe UPS (p. 13).Make suregenerator positiveoutput side ofcoupler isconnected topositive terminalof UPS batterystring.Replace or repairfaulty componentsas necessary.

1.

2.

3.

4.

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57


Possible Cause CorrectionForced OutputFunction CannotBe Used

Overload indicatoris OFF.

The UPS batteryvoltage is not inthe tolerance levelfor the forcedoutput.

The protectionfunction isoperating or theoutput switch hasbeen used to stopthe generatoroutput.Faulty generator.

Check overloadindicator.

Check thevoltmeter.

Restart theengine.

Take generatorto an authorizedAlphagenservicing dealer,or refer to shopmanual.

Check that thepower cord fromthe UPS isconnected to theDC output coupler.If not, stop theengine andconnect the powercord to the DCoutput coupler.Check the UPSbattery voltage.Replace the UPSbattery with a newone if the UPSbattery voltage is0 2 V (P. 26).Check the UPSbattery voltage.Forced output willonly operate if thebattery voltage issufficient. (P. 26).To reset , stop andrestart the engine.


1.

2.

3.

4.

04/10/12 11:54:45 31ZS9700_058

58

TECHNICAL INFORMATION

Serial Number Location

TECHNICAL & CONSUMER INFORMATION

FRAME SERIAL NUMBER

Frame serial number:

Date purchased:

Record the frame serial number and date purchased in the spacesbelow. You will need this information when ordering parts, and whenmaking technical or warranty inquiries.

07/06/26 13:03:57 31ZS9700_059

59


Carburetor Modification for High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be toorich. Performance will decrease, and fuel consumption will increase. Avery rich mixture will also foul the spark plug and cause hard starting.Operation at an altitude that differs from that at which this engine wascertified, for extended periods of time, may increase emissions.

Even with carburetor modification, engine horsepower will decreaseabout 3.5% for each 1,000-foot (300-meter) increase in altitude. Theeffect of altitude on horsepower will be greater than this if nocarburetor modification is made.

When the carburetor has been modified for high altitude operation,the air/fuel mixture will be too lean for low altitude use. Operation ataltitudes below 5,000 feet (1,500 meters) with a modified carburetormay cause the engine to overheat and result in serious engine damage.For use at low altitudes, have your servicing dealer return thecarburetor to original factory specifications.

High altitude performance can be improved by specific modificationsto the carburetor. If you always operate your generator at altitudesabove 5,000 feet (1,500 meters), have your authorized Alphagenservicing dealer perform this carburetor modification. This engine,when operated at high altitude with the carburetor modifications forhigh altitude use, will meet each emission standard throughout itsuseful life.

04/10/12 11:54:59 31ZS9700_060

60


Emission Control System Information

Source of Emissions

Tampering and Altering

The U.S. and California Clean Air Acts

The combustion process produces carbon monoxide, oxides ofnitrogen, and hydrocarbons. Control of hydrocarbons and oxides ofnitrogen is very important because, under certain conditions, theyreact to form photochemical smog when subjected to sunlight. Carbonmonoxide does not react in the same way, but it is toxic.

Honda utilizes appropriate air/fuel ratios and other emissions controlsystems to reduce the emissions of carbon monoxide, oxides ofnitrogen, and hydrocarbons.Additionally, Honda fuel systems utilize components and controltechnologies to reduce evaporative emissions.

Removal or alteration of any part of intake, fuel, or exhaust systems.

Altering or defeating the governor linkage or speed-adjustingmechanism to cause the engine to operate outside its designparameters.

Tampering with or altering the emission control system may increaseemissions beyond the legal limit. Among those acts that constitutetampering are:

EPA and California regulations require all manufacturers to furnishwritten instructions describing the operation and maintenance ofemission control systems.

The following instructions and procedures must be followed in orderto keep the Honda engine emissions within the emission standards.

07/06/26 13:04:04 31ZS9700_061

61


Problems That May Affect Emissions

Replacement Parts

Maintenance

If you are aware of any of the following symptoms, have your engineinspected and repaired by your authorized Alphagen servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Afterburning (backfiring).

Black exhaust smoke or high fuel consumption.

The emission control systems on your Honda engine were designed,built, and certified to conform with EPA and California emissionregulations (models certified for sale in California). We recommendthe use of genuine Honda parts whenever you have maintenance done.These original-design replacement parts are manufactured to thesame standards as the original parts, so you can be confident of theirperformance. The use of replacement parts that are not of the originaldesign and quality may impair the effectiveness of your emissioncontrol system.

A manufacturer of an aftermarket part assumes the responsibility thatthe part will not adversely affect emission performance. Themanufacturer or rebuilder of the part must certify that use of the partwill not result in a failure of the engine to comply with emissionregulations.

Follow the MAINTENANCE SCHEDULE on page . Remember thatthis schedule is based on the assumption that your machine will beused for its designed purpose. Sustained high-load or high-temperature operation, or use in dusty conditions, will require morefrequent service.

32

07/06/26 13:04:11 31ZS9700_062

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－

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62


Air Index

An Air Index Information label is applied to engines certified to anemission durability time period in accordance with the requirementsof the California Air Resources Board.

The bar graph is intended to provide you, our customer, the ability tocompare the emissions performance of available engines. The lowerthe Air Index, the less pollution.

The durability description is intended to provide you with informationrelating to the engine’s emission durability period. The descriptiveterm indicates the useful life period for the engine’s emission controlsystem. See your Emission Control System Warranty for additionalinformation.

Descriptive TermModerate

Intermediate

Extended

Applicable to Emission Durability Period50 hours (0 80 cc, inclusive)

125 hours (greater than 80 cc)125 hours (0 80 cc, inclusive)250 hours (greater than 80 cc)300 hours (0 80 cc, inclusive)500 hours (greater than 80 cc)

1,000 hours (225 cc and greater)

08/03/28 11:20:07 31ZS9700_063

× × ×

－－

±±

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63


Specifications

Dimensions

Engine

Generator

Tuneup Specifications

ITEM SPECIFICATION MAINTENANCE

DCX3000ModelDescription codeLengthWidthHeightDry weight

ModelEngine typeDisplacement[Bore Stroke]Compression ratioEngine speed at 39.5V

at 52.5VCooling systemIgnition systemOil capacityFuel tank capacitySpark plug

Rated voltageDC output Rated current

Rated outputMaximum output

EAMJ25.9 in (657 mm)17.6 in (447 mm)21.9 in (557 mm)

117.9 lbs (53.5 kg)

GX2004-stroke, overhead valve, single cylinder

12.0 cu-in (196 cm )[2.68 2.13 in (68.0 54.0 mm)]

8.5:12,500 3,300 rpm2,800 3,600 rpm

Forced airTransistorized magneto

0.58 US qt (0.55 )3.51 US gal (13.3 )

BPR5ES (NGK)W16EPR-U (DENSO)

39.5/52.5 V70.8/53.3 A

2.8 kW3.0 kW

Spark plug gapValve clearance (cold)

Other specifications

Refer to page: 43See your authorizedAlphagen dealer

IN: 0.15 0.02 mmEX: 0.20 0.02 mm

No other adjustments needed.

Specifications may vary according to the types, and are subject tochange without notice.

0.028 0.031 in (0.7 0.8 mm)

08/03/28 11:20:25 31ZS9700_064

±±

× ×

－－

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64


SPECIFICATION

Tuneup Specifications

ITEM MAINTENANCE

Dimensions

Engine

Generator

Specifications

Specifications may vary according to the types, and are subject tochange without notice.

No other adjustments needed.

Spark plug gapValve clearance (cold)

Other specifications

IN: 0.15 0.02 mmEX: 0.20 0.02 mm

EAMJ25.9 in (657 mm)17.6 in (447 mm)21.9 in (557 mm)

117.3 lbs (53.2 kg)

GX2004-stroke, overhead valve, single cylinder

12.0 cu-in (196 cm )2.7 2.1 in (68 54 mm)

8.5:12,500 3,300 rpm

Forced airTransistorized magneto

0.58 US qt (0.55 )

2,800 3,600 rpm

3.51 US gal (13.3 )BPR5ES (NGK)

W16EPR-U (DENSO)

39.5/52.5 V70.8/53.3 A

2.8 kW3.0 kW

Refer to page: 43See your authorizedAlphagen dealer

Model

LengthWidthHeightDry weight

ModelEngine TypeDisplacementBore x StrokeCompression RatioEngine Speed at 39.5V

at 52.5VCooling SystemIgnition SystemOil CapacityFuel Tank CapacitySpark Plug

Rated voltageDC output Rated Ampere

Rated OutputMaximum Output

DCX3000

0.028 0.031 in (0.70 0.80 mm)

Power product description code

06/10/19 10:03:57 31ZS9700_065

65


Wiring Diagram

04/10/12 11:56:15 31ZS9700_066

66


CONSUMER INFORMATION

Shop Manual

Parts Catalog

Publications

This manual covers complete maintenance and overhaul procedures.It is intended to be used by a skilled technician.

This manual provides complete, illustrated parts lists.

These publications will give you additional information formaintaining and repairing your generator. You may order them fromyour Alphagen dealer.

04/10/12 11:56:23 31ZS9700_067

67

INDEX

A

B

C

D

....................................................................BEFORE OPERATION .20

.................................................................AIR CLEANER SERVICE .38.........................................................................................Air Index .62

........................................ARE YOU READY TO GET STARTED ? .20

.............................................................Carbon Monoxide Hazards .6................Carburetor Modification for High Altitude Operation .59

...........................................................................Check the Engine .21....................................................................................Choke Knob .14

.........................................................................................Cleaning .48....................................COMPONENT & CONTROL LOCATIONS .11

........................................................CONSUMER INFORMATION .65....................................................................................CONTROLS .13

.............................................................CONTROLS & FEATURES .11.....................................................Customer Service Information .66

.................................................................................DC Operation .23........................................................................DC Output Coupler .17

..........................................................DC Voltage Selector Switch .13

08/03/28 11:20:32 31ZS9700_068

68

INDEX

E

F

G.............................................................GENERATOR PROBLEMS .56

.....................................................................GENERATOR SAFETY .6...........................................................................Ground Terminal .17

......................................................................Eco-Throttle System .17....................................................................Electric Shock Hazards .7

........................................Emission Control System Information .60........................................................................Engine Preparation .51

...................................................................ENGINE OIL CHANGE .36...........................................................ENGINE OIL LEVEL CHECK .35

............................................ENGINE OIL RECOMMENDATIONS .37......................................................................ENGINE PROBLEMS .54

................................................................................Engine Switch .14

.....................................................................................FEATURES .17.....................................................................Fire and Burn Hazards .7

......................................................FOAM AIR FILTER CLEANING .40................................................................................Forced Output .26

.................................................................................................Fuel .48.....................................................................................Fuel Gauge .19

........................................................FUEL RECOMMENDATIONS .34............................................................................Fuel Valve Lever .13

08/03/28 11:20:37 31ZS9700_069

69

INDEX

I

K

M

O

Q

R

P

.....................................................................................Knowledge .20

..............................................................MAINTENANCE SAFETY .31.........................................................MAINTENANCE SCHEDULE .32

...........................................IMPORTANT SAFETY INFORMATION .6.............................................................................................INDEX .67

.....................................IS YOUR GENERATOR READY TO GO ? .20

...................................................................................Publications .65

..................QUICK REFERENCE INFORMATION .Inside back cover

....................................................................................REFUELING .33..............................................................................Refuel With Care .8

........................................................REMOVAL FROM STORAGE .52

..........................................................................Oil Alert Indicator .19...................................................................................OPERATION .22

..................................................................Operator Responsibility .6............................................................................Output Indicator .18

................................................................................Output Switch .16.........................................................................Overload Indicator .18

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70

INDEX

S

T

W

V

...............................TAKING CARE OF UNEXPECTED PROBLEMS .54.............................................................TECHNICAL INFORMATION .58

...................................TECHNICAL & CONSUMER INFORMATION .58..........................................THE IMPORTANCE OF MAINTENANCE .30

...............................................................................TRANSPORTING .53

...........................................................................................Voltmeter .17

.................................................................................Wiring Diagram .64

..................................................SAFE OPERATING PRECAUTIONS .22..............................................................SAFETY LABEL LOCATIONS .9

............................................................................Safety Precautions .31.............................................................SEDIMENT CUP CLEANING .41

...................................................................Serial Number Location .58.....................................................SERVICING YOUR GENERATOR .30

....................................................................................Specifications .63............................................................SPARK ARRESTER SERVICE .45

.....................................................................SPARK PLUG SERVICE .43........................................................................................Starter Grip .15

...................................................................STARTING THE ENGINE .23

...................................................................STOPPING THE ENGINE .28..........................................................................................STORAGE .48

...............................................................STORAGE PRECAUTIONS .52................................................................STORAGE PREPARATION .48

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INDEX

S

T

W

V...........................................................................................Voltmeter .17

..................................................SAFE OPERATING PRECAUTIONS .22..............................................................SAFETY LABEL LOCATIONS .9

............................................................................Safety Precautions .31.............................................................SEDIMENT CUP CLEANING .41

...................................................................Serial Number Location .58.....................................................SERVICING YOUR GENERATOR .30

....................................................................................Specifications .64............................................................SPARK ARRESTER SERVICE .45

.....................................................................SPARK PLUG SERVICE .43...................................................................STARTING THE ENGINE .23...................................................................STOPPING THE ENGINE .28

..........................................................................................STORAGE .48...............................................................STORAGE PRECAUTIONS .52................................................................STORAGE PREPARATION .48

...............................TAKING CARE OF UNEXPECTED PROBLEMS .54.............................................................TECHNICAL INFORMATION .58

...................................TECHNICAL & CONSUMER INFORMATION .58..........................................THE IMPORTANCE OF MAINTENANCE .30

...............................................................................TRANSPORTING .53

.................................................................................Wiring Diagram .65

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MEMO

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－－

QUICK REFERENCE INFORMATION

Unleaded gasoline with a pumpoctane rating of 86 or higher

Fuel

Spark Plug

Maintenance

Type

Type

Subsequent

Check engine oil level.Check air filter.Change engine oil.See Maintenance Schedule(page 32 )

BPR5ES (NGK)W16EPR-U (DENSO)0.028 0.031 in (0.7 0.8 mm)Electrode Gap

First 20 hours

Before each use

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generator safety refuel with care gasoline is extremely flammable, and gasoline vapor can explode....

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