Alpha Works Inverter Generator Operator's Manual

Section 1: Safety Instructions and Warnings

1.1 Important Manual Information

Important information is distinguished by the following notes:

Symbol Usage: This manual contains important information for your safety and proper operation. Pay attention to sections marked with symbols.

WARNING: Indicates a certainty or strong possibility of personal injury or death if instructions are not followed.

NOTE: Provides helpful information.

The manufacturer continually seeks advancements in product design and quality. Minor variances may exist between your product and this manual. Consult your dealer if you have questions. This manual should be considered a permanent part of the product.

1.2 Safety Information

Fuel Is Highly Flammable And Poisonous

• Always turn off the engine when refueling.
• Never refuel while smoking or near an open flame.
• Take care not to spill fuel on the engine or muffler.
• If fuel is swallowed, inhaled, or gets in eyes, see a doctor immediately. Wash skin and change clothing if fuel spills on you.
• Keep the machine upright when operating or transporting to prevent fuel leaks.

Exhaust Fumes Are Poisonous

• Never operate this product in a closed area; it can cause unconsciousness and death. Always operate in a well-ventilated outdoor area.

Engine And Muffler May Be Hot

• Operate the generator in a safe area away from pedestrians or children.
• Avoid placing flammable materials near the exhaust outlet.
• Keep the generator at least 1m (3 ft) from buildings or other equipment to prevent overheating.
• Do not operate with a dust cover or other objects covering it.
• Cover the generator only after the engine and muffler have completely cooled down.
• Carry the generator only by its carrying handles.
• Do not place obstacles on the generator.

To Prevent Electric Shock

• Never operate the product in rain or snow.
• Never touch the generator with wet hands.

DANGER: USING A GENERATOR INDOORS CAN KILL YOU IN MINUTES. GENERATOR EXHAUST CONTAINS CARBON MONOXIDE. THIS IS A POISON YOU CANNOT SEE OR SMELL. NEVER USE INSIDE A HOME OR GARAGE, EVEN IF DOORS AND WINDOWS ARE OPEN. ONLY USE OUTSIDE AND FAR AWAY FROM WINDOWS, DOORS, AND VENTS.

Grounding

• Properly ground the generator to prevent electric shock. Connect the ground terminal to a ground electrode buried in the ground.
• Failure to properly ground the generator can result in electric shock.
• Always comply with electric load requirements.

Connection

Before connecting the generator to a building's electrical system, a licensed electrician must install an isolation (transfer) switch. This prevents backfeeding, which can electrocute or injure line maintenance personnel and damage the generator and building's electrical system.

WARNING: Always use proper approved electrical cords and comply with all electric codes. Do not use worn or damaged cords. Always use a GFCI (ground fault circuit interrupter) for damp locations. Always use a proper approved transfer switch.

Section 2: Controls and Features

2.1 Generator

Components:

• 1: Carrying handle
• 2: Vented Gas Cap
• 3: Recoil Starter
• 4: Control Panel
• 5: Spark plug
• 6: Exhaust and Spark Arrestor
• 7: Oil filler cap

2.2 Control Panel

The control panel includes:

• LOW IDLE MODE Switch: Controls engine speed based on electrical load for better fuel consumption and less noise. When OFF, the engine runs at 5000 rpm regardless of load.
• LED Indicators:
• Output Indicator (Green): Illuminates when the engine starts and produces power.
• Overload Alarm (Red): Illuminates when a connected device exceeds the generator's output capacity. The Output Indicator (Green) will turn off.
• Low Oil Alarm (Red): Illuminates when engine oil is low, and the engine will stop automatically. The engine will not restart until oil is added.
• 120V AC Outlets: For powering 120V loads up to 1600W continuous. A 120VAC twist lock receptacle is available for parallel connection.
• 5V DC USB Outlet: For charging devices.
• 12V 8A DC Output: For battery charging.
• 8A DC Circuit Breaker: Automatically turns off if current exceeds 8A. Reset by pushing the button.
• Multi-Switch: Controls fuel valve, choke, and engine switch. Rotate counter-clockwise from OFF to START, then pull recoil cord. After starting, rotate to RUN. Rotate clockwise to OFF to shut down.
• Ground Terminal: For grounding the generator.

To Reset the Generator:

1. Turn off and disconnect all connected electric devices.
2. Stop the engine.
3. Reduce the total wattage of connected devices within the rated output.
4. Ensure proper ventilation (at least 3ft clearance on all sides).
5. Restart the engine.

NOTE: The Overload Alarm may briefly illuminate when starting devices with high surge current (e.g., compressors, pumps, refrigerators). This is normal.

NOTE: If the Low Oil Alarm light flickers and the engine won't start, add engine oil before restarting.

NOTE: Operate the generator on a level surface. Avoid loose ground or inclines, which can prematurely activate the low oil shutdown feature.

Section 3: Getting Started

3.1 Unpacking the Generator

• Remove the generator from its packaging.
• WARNING: Packaging is flammable. Do not add fuel before removing from packaging.
• Inspect for shipping damage. Do not add fuel or attempt to start if damaged.
• Included items: Generator, Parallel output wire, Oil Funnel, RV Adaptor.

3.2 Adding Engine Oil

The generator is shipped without engine oil. Add oil before adding fuel or starting the engine.

1. Remove the side panel using a Phillips-head screwdriver.
2. Place the generator on a level surface. Do not tilt.
3. Remove the oil filler cap.
4. Using the provided funnel, fill with 0.42 quart of SAE 10W-30 or 10W-40 oil.
5. Check the oil level using the dipstick.
6. Replace the oil filler cap and secure the side panel.

Recommended engine oil: YAMALUBE 4 (10W-40), SAE 10W-30, 10W-40, SAE #30, SAE #20, SAE 10W.

3.3 Adding Fuel

WARNING: Do not overfill the tank. Fuel may overflow when it expands.

NOTE: Once fuel is added, the unit cannot be returned.

1. Use clean, fresh, regular unleaded fuel with a minimum octane rating of 85.
2. Do not mix oil with fuel.
3. Clean the area around the fuel cap.
4. Remove the fuel cap.
5. Ensure the fuel strainer is in place.
6. Slowly add fuel, not exceeding the red marker on the fuel filter.
7. Screw on the fuel cap and wipe off any spilled fuel.

NOTE: Use only unleaded gasoline. Leaded gasoline will damage internal engine parts. Ensure the fuel tank cap is tightened securely.

3.4 Starting the Engine

1. Turn the LOW IDLE MODE switch to OFF. The Economy Throttle switch can be turned ON after the engine starts and stabilizes.
2. Turn the air vent knob on the fuel tank cap to ON.
3. Turn the multi-switch to the START position.
4. Grasp the carrying handle firmly.
5. Pull the recoil starter slowly until engaged, then pull briskly.
6. After the engine starts, warm it up until it runs smoothly without the choke.

3.5 Stopping the Engine

1. Turn off and disconnect any electronic devices.
2. Turn the multi-switch to the OFF position.
3. Turn the air vent knob on the fuel tank cap to OFF.

Section 4: Electrical Connection

4.1 Capacity

Calculate running and starting watts needed for your devices. Refer to the Wattage Reference Guide (Section 4.5).

1. Select devices to run simultaneously.
2. Total their running watts.
3. Identify the highest starting wattage among these devices.
4. Add the highest starting wattage to the total running watts. Surge wattage is the power needed to start some electric motors.

4.2 Power Management

Use the formula: Volts x Amps = Watts.

To prolong generator and device life:

1. Start the generator with no load.
2. Allow the engine to stabilize.
3. Connect and turn on the device with the largest load first.
4. Allow the engine to stabilize.
5. Connect and turn on the next item.
6. Repeat for additional devices.

4.3 Connecting Electrical Loads

1. Allow the engine to stabilize and warm up after starting.
2. Ensure the generator's capacity (120V AC @ 7 Amps, 5V DC @ 8 Amps) is adequate for all loads. Group devices or use a separate generator if capacity is exceeded.
3. Connect 120V AC devices to the 120V AC outlets and 5V DC devices to the DC terminals.
4. Do not connect 3-phase loads.
5. Do not connect 50 Hz loads.
6. Do not overload the generator.

NOTE: The DC terminals are for charging 5V automotive-type batteries only.

4.4 Battery Charging

1. Start the engine and let it reach idle before connecting to the battery. Use the 12V DC outlet only.
2. Ensure the Throttle switch is OFF while charging.
3. Connect the red charger lead to the positive (+) battery terminal and the black lead to the negative (-) terminal. Do not reverse.
4. Connect leads securely to prevent disconnection due to vibration.
5. Charge the battery according to its owner's manual.
6. The DC Circuit Breaker will trip if current exceeds rated output. Reset by pressing the button.
7. Refer to the battery's owner's manual for charging times.

NOTE: Never start or stop the generator with electrical devices plugged in or turned on.

4.5 Wattage Reference Guide

These are estimates. Check your tool or appliance for exact wattage requirements. Operating voltage and frequency requirements should be checked prior to connecting equipment. Damage may occur if equipment is not designed for +/-10% voltage variation and +/-3 Hz frequency variation.

Your Power Needs:

Section 5: Maintenance

5.1 Periodic Maintenance

Regular inspection, adjustment, and lubrication ensure safe and efficient operation.

*Initial replacement of engine oil is after one month or 20 hours of operation.

5.2 Spark Plug Maintenance

Spark Plug Inspection:

1. Remove the cover.
2. Remove the spark plug cap and access cap.
3. Use the provided tool to remove the spark plug counterclockwise.
4. Check for discoloration. The porcelain insulator should be medium to light tan.
5. Check the spark plug type and gap. Adjust if necessary using a wire thickness gauge.
6. Install the spark plug, cap, cover, and screws.

WARNING: To prevent fire hazards, ensure no fuel is present in the spark plug area. To prevent electric shock, do not hold the spark plug lead while testing.

5.3 Engine Oil Replacement

Initial replacement is after one month or 20 hours of operation.

1. Place the generator on a level surface, warm up the engine, then stop it. Turn the Fuel Petcock knob and Fuel Tank Cap Air Vent knob to OFF.
2. Remove the cover.
3. Remove the oil filler cap.
4. Place an oil pan under the engine and tilt the generator to drain the oil completely.
5. Return the generator to a level surface.
6. NOTE: Do not tilt the generator when adding oil to avoid overfilling and engine damage.
7. Add engine oil to the upper level mark.

Recommended engine oil: YAMALUBE 4 (10W-40), SAE 10W-30 or 10W-40, SAE #30, SAE #20, SAE 10W.

Recommended engine oil grade: API Service SE type or higher.

Engine oil quantity: 0.4L (0.42 US qt).

7. Install the oil filler cap, cover, and screws.

5.4 Air Filter Maintenance

Perform every 6 months or 100 hours. Clean more frequently in dusty or wet conditions.

1. Remove the cover and air filter case cover.
2. Remove the foam element.
3. Wash the foam element in solvent and dry it.
4. Oil the foam element and squeeze out excess oil until it is damp but not dripping.
5. NOTE: Do not wring the foam element, as it may tear.
6. Insert the foam element into the air filter case, ensuring a proper seal to prevent air leaks.
7. NOTE: Never operate the engine without the foam element.
8. Install the air filter case cover, cover, and screws.

5.5 Muffler Screen and Spark Arrestor Maintenance

Perform every 6 months or 100 hours.

1. Remove the cover.
2. Loosen the bolt, then remove the muffler cap, muffler screen, and spark arrester.
3. Clean carbon deposits from the muffler screen and spark arrester using a wire brush. Use the brush lightly to avoid damage.
4. Check the muffler screen and spark arrester for damage; replace if necessary.
5. Install the spark arrester, muffler cap, and cover, then tighten the screws.

5.6 Fuel Filter Maintenance

Perform every 12 months or 300 hours.

1. Remove the fuel tank cap and filter.
2. Clean the filter with gasoline.
3. Replace the filter if damaged.
4. Wipe the filter and install it.
5. Install the fuel tank cap.

WARNING: Gasoline is flammable. Do not perform this maintenance while smoking or near an open flame.

Section 6: Storage

6.1 Long Term Storage

Follow these procedures to protect the generator during long-term storage:

1. Drain the fuel: Remove the fuel tank cap and siphon fuel into an approved container. Install the fuel tank cap.
2. WARNING: Gasoline is flammable. Wipe off spilled fuel immediately as it can damage surfaces.
3. Start the engine and let it run until it stops from lack of fuel.
4. Remove the cover. Drain fuel from the carburetor by loosening the drain screw. Tighten the drain screw.
5. Remove the dipstick and drain the engine oil. Tighten the dipstick.
6. Install the cover and tighten the screws.
7. Turn the fuel tank cap air vent knob to OFF.
8. Store the generator in a dry, well-ventilated place, covered.

Engine Protection:

1. Remove the spark plug. Pour about one tablespoon of SAE 10W-30 or 20W-40 motor oil into the spark plug hole. Reinstall the spark plug.
2. Recoil start the engine several times (with ignition off) to coat cylinder walls with oil.
3. Pull the recoil starter until compression is felt, then stop. This prevents cylinder and valve rusting.
4. Clean the generator's exterior and apply a rust inhibitor.
5. Store the generator in a dry, well-ventilated place, covered.
6. Keep the generator in a vertical position during storage, transport, or operation.

Section 7: Troubleshooting and Specifications

7.1 Troubleshooting Diagram

Engine Does Not Start:

• Check if the engine switch is ON and pull the recoil starter.
• If the oil warning light flickers (E), check engine oil level (F: OK, G: Low - add oil).
• If the oil warning light does not flicker (H), pull the recoil starter and check spark plug strength.
• WARNING: Ensure no fire hazard when checking spark plug. Avoid electric shock by not holding the spark plug lead.
• If spark is OK (I), check fuel line and air cleaner element for clogging (N). If clogged (O), clean or replace. If OK (P), consult a dealer (R).
• If spark is not present (J), check the spark plug (K). If incorrect, replace or adjust gap (L). If OK, clean the spark plug (M).

7.2 Fuel Filter Maintenance

Use this section to troubleshoot common errors.

Engine Won't Start:

• Fuel systems: No fuel supplied to combustion chamber.
• No fuel in tank: Supply fuel.
• Fuel in tank: Ensure fuel tank cap air vent knob and fuel cock knob are ON.
• Clogged fuel line: Clean fuel line.
• Clogged carburetor: Clean carburetor.
• Engine oil system insufficient: Oil level is low. Add engine oil.
• Electrical systems: Poor spark.
• Spark plug dirty: Remove carbon or wipe spark plug dry.
• Faulty ignition system: Consult a service center.

Generator Won't Produce Power:

• Safety device (DC protector) is OFF: Press the DC protector to ON.
• Safety device (AC) is OFF: Stop the engine, then restart.

Section 8: Specifications