DeVillbiss Air Power Company PowerBack GM1000 Troubleshooting guide

GENERAL MANUAL FOR
DeVILBISS GENERATORS
TABLE OF CONTENTS
WARRANTY STATEMENT ....................................... 2
SAFETY GUIDELINES - DEFINITIONS
SAFETY INSTRUCTIONS ..................................... 3-8
ASSEMBLY ......................................................... 9-10
OPERATION ...................................................... 11-12
MAINTENANCE ..................................................... 13
STORAGE .............................................................. 14
WATTAGE CALCULATING ............................... 15-17
TROUBLESHOOTING GUIDE ............................... 18
QUICK FACTS ................................... BACK COVER
•
•
This product is not equipped with a spark arresting muffler. If the product will be used around
flammable materials, or on land covered with materials such as agricultural crops, forest, brush, grass, or
other similar items, then an approved spark arrester must be installed and is legally required in the state of
California. It is a violation of California statutes section 130050 and/or sections 4442 and 4443 of the California Public Resources Code, unless the engine is equipped with a spark arrestor, as defined in section 4442,
and maintained in effective working order. Spark arresters are also required on some U. S. Forest service
land and may also be legally required under other statutes and ordinances.
This product may contain chemicals known to the state of California to cause cancer, birth defects, or other
reproductive harm. This warning is given in compliance with California Proposition 65, as detectable amounts
of chemicals subject to proposition 65 may be contained in this product.
MG-GENMAN-F 11/8/99
DeVilbiss Air Power Company • 213 Industrial Drive • Jackson, TN 38301-9615
LIMITED WARRANTY
ONE YEAR FROM DATE OF PURCHASE
All merchandise manufactured by DeVilbiss Air Power Company Manufacturing is warranted to be free of defects in
workmanship and material which occur during the first year from the date of purchase by the original purchaser (initial
user). Products covered under this warranty include: air compressors, *air tools, accessories, service parts, pressure
washers, and generators used in consumer applications (i.e., personal residential household usage only).
Air compressors, *air tools, accessories, service parts, pressure washers, and generators used in commercial applications (income producing) are covered by a 90 day warranty.
DeVilbiss Air Power Manufacturing will repair or replace, at DeVilbiss’ option, products or components which have
failed within the warranty period. Repair or replacement, and service calls on 60 and 80 gallon air compressors, will be
handled by Authorized Warranty Service Centers and will be scheduled and serviced according to the normal work
flow and business hours at the service center location, and depending on the availability of replacement parts.
All decisions of DeVilbiss Air Power Company Manufacturing with regard to this policy shall be final.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
RESPONSIBILITY OF ORIGINAL PURCHASER (Initial User):
❏
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Retain original cash register sales receipt as proof of purchase for warranty work.
Use reasonable care in the operation and maintenance of the product as described in the Owners Manual(s).
Deliver or ship the product to the nearest DeVilbiss Air Power Manufacturing Authorized Warranty Service
Center. Freight costs, if any, must be paid by the purchaser.
Air compressors with 60 and 80 gallon tanks only will be inspected at the site of installation. Contact the
nearest Authorized Warranty Service Center, that provides on-site service calls, for service call arrangement.
If the purchaser does not receive satisfactory results from the Authorized Warranty Service Center, the purchaser should contact DeVilbiss Air Power Company Manufacturing.
THIS WARRANTY DOES NOT COVER:
❏
❏
❏
❏
❏
❏
❏
❏
❏
Merchandise sold as reconditioned, floor models and/or display models. Any damaged or incomplete equipment sold "as is".
Merchandise used as "rental" equipment.
Merchandise that has become inoperative because of ordinary wear, misuse, freeze damage, use of improper
chemicals, negligence, accident, improper and/or unauthorized repair or alterations including failure to operate
the product in accordance with the instructions provided in the Owners Manual (s) supplied with the product.
*Air Tools: O-Rings and driver blades are considered ordinary wear parts, therefore, they are warranted for a
period of 45 days from the date of purchase.
An air compressor that pumps air more than 50% during a one hour period is considered misuse because the
air compressor is undersized for the required air demand. Maximum compressor pumping time per hour is 30
minutes.
Merchandise sold by DeVilbiss Air Power Manufacturing which has been manufactured by and identified as the
product of another company. The product manufacturer's warranty will apply.
Repair and transportation costs of merchandise determined not to be defective.
Cost associated with assembly, required oil, adjustments or other installation and start-up cost.
ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT
FROM ANY DEFECT, FAILURE OR MALFUNCTION OF THE PRODUCT. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not
apply to you.
IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.
213 Industrial Drive • Jackson, TN 38301-9615
Telephone: 1-800-888-2468 , Ext. 2
FAX: 1-800-888-9036
Form: SP-100-G - 9/29/99
MG-GENMAN-F
2 — ENG
SAFETY GUIDELINES - DEFINITIONS
This manual contains information
that is important for you to know
and understand. This information
relates to protecting YOUR
SAFETY and PREVENTING
EQUIPMENT PROBLEMS. To help
you recognize this information, we
use symbols to the right. Please
read the manual and pay attention
to these sections.
URGENT SAFETY INFORMATION - A HAZARD
THAT WILL CAUSE SERIOUS INJURY OR
LOSS OF LIFE.
IMPORTANT SAFETY INFORMATION - A
HAZARD THAT MIGHT CAUSE SERIOUS
INJURY OR LOSS OF LIFE.
Information for preventing damage to
equipment.
Information that you should pay special
attention to.
IMPORTANT SAFETY INSTRUCTIONS
• SAVE THESE INSTRUCTIONS •
When using this product basic precautions should always be followed
including the following:
RISK OF ELECTROCUTION AND FIRE
HAZARD
Attempting to connect generator
directly to the electrical system of
any building structure.
WHAT COULD HAPPEN
Back feeding electricity through a
building’s electrical system to the
outside utility feed lines could endanger repair persons attempting to
restore service.
Attempting to connect to the incoming utility service could result in
electrocution.
Restoration of electrical service while
the generator is connected to the
incoming utility could result in a fire or
serious damage if a isolator switch is
not installed.
HOW TO PREVENT IT
Never backfeed electricity through
a structure's electrical system.
To connect to a structure's electrical system in a safe manner,
always have a Double-Throw
Transfer Switch installed by a
qualified electrician and in compliance with local ordinances. (When
installing a Double-Throw
Transfer Switch, a minimum of
10 gauge wiring must be used.)
Failure to use a double throw transfer
switch when connecting to a
structure's electrical system can
damage appliances and WILL VOID
the manufacturer's warranty.
3 — ENG
MG-GENMAN-F
READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
RISK OF ELECTROCUTION AND FIRE (cont’d)
HAZARD
Operation of generator in rain, wet,
icy, or flooded conditions.
Use of worn damaged, undersized or
ungrounded extension cords.
Placing generator on or against highly
conductive surface, such as a steel
walkway or metal roof.
WHAT COULD HAPPEN
HOW TO PREVENT IT
Water is an excellent conductor of
Operate generator in a clean, dry,
electricity! Water which comes in
well ventilated area. Make sure
contact with electrically charged
hands are dry before touching unit.
components can transmit electricity to
the frame and other surfaces, resulting
in electrical shock to anyone contacting them.
Contact with worn or damaged
extension cords could result in
electrocution.
Inspect extension cords before
use and replace with new cord if
required.
Use of undersize extension cords
could result in overheating of the
wires or attached items, resulting in
fire.
Use proper size (wire gauge)
cordset for application see chart in
the Assembly section of this
manual.
Use of ungrounded cordsets could
prevent operation of circuit breakers
and result in electrical shock.
Always use a cordset having a
grounding wire with an appropriate
grounding plug. DO NOT use an
ungrounded plug.
Accidental leakage of electrical
current could charge conductive
surfaces in contact with the generator.
Place generator on low conductivity surface such as a concrete
slab.
ALWAYS operate generator a
minimum of six feet from any
conductive surface.
Improper connection of items to
generator.
Exceeding the load capacity of the
generator by attaching too many
items, or items with very high load
ratings to it could result in overheating
of some items or their attachment
wiring resulting in fire or electrical
shock.
Read the load rating chart and
instructions in the Wattage Calculation section. Make sure that the
summation of electrical loads for
all attachments does not exceed
the load rating of the generator.
Operation of unit when damaged, or
with guards or panels removed.
Attempting to use the unit when it has
been damaged, or when it is not
functioning normally could result in
fire or electrocution.
Do not operate generator with
mechanical or electrical problem.
Have unit repaired by an Authorized Service Center.
Removal of guarding could expose
electrically charged components and
result in electrocution.
Do not operate generator with
protective guarding removed.
MG-GENMAN-F
4 — ENG
READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
RISK OF FIRE
HAZARD
WHAT COULD HAPPEN
HOW TO PREVENT IT
Attempting to fill the fuel tank while the
engine is running.
Gasoline and gasoline vapors can
become ignited by coming in contact
with hot components such as the
muffler, engine exhaust gases, or from
an electrical spark.
Turn engine off and allow it to cool
before adding fuel to the tank. Equip
area of operation with a fire extinguisher certified to handle gasoline
or fuel fires.
Sparks, fire, hot objects
Cigarettes, sparks, fires, or other hot
objects can cause gasoline or gasoline vapors to ignite.
Add fuel to tank in well ventilated
area. Make sure there are no
sources of ignition near the generator.
Improper storage of fuel
Improperly stored fuel could lead to accidental ignition. Fuel improperly secured could get into the hands of children or other unqualified persons.
Store fuel in a OSHA approved container designed to hold gasoline.
Store container in secure location to
prevent use by others.
Inadequate ventilation for generator
Materials placed against or near the
generator or operating the generator in
areas where the temperature exceeds
104° F. ambient (such as storage rooms
or garages) can interfere with its proper
ventilation features causing overheating and possible ignition of the materials or buildings.
Operate generator in a clean, dry,
well ventilated area a minimum of
four feet from any building, object
or wall. DO NOT OPERATE UNIT
INDOORS OR IN ANY CONFINED
AREA.
Tampering with factory set engine
speed settings.
Engine speed has been factory set to
provide safe operation. Tampering with
the engine speed adjustment could result in overheating of attachments and
could cause a fire.
Never attempt to “speed-up” the
engine to obtain more performance.
Both the output voltage and frequency will be thrown out of standard by this practice, endangering
attachments and the user.
Overfilling the fuel tank – fuel spillage.
Spilled fuel and its vapors can become
ignited from hot surfaces or sparks.
Use care in filling the tank to avoid
spilling fuel. Make sure fuel cap is
secured tightly and check engine
for fuel leaks before starting
engine. Move generator away
from refueling area or any spillage
before starting engine. Allow for
fuel expansion. Keep maximum
fuel level ¼ inch below the tip of
the fuel tank. Never refuel with the
engine running.
5 — ENG
MG-GENMAN-F
READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
Risk of Injury and Property Damage When
Transporting Generator
WHAT COULD HAPPEN
HAZARD
Fire, Inhalation, Damage to Vehicle
Surfaces
Fuel or oil can leak or spill and could
result in fire or breathing hazard, serious injury or death can result. Fuel or
oil leaks will damage carpet, paint or
other surfaces in vehicles or trailers.
HOW TO PREVENT IT
If generator is equipped with a fuel
shut-off valve, turn the valve to the
off position before transporting to
avoid fuel leaks. If generator is not
equipped with a fuel shut-off valve,
drain the fuel from tank before transporting. Transport fuel only in an
OSHA approved container. Always
place generator on a protective mat
when transporting to protect against
damage to vehicle from leaks. Remove generator from vehicle immediately upon arrival at your destination
RISK OF BREATHING - INHALATION HAZARD
HAZARD
Gasoline engines produce toxic carbon
monoxide exhaust fumes.
MG-GENMAN-F
WHAT COULD HAPPEN
Breathing exhaust fumes will cause serious injury or death.
6 — ENG
HOW TO PREVENT IT
Operate generator in clean, dry, well
ventilated area. Never operate unit
in enclosed areas such as garages,
basements, storage, sheds, or in
any location occupied by humans or
animals. Keep children, pets and
others away from area of operating
unit.
READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
RISK OF UNSAFE OPERATION
HAZARD
Operation of generator in careless manner.
WHAT COULD HAPPEN
All sources of energy include the potential for injury. Unsafe operation or
maintenance of your generator could
lead to serious injury or death to you or
others.
HOW TO PREVENT IT
•
•
•
•
Operation of voltage sensitive appliances without a voltage surge protector.
Any gasoline operated household generator will incur voltage variations causing damage to voltage sensitive appliances or could result in fire.
Review and understand all of
the operating instructions and
warnings in this manual.
Become familiar with the
operation and controls of the
generator. Know how to shut it
off quickly.
Equip area of operation with a
fire extinguisher certified to
handle gasoline or fuel fires.
Keep children or others away
from the generator at all times.
Always use a U.L. listed voltage sensitive surge protector to connect
voltage sensitive appliances (TV,
computer, stereo, etc.). Failure to
use a U.L. listed voltage surge
protector will void the warranty on
your generator.
Notice: A multiple outlet strip is not
a surge protector make sure you use
a U.L. listed voltage surge protector.
Raising or suspending generators
equipped with lift rings improperly
Generator could fall causing serious injury or death to you or others.
Improper raising or suspending can
cause damage to the generator.
Always use proper connecting procedures as described in this manual
when connecting cables, chains, or
straps for raising or suspending generators equipped with lift rings.
Always use cables, chains, or straps
rated at 2000 lbs working load or
more to raise or suspend generator.
Operating generator while suspended
Generator will not operate properly and
will cause damage to the generator and
could cause serious injury or death to
you or others.
7 — ENG
Never operate generator while suspended or in an unlevel position.
Always operate generate on a flat,
level surface.
MG-GENMAN-F
READ AND UNDERSTAND ALL WARNINGS BEFORE
ATTEMPTING TO OPERATE GENERATOR.
RISK OF HOT SURFACES
HAZARD
Contact with hot engine and generator
components.
WHAT COULD HAPPEN
Contact with hot surfaces, such as engines exhaust components, could result in serious burns.
HOW TO PREVENT IT
During operation, touch only the
control surfaces of the generator.
Keep children away from the generator at all times. They may not be
able to recognize the hazards of this
product.
RISK OF MOVING PARTS
HAZARD
Contact with moving parts can result in
serious injury.
WHAT COULD HAPPEN
The generator contains parts which rotate at high speed during operation.
These parts are covered by guarding
to prevent injury.
HOW TO PREVENT IT
Never operate generator with guarding or cover plates removed. Avoid
wearing loose fitting clothing or jewelry which could be caught by moving parts.
RISK FROM LIFTING
HAZARD
Lifting a very heavy object.
MG-GENMAN-F
WHAT COULD HAPPEN
Serious injury can result from attempting to lift too heavy an object.
8 — ENG
HOW TO PREVENT IT
The generator is too heavy to be
lifted by one person. Obtain assistance from others before you try to
move it.
ASSEMBLY
TYPICAL INSTALLATION OF BATTERY
(Electric Start Units Only)
Read this manual. Do not attempt to operate
equipment until you have read this Manual for
Safety, Operation, and Maintenance Instructions.
NOTE: This manual is a general manual. Information
in this manual may or may not pertain to your model.
Please read carefully.
NOTE: Left and right describes the location of a part
with the operator facing the outlet panel.
REMOVE GENERATOR FROM CARTON
●
Recommended Battery for Electric Start: 12V - 45
A H. or 210 CCA (Cold Cranking Amps)
●
Purchase battery and battery hardware separately,
not included with unit.
1. Place battery in rack with terminals facing towards
generator head.
2. Place battery bracket (A) over battery as shown in
Figure 3 (opposite battery terminals).
3. Place "L" bolt (B) through top and bottom brackets
and secure with wing nut (C).
•
Open carton from top.
•
Cut carton along dotted lines.
•
Remove all carton inserts.
•
Remove generator through opening in carton.
•
(if equipped) Remove shipping block from under
the gen head by unscrewing the bolt and remove the
wood block. It is very important that this is removed
before starting your generator. See Figure 1.
Figure 3
To Prevent sparks connect the red (positive)
cable to the positive (+) terminal before connecting the black negative cable.
Figure 1
IMPORTANT: Before any attempt to start your generator
be sure to check engine oil (See Engine Operator's
manual)
GROUNDING THE GENERATOR
A grounding lug is supplied with the generator for use
when required by local electrical ordinances. Refer to
article 250 of the National Electrical Code to clarify any
needed grounding information. Your local electric
company or a certified electrician should be able to help
you with this information.
4. Locate the solenoid on the left side of the unit. See
Figure 4 and 5.
For GBE4010 and GBFE6010
5. Remove the nut from the solenoid post with the
panel assembly wire harness. Place one end of the
positive (red) battery cable onto this post with the
panel assembly wire. Reassemble nut and tighten
securely. See Figures 4.
Panel Assembly
Wire Harness
Solenoid
Grounding Lug
Figure 2
NOTE: Your engine is already grounded to the frame by
a grounding strap.
9 — ENG
Figure 4
MG-GENMAN-F
For GBV7000, GBV7010, GBVE8000
Extension Cords
5. Remove the nut from the solenoid post and place
one end of the positive (red) battery cable onto the
post. Reassemble nut and tighten securely. See
Figures 5.
When using an appliance or tool at a considerable
distance from the generator, a 3-wire extension cord that
has a 3-blade grounding plug and a 3-slot receptacle
that accepts the tool's plug MUST be used in order to
reduce the risk of electrical shock. A cord of adequate
size must be used. Using the following chart to determine the minimum wire size required.
Nut
Positive (+)
Battery Cable
Extension Cord Wire Gauge Chart
Cord
Length
Wire Gauge
Size
Amperage
0 to 100 ft.
12 ga.
*Up to 20 amp draw
0 to 100 ft.
10 ga.
Up to 30 amp draw
*NOTE: When amperage exceeds 20 amp; a 12 gauge
extension cord should not be used for long distances.
Solenoid
An extension cord that is hot to the touch is
overloaded. Repair or replace damaged extension cords immediately.
Figure 5
6. Attach the other end of the positive (red) battery
cable to the positive (+) terminal on the battery.
7. Attach one end of the negative (black) cable to the
negative (-) terminal on the battery.
Double Throw Transfer Switch
8. Attach the other end of the negative (black) cable to
the frame as shown. Install the star washer between
the cable and the frame. See Figure 6.
(-) Negative Battery
Cable Connection
Potential hazards exist when a portable electric generator is connected to the main electrical supply coming
into the house. It is at that point that the electrical
generator could feed back into the utility company's
system causing possible electrocution of workers who
are repairing the electrical lines.
To avoid back feeding of electricity into utility systems, a
double-throw transfer switch must be installed between
the generator and utility power. The Double-Throw
Transfer Switch should be installed by a licensed electrician and in compliance with all state and local electrical
codes. (When installing a Double-Throw Transfer
Switch, a minimum of 10 gauge wiring must be
used.)
Negative
(-) Battery
Cable
Star
Washer
The electrician should also install a sub-panel to isolate
the circuits you would want to use during an emergency
or electrical power outage. Your generator will not be
large enough to handle the load of all the lights, appliances, TV, etc. at one time. To select which items to run
during the electrical power outage, see Wattage Calculation section in this manual.
(-) Negative Battery Cable Connection
Figure 6
OBTAINING ELECTRICITY FROM THE
GENERATOR
There are basically 2 ways to obtain electricity from a generator:
1. Use of extension cords directly from the generator to
the appliance, lights, tools, etc.
2. Use of a double-throw transfer switch installed
directly to the main electrical supply outside of
house.
MG-GENMAN-F
10 — ENG
OPERATION
KNOW YOUR GENERATOR
Read this General Manual and Safety Rules before
operation of your Generator. Compare the illustration
in your parts manual with your generator to familiarize
yourself with the location of various controls and
adjustments. Save all manuals for future references.
GENERATOR CAPACITY
IMPORTANT: Exceeding the rated capacity of your
generator can result in serious damage to your generator and connected electrical devices. See the Wattage
Calculation section in this manual to assist you in
determining the appliances and tools that can be ran
with the wattage capacity of your generator.
CIRCUIT BREAKERS
Each receptacle has a circuit breaker to protect the
generator from overloading. If the circuit breaker trips,
unplug all electrical loads from the generator. Let the
circuit breaker cool down. Push circuit breaker button to
reset.
LOW OIL SHUTDOWN (if equipped)
Your generator engine is equipped with Low Oil Shutdown. Low Oil Shutdown is a safety device designed to
protect your engine from damage in the event the oil
level in the crankcase is low.
If while the engine is running, the oil gets low, it will
automatically shut itself down and will not restart until
the oil is added. If the oil is low before start-up, the
generator will not start until oil is added.
2. Check fuel level, fill as required. Make sure generator
is turned off and has been allowed time to cool down.
Use clean, fresh, regular unleaded gasoline with a
minimum of 85 octane. Do not mix oil with gasoline.
Never fill fuel tank completely. Fill tank to 1/2"
below the bottom of the filler neck to provide
space for fuel expansion. Wipe any fuel spillage
from engine and equipment before starting engine.
Never fill fuel tank indoors. Never fill fuel tank
when engine is running or hot. Do not smoke
when filling fuel tank.
Never run engine indoors or in enclosed, poor
ventilated areas, engine exhaust contains carbon
monoxide, an odorless and deadly gas.
3. Make sure generator is grounded in accordance with
local requirements.
4. All electrical loads MUST be disconnected.
5. (if equipped) Idle control switch must be in the OFF
position.
NOTE: The Low Oil Shutdown mechanism is very
sensitive. You must fill the engine to the full mark on the
dipstick to inactivate this safety device.
BEFORE START UP
Engine speed has been factory set to provide safe
operation. Tampering with the engine speed
adjustment could result in overheating of attachments and could cause a fire. Never attempt to
“speed-up” the engine to obtain more performance. Both the output voltage and frequency will
be thrown out of standard by this practice, endangering attachments and the user.
This generator has been shipped from the
factory without oil in the crankcase. Operating
the unit without oil can damage the engine.
You MUST unplug any load from the generator
before starting to prevent permanent damage to
any appliances.
Always check engine oil level before every start.
Running engine low of oil or out of oil could
result in serious damage to the engine.
Follow the steps listed below before starting generator:
1. Check engine oil. Refer to the Engine Operator's
Manual for correct grade and quantity of oil.
11 — ENG
MG-GENMAN-F
OPERATION
5. When engine starts, gradually move the choke to the
"NO Choke" position.
TO START THE ENGINE
(Recoil start/Pull start)
IMPORTANT: Allow generator to run at no load for 5
minutes upon each initial start-up to allow engine and
generator to stabilize.
Never run engine indoors or in enclosed, poor
ventilated areas, engine exhaust contains carbon
monoxide, an odorless and deadly gas.
STOPPING ENGINE
1. Open the fuel shut-off valve. Turn counter clockwise
until the valve stops. See Figure 7.
1. Disconnect all electrical loads.
2. (if equipped) Turn ON/OFF switch to "OFF" position.
3. Close fuel shut-off valve.
CONNECTING ELECTRICAL LOADS
1. Let engine run and warm up for five minutes after
starting with no electrical load.
Connect loads in the following manner to prevent
damage to equipment:
2. Connect inductive load equipment first, inductive
loads consist of refrigerators, freezers, water pumps,
air conditioners, or small hand tools. Connect the
items that require the most wattage first. See
Wattage Calculation Section in this manual.
3. Connect the lights next.
4. Voltage sensitive equipment should be the last
equipment connected to the generator. Plug voltage
sensitive appliances such at TV's, VCR's, microwaves, ovens, computers, and cordless telephones
into a UL listed voltage surge protector, then connect the UL listed voltage surge protector to the
generator.
OR
Figure 7
2. (if equipped) On the engine there is a ON/OFF
switch located on the front panel of the engine.
Place this switch to the "ON" position.
3. Move the choke control located on the engine to
"CHOKE" position.
NOTE: No choke is required on warm engines. Make
sure choke is in the "RUN" position on warm engine
starts.
4. Grasp handle on rope starter and pull slowly until
resistance is felt. Let the rope rewind slowly. Pull
rope with a rapid full arm stroke. Let rope rewind
slowly. Repeat if necessary.
NOTE: IF ENGINE OIL LEVEL IS TOO LOW, ENGINE
WILL NOT START. CHECK OIL LEVEL AND ADD IF
NECESSARY.
5. When engine starts, gradually move the choke to the
"RUN" position.
IMPORTANT: Allow generator to run at no load for 5
minutes upon each initial start-up to allow engine and
generator to stabilize.
TO START GENERATOR
(Electric start)
1. Open the fuel shut-off valve. See Figure 7.
2. (if equipped) On the engine there is a ON/OFF
switch located on the front panel of the engine.
Place this switch to the "ON" position.
3. Move the choke control located on the engine to
"CHOKE" position. A cold engine may require to be
choked longer than a warm engine.
4. Push ON\OFF\START switch on control panel to the
"START" position to start engine. Hold in "START"
position no longer than 15 seconds per minute when
trying to start engine. Extended cranking can damage the starter motor.
MG-GENMAN-F
Failure to connect and operate equipment in this
sequence can cause damage to equipment and
will void the warranty on your generator.
Follow the wattage calculation table in the
Wattage Calculation section of this manual.
Overloading the generator will cause power
fluctuations and can damage equipment and
appliances.
DeVilbiss Air Power Company will only be responsible for damage to customer's equipment
when the generator is determined to be defective. This determination will only be made by an
authorized representative of DeVilbiss Air Power
Company and this decision will be final.
DeVilbiss Air Power Company reserves the right
to inspect the electrical connections at the
customer's site of operation and test the generator for proper operation before any determination
of liability is made. Failure to maintain the equipment or wiring for inspection will void any claim
for damages by the customer. DeVilbiss Air
Power Company will not be responsible for
equipment damaged as a result of voltage
surges, improper operation or improper installation of the generator.
12 — ENG
1. Route cable, chain, or strap through both lift rings as
shown. ALWAYS use both lift rings when raising or suspending generator.
NOTE: Make sure the generator is in a level position
before raising or suspending to prevent damage.
CONNECTING PROCEDURE FOR RAISING OR
SUSPENDING GENERATORS EQUIPPED WITH
LIFT RINGS
Failure to properly connect lifting cables, chains,
or straps can cause property damage, serious
injury or death, and void the manufacturer's
warranty.
Always use cables, chains, or straps rated at 2000
lbs. working load or more to raise or suspend generator.
Lift Ring
Lift Ring
Never operate generator while suspended. This
could cause property damage, serious injury or
death.
MAINTENANCE
CUSTOMER RESPONSIBILITIES TABLE
Before each
use
Every 25
Hours of Every
Season
Every 50
Hours of Every
Season
Every 100
Hours of Every
Season
MAINTENANCE TASK
Check oil level
X
See Note 2
See Note 1
Change oil
Clean Air Filter Assembly
X
X
Check Spark Plug
Prepare Unit for Storage
X
Prepare unit for storage if it is to remain idle for more than 30 days.
Note 1: Change oil after first two (2) operating hours and every 50 operating hours thereafter, more often if operated in
extreme dusty or dirty conditions.
Note 2: Check oil after 5 hours of operation
GENERAL RECOMMENDATIONS
The warranty of the generator does not cover items that
have been subjected to operator abuse or negligence.
To receive full value from the warranty, operator must
maintain the generator as instructed in this manual.
ENGINE MAINTENANCE
Refer to the Engine Operator's manual for service and
maintenance of the engine.
GENERATOR MAINTENANCE
Your generator should be kept clean and dry at all
times. The generator should not be stored or operated
in environments that includes excessive moisture, dust
or any corrosive vapors. If these substances are on the
generator, clean with a cloth or soft bristle brush. Do not
use a garden hose or anything with water pressure to
clean the generator. Water may enter the cooling air
slots and could possibly damage the rotor, stator and
the internal windings of the gen head.
(if equipped) Ground Fault Circuit Interrupter
GFCI receptacle)
MONTHLY: For maximum protection against electrical
shock the GFCI should be tested monthly.
To test:
1. Depress the TEST button. The RESET button should
extend. If the RESET button does not extend, notify
a DeVilbiss Air Power Company Authorized Warranty
Service Center.
2. To restore power, depress the RESET button firmly
into the GFCI unit until an audible click is heard. If
reset properly, the RESET button is flush with the
surface of the test button. When the button stays in,
the power is ON.
13 — ENG
MG-GENMAN-F
STORAGE
If you are going to store your generator for more than 30
days, use the following information as a guide to prepare
the generator for storage.
6. Place rag over spark plug hole and pull the recoil a
few times to lubricate the combustion chamber.
7. Replace the spark plug, but do not connect the
spark plug wire.
NOTE: If a fuel stabilizer is not used, all gasoline must
be drained from the tank and carburetor to prevent gum
deposits from forming on these parts and causing
possible malfunction of the engine.
Never store generator with fuel in the tank indoors
or in enclosed, poorly ventilated areas, where
fumes can reach an open flame, spark or pilot light
as on a furnace, water heater, clothes dryer or
other gas appliances.
Generator
•
Clean the generator as outlined in the Maintenance
Section on this manual.
Engine Preparation
•
1. Add fuel stabilizer to fuel tank to minimize the
formation of fuel gum deposits during storage.
Check that cooling air slots and openings on generator are open and unobstructed.
Battery (Electric Start Units Only)
2. Run engine at least 10 minutes after adding stabilizer to allow it to enter the fuel system.
•
3. Next shut off engine.
NOTE: After storing battery for a long period of time it
may lose it's charge. If the battery loses it's charge,
manually start the engine with the battery connected.
The engine will recharge the battery as it runs.
4. Disconnect the spark plug wire and remove the
spark plug.
5. Add one teaspoon of oil through the spark plug hole.
MG-GENMAN-F
14 — ENG
Store battery as described by the battery manufacturer.
WATTAGE CALCULATIONS
IMPORTANT
Never exceed the rated capacity of your generator. Serious damage to the generator or appliance could result
from an overload.
1. Starting and running wattage requirements should always be calculated when matching a generators
wattage capacity to the appliance or tool.
2. There are two types of electrical appliances that can be powered by your generator:
A.
B.
C.
Items such as radios, light bulbs, television sets, and microwaves have a "resistive load". Starting
wattage and running wattage are the same.
Items such as refrigerators, air compressors, washer, dryer, and hand tools that use an electrical
motor have an "inductive load". Inductive load appliances and tools require approximately 2 to 4 times
the listed wattage for starting the equipment. This initial load only lasts for a few seconds on start-up
but is very important when figuring your total wattage to be used.
Always start your largest electric motor first, and then plug in other items, one at a time.
NOTE: On 120-volt loads the maximum starting wattage should NOT exceed one half of the rated generator
wattage. Example: a 5000 rated wattage generator = 2500 maximum starting wattage.
DETERMINING WATTAGE REQUIREMENTS
Before operating this generator list all of the appliances and/or tools that are going to operate at the same time. (Then
determine the starting wattage requirements and the running wattage requirements by following example and/or refer to
wattage calculator on page 16.)
1. First total the running wattage of all appliances and/or tools that will be operated at the same time.
Running Watts
Starting Watts
Example 1:
Lights
Television
Slow Cooker
=
=
=
TOTAL
100 Watts
300 Watts
250 Watts
=
0
0
0
650 Watts
0
2. Next the starting wattages of any appliances and/or tools that will start and stop during operation.
Running Watts
Example 2:
Starting Watts
Small Refrigerator
500 Watts
2000 Watts
TOTAL
500 Watts
2000 Watts
=
3. The running wattage of examples 1 & 2 totals 1150 watts. The starting wattage of the small refrigerator is 2000 watts
which is 1500 watts more than the running watts. Take this difference of 1500 starting watts from the refrigerator and
add to the total running watts of 1150.
Example 3:
1500 Starting Watts
1150 Running Watts
TOTAL
=
2650 Total Watts
Generator must have a maximum capacity of at least 2650 watts.
15 — ENG
MG-GENMAN-F
WATTAGE CALCULATIONS
STARTING WATTAGE REQUIREMENTS
1. Some appliances and tools will list on the motor name
plate the starting and running voltage and amperage
requirements. Use the following formula to convert
voltage and amperage to wattage:
Volts X Amp = Watts
Example 1: (Starting voltage and amperage for 1/3
HP furnace fan)
120 volts x 10 amps = 1200 watts
MG-GENMAN-F
2. To determine the approximate starting wattage requirement for most appliances and tools with inductive type
motors, multiply the wattage that was calculated by 2
to 4 times to assure adequate generator capacity. If
the nameplate information is not available use the
values on the following chart as a guide.
3. Remember that the starting and running wattage for
resistive loads are the same. (Example: a 100 watt
light bulb requires only 100 watts to start.) Most resistive loads will be listed in wattage. (Refer to page 11 for
wattage calculations.)
16 — ENG
WATTAGE CALCULATIONS
HOUSEHOLD WATTAGE CALCULATOR
DEVICES WITH HIGH STARTING (INDUCTIVE)LOADS
RUN WATTS
TIMES (X) START FACTOR
APPLIANCE OR
LOAD DEVICE*
TYPICAL DEVICE
WATTAGE**
TOTAL
750
x
3
REFRIGERATOR/
FREEZER
=
2250
=
380
x
2
FURNACE(GAS/OIL)
=
760
=
1490
x
3
AIR COND.(ROOM)
=
4470
=
560
x
6
WATER PUMP
=
3360
=
575
x
3-4
FAN
=
1725-2300
=
1000
x
5
JET PUMP
=
5000
=
HOT PLATE
=
2500
=
TELEVISION
=
250
=
MICROWAVE
=
800
=
SPACE HEATER
=
1800
=
WATER HEATER
=
3360
=
CAUTION !
DO NOT CONNECT VOLTAGE SENSITIVE
ELECTRONIC EQUIPMENT (TV SET, COMPUTER,
ETC.) DIRECTLY TO YOUR GENERATOR. IF YOU USE
THE GENERATOR TO POWER SENSITIVE EQUIPMENT
YOU MUST USE A U.L. LISTED VOLTAGE SURGE
PROTECTOR.
NOTICE: FAILURE TO USE A U.L. LISTED VOLTAGE
SURGE PROTECTOR WILL DAMAGE YOUR
EQUIPMENT AND VOID YOUR WARRANTY.
THE IDLE CONTROL MUST BE IN THE
OFF POSITION WHEN OPERATING
LARGE MOTOR LOADS (FREEZERS,
REFRIGERATORS,ETC.) OR VOLTAGE
SENSITIVE ELECTRONIC EQUIPMENT
(TV, COMPUTERS, ETC.)
*FOR PRODUCTS NOT
LISTED REFER TO
PAGE 14 FOR
CALCULATIONS
**AVERAGE VALUES ACTUAL INDIVIDUAL
DEVICE VOLTAGES MAY
BE HIGHER OR LOWER
LIGHTING
CAUTION!!
TIMES NUMBER
OF BULBS
WATTS
60 WATT BULBS
60
x
=
75 WATT BULBS
75
x
=
100 WATT BULBS
100
x
=
300 WATT BULBS
300
x
=
ELECTRIC LOAD GRAND TOTAL
THIS TOTAL MUST BE LESS THAN YOUR GENERATOR RATING
WATTAGE RATING OF YOUR GENERATOR
THIS TOTAL MUST BE GREATER THAN YOUR HOUSEHOLD WATTAGE LOAD
Rev. 9/8/99
17 — ENG
MG-GENMAN-F
TROUBLESHOOTING GUIDE
PROBLEM
Engine will not start
CAUSE
CORRECTION
1. Low on fuel or oil.
1. Add fuel or oil.
2. Ignition switch in "Off" position.
2. Turn to "ON" position
3. Faulty spark plug.
3. Replace spark plug.
4. Choke in wrong position.
4. Adjust choke accordingly.
5. Fuel shut-off valve in closed
position.
5. Open fuel shut-off valve.
6. Unit loaded during start-up.
6. Remove load from unit.
7. Spark plug wire loose.
7. Attach wire to spark plug.
1. Faulty receptacle.
1. Have Service Center replace.
2. Circuit breaker kicked out.
2. Depress and reset.
3. Defective capacitor.
3. Have Service Center replace
capacitor.
4. Faulty power cord.
4. Repair or replace cord.
5. GFCI switch breaker kicked out
(if equipped)
5. Depress and reset
Repeated circuit breaker tripping
1. Overload
2. Faulty cords or equipment.
1. Reduce load.
2. Check for damaged, bare, or
frayed wires on equipment.
Replace.
Generator overheating
1. Generator overloaded.
1. Reduce load.
2. Insufficient ventilation.
2. Move to adequate supply of
fresh air.
1. Faulty solenoid
1. Have Service Center replace.
2. Faulty idle control switch
2. Have Service Center replace.
3. Faulty windings in stator
3. Have Service Center replace.
4. Faulty circuit board
4. Have Service Center replace.
5. Faulty wire harness
5. Have Service Center replace
1. Faulty rectifier
1. Have Service Center replace.
2. Faulty windings in stator
2. Have Service Center replace.
3. Faulty wire harness
3. Have Service Center replace.
No electrical output
No auto idle (if equipped)
DC does not have power with the
circuit breaker depressed
(if equipped)
MG-GENMAN-F
18 — ENG
NOTES
19 — ENG
MG-GENMAN-F
Generator Quick Facts
CALL 1-800-888-2468 EXT. 2,1
TO FIND A LOCAL AUTHORIZED SERVICE CENTER NEAR YOU FOR
REPAIRS AND SERVICE PART PURCHASES.
ENGINE
GAS
ENGINE
OIL
WATTAGE
WIRING
Use clean, fresh gasoline with a minimum 87 octane rating. Do not add gasoline during or
immediately after use.
Refer to engine owner’s manual for oil recommendations.
Most generators are equipped with a low-oil shutdown. If the oil is low or if the Generator
is not level, the engine will not start.
Make wattage calculations before use. Refer to general operator’s manual for further
instructions.
Contact an electrician for any wiring instructions. If wiring into a house, a double-throw
transfer switch and a heavy duty cord set must be used.
Use a standard (12V) lawn and garden battery with a minimum of 45 A.H. or 210 CCA.
BATTERY
VOLT
REG.
The voltage and frequency are regulated by the rpm’s of the engine. Do not adjust the
throttle or governor to achieve higher performance. This will only alter the factory Pre-set
settings and damage anything connected to the generator.
Be sure a volt/amp surge protector is used when sensitive electronic equipment is used,
such as: televisions, computers, stereos, and etc… The damage of such equipment
without the use of a protector WILL NOT be covered under warranty.
ENGINE
Do not adjust or attempt maintenance without consulting engine manual or an authorized
engine service center.
Add stabilizer to fuel tank and run engine for 5 minutes before storage.
STORAGE When in long term storage, operate the generator every 60 days for at least 10 minutes
with a load on it. This will prevent the loss of residual magnetism that produces the
electricity.
Allow the generator to run 5 minutes at no load for the engine and the genhead to
stabilize.
Make sure the adequate size of extension cord is used. Refer to the Grounding
OPERATION
Instructions/Extension Cord section of the owners manual.
If the generator is operating equipment that is drawing half of the rated watts it is
considered 50% load. Using all of the rated watts is considered 100% load.
ALWAYS REFER TO THE MANUALS SUPPLIED WITH THIS UNIT
Call our Toll Free Number 1-800-888-2468, Ext 2, then 1,
to obtain the location of the nearest Authorized Service
Center for ordering repair parts and for warranty repairs.
When ordering repair parts from your local Authorized
Service Center, always give the following information:
• Model number of your product
• Part number and description of the item you wish to
purchase
Attach Sales Receipt Here.
Retain Original Sales Receipt as Proof of
Purchase for Warranty Repair Work.
WARRANTY
This product is covered by the DeVilbiss
one year limited warranty. The warranty
can be found on page 2 or is available upon
request.
DeVilbiss Air Power Company • 213 Industrial Drive • Jackson, TN 38301-9615