GENERAL MANUAL FOR DeVILBISS GENERATORS · general manual for devilbiss generators table of contents warranty statement ..... 2 safety guidelines - definitions safety instructions

MG-GENMAN-F 11/8/99DeVilbiss Air Power Company • 213 Industrial Drive • Jackson, TN 38301-9615

GENERAL MANUAL FOR

DeVILBISS GENERATORS

TABLE OF CONTENTSWARRANTY STATEMENT ....................................... 2

SAFETY GUIDELINES - DEFINITIONSSAFETY 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 mu�er. If the product will be used around�ammable materials, or on land covered with materials such as agricultural crops, forest, brush, grass, orother similar items, then an approved spark arrester must be installed and is legally required in the state ofCalifornia. It is a violation of California statutes section 130050 and/or sections 4442 and 4443 of the Califor-nia Public Resources Code, unless the engine is equipped with a spark arrestor, as de�ned in section 4442,and maintained in e�ective working order. Spark arresters are also required on some U. S. Forest serviceland 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 otherreproductive harm. This warning is given in compliance with California Proposition 65, as detectable amountsof chemicals subject to proposition 65 may be contained in this product.

Allparts Equipment Inc 1-877-475-5660 www.allpartsinc.com June, 2011

2 — ENGMG-GENMAN-F

❏ 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 pur-

chaser should contact DeVilbiss Air Power Company Manufacturing.

❏ Merchandise sold as reconditioned, floor models and/or display models. Any damaged or incomplete equip-ment 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 operatethe 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 aperiod 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 theair compressor is undersized for the required air demand. Maximum compressor pumping time per hour is 30minutes.

❏ Merchandise sold by DeVilbiss Air Power Manufacturing which has been manufactured by and identified as theproduct 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 theexclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may notapply to you.

❏ IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULARPURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE. Some states do notallow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

LIMITED WARRANTYONE YEAR FROM DATE OF PURCHASE

All merchandise manufactured by DeVilbiss Air Power Company Manufacturing is warranted to be free of defects inworkmanship and material which occur during the first year from the date of purchase by the original purchaser (initialuser). Products covered under this warranty include: air compressors, *air tools, accessories, service parts, pressurewashers, 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 applica-tions (income producing) are covered by a 90 day warranty.

DeVilbiss Air Power Manufacturing will repair or replace, at DeVilbiss’ option, products or components which havefailed within the warranty period. Repair or replacement, and service calls on 60 and 80 gallon air compressors, will behandled by Authorized Warranty Service Centers and will be scheduled and serviced according to the normal workflow 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.

Form: SP-100-G - 9/29/99

THIS WARRANTY DOES NOT COVER:

RESPONSIBILITY OF ORIGINAL PURCHASER (Initial User):

213 Industrial Drive • Jackson, TN 38301-9615Telephone: 1-800-888-2468 , Ext. 2

FAX: 1-800-888-9036

3 — ENG MG-GENMAN-F

Attempting to connect generatordirectly to the electrical system ofany building structure.

Back feeding electricity through abuilding’s electrical system to theoutside utility feed lines could en-danger repair persons attempting torestore service.

Attempting to connect to the incom-ing utility service could result inelectrocution.

Restoration of electrical service whilethe generator is connected to theincoming utility could result in a fire orserious damage if a isolator switch isnot installed.

Failure to use a double throw transferswitch when connecting to astructure's electrical system candamage appliances and WILL VOIDthe manufacturer's warranty.

Never backfeed electricity througha structure's electrical system.

To connect to a structure's electri-cal system in a safe manner,always have a Double-ThrowTransfer Switch installed by aqualified electrician and in compli-ance with local ordinances. (Wheninstalling a Double-ThrowTransfer Switch, a minimum of10 gauge wiring must be used.)

HAZARD HOW TO PREVENT ITWHAT COULD HAPPEN

RISK OF ELECTROCUTION AND FIRE

When using this product basic precautions should always be followedincluding the following:

• SAVE THESE INSTRUCTIONS •

IMPORTANT SAFETY INSTRUCTIONS

SAFETY GUIDELINES - DEFINITIONS

URGENT SAFETY INFORMATION - A HAZARDTHAT WILL CAUSE SERIOUS INJURY ORLOSS OF LIFE.

IMPORTANT SAFETY INFORMATION - AHAZARD THAT MIGHT CAUSE SERIOUSINJURY OR LOSS OF LIFE.

Information for preventing damage to

equipment.

Information that you should pay special

attention to.

This manual contains informationthat is important for you to knowand understand. This informationrelates to protecting YOURSAFETY and PREVENTINGEQUIPMENT PROBLEMS. To helpyou recognize this information, weuse symbols to the right. Pleaseread the manual and pay attentionto these sections.


READ AND UNDERSTAND ALL WARNINGS BEFOREATTEMPTING TO OPERATE GENERATOR.

Use of worn damaged, undersized orungrounded extension cords.

Placing generator on or against highlyconductive surface, such as a steelwalkway or metal roof.

Improper connection of items togenerator.

Operation of unit when damaged, orwith guards or panels removed.

Contact with worn or damagedextension cords could result inelectrocution.

Use of undersize extension cordscould result in overheating of thewires or attached items, resulting infire.

Use of ungrounded cordsets couldprevent operation of circuit breakersand result in electrical shock.

Accidental leakage of electricalcurrent could charge conductivesurfaces in contact with the generator.

Exceeding the load capacity of thegenerator by attaching too manyitems, or items with very high loadratings to it could result in overheatingof some items or their attachmentwiring resulting in fire or electricalshock.

Attempting to use the unit when it hasbeen damaged, or when it is notfunctioning normally could result infire or electrocution.

Removal of guarding could exposeelectrically charged components andresult in electrocution.

Inspect extension cords beforeuse and replace with new cord ifrequired.

Use proper size (wire gauge)cordset for application see chart inthe Assembly section of thismanual.

Always use a cordset having agrounding wire with an appropriategrounding plug. DO NOT use anungrounded plug.

Place generator on low conductiv-ity surface such as a concreteslab.

ALWAYS operate generator aminimum of six feet from anyconductive surface.

Read the load rating chart andinstructions in the Wattage Calcu-lation section. Make sure that thesummation of electrical loads forall attachments does not exceedthe load rating of the generator.

Do not operate generator withmechanical or electrical problem.Have unit repaired by an Autho-rized Service Center.

Do not operate generator withprotective guarding removed.

RISK OF ELECTROCUTION AND FIRE (cont’d)


Operation of generator in rain, wet,icy, or flooded conditions.

Water is an excellent conductor ofelectricity! Water which comes incontact with electrically chargedcomponents can transmit electricity tothe frame and other surfaces, resultingin electrical shock to anyone contact-ing them.

Operate generator in a clean, dry,well ventilated area. Make surehands are dry before touching unit.



RISK OF FIRE

Turn engine off and allow it to coolbefore adding fuel to the tank. Equiparea of operation with a fire extin-guisher certified to handle gasolineor fuel fires.

Add fuel to tank in well ventilatedarea. Make sure there are nosources of ignition near the genera-tor.

Store fuel in a OSHA approved con-tainer designed to hold gasoline.Store container in secure location toprevent use by others.

Operate generator in a clean, dry,well ventilated area a minimum offour feet from any building, objector wall. DO NOT OPERATE UNITINDOORS OR IN ANY CONFINEDAREA.

Gasoline and gasoline vapors canbecome ignited by coming in contactwith hot components such as themuffler, engine exhaust gases, or froman electrical spark.

Cigarettes, sparks, fires, or other hotobjects can cause gasoline or gaso-line vapors to ignite.

Improperly stored fuel could lead to ac-cidental ignition. Fuel improperly se-cured could get into the hands of chil-dren or other unqualified persons.

Materials placed against or near thegenerator or operating the generator inareas where the temperature exceeds104° F. ambient (such as storage roomsor garages) can interfere with its properventilation features causing overheat-ing and possible ignition of the materi-als or buildings.

Attempting to fill the fuel tank while theengine is running.

Sparks, fire, hot objects

Improper storage of fuel

Inadequate ventilation for generator

Never attempt to “speed-up” theengine to obtain more performance.Both the output voltage and fre-quency will be thrown out of stan-dard by this practice, endangeringattachments and the user.

Use care in filling the tank to avoidspilling fuel. Make sure fuel cap issecured tightly and check enginefor fuel leaks before startingengine. Move generator awayfrom refueling area or any spillagebefore starting engine. Allow forfuel expansion. Keep maximumfuel level ¼ inch below the tip ofthe fuel tank. Never refuel with theengine running.

Engine speed has been factory set toprovide safe operation. Tampering withthe engine speed adjustment could re-sult in overheating of attachments andcould cause a fire.

Spilled fuel and its vapors can becomeignited from hot surfaces or sparks.

Tampering with factory set enginespeed settings.

Overfilling the fuel tank – fuel spillage.




RISK OF BREATHING - INHALATION HAZARD

Operate generator in clean, dry, wellventilated area. Never operate unitin enclosed areas such as garages,basements, storage, sheds, or inany location occupied by humans oranimals. Keep children, pets andothers away from area of operatingunit.

Breathing exhaust fumes will cause se-rious injury or death.

Gasoline engines produce toxic carbonmonoxide exhaust fumes.


Risk of Injury and Property Damage WhenTransporting Generator

If generator is equipped with a fuelshut-off valve, turn the valve to theoff position before transporting toavoid fuel leaks. If generator is notequipped with a fuel shut-off valve,drain the fuel from tank before trans-porting. Transport fuel only in anOSHA approved container. Alwaysplace generator on a protective matwhen transporting to protect againstdamage to vehicle from leaks. Re-move generator from vehicle imme-diately upon arrival at your destina-tion

Fuel or oil can leak or spill and couldresult in fire or breathing hazard, seri-ous injury or death can result. Fuel oroil leaks will damage carpet, paint orother surfaces in vehicles or trailers.

Fire, Inhalation, Damage to VehicleSurfaces




• Review and understand all ofthe operating instructions andwarnings in this manual.

• Become familiar with theoperation and controls of thegenerator. Know how to shut itoff quickly.

• Equip area of operation with afire extinguisher certified tohandle gasoline or fuel fires.

• Keep children or others awayfrom the generator at all times.

Always use a U.L. listed voltage sen-sitive surge protector to connectvoltage sensitive appliances (TV,computer, stereo, etc.). Failure touse a U.L. listed voltage surgeprotector will void the warranty onyour generator.

Notice: A multiple outlet strip is nota surge protector make sure you usea U.L. listed voltage surge protec-tor.

All sources of energy include the po-tential for injury. Unsafe operation ormaintenance of your generator couldlead to serious injury or death to you orothers.

Any gasoline operated household gen-erator will incur voltage variations caus-ing damage to voltage sensitive appli-ances or could result in fire.

Operation of generator in careless man-ner.

Operation of voltage sensitive appli-ances without a voltage surge protec-tor.

RISK OF UNSAFE OPERATION


Raising or suspending generatorsequipped with lift rings improperly

Generator could fall causing serious in-jury or death to you or others.

Improper raising or suspending cancause damage to the generator.

Always use proper connecting pro-cedures as described in this manualwhen connecting cables, chains, orstraps for raising or suspending gen-erators equipped with lift rings.

Always use cables, chains, or strapsrated at 2000 lbs working load ormore to raise or suspend generator.

Generator will not operate properly andwill cause damage to the generator andcould cause serious injury or death toyou or others.

Operating generator while suspended Never operate generator while sus-pended or in an unlevel position.Always operate generate on a flat,level surface.


RISK FROM LIFTING


The generator is too heavy to belifted by one person. Obtain assis-tance from others before you try tomove it.

Serious injury can result from attempt-ing to lift too heavy an object.

Lifting a very heavy object.


RISK OF MOVING PARTS


Never operate generator with guard-ing or cover plates removed. Avoidwearing loose fitting clothing or jew-elry which could be caught by mov-ing parts.

The generator contains parts which ro-tate at high speed during operation.These parts are covered by guardingto prevent injury.

Contact with moving parts can result inserious injury.


During operation, touch only thecontrol surfaces of the generator.Keep children away from the gen-erator at all times. They may not beable to recognize the hazards of thisproduct.

Contact with hot surfaces, such as en-gines exhaust components, could re-sult in serious burns.

Contact with hot engine and generatorcomponents.

RISK OF HOT SURFACES


ASSEMBLY

Read this manual. Do not attempt to operateequipment until you have read this Manual forSafety, Operation, and Maintenance Instructions.

NOTE: This manual is a general manual. Informationin this manual may or may not pertain to your model.Please read carefully.

NOTE: Left and right describes the location of a partwith the operator facing the outlet panel.

REMOVE GENERATOR FROM CARTON• 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 underthe gen head by unscrewing the bolt and remove thewood block. It is very important that this is removedbefore starting your generator. See Figure 1.

IMPORTANT: Before any attempt to start your generatorbe sure to check engine oil (See Engine Operator'smanual)

GROUNDING THE GENERATORA grounding lug is supplied with the generator for usewhen required by local electrical ordinances. Refer toarticle 250 of the National Electrical Code to clarify anyneeded grounding information. Your local electriccompany or a certified electrician should be able to helpyou with this information.

Figure 1

TYPICAL INSTALLATION OF BATTERY

(Electric Start Units Only)● 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 towardsgenerator head.

2. Place battery bracket (A) over battery as shown inFigure 3 (opposite battery terminals).

3. Place "L" bolt (B) through top and bottom bracketsand secure with wing nut (C).

To Prevent sparks connect the red (positive)cable to the positive (+) terminal before connect-ing the black negative cable.

4. Locate the solenoid on the left side of the unit. SeeFigure 4 and 5.

For GBE4010 and GBFE6010

5. Remove the nut from the solenoid post with thepanel assembly wire harness. Place one end of thepositive (red) battery cable onto this post with thepanel assembly wire. Reassemble nut and tightensecurely. See Figures 4.

Figure 3

Figure 4

Grounding Lug

Figure 2

NOTE: Your engine is already grounded to the frame bya grounding strap.

Panel AssemblyWire Harness

Solenoid


For GBV7000, GBV7010, GBVE8000

5. Remove the nut from the solenoid post and placeone end of the positive (red) battery cable onto thepost. Reassemble nut and tighten securely. SeeFigures 5.

Figure 5

Figure 6

OBTAINING ELECTRICITY FROM THEGENERATORThere are basically 2 ways to obtain electricity from a gen-erator:

1. Use of extension cords directly from the generator tothe appliance, lights, tools, etc.

2. Use of a double-throw transfer switch installeddirectly to the main electrical supply outside ofhouse.

Extension Cord Wire Gauge Chart

Amperage

*Up to 20 amp draw

Up to 30 amp draw

CordLength

0 to 100 ft.

0 to 100 ft.

Wire GaugeSize

12 ga.

10 ga.

*NOTE: When amperage exceeds 20 amp; a 12 gaugeextension cord should not be used for long distances.

Extension CordsWhen using an appliance or tool at a considerabledistance from the generator, a 3-wire extension cord thathas a 3-blade grounding plug and a 3-slot receptaclethat accepts the tool's plug MUST be used in order toreduce the risk of electrical shock. A cord of adequatesize must be used. Using the following chart to deter-mine the minimum wire size required.

An extension cord that is hot to the touch isoverloaded. Repair or replace damaged exten-sion cords immediately.

Potential hazards exist when a portable electric genera-tor is connected to the main electrical supply cominginto the house. It is at that point that the electricalgenerator could feed back into the utility company'ssystem causing possible electrocution of workers whoare repairing the electrical lines.

To avoid back feeding of electricity into utility systems, adouble-throw transfer switch must be installed betweenthe generator and utility power. The Double-ThrowTransfer Switch should be installed by a licensed electri-cian and in compliance with all state and local electricalcodes. (When installing a Double-Throw TransferSwitch, a minimum of 10 gauge wiring must beused.)

The electrician should also install a sub-panel to isolatethe circuits you would want to use during an emergencyor electrical power outage. Your generator will not belarge enough to handle the load of all the lights, appli-ances, TV, etc. at one time. To select which items to runduring the electrical power outage, see Wattage Calcu-lation section in this manual.

Double Throw Transfer Switch

Positive (+)Battery Cable

Solenoid

6. Attach the other end of the positive (red) batterycable to the positive (+) terminal on the battery.

7. Attach one end of the negative (black) cable to thenegative (-) terminal on the battery.

8. Attach the other end of the negative (black) cable tothe frame as shown. Install the star washer betweenthe cable and the frame. See Figure 6.

Nut

(-) Negative Battery Cable Connection

StarWasher

Negative(-) Battery

Cable

(-) Negative BatteryCable Connection


OPERATION

KNOW YOUR GENERATORRead this General Manual and Safety Rules beforeoperation of your Generator. Compare the illustrationin your parts manual with your generator to familiarizeyourself with the location of various controls andadjustments. Save all manuals for future references.

GENERATOR CAPACITYIMPORTANT: Exceeding the rated capacity of yourgenerator can result in serious damage to your genera-tor and connected electrical devices. See the WattageCalculation section in this manual to assist you indetermining the appliances and tools that can be ranwith the wattage capacity of your generator.

CIRCUIT BREAKERSEach receptacle has a circuit breaker to protect thegenerator from overloading. If the circuit breaker trips,unplug all electrical loads from the generator. Let thecircuit breaker cool down. Push circuit breaker button toreset.

LOW OIL SHUTDOWN (if equipped)Your generator engine is equipped with Low Oil Shut-down. Low Oil Shutdown is a safety device designed toprotect your engine from damage in the event the oillevel in the crankcase is low.

If while the engine is running, the oil gets low, it willautomatically shut itself down and will not restart untilthe oil is added. If the oil is low before start-up, thegenerator will not start until oil is added.

NOTE: The Low Oil Shutdown mechanism is verysensitive. You must fill the engine to the full mark on thedipstick to inactivate this safety device.

2. Check fuel level, fill as required. Make sure generatoris turned off and has been allowed time to cool down.Use clean, fresh, regular unleaded gasoline with aminimum 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 providespace for fuel expansion. Wipe any fuel spillagefrom engine and equipment before starting en-gine.

Never fill fuel tank indoors. Never fill fuel tankwhen engine is running or hot. Do not smokewhen filling fuel tank.

Never run engine indoors or in enclosed, poorventilated areas, engine exhaust contains carbonmonoxide, an odorless and deadly gas.

3. Make sure generator is grounded in accordance withlocal requirements.

4. All electrical loads MUST be disconnected.

5. (if equipped) Idle control switch must be in the OFFposition.

Engine speed has been factory set to provide safeoperation. Tampering with the engine speedadjustment could result in overheating of attach-ments and could cause a fire. Never attempt to“speed-up” the engine to obtain more perfor-mance. Both the output voltage and frequency willbe thrown out of standard by this practice, endan-gering attachments and the user.

You MUST unplug any load from the generatorbefore starting to prevent permanent damage toany appliances.

BEFORE START UP

This generator has been shipped from thefactory without oil in the crankcase. Operatingthe unit without oil can damage the engine.

Always check engine oil level before every start.Running engine low of oil or out of oil couldresult in serious damage to the engine.

Follow the steps listed below before starting generator:

1. Check engine oil. Refer to the Engine Operator'sManual for correct grade and quantity of oil.


TO START THE ENGINE(Recoil start/Pull start)

Never run engine indoors or in enclosed, poorventilated areas, engine exhaust contains carbonmonoxide, an odorless and deadly gas.

1. Open the fuel shut-off valve. Turn counter clockwiseuntil the valve stops. See Figure 7.

2. (if equipped) On the engine there is a ON/OFFswitch 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. Makesure choke is in the "RUN" position on warm enginestarts.

4. Grasp handle on rope starter and pull slowly untilresistance is felt. Let the rope rewind slowly. Pullrope with a rapid full arm stroke. Let rope rewindslowly. Repeat if necessary.

NOTE: IF ENGINE OIL LEVEL IS TOO LOW, ENGINEWILL NOT START. CHECK OIL LEVEL AND ADD IFNECESSARY.

5. When engine starts, gradually move the choke to the"RUN" position.

IMPORTANT: Allow generator to run at no load for 5minutes upon each initial start-up to allow engine andgenerator 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/OFFswitch 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 bechoked 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 whentrying to start engine. Extended cranking can dam-age the starter motor.

OPERATION

OR

Figure 7

5. When engine starts, gradually move the choke to the"NO Choke" position.

IMPORTANT: Allow generator to run at no load for 5minutes upon each initial start-up to allow engine andgenerator to stabilize.

STOPPING ENGINE1. Disconnect all electrical loads.

2. (if equipped) Turn ON/OFF switch to "OFF" position.

3. Close fuel shut-off valve.

CONNECTING ELECTRICAL LOADS1. Let engine run and warm up for five minutes after

starting with no electrical load.

Connect loads in the following manner to preventdamage to equipment:

2. Connect inductive load equipment first, inductiveloads consist of refrigerators, freezers, water pumps,air conditioners, or small hand tools. Connect theitems that require the most wattage first. SeeWattage Calculation Section in this manual.

3. Connect the lights next.

4. Voltage sensitive equipment should be the lastequipment connected to the generator. Plug voltagesensitive appliances such at TV's, VCR's, micro-waves, ovens, computers, and cordless telephonesinto a UL listed voltage surge protector, then con-nect the UL listed voltage surge protector to thegenerator.

Failure to connect and operate equipment in thissequence can cause damage to equipment andwill void the warranty on your generator.

Follow the wattage calculation table in theWattage Calculation section of this manual.Overloading the generator will cause powerfluctuations and can damage equipment andappliances.

DeVilbiss Air Power Company will only be re-sponsible for damage to customer's equipmentwhen the generator is determined to be defec-tive. This determination will only be made by anauthorized representative of DeVilbiss Air PowerCompany and this decision will be final.DeVilbiss Air Power Company reserves the rightto inspect the electrical connections at thecustomer's site of operation and test the genera-tor for proper operation before any determinationof liability is made. Failure to maintain the equip-ment or wiring for inspection will void any claimfor damages by the customer. DeVilbiss AirPower Company will not be responsible forequipment damaged as a result of voltagesurges, improper operation or improper installa-tion of the generator.


MAINTENANCE

GENERAL RECOMMENDATIONSThe warranty of the generator does not cover items thathave been subjected to operator abuse or negligence.To receive full value from the warranty, operator mustmaintain the generator as instructed in this manual.

ENGINE MAINTENANCERefer to the Engine Operator's manual for service andmaintenance of the engine.

GENERATOR MAINTENANCEYour generator should be kept clean and dry at alltimes. The generator should not be stored or operatedin environments that includes excessive moisture, dustor any corrosive vapors. If these substances are on thegenerator, clean with a cloth or soft bristle brush. Do notuse a garden hose or anything with water pressure toclean the generator. Water may enter the cooling air

slots and could possibly damage the rotor, stator andthe internal windings of the gen head.

(if equipped) Ground Fault Circuit InterrupterGFCI receptacle)MONTHLY: For maximum protection against electricalshock 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, notifya DeVilbiss Air Power Company Authorized WarrantyService Center.

2. To restore power, depress the RESET button firmlyinto the GFCI unit until an audible click is heard. Ifreset properly, the RESET button is flush with thesurface of the test button. When the button stays in,the power is ON.

Note 1: Change oil after first two (2) operating hours and every 50 operating hours thereafter, more often if operated inextreme dusty or dirty conditions.Note 2: Check oil after 5 hours of operation

CUSTOMER RESPONSIBILITIES TABLE

MAINTENANCE TASK

Before eachuse

X

Every 25Hours of EverySeason

See Note 2

XX


See Note 1


X

Check oil level

Change oil

Clean Air Filter Assembly

Check Spark Plug

Prepare Unit for Storage Prepare unit for storage if it is to remain idle for more than 30 days.

CONNECTING PROCEDURE FOR RAISING ORSUSPENDING GENERATORS EQUIPPED WITHLIFT RINGS

Failure to properly connect lifting cables, chains,or straps can cause property damage, seriousinjury or death, and void the manufacturer'swarranty.

Always use cables, chains, or straps rated at 2000lbs. working load or more to raise or suspend gen-erator.

Never operate generator while suspended. Thiscould cause property damage, serious injury ordeath.

Lift RingLift Ring

1. Route cable, chain, or strap through both lift rings asshown. ALWAYS use both lift rings when raising or sus-pending generator.

NOTE: Make sure the generator is in a level positionbefore raising or suspending to prevent damage.


STORAGE

If you are going to store your generator for more than 30days, use the following information as a guide to preparethe generator for storage.

Never store generator with fuel in the tank indoorsor in enclosed, poorly ventilated areas, wherefumes can reach an open flame, spark or pilot lightas on a furnace, water heater, clothes dryer orother gas appliances.

Engine Preparation

1. Add fuel stabilizer to fuel tank to minimize theformation of fuel gum deposits during storage.

2. Run engine at least 10 minutes after adding stabi-lizer to allow it to enter the fuel system.

3. Next shut off engine.

4. Disconnect the spark plug wire and remove thespark plug.

5. Add one teaspoon of oil through the spark plug hole.

6. Place rag over spark plug hole and pull the recoil afew times to lubricate the combustion chamber.

7. Replace the spark plug, but do not connect thespark plug wire.

NOTE: If a fuel stabilizer is not used, all gasoline mustbe drained from the tank and carburetor to prevent gumdeposits from forming on these parts and causingpossible malfunction of the engine.

Generator

• Clean the generator as outlined in the MaintenanceSection on this manual.

• Check that cooling air slots and openings on genera-tor are open and unobstructed.

Battery (Electric Start Units Only)

• Store battery as described by the battery manufac-turer.

NOTE: After storing battery for a long period of time itmay 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.


Never exceed the rated capacity of your generator. Serious damage to the generator or appliance could resultfrom an overload.

1. Starting and running wattage requirements should always be calculated when matching a generatorswattage capacity to the appliance or tool.

2. There are two types of electrical appliances that can be powered by your generator:

A. Items such as radios, light bulbs, television sets, and microwaves have a "resistive load". Startingwattage and running wattage are the same.

B. Items such as refrigerators, air compressors, washer, dryer, and hand tools that use an electricalmotor have an "inductive load". Inductive load appliances and tools require approximately 2 to 4 timesthe listed wattage for starting the equipment. This initial load only lasts for a few seconds on start-upbut is very important when figuring your total wattage to be used.

C. 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 generatorwattage. Example: a 5000 rated wattage generator = 2500 maximum starting wattage.

IMPORTANT

DETERMINING WATTAGE REQUIREMENTS

Before operating this generator list all of the appliances and/or tools that are going to operate at the same time. (Thendetermine the starting wattage requirements and the running wattage requirements by following example and/or refer towattage 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 = 100 Watts 0Television = 300 Watts 0Slow Cooker = 250 Watts 0

TOTAL = 650 Watts 0

2. Next the starting wattages of any appliances and/or tools that will start and stop during operation.

Running Watts Starting Watts

Example 2: 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 wattswhich is 1500 watts more than the running watts. Take this difference of 1500 starting watts from the refrigerator andadd to the total running watts of 1150.

Example 3: 1500 Starting Watts1150 Running Watts

TOTAL = 2650 Total Watts

Generator must have a maximum capacity of at least 2650 watts.

WATTAGE CALCULATIONS


STARTING WATTAGE REQUIREMENTS

1. Some appliances and tools will list on the motor nameplate the starting and running voltage and amperagerequirements. Use the following formula to convertvoltage 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

2. To determine the approximate starting wattage require-ment for most appliances and tools with inductive typemotors, multiply the wattage that was calculated by 2to 4 times to assure adequate generator capacity. Ifthe nameplate information is not available use thevalues on the following chart as a guide.

3. Remember that the starting and running wattage forresistive loads are the same. (Example: a 100 wattlight bulb requires only 100 watts to start.) Most resis-tive loads will be listed in wattage. (Refer to page 11 forwattage calculations.)



HOUSEHOLD WATTAGE CALCULATOR


APPLIANCE OR LOAD DEVICE*

REFRIGERATOR/ FREEZER

750

FURNACE(GAS/OIL)

AIR COND.(ROOM)

WATER PUMP

380

TELEVISION CAUTION!!

HOT PLATE

MICROWAVE

SPACE HEATER

1490

560

3

6

LIGHTING

60 WATT BULBS

75 WATT BULBS

100 WATT BULBS

300 WATT BULBS

ELECTRIC LOAD GRAND TOTAL

THIS TOTAL MUST BE LESS THAN YOUR GENERATOR RATING

WATTAGE RATING OF YOUR GENERATOR

TOTAL

THIS TOTAL MUST BE GREATER THAN YOUR HOUSEHOLD WATTAGE LOAD

TYPICAL DEVICE WATTAGE**

2250

760

4470

3360

250

2500

800

1800

WATER HEATER 3360

TIMES NUMBER OF BULBS

60

75

100

300

CAUTION !

WATTS

DEVICES WITH HIGH STARTING (INDUCTIVE)LOADS

RUN WATTS TIMES (X) START FACTOR

DO NOT CONNECT VOLTAGE SENSITIVE

ELECTRONIC EQUIPMENT (TV SET, COMPUTER,ETC.) DIRECTLY TO YOUR GENERATOR. IF YOU USE THE GENERATOR TO POWER SENSITIVE EQUIPMENTYOU MUST USE A U.L. LISTED VOLTAGE SURGE PROTECTOR.

NOTICE:

FAILURE TO USE A U.L. LISTED VOLTAGESURGE PROTECTOR WILL DAMAGE YOUR EQUIPMENT AND VOID YOUR WARRANTY.

2

3

THE IDLE CONTROL MUST BE IN THEOFF POSITION WHEN OPERATING LARGE MOTOR LOADS (FREEZERS, REFRIGERATORS,ETC.) OR VOLTAGE SENSITIVE ELECTRONIC EQUIPMENT (TV, COMPUTERS, ETC.)

FAN575 3-4 1725-2300

JET PUMP1000 5 5000

*FOR PRODUCTS NOT LISTED REFER TO

PAGE 14 FORCALCULATIONS

**AVERAGE VALUES -ACTUAL INDIVIDUAL

DEVICE VOLTAGES MAYBE HIGHER OR LOWER

x

x

x

x

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

x

x

x

x

x

x

=

=

=

=

=

=

=

=

=

=

=

Rev. 9/8/99


PROBLEM CAUSE CORRECTION

Engine will not start

No electrical output

Repeated circuit breaker tripping

Generator overheating

No auto idle (if equipped)

DC does not have power with thecircuit breaker depressed(if equipped)

1. Low on fuel or oil.

2. Ignition switch in "Off" position.

3. Faulty spark plug.

4. Choke in wrong position.

5. Fuel shut-off valve in closedposition.

6. Unit loaded during start-up.

7. Spark plug wire loose.

1. Faulty receptacle.

2. Circuit breaker kicked out.

3. Defective capacitor.

4. Faulty power cord.

5. GFCI switch breaker kicked out(if equipped)

1. Overload2. Faulty cords or equipment.

1. Generator overloaded.

2. Insufficient ventilation.

1. Faulty solenoid

2. Faulty idle control switch

3. Faulty windings in stator

4. Faulty circuit board

5. Faulty wire harness

1. Faulty rectifier

2. Faulty windings in stator

3. Faulty wire harness

1. Add fuel or oil.

2. Turn to "ON" position

3. Replace spark plug.

4. Adjust choke accordingly.

5. Open fuel shut-off valve.

6. Remove load from unit.

7. Attach wire to spark plug.

1. Have Service Center replace.

2. Depress and reset.

3. Have Service Center replacecapacitor.

4. Repair or replace cord.

5. Depress and reset

1. Reduce load.2. Check for damaged, bare, or

frayed wires on equipment.Replace.

1. Reduce load.

2. Move to adequate supply offresh air.





5. Have Service Center replace




TROUBLESHOOTING GUIDE


NOTES

DeVilbiss Air Power Company • 213 Industrial Drive • Jackson, TN 38301-9615

ENGINE GAS

WATTAGE

WIRING

ENGINE

Generator Quick Facts

Use clean, fresh gasoline with a minimum 87 octane rating. Do not add gasoline during or immediately after use.

ALWAYS REFER TO THE MANUALS SUPPLIED WITH THIS UNIT

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.

Refer to engine owner’s manual for oil recommendations.

TO FIND A LOCAL AUTHORIZED SERVICE CENTER NEAR YOU FOR REPAIRS AND SERVICE PART PURCHASES.

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.

Add stabilizer to fuel tank and run engine for 5 minutes before storage.

ENGINE OIL

Use a standard (12V) lawn and garden battery with a minimum of 45 A.H. or 210 CCA.

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.

CALL 1-800-888-2468 EXT. 2,1

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.

BATTERY VOLT REG.

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.

Do not adjust or attempt maintenance without consulting engine manual or an authorized engine service center.

Allow the generator to run 5 minutes at no load for the engine and the genhead to stabilize.

OPERATIONMake sure the adequate size of extension cord is used. Refer to the Grounding 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.

Attach Sales Receipt Here.Retain Original Sales Receipt as Proof ofPurchase for Warranty Repair Work.

WARRANTYThis product is covered by the DeVilbissone year limited warranty. The warrantycan be found on page 2 or is available upon

request.

Call our Toll Free Number 1-800-888-2468, Ext 2, then 1,to obtain the location of the nearest Authorized ServiceCenter for ordering repair parts and for warranty repairs.

When ordering repair parts from your local AuthorizedService Center, always give the following information:

• Model number of your product

• Part number and description of the item you wish topurchase

Documents

GENERAL MANUAL FOR DeVILBISS GENERATORS · general manual for devilbiss generators table of contents warranty statement ..... 2 safety guidelines - definitions safety instructions