Campbell Hausfeld GN0950, GN0800 User Manual

9. Keep all persons away from parts that move or become hot during operation.

10. Be sure all powered devices are shut off prior to connecting them to the generator.

11. Keep the generator clean and well maintained at all times.

Never operate this generator in an explosive atmosphere or poorly ventilated area.

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

IN284700AV 9/02

Operating Instructions Models GN0950 and GN0800

Portable Generators

BUILT TO LAST

This generator is powered by an aircooled two-cycle engine. It is designed to run at maximum RPM and give a continuous wattage as rated.

When unpacking, inspect carefully for any damage that may have occurred during transit. Make sure any loose fittings, bolts, etc., are tightened before putting unit into service.

1. Before starting or servicing any generator, read and understand all instructions. Failure to follow safety precautions or instructions can cause equipment damage and/or serious personal injury. Retain all manuals for future reference.

2. Never use this generator for any application other than that specified by the manufacturer. Never operate this generator under conditions not approved by the manufacturer. Never attempt to modify this generator to perform in any manner not intended by the manufacturer.

3. For maintenance and repairs, use only products and parts recommended by the manufacturer.

4. Be sure that the generator is properly grounded to an external ground path prior to operation. Refer to the section entitled “Grounding Instructions” for proper grounding procedures.

5. Be sure that the generator is operated only by persons who have read and understand these instructions.

6. Be sure that the generator is placed on a flat level surface prior to and during operation. The generator must not slide or shift during operation.

7. Keep all persons away from the generator during operation.

8. Do not allow persons wearing loose clothing or jewelry to start or operate the generator. Loose clothing or jewelry may become entangled in moving components, causing equipment damage and or personal injury.

Fig. 1 - Assembled Units GN0950 and GN0800

Description

Unpacking

General Safety

See Warranty on page 6 for important information about commercial use of this product.

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

MANUAL

WARNING

A Ground Fault

Circuit Interrupter may not be effective if used on a generator that is not grounded!

3. When installing a GFCI, be sure to

follow all national and local regulations, or call a licensed or certified electrical technician.

GROUNDING

1. Use the ground

terminal on the generator frame to connect the unit to a suitable ground source. Securely fasten the end terminal of the ground wire to the ground terminal on the generator frame.

2. The ground wire should be made of

#8 gauge wire. Do not use wire with a higher gauge number. Higher gauge numbers indicate thinner wire, which may not provide an adequate ground path.

3. The other end of the ground wire

must be securely fastened to an approved ground source.

The following are ground sources approved by the National Electric Code. Other ground sources may be acceptable. Refer to the National Electric Code and local regulations for further ground source information. If not sure

of regulations or procedures, obtain assistance from a qualified (licensed or certified) electrical technician.

a. An underground water pipe at

least ten feet in length.

b. A non-corrosive underground

pipe at least eight feet in length and 3/4 inch diameter.

c. A steel or iron underground rod

at least eight feet in length and 5/8 inch diameter.

d. A non-ferrous rod at least eight

feet in length, 1/2 inch in diameter, and approved for grounding purposes.

Any rod or pipe used for grounding must be driven to eight feet deep or buried in the deepest possible trench.

STARTING

1. Check fuel – Use a 50:1 mix of gas and oil (2.6 ounces of oil to one gallon of gasoline).

2. Remove all electrical loads from the generator.

3. Set the fuel switch to the open (vertical) position – pointing down.

Operating Instructions

12. Be sure that all tools and appliances are in good repair and are properly grounded. Use devices that have three prong power cords. If an extension cord is used, be sure that it has three prongs for proper grounding.

Do not operate this generator on wet

surfaces or in the rain.

13. Never operate the generator with damaged, broken or missing parts, or with any guarding components removed.

Shut off the

generator engine and disconnect the spark plug wire before performing any service or maintenance to the unit.

14. Do not refill the fuel tank while the

engine is running. Use precautions to prevent fuel spillage during refills. Be sure the fuel tank cap is securely in place before starting the engine. Allow engine to cool for at least two minutes before refueling.

15. Be sure to store gasoline in clean

containers that do not contain water, dirt or rust because this will cause the engine to shut down.

PRE-OPERATION

1.Check fuel every

time you start your generator. Always use clean fuel – see #15 above. Use a 50:1 mix of gas and oil (2.6 ounces of oil to one gallon of gasoline). It is best to use 89 octane gasoline and a certified 2-cycle oil.

2. Use of a Ground Fault Circuit

Interrupter (GFCI) is strongly recommended. Ground Fault Circuit Interrupters can significantly reduce the possibility of injury if an electrical short occurs.

NEVER OPERATE YOUR GENERATOR UNDER THESE CONDITIONS:

1. Rain or inclement weather

2. Excessive vibration

3. Sparking

4. Engine misfire

5. Electric output loss

6. Changing or fluctuating engine speed

7. Overheating in connected equipment

8. Damaged receptacles

9. Damaged, broken or missing parts

10. Guarding components removed

ALWAYS OPERATE YOUR GENERATOR UNDER THESE CONDITIONS:

1. Read and understand these instructions

2. Clear of all persons

3. Properly grounded (generator)

4. Properly grounded (tools, appliances, etc.)

5. Flat level surfaces

6. Well ventilated areas

General Safety

(Continued)

Operation

WARNING

DANGER

WARNING

GN0950 and GN0800

4. Move the choke/run switch to the choke position.

5. Turn engine switch on by pressing the top of the switch.

6. Pull the starter rope with a brisk smooth motion.

7. Return choke/run switch to the run position.

8. After each start up, allow engine to run 2-3 minutes with no load.

Engine speed is

preset to provide proper output voltage. Never attempt to modify or adjust engine speed or output voltage.

ENGINE BREAK-IN

The first 25 hours of operation is considered the break-in period for the engine. During this time, use a 30:1 mix of gas and oil and operate at less than 75% of the load limit.

GENERATOR SHUT OFF

1. Remove all electrical load devices

from the generator.

2. Allow the engine to run for 2-3

minutes with no electrical loads.

3. Turn engine switch

off by pressing the bottom of the switch. This will stall the engine.

4. Set the fuel switch to the closed (horizontal) position.

5. Verify that the generator has completely stopped.

6. Allow unit to cool before placing in storage.

LOAD DEVICES

1. The 120 volt receptacles (type NEMA 5-15) are rated for 13 amps on 60 Hz models (GN950). The 220 volt receptacles are rated for 10 amps on 50 Hz models (GN800).

2. Total combined load through any combination of receptacles must not exceed rated load limits of generator.

3. Reduce load if AC Protector (circuit breaker) turns off. Press button to reset.

NOTE: Power draw can be calculated by multiplying volts and amps. The resulting number is wattage.

Never exceed the posted maximum wattage for the generator or any individual receptacle. Refer to owner's

manuals and product tags to determine the wattage of electrical load devices.

Long power cords and extension cords draw additional power. Keep cords at minimum possible length. See chart above.

INFREQUENT USAGE

If the generator is used infrequently, starting difficulty may occur. To help prevent difficulty starting, the generator should be run for approximately 30 minutes per week.

STORAGE

If the generator is not to be used for extended periods of time, the following pre-storage procedures should be performed:

1. Drain all fuel from the tank, lines, and carburetor.

2. Remove spark plug. Clean off any carbon deposits. Check for discoloration – plug should be tan in color. Check the gap; it should be 0.7 –

0.8mm.

3. Pour approximately one teaspoon of oil into spark plug hole.

4. Pull starter cord several times to spread the oil throughout the cylinder.

5. Slowly pull the starter cord until resistance is felt. This indicates that the piston is moving upward on the

2.5 300 600 1000 600 375 250 5 600 1200 500 300 200 125

7.5 900 1800 350 200 125 100

Amps Watts Watts #8 #10 #12 #14 #16

120 V 220 V Wire Wire Wire Wire Wire

EXTENSION CORDS

MAXIMUM RECOMMENDED LENGTHS (IN FEET)

Operation

(Continued)

Computer 300 CD Player 100 VCR 100 Radio 100 Television 300 Receiver 420 Microwave 800 Blender 300

Load Device Watts Load Device Watts

Hand Vacuum 500 Power Drill 500 Hedge Trimmer 500 Weed Whip 500 Coffee Maker 1200 Slow Cooker/Frying Pan 200 Outdoor Lights 75-150 Bug Light 50

ESTIMATED POWER USAGE (WATTS)

Maintenance

CAUTION

Operating Instructions

compression cycle, and the intake and exhaust valves are closed. (The piston pushes a small amount of air from the spark plug hole on compression).

6. To clean air filter – Remove filter from generator. Wash in a solvent. Pour motor oil (SAE #20) on filter, squeeze out excess and reinstall in generator.

Maintenance

(Continued)

Spark Plug Remove carbon

Adjust gap ● Replace if necessary

Air Filter Clean

Replace if necessary ●

Fuel Filter Clean

Replace if necessary ●

Decarbonization Remove carbon deposits

Check and adjust at ● your dealer

Item Action Every 50 hours Every 150 hours

or every month or every 3 months

MAINTENANCE SCHEDULE

AC receptacle

AC protector

Output light

24 µ F/300VAC

Stator assembly

Rotor assembly

Oil annunciator

Oil sensor

Oil pilot light

OFF/ON

Engine stop switch

T.C.I. unit

10A (6.5A)

2 3

G/Y

B/W

220V

G/Y

7. To clean fuel filter – Stop engine. Turn fuel switch to closed (horizontal) position. Remove fuel filter and disassemble.

Wash filter in a solvent. Dry with a clean cloth. Reinstall in generator.

Wiring diagram for GN0950

Wiring diagram for GN0800

G/Y

AC receptacle

Engine stop switch

Ignition coil

24 µ F/250VAC (10µF/300VAC)

AC circuit breaker

3A (2A)

Stator assembly

Rotor assembly

Magneto

C.D.I unit

Spark plug

OFF/ON

G/Y

W/R

Capacitor

B = Black R = Red G = Green Br = Brown O = Orange G/Y = Green/Yellow B/W= Black/White

B = Black R = Red G = Green Br = Brown G/Y = Green/Yellow B/W= Black/White

Zero output from receptacles

Low output voltage with no load

6 Vac or above

Below 6 Vac

High output voltage with no load

Low output voltage under load

Erratic output voltage

Noisy operation

Engine won’t start

1. Engine speed is too slow

2. Open or shorted wiring

3. Faulty capacitor

4. Open/shorted rotor or stator windings

5. Open rectifier

1. Engine speed is too slow

2. Open rectifier

3. Faulty capacitor

4. Open/shorted rotor or stator windings

1. Generator head not magnetized

1. Faulty capacitor

2. Engine speed is too fast

1. Open rectifier

2. Engine speed too slow at full load

3. Excessive load applied

1. Dirty, corroded, or loose wiring connection

2. Unbalanced load applied

1. Loose generator or engine bolt

2. Short circuit in generator field or load

3. Faulty bearing

1. No fuel.

2. Fuel switch is in closed position.

3. Engine switch is in closed position.

4. Spark plug dirty or wrong gap

1. Adjust engine speed

✽

2. Clean and reconnect all wiring

✽

3. Replace capacitor

✽

4. Test winding resistance, replace winding if necessary

✽

5. Test rectifier, replace if necessary

✽

1. Adjust engine speed

✽

2. Test rectifier, replace if necessary

✽

3. Replace capacitor

✽

4. Test winding resistance, replace winding if necessary

✽

1. Re-magnetize generator head

✽

1. Replace capacitor

✽

2. Adjust engine speed

✽

1. Test rectifier, replace if necessary

✽

2. Adjust engine speed

✽

3. Reduce the applied load

1. Referring to the wiring diagram, clean and reconnect all wiring

✽

2. Remove all loads, then apply each one individually to determine which one is causing erratic function

1. Tighten all mountings

2. Test winding resistance, replace field winding if necessary

✽

Test load devices for shorts. Replace defective load device.

3. Replace bearing

1. Check fuel. Use a 50:1 mix of gas and oil. (See page 2)

2. Place fuel switch in open position.

3. Place engine switch in open position.

4. Clean spark plug. Adjust gap. (See page 3) Replace if necessary.

✽

These diagnostic and repair procedures should be performed by an authorized service center.

Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

GN0950 and GN0800

Operating Instructions

Limited Warranty

1. DURATION: Ninety (90) days from the date of purchase by the original purchaser. Units used for rental, industrial or commercial purposes are warranted for 90 days from date of purchase.

2. WHO GIVES THIS WARRANTY (WARRANTOR): Campbell Hausfeld / Scott Fetzer Company, 100 Production Drive, Harrison, Ohio, 45030, Telephone: (800) 803-1436

3. WHO RECEIVES THIS WARRANTY (PURCHASER): The original purchaser (other than for purposes of resale) of the Campbell Hausfeld generator.

4. WHAT PRODUCTS ARE COVERED BY THIS WARRANTY: Any Campbell Hausfeld portable generator supplied or manufactured by Warrantor.

5. WHAT IS COVERED UNDER THIS WARRANTY: Substantial defects on material and workmanship which occur within the duration of the warranty period.

6. WHAT IS NOT COVERED UNDER THIS WARRANTY: A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED FROM

THE DATE OF ORIGINAL PURCHASE AS STATED IN THE DURATION. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY

DEFECT, FAILURE, OR MALFUNCTION OF THE CAMPBELL HAUSFELD 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.

C. Any failure that results from an accident, shipping damage, purchaser’s abuse, neglect or failure to operate

products in accordance with instructions provided in the owner’s manual(s) supplied with product. D. Pre-delivery service, i.e. assembly, oil or lubricants, and adjustment. E. Items or service that are normally required to maintain the product, i.e. lubricants and filters. F. Gasoline engine components are expressly excluded from coverage under this limited warranty. Such components

should be returned by the purchaser to the original manufacturer or to its authorized repair stations for service.

7. RESPONSIBILITIES OF WARRANTOR UNDER THIS WARRANTY: Repair or replace, at Warrantor’s option, generator or component(s) which have failed within duration of the warranty period.

8. RESPONSIBILITIES OF PURCHASER UNDER THIS WARRANTY: A. Provide dated proof of purchase and maintenance records. B. Deliver or ship the Campbell Hausfeld generator or component to the nearest Campbell Hausfeld Authorized

Service Center. Freight costs, if any, must be borne by the purchaser.

C. Use reasonable care in the operation and maintenance of the generator as described in the owner’s manual(s).

9. WHEN WARRANTOR WILL PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY: Repair or replacement will be scheduled and serviced according to the normal work flow at the servicing location, and depending on the availability of replacement parts.

Limited Warranty applies in the U.S., Canada and Mexico only and gives you specific legal rights. You may also have other rights which vary from State to State or country to country.

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