Campbell Hausfeld IN198203AV User Manual

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.

1

IN198203AV 11/96

Operating Instructions

Generators

CAMPBELL
HAUSFELD

Description

These generators are powered by air­cooled four cycle engines and designed
to run at maximum RPM and give a
continuous wattage as rated. On
certain models, a low-oil level shutoff
is provided to protect the engine. This
feature is usually associated with
extended run models.

Unpacking

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.

General Safety

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. Engine
instructions for these units are
contained in a separate manual.
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.

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.

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. Use only unleaded fuel. 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. Clean up
any spilled fuel before starting the
engine. Allow engine to cool for at
least two minutes before refueling.

15. This generator may be used for

emergency stand-by service. In such
cases, a manual transfer switch must
be installed between the electric
utilities meter and the electrical
distribution box. This switch should
be installed by a licensed electrician.

Never mix oil with

gasoline for this
engine. This is a four cycle engine
designed to run on pure gasoline. Oil is
used for engine lubrication purposes only.

Operation

PRE-OPERATION

1. Check engine oil level. Oil is NOT

mixed with the gasoline, however
adequate oil supply is necessary for
proper engine lubrication. Refer to
the Engine Manual for SAE, API and
fill quantity specifications.

MANUAL

© 1996 Campbell Hausfeld

2

Operating Instructions

2. Use of a Ground Fault Interrupter
(GFI) is strongly recommended.
Ground Fault Interrupters can
significantly reduce the possibility of
injury if an electrical short occurs. In
order to install a GFI, the generator
neutral wire must be internally
grounded to the generator frame,
and the frame must be properly
grounded to the earth.

A Ground Fault

Interrupter may
not be effective if used on a generator
that is not grounded! Refer to the
section entitled Grounding for proper
steps to ground the generator.

3. When installing a GFI, be sure to

follow all national and local
regulations. If not sure of
regulations or procedures, obtain
assistance from a qualified (licensed
or certified) electrical technician.

GROUNDING

1. Use the ground terminal and wing

nut 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. Tighten the
washer and wing nut on top of the
ground wire end terminal.

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. Remove all electrical loads from the
generator.

2. Rotate fuel shut-off valve counter
clockwise to enable fuel flow.

3. Rotate the engine switch to the ON
position.

4. Adjust the choke lever as follows:
a. For cold engine, move the choke

lever as far as possible to the left,
choke fully ON, position.

b. For warm/hot engine, move the

choke lever midway between the
choke and run positions.

5. Pull the starter rope with a brisk,
smooth motion.

NOTE: Some models may be equipped
with an electric starter. For models
equipped with an electric starter, press
the start button.

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

7. As the engine warms up and
stabilizes, adjust the choke lever to
the right, until the lever is
positioned at the RUN label.

Engine speed is

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

ENGINE BREAK-IN

After initial start-up, the engine should
be broken in according to the
manufacturer's instructions. Refer to
the engine manual for the proper
break-in procedure.

GENERATOR SHUT OFF

1. Shut off and remove all electrical

load devices from the generator.

2. Allow the engine to run for 2-3

minutes with no electrical loads.

3. Rotate the engine switch to the OFF

position.

4. Verify that the generator has

completely stopped.

5. Close the fuel supply valve.

6. Allow the unit to cool before

installing any covers.

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

7.5 900 1800 350 200 125 100

10 1200 2400 250 150 100 50
15 1800 3600 150 100 65
20 2400 4800 175 125 75 50
25 3000 6000 150 100 60
30 3600 7200 125 65
40 4800 9600 90

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

120 V 240 V Wire Wire Wire Wire Wire

EXTENSION CORDS

MAXIMUM RECOMMENDED LENGTHS (IN FEET)

3

Operating Instructions

LOAD DEVICES

1. All load devices and extension cords
should use three prong terminals.
Refer to the following chart for
extension cord and cable size
requirements.

2. Allow the engine to run for 2-3
minutes before applying any
electrical loads.

3. The 120 volt receptacles are rated
for 15 amps and may be used in any
combination of 120 volt loads and
also with 240 volt loads through the
240 volt receptacles.
The 240 volt receptacles are rated
for 20 amps and may be used in any
combination of 240 volt loads and
also with 120 volt loads through the
120 volt receptacles.
The 120/240 volt twist lock
receptacle, found on some units, is
rated for 20 amps and may be used
in any combination of 120 volt and
240 volt loads.

4. Individual receptacles should not be
loaded beyond the amperage
rating.

5. Total combined load through any
combination of receptacle must not
exceed the rated load limits of the
generator. Refer to the
identification plate on the
generator for amp and wattage
specifications.

6. Always shut off and remove loads
before starting or shutting off the
generator engine.

7. When plugging multiple electrical
load devices into the generator
receptacles, be sure to connect and
activate the highest power draw
item first. Allow the generator
engine to stabilize, then connect
and activate the next highest power
draw device. The smallest power
draw device should be connected to
the receptacle and activated last.

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 all electrical load devices.

If actual watt ratings are not available,
the following chart may be used as a
general guideline.

Remember that devices which generate
heat during operation such as heaters,
incandescent light bulbs, motors and
hair dryers have a higher power draw
than devices which generate little heat
during operation such as florescent
bulbs, radios, and clocks.

Long power cords and extension cords
also draw additional power. Keep cords
at minimum possible length.

Refer to the chart provided for
maximum limits for lengths of
extension cords.

8. Circuit protection is provided by a
circuit breaker. The circuit breaker
opens when the generator load
exceeds its maximum capacity or a
short circuit occurs. If the circuit
breaker opens, perform the following
procedures to correct the problem:

a. Shut off and disconnect all

electrical loads.

b. Attempt to determine the cause

of the electrical problem ­overloading or short circuit.

c. Do not use any devices that have

short circuits. Avoid overloading
the generator.

d. Press the circuit breaker

pushbutton to reset the circuit
breaker.

Air conditioner 2000-3000
Automatic washer 150-1500
Brooder 100+
Clothes dryer 5000-10,000
Coffee maker 400-700
Electric drill (small) 225-1000
Electric drill (large) 500-1000
Fan 40-200
Freezer 300-500
Hot plate 330-1100
Iron 500-1500
Light bulb As Rated

Load Device Watts Load Device Watts

Radio 50-200
Refrigerator 190-2000
Skillet 1200
Space heater 600-4800
Sump pump 400-3000
Television 200-500
Toaster 900-1700
Vacuum cleaner 200-300
Water pump 1000-3000
Water heater 1000-5000
Small hand saw 1000-2000
Large hand saw 1500-2500

Repeated cycling

of the circuit
breaker indicates a problem and may
cause damage to the generator or load
devices. Do not operate the generator
if repeated cycling of the circuit
breaker occurs.

LOW OIL SHUTDOWN

A low oil shutdown switch is provided
to protect the engine and generator on
most extended run models. When
engine oil level drops too low for
proper engine operation, the low oil
shutdown switch causes the engine to
shut off. If oil level is low when
attempting to start the generator
engine, the low oil level shutdown
switch prevents the engine from
starting. If engine does not start, check
oil level.

NOTE: It is important to keep the
generator unit on a level surface. The
oil level shutdown switch can prevent
the engine from starting even if oil
level is sufficient, when the generator
unit is placed on an uneven surface.

Installation for Stand-by Use

Precautions must be taken to prevent
electrical back feeding into utility
systems. This requires isolation of the
electrical system. To isolate the
electrical system, perform the following
procedures:

1. Turn off the main electrical system

switch prior to connecting the
generator.

ESTIMATED POWER USAGE (WATTS)