Global Machinery Company GEN800 Portable Generator User Manual
Contents
1. GENERATOR BENGON INSTRUCTION MANUAL Code GEN800 Date 080711 Edition 06 Op PS Warranty Introduction Environmental protection Scope of product Description of symbols Specifications General safety instructions for power tools Risk of electrocution and fire Risk of fire Risk of injury and property damage when transporting generator Risk of breathing inhalation hazard Risk of unsafe operation Risk of hot surfaces Risk of moving parts Risk from lifting Additional safety rules for generators Unpacking Know your product Fitting the handle Mixing the fuel Filling the tank Starting the engine Stopping the engine Connecting apparatus to the generator AC Connecting apparatus to the generator DC AC overload cut out Periodic maintenance Generator maintenance Storage Spark plugs Air filter Tap extension fuel filter Fuel tap bowl filter Petrol tank filter Cleaning Repairs Troubleshooting O QO A OUO DD DI GW GW PY O 00 NI NIN all al a a af a a af a 2 a a2 N N al gt O oo GI on A Ww WW Ww OD NIN a dd O Oo Warranty Generators Whilst every effort is made to ensure your complete satisfaction with this tool occasionally due to the mass manufacturing techniques a tool may not live up to our required level of performance and you may need the assistance of our service department This product is warranted for a 6 month period for home domestic use from the date2. position pP 4 Press on the on off rocker switch 5 Slowly pull the recoil starter until you feel it engage and then pull it briskly Note When the engine is started for the very first time it will require a number of attempts to start until the fuel has travelled from the tank to the engine 6 Once the engine has been operating for 10 15 seconds slowly return the choke lever back to the right hand side position This position will switch the choke off Note Ifthe generator stops move the choke back to the full left hand side and repeat the starting operation Stopping the engine 1 Before stopping ensure that no electrical apparatus is connected to the generator 2 Press O on the engine switch 6 to stop the engine 3 Turn the fuel tap 4 anti clockwise to the off position Connecting apparatus to the generator AC 1 Start the engine Allow the engine to run for a couple of minutes to warm up prior to connecting any apparatus to the generator The green power on light 12 will illuminate when the generator is P operational and power is available at the socket NO For AC current plug the power cord into the AC output socket 10 12 Connecting apparatus to the generator DC This generator is fitted with a 13 8V DC regulator The DC output should only be used for the purpose of charging suitable lead acid car batteries Do Not use th
3. to you or others Never operate generator while suspended or in an unlevel position Always operate generate on a flat level surface Risk of hot surfaces Hazard What could happen How to prevent it Contact with hot engine and Contact with hot surfaces such as generator components engines exhaust components could result in serious burns 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 s s isCY What could happen How to prevent it Contact with moving parts can The generator contains parts which rotate Never operate generator with guarding result in serious injury at high speed during operation These parts are covered by guarding to prevent injury or cover plates removed Avoid wearing loose fitting clothing or jewellery which could be caught by moving parts Risk from lifting Hazard What could happen How to prevent it Lifting a very heavy object Serious injury can result from attempting to lift too heavy an object When lifting always keep the object you are lifting near the vertical axis of your body DO NOT use you back to lift heavy loads Both people should crouch down grab the underside of unit and use your legs to carry the weight Keep the object as near the centre of your body s gravity as possible Avoid twisting your bodies when c
4. to see that keys and adjusting wrenches are removed from the tool before switching on 13 Stay alert Watch what you are doing Use common sense Do not operate a tool when you are tired 14 Check for damaged parts Before using a tool check that there are no damaged parts If a part is slightly damaged carefully determine if it will operate properly and perform its intended function Check for alignment of moving parts binding of moving parts breakage of parts proper mounting and any other conditions that may affect the operation of the tool A part that is damaged should be properly repaired or replaced by an authorised service facility unless otherwise indicated in this Instruction Manual 15 Use only approved parts When servicing use only identical replacement parts Use an authorised service facility to fit replacement parts WARNING The use of an accessory or attachment other than those recommended in this Instruction Manual may present a risk of personal injury Save these important safety instructions Risk of electrocution and fire Hazard What could happen How to prevent it Improper storage of extension cord Operation of generator in rain wet icy or flooded conditions Placing generator on or against highly conductive surface such as a steel walkway or metal roof Use of worn damaged or ungrounded extension cords Operation of unit when damaged or with guards or panels removed Extension
5. NING Prior to connecting any product to the generator check the rating label of the product The generator is rated at 650W so if the product being connected is higher than 650W the protective cut out on the generator may operate to prevent over load damage to the generator The generator will withstand short operation and spikes up to 800W It should also be very clearly understood that output voltage fluctuations will occur when various loads are connected and disconnected It is best to always use a voltage or surge protector with this generator It is NOT recommended to connect any electronic equipment to the generator such as computers televisions or stereo equipment They are very sensitive to the input supply fluctuations and could be damaged if run off this generator This warning also includes caravans where electronic equipment is incorporated as part of the wiring AC and DC overload cut out IMPORTANT Exceeding the rated capacity of your generator can result in serious damage to your generator and connected apparatus 1 Each receptacle has a circuit breaker to protect the generator from over loading 2 If the circuit breaker trips unplug all electrical apparatus from the generator 3 Let the overload cut out switch cool down 4 If it is an AC apparatus causing the overload push the AC circuit breaker button 11 If it is a DC apparatus causing the overload push the DC circuit breaker button 14 Commence to s
6. arrying the unit instead turn your whole body using your feet Additional safety rules for generators 1 Do not operate in a hazardous location Such areas include where there is a risk of explosion of petrol fumes leaking gas or explosive dust 2 Do not operate in a confined area Exhaust gases smoke or fumes could reach dangerous concentrations 3 The output of this generator is potentially lethal The generator should not be connected to a fixed electrical installation except by an appropriately licensed person 4 Protect your generator This generator is NOT WEATHERPROOF and should not be exposed to direct sunlight high ambient temperature and damp wet or high humidity conditions 5 Do not smoke while refuelling This is potentially dangerous as it may ignite the fuel and cause an explosion 6 Take care not to spill fuel When refuelling the generator ensure that the engine has been switched off Prevent the spilling of fuel as this may also ignite with the hot engine Never refuel whilst the engine running 7 Be careful where you store the generator Store the generator in a dry area away from inflammable liquids 8 Keep your distance The generator emits exhaust fumes As a Safety precaution do not stand close to the unit whilst it is in operation Ensure bystanders also keep their distance 9 Ensure you use oil mix fuel Ensure that you mix 40 parts unleaded fuel to 1 part 2 stroke grade oil If not mixed
7. cal or electrical problem Have unit repaired by an Authorized Service Centre Do not operate generator with protective guarding removed Hazard What could happen How to prevent it Attempting to fill the fuel tank while the engine is running Sparks fire hot objects Improper storage of fuel Tampering with factory set engine speed settings Inadequate ventilation for generator Overfilling the fuel tank fuel spillage Fuel and fuel vapours can become ignited by coming in contact with hot components such as the muffler engine exhaust gases or from an electrical spark Cigarettes sparks fires or other hot objects can cause fuel or fuel vapours to ignite Improperly stored fuel could lead to accidental ignition Fuel improperly secured could get into the hands of children or other unqualified persons 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 Materials placed against or near the generator or operating the generator in areas where the temperature exceeds 40 C ambient such as storage rooms or garages can interfere with its proper ventilation features causing overheating and possible ignition of the materials or buildings Spilled fuel and its vapours can become ignited from hot surfaces or sparks Turn engine off and allow it to cool before adding fuel to the tank Eq
8. cord can come into contact with hot engine parts resulting in damage Using a damaged extension cord can result in electrocution or death Water is an excellent conductor of electricity Water which comes in contact with electrically charged components can transmit electricity to the frame and other surfaces resulting in electrical shock to anyone contacting them Accidental leakage of electrical current could charge conductive surfaces in contact with the generator Contact with worn or damaged extension cords could result in electrocution Use of ungrounded cordsets could prevent operation of circuit breakers and result in electrical shock Attempting to use the unit when it has been damaged or when it is not functioning normally could result in fire or electrocution Removal of guarding could expose electrically charged components and result in electrocution Remove extension cord from the generator and store separately away from generator Operate generator in a clean dry well ventilated area Make sure hands are dry before touching unit Place generator on low conductivity surface such as a concrete slab ALWAYS operate generator a minimum of 2 meters from any conductive surface Inspect extension cords before use and replace with new cord if required Always use a cordset having a grounding wire with an appropriate grounding plug DO NOT use an ungrounded plug Do not operate generator with mechani
9. correctly at 40 1 the engine will overheat and cause damage to your generator 10 Never fill fuel tank indoors Never fill fuel tank when engine is running or hot Do not smoke when filling fuel tank 11 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 You MUST unplug any load from the generator before starting and stopping to prevent permanent damage to any appliances Unpacking Due to modern mass production techniques it is unlikely that your GMC Power Tool is faulty or that a part is missing If you find anything wrong do not operate the tool until the parts have been replaced or the fault has been rectified Failure to do so could result in serious personal injury Know your product 1 Handle 1 2 2 Fuel cap 3 Fuel tank 4 Fuel tap 5 Recoil starter 6 On off switch 7 Choke 8 Air filter cover 9 Tap extension fuel filter 10 AC Output 240V 11 AC circuit breaker 12 Power ON light 13 DC Output 13 8V 14 DC circuit breaker 15 DC leads 13 10 Fitting the handle Firstly place the 2 handle gaskets supplied with the generator over the holes on the petrol tank Then
10. ct with the tool or extension cord 4 Store tools safely When not in use tools should be locked up out of reach 5 Do not force the tool The tool will do the job better and safer working at the rate for which it was designed 6 Use the correct tool for the job Do not force small tools or attachments to do the job best handled by a heavier duty tool Never use a tool for a purpose for which it was not intended 7 Dress correctly Do not wear loose clothing or jewellery They can be caught in moving parts Rubber gloves and non slip footwear are recommended when working outdoors If you have long hair wear a protective hair covering 8 Use safety accessories Safety glasses and earmuffs should always be worn A face or dust mask is also required if the drilling operation creates dust 9 Secure the work piece Use clamps or a vice to hold the work piece It is safer than using your hand and frees both hands to operate the tool 10 Do not overreach Keep your footing secure and balanced at all times 11 Look after your tools Keep tools sharp and clean for better and safer performance Follow the instructions regarding lubrication and accessory changes Inspect tool cords periodically and if damaged have them repaired by an authorised service facility Inspect extension cords periodically and replace them if damaged Keep tool handles dry clean and free from oil and grease 12 Remove adjusting keys and wrenches Check
11. e DC of the generator for any other purpose than to charge batteries When charging lead acid batteries it is important that you adhere to these important safety tips Do Not attempt to charge any other type of batteries Do Not use the DC output when 240V output is in use Do Not charge batteries while they are connected to a vehicle Make sure they have been totally disconnected prior to connecting to the generator for recharging Do Not charge the battery in a confined space The charge area should be open with adequate ventilation Prior to charging remove the filler caps and top up the cells with distilled water to the correct level if needed To charge your car battery connect the alligator clips to the corresponding terminals on your battery The red lead goes to the positive terminal and the black lead goes to the negative terminal This DC cord has been supplied with the unit The generator will charge batteries up to 500CCA capacity provided the battery is in reasonable condition Batteries of larger capacity may charge but will depend on the condition and also the level of charge in the battery In cases where the current exceeds the rating of the Generator the circuit breaker on the DC side will open circuit and will need to be re set to continue Refer to the AC and DC overload cut out section of this manual Note Only use the DC leads provided with this generator when using the DC output WAR
12. ecial care to heed the Cautions and Warnings Your GMC power tool has many features that will make your job faster and easier Safety performance and dependability have been given top priority in the development of this tool making it easy to maintain and operate Environmental protection N Recycle unwanted materials instead of disposing of them as waste All tools hoses and packaging should be sorted taken to the local recycling centre and Scope of product This product is suited for lighting camping and car battery recharging applications It is not recommended to be used with any electronic devices disposed of in an environmentally safe way Description of symbols The rating plate on your tool may show symbols These represent important information about the product or instructions on its use Wear hearing protection Wear eye protection Wear breathing protection Conforms to relevant standards nago fOr electromagnetic compatibility Specifications AC Output 240Vac 50Hz Rated Power 650W Peak Power 800W Phase Single Power Factor cose 1 Displacement 64cc DC Output 13 8V DC maximum current 8A Engine 2HP 2 stroke No Load Speed 3000 RPM Fuel Tank Capacity 4 2L Fuel Type Unleaded petrol Oil Type 2 Stroke Fuel Mixture Unleaded petrol 2 stroke oil 40 1 Spark Plug F6RTC Equivalent Spark Plugs Bosch WR6DC NGK BPR6ES DENSO W16EXR CHAMPION RN11YC Operation Noise Le
13. ent ventilation 16 2 Turn to ON position on equipment Replace For prompt service we suggest you log your service request online at www gmcservice com au Should you not have x access to the Internet please contact our service department on 1300 880 001 Australia or 0800 445 721 New Zealand 7am 7pm 7days a week AEST You will need the following details at hand to log your service request Personal details First amp Last name address pick up address contact phone numbers email address Product details Product number date of purchase retailer bought from State amp postcode receipt number reason for the request copy of official purchase receipt Attach your purchase receipt and save with this Manual for future reference Please refer to our website www gmcompany com for full GMC warranty Terms and Conditions
14. er amp wash thoroughly in a solvent 5 Re assemble N a 15 Cleaning 1 Keep your machine clean The outside of the machine can be cleaned using a damp soft cloth with a mild detergent if required Never use water to clean the generator as it may cause damage to internal parts 2 Some maintenance products and solvents may damage the plastic parts these include products containing benzene trichloroethylene chloride and ammonia 3 Use a vacuum to clean air inlet and outlet louvres of the alternator 4 Take special care to keep the ventilation inlets outlets free from obstruction cleaning with a soft brush followed by a compressed air jet will usually be sufficient to ensure acceptable internal cleanliness 5 Wear eye protection when carrying out cleaning Repairs Only an authorised service centre should repair the generator Troubleshooting Engine will not start or will not keep running No electrical output Repeated circuit breaker tripping Generator overheating Possible cause 1 Low on fuel oil content 2 Ignition switch in Off position 3 Faulty spark plug 4 Choke in wrong position 5 Fuel tap in closed position 6 Unit loaded during start up 7 Spark plug wire loose 8 Dirty fuel filters 1 Faulty receptacle 2 Circuit breaker kicked out 3 Defective capacitor 4 Faulty power cord 1 Overload 2 Faulty cords or equipment 1 Generator overloaded 2 Insuffici
15. hould be between 0 7 0 8mm Air filter 1 Remove the cover 8 on the front of the generator by removing the two screws 2 Remove the air filter 3 Wash the air filter in solvent 4 Lubricate the filter using engine oil SEA 20 5 Thoroughly squeeze the filter removing excess oil 6 Replace air filter back into the engine 7 Secure the cover back onto the front panel of the generator IMPORTANT Never run the engine without the air filter element in place Tap extension fuel filter A small fuel filter has been fitted to the inlet side of the fuel tap 4 inside the tank This tap extension fuel filter 9 prevents any dirt in the fuel from entering the fuel system The procedure for removing this filter in order to replace or clean it is given below Note the following procedure should be performed in a well ventilated area with no naked flames sparks or cigarettes Safety glasses should also be worn and switch 6 set to the OFF position 1 Completely empty the tank of fuel Ensure the fuel tap 4 is in the OFF position 2 Compress the two wire arms of the hose clamp on the outlet hose at the tap 4 and slide the clamp back from the end of the hose by approx 25mm Slide the fuel hose off the outlet of the tap 4 14 3 Remove the 4 screws holding the fuel tank 3 to the generator assembly and lift the tank clear of the generator 4 Loosen the lock nut locking the tap 4 on to the
16. of the original purchase If found to be defective in materials or workmanship the tool or the offending faulty component will be replaced free of charge with another of the same item Asmall freight charge may apply Proof of purchase is essential We reserve the right to reject any claim where the purchase cannot be verified This warranty does not include damage or defects to the tool caused by or resulting from abuse accidents alterations or commercial or business use It also does not cover any bonus items or included accessories Only the powertool is covered under this warranty Please ensure that you store your receipt in a safe place Conditions apply to the above warranty For full details of the warranty terms and conditions please refer to our website www gmcompany com For prompt service we suggest you log your service request online www gmcservice com au Should you not have access to the internet please contact our service department on 1300 880 001 Australia or 0800 445 721 New Zealand Introduction Your new GMC power tool will more than satisfy your expectations lt has been manufactured under stringent GMC Quality Standards to meet superior performance criteria You will find your new tool easy and safe to operate and with proper care it will give you many years of dependable service CAUTION Carefully read through this entire Instruction Manual before using your new GMC Power Tool Take sp
17. proceed by placing the handle on top of the gaskets ensuring the 2 holes in the handles line up with the holes on the tank Screw the handle onto the petrol tank using the 2 screws provided with the unit Ensure the flat washers and spring washers are fitted under the heads of the screws Mixing the fuel 1 The generator uses unleaded fuel and 2 stroke grade oil 2 You need to mix both unleaded fuel and 2 stroke oil together 3 The proportion should be 40 parts unleaded fuel and 1 part 2 stroke oil Quick reference common fuel mixture requirements for 40 1 is 1 Litre of unleaded fuel mixed with 25mL of 2 stroke oil 5 Litres of unleaded fuel mixed with 125mL of 2 stroke oil 4 The mixture should be poured into an approved fuel container This fuel container should be clearly marked as a fuel container sealed and made from fuel resistant material 5 Once the mixture has been poured shake the fuel container well to ensure that the contents have been thoroughly mixed Filling the fuel tank 1 Switch off the engine 2 Remove the fuel cap 2 by turning anticlockwise 3 Pour the fuel oil mix from the fuel container into the fuel tank 3 Because fuel expands DO NOT FILL to the tip of the tank 4 Replace fuel cap and turn clockwise to lock 11 Starting the engine 1 Before starting ensure that no electrical apparatus has been connected to the generator 2 Turn the fuel tap 4 clockwise to the on
18. r 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 i What could happen How to prevent it Gasoline engines produce toxic Breathing exhaust fumes will cause Operate generator in clean dry well carbon monoxide exhaust fumes serious injury or death 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 Risk of unsafe operation Hazard i What could happen How to prevent it Operation of generator in All sources of energy include the e Review and understand all of the careless manner potential for injury Unsafe operation operating instructions and warnings in or maintenance of your generator could this manual lead to serious injury or death to you Become familiar with the operation or others 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 Risk of unsafe operation continued Operating generator while Generator will not operate properly and suspended will cause damage to the generator and could cause serious injury or death
19. tank Unscrew the tap from the tank and withdraw the tap from the tank Be careful not to lose the small seal on the thread of the tap 5 Unscrew the tap extension fuel filter 9 This filter can be cleaned in petrol to remove any build up of dirt on the outside of the filter or the filter can be replaced Do not operate the generator without this filter in place To replace the filter after cleaning or with a new filter simply screw the filter into the inlet side of the tap 6 Ensuring the small seal is fitted to the tap thread screw the tap back into the tank by a FULL 3 4 turns Orientate the tap so the outlet of the tap is towards the rear of the tank and the tap control is to the right hand side of the tank Holding the tap firm tighten the lock nut ensuring the seal is clamped between the lock nut and the tank Refit the fuel hose to the outlet of the tap and with the wire arms compressed slide the hose clamp up onto the connection of the hose and the tap Refill the tank with fuel and ensure there are no leaks between the tap and the tank and with the fuel tap turned on ensure there are no leaks where the fuel hose is fitted to the outlet of the tap Petrol tank filter 1 Stop the engine 2 Turn the fuel tap 4 to the off position 3 The petrol tank filter is located directly under the petrol cap This protects impurities entering the fuel tank during refuelling 4 Remove the filt
20. tart your generator accordingly 5 When re connecting appliances reduce the load to that which previously overloaded the generator Periodic maintenance Spark Plug Remove Carbon Every 50hrs Every 150 hrs or every month Fuel Filters Decarbon Clean isation 13 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 vapours 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 generator head 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 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 Spark plugs 1 Remove spark plug from the generator with a spark plug spanner socket 2 Remove carbon deposits using a wire brush 3 Check for discoloration on the top of the spark plug The standard colour should be a tan colour 4 Check the spark plug gap The acceptable gap s
21. uip area of operation with a fire extinguisher certified to handle gasoline or fuel fires Add fuel to tank in well ventilated area Make sure there are no sources of ignition near the generator Store fuel in an approved container designed to hold fuel Store container in secure location to prevent use by others 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 Operate generator in a clean dry well ventilated area DO NOT OPERATE UNIT INDOORS OR IN ANY CONFINED AREA 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 refuelling area or any spillage before starting engine Allow for fuel expansion Never refuel with the engine running Risk of injury and property damage when transporting generator Hazard Whatcouldiappen How to preventit Fire Inhalation Damage Fuel or oil can leak or spill and could The generator is equipped with a fuel to Vehicle Surfaces result in fire or breathing hazard serious tap turn the lever of this valve to the off injury or death can result Fuel or oil position before transporting to avoid fuel leaks can damage carpet paint or other leaks Transport fuel only in an approved surfaces in vehicles or trailers fuel containe
22. vel 68dB 7m Net Weight 17kg General safety instructions for power tools To use this tool properly you must observe the safety regulations the assembly instructions and the operating instructions to be found in this Manual All persons who use and service the machine have to be acquainted with this Manual and must be informed about its potential hazards Children and infirm people must not use this tool Children should be supervised at all times if they are in the area in which the tool is being used It is also imperative that you observe the accident prevention regulations in force in your area The same applies for general rules of occupational health and safety WARNING When using power tools basic safety precautions should always be taken to reduce the risk of fire electric shock and personal injury Also please read and heed the advice given in the additional important safety instructions 1 Keep the work area clean and tidy Cluttered work areas and benches invite accidents and injury 2 Consider the environment in which you are working Do not use power tools in damp or wet locations Keep the work area well lit Do not expose power tools to rain Do not use power tools in the presence of flammable liquids or gases 3 Keep visitors away from the work area All visitors and onlookers especially children and infirm persons should be kept well away from where you are working Do not let others in the vicinity make conta
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