Desa PGH7500IE, PGH1100IE Portable Generator User Manual
Contents
1. r les m Green 1 I gt 5 Black bc r 120 240V 30A 120V 15A 120V 15A 120V 15A i a8 Switch Receptacle Receptacle Receptacle Receptacle Breaker White eat OTO 20A EAN EO T1 Circuit Red o Send 1 Breaker o Solenoi j 4 White Circuit Breaker l 20A Circuit O Black Breaker T3 TA o Hour l Meter 11 Yellow Black Red Black Red Black l Tal Sa SS SS SSS E SS SS Capacitor Main Auxiliary Whit Windings Phase Stator ite ren PA Whitej TI Tah T3 T2 T2 TI 73 T4 Rotor Stator TI T2 HK T4 Green White het Red Diode Diode A 220 240V LI 2 Black a zoja gt Yellow Brown 110 120V 1101 20V Figure 22 Wiring Diagram Model PGH7500IE White White Green Green Black Black 250V 30A 125V 15A GFCI 125V 15A 125V 30A Auto Idle Receptacle Receptacle Receptacle Receptacle o Control Board T zo Red gt 250V50A AI Q Circuit gxesrsy S Receptacle 7 Breaker 031111 n n Circuit White White g Aa J Circuit o di Breaker iie g Breaker 304 White 5A 9 Black i ace 1 F Black Run Black pape Light Circuit Solenoid Yellow a Vigh Breake T FEAL Circuit Breaker 208 tr2. Always use starting watts not running watts when figuring correct electrical load x Motors of higher horsepower are not generally used for motors you must use the starting watts figure Do not use the running watts figure Note Some motors re quire nearly the same wattage to run as to start These items include saws drills hair dryers and food mixers See Chart 1 for typical appliance wattage examples Add watts and starting watts of all items This total must not be larger than the rated wattage of your generator It is a good idea to have up to 25 extra capacity for future needs or extra equipment 106746 OPERATION GENERAL INFORMATION This generator is not large enough to power your entire home Do not connect generator to any existing electrical circuits Plug items directly into generator receptacles Do not exceed amperage rating of receptacles Only use grounded cords A DANGER Use only in well vented areas Make sure area has plenty of free moving fresh out side air Never run generator in an enclosed or confined area Never run generator inside occu pied building Engine exhaust contains poisonous carbon mon oxide gas Overexposure will cause loss of consciousness and will lead to death A DANGER Never connect gen erator to any existing electrical circuits The generator output will back feed into the utility power line This may electrocute a power compan
3. Powerfast PORTABLE GASOLINE GENERATORS OWNER S OPERATION AND INSTALLATION MANUAL Generator Models PGH7500IE and PGH110001E IMPORTANT Read and understand this manual before operating or servicing generator Improper use of generator can cause serious injury Keep this manual for future reference Powerkast PORTABLE GASOLINE GENERATORS SAFETY INFORMATION A WARNINGS IMPORTANT Read this Owner s Manual and the engine Owner s Manual carefully Become famil iar with this generator before try ing to operate or service it Know its uses limitations and any haz ards involved Improper use of generator can cause severe in jury or death from explosion fire burns electrical shock or car bon monoxide poisoning AX DANGER Carbon monoxide poisoning may lead to death Engine exhaust contains poisonous carbon monoxide gas Overexposure will cause loss of consciousness and will lead to death Use only in well vented areas Make sure area has plenty of free moving fresh outside air Never run generator in an enclosed or confined area Never run generator inside occupied building Carbon Monoxide Poisoning Early signs of carbon monoxide poisoning re semble the flu with headaches dizziness and nausea If you have these signs get fresh air at once Some people are more affected by carbon monoxide than others These include pregnant women persons with heart or
4. L14 20P j Plug Ground Green Hot L14 20P M Plug 120 240 Volt 20 and 30 Ami P Ground L14 50P Plug Ground Green Neutral Y Hot Figure 15 Cord and Plug Configurations Continued Powerkast PORTABLE GASOLINE GENERATORS OPERATION Continued PRESTART Operate generator on a firm dry and clean surface The surface must be level Protect generator from heavy dust sand dirt rain or snow Do not locate generator near stand ing water and snow Make sure area is well vented A WARNING Only responsible adults should use generator Never let anyone operate genera tor without proper instructions Note If oil level is too low oil alert system will keep engine from starting see Oil Alert System page 6 Make sure oil level is full before starting See Engine Oil page 7 Before starting the engine disconnect all electric loads from generator STARTING IMPORTANT The engine speed is preset The throttle is locked in preset position Do not adjust throttle Preset position lets en gine run at 3600 RPM under load The engine must maintain 3600 RPM for gen erator to create correct voltage Running engine at lower speeds will damage genera tor and powered items IMPORTANT Never start generator with electrical loads connected Start engine be fore adding electrical loads 1 Make sure gasoline tank is full See Fuel page 7 for fuel information
5. 2 Move fuel valve lever to the ON posi tion see Figure 16 3 Move choke lever fully to the left see Figure 16 or pull choke button out Model PGH11000IE only see Figure 17 This closes the choke Note You may not need to close choke if engine is warm or air temperature is high 4 Start the engine A Recoil Starter Turn engine switch to the ON position see Figure 18 Remove slack from starter rope by lightly pulling starter grip Next pull starter rope briskly IMPORTANT Do not let starter grip snap back against engine Return it gen tly This will prevent damage to starter Note If engine does not start check the oil in the crankcase Add oil as nec essary Be sure engine is on a level sur face See Oil Alert System page 6 B Electric Starter Turn the engine switch to the START position see Figure 18 Hold it there until engine starts When engine starts let switch return to the ON position IMPORTANT Do not use electric starter more than five seconds Starter motor damage may occur If engine fails to start release the switch and wait ten seconds After ten seconds try start ing again Note If engine does not start check the oil in the crankcase Add oil as nec essary Be sure engine is on a level sur face See Oil Alert System page 6 5 As engine warms up slowly move choke lever fully to the right see Fig ure 19 This opens the choke On Model PGH11000IE the choke will au
6. tomatically open Choke Lever Closed Position Fuel Valve Lever ON Position Figure 16 Fuel Valve Lever On Choke Lever Closed Model PGH7500IE Shown Choke Button Pulled Out Closed Position Figure 17 Choke Button Closed Model PGH11000IE Only Engine Switch oe VA Figure 18 Engine Switch Choke Lever Open Position Figure 19 Choke Lever Opened Model PGH7500IE Shown 106746 OPERATION Continued HIGH ALTITUDE OPERATION This generator will not perform well at high altitudes without proper adjustment See engine Owner s Manual for details ADDING ELECTRICAL LOADS IMPORTANT Do not overload generator Make sure total wattage of all electrical loads does not exceed rated wattage of gen erator Overloading may shorten generator life It could also cause internal damage to generator Overloading will trip circuit breaker 1 Check items to be powered Their nameplate lists their wattage ratings Note The wattage ratings for some electrical motors are misleading They may require up to three times their rated wattage to start You must figure total electrical load wattage Make sure total wattage of all electrical loads does not exceed rated wattage of generator See Determining Electrical Load For Generator page 10 2 Start engine Let engine reach full speed 3 Connect electrical loads one at a time If the load consists of electric
7. Continued 9 Only a qualified electrical service per son should service and repair generator e Generator produces high voltage Use extreme caution when working on electrical parts Always remove spark plug wire from spark plug before servicing This will prevent accidental starting When working on generator avoid hot muffler exhaust manifold and engine parts Severe burns may occur Do not work on generator when tired Use only factory approved replace ment parts 10 Store generator in a well vented area Make sure fuel tank is empty Never store with fuel in tank Vapors may reach an open flame or spark Fire or explosion may result 11 Never operate generator if engine speed changes greatly if engine misfires often if powered items overheat if electrical output drops if it is sparking if it produces smoke or flames if it vibrates at high levels if it has a damaged receptacle 12 Keep generator and nearby areas clean Keep generator free of oil mud and other foreign matter Remove anything that creates slip pery areas around generator Remove oily rags and other items that create fire hazards Keep a fire extinguisher nearby Make sure it is rated ABC by the NFPA They are good for all uses Consult your local fire department Keep fire extinguisher well main tained Be familiar with its use 13 Know how to stop engine quickly Know how to use all controls 14 Prolonged exposure to l
8. a hazard of fire or explosion Gasoline is flammable Its vapor is explosive e Keep fuel out of children s reach e Refuel generator in a well vented area Do not fill fuel tank in the dark Do not refuel while engine is running Unhook all electrical loads and shut off engine before refueling Do not overfill fuel tank Al ways allow room for fuel to expand If you overfill tank fuel can overflow onto hot engine This can cause fire or explo sion After refueling tightly close fuel tank cap Do not spill fuel Fuel or fuel vapor may ignite If fuel spills make sure area is dry before starting engine Never smoke in refueling area Never allow open flames or sparks in area e Store fuel in approved con tainer Store fuel in a well vented area free of open flames or sparks Use clean fresh unleaded gasoline Use gasoline with octane rating of 86 or higher Service station gasoline pumps should dis play the octane rating Using gasoline with lower octane level could damage engine Avoid getting dirt dust or water in fuel tank Do not mix oil with gasoline See engine Owner s Manual for more information A WARNING Battery gives off explosive gases Keep sparks flames and cigarettes away Do not remove or install battery cables when engine is cranking or running Only service or use battery in a well vented area A WARNING Battery contains sulfuric acid Contact with skin o
9. 103880 01 NEC 5C 14138000 099853 02 WLE 5 WLI 3 WP 5C HC5 11C 099756 01 099750 01 099749 01 NEC 5C 100410 01 M10908 74 WP 4C 099965 01 WP 3C 099742 01 Gas Cap Fuel Gage Gas Tank with 90 fitting Breather Assembly Screw 1 4 20 x 1 Screw M5 x 10 Gas Line Clamp Fuel Line Fuel Filter Roll Cage Lock Nut 1 4 20 Lock Nut 5 16 18 Ground Strap Shock Mounts Lock Washer 5 16 Lock Washer 10 Flat Washer 5 16 Bolt 5 16 18 x 1 9 4 Engine Spreader Hook Bolt 5 16 18 Battery Mounting Bracket Lock Nut 5 16 18 Sems Screw 8 18 x 1 2 Screw 1 4 20 x 1 2 Washer 1 4 Linkage Cover Washer 10 90 Fitting with barbs PARTS AVAILABLE NOT SHOWN 099866 02 100003 02 099873 01 099873 02 03157000 Safety Information Decal Operation Decal Battery Cable Positive Red Battery Cable Negative Black Fuel Line Grommet OWNER S MANUAL KEY PART NUMBER DESCRIPTION 4 4 4 p 2 1 1 4 5 8 1 3 3 1 9 2 1 2 1 2 4 3 5 1 1 1 PowerFast PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST FOR MODEL PGH11000IE FUEL TANK AND ROLL CAGE 20 106746 OWNER S MANUAL ILLUSTRATED PARTS LIST NG finer sesonenon jam 25954000 Gas Cap Fuel Gage FOR MODEL PGH11000IE 099832 01 Gas Tank with 90 fitting FUEL TANK AND ROLL 25978000 Breather Assembly CAGE M51043 01 1 4 20 x 1 Screw 26302006 1 2 20 x 1 Bolt 19508001 Gas Line Cla
10. Add oil to engine see Engine Oil page 7 Note Operate generator on a level surface If not level the oil may flow away from the oil level sensing device This will cause the oil alert system to shut down engine See engine Owner s Manual for more information ats sw CIRCUIT eS NI Figure 2 Engine Switch Location ELECTRIC START A battery is not supplied with generator You must provide a 12 volt 32 amp hour battery For more battery information see Battery pages 7 and 8 GROUND FAULT CIRCUIT INTERRUPTER RECEPTACLE All models have a 120 volt ground fault circuit interrupter GFCI receptacle The GFCI protects you against hazardous elec trical shock caused when your body be comes a path through which electricity trav els toreach ground This couldhappen when you touch an appliance or cord that is live through faulty mechanism damp or worn insulation etc When protected by the GFCI you may still feel a shock but the GFCI should cut it off quickly A person in normal health should not receive serious injury Note Infants and very small children may still be affected Test Procedure Check the GFCI receptacle every month This insures it is working right 1 Push black TEST button Red RESET button should pop out This should trip GFCI resulting in no electrical power at receptacle Verify this by plugging test lamp with good bulb into recep tacle If lamp d
11. Check for loose or missing parts Check for shipping damage If any parts are missing or damaged promptly inform dealer where you bought generator 4 Battery cables are supplied These cables are in a separate bag inside generator carton You must install these cables to engine See Battery pages 7 and 8 for installation instruc tions VENTILATION A DANGER Use only in well vented areas Make sure area has plenty of free moving fresh out side air Never run generator in an enclosed or confined area Never run generator inside occu pied building Engine exhaust contains poisonous carbon mon oxide gas Overexposure will cause loss of consciousness and will lead to death This generator needs cooling air to run prop erly Never block free flowing cooling air to generator Overheating will occur with out cooling air This will damage the gen erator Keep generator at least three feet away from any object DUST DIRT RAIN AND SNOW A WARNING Do not use gen erator outdoors in rain or snow Do not use generator near stand ing water or snow Do not use if generator is wet or damp Oper ating generator in these condi tions increases the risk of elec trocution Severe injury or death can occur Do not use generator in extremely dusty or dirty conditions This will severely affect its life Keep generator clean Do not allow dust dirt rain or snow to collect on it Protect generator
12. factory authorized dealers and service centers for this product These dealers and service centers will provide original factory replacement parts Failure to use original factory replacement parts voids this warranty This warranty does not apply to parts that are not in original condition because of normal wear and tear or parts that fail or become damaged as a result of misuse abuse negligence accident lack of proper maintenance alteration modification tampering contaminated fuels repair using improper parts or repair by anyone other than an authorized dealer or service center Routine maintenance is the responsibility of the owner Travel handling transportation and incidental costs associated with warranty repairs are not reimbursable under this warranty and are the responsibility of the owner DESA International makes no warranty with respect to the engine and engine components not of its manufacture They are subject to warranties of their manufacturers To the full extent allowed by the law of the jurisdiction that governs the sale of the product this express warranty excludes any and all other expressed warranties and limits the duration of any and all implied warranties including warranties of merchantability and fitness for a particular purpose to two years from the date of first purchase and DESA International s liability is hereby limited to the purchase price of the product and DESA International shall not be liable for any
13. from outdoor elements HIGH AND LOW TEMPERATURE OPERATION Air temperature affects generator output Output drops 1 for each 10 temperature rise above 60 F Very low temperatures may make the engine hard to start See engine Owner s Manual for more information 106746 OWNER S MANUAL SPECIFICATIONS MODEL PGH7500IE PGH11000IE Electrical Rated Wattage 7000 10 000 Rated Amperage 120 V 57 83 3 240 V 28 3 41 7 Receptacle 120 V Duplex Yes Yes 120 V 15 A GFCI Yes Yes 120 V Twist Lock 30 Amp 30 Amp 120 240 V Twist Lock 30 Amp 30 Amp 120 240 V 50 A No Yes General Honda Engine H P 13 20 Honda Model GX390K1VXE GX620VXA3 Fuel Type Gasoline Gasoline Fuel Tank Capacity 5 gal 5 gal Oil Alert System Yes Yes Start Method Electric Electric Weight pounds 247 325 Single phase 1 0 power factor Note Ratings apply to SAE standard conditions Reduce ratings 3 2 for each 1000 feet above sea level and 1 for each 10 Fahrenheit rise above 60 F 106746 5 PowerFast PORTABLE GASOLINE GENERATORS GENERATOR FEATURES OIL ALERT SYSTEM The oil alert system protects the engine from low oil damage This system automatically shuts down the engine and prevents engine restarting if the oil level falls too low Note When this happens the engine switch remains in the ON position The oil alert system is wired into the ON OFF Switch If this system shuts down the engine the engine will not start until you add oil
14. load The engine must maintain 3600 RPM for generator to create cor rect voltage Running engine at lower speeds will damage gen erator and powered items A CAUTION Shut off generator before performing maintenance TROUBLESHOOTING Note For additional help vist DESA International s Technical Service web site at www desatech com Note See engine Owner s Manual for en gine troubleshooting OBSERVED PROBLEM IMPORTANT Keep generator level when servicing Never turn generator upside down or stand it on end to service Note We supply the engine Owner s Manual with generator Refer to that manual for questions concerning engine mainte nance and repairs Non engine parts require little maintenance Keep generator clean Use a damp cloth to clean outside surfaces Never use water to clean generator Water can cause damage to internal parts Use vacuum to clean air inlet and outlet louvers of alternator STORAGE AX WARNING Remove all fuel from fuel tank before storing gen erator Store fuel in approved con tainer Store fuel in a well vented area free of open flames or sparks AX WARNING The muffler be comes very hot during operation The muffler remains hot for a while after shutdown Let engine cool before storing IMPORTANT Keep generator level while in storage Never store generator upside down or standing on end Note We supply the engine
15. other damages whatsoever including indirect incidental or consequential damages Some states do not allow limitation of how long an implied warranty lasts or an exclusion or limitation of incidental or consequential damages so the above limitation of damages may not apply to you This warranty provides the original purchaser with specific rights For information regarding those rights please consult the applicable state laws 106746 01 INTERNATIONAL 2701 Industrial Drive P O Box 90004 Bowling Green KY 42102 9004 NOT A UPC www desatech com 106746 01 REV A 09 99
16. remain alert when using generator e Keep children and animals away from generator while it is running or hot e Keep all covers and shields in place Keep them tightly secured e The muffler becomes very hot dur ing operation The muffler remains hot for a while after shutdown Do not touch muffler while it is hot Do not let muffler touch anything flam mable Let engine cool before trans porting or storing Have standby installation to home or building performed by a licensed elec trician Do not let anyone else wire into a utility circuit Personal injury equip ment damage or damage to home could occur Never connect generator to any exist ing electrical circuits The generator output will back feed into the utility power line This may electrocute a power company line repair person Also if generator is powering electri cal circuits the chance of an electrical fire exists Battery gives off explosive gases Keep sparks flames and cigarettes away Do not remove or install battery cables when engine is cranking or running Only service or use battery in a well vented area Battery contains sulfuric acid Battery acid is poisonous if swallowed Con tact with skin or eyes may cause severe burns Do not tilt generator with bat tery installed Tilting could cause bat tery acid to spill Wear protective cloth ing and face shield when servicing Keep out of children s reach 106746 SAFETY INFORMATION
17. 0A Twist Lock Receptacle 22616010 30 Amp Circuit Breaker 099760 01 Bushing 103185 01 Control Box 100366 01 Rocker Switch 15324000 120V 15A Duplex Receptacle 102927 01 Control Panel Assembly 100177 05 Panel Schematic Diagram 103257 01 Auto Idle PC Board Kit 103258 02 Solenoid Assembly Kit With Bracket Includes reference numbers 1 through 16 A Not shown 106746 23 PowerFast PORTABLE GASOLINE GENERATORS TECHNICAL SERVICE You may have further guestions about in stallation operation or troubleshooting If so contact DESA International s Techni cal Service Department at 1 800 323 5190 You can also visit DESA International s Technical Service web site at www desatech com SERVICING THE ENGINE Honda parts and services should be handled by your nearest authorized engine service firm Check the yellow pages of your tele phone directory under the listing Engines Gasoline Honda REPLACEMENT PARTS Note Use only original replacement parts This will protect your warranty coverage for parts replaced under warranty PARTS UNDER WARRANTY Contact authorized dealers of this product If they cannot supply original replacement part s either contact your nearest Parts Central or call DESA International s Tech nical Service Department at 1 800 323 5190 When calling DESA International have ready e your name e your address e model and serial numbers of your gen erator e how generato
18. 10001E ALTERNATOR ASSEMBLY This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 24 of this manual 3 8 iien osscarnon an NO NUMBER DESCRIPTION QTY Stator A Rotor 103188 01 Draw Bolt 103191 01 Fan 103192 01 Balancing Disc 103193 01 Lifting Eyes 103194 01 D E Bracket 103195 01 N D E Bracket 099847 05 Mounting Bolts 099891 01 Nuts 103189 01 Top Box 099701 01 Screw and Washer 103198 01 Plastic Cap 103199 01 Bearing 103200 01 Borelly Washer 270030125 Diode 103201 01 Terminal Block 099845 02 Capacitor 103204 01 Tie Wrap 099892 02 Foam Pad 103202 01 Capacitor Bracket 103190 01 Engine Flange 270030155 Bolts 103203 01 O Ring WLE 5 Washer 099891 01 Hex Head Nut 102938 01 Alternator Assembly Part not available by itself Must purchase Alternator Assembly dd PAH HSH HSH aH aH a pH DAR A ZU HAHAH a a 106746 17 Powerfast PORTABLE GASOLINE GENERATORS ILLUSTRATED PART S LIST FOR MODEL PGH75001E FUEL TANK AND ROLL CAGE 106746 ILLUSTRATED PARTS LIST FOR MODEL PGH75001E FUEL TANK AND ROLL CAGE This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 24 of this manual 106746 25954000 099832 01 25978000 M51043 01 099701 01 19508001 25985005 099743 01 099752 01
19. 615 299 8777 Tuco Industrial Products 5223 180th St SW Suite 4A 1 Lynnwood WA 98037 4506 425 743 9533 1 800 735 1268 106746 OWNER S MANUAL NOTES WARRANTY INFORMATION KEEP THIS WARRANTY Model Serial No Date Purchased Always specify model and serial numbers when communicating with the factory We reserve the right to amend these specifications at any time without notice The only warranty applicable is our standard written warranty We make no other warranty expressed or implied Note The two year limited warranty below covers all non engine parts of this generator including the alternator Honda warrants the engine See engine Owner s Manual for engine warranty information TWO YEAR LIMITED WARRANTY GASOLINE PORTABLE GENERATORS DESA International warrants each alternator generator or electric product of its manufacture to be free from defects in material and workmanship for two years from the date of first purchase from an authorized dealer provided that the product has been properly installed maintained and operated in accordance with all applicable instructions The bill of sale or proof of purchase must be presented at the time a claim is made under this warranty This warranty is extended only to the original retail purchaser This warranty covers only the parts and labor required to restore this unit to its proper operating condition Warranty parts must be obtained through
20. BATTERY CABLES TO ENGINE 1 Attach the red positive battery cable to the starter solenoid on engine see Figure 7 The starter solenoid is located directly above the starter on Model PGH11000IE This cable is fac tory installed A CAUTION Do notovertighten positive terminal on starter sole noid Positive terminal could ro tate and cut into negative termi nal causing a short 2 Attach the black negative battery cable to the engine block Use the bolt nut and two washers provided with the battery cables Use long mounting hole on opposite side of engine from starter solenoid Attach cable as shown in Figure 8 Starter Solenoid Red Positive S Battery Cable Figure 7 Connecting Red Positive Battery Cable to Engine Starter Solenoid Model PGH7500IE Shown Black Negative Battery Cable Figure 8 Connecting Black Negative Battery Cable to Engine Block Model PGH7500IE Shown MOUNTING BATTERY TO GENERATOR 1 Secure battery to generator by battery hold down system This system consists of the battery mounting bracket hook bolts and nut see Figure 9 Note Model PGH11000IE battery is located on opposite side as shown see Figure 10 2 Locate the red positive battery cable from starter solenoid Connect it to the positive battery terminal see Figures 11 and 12 3 Locate the black negative battery cable attached to engin
21. Owner s Manual with generator Refer to that manual for questions concerning engine storage Use a fuel additive such as STA BIL or an equivalent when storing generator with fuel in fuel tank This will minimize fuel gum deposits from forming in engine Cover and store generator in a clean dry place Do not expose generator to extreme high or low temperatures during storage A WARNING Only a qualified electrical service person should service and repair generator Use only factory approved replacement parts POSSIBLE CAUSE REMEDY No voltage when starting generator with no electrical load 1 Defective capacitor 2 Winding short circuit or loose connections 3 Defective rotor diode 4 Loss of residual magnetism 1 Replace capacitor 2 Check resistance of coils see Electri cal Component Specifications page 15 3 Replace both diodes on rotor 4 Apply 12 volt battery to capacitor ter minals for 2 3 seconds Voltage is less than normal voltage with no electrical load 1 Engine speed too low 2 Defective rotor diode 3 Partial short circuit in winding 4 Defective capacitor 1 Set engine speed to 3720 RPM 62 Hz with no load 2 Replace both diodes on rotor 3 Check resistance of coils see Electri cal Component Specifications page 15 4 Replace capacitor Voltmeter reading more than 10 high with no electrical load 1 Engine speed too high 1 Set engine speed to 3720 R
22. PM 62 Hz with no load Voltmeter reading correct with no electrical load but more than 10 low when electri cal load is added pi Defective rotor diode Electrical load too high Engine not running properly Wn www desatech com 14 1 Replace both diodes on rotor 2 Do not overload generator 3 Contact an authorized engine service center 106746 OWNER S MANUAL ELECTRICAL COMPONENT SPECIFICATIONS Resistance in Ohms Stator Stator Rotor Rotor Capacitor Main Auxiliary Primary Secondary MFD Diodes 2 Model Winding Winding A Winding t Winding t 450 Volt 800 Volt PGH75001E 0 28 0 78 0 77 2 9 70 70 Amp PGH110001E 0 40 0 90 0 37 0 50 80 70 Amp Connect T2 green and T3 black Measure resistance between T1 red and T4 yellow A Resistance between brown and white leads t Remove diodes to check resistance WIRING DIAGRAMS
23. W 1000 watts Note The name plate may not list wattage It may only list volts and amps The formula for finding wattage is Volts x Amps Watts For example An appliance nameplate states 3 amps at 120 volts 3 amps x 120 volts 360 watts Electric motors present a special prob lem They require up to three times their rated wattage to start Chart 2 below shows starting watts for differ ent size motors For example an elec tric motor nameplate states 5 amps at 120 volts 5 amps x 120 volts 600 watts running Multiply this figure by 3 This will show the starting watts needed 600 watts x 3 1800 watts to start When figuring the generator load Chart 1 Typical Electric Appliance Wattages Equipment Running Watts Starting Equipment Running Watts Starting Watts Light bulb 100W Radio Fan Television Furnace fan 1 3 hp with blower Vacuum cleaner Sump pump 1 3 hp Refrigerator freezer 6 Circular saw Floodlight Chart 2 Approximate Running Watts 1 2 Drill Toaster Coffee maker Skillet 14 Chain saw Water well pump Hot plate range 10 Table saw Water heater 1000 1250 1 2 hp per burner storage type Approximate Starting Watts Universal Motors small appliance Repulsion Induction Capacitor Motors Motors 275 400 450 600 850 1000 1600 2000 3000 400 500 600 850 850 1050 975 1350 1300 1800
24. e block Connect it to the negative battery terminal see Figures 11 and 12 4 Check battery before starting engine Make sure fluid levels are full Make sure battery is charged See engine Owner s Manual for more information Battery Mounting Bracket Pd S Hook Bolt Figure 9 Battery Hold Down System Model PGH7500IE Shown 8 Nut Battery Battery Hook gt Mounting Bracket Bolt l l Figure 10 Battery Hold Down System Model PGH11000IE Shown Figure 11 Connecting Positive and Negative Cables to Battery Model PGH7500IE Shown TO STARTER SOLENOID Figure 12 Connecting Positive and Negative Cables to Battery Model PGH11000IE Shown 106746 GENERATOR GROUNDING A WARNING You must prop erly earth ground generator be fore starting This will help guard against deadly electric shock Only use grounded plugs with generator Only use grounded ex tension cords Only use three wire or double insulated power tools Grounding generator helps prevent electric shock froma ground fault condition Locate ground lug on end of generator housing see Figure 13 Attach a 10 stranded copper ground wire to ground lug Drive grounding point into ground Grounding point can bea stake grounding rod or pipe Grounding point should be copper or brass Attach ground wire to grounding point You must supply the ground wire and gr
25. e parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 24 of this manual PART NUMBER 103349 04 22616009 099833 01 15324000 100445 01 100366 01 22616010 099835 01 101350 01 099760 01 100410 01 100149 01 22261000 103348 04 103348 08 100177 07 DESCRIPTION Control Panel Circuit Breaker 20 Amp 120V 30A Twist Lock Receptacle 120V 15A Duplex Receptacle 120V 15A Duplex GFCI Receptacle Rocker Switch Circuit Breaker 30 Amp 120 240V 30A Twist Lock Receptacle Hour Meter Bushing Sems Screw 8 18 x 1 2 Control Box U Nut Control Panel Assembly Control Panel Assembly Auto Idle Models Panel Schematic Decal Includes fastening hardware A Not shown Includes reference numbers 1 through 13 22 106746 OWNER S MANUAL ILLUSTRATED PARTS LIST FOR MODEL PGH110001E CONTROL PANEL This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 24 of this manual KEY PART NO NUMBER DESCRIPTION QTY 103182 01 Control Panel 22616009 20 Amp Circuit Breaker 099833 01 120V 30A Twist Lock Receptacle 100410 01 8 18 x 1 2 Sems Screw 22261000 U Nut 100445 01 120V 15A Duplex GFCI Receptacle 103183 01 125 250V 50A Receptacle 103184 01 45 Amp Circuit Breaker 26299000 Run Light 101350 01 Hour Meter 099834 01 120 240V 2
26. faz i Hour Meter mi A 5 o LO gt Red o Black Black Yellow Red Black Black White CSS SS A eS ee a eS e Black Capacitor Stator 2 2 TY T4 Stator 1 I SlE T T2 173 T4 s Diode k Ld 220 240V 2 110 120V 110 120V Figure 23 Wiring Diagram Model PGH11000IE 106746 15 PowerFast PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST FOR MODEL PGH7500IE ALTERNATOR ASSEMBLY This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 24 of this manual 1 2 3 4 5 6 7 8 9 Part not available by itself Must purchase Alternator Assembly 099723 04 099844 01 099701 01 099760 01 WLE 6 099863 02 17587000 M11084 26 099847 04 WLE 5 099843 01 27007004S 100054 01 27003002 27003015S 099891 01 099892 01 099842 04 27003003 27003012S 27003008 27003007S 26322004 Alternator Assembly End Cover Screw M5 x 13 Bushing Lock Washer 3 8 Terminal Block 2 block Ground Lug Screw 10 16 x 3 8 Stator Bolt Lock Washer 5 16 Bearing Housing Capacitor Terminal Post Stator Fan Bracket Screw M8 x 20 Rotor Nut Flanged 8mm Foam Pad Draw Bolt Bearing Diode Rotor Fan Engine Flange Bolt 3 8 16 x 5 8 PART NUMBER DESCRIPTION QTY he SH Ss PO HH HSH HSK PH SH RH KH DA HSH HSH RAO AH AH 106746 OWNER S MANUAL ILLUSTRATED PARTS LIST FOR MODEL PGH1
27. in refueling area Never allow open flames or sparks in area e Store fuel in approved container Store fuel in a well vented area free of open flames or sparks Guard against fire hazard Keep opera tion area well vented Keep generator at least three feet away from any ob ject Do not place flammable objects near generator e Do not use generator where flam mable vapors are present Some va pors are heavier than air These va pors settle in low lying places e Do not use generator in enclosed spaces This includes motor home or RV generator compartments Guard against electric shock Generator produces high voltage This high voltage can cause severe electric shock Only re sponsible adults should use generator e Properly ground generator before starting e Never let anyone operate or service generator without proper instruc tions e Avoid contact with live terminals or bare wires e Do not use generator outdoors in rain or snow e Do not use generator near standing water or snow e Do not use if generator is wet or damp e Do not use generator in highly con ductive areas These areas include metal decking and steelwork e Only use grounded extension cords e Do not use any worn or damaged electric cords Electric shock or dam age to generator may result e Do not wear damp clothing or wet shoes when using generator Guard against burns Hot engine parts can cause severe injury Use caution and
28. is generator as a standby power source During a power out age the generator will power selected items in a building Have generator and additional wiring installed by a skilled licensed elec trician This is not a do it yourself job Fol low all local codes AX WARNING The electrician must installa double throw trans fer switch This isolates existing electrical circuits from the utility power line If not isolated gen erator output will back feed into utility power line This may elec trocute a power company line repair person PowerFast PORTABLE GASOLINE GENERATORS DETERMINING ELECTRICAL LOAD FOR GENERATOR You must decide what electrical load your generator can power Do this before using generator Use the following four step method It will help you select a load that is not too large Make sure total wattage of all electrical loads does not exceed rated watt age of generator For rated wattage of your generator see Specifications page 5 Elec tric motors present a special problem when figuring load Read Step 3 carefully 1 Make two lists of items you want pow ered by generator List all motors and motor powered appliances in one List all lights small appliances etc in the other For standby service to home or building Z only include items you must power Enter running watts of each item ex cept motors The light bulb or appliance nameplate lists its wattage Remember 1K
29. lung disease or anemia those under the influence of alcohol and those at high altitudes Make certain you read and understand all warnings Keep this manual for reference It is your guide to safe and proper operation of this generator Safety information appears throughout these instructions Pay close attention to them Below are definitions for the safety infor mation listed throughout this manual DANGER indicates a hazard which will cause severe personal injury death or substan tial property damage if you ignore warning WARNING indicates a hazard which can cause severe personal injury death or substan tial property damage if you ignore warning CAUTION indicates a hazard which will or can cause minor personal injury or prop erty damage if you ignore warning Gasoline presents a hazard of fire or ex plosion Gasoline is flammable Its va por is explosive e Keep fuel out of children s reach e Refuel generator in a well vented area Do not fill fuel tank in the dark Do not refuel while engine is run ning Unhook all electrical loads and shut off engine before refueling e Do not overfill fuel tank Always al low room for fuel to expand If you overfill tank fuel can overflow onto hot generator This can cause fire or explosion After refueling tightly close fuel tank cap e Do not spill fuel Fuel or fuel vapor may ignite If fuel spills make sure area is dry before starting engine e Never smoke
30. motors start them first Always start the larg est first Start each motor individually DISCONNECTING ELECTRIC LOADS Remove electrical loads one at a time Re move voltage sensitive items first Voltage sensitive items include TVs VCRs and other home electronic items 106746 OWNER S MANUAL STOPPING ENGINE IMPORTANT The engine speed is preset The throttle is locked in preset position Do not adjust throttle Follow the steps below to stop engine 1 Remove all electrical loads from gen erator see Disconnecting Electrical Loads Remove electrical loads one at a time 2 Let engine run for two or three min utes after removing electrical loads This lets engine cool slightly 3 Turn engine switch to the OFF posi tion see Figure 20 4 Turn fuel valve lever off Do this by moving valve lever fully to the left see Figure 21 ON OFF START 7 m Figure 20 Engine Switch In OFF Position Fuel Valve Lever Off Position Figure 21 Fuel Valve Lever Off Model PGH75001E Shown PowerFast PORTABLE GASOLINE GENERATORS MAINTENANCE AND REPAIRS Ay WARNING Only a qualified electrical service person should service and repair the alternator on this generator Use only fac tory approved replacement parts A CAUTION The engine speed is preset The throttle is locked in preset position Do not adjust throttle Preset position lets en gine run at 3600 RPM under
31. mp 25985006 Fuel Line WLE 6 3 8 Lock Washer 105111 01 Roll Cage 103880 01 1 4 20 Lock Nut NEC 5C 5 16 18 Lock Nut 14138000 Ground Strap 17529000 Shock Mounts WLE 5 5 16 Lock Washer HC6 10C 3 8 16 x 1 1 4 Screw WP 6C 3 8 Flat Washer HC5 11C 5 16 18 x 1 3 4 Bolt 102962 01 Engine Spreader 099750 01 5 16 18 Hook Bolt 099749 01 Battery Mounting Bracket 102933 01 Axle 100410 01 8 18 x 1 2 Sems Screw M10908 74 1 4 20 x 1 2 Screw WP 5C 5 16 Washer 26007004 5 16 18 x 3 4 Bolt WP 4C 1 4 Washer WLI 8 1 2 Lock Washer H8C5 20C 5 16 18 x 2 50 Screw 105035 01 Handle 103046 01 Handle Grip 103057 01 Handle Plug 102936 02 Stand 100135 01 U Bolt WP 16C Flat Washer 102932 01 Wheels C4 12C Cotter Pin 099742 01 90 Fitting with Barbs 099866 02 Safety Information Decal 100003 04 Operation Decal 099873 04 Red Battery Cable Positive 099873 02 Black Battery Cable Negative 03157000 Grommet HC4 6C Screw 250 x 75 103818 03 Wheel Kit Hardware This list contains replaceable parts used in your generator When ordering parts fol low the instructions listed under Replace ment Parts on page 24 of this manual r POND HH HSH HS i 4 3 1 1 1 2 1 2 1 2 4 1 24 10 4 2 4 2 12 2 1 2 4 2 2 1 1 1 1 1 3 2 1 A Not shown 106746 21 PowerFast PORTABLE GASOLINE GENERATORS ILLUSTRATED PARTS LIST FOR MODEL PGH7500IE CONTROL PANEL This list contains replaceabl
32. oes not work GFCI re ceptacle is good A WARNING If RESET button does not pop out do not use the GFCI receptacle Contact a quali fied electrician for repairs 2 If the GFCI receptacle tests okay re store power by pushing the RESET button back in The test lamp should work at this time IMPORTANT You must press the RESET button firmly and fully It should lock into place If the GFCI does not lock into place do not use receptacle Contact a qualified electrician for repairs Figure 3 GFCI Receptacle ENGINE CIRCUIT BREAKER This circuit breaker or fuse protects the battery charging circuit A short circuit will trip the circuit breaker The circuit breaker will also trip if you install battery wrong Push circuit breaker button to reset On Model PGH11000IE the fuse is located inside of the Keyswitch box ON OFF START or Y ENGINE SW Engine Circuit BREAKER Breaker Button Figure 4 Engine Circuit Breaker RECEPTACLE CIRCUIT BREAKER The circuit breakers protect the receptacles and alternator Overloading generator will trip circuit breaker A short circuit in item being powered will also trip breaker If this occurs unplug electrical load from recep tacle Let circuit breaker cool down Push circuit breaker button to reset Electric motors need higher starting current They require up to three times their rated wattage to start The starting cu
33. oud noise can cause hearing loss e When working around generator wear approved hearing protection e Remember neighbors when using generator 106746 OWNER S MANUAL PRODUCT IDENTIFICATION Gas Cap Fuel Gauge Control Panel 120 Volt Receptacle 120 Volt Receptacle GFCI 120 Volt Receptacle Duplex Hour Meter 120 240 Volt Receptacle Circuit Breaker Fuel Valve Lever Engine Engine ON OFF Switch Oil Dipstick Figure 1 Portable Generator Model PGH7500IE Shown 3 Gas Tank Alternator Roll Cage PowerFast PORTABLE GASOLINE GENERATORS GENERAL INFORMATION Powerfast portable generators are rugged and compact These models provide depend able trouble free service The alternators are brushless with revolving fields Honda gaso line engines provide long life under heavy use Honda engines have overhead valves OHV This provides high performance with lower fuel consumption These engines are governed to maintain engine speed of 3600 RPM under load 3600 RPM engine speed provides 120 240V 60 Hz power ADDITIONAL FEATURES e Circuit breaker protection e Spark arresting muffler except model PGH11000IE e Large fuel tank e Oil alert system e Electric starter e 15 Amp ground fault circuit interrupter GFCI receptacle UNPACKING 1 Remove generator from carton 2 Remove any protective packaging ap plied to generator for shipment 3
34. ounding point These do not come with generator Follow the National Electrical Code and all state and local codes Consult your power com pany or a licensed electrician A WARNING For a grounding point do not use metal pipe be ing used to carry combustible materials or gases Ground Lug Copper or Brass Grounding Point BLN Figure 13 Grounding Generator Model PGH7500IE Shown Ground Wire 106746 OWNER S MANUAL EXTENSION CORDS Only use grounded extension cords Be sure to use extension cord with proper wire gauge size See chart below Recommended Minimum Wire Gauges AWG for Extension Cords Ampere AWG for Length of Load Cord in Feet 50 100 150 2 18 18 18 3 18 18 18 4 16 16 16 5 16 16 16 6 16 16 14 8 16 14 12 10 16 14 12 12 14 14 12 14 14 12 10 16 12 12 10 20 10 10 8 STANDBY INSTALLATION TO HOME OR BUILDING A WARNING Have standby in stallation performed by a skilled licensed electrician Do not let anyone else wire into a utility circuit Personal injury eguip ment damage or damage to home could occur IMPORTANT This generator will not power your entire home Most home utility electric service is more than 60 amps This will exceed generator output Only power needed items during a power outage Make sure total wattage of electrical load does not exceed rated wattage of generator You may need to use th
35. r eyes may cause severe burns Do not tilt generator with battery installed Tilting could cause bat tery acid to spill Wear protective clothing and face shield when servicing Keep out of children s reach If battery acid gets on your skin wash with water Ifbattery acid gets in your eyes flush with water atleast 15 min utes Call a doctor at once Battery acid is poisonous If swallowed drink large amounts of water or milk Fol low with milk of magnesia or vegetable oil Call a doctor at once A CAUTION If you remove bat tery insulate the red positive battery cable terminal Insulate with electrical tape Exposed ter minal may spark when generator runs IMPORTANT Make sure battery connec tions are the correct polarity Electric start generators use negative ground 12 volt DC starting system A battery is not supplied with generator You must provide a 12 volt 32 amp hour battery The positive and negative battery cables are supplied with generator You must install these cables before mounting battery Continued PowerFast PORTABLE GASOLINE GENERATORS BATTERY Continued Always wear safety glasses when working with battery Make sure battery terminals are clean Make sure cable connections are tight Always shut down engine before removing or attaching battery cables Always remove the negative cable first Always attach negative cable last INSTALLING
36. r is malfunctioning e purchase date Usually we will ask you to return the defec tive part to the factory PARTS NOT UNDER WARRANTY Contact authorized dealers of this product If they cannot supply original replacement part s either contact your nearest Parts Central or call DESA International s Parts Department at 1 800 972 7879 for referral information When calling DESA International have ready e model number of your generator e the replacement part number 24 PARTS CENTRALS These Parts Centrals are privately owned businesses They have agreed to support our customer s needs by providing original re placement parts and accessories Baltimore Electric 1348 Dixwell Avenue Hamden CT 06514 0322 1 800 397 7553 203 248 7553 Parts Company of America 1657 Shermer Road Northbrook IL 60062 5362 1 800 323 0620 708 498 5900 Portable Heater Parts 342 N County Road 400 East Valparaiso IN 46383 9704 1 800 362 6951 219 462 7441 FBD 1349 Adams Street Bowling Green KY 42103 3414 270 846 1199 1 800 654 8534 Master Parts Dist 1251 Mound Ave NW Grand Rapids MI 49504 2672 1 800 446 1446 616 791 0505 Fax 616 791 8270 Four Flags Power Products 1115 Stateline Road Niles MI 49120 4728 1 800 268 4983 616 684 2697 Laportes Parts amp Service 2444 N 5th Street Hartsville SC 29550 7704 803 332 0191 MTA Distributors 555 Hickory Hills Blvd Nashville TN 37189 9244 1 800 264 0225
37. rrent needed may be too high This can cause nuisance circuit breaker tripping To help prevent this start electric motors first Connect ad ditional items to generator after starting motors If this continues to happen reduce the total generator load 9 Normal Tripped Figure 5 Receptacle Circuit Breaker Button Note High ambient temperature will cause nuisance tripping 106746 ENGINE OIL We ship the generator without oil in the engine crankcase You must add oil before starting engine See engine Owner s Manual for specific oil type CHECKING OIL LEVEL AND ADDING OIL Follow steps below to check oil level Make sure engine is level and stopped 1 Remove dipstick see Figure 6 Wipe dipstick clean 2 Insert dipstick into oil filler neck Do not screw it in Oil level should be at top of filler neck Oil should cover most of dipstick For Model PGH11000IE only the oil should be between the two dots on dipstick 3 Iflevel is low fill to top of oil filler neck see Figure 6 For Model PGH110001E only fill to top dot on dipstick Only use oil recommended in engine Owner s Manual Note If oil level is too low oil alert system will shutdown engine and prevent engine from restarting Oil Level At Top Of Filler Neck Oil Dipstick Figure 6 Checking Oil Level Model PGH7500IE Shown 106746 OWNER S MANUAL FUEL BATTERY A WARNING Gasoline presents
38. y line repair person Also if generator is powering electri cal circuits the chance of an elec trical fire exists Note We supply the engine Owner s Manual with generator Refer to that manual for questions concerning engine operation USING RECEPTACLE Note Do not exceed amperage rating of receptacles Exceeding rating will trip re ceptacle circuit breaker Use receptacles properly Improper use could damage generator Use only grounded ex tension cords Power only grounded or double insulated items Do not overload receptacles Both generators have the fol lowing receptacles see Figure 14 e 120V 15 amp GFCI duplex receptacle e 120V 30 amp twist lock receptacle e 120 240V 20 or 30 amp twist lock receptacle e 120V 15 amp duplex receptacle Model PGH11000IE also has a 120 240V 50 amp receptacle see Figure 14 106746 OWNER S MANUAL 120V 15 Amp GFCI Duplex 120V 15 Amp Duplex 120 240V 20 or 30 Amp Twist Lock 120V 30 Amp Twist Lock 120 240V 50 Amp Model PGH11000IE only Figure 14 Receptacle Locations POWER CORD AND PLUG REQUIREMENTS 120V 30 amp twist lock receptacle e NEMA L5 30P plug e Three wire 30 amp cord 120 240V 20 or 30 amp twist lock receptacle e NEMA L14 20P 20 amp or L14 30P 30 amp plug e Four wire 20 amp or 30 amp cord 120 240V 50 amp receptacle e NEMA L14 50P e Four wire 50 amp cord 120 240 Volt 20 Amp
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