Fabco Power-Mite 110 User manual

INSTALLATION INSTRUCTIONS
POWER MITE110
®
The Originators of Belt Driven & Hydraulically Powered AC Generators
Fabco Power • 1570 Kings Highway • Chester, NY 10918
tel: (845) 469-9151 • fax: (845) 469-7871
To view all Fabco Power's innovative products
visit our web site at www.fabcopower.com
MANUAL 102-11
INSTALLATION INSTRUCTIONS
POWER MITE110
®
The Originators of Belt Driven & Hydraulically Powered AC Generators
Fabco Power • 1570 Kings Highway • Chester, NY 10918
tel: (845) 469-9151 • fax: (845) 469-7871
To view all Fabco Power's innovative products
visit our web site at www.fabcopower.com
MANUAL 102-11
Fabco Cover.indd 1 6/17/11 2:20 PM

Fabco Cover.indd 2 6/17/11 2:20 PM

POWER MITE®
INSTALLATION INSTRUCTIONS
TABLE OF CONTENTS
1) INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . .1
2) UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3) MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
4) CONTROL PANEL WIRING . . . . . . . . . . . . . . . .4
5) INITIAL START UP AND OPERATION . . . . . . .5
6) FREQUENTLY ASKED QUESTIONS . . . . . . . . . .6
7) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
8) TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . .8
9) REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . .9
10) OPTIONAL VOLTAGE REGULATOR . . . . . . .10
11) OTHER FABCO POWER PRODUCTS . . . . . .12
IN
T

1
INTRODUCTION
The Power-Mite®110 and P/M/ 220 AC Electric Generator is a unique
miniature power source that mounts easily on any gasoline or diesel
engine.The Power-Mite®provides AC power whenever and wherever
you need it. For over 50 years the Power-Mite™ 110 has proven to be
a reliable, miniature heavy-duty power source.This unique generator
will operate all AC and AC/DC tools and appliances efficiently & safely.
The Power-Mite®features an isolated ground which provides safe op-
eration for the user.
PLEASE READ ALL THE INSTRUCTIONS
IN THIS MANUAL CAREFULLY
PRIOR TO INSTALLATION
UNPACKING
Remove packing foam on the top and lift the unit up carefully, firmly
grasping the two silver mounting ears on the generator. Place the unit
down and remove the plastic bag, remove the rest of the packing ma-
terial, brackets and hardware and layout on a clean surface. Save the
box and packing material in case the unit was damaged in shipment
and has to be returned.

CAUTION
The Generator, Base Plate and ALL supports
MUST be mounted to the engine.
2
MOUNTING
The Installation Must Be Performed By A Qualified Mechanic using
the standard mounting hardware supplied.The installer should figure
how to use the component parts furnished with the unit before
attempting the installation. (REFER TO THE ILLUSTRATIONS
ENCLOSED IN THIS MANUAL FOR PART DESCRIPTIONS AND
IDENTIFICATION) NOTE: ONLY USE ONE BELT TO DRIVE
THE POWER-MITE GENERATOR.THE BELT WIDTH
SHOULD BE 7/16” WIDE.
The #1 Base Plate, may be attached to any part of the engine block,
either by direct attachment or by use of the #4 strips furnished with
the kit. The #4 strips may be connected to the manifold bolts and
the #1 Base Plate mounted on the strips. The #4 Strips, may be
welded, bent, drilled or cut to accomplish the installation of the
generator within the confines of the engine compartment. Aligning
the generator with the drive belt is very important and it must
be precisely aligned. Both #4 strips are used to hold the #1 Base
Plate. They support the platform for a rigid and secure mount.
The #2 Saddle Bracket is used to hold the generator. Fasten it to
the #1 Base Plate. Notice that the slots in the #1 Base Plate are
cut opposite in direction to the slots in the #2 Saddle Bracket.
This permits positioning of the generator both laterally and horizon-
tally, thereby assuring both proper belt tension and proper belt align-
ment. As a further aid to the installation, the #1 Base Plate has
slots cut instead of holes, this permits the use of the Base Plate on
different centered holes. Use locktite on bolts on all diesel engine
installations.
The #3 belt tension strip has a long slotted hole that enables the
generator to move enabling belt tension adjustments. Attach the #3
strip with the bolt supplied through the slotted hole directly to the
generators front end bell and mount the opposite end directly to the
engine block.

3
#2 Saddle Bracket
#1 Base Plate
#3 Belt Tension
Strap
#4 Straps
Mounting to the engine permits the generator to become an integral
part of the driving engine, isolated from the engines’ floating mounts.
This precaution does not include the throttle or control panel, these
may be placed in the most convenient and accessible places. The
Power-Mite®generator is supplied with a double groove pulley for
installation convenience, only one belt is necessary. Be sure that the
fan belt used will have a minimum of a 90° enclosed angle or wrap
from the AC generator and a 90° enclosed angle or wrap from the
driving engine pulley. If the engine has a serpentine belt and no air
conditioning, you can mount the generator in the spot the air condi-
tioner would have occupied. If the vehicle has air conditioning, you
can purchase an after market pulley and mount it to the harmonic
vibration damper, then use a separate V-belt to drive the Power-Mite®.
Any snow plow dealer, such as Fisher Plow, can supply a pulley for
your particular engine.

4
CONTROL PANEL WIRING
SEE PAGE # 10 FOR OPTIONAL VOLTAGE REGULATOR
The AC generator control panel furnished is used for control and
monitoring for the AC generator. The Power Panel has two double
AC grounding type receptacles and a voltmeter which monitors the
AC output voltage. It also has a current overload protection device.
The Direct Current field supply is controlled by a heavy duty on-off
switch. A red light is illuminated to indicate field current draw, con-
trolled by the switch, this also is a warning that the current is on,
safeguarding the battery when generator is not in operation.
The control panel should be mounted on or near the existing engine
controls, so the operator can turn the unit on and off and observe
the volt meter and field power operating light. The control panel
switch should always be turned off when generator is not in
use.
Connect the Red wire from the control panel to the hot side (+) of
the battery using an in-line series 30 amp fuse, or the side of the
battery that is not grounded to the frame. The cable from the
generator to the control box has three wires (refer to FIGURE #1).
The Green wire is the field wire for the generator and should be
connected on the switch as shown. The White wire should be
connected on the vacant Silver screw of the 110 volt outlet as
shown. The Black wire should be connected on the vacant screw
of the I10 volt Overload Trip, as shown. This completes the
installation of your AC generator.
25

5
110
GREEN
CONTROL BOX
WHITE
Connect Red wire from
switch to positive of the
battery.(+)
BLACK
RED
FIGURE 1
Power Mite™
Generator
NEVER START GENERATOR WITH AN AC LOAD “ON”
INITIAL START UP AND OPERATION PROCEDURE
Every AC generator has been thoroughly tested and inspected before
it leaves the factory. Only a minimum of service is necessary for the
AC generator to give years of satisfactory power output. Every unit
has a shielded sealed and special grease packed bearings on each end.
Keep the drive belt only as tight as necessary to prevent power loss.
A “LOOSE” OR “TOO TIGHT” DRIVE BELT CAN DAMAGE THE
BEARINGS.ALWAYS BE SURE THAT THE PULLEY NUT AND ALL
MOUNTING BOLTS AND HARDWARE ARE SECURELY TIGHT TO
PREVENT DAMAGE TO THE BEARINGS.
To check the operation of the AC generator, start the engine. Place
the Control Switch to the ON position. The voltage output of the
Unit varies with your engine speed. Look at the Voltmeter. If your
engine is idling slowly, you will notice no voltage. Accelerate your
engine slowly, the voltmeter will respond instantly and should
approach the maximum reading. This demonstrates the operation of
the AC generator. The desired voltage for the operation of tools,
appliances, lights, etc, is between 110-130 volts AC. This voltage range
is indicated when the needle is in the green area of the voltmeter.
Get your voltage up to the green area before turning on any AC load.

6
ANSWERS TO SOME FREQUENTLY ASKED QUESTIONS
Q: Can I operate a three phase motor?
ANS: No, only single phase motors up to 1 horse power.
Q: Will it charge a battery?
ANS: No. AC POWER cannot be used to charge a battery, however
it will operate a 120 VAC input DC battery charger.
Q: Is our AC generator an inverter?
ANS: No, it is an AC Generator or alternator.
Q: Will the Power-Mite®A.C generator discharge my battery
ANS: No. Not if the engines DC generator is working properly to
keep the battery charged while the Power-Mite®is operating.
Q: What speed does my engine turn to operate the Power Mite®
generator at 3600 RPM?
ANS: Usually from 1200 to 1600 RPM, this is necessary to properly
circulate the air, oil and water to keep engine cool.
Q: How much horsepower is required when my Power-Mite®is
turned on?
ANS: Approximately SEVEN horsepower is required at full load and
a fraction of a horsepower when it is not activated.
Q: If I am using 500 watts and add 1000 watts, my voltage drops
and the increased engine speed fails to bring my voltage up,
instead it continues to drop. What causes this?
ANS: This is the most common of all “low voltages”. The belt is not
tight and the increase load causes it to slip, as the belt slips
this creates heat, the belt stretches and causes it to slip more
causing the output voltage to continue to drop.
Q: Can my original engines' alternator belt cause “Low Voltage”?
ANS: Yes, if it is loose. Be sure all of the engine belts are tight so it
can keep the battery charged.
Q: Why does the voltage drop when more wattage or load is added?
ANS: The increase load on the engine causes it to slow down. The
wattage being used by additional tools, set of lights or appli-
ances would reduce the output voltage. If increasing the
engine speed does not increase the output voltage, reduce the load.
Q: If the Power-Mite®is running over l0,000 rpm will it damage
hand tools or lights?
ANS: No, tools and lights are AC/DC and they run more efficient at
higher cycles up to 75 HZ.The Power Mite can withstand
intermittent speeds up to 10,000 RPM with out damage, if
properly installed.

7
OPERATION
Start engine, switch Power-Mite®on, adjust speed control for nee-
dle in “HIGH GREEN” area, and keep in green, readjust engine
speed if necessary. Turn off Power-Mite®before shutting engine
off. Never leave switch in the “on” position when engine is not
running. (Check belt tension frequently).
NOTE: The voltage will increase when the tool or load is turned OFF,
but will decrease when tool is again turned ON. You DO NOT HAVE TO
READJUST the engine speed between intermittent periods varying load
conditions.
Many appliances or devices have no OFF-ON Switch. In this event
increase your engine speed until the voltmeter on the Control
Panel indicates in the “HIGH GREEN” area.Then plug in the appli-
ance. Readjust the engine speed to keep needle in green area, if
necessary. Do not leave appliances without an ON-OFF switch plugged
into the unit when the generator is not up to operating speed. Also
never plug them in until the generators output voltage is in the
green operating range.
If you have a specific use for 60 cycle frequency, the shaft of
the AC generator must turn at 3600 RPM, at this speed the
AC generator will produce exactly 60 cycles.
Note: The engine speed would be approximately 1200 to 1600 rpm to
obtain 60 cycles at full load. If the engine is equipped with a tachome-
ter it would not give a true indication of the AC generators output fre-
quency because of different pulley sizes. The shaft speed of the Power-
Mite™ must be turning at exactly 3600 rpm. The speed can be mea-
sured by using a stroboscopic thahometer or by plugging an AC frequen-
cy meter into the power outlet.

8
TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE REMEDY
NO VOLTAGE OUTPUT BRUSHES WORN REPLACE BRUSHES
POWER SWITCH DEFECTIVE REPLACE SWITCH
DEFECTIVE VOLTMETER REPLACE METER
DEFECTIVE RECEPTACLE REPLACE RECEPTACLE
UNSTABLE VOLTAGE LOOSE CONNECTION CHECK CONNECTIONS
LOOSE BELT CHECK BELT TENSION
NOISY GENERATOR DEFECTIVE BEARING REPLACE BEARING
BROKEN FAN REPLACE FAN
BELT WORN REPLACE BELT
GENERATOR WILL NOT
HOLD THE LOAD DEFECTIVE OVERLOAD REPLACE OVERLOAD
LOAD EXCEEDS RATING REDUCE THE LOAD
LOOSE BELT TIGHTEN BELT

9
REPLACEMENT PARTS
PART # DESCRIPTION QUANTITY
572024 Housing 1
572025 End Plate MP-2 1
572026 End Plate MP-1 1
572027 Field Poles 2
572028 Field Pole screws 2
572029 Field Coils 2
572030 Brush Holder 4
572031 Brushes 4
572032 Brush Holder Caps 4
572033 Armature w/Slip Rings 1
572198 Armature/Blue Max 1
572236 Armature 220 Volt
572035 Thru-Bolts 2
572036 Bearings 2
572037 Fan 1
571275 Pulley STD. 2&314” 1
572038 Space- Small 1
572039 Spacer- Large 1
572040 Woodruff Key 1
572041 Washer 1
572042 Nut 1
572043 Retainer Disc (Rear) 1
572044 Washers 6
572045 Band Assembly 1
572046 Screws 6
572047 Retainer (Bearing) 1
572048 Throttle Control Kit 1
572049 Dust Filter 1
572050 Mounting Brackets (SET) 1
572051 Toggle switch 1
572052 Meter 0-150 VAC 1
572093 Meter 0-300 VAC 1
572053 Power Cord 1

10
572054 Dual Receptacle 120 VAG 1
Dual Receptacle 120 VAG
572341 Twist Lock Receptacle 240 VAC
572345 Pulley 3” Single Groove
572055 Lamp Assembly 1
572056 Complete Control Panel 1
572259 Complete Control Panel W GFI 1
572057 Control Box shell 1
572058 Adjustable Arm Bracket 1
572074 Circuit Breaker (OVERLOAD) 1
572020 Mounting Plate 4’x 8” 1
572075 U-Bracket 1
572084 Pulley Large 3-1/4” Double Groove 1
572242 Pulley Serpentine 6 Groove 1
572255 Pulley Serpentine 8 Grooved 1
572247 Large Pulley S Groove 3 5/8” 1
572256 PM Only 1
572257 Blue Max Only 1
OPTIONAL PMVR 120-C AC VOLTAGE REGULATOR
The PMVR 120-C AC voltage regulator is a solid state control device
which controls the sum total of current entering the Direct Current
fields of the Power-Mite®. The regulator senses the AC output voltage
drop when a load is applied, or a voltage increase when the load is
removed. This is accomplished instantaneously by the AC preset out-
put voltage which is electronically compared to the input DC voltage
applied to the field through the voltage regulator. The AC output
voltage is factory calibrated at 120 VAC. During variable load applica-
tions the voltage regulator will hold the AC output voltage steady at
between 110 and 130 VAC. The PMVR 120-c Solid State Voltage
Regulator is ruggedly designed for severe commercial use; because of
high quality parts and expert factory assembly and testing.There are
no moving parts or no relays or moving electrical contacts or trans-
formers.This device compensates for all over-voltage conditions for

11
WARRANTY TERMS
EACH FABCO POWER GENERATOR IS
WARRANTED TO THE ORIGINAL OWNER
TO BE FREE FROM DEFECTS IN MATERIAL OR
WORKMANSHIP UNDER NORMAL USE
AND SERVICE FOR ONE (1) YEAR FROM
THE DATE OF PURCHASE.
OUR OBLIGATION UNDER THIS WARRANTY
IS LIMITED TO REPLACING OR REPAIRING,
AT OUR OPTION, ANY PART OR PARTS
PROVED TO BE SO DEFECTIVE WHICH
ARE RETURNED FREIGHT PREPAID
use with most electronic equipment.The PMVR, patent applied for,
comes from the factory ready for use with any Negative ground, 12
volt DC system, however, it can easily be adapted to a Positive
Ground system in the field in a matter of minutes.
The voltage regulators are available with 24 VDC field inputs with
120 or 220 VAC outputs, the 12 VDC field input units can also pro-
duce 220 VAC outputs when used with the corresponding Power-
Mite®generator models ask your local dealer.

OTHER INNOVATIVE FABCO POWER PRODUCTS
Fabco Power manufactures a full line of VEHICLE MOUNTED hydraulic
powered generators from 3,000 to 12,000 watts.The hydraulic driven gener-
ators are used in many industries where
reliable portable electric power is needed such as Telephone & Utilities, Fire
& Rescue, Construction, Night Paving, Public Works,Airline Maintenance,
Plastic Pipe Fusion, Mining and Much More!
The FABCO HYDRO SERIES GENERATORS are lightweight and compact;
they are one-third the size of an engine driven generator of the same power
output. They are QUIET, ENVIRONMENTALLY CLEAN, NON-POLLUTING
AND MAINTENANCE FREE. (YOU NEVER HAVE TO WORRY IF THE
GENERATOR WILL START)! The generator is brushless and has built-in
overload protection, it is easily RE-CONNECTABLE for 120 or 240 volts
AC. The output voltage regulation is within +/- 3% from no load to full load
without a voltage regulator. For more information call us at (845) 469-9151,
Fax (845) 469-7871 or visit our Web Site www.fabcopower.com

Fabco Cover.indd 2 6/17/11 2:20 PM

INSTALLATION INSTRUCTIONS
POWER MITE110
®
The Originators of Belt Driven & Hydraulically Powered AC Generators
Fabco Power • 1570 Kings Highway • Chester, NY 10918
tel: (845) 469-9151 • fax: (845) 469-7871
To view all Fabco Power's innovative products
visit our web site at www.fabcopower.com
MANUAL 102-11
INSTALLATION INSTRUCTIONS
POWER MITE110
®
The Originators of Belt Driven & Hydraulically Powered AC Generators
Fabco Power • 1570 Kings Highway • Chester, NY 10918
tel: (845) 469-9151 • fax: (845) 469-7871
To view all Fabco Power's innovative products
visit our web site at www.fabcopower.com
MANUAL 102-11
Fabco Cover.indd 1 6/17/11 2:20 PM

Fabco&Power&PO&Box&582&Chester&NY&10918&845-469-9151&
www.fabcopower.com&&
!
!
GFCI!GENERAL!INFORMATION!
The!Powermite!110!belt-driven!generator!system!was!introduced!in!1962.!!Over!the!years!there!
have!been!questions!about!using!it!in!conjunction!with!Ground!Fault!Current!Interrupters,!also!
known!as!GFI’s!or!GFCI’s.!
In! a! residential! or! industrial! setting,! there! are! the! three! conductors! in! a! standard! 120! volt!
electric!outlet!(240!volts!in!most!countries!outside!the!US)!HOT,!NEUTRAL!and!GROUND.!!The!
ground!terminal!is!affixed!to!a!water!main!and/or!a!ground!rod.!!The!hot!and!neutral!provide!
the! 120! volt! power! to! home! appliances.! ! The! neutral! line! is! tied! to! the! ground! at! only! ONE!
POINT!inside!the!circuit!breaker!panel.!!
!
Since!the!Powermite!110!is!mounted!in!a!motor!vehicle,!there!is!no!earth!ground!in!the!system.!!
As!with!portable!gasoline!generators,!the!Powermite!110!has!an!ISOLATED!circuit,!meaning!that!
both! legs! of! the! 120! volt! circuit! are! floating! and! not! connected! to! the! ground,! which! is! the!
chassis!of!the!vehicle.!!This!is!standard!practice!and!we!believe!is!the!safest!approach.!!
!
It!is!still!a!good!practice!to!place!a!GFCI!outlet!on!the!output!of!the!Powermite!110!because!if!at!
any!point,!one!of!the!output!terminals!were!to!accidently!become!grounded,!due!to!a!defective!
appliance!connected!to!it,!or!miswiring!by!personnel,!the!opposite!leg!of!the!output!could!have!
a!potential!of!120!volts!to!ground,!creating!potential!dangerous!condition.!!
!
Using!an!isolated!circuit!is!much!safer,!but!does!create!confusion!with!GFCI!testers.!!
It’s!best!to!test!the!wiring!of!the!GFCI!as!suggested!by!the!GFCI!manufacturer!(Enclosed).!
The!GFCI!manufacturer!recommends!this!testing!procedure,!rather!than!using!a!“tester”!which!
may!or!may!not!show!a!correct!reading!on!isolated!ground!systems.!!!
!

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