Operation and Maintenance Manual - hgigenerators.com · HRD Events Diesel Generator 498-10691...

Ravenstor RoadWirksworthDerbyshire DE4 4FYENGLAND

Sales Tel: +44 (0) 1629 824 284Sales Fax: +44 (0) 1629 824 613Email: [email protected] [email protected]: www.hgigenerators.com

Operation and Maintenance Manual

80-100kVA 3 Phase Diesel Generator

Build No: HRD800T-E, HRD1000T-E

Publication No 498-1069

© Harrington Generators International Limited All rights reserved. No part of this publication may be reproduced in any material form (including photography or storing in any medium by electronic means or other) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988.Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to Harrington Generators International Limited at the address above.

Any reference to trademarked product names used within this publication is owned by their respective companies.

Harrington Generators International Limited reserves the right to change the contents of this document without prior notice.

Change Control

Date Version Author Mod No Reason for changeMay 16 Provisional LMG Draft for Review by Andrew PalmerJan 17 A MC 401465-BQ Updated and Release following reviewSept 17 B MC 900262 Warranty, DofC

HRD Events Diesel Generator 498-1069

Harrington Generators International Contents

Contents

INTRODUCTION ............................................................................................. 1

CERTIFICATION ............................................................................................. 2

EC Declaration of Conformity HRD800T-E .................................................. 2

EC Declaration of Conformity HRD1000T-E ................................................ 3

Data Plate ....................................................................................................... 4

SPECIFICATION ............................................................................................. 5

SAFETY .......................................................................................................... 9

A few words about safety ............................................................................. 9

Operator Responsibility ................................................................................ 9

Precautions .................................................................................................... 9

Electrical Safety ........................................................................................... 18

Lifting and Moving ....................................................................................... 18

Hazards to Health ........................................................................................ 19

OPERATION ................................................................................................. 21

Generator Layout......................................................................................... 21

Output Panel ............................................................................................... 21

Control Panel .............................................................................................. 22

Remote Connection Socket ........................................................................ 23

Terminal Output Pod ................................................................................... 24

Installations.................................................................................................. 24

Pre-Operation Checks ................................................................................. 25

Starting ........................................................................................................ 27

Stopping ....................................................................................................... 28

Shutdown Protections ................................................................................ 28


Harrington Generators InternationalContents

FAULT FINDING ........................................................................................... 29

Engine Fails to Start .................................................................................... 29

Engine Starts but then Stops ..................................................................... 30

Other Generator Faults ............................................................................... 30

No Electrical Output .................................................................................... 31

MAINTENANCE ............................................................................................ 32

Maintenance Schedule ................................................................................ 32

Maintenance Safety ..................................................................................... 33

Maintenance Routine .................................................................................. 33

PARTS AND SERVICE ................................................................................. 41

Contact Details ............................................................................................ 41

Warranty Statement ..................................................................................... 41

Functional Spares ....................................................................................... 41

TRANSPORTATION AND STORAGE .......................................................... 42

WIRING ......................................................................................................... 43

80kVA ............................................................................................................ 43

100kVA .......................................................................................................... 44

MANUFACTURER’S SERVICE AND USER GUIDES LINKS ...................... 45

Perkins Operators and Maintenance Manual ........................................... 45

Deep Sea 7310 User Guide ........................................................................ 45

Mecc Alte ECO / ECP User Manual ........................................................... 45

80-100kVAEvents Range1500 RPMDiesel Generator

Harrington Generators International

1HRD Events Diesel Generator 498-1069

Introduction

IntroductionThank you for purchasing a quality generator, carefully manufactured to the highest standards by one of the World’s leading generator manufacturers, HGI International.

The HRD Events 1500rpm range of generators have been specifi cally designed for the most demanding jobs and ultimate long-term performance. The design encompasses a single sided service access, large fully bunded fuel tank and noise and vibration attenuation. These facilitate ease of operation and maintenance, and considerate working environment.

Before operating the generator, read this manual and make sure that all personnel who operate the equipment have access to the manual (and any additional documentation supplied with it) and are fully aware with the operation and functionality of the generator prior to use. Misuse of the instructions may invalidate the product warranty and lead to potential accidents.

This manual is an essential part of the generator and should be kept with the generator at all times. There is a convenient document holder located on the inside of the service side door to store the manual and other documents in. Make sure that the manual is available to all users throughout the generator’s life-span.

If in doubt about the functionality of any of the equipment within this document please contact HGI or seek other expert advice.

Every effort has been made to ensure that the information given in this manual is correct at the time of publishing. However, it may be superseded due to our continuous improvement processes.

HGI Limited manufacture a wide range of generating sets and accessories, including generators approved for use in Telecoms, Railway and Military applications where quality and reliability are essential. These include:

• Petrol Generators • Petrol Welders• Gas & Water ECE3 (TIN12) • Trackside• Tractor PTO • Super Silent Diesel Generators (3000rpm)• Super Silent Diesel Generators (1500rpm• Automatic Mains Failure Control Systems• Welf-Air Generators • Compact Welf-Air Generators• Super Compact Welf-Air Generators• Super Silent Diesel Welders

For further information call us now on :

+44 (0)1629 824 284

our experienced and knowledgeable sales staff will be happy to advise you and provide a detailed quotation for all your generator requirements or visit our website www.HGIgenerators.com


2 HRD Events Diesel Generator 498-1069

Certifi cation

Certifi cation

EC Declaration of Conformity HRD800T-E

In accordance with ISO/IEC 17050-1:2010 Conformity Assessment - Suppliers’ Declaration of Conformity

EU DECLARATION OF CONFORMITY

We: HGI Harrington Generators International Ltd.Ravenstor Road Wirksworth, Derbyshire DE4 4FY

Declare that Equipment : Diesel Generator

Model name /Number : HRD800 range

Electrical Power Pel : 64 kW e

Measured Sound Power Level: 89 dB(A)

Guaranteed Sound Power Level 90 dB(A)

Conforms to the protection requirements of the following EC Council Directives:2006/42/EC Machinery Directive2014/35/EU Low Voltage Directive2014/30/EU EMC Directive

2000/14/EC Noise Emission in the Environment by Equipment for use Outdoors Directive Annex VIII

And has been designed and manufactured to the following Standards:BS5000 Part 3 Rotating electrical machines of particular types or for particular applications. Generators to be driv-

en by reciprocating internal combustion engines.EN60204-1 Safety of machinery. Electrical equipment of machines. General requirementsEN12601 Reciprocating internal combustion engine driven generating sets. SafetyBS EN 61000-6-1 EMC. Generic standards. Immunity for residential, commercial and light-industrial environments.BS EN 61000-6-2 EMC. Generic standards. Immunity for industrial environmentsBS EN 61000-6-3 EMC. Generic standards. Emission standard for residential, commercial and light-industrial

environmentsBS EN 61000-6-4 EMC. Generic standards. Emission standard for industrial environmentsBS ISO 3744 Acoustics. Determination of sound power levels of noise sources using sound pressure.

Notifi ed Body for 2000/14/EC Noise Emission in the Environment by Equipment for use Outdoors Directive

HORIBA MIRA UKWatling StreetNuneatonWarwickshire CV10 0UT

Notifi ed Body Number : 0888

I declare that as the authorised representative, the above information in relation to the supply and manufacture of this product is in conformity with the stated standards and other related documents following the provision of the above EC Directives.

Signed: Date: 20/06/17

Printed: D.C.Coulton Position: Head of Systems



Certifi cation

EC Declaration of Conformity HRD1000T-E

In accordance with ISO/IEC 17050-1:2010 Conformity Assessment - Suppliers’ Declaration of Conformity

EU DECLARATION OF CONFORMITY

We: HGI Harrington Generators International Ltd.Ravenstor Road Wirksworth, Derbyshire DE4 4FY

Declare that Equipment : Diesel Generator

Model name /Number : HRD1000 range

Electrical Power Pel : 80 kWe

Measured Sound Power Level: 90 dB(A)

Guaranteed Sound Power Level 90 dB(A)

Conforms to the protection requirements of the following EC Council Directives:2006/42/EC Machinery Directive2014/35/EU Low Voltage Directive2014/30/EU EMC Directive

2000/14/EC Noise Emission in the Environment by Equipment for use Outdoors Directive Annex VIII

And has been designed and manufactured to the following Standards:BS5000 Part 3 Rotating electrical machines of particular types or for particular applications. Generators to be driv-

en by reciprocating internal combustion engines.EN60204-1 Safety of machinery. Electrical equipment of machines. General requirementsEN12601 Reciprocating internal combustion engine driven generating sets. SafetyBS EN 61000-6-1 EMC. Generic standards. Immunity for residential, commercial and light-industrial environments.BS EN 61000-6-2 EMC. Generic standards. Immunity for industrial environmentsBS EN 61000-6-3 EMC. Generic standards. Emission standard for residential, commercial and light-industrial

environmentsBS EN 61000-6-4 EMC. Generic standards. Emission standard for industrial environmentsBS ISO 3744 Acoustics. Determination of sound power levels of noise sources using sound pressure.

Notifi ed Body for 2000/14/EC Noise Emission in the Environment by Equipment for use Outdoors Directive

HORIBA MIRA UKWatling StreetNuneatonWarwickshire CV10 0UT

Notifi ed Body Number : 0888

I declare that as the authorised representative, the above information in relation to the supply and manufacture of this product is in conformity with the stated standards and other related documents following the provision of the above EC Directives.

Signed: Date: 21/06/17

Printed: D.C.Coulton Position: Head of Systems



Certifi cation

Data Plate

Each generator supplied will have a data plate attached to the canopy of the set. Below is an exemplar data plate with notes to help understand the terminology and information supplied on the data plate of your machine.

Harrington Generators International LtdRavenstor Road Wirksworth Derbyshire, DE4 4FYTel: +44(0)1629 824284 Fax +44(0)1629 824613www.hgigenerators.com [email protected]

Generating Set ISO 8528 COP Class G2Model: HRD Serial No: 70366893

Build Code: HRD1000T-E Year of Manufacture: 2014

Electrical Power: 100kVA / 80kW PF: 0.8 Frequency: 50 Hz

Voltage Volts: 400V 230V 110V

Current Amps: 145 3 off 145 n/a

Max Altitude: 1500m Max Ambient Temperature: 40°C

Weight Fuel Tank Empty / Full: 1910 / 2165 kgs

Fuel: Diesel Engine Speed: 1500 rpm Sound Level LwA 90 dB(A)

This is the “CE” mark and indicates that the generator complies with the European Directives as detailed in the Certifi cate of Conformance

Model: This is the build model of the machine e.g. HRD

Build Code:This is a code number, which tells us the exact build standard to which the generator was built. This is important when ordering spares or contacting our Technical Help Line

Serial No:This is a unique number, which identifi es the generator. This is important when ordering spares or contacting our Technical Help Line

Year of Manufacture: Year of Manufacture e.g. 2013Electrical Power: This is the power in kVA and kW, the power factor and frequencyVoltage: This is the nominal voltage e.g. 400V, 230V or 110V Current Amps: This is the nominal electrical current of the principal voltage

Performance Class G2 provides steady state voltage deviation ± 2.5% for use with standard electronic equipment.

Sound Pressure Level:This is the level of sound produced by the generator when running at 75% auxiliary power. This generator complies with the CE Directive on sound levels

Maximum Altitude / Ambient Temperature:

These are given and if the generator is to be used at higher altitudes or at higher ambient temperatures HGI should be consulted

Weight: This provides weights including and excluding a full tank of fuel

Fuel:Only commercially available diesel fuel can be used. If a special type of diesel is to be used please consult HGI fi rst to discuss its suitability



Specifi cation

Specifi cation

General Specifi cationCanopied set with integral bunded 220 Litre fuel tank.With local or remote starting using DeepSea 7310 module.400V 3 Phase 230V Single Phase Fixed Voltage Output

Model HRD800T HRD1000T

Rated Output:400V 3 Ph 80kVA 64kW PF 0.8230V 1 Ph 3 off 26kVA 21kW PF 0.8 on different phases

400V 3 Ph 100kVA 80kW PF 0.8230V 1 Ph 3 off 33kVA 26kW PF 0.8 on different phases

Environment: Temperature range: -10°C ( without additional starting aids ) to +40°C Relative Humidity: 10% to 90%

Performance Class ISO 8528: Prime Power “PRP” Electrical Class G2 Steady state voltage: +/- 2.5% Frequency droop < 5%

Dimensions L x W x H Approx. 2800 x 1050 x 1774mm Operating Clearance: Minimum of 1200mm all around and above. Access for Servicing: Access of 1050 mm required both sides to open doors.Weight – fuel tank empty: Approx. 1820 kgs Approx. 1910 kgsWeight – fuel tank full: Approx. 2085 kgs Approx. 2165 kgsFuel: Commercial diesel with up to 10% bio-diesel .i.e. B10 blend.OutputOutput Type: Fixed VoltagesFrequency: 50 HzVoltages: 230/400VStarting System: Electric Start via Control Module as local or remote start.Output Confi guration: Sockets and Terminal OutputTerminals: 400V 3 Phase terminals in terminal compartment.Output Protection: 3 pole main MCBGenerator Control SystemStarting Method: Electric Start via Control Module as local or remote start.Control Module: Deep Sea Electronics 7310 Engine and Generator Control ModuleEngine Protection: High engine temperature, Low Oil Pressure, Over/Under speedEngine Monitoring: Low Fuel, RPM, battery voltage, hours run.Electrical Protection: Over/Under Voltage and Frequency Electrical Monitoring: Volts, Frequency, AmpsAlarms: Bund AlarmBatteryBattery: 12V DC maintenance free 70 Ah.Battery isolator: Fitted inside canopy.

Cont....



Specifi cation

EngineEngine Manufacturer PerkinsEngine model: 1104DE44TAG2Service Interval: 500 hoursEngine Speed: 1500 rpmEngine Cooling: Water cooledStarting Method: Electric StartSpecifi c Fuel Consumption 232 g / kW hElectrical System: 12V DC systemEmissions Level: European Stage 3 A.Lowest starting temperature: -10°C with standard glow plugs without extra aidsAlternatorAlternator Model: ECP34-1S/4 ECP34-2S/4Alternator Performance: 85kVA DER1 4-pole Class H with

AVR105kVA 4-pole Class H with AVR

Fuel SystemFuel Tank Capacity: 320 litres

Fuel Tank Bund: YesRun Time 100% load – approx. 16.1 hrs 13.1 hrsConsumption at 100% load 19.8l / hr 24.5 l / hrRun Time 75% load - approx. 19.1 hrs 16.2 hrsConsumption at 75% load 16.1 l / hr 19.8 l / hrCanopyCanopy Type: Canopied set with integral bunded fuel tank.

Material: Base: Structural Steel.Canopy: Smooth galvanised steel.

Finish:

Base: Iron phosphate pre-treatment, zinc rich primer then architectural grade powder coating. Canopy: Iron phosphate pre-treatment then architectural grade powder coating.

Colour:Base: RAL9005 Jet Black (Semi-Gloss)Canopy: RAL5013 Cobalt Blue* or RAL9016 Artic WhitePanel: RAL5013 Cobalt Blue* or RAL9005 Jet Black

Doors: Hinged doors

Catches: Catches have keyed locks (but locks do not have to be used).Catches have hasps for padlocks.

Lifting:With forklift from below using integral fork lift pods.With single point lifting beam with concealed lifting eye.With slings below and a spreader frame above.

Fixing Down: Through skid tubes underneath the base.Towing: Towing tube for fi nal adjustment on siteOther: Remote Start and USB Controller Program Socket on Control Panel.

*Older models



Specifi cation

This Drawing & Dimensions for reference only



Safety

Safety

A few words about safety

Your safety and the safety of others are very important and using this generator safely is an important responsibility.

HGI have designed this generator to give safe and dependable service if operated in accordance to these instructions. Please ensure that you read this owner’s manual and understand the functionality of the generator before using. You can help prevent accidents and harm to yourself and nearby personnel by being familiar with the controls, and by observing safe operating procedures.

The warnings and safety instructions appearing in this guide are not meant to cover every eventuality and hazards associated with operating or maintaining a generator. You must use your own good judgement, care and caution.

This is the safety alert symbol. It is used to alert you to potential hazards. Obey all safety

messages that follow this symbol to avoid possible injury or death.

here are four types of safety alert messages used in this manual:

DANGERDanger refers to immediate hazards which WILLresult in severe personal injury or death.

WARNINGWarning refers to a hazard or unsafe method or practice which CAN result in severe personal injury or possible death.

CAUTIONCaution refers to a hazard or unsafe method or practice which CAN result in personal injury.

NOTICENotice refers to a method or practice which can result in product damage, or to draw attention to additional information or explanations.

Operator Responsibility

• Know how to stop the generator quickly in case of emergency.• Understand the use of all generator controls, output sockets, and connections. • Be sure that anyone who operates the generator receives proper instruction.

If you have any doubts about the safe operation of this equipment, please contact HGI or a competent operator or qualifi ed technician.

Precautions

The generator can constitute a hazard to users, nearby personnel and property unless the following precautions are observed during operation:

• Ensure that you know how to stop the engine in an emergency.

• Exhaust fumes are poisonous and can kill.• Ensure that the area surrounding the machine

has no restrictions that would prevent an ad-equate fl ow of clean, ambient air.

• Fuel is highly fl ammable, when refuelling:• Do not run the engine.• Do not smoke.• Avoid overfi lling the fuel tank.• Wipe up any fuel spilt on the machine and

move the equipment away from the area where fuel has been spilt.

• Parts of the engine, and particularly the exhaust system will get very hot during use, and will remain hot for some time after the generator has stopped.

• Do not use the equipment with loose or missing components or guards.

• Additional care should be applied if using the generator in damp or wet conditions.

• Regularly inspect the condition of trailing cables and integrity of connectors. Only use correctly rated cable and standard plugs of suitable capacity for the application.

• During servicing, follow HSE recommendations regarding the handling and disposal of contaminated oil products.


The generator is fi tted with a number of labels that alert the user to the safe operation and safety requirements. A full explanation of these is contained here. If any of the labels are missing or unreadable a duplicate should be obtained and fi tted.

Label Part No, Qty, Location DescriptionPt No. 499-945-002

Qty 1

Roof Panel Side Next to Exhaust

CAUTION HOT EXHAUST

The exhaust pipe is shielded as much as is practical but the fi nal outlet is hot.

Pt No. 499-945-003

Qty 1

On Filler Cap

DIESEL FUEL ONLY

This generator must only be fi lled with commercial diesel fuel containing up to 10% bio-fuel. If special grades of diesel e.g. 100% Bio-Diesel are to be used consult HGI fi rst to discuss its suitability.

Pt No. 499-945-004

Qty 2

Next to Inlet Outlet Vents

INLET AND OUTLET VENTS TO BE KEPT CLEAR

These must be kept free from obstructions to allow a free fl ow of cooling air or the engine and alternator could over heat.

Pt No. 499-945-005

Qty 1

On Roof

NO STEP

The generator should not be used as a step.

Pt No. 499-945-015

Qty 1

On Control Panel 3 phase Generators

FUSE IDENTIFICATION

Informational label advising the Identity of the Fuse.

Pt No. 499-945-008

Qty 1

Inside Terminal Pod

EARTH POINT

An M10 brass earth stud is supplied next to the output sockets for the external earth connection.



Safety

Pt No. 499-945-009

Qty 4

Above Fork Lift Pockets

FORK LIFT POINT

The generator can be lifted from the sides or from the front or rear using a fork lift truck with correctly spaced forks.

It is intended that when lifting from the sides, that one fork passes through the part of the frame that forms a loop and foot.

Pt No. 499-945-010

Qty 1

On Lifting Beam Dipstick Side

CHECK ENGINE OIL LEVEL DAILY

The oil level should be seen on the oil dip stick as per the diagram on the label.

Pt No 499-945-011

On side panel:

ELECTRICITY IS DANGEROUS

If in doubt about the correct use consult a qualifi ed electrician or contact our Technical Help Line.

Pt No 499-945-011

On side panel:

CHECK ENGINE OIL LEVEL DAILY

Check the oil level each day and top up if necessary to the top mark given in the oil level diagram above. If oil consumption is excessive investigate further.

Pt No 499-945-011

On side panel:

LOW LOAD RUNNING:

Operating the generator at low load levels for extended periods can result in high levels of carbon build up in the engine and exhaust system which can lead to excessive smoking, reduced effi ciency and overheating.

If the generator is not required switch it off and avoid running with light or no load wherever possible. Also see Maintenance Section.

Pt No 499-945-011

On side panel:

ENSURE Generator IS AT LEAST 1 METRE AWAY FROM BUILDINGS, VEHICLES etc. WHEN IN USE.

This is to ensure a free fl ow of cooling air to the generator and that the exhaust from the generator does not affect other items.



Safety

Pt No 499-945-011

On side panel:

KEEP FLAMMABLE MATERIAL AWAY FROM THE GENERATOR

The exhaust and some surfaces are hot and fl ammable material should not be allowed near the generator.

Pt No 499-945-011

On side panel:

OPERATE ONLY IN WELL VENTILATED AREAS. EXHAUST FUMES CAN KILL.

Generally the generator will be installed outside. If the generator is to be installed inside a building please consult the Technical Help Line.

Pt No 499-945-011

On side panel:

STOP ENGINE AND ALLOW TO COOL DOWN FOR A FEW MINUTES BEFORE REFUELLING.

In addition DO NOT SMOKE while refuelling, use a funnel or similar to prevent fuel spillage, avoid over fi lling the fuel tank and wipe up any spilt fuel. Avoid contact of fuel with skin.

Pt No 499-945-011

On side panel:

DO NOT SPILL FUEL ONTO HOT SURFACES

The exhaust outlet and the area around it in particular are hot.

Pt No 499-945-011

On side panel:

DO NOT ADJUST THE SPEED OF THE ENGINE UNLESS YOU HAVE BEEN TRAINED TO DO SO

If the generator is not producing enough power for the application or you suspect a problem do not adjust the engine speed. This may damage the engine, alternator and any power equipment plugged into the generator.

Pt No 499-945-011

On side panel:

KEEP CHILDREN AT A SAFE DISTANCE FROM THE EQUIPMENT AND DO NOT ALLOW THEM TO OPERATE IT

This is a mandatory Health and Safety Requirement for this equipment. A version with a key switch is available if required.



Safety

Pt No 499-945-011

On side panel:

DO NOT OPERATE WITH ANY COVERS OPEN

If covers are open (or missing) the generator will exceed the European Noise Regulations and the cooling of the engine and alternator will be affected which could cause damage to them.

Pt No 499-945-011

On side panel:

ONLY OPERATE ON A LEVEL SURFACE

Generally the generator will only be used on a level surface. It can be used on small inclines as given in the Specifi cation as given previously but additional precautions may be needed to stop it moving due to vibration.

Pt No 499-945-011

On side panel:

AN EARTH LEAKAGE TRIP (RCD) IS FITTED THE GENERATOR’S BRASS EARTH STUD SHOULD BE CONNECT-ED TO AN EXTERNAL EARTH. THIS EXTERNAL EARTH CAN BE AN EARTH SPIKE OR ANY SUITABLE EARTH POINT. THE RCD SHOULD BE TESTED DAILY BY PRESSING THE TEST BUT-TON AND CHECKING IT DOES TRIP.

If the generator is to be used for a fi xed installation or installed on the same site for a long period it should be installed by a competent person. The User should be shown where the TEST button is located and shown how to use it. An earth spike kit is available as an optional extra.

Pt No. 499-945-012

Qty 1

On Control Panel around the DC Isolator Switch

DC ISOLATOR IDENTIFICATION

Informational label showing the ON / OFF positions of the switch.

Pt No. 499-945-013

Qty 1

On Fuel Switch Bracket

EXTERNAL INTERNAL FUEL SWITCHIDENTIFICATION

Informational Label showing the positions of the Fuel Lever and the Fuel Toggle switch to use Internal or External Fuel supply



Safety

Pt No. 499-945-014

Qty 1

On Control Panel for DC MCB

MCB1 IDENTIFICATION

Informational label showing position of MCB1.

Pt No. 499-945-019

Qty 1

Below Terminals in Terminal Pod of 3 Phase Generators

3 PhaseTERMINALS

Informational label showing terminal posi-tions.

Pt No. 499-945-017

Qty 1

On Battery Isolator Bracket

BATTERY ISOLATOR

Identifi cation label showing the ON / OFF position of the Battery Isolator.

Pt No. 499-945-020 Qty 1 Below Snap Connectors

EXTERNAL FUEL SUPPLY

Information label showing the positions of the snap connectors when using an ex-ternal fuel supply. Label also advises that Diesel Only should be used.

Pt No. 499-945-021

Qty 1

On Control Panel Dual Voltage Generators

230V OUTPUT

Advisory label showing voltage of the generator

Pt No. 499-945-022

Qty 1

On Control Panel Dual Voltage Generators

400V OUTPUT

Advisory label showing voltage of the generator

Pt No. 499-945-023

Qty 2

One per Service Access Door

AUTOMATIC MACHINERY – MAY START WITHOUT WARNING This is only fi tted if the generator is an AMF (automatic mains failure) version in-tended to start the set automatically if the mains electricity fails OR a Remote Start Version. While checking the oil level or doing any type of maintenance on this generator it should be made safe so it cannot start automatically by removing the control fuse or using the Emergency Stop button.



Safety

Pt No. 499-945-024

Qty 1

On Control Panel below the USB Port

USB PORT

Information label advising position of USB Port.

Pt No. 499-945-025

Qty 1

On Bottom of Radiator next to Drain Point

RADIATOR DRAIN

Advisory label showing the position of the Radiator Drain Point

Pt No. 499-945-026

Qty 1

Base of Generator next to Drain Point

ENGINE OIL DRAIN Engine oil is drained by removing the cap on the front RHS of the base. The oil will drain easier from a warm engine. Observe correct disposal practices.

Pt No. 499-945-049

Qty 1

On lifting Beam Service Access Side

HOT WATER UNDER PRESSURE CHECK COOLANTLEVEL DAILY Coolant level must be suffi cient to appear in the fi ller neck. DO NOT OPEN A HOT RADIATOR

Pt No. 499-945-035

Qty 1

On lifting Beam Expansion Bottle Side

EXPANSION BOTTLE Coolant level should reach the bottom of the radiator fi ller neck and should be between the level marks on the expansion bottle. Filling the expansion bottle does NOT refi ll the cooling system.

Pt No. 499-945-028

Qty 1

On Terminal Pod Cover

DANGER 400V

Alerting to voltages behind cover

Pt No. 499-945-037

Qty 1

On the DC box inside the genera-tor

DANGER ELECTRICITY The battery is 12 V DC and care should be taken not to come into contact with the terminals.



Safety

Pt No. 499-945-040

Qty 1

On Top of the Top 400V Socket if used

400V

Advisory of voltage on socket output

Pt No. 499-945-041

Qty 1

On Top of the Top 230V Sockets if used

230V

Advisory of voltage on socket output.

Pt No. 499-945-042

Qty 1

On the DC box inside the genera-tor

12 V DC Advisory of the battery voltages and care should be taken not to come into contact with the terminals.

Pt No. 499-945-043

Qty 1

On the Terminal Box Cover top right, close to Sockets

ELECTRICITY IS DANGEROUS

Warning about the danger or using Elec-trical equipment and the difference in phases.

Pt No. 499-945-044

Qty 1

On High Mark Level of Expansion Bottle if not embossed on bottle

HIGH LEVEL

Informational to denote the High Level mark on the expansion bottle.

Pt No. 499-945-045

Qty 1

On Low Mark Level of Expansion Bottle if not embossed on bottle

LOW LEVEL

Informational to denote the Low Level mark on the expansion bottle.



Safety

Battery Compartment

On front panel over battery compartment

Part of label No: 499-945-006

DANGER ELECTRICITY

The battery is 12 V DC and care should be taken not to come into contact with the terminals.



DANGER ACID

The battery contains acid and if any liquid is seen check the source, but assume fi rst that it is acid. Care should be taken in cleaning up acid.



WARNING EXPLOSIVE MATERIAL

The battery can under certain conditions give off small quantities of hydrogen gas. Do not smoke or use naked fl ames while working on a battery. NEVER attempt to burn a battery as a method of disposal.



DISCONNECT NEGATIVE LEAD FIRST AND RECONNECT LAST

This is to ensure that if a spanner slips you cannot create a circuit from the live battery post to the generator chassis.



NO SMOKING OR NAKED LIGHTS

The battery can under certain conditions give off small quantities of hydrogen gas. Do not smoke or use naked fl ames while working on a battery.



RECYCLE

The battery contains lead and sulphuric acid and should be recycled at an approved facil-ity only and not put into a dust bin.



Safety

Electrical Safety

In addition to the information given previously the-generator should be installed, earthed and used with reference to the following:-

• I.E.E Regulations 17th Edition (BS 7671:2008)• Health and Safety Executive Publications GS27

Protection Against Electric Shock• Health and Safety Executive Publications GS24

Electricity On Construction Sites• Health and Safety Executive Publications PM53

Emergency Private Generation available from HMSO. Alternatively the HGI Technical Help Line would be pleased to advise you on the best measures for your particular application.

NOTICEDO NOT use a pressure washer to clean the generator as high pressure water may enter the electrical system.

Lifting and Moving

In addition to the information given previously the following apply:-

Mechanically Assisted Lifting

In Great Britain all assisted lifting is governed by:-

• Lifting Operations & Lifting Equipment Regulations 1998 (LOLER) SI 1998 No: 2307

and the following publication should be observed:-

• HSE ACoP publication L113 Safe Use of Lifting Equipment, Lifting Operations and Lifting Equipment Regulations.

As a guide line only you should ensure that all lifting equipment is:-

• Suffi ciently strong, stable and suitable for the proposed use.

• The load and anything attached must be suitable to be lifted.

• Positioned or installed to prevent the risk of injury, e.g. from the equipment or the load falling or striking people.

• Visibly marked with any appropriate information to be taken into account for its safe use, e.g. safe working loads.

• Accessories, e.g. slings, clamps etc. should be similarly marked.

You must ensure that a lifting operation must be planned, supervised and carried out in a safe manner by people who are competent.

No personnel should be present in an area where a mechanical lifting operation is taking place.

Lifting by Fork Lift Truck

The generator can be lifted from the sides using the pockets integrated into the base, and a fork lift truck with correctly spaced forks.

Lifting Beam

The generator can be lifted using a single point lifting beam. This can be accessed via the cover on the roof of the generator. The fi xing of this beam should be inspected to make sure that no fi xing bolts have been removed or loosened and that it has not been damaged.



Safety

Hazards to HealthA list of the hazards that may affect health are included with safety precautions and fi rst aid instructions.

Material / Location

Hazard First Aid Measures

Engine Oil When hot may burn the skin but not expected to give rise to an acute hazard under normal conditions of use. May cause an allergic skin reaction in sensitive individuals. Continuous skin exposure may give rise to dermatitis.

Gloves, overalls and eye protection should be worn when handling this product.

Do not burn old oil as a method of disposal as combustion is likely to give rise to a complex mixture of airborne solids, liquid particulates and gases including carbon monoxide and unidentifi ed organic and inorganic compounds .

Old engine oil has potential health implications and should not come into contact with the skin.

Burns: Rinse with clean water, cover with a ster-ile pad and obtain medical assistance.Skin Contact: Remove contaminated clothing and wash thoroughly with soap and water. If per-sistent irritation occurs obtain medical attention. If the material is injected under high pressure into the body obtain medical assistance immediately.Inhalation: In the unlikely event of inhalation of fumes if dizziness or nausea occurs move the individual to fresh air. If symptoms persist, obtain medical attention. If diffi culties are experienced with breathing a qualifi ed person should admin-ister oxygen. If breathing stops give artifi cial respiration.Eyes: In the unlikely event that the material enters the eye fl ush with copious quantities of clean water. If persistent irritation occurs obtain medical attention.Ingestion: In the unlikely event that ingestion occurs, wash out the mouth with water and seek medical attention. Do not induce vomiting.

Diesel Fuel

May cause skin irritation.Gloves, overalls and eye protection should be worn when handling this product.

As for engine oil above.

Fibre Glass Insulation (over exhaust pipe duct and lining exhaust pipe box)

The User will not normally come into contact with this material but Service Technicians may.

May cause skin and respiratory tract irritation.

Gloves, overalls, dust mask and eye protection should be worn when handling this product.

Skin Contact: Remove contaminated clothing and wash thoroughly with soap and water. If per-sistent irritation occurs obtain medical attention. If the material is injected under high pressure into the body obtain medical assistance immediately.Inhalation: In the unlikely event of inhalation of fumes if dizziness or nausea occurs move the individual to fresh air. If symptoms persist, obtain medical attention. If diffi culties are experienced with breathing a qualifi ed person should admin-ister oxygen. If breathing stops give artifi cial respiration.Eyes: In the unlikely event that the material enters the eye fl ush with copious quantities of clean water. If persistent irritation occurs obtain medical attention.

Other insulation, gaskets and seals

No specifi c hazards under normal use conditions.

DO NOT burn as a method of disposal as combustion is likely to give rise to a complex mixture of airborne solids, liquid particulates and gases including carbon monoxide and unidentifi ed organic and inorganic compounds which may be haz-ardous to health.

N/A



Safety

Asbestos This generator is asbestos free. N/ABattery Acid

Battery is located in the battery box in the engine canopy

The User and Service Technicians will not normally come into contact with acid.

Battery contains acid electrolyte which is absorbed in the separator glass mat ma-terial. If battery case is punctured, com-pletely fl ush any released material from skin or eyes with water.

Battery posts, terminals and related accessories contain lead and lead com-pounds which have been known to cause cancer and reproductive harm. Batter-ies also contain other chemicals which have been known to cause cancer. Wash hands after handling. Avoid contact with acid materials. Use soda ash or lime to neutralize material released or spilled: Flush with copious amounts of water.

Skin Contact: Remove contaminated clothing and wash thoroughly with soap and water. If persistent irritation occurs obtain medical attention. If the material is injected under high pressure into the body obtain medical assistance immediately.Inhalation: In the unlikely event of inhalation of fumes if dizziness or nausea occurs move the individual to fresh air. If symptoms persist, obtain medical attention. If diffi culties are experienced with breathing a qualifi ed person should administer oxygen. If breathing stops give artifi cial respiration.Eyes: In the unlikely event that the material enters the eye fl ush with copious quantities of clean water. If persistent irritation occurs obtain medical attention.Ingestion: In the unlikely event that ingestion occurs, wash out the mouth with water and seek medical attention. Do not induce vomiting.

Exhaust Fumes

Exhaust fumes are very hot and con-tain carbon monoxide which can cause unconsciousness and death in humans and animals. It is odourless and tasteless but diesel exhaust fumes contain other chemicals and soot which will irritate the eyes and breathing and will usually alert the user to the presence of fumes.

Symptoms of carbon monoxide poisoning are dizziness, nausea, fatigue and vertigo.

Skin Contact: Remove contaminated clothing and wash thoroughly with soap and water. If persistent irritation occurs obtain medical attention. If the material is injected under high pressure into the body obtain medical assistance immediately.Inhalation: In the unlikely event of inhalation of fumes if dizziness or nausea occurs move the individual to fresh air. If symptoms persist, obtain medical attention. If diffi culties are experienced with breathing a qualifi ed person should administer oxygen. If breathing stops give artifi cial respiration.Eyes: In the unlikely event that the material enters the eye fl ush with copious quantities of clean water. If persistent irritation occurs obtain medical attention.

Electric Shock

• Assess the situation fi rst.• DO NOT touch the person until it is safe for you to do so.• Identify where the electricity is coming from. DO NOT assume it is the generator• Turn off the electricity at the source.• To stop generators in an emergency press the RED stop button on the generator control

panel or remove the plug from the socket. On Automatic Mains Failure Units (AMF) press the emergency stop button on the main control panel.

• If necessary check patients air ways, administer artifi cial resuscitation, move the person to the recovery position.

• Even if the person remains conscious anticipate that they will pass into shock.• Local burns where contact was made should be covered by a sterile dressing. • Obtain medical attention immediately.



Operation

NOTICEFor safety reasons, the battery isolator will be turned off prior to delivery. It is recommended that this action is repeated when moving the generator or for long term storage.

OperationThe guidelines for operating the generator are outlined in the section.

The HRD 1500rpm range of generators are resiliently enclosed within an acoustically treated housing providing noise attenuation. Large access doors on both sides enable ease of servicing and maintenance in a tight space.

The HRD range utilises a standard control panel using a Deep Sea Electronics 7310 (DSE7310) controller.

The Deep Sea controller can be confi gured for local and remote operation.

When confi gured for local operation the operator can stop and start the set and monitor the generator and engine condition at the set using the green start and red stop buttons and instrument panel on the DSE7310 control module.

When confi gured for remote start the 3 pin socket on the output panel is used to connect the set to a remote Automatic Mains Failure (AMF) panel or timer volt free switch. The switched connection can then transmit a start and stop signal to the DSE7310 to initiate the generator’s start up or shutdown procedure. In order to action this signal the DSE7310 will need to be placed in AUTO mode.

Output Panel

Remote Control /

Panel

OutputTerminal

Pod400/230V

3Ph Output

Generator

3 pin remote start/stop

*Schematic for illustration only.

Generator Layout

Output Panel

EmergencyStop

Service Access Door

Radiator Access

Lifting Beam Access

Exhaust

Fork Lift Pockets

NB Layout may vary depending upon model please refer to General Arrangement Diagrams.

Output Panel

(1) (3)

(4)

(5) (2)

(6)

Item Description1 Control Panel2 MCB Panel containing Output Breaker3 Control Panel Key Lock4 Remote Connection Socket5 Emergency Stop6 Terminal Output Pod



Operation

Control Panel

The control panel is accessed via the lockable control panel door.

F6 F7 F8 F9

(1) (2)

(3) (4) (5)

Item Description1 DSE7310 Control Module2 USB Controller Program Socket3 Fuses:

F6 - 5A Control Module FuseF7 - Generator Sense L1F8 - Generator Sense L2F9 - Generator Sense L3

4 DC Isolation Switch5 Control Module Protection MCB

DSE7310 Control Module

The control panel has a Deep Sea Electronics 7310 engine and generator management system which combines engine management, condition monitoring and general operational control of the machine. It is designed for ease of use and provides information via a large LCD display which is accessed through a simple scroll menu system.

Control Button Descriptions:

Item Description

This button allows you to STOP the unit or reset any cleared alarms.

By selecting this button you can place the unit into manual mode a LED will illuminate, this now allow the unit to be started when the button is pressed.Selecting this button places the unit into AUTO mode and will automatically start when the mains fails or the unit receives a remote start signal.This button places the module into its ‘Test’ mode. This allows an on load test of the generator.

Alarm cancel button and lamp test

Press this button to start the generator (Used in conjunction with the manual start control button)When the unit is in manual mode this button closes a control contactor or motorised breaker when fi tted. (May be disabled if manual MCCB fi tted)When the unit is in manual mode this button opens a control contactor or motorised breaker when fi tted. (May be disabled if manual MCCB fi tted)

Menu scroll keys left and right

Menu scroll keys up and down

Accept or OK button to enter different menus levels

The DSE7310 control module allows the user to con-trol the operation of the generator engine.

The DSE7310 also provides instrumentation for;



Operation

• Engine Speed• Generator Voltage• Generator Current• Generator Frequency• Engine Run Time

• Battery Volts • Generator kW• Generator kVA• Alarm messages

The DSE7310 module will go into standby when no common alarms have been triggered after 1 minute of inactivity. When the emergency stop is pressed in the DSE7310 module will not go into standby, so while the generator is in storage ensure that it is on charge us-ing the appliance plug.

Instrumentation

To access various instrumentation displays you will need to press the “page” button on the engine control module. Each “page” of instrumentation can be ac-cessed sequentially in this order.

• Status• Engine • Generator• Mains• Alarms

If an alarm is raised while an instrumentation view is being displayed the instrumentation view is changed to the alarm page. The alarm page is only available when an alarm has been raised.

The confi guration settings for the DSE7310 can be found later in this document.

DC Isolator Switch

The DC Isolator Switch enables operation of the generator. It is a simples ON / OFF switch.

Turning the Switch to the ON position activates the Deep Sea Electronics 7310 control module.

NOTICEWhen generator not required switch off to minimise battery drain.

USB Controller Programme Socket

This USB connection can be used to install and modify the DSE7310 generator control module programme.

Remote Connection Socket

This can be used to connect the set to a remote Automatic Mains Failure (AMF) panel, remote control panel or timer volt free switch. The switched connection can then transmit a start and stop signal to the DSE7310 to initiate the generator start up or shutdown procedure.

Please contact HGI sales to discuss any requirement to extend the generator functionality for remote connectivity.

Emergency Stop

Pressing the emergency stop pushbutton will immediately stop the engine and prevent it from restarting.

The emergency stop button must only be used to stop the machine in an emergency and not to stop the set during normal operation.

To restart the generator, release the emergency stop button by twisting clockwise, reset the control module by pressing the Fault Reset button, and start the generator by pressing the green Run button.



Operation

Terminal Output Pod

WARNINGRisk of Electrocution. Disconnect Power before making electrical connections. Terminal connections should be made by qualifi ed personnel only.

The Terminal Output Pod can be accessed by removing the Terminal Output cover’s wingnuts. The cover is hinged from the bottom and folds down to reveal the terminals.

(1)

(2)

(3)

(4)

Item Description1 MCB 3 Pole set to 116A 80kVA or 144A

100kVA2 3 Phase Output Terminals3 M10 Earth Stud4 Cable Gland Opening

If the set has been confi gure to provide terminal output supply, the electrical connections from the generator will have been made and tested during installation. All cables connecting to external panels and output will have been passed through the cable gland opening.

NOTICEIf the Terminal Box Cover is open the set will not run. An emergency stop alarm will appear in the DSE7310.

Three Phase Terminal Connections

Ensure that the connections are secure and correctly sequenced. Please refer to the wirring diagram later in this manual.

Earth Stud

The M10 brass stud in the terminal pod should be connected to an external earth point or to an earth spike. An earth spike can be supplied as an optional extra and should be driven at least 600 mm into soil.

Installations

Installation of the generator is to be made by qualifi ed personnel in accordance with appropriate regulations e.g., Electricity Safety, Quality and Continuity Regulations 2002 (S.I. 2002/2665), and Electrical Safety regulations cited previously in this document



Operation

Pre-Operation Checks

Engine Oil

Check the oil level BEFORE EACH USE with the generator on a level surface and the engine stopped.

Engine oil should have properties of API classifi cation CH grade or higher. SAE10W-30 is recommended for general, all temperature use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.

Oil ViscosityEMA LRG-1

API CH-4Viscosity Grade

Ambient Temperature

Min Max

SAE 0W20 -40°C (-40°F) 10°C (50°F)SAE 0W30 -40°C (-40°F) 30°C (86°F)SAE 0W40 -40°C (-40°F) 40°C (104°F)SAE 5W30 -30°C (-22°F) 30°C (86°F)SAE 5W40 -30°C (-22°F) 40°C (104°F)

SAE 10W30 -20°C (-4°F) 40°C (104°F)SAE 15W40 -10°C (14°F) 50°C (122°F)

* Please refer to engine manufacture’s O&M for full details of operational oil grade requirements.

To check the oil level:

1. If the generator has been running then wait for 10 minutes to allow the oil to drain back into the oil pan.

2. Access the engine via Service Access doors

3. Remove the dipstick (a) and wipe the dipstick clean.

(a)

4. Insert the dipstick back into the dip tube and then remove again, checking where the oil level lies on between the minimum and maximum positions on the dip stick.

5. If the level is low, remove the oil fi ller cap located on the rocker cover and top up.

Oil Capacity 8 litres

Replace the engine oil after 500 hours, then every 500hr or yearly. When changing the oil or topping-up, use oil of a grade suitable for the prevailing ambient temperatures (see table in engine handbook).

Coolant Level Check

WARNINGExplosive release of fl uids from pressurised cooling systems can cause serious burns. Only remove fi ller cap when engine is cold or when cool enough to touch with bare hands. Slowly loosen cap to fi rst stop to relieve pressure before removing completely.

The radiator fi ller point is located at the front of the set.To check the coolant level:

1. Access the radiator fi ller cap via the cover on the roof of the generator. Turn the cover anti-clockwise to open.

2. Remove the radiator cap after the engine has completely cooled and check to see that coolant reaches the bottom of the neck.



Operation

(a) (b)

3. If coolant level is low top up. Refer to Engine Manufacturer’s Operation and Maintenance Manual for details of Coolant Mix.

Coolant Capacity 17 litres

Fuel

WARNINGDiesel is highly fl ammable and explosive.You can be burned or seriously injured when handling fuel. Stop the engine and keep heat, sparks, and fl ame away. Handle fuel only outdoors.Wipe up spills immediately.

Fuel Source

The generator uses Commercial diesel with up to 10% bio-diesel .i.e. B10 blend.

The fuel is stored in an on-board bunded fuel tank within the base of the generator. The tank has a capacity of 320 Litres.

Some generators have an option to have fuel sourced either by using the on-board fuel tank or by using an external fuel tank connected using the snap connectors on the front left side of the generator base.

On these the respective fuel source must be selected prior to use.

To select the fuel source:

1. Open the Left Hand Service Access Door. 2. Locate the fuel lever mounted on a bracket from

the base of the generator.

3. To use the internal tank the lever must be positioned to the left (as shown above). To use an external fuel supply then move the lever to the right.

Fuel Prime Switch

There is a fuel priming switch that is spring loaded. When used this will energise the electric fuel pump and solenoid to prime the system.

To operate the fuel prime switch.

1. Open the Left Hand Service Access Door. 2. Locate the fuel prime switch mounted on the back

of the control panel. 3. Move the toggle switch to the left to engage fuel

priming. 4. Return the switch to the right after priming.

Prime the fuel after switching fuel source or after routine maintenance involving the fuel system.

Fuel Level

If an external tank is used please refer to the manufacturers instructions for checking the fuel and ensure that suffi cient fuel is available prior to using the generator.

If the internal tank is being used then the fuel level can be checked using the sight level in the base of the generator.

If the engine is running the fuel level can be checked at the DSE4510 control module. If the fuel is low the Low Fuel Alarm indicator will be lit and the generator will shutdown to prevent air locking in the fuel system. This functionality is only available when using the internal tank.



Operation

To refuel the internal tank

1. Open the Left Hand Service Access Door

2. Locate the Fuel Level Sight Glass located on the base of the generator next to the fuel fi lller cap.

3. If the gauge is low top up with fuel. Locate the fi lling point located inside the generator on the base next to the fuel supply switching lever.

4. Remove the fuel tank cap.

5. Refi ll the fuel tank avoiding spilling fuel.

6. Do not over fi ll.

NOTICEFuel can damage paint and plastic. Be careful not to spill fuel when fi lling your fuel tank. Damage caused by spilled fuel is not covered under warranty.

7. After refuelling tighten the fuel cap securely.

Fuel Capacity: 320 Litres

Installation

Installation of the generator is to be made by qualifi edpersonnel in accordance with appropriate regulationse.g., Electricity Safety, Quality and ContinuityRegulations 2002 (S.I. 2002/2665), and ElectricalSafety regulations cited previously in this document.

Starting

WARNINGPlease check that all equipment is disconnected or the load isolated from the generator prior to starting.

Local Operation

1. Perform the Pre-Operation Checks.

2. Check MCB and RCD are in the ON positions.

3. Turn the DC ISolation Switch to the “ON” position.

4. Press the Red Stop/Reset button once.

5. Press the Green Run/Start pushbutton once only and engine will pre-heat and the starter motor will turn and the engine will crank.

If the engine fails to start within 10 seconds, the control module will pause and attempt 3 cranks.

6. After Starting, allow the engine to warm up for 1 minute before sconnecting any load to the generator output.

Remote Operation

For remote starting the generator needs to be prepared at the set:

1. Perform the Pre-Operation Checks.

2. Check MCB and RCD are in the ON positions.

3. Turn the DC ISolation Switch to the “ON” position.

4. Press the Red Stop/Reset button once.

5. Ensure that the remote panel/timer stop/start signal is plugged in using the 3 way socket.

6. Press the White Auto button.

7. The generator will now start upon the Start signal being received from the remote panel/timer.



Operation

CAUTION

Generator can now start automatically

If the engine fails to start after 3 attempts then inititate fault fi nding to rectify the problem.

NOTICEIf the generator is not required switch it off and avoid running with light or no load wherever possible. Also see Maintenance Section.

Stopping

1. Switch off the electrical output and disconnect the load from the generator’s output sockets.

2. Allow the generator to run off load for 2 minutes to cool down.

3. Press the red stop/reset button on the DSE7310 moudle or if being operated remotely the Stop signal will be transmitted to the DSE7310

4. The engine will then stop after the shutdown process and cool down period is competed.

Shutdown Protections

The generator is fi tted with the following protection devices that will shut down the generator in the event of a fault. They are indicated on the engine control module.

Charge Fail: Operates if the battery is not charging, this could be caused by parasitic drain (leaving engine control module illuminated), generator inactivity, or faulty alternator charging.

Low Oil Pressure: This operates if the oil pressure falls below a safe level. This can be caused by a lack of oil, wrong type of oil or high temperature. Check and top up the oil level as necessary. During starting, the alarm is held off for 10 seconds to allow the oil pressure to build up to normal running level. The engine will not crank if there is a false oil pressure signal prior to starting.

Low Fuel Level: The fuel gauge also incorporates a low fuel shutdown facility. The set will give a warning and then shut down when the level falls to approximately 10-12% of its capacity, thus eliminating the need to bleed the system at restart.

High Engine Temperature: If the temperature is out side the value programmed into the controller the generator will close down.



Fault Finding

Fault FindingIMPORTANT:If the following checks and investigations can be completed without the use of tools then the operator can safely undertake them. If tools are needed then ONLY trained technicians can undertake the work safely. Wiring diagrams can be obtained from HGI to help with electrical fault fi nding.

Engine Fails to Start

Symptom Cause and Remedy

Starter motor did not attempt to turn the engine over and no fault icons are displayed on the engine module.

• Check the emergency stop button is not pressed IN.• Check the control fuse or MCB has not failed.• Flat battery or wrong polarity from battery.• Check that the battery is producing over 12V DC from the positive

terminal relative to the chassis of the generator.• Check the connections to the control module. • Check the operation of the slave relay, module and its fuses. • Check the connections to the starter motor.• Check the operation of the starter motor by making a temporary

connection to its solenoid.

Starter motor did not attempt to turn the engine over and the oil pressure icon is displayed on the Engine module.

• The control module believes that oil pressure is present when the engine is off.

• Check the oil pressure switch has not gone faulty.• Check the control module has not gone faulty by swapping it.• If running off local internal tank check fuel in tank, check 3 way valve

set to internal tank. If running from external tank, check the fuel in tank, connections are made, check 3 way valve set to external tank and fuel transfer pump is set to on.

Engine turns over but will not start.

No smoke seen from exhaust pipe.

• Check that the fuel fi lter is not blocked or full of water.• Check there is a 12V DC supply to the fuel solenoid valve. • Check* fuel is getting past the fuel solenoid valve.• Check* fuel is fl owing at high pressure out of the fuel pump located

next to the fuel solenoid.• Suspect the fuel system is air locked or there is contamination

blocking the fuel system or injector.

Engine turns over but will not start.after 3 attempts to start). “Start Fail” will be displayed on control moduleSmoke seen from exhaust pipe.

• Suspect faulty fuel supply as above.• Suspect faulty fuel injector nozzle.• Suspect contaminated / unsuitable fuel.• Suspect starter motor is not turning engine over quickly enough

particularly if the temperature is too low.• Suspect serious fault with the engine.

* Care should be taken while working on the fuel system particularly when fuel is under high pressure.



Fault Finding

Engine Starts but then Stops


Engine starts but then closes down.

• Check control circuit fuse and MCB.• Check battery charger circuit fuse.• Check the 12V DC supply from the battery and battery charger has

not been lost. • Suspect faulty control module. Swap it to check it.

Engine starts but then closes down.Common alarm on the control module triggered.

• Check the fuel level and that the fuel system is not blocked or air locked.

• Then check for faulty fuel level switch.• Check oil level then check for faulty oil pressure switch.• Check the fuel solenoid valve has not closed prematurely.• Check the fuel system has not become contaminated or defective as

given previously.

Engine starts but then closes down on Speed Fault on the Control Module.

• Speed Fault - If the engine does not run at 1500 rpm it will close down. The most common cause of incorrect speed is air or contamination in the fuel system. Bleed the system and try starting again

Other Generator Faults


Has the miniature circuit breaker (MCB) or Main MCCB tripped or pop-out breaker tripped.

• Before resetting disconnect all equipment plugged into the sockets. Look for any obvious reasons or faults as to why the equipment has caused the unit to trip.Reset the MCB or MCCB and reconnect and switch on equipment one piece at a time. Do not hold the suspect equipment and use the selector switch on the generator to turn the supply ON to the suspect equipment. If a piece of equipment trips the MCB repeatedly make sure it cannot be used again by removing the plug and labelling faulty/unsafe.

The miniature circuit breakers have not tripped.

• Connect another piece of electrical equipment that is not faulty to confi rm that the generator is faulty.

• Suspect a major fault with the alternator or its voltage regulation unit.



Fault Finding

No Electrical Output


Check the phase rotation. • For three phase generators ensure that the phase rotation of the load is correct.

• Swap phases if necessary.

Check the miniature circuit breaker (MCB) and main MCCB.

• Each 110V/230V output socket has its own MCB to prevent excessive electrical load being taken through that socket. Check if the miniature circuit breaker (MCB) has tripped or 2-pole circuit breakers have been set to OFF.

• Check main MCCB under cover has not tripped.

The earth leakage unit has not tripped, the miniature circuit breakers have not tripped.

• Connect another piece of electrical equipment that is not faulty to confi rm that the generator is faulty.

• Suspect a major fault with the alternator or its voltage regulation unit.• The voltage can also be read on the Deep Sea Module if present.



Maintenance

MaintenanceGood maintenance is essential for safe, economical, and trouble free operation. This not only ensures that your engine is at its optimum in fuel effi ciency, but maintains the engine in order to minimize the risk of breakdowns.

Maintenance Schedule

Service intervals will have to be reduced if the generator is operated in dusty or severe conditions.

Servicing must be carried out by a competent engineer. A written record of the service work should be made. The generator must be serviced in accordance with our recommendations for the warranty to be valid. Please refer to the Engine Manufacturer’s Operation and Maintenance Manual for full servicing requirements.

DO NOT use a pressure washer to clean the welder-generator as high pressure water may enter the electrical system. Use a damp cloth or similar.

OPERATION DESCRIPTIONPERIODICITY (HOURS)

Daily 500 1000 2000 3000 4000 12000Check and Replenish Engine Oil º º º º º º ºCoolant Level Check º º º º º º ºGeneral Inspection º º º º º º ºMCB Test º º º º º º ºEngine Air Cleaner Service Indicator Check º º º º º º ºBattery Check º º º º º º ºFuel System Primary Filter/Water Separator Drain º º º º º º ºRadiator º º º º º ºEngine Air Cleaner Check/Clean/Replace º º º º º ºRun on ¼, ½, ¾ full load for 30 mins º º º º º ºElectrical Checks º º º º º ºControl Module Checks º º º º º ºEngine Oil Replace º º º º º ºOil Filter Cartridge Replace º º º º º ºPrimary Fuel Filter Replace º º º º º ºSecondary Fuel Filter Replace º º º º º ºExhaust System º º º º º ºBattery Charger º º º º º ºGlow Plugs Check / Replace º º º º º ºEngine Valve Lash Inspect/Replace º (1) º º º º ºCanopy Checks º º º º ºStarter Motor Check º º ºAlternator Check º º ºTurbocharger Inspect º º ºCooling System Cooling Change º ºAlternator Belt Tension Check and Adjust º ºCoolng System Coolant Extender (ELC) Add ºCooling System Coolant (ELC) Change º

(1) On the initial 500hrs service.

If you’d like to make an appointment for HGI to service your generator using our in house 26-point health checker guide then please contact the Service Department.



Maintenance

Maintenance Safety

Some of the most important safety precautions follow. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance. Only you can decide whether or not you should perform a given task.

WARNINGFailure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or death.Always follow the procedures and precautions in the operations’ manual. Where third party equipment is incorporated into the generator always refer to their guides for familiarisation and information.

Safety Precautions

• Make sure the engine is off before you begin any maintenance or repairs. This will eliminate several potential hazards:

• Read the instructions before you begin, and make sure you have the tools and skills required.

Maintenance Routine

The following procedures refer to the common maintenance items for servicing your generator.

Check and Replenish Engine Oil

Refer to Pre-Operational Checks to check the engine oil level and replenish.

Replace the engine oil after 500 hours operation. When changing the oil or topping up, it is recommended to use oil of grade SAE10W-30.

Use the Eazy-Drain system to drain the oil in the engine while the engine is warm. Warm oil drains quickly and completely.

Place the generator on a level surface, and place a suitable container under the generator at the service access panel side of the generator.

Remove the oil fi ller cap / dipstick.

Drain the oil into the suitable container.

Follow HSE recommendations regarding the handling

and disposal of contaminated oil products.

The oil fi lter element is a replacement type, and should be replaced in line with the procedure below

Replace components in reverse order.

Fill with recommended oil to the max level shown on the dipstick.

Coolant Level Check

Check the coolant level daily and top up if necessary.

Check the radiator and hoses for signs of damage or leaks. Check the cap and seal for signs of damage. Clean the radiator matrix of leaves or similar debris.

Check the coolant level when the engine is stationary and on a level surface.

The radiator should be fi lled to typically 1 cm above the core of the radiators matrix. If the engine has an expansion bottle, the coolant level should be fi lled as marked on the expansion bottle or label.

Top or change with a Coolant Mixture in line with the Engine manufacturers guidelines. Never use neat antifreeze.

If fi tted, DO NOT use the expansion bottle to decide if the radiator needs topping up.

Drain the waste fl uids into suitable waste containers, and follow HSE recommendations regarding the handling and disposal of contaminated oil products. Check the radiator and hoses for signs of damage or leaks.

Cooling System Coolant Change

Clean the cooling system and fl ush the coolingsystem as as specifi ed by the engine manufacturer’s maintenance interval or as necessary.

Drain

1. Stop the engine and allow the engine to cool. Loosen the cooling system fi ller cap slowly in order to relieve any pressure. Remove the cooling system fi ller cap.



Maintenance

2. Open the drain cock or remove the drain plug (1) on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the coolant to drain.

3. Dispose of used engine coolant or recycle in local with local HSE regulations.

Flush

1. Flush the cooling system with clean water in order to remove any debris.

2. Close the drain cock or install the drain plug in the engine. Close the drain cock or install the drain plug on the radiator.

NOTICE Do not fi ll the cooling system faster than 5 L per minute to avoid air locks. Cooling system air locks may result in engine damage.

3. Fill the cooling system with clean water. Install the cooling system fi ller cap.

4. Start and run the engine at low idle until the temperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool. Loosen the cooling system fi ller cap slowly in order to relieve any pressure. Remove the cooling system fi ller cap. Open the drain cock or remove the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to drain. Flush the cooling system with clean water.

Fill

1. Close the drain cock or install the drain plug on the engine. Close the drain cock or install the drain plug on the radiator.

NOTICE Do not fi ll the cooling system faster than 5 L per minute to avoid air locks. Cooling systemair locksmay result in engine damage.

2. Fill the cooling system with an approriate mix of antifreeze and water for the respective ambient operating conditions. Do not install the cooling system fi ller cap. Refer to Engine Manufacturer’s Operation and Maintenance Manual for details of Coolant Mix.

3. Start and run the engine for one minute in order to purge the air from the cavities of the engine block. Stop the engine.

4. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for fi lling. Maintain the coolant level in the expansion bottle (if equipped) at the correct level.

5. Clean the cooling system fi ller cap. Inspect the gasket that is on the cooling system fi ller cap. If the gasket that is on the cooling system fi ller cap is damaged, discard the old cooling system fi ller cap and install a new cooling system fi ller cap. If the gasket that is on the cooling system fi ller cap is not damaged, use a suitable pressurizing pump in order to pressure test the cooling system fi ller cap. The correct pressure for the cooling system fi ller cap is stamped on the face of the cooling system fi ller cap. If the cooling system fi ller cap does not retain the correct pressure, install a new cooling system fi ller cap.

6. Start the engine. Inspect the cooling system for leaks and for correct operating temperature.

Primary Fuel Filter Replace

1. Turn the fuel supply valve (if equipped) to the OFF

position.

2. Place a suitable container under the water separator. Clean the outside of the water separator.

3. Install a suitable tube onto drain (1). Open the drain (1). Allow the fl uid to drain into the container.



Maintenance

Remove the tube.

4. Tighten drain (1) by hand pressure only.

5. If equipped, remove the wiring harness from the sensor on the bottom of the glass bowl.

6. Hold glass bowl (3) and remove screw (2). Remove glass bowl (3) from canister (4).

7. Use a suitable tool in order to remove canister (4). Discard the old seals (5 and 6) and the canister in a safe place.

8. Clean glass bowl (3). Prime the fuel system.

9. Install the new canister. Do not use a tool in order to install the canister. Tighten the canister by hand.

10. Install new O ring seal (5) onto setscrew (2). Install new O ring seal (6) into the glass bowl.

11. Align the glass bowl to the canister. Ensure that the sensor (if equipped) is in the correct position. Install setscrew (2). Tighten the setscrew to a torque of 5 N·m (44 lb in).

12. If equipped, install the wiring harness to the sensor.

13. Remove the container and dispose of the fuel in a safe place.

14. The secondary fi lter must be replaced at the same time as the primary fi lter. See below or tefer to the Operation and Maintenance Manual , “Fuel System Filter - Replace”.

Secondary Fuel Filter Replace

After the engine has stopped, you must wait for60 seconds in order to allow the fuel pressure tobe purged from the high pressure fuel lines beforeany service or repair is performed on the enginefuel lines.

To replace the secondary fuel fi lter:

1. Ensure that the fuel supply valve (if equipped) is in the OFF position. Place a suitable container under the fuel fi lter in order to catch any fuel that might spill. Clean up any spilled fuel.

2. Clean the outside of the fuel fi lter. Use a suitable tool in order to remove the canister (2) from the engine and dispose of the canister in a safe place.

3. Ensure that dirt can not enter the new canister. Do not fi ll the canister with fuel before the canister is installed. Lubricate the O ring seal (1) with clean engine oil on the new canister.

4. Install the new canister. Do not use a tool in order to install the canister. Tighten the canister by hand.

5. Spin on the canister until the O ring seal contacts the sealing surface. The 6 drain hole vesion canister will require a ¾ of a full turn in order to tighten the canister correctly. The 12 drain hole version will require a full 360 degree rotation to tighten the cannister correctly.

6. Prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information.

Drain Fuel Tank

Drain and fl ush the fuel tank periodically to prevent the build-up of contaminants, particularly when the generator has operated in high humidity and dusty environments.



Maintenance

Change the Oil Filter

1. Replace the oil fi lter cartridge every 500 hours.

2. Remove the old oil fi lter cartridge with a fi lter wrench.

3. Clean the sealing surface of the oil fi lter head (2). Ensure that the union is secure in the fi lter head.

4. Apply a fi lm of oil to the O ring seat (3) for the new fi lter.

5. Install the oil fi lter. Tighten the oil fi lter to 12 N·m (8.8 lb ft). Do not overtighten the oil fi lter.

Battery

The battery is a maintenance free unit and should not require the electrolyte being topped up.

Check that the positive and negative terminals are tight and secure, and free from corrosion. Lightly coat them with petroleum jelly or similar to protect from corrosion.

Check that the battery securing strap or bracket is tight and the battery is held fi rmly.

Engine Air Cleaner Service Indicator Check

The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element. As the air cleaner element becomes dirty, the pressure differential rises.

The service indicator is mounted on the air cleaner element or in a remote location. The air cleanerelement should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.• The red piston locks in the visible position.

Refer to Engine Manufacturer’s O&M for full information about checking the Service Indicator.

Engines Glow Plugs

With the engine starting normally measure thecurrent being drawn by each glow plug or heaterto confi rm operational.

Replace them periodically as recommended in the engine manufacturer’s manual.

Check Operation of MCBs and MCCB

No maintenance can be carried out on these other than a physical check to ensure they latch in the On position and no sign of external damage can be seen.

Alternator Fan Belt Check and Adjust

To maximize the engine performance, inspect thebelts for wear and for cracking. Replace belts that areworn or damaged. Refer to Engine Manufacturer’s O&M for full information about checking and adjusting the Fan Belt.

Radiator

Inspect the radiator for these items: Damaged fi ns,corrosion, dirt, grease, insects, leaves, oil, and otherdebris. Clean the radiator, if necessary.

Engine Air Cleaner Check/Replace

The Air Cleaner has a Dual Element fi ltering system.

If the air cleaner element becomes blocked, the air pressure can split the material of the air cleaner element. Unfi ltered air will drastically accelerate internal engine wear.

• Check the precleaner (if equipped) and the dust bowl daily for accumulation of dirt and debris.Remove any dirt and debris, as needed.

• Operating conditions (dust, dirt and debris) may require more frequent service of the air cleanerelement.



Maintenance

• The air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

Replace the dirty air cleaner elements with clean air cleaner elements.

The primary air cleaner element can be cleaned and used for up to six times

1. Remove the cover. Remove the primary air cleaner element.

2. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element.

3. Clean the primary element by using pressurised air or a vacuum cleaner.

4. Cover the air inlet with tape in order to keep dirt out.

5. Clean the inside of the air cleaner cover and body with a clean, dry cloth.

6. Remove the tape for the air inlet. Install the sec-ondary air cleaner element. Install a primary air cleaner element that is new or cleaned.

7. Install the air cleaner cover.

8. Reset the air cleaner service indicator.

Adjust Valve Clearance

Valve Clearances should be checked after the fi rst 12 months or 1000hrs and reset in accordance with the engine manufacutrer’s guidelines. Refi t the rocker cover with a new gasket.

Alternator

Ensure that the cooling air vents do not become blocked by dirt, debris etc. and that the cooling fan is not damaged. Service in line with alternator manufac-turer’s guidelines.

Control Module Safety Shut Down

This module will prevent the generator from starting or shut it down if faults occur. Check the following:-

Hours Run Counter; confi rm counter is working.

Emergency Stop: with the engine running use the E-Stop Button. The engine should stop and the E-Stop alarm should be seen.

Terminal Door Safety Switch: with the engine running open the Terminal Output Pod cover. The engine should stop and the E-Stop alarm should be seen.

Low Fuel Level; With the engine running allow the fuel tank to run out of fuel and the engine should stop and the Low Oil alarm should be seen. Refi ll with fuel and the engine should start and run normally.

Battery Charger

Stop and start the engine a few times if needed to draw off the battery.

Start the engine and allow running for 5 minutes, then checking that the battery charger is delivering at least 13.2V DC into the battery.

Starter Motor

These are normally sealed for life but should be inspected and serviced in accordance with the engine manufacturers instructions.

Engine Valve Lash Inspection/Replace

Refer the the Engine Manufacturer’s instructions for performing this maintenance activity.

Exhaust System

Inspect the exhaust system and silencer at the fl exible sections and joints in particular.

Check the exhaust is adequately supported and secured. Check for leaks and signs of burning of the insulation. Replace insulation if necessary.

If the engine has run on low load for a considerable period the exhaust may be sooted up. Run the engine on low load for 10 minutes and gradually increase to full load for 30 minutes to blow and burn any soot out of the exhaust. Care should be taken that hot soot does not land on combustible material.



Maintenance

Canopy

Check security of fi xings and fasteners on the machine. Lubricate hinges and latches with light machine oil.

Ensure that the inlet and outlet louvres are kept clean and unimpeded at all times. Check that no sound insulation has become loose and obstructed them.

General Inspections Inspect generally for:-

Fuel and Oil Leaks: Look for excessive oil in the base tray. Look for weeps from fuel hoses and connections. Check the insulation is dry and not contaminated with fuel or oil.

Worn or Failed Anti Vibration Mounts: When the side panels are removed rock the engine and check all four anti vibration mounts are fl exing slightly and have not failed or broken up.

Damaged or missing insulation and seals: Generally look at the sound insulation and seals and check it is still securely fi tted and has not deteriorated.

Hoses and Clamps: Inspect all hoses for leaks that are caused by the following conditions:• Cracking• Softness• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

Missing Safety Labels: These labels are a mandatory safety requirement and if any are missing or not easy to read they should be replaced. Full details of all labels are contained in this manual. A replacement label kit is available.

Chaffi ng or Stretching of Cables: Inspect all cables and connections and look for obvious signs of wear or damage.

Lifting Points: Inspect the lifting points for obvious signs of wear, damage or distortion.

Signs of Over Heating: Look for obvious deterioration due to heat and investigate the cause and rectify as necessary.

Fuel Cap: Check the cap seals correctly. Check for obvious signs of fuel spillage.

Electrical:• Inspect sockets, and replace if damaged or

contact pins are burnt. • Check all wiring is secure and not damaged. • Check the output voltage and frequency are

correct. • Check the earth continuity between the socket

earth pins and the generator frame.

Run on ¼, ½, ¾ then full load Operating the generator at low load levels for extended periods can result in high levels of carbon build up in the engine and exhaust system which can lead to excessive smoking, reduced effi ciency and overheating. Looking at the silencer’s outlet will give some indication this has happened.

After each service the generator should be run fi rst on ¼, then ½, then ¾ and fi nally full load using a load bank, to burn out any deposits of soot in the engine and silencer.

Each level of load should be applied for at least 10 minutes or until the exhaust is clear of soot and smoke. If you suspect the engine is badly sooted, DO NOT apply full load but build the load up gradually.

It should be anticipated that hot soot will be expelled from the engine during this procedure and it should be done in a safe place away from combustible material and under supervision at all times.

Turbocharger Inspect

A visual inspection of the turbocharger can minimizeunscheduled downtime. A visual inspection of theturbocharger can also reduce the chance for potentialdamage to other engine parts. To inspect the Turbo-charger:

1. Remove the pipe from the turbocharger exhaust outlet and remove the air intake pipe to the turbo-charger. Visually inspect the piping for the pres-ence of oil. Clean the interior of the pipes in order to prevent dirt from entering during reassembly.

2. Check for the presence of oil. If oil is leaking from the back side of the compressor wheel, there is a possibility of a failed turbocharger oil seal. The presence of oil may be the result of extended engine operation at low idle. The presence of oil may also be the result of a restriction of the line for the intake air (clogged air fi lters), which causes the turbocharger to slobber.



Maintenance

3. Inspect the bore of the housing of the turbine outlet for corrosion.

4. Fasten the air intake pipe and the exhaust outlet pipe to the turbocharger housing.

Cooling System Coolant Extender (ELC) Add

The Perkins Extended Life Coolant (ELC) does notneed the frequent addition of Supplemental CoolantAdditives (SCA) that are associated with conventionalcoolants. The Extender only needs to be added once.Check the cooling system only when the engine isstopped and cool.

1. Loosen the cooling system fi ller cap slowly in order to relieve pressure. Remove the cooling system fi ller cap.

2. It may be necessary to drain enough coolant from the cooling system in order to add the Extender.

3. Add Extender according to the requirements for your engine’s cooling system capacity.

4. Clean the cooling system fi ller cap and inspect the gasket. If the gasket is damaged, discard the old fi ller cap and install a new fi ller cap. If the gasket is not damaged, use a suitable pressurising pump in order to pressure test the fi ller cap. The correct pressure is stamped on the face of the fi ller cap. If the fi ller cap does not retain the correct pressure, install a new fi ller cap.

Cooling System Coolant Extender (ELC) Change

Refer to changing the standard Cooling System Change. When refi lling use the Perkins Extended Life Coolant.

498-1069


40

Maintenance

Maintenance Record Sheet (for use by owner / service agent)

Name of Owner:Address:

Order No:

Name of Service Organisation:Address:

Job No:

Generator Details (from Data Plate)Model:Serial No:Build Code:Year of Manufacture:Rated Power:Power Factor PF:Voltage (Current):Fuel Type

Date of Service:

Hours Run meter reading: (hrs)

Service Interval: Daily / 500 / 1000 / 2000 / 3000 / 4000 / 12000

General Condition:

Daily Checks:1. Fuel Level Checked2. Oil Level Checked3. Coolant Checked4. Battery Checked5. Check for oil / fuel leaks6. MCB/MCCB/RCD/RCBOs checked7. Check fuel fi lter not contaminated

Yes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / No

After 1000hrs:1. Complete 500hrs check2. Canopy checked3. Engine Valve Inspect / Lash /

Replace

Yes / NoYes / NoYes / No

After 2000hrs:1. Complete 1000hrs check2. Starter Motor checked3. Alternator checked4. Turbocharger inspect

Yes / NoYes / NoYes / NoYes / No

After 500hrs:1. Complete daily checks2. Check Radiator3. Change the engine oil4. Change the oil fi lter5. Check the air fi lter clean6. Electrical checks7. Control Module checks8. Primary Fuel Filter replace9. Secondary Fuel Fileter replace10. Run at ¼, ½, ¾ and full load11. Exhaust System check12. Battery Charger 13. Glow Plugs14. ...............................................

Yes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / NoYes / No

After 3000hrs:1. Cooling System Change2. Alternator Belt Tension check /

Adjust

Yes / NoYes / No

After 4000hrs:1. Complete 2000hrs check2. Coolant Extender (ELC) Add

Yes / NoYes / No

After 12000hrs:1. Complete 4000hrs check2. Coolant Extender(ELC) Change

Yes / NoYes / No

Spare parts used:

Notes:

Signed: Representing: Date:



Parts & Service

Parts and Service

Contact Details

Parts Department

Tel: +44 (0) 1629 821 645Fax: +44 (0) 1629 821 606email: [email protected]: www.hgiparts.com

Service Department

Tel: +44 (0) 1629 821 647Email: [email protected]

Technical Help Line

Staffed by friendly Technical Engineers who will advise on the correct generator for your power requirements, its application and safe use.

Tel: +44 (0) 1629 821 614 or 821 652

Functional Spares

Description Part Number Engine PartsOil Filter A1003-080Air Filter Inner A1003-119Air Filter Outer A1003-081Fuel Filter Main A1003-082Fuel Pre-Filter A1003-118lFan Belt A1003-056Glow Plug A1003-085Rocker Cover Gasket A1003-084Generator PartsDSE7310 Controller 125-0881 Phase 45A 1 Pole MCB Pushbutton 110-045Fuse 5A 20mm 100-005

Warranty Statement

See HGI Website for latest warranty statement

https://www.hgigenerators.com/warranty-statement-2.html



Transportation / Storage

Transportation and Storage

NOTICE Do not lay the generator on its side when moving, storing, or operat-ing it. Oil may leak and damage the engine or your property

If the generator has been used, allow it cool for at least 15 minutes before loading the generator on the transport vehicle. A hot engine and exhaust system can burn you and can ignite some material. To prevent fuel spillage when transporting, the generator should be secured upright in its normal operating position, with the engineControl Module switched OFF.

Take care not to drop or strike the generator when transporting. Do not place heavy objects on the generator.

Item DescriptionEngine: Turn the Engine Control Module “OFF”

Short Term typically up to 6 months:

Do not run the generator out of fuel. If the engine runs out of fuel the fuel system will become air locked and will have to be bled before the engine will restart. Leave a small quantity of fuel in the fuel tank. Drain any water from the water separator / fi lter. Run the engine for a few minutes and drain the warm oil and fi ll with new oil as for a normal service. Turn battery isolator off. Disconnect battery and grease terminals with petroleum jelly.

Long Term over 6 months:

For long term storage each engine manufacturer will have their own recommendations typically:

1. Replace engine oil with a special inhibiting oil.2. Flush through fuel system and leave full with a special inhibiting compound.3. Spray connectors in the loom and plug in sensors with Vaporol Inhibitor or similar.

Please contact HGI for further details.Alternator: No special requirements other than store in a dry well ventilated place.

If the generator has been stored for a considerable period of time e.g. several years the alternator insulation winding resistance should be checked as they can absorb moisture. The insulation resistance must be at least 2 MΏ (2 mega ohms). If it is less than this then the alternator windings can be dried out by placing the alternator in an oven at 60-70°C for a few hours with plenty of air movement. Generally if this procedure is required consider replacing the alternator.

Please contact HGI for details.Electrical : No special requirements other than store in a dry well ventilated place.

General: Store in dry, well ventilated and dust free place.

Whilst in storage it is recommended that the battery is trickle charged via the 3-pin socket (buccaneer) on the control panel.

If the generator is to be stored long term it would be benefi cial to start and run the generator under electrical load for half an hour every three months and then store as above ( but no need to change the oil).



Wiring

Wiring80kVA



Wiring

100kVA



Manufacturer’s Service and User Guides

Manufacturer’s Service and User Guides LinksEvery effort is made to ensure that the manufacturer’s user and service guides contained in this manual are the latest available at the time of publication. If in doubt about the recency of the documents then please contact the manufacturer or visit their website for the latest information.

Perkins Operators and Maintenance Manual

- http://www.perkins.com/Manuals

Deep Sea 7310 User Guide

- http://www.deepseaplc.com/products/dse-genset

Mecc Alte ECO / ECP User Manual

- http://www.meccalte.com

If you are still unsure then please contact HGI Technical Helpline: +44 (0) 1629 821 614 or 821 652

Operation and Maintenance Manual - hgigenerators.com · HRD Events Diesel Generator 498-10691...

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