User Guide

User Guide

Petrol Generator MH640

Impact Test Equipment Ltd www.impact-test.co.uk & www.impact-test.com

Impact Test Equipment Ltd. Building 21 Stevenston Ind. Est.

Stevenston Ayrshire

KA20 3LR

T: 01294 602626 F: 01294 461168

E: sales@impact-test.co.uk

Test Equipment Web Site www.impact-test.co.uk

Test Sieves & Accessories Web Site

www.impact-test.com

Contents

1.0 Introduction

2.0 Specifications

3.0 SafetyPrecautionsEarthing

4.0 OperationEngine ControlsStartingStoppingPower OutputWelding Output

5.0 MaintenanceFuelLubrication OilBatteryAlternatorElectrical

6.0 Wiring Diagrams2-pole toggle switch - Drg No. PD950-009/14-pole toggle switch - Drg No. PD950-107/14-pole rotary switch - Drg No. PD950-066 1/3

& PD950-066 2/3

7.0 Spares & Service

1.0 Introduction

Thank you for purchasing a quality generator, carefully manufactured to the highest standards. Please read this manual carefully to ensure that your new generator provides you with many years of reliable operation.

2.0 Specification

Engine: 2.4kW – 6kW:Honda GX Range, Single cylinderOHV, Oil alert.

7.5kW – 16kW:Vanguard V-twin cylinder.

Engine speed 3000rpm

Alternator: 2-pole, brushless, self exciting,Capacitor controlled(optional: brush type, AVR control)

Frame: Mild steel, polyester powder coat finish

Generator Serial No.

Rating

Phases

Voltage

Frequency

Engine Manufacturer

Model

Serial No

Alternator Manufacturer

Model

Serial No

3.0 Safety

Read these instructions thoroughly before attempting to operate the machine. If you have any doubts about the safe operation of this equipment, consult the manufacturer or a competent operator. The generator can constitute a hazard to users and nearby personnel and property unless the following precautions are observed during operation:

Precautions

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

Exhaust fumes are poisonous and can kill.

Do not operate the generator in a confined area.Ensure that the area surrounding the machine has no restrictions that would preventan adequate flow of clean, ambient air.

Fuel is highly flammable. When refuelling:

Do not run the engine.Do not smoke.Avoid overfilling the fuel tank.Wipe up any fuel spilt on the machine and movethe equipment away from the area where fuel hasbeen spilt.Store fuel in approved containers only and do not expose to direct sunlight.

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.

The generator should be operated in an open space with free air flow on all sides, at least one metre from other equipment and buildings. The surrounding area should be clear of any combustible material.

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

Do not use the equipment in damp or wet conditions.

The throttle control lever is preset to the correct engine speed and must not be adjusted, otherwise damage to equipment or the generator may be caused and will invalidate the warranty.

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 recommendations regarding the handling and disposal of contaminated oil products.

When welding, always use a welding mask, gloves and protective clothing to prevent burns from the arc and sparks. Ensure that nearby personnel avoid eye contact with the arc.

Earthing

The earth pins of the output socket(s) are electrically connected to the metalwork of the generator.

The alternator windings are not referenced to earth unless requested, or 110V CTE windings are specified.

Further advice on earthing can be found in the following Health & Safety Executive publications (available from HMSO):

GS27 Protection Against Electric ShockGS24 Electricity on Construction SitePM53 Emergency Private Generation

4.0 Operation

Engine Controls

Engine Switch

Fig 1. TypicalHonda EngineControls

Start Handle

Fuel Valve

Choke

Fig 2. TypicalVanguard EngineControls

Fuel Valve

Engine Switch

Start Handle

Choke

Starting

The throttle control lever is preset to the correct engine speed and must not be adjusted, otherwise damage to equipment or the generator may be caused and will invalidate any warranty.

Check that the generator is located on level ground and in an open space with free air flow on all sides, at least one metre from other equipment and buildings, and clear of any combustible material.

Check the lubricating oil level and fuel level; top up as necessary. Do not overfill. The engine must be level when checking the oil.

Honda Engines: Oil level should reach the edge of the filler neck.

Vanguard Engines: Oil level should be as marked on the dipstick.

The generator will not start if the oil level is below a preset level. However, the oil level should never be allowed to fall this low as serious engine damage may still occur.

Check that all equipment is disconnected from the generator.

Fig 3.Typical Fuel Controls

Move the FuelValve Lever

to the ON Position.

To start a cold Engine Move the Choke Lever to the

CLOSED position.(Do not use the choke if the engineis warm).

Recoil Start: Turn the engine switch to the ON position. Pull the starter handle slowly until resistance is felt, and then pull briskly to start the engine.

Electric Start: Turn the engine switch to the START position until the generator starts. Return the swtich to the ON / RUN position.

Fig 4.Typical Recoil Start On-Off Switches

Move the Choke Lever to theOPEN position.

Allow the engine to warm up for 1 minute before connecting any load to the generator output.

Honda GX Range – Recoil Start

Vanguard V Twin – Electric Start

CIRCUIT BREAKER

Fig 5. Typical Electric Start On-Off Switches

Stopping

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

Turn the Engine Switch to the OFF position.

Move the Fuel Valve to the OFF position.

The generator will automatically shut down if the oil level falls below a preset level. However, the oil level should never be allowed to fall this low as serious engine damage may still occur. Always check the oil level before use and top up as necessary.

Power Output

On Dual Voltage models, select the required voltage with the voltage selector switch. On welders select auxiliary power output with the selector switch.

Connect the equipment to be powered (load) into the socket outlets on the generator control panel.

Do not overload the generator as this will cause overheating, and shorten the life of the generator. Check that the total load from all equipment connected does not exceed the generator rating. The output (auxiliary output only on welders) may be protected against severe overload by circuit breakers, when fitted.

Fig 6.WelderControls

Welding Output

Select welding output with the selector switch. (AC Welders Only).

Connect the welding leads to the appropriate sockets.

Adjust the current control to the required level.

The welder is designed to give the maximum welding output for a limited time only. Do not exceed the stated duty cycle as shown on the welder control panel (normally 35% at full output), otherwise damage to the generator will be caused through overheating.

A thermal protection device will reduce or switch off the output if the alternator temperature exceeds a preset level. If the thermal protection is activated, switch off any load and leave the generator running so that cooling air is drawn through the alternator. The thermal protection will automatically reset itself after a few minutes when the alternator has cooled down.

Overheating the alternator to the point where the thermal protection operates may damage the alternator, and will reduce the life of the generator.

Always use a welding mask, gloves and protective clothing to prevent burns from the arc and sparks. Ensure that nearby personnel are protected from direct eye contact with the arc.

5.0 Maintenance

The Maintenance schedule for the generator is detailed below:

Perform at indicated month or operating hours, whichever comes first

Daily6 Months 100 Hours

12 Months 250 Hours

Check & replenish fuel

Check & replenish lube oil

Check battery fluid

Check for oil leaks

Check & clean spark plug (s)

Change lubrication oil

Clean oil filter

Check & clean air filter

Clean fuel tank & strainer

Adjust valve clearances

Check alternator brushes

Carry out electrical checks

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

Servicing must be carried out by a qualified and competent engineer.

Fuel

Drain and flush the fuel tank every 12 months / 300 hours operation to prevent the build-up of contaminants.

Clean the fuel strainer to prevent build up of contaminants, which will restrict flow and reduce engine performance.

Fuel Tank Capacities: Standard Long Run

Honda GX160 – GX 200 3.6 Litres 11 LitresHonda GX270 6.0 Litres 11 LitresHonda GX390 6.5 Litres 19 Litres

Vanguard V-Twin 16/18hp 7.5 Litres n/aVanguard V-Twin 31hp 20 Litres Nato Jerry Can

Lubrication Oil

Check the oil level daily and top up as necessary. Check the oil level when the engine is stationary. Do not overfill. The oil level should be as marked on the dipstick when it is NOT screwed into the engine.

Replace the oil every 6 months or 100 hours operation. When changing the oil or topping up, use oil of grade 10W30 or 15W40.

The oil filter element should be replaced at every oil change (Vanguard engines only).

Drain the oil into a suitable waste oil container and follow HSE recommendations regarding the handling and disposal of contaminated oil products.

Lubrication Oil Capacities:

Honda GX160 - GX200 0.6 LitresHonda GX270 - GX390 1.1 Litres

Vanguard V-Twin: 1.7 Litres

Battery (when fitted)

Check the level of the battery electrolyte every day. The battery electrolyte should be topped up with distilled water to the level marker.

Check that the positive and negative terminals are tight and secure, and free from corrosion. Check that the battery securing clamp is tight and the battery is held firmly.

When replacing the battery, ensure that the cables are not trapped when the battery is clamped in position.

Alternator

Ensure that the cooling air vents do not become blocked by dirt, debris etc.

Check the brushes and slip rings for wear every 12 months / 300 hours operation and replace if worn (brush – type alternators only).

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.