Operators Manual 12KVA GT12E PETROL GENERATOR IMPORTANT - Ensure that persons intending to use this Portable Generator, thoroughly read and understand this user’s manual before attempting to operate the unit.
1
CONTENTS Safety ............................................................................................................................................... 2 Do’s and Dont’s………… .......................................................................................................... ….5 Oil
Types..............................................................................................................………………..6
Oil
Adding....................................................................................................……………………7
Oil Alert System. .................................................................................................................... ….. 7 Fuel Types………. ................................................................................................................ …… 8 High Altitude Use. .............................................................................................................. …….. 9 Components
Map............................................................................................................……… 10
Controls.......................................................................................................................................... 11 Safety Switch RCD ...................................................................................................................... 12 Earth Stake .................................................................................................................... ………… 12 Wheel Kit Assembly ..........................................................................................................……... 13 Starting and Stopping The Engine. ............................................................................ …………. 15 Maintenance Schedule .......................................................................................................…….. 18 Engine Oil & Filter Change ........................................................................................................... 19 Air Filter...........................................................................................................................…………. 20 Spark Plug. ................................................................................................................. ……………. 21 Fuel Tap. .................................................................................................................. ..................... 22 Valve Clearance................................................................................................................. ………. 23 12v DC Operation. ......................................................................................................... ………… 24 Transporting .................................................................................................................................. 25 Storage…………………….……………………………………………………………………………….. 26 Trouble Shooting………………… ............................................................................................... 28 Wiring Diagram. ................................................................................................................. …….. 30 Specifications. ................................................................................................................................31 Warranty Documents. ................................................................................................................... 32 Product Registration …………………………………………………………….………………………. 34
Print version - 062015
1
1
1. SAFETY
The generators are designed to give safe and dependable service when operated according to instructions. Read and understand this owner’s manual before operating your generator. You can help prevent accidents by being familiar with your generator’s controls, and by observing safe operating procedures.
Operator Responsibility •
Know how to stop the generator quickly in case of emergency.
•
Understand the use of all generator controls, output receptacles, and connections.
•
Be sure that anyone who operates the generator receives proper instruction. Do not let children operate the generator without parental supervision. Keep children and pets away from the area of operation.
•
Place the generator on a firm, level surface and avoid loose sand or snow. If the generator is tilted or overturned, fuel spillage may result. Also, if the generator is overturned or sinks into a soft surface, sand, dirt, or water may enter the generator.
Intended application: • • • • •
• • •
Standalone temporary power supply solutions Light industrial, portable tools, camping, lights etc. Mains-failure back-up, property maintenance, farm use. Suitable for use under 1000 meters altitude
Should you intend to drive large electric motors e.g. refrigerators, grinders, water pumps, air conditioners and the like, you must make allowance for the start up power requirement of an electric motor. Which is typically 3 to 5 times the quoted run requirement for the motor and possibly as high as 7 times. As an absolute minimum, always ensure that the generator being used to drive an electric motor has the capacity to supply at least 3 times the quoted power requirement for the electric motor you wish to operate. For example: A 1 horsepower electric motor which requires 750watts (w) to run will need a generator capable of delivering a minimum of (3 x 750w) = 2250w in order to effectively start the motor, without risking damage to either the motor or the generator. Use extension cords sparingly, only use extension cords with an adequate current rating. Using a light weight household extension cord with thin conductors will cause overheating, appliance damage or even fire. Your portable generator is not built for continuous 24 / 7 operation. If your application requires more than a temporary power supply, seek a generator designed for such a purpose, continuous duty generators are normally stationary in nature having water cooled engines with large capacity sumps, replaceable oil and fuel filters. NB. Using your generator beyond its intended design purpose will void the warranty agreement.
2 2
•
•
•
Remember to also maintain a minimum load of not less than one third of the generator’s rated output in order to avoid the build up of excessive carbon within the combustion chamber. You must also avoid any continuous loads in excess of the rated output, exceeding the rated output of the generator will start to overheat the alternator. Damage to the alternator caused by electrical overloading is not covered by the Limited Warranty Policy. Your portable generator has an air cooled engine as well as an air cooled alternator, it is important not to run the generator on loose surfaces such as dirt, dust or sand, otherwise abrasive particles can be sucked into the air stream and cause premature wear of components. Also should the ambient temperature exceed 38°C the rated load must be reduced to compensate. Used and maintained correctly, your portable generator will provide many years of trouble free operation. Your generator has been manufactured to a high standard in order to ensure a long service life. The realization of the intended design life is wholly dependent on adhering to the service, operation and maintaince requirements as described in this manual.
IMPORTANT SAFETY INSTRUCTIONS
All information and specifications in this publication is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice and without incurring any obligation. No part of this publication may be reproduced without written permission. DC type is equipped for DC outlet. DDC type is equipped for both electric starting and DC outlet. This manual should be considered a permanent part of the generator and should remain with it if it is resold. Safety Messages Your safety and the safety of others are very important. We have provided important safety messages in this manual and on the generator. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol and one of three words: DANGER, WARNING, or CAUTION. These mean: You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions.
3
3
Damage Prevention Messages Other important messages are preceded by the word NOTICE. This word means: Your generator or other property could be damaged if you don’t follow instructions. The purpose of these messages is to help prevent damage to your generator, other property, or the environment.
1.5m
Spilled fuel and its vapors can become ignited from cigarette sparks, electrical arcing, exhaust gases, and hot engine components such as the muffler. Heat will expand fuel in the tank which could result in spillage and possible fire explosion. Operating the generator in an explosive environment could result in a fire. Materials placed against or near the generator can interfere with its proper ventilation causing overheating and possible ignition of the materials. Muffler exhaust heat can damage painted surfaces, melt any heat sensitive material (such as siding, plastic, rubber, or vinyl), and damage live plants. Improperly stored fuel could lead to accidental ignition. Fuel improperly secured could get into the hands of children or other unqualified persons.
Shut off engine and allow it to cool before adding fuel to the tank. Use care in filling tank to avoid spilling fuel. Move the generator away from the fueling area before starting the engine. Keep maximum fuel level 15mm below the top of the fuel tank to allow for heat expansion. Operate the generator in well ventilated areas free from obstructions. Equip areas with fire extinguishers suitable for diesel fuel fires. Never operate the generator in an area containing dry brush or weeds. Always keep the generator a safe distance (1.5m) away from surfaces (such as houses, automobiles, or live plants) that could be damaged from muffler exhaust heat. Store fuel in approved containers, in a secure location away from the work area.
Min clearance 1.5m around generator Breathing exhaust fumes will cause serious injury or death. Exhaust fumes contain poisonous carbon monoxide gas.
Operate the generator in a well ventilated area. Avoid enclosed areas such as garages, basements, etc. Never operate a generator in a closed location occupied by humans or animals.
Water directed at electrical outlets or switches, or objects connected to an electrical circuit, could result in a fatal electrical shock. Moisture of any kind may conduct electricity and could result in a fatal electrical shock. The generator is not waterproof.
Never attempt to clean the generator while it is running. Direct any water or spray away from electric outlets and switches. Keep your generator out of the elements and well sheltered from rain, snow, dew, water or mist of any kind.
4
Contact with hot surfaces, such as engine’s exhaust components, could result in serious burns.
Fuel or oil can leak or spill and could result in fire or breathing hazard, serious injury or death. Fuel or oil leaks will damage carpet, paint or other surfaces in vehicles or trailers.
During operation, touch only the control surfaces of the generator. Keep children and live stock far away from the generator at all times. They may not be able to recognize the hazards of this product.
Turn the fuel tap to the “Off” position before transporting the unit to avoid fuel leaks. Only transport fuel in approved containers. Always place the generator on a protective mat when transporting to guard against damage to vehicle from leaks. Remove generator from vehicle immediately upon arrival at your destination.
General do’s and don'ts •
Operate the generator outside. Never use it indoors.
•
Keep the generator dry. Do not use it in the rain or in wet conditions. To protect from moisture, operate it on a dry surface under an open, canopy-like structure.
•
If wet, dry your hands before touching the generator.
•
Plug appliances directly into the generator, or use a heavy duty, outdoor extension cord that is rated (in watts or amps) at least equal to the sum of
the connected
appliance loads. Check that the entire cord is free of cuts or tears and that the plug has all three prongs, especially an earth pin. Improper connections to a building’s electrical system during a power outage, can allow electrical current from the generator to feedback into the utility lines. Such feedback may electrocute utility company workers or neighbors who contact the lines. served by the same utility transformer. It also bypasses the built-in household circuit protection devices. Never try to power the house by plugging the generator into a wall outlet, Consult a qualified electrician. Improper connections to a building’s electrical system can allow electrical current from the utility company to flow into the generator. When utility power is restored, the generator may explode, burn, or cause fires in the building’s electrical system.
5
•
If intending to connect your portable generator to house wiring you must, get a licensed electrical contractor to do it in accordance with AS/NZS 3000 Electrical Installations and Energex or Ergon Energy requirements.
•
Avoid creating a fire hazard. Store fuel for your generator in properly labeled non-glass safety containers, out of the home and away from fuel-burning appliances (such as gas water heater in the garage).
•
Before refueling the generator, turn it off and let it cool down. Fuel spilt on hot engine parts could ignite. ATTENTION:
Minimum electrical load: You must maintain a minimum electrical load of one third the generator’s rated output. Failure to maintain a minimum load will cause carbon deposits within the combustion chamber, serious engine damage can be caused by long periods of running with no load. Engine damage or the removal of carbon deposits due to a lack of engine load is not warrantable, as it is caused by the manner of operation.
Preparation before starting WARNING! Read Owner’s Manual. Do not operate equipment until you have read the Owner’s Manual for Safety, Operation, and Maintenance Instructions. Engine oil
Engine oil is a major factor affecting engine performance and service life. Non-detergent and 2-stroke engine oils will damage the engine and are not recommended.
Check the oil level BEFORE EACH USE with the generator on a level surface with the engine stopped. Use 4-stroke oil, or equivalent high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for Service Classification SG, SF/CC, CD. Motor oils classified SG, SF/CC, CD will show this designation on the container.
Recommended oil types: • •
For operation in Hot climates +10˚C to 40˚C use SAE 30 - API grade CC or CD For cooler climates operation -10˚C to 30˚C use 10W30 - API grade CC or CD
6
Â
Adding oil to the engine Place the generator on a level surface. 1. Remove the oil filler cap and wipe the dipstick clean. 2. Check the oil level by inserting the dipstick into the filler neck without screwing it in. 3. If the level is low, add the recommended oil to the upper mark on the dipstick. Never attempt to add oil to the engine while it is running. Hot oil may splash on your face or hands causing serious injury.
Oil Alert System
The oil alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the oil alert system will automatically shut down the engine (the engine switch will remain in the ON position). The oil alert system shuts down the engine and the engine will not start. If this occurs, first check engine oil.
Refueling recommendations 1. Refill the tank if the fuel level is low. Do not fill above the shoulder of the fuel strainer. 2. Avoid the generator stopping by running out of fuel, power variations will occur.
7
Gasoline is extremely flammable and is explosive under certain conditions. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored. Do not overfill the fuel tank (there should be no fuel in the filler neck). After refueling, make sure the tank cap is closed properly and securely. Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled, make sure the area is dry before starting the engine. Avoid repeated or prolonged contact with skin or breathing of vapor. •
• •
•
KEEP OUT OF REACH OF CHILDREN.
Fuel type
Only use regular unleaded fuel. The fuel should be fresh, filtered cleanly and care taken not to let any dust or water enter the fuel tank. Otherwise the filters and carburetor may be blocked or damaged. Use gasoline with a pump octane rating of 86 or higher. We recommend unleaded gasoline because it produces fewer engine and spark plug deposits and extends exhaust system life. Never use stale or contaminated gasoline or oil/gasoline mixture. Avoid getting dirt or water in the fuel tank. Occasionally you may hear light “spark knock” or “pinging” (metallic rapping noise) while operating under heavy loads. This is no cause for concern. If spark knock or pinging occurs at a steady engine speed, under normal load, change brands of gasoline. If spark knock or pinging persists, see an authorized generator dealer. Oxygenated Fuels Some gasoline’s are blended with alcohol or an ether compound to increase the octane. These type of gasoline are collectively referred to as oxygenated fuels. Some areas use oxygenated fuels to help meet clean air standards. If you use an oxygenated fuel, be sure its pump octane rating is 86 or higher. Ethanol (ethyl or grain alcohol) Gasoline containing more than 10% ethanol by volume may cause starting or performance problems. Gasoline containing ethanol may be marketed under the name “Gasohol”.
8
Methanol (methyl or wood alcohol) Gasoline containing methanol must contain co-solvents and corrosion inhibitors to protect the fuel system. Gasoline containing more than 5% methanol by volume may cause starting and/or performance problems and may damage metal, rubber and plastic parts of your fuel system. MTBE (methyl tertiary butyl ether) You may use gasoline containing up to 15% MTBE by volume. Before using an oxygenated fuel, try to confirm the fuel’s contents. Some states (provinces in Canada) require this information to be posted on the pump. If you notice any undesirable operating symptoms, switch to a conventional unleaded gasoline. Fuel system damage or performance problems resulting from the use of an oxygenated fuel are not our responsibility and are not covered under warranty. Oxygenated fuels can damage paint and plastic. Be careful not to spill fuel when filling your fuel tank. Damage caused by spilled fuel is not covered under warranty. Running the engine with persistent spark knock or pinging
can
cause engine damage. Running the engine with persistent spark knock or pinging is misuse, and the Distributor’s Limited Warranty does not cover parts damaged by misuse.
High Altitude Operation •
At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase.
•
High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screw. If you always operate the engine at altitudes higher than 5000 feet (1500 meters) above sea level, have an authorized generator dealer perform this carburetor modification.
•
Even with suitable carburetor jetting, engine horsepower will decrease approximately 3.5% for each 1000 foot (300 meter) increase in altitude. The effect of altitude on horsepower will be greater than this if no carburetor modification is made. If a engine jetted for high altitude is used at a lower altitude, the lean air fuel mixture will reduce performance and may over-heat and seriously damage the engine.
9
COMPONENT IDENTIFICATION (1)
AC Circuit Breaker
(2)
RCD
(3)
AC Outlets
(4)
AC Reset Buttons
(5)
12V DC Outlet
(6)
Data Meter
(8)
(7)
Key Start: On / Off
(9)
(8)
Choke
(9)
Fuel Tap
(10)
Air cleaner
(11)
Folding Handle
(12)
Recoil Starter
(13)
Oil Pressure Sensor
(14)
Oil Filter
(15)
Dip Stick
(16)
Battery
(17)
Fuel cap
(18)
Fuel Tank (48L)
(19)
Exhaust outlet
(20)
Wheel
(21)
Tappet Cover
(22)
Spark Plug (BPR7ES)
(5)
(6)
(7)
(4)
(3) (2) (1)
(10) (11) (12) (13)
(14)
(18)
(16)
(15) (17)
(22) (19) (20)
(21)
10
10
CONTROLS Engine Switch Electric (key) start :
ON
•
Position 1
-
To run the engine (ON)
•
Position 2
-
To stop the engine.(OFF)
•
Position 3
-
To start the engine (START)
START
OFF
Circuit Breakers There are 3 separate levels of AC circuit protection. The main circuit breaker (1), the RCD (2), and each power outlet also has its own push to reset circuit breaker (3) The main circuit breaker (1) will automatically switch OFF if there is a short circuit or other very large overload of the generator circuit. If the circuit breaker is switched OFF automatically, check that the appliance is working properly and does not exceed the rated load capacity of the generator before switching the circuit breaker ON again. The circuit breaker (1) may also be used as a switch to turn generator power ON or OFF.
(3)
(2)
(1)
11
SAFETY SWITCH
[RCD] (2) •
•
The Residual Current Devices (RCD) will not function if the generator is not earthed correctly. You must connect the earth terminal to a copper coated earth stake of sufficient length to ensure good continuity to earth.
Test the Safety Switch every 3 months by pressing button marked “T” for test. The Safety Switch should Trip immediately, if it does not trip, contact you’re closest authorised Service Dealer.
A good connection to earth is absolutely vital for the RCD to function correctly. To prevent electrical shock from faulty appliances, the generator must be grounded. Ensure a good electrical continuity between ground and the generator. The generator ground terminal beneath the right hand corner of panel. it provides an electrical point from which to earth the metal generator
is located the control connection parts of the
EARTH STAKE (Copper coated steel rod) This Portable Generators is not designed to be connected to buildings directly, if done the RCD in your generator will see the RCD in your building as a fault. If you choose to connect a portable generator with an RCD directly to your household wiring, a licensed electrical contractor must first install a changeover switch and the generator must also be modified. get a licensed electrical contractor to do it in accordance with AS/NZS 3000 Electrical Installations and Energex or Ergon Energy requirements
12
Wheel kit Assembly
AC Applications Before connecting an appliance or power cord to the generator: • Make sure that it is in good working order. Faulty appliances or power cords can create a potential for electrical shock. • If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, turn it off immediately. Disconnect the appliance, and determine whether the problem is the appliance, or if the rated load capacity of the generator has been exceeded. • Make sure that the electrical rating of the tool or appliance does not exceed that of the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may only be used for periods not more than 30 minutes. Substantial overloading will switch off the circuit breaker. However slightly exceeding the maximum power specification will not cause the circuit breaker to switch OFF. It will however start to overheat the alternator and will eventually cause an insulation failure. •
Limit maximum power operation to 20 minutes only.
•
For long duration operation, do not load above the Rated Power specification.
In either case, the total power requirements (Watts) of all appliances connected must be considered. Appliance and power tool manufacturers usually list rating information near the model number or serial number.
13
AC Operation Electrical Load Load according to the stipulated parameters, Rated watts is the maximum continuous duty load which can be sustained by the alternator without overheating (in air temperatures up to 38°C). Maximum watts is the total measure of power which is available for short duration (less than 20 minutes) use, e.g. The start up of electric motors, boiling a jug, etc. continuous operation of the generator with connected loads above the rated watts will start to overheat the alternator. kW: A Kilowatt is a measure of effective power, it is the net power that is flowing from the source to the load, also known as real power or kilowatts (kW). In electricity it is the product of the voltage by the current. 240 volts x 10amps = 2400 watts or 2.4kW. kVA: A Kilovolt Ampere is the power that is circulating between the source and the load also known as reactive volt-amperes, it is what we call apparent power as it does not take into account the phase difference between the voltage and the current. All AC. plant requires reactive power; which has to be supplied by the generator. For example if you want to use a 5kW motor the power it consumes is volts times amps .but it will also need about 1.25k reactive volt times amps. Making the kVA rating for a 5kW motor 6.25kVA@0.8 PF
240 volt AC application After starting and warming up the engine • • • •
• • •
Now electrical loading can be carried out. Ensure the RCD is in the ON position and the case is kept sealed. Move the control panel circuit breaker to the “ON” position. At the time of connecting with the generator, different kinds of equipment should be connected in order, so as not to shock load the motor. Firstly the larger equipment should be connected, after the operation is normal, then the small equipment can be connected. If the load is so much that the motor speed slows, it is necessary to unload immediately, turn the circuit breaker off. This situation will cause equipment damage. It is necessary to reduce the circuit load. If the equipment connected makes the AC circuit breaker trip, it is necessary to reduce the circuit load. It is not allowed that the set runs in an overloaded condition. Maximum output power for the generator must not be exceeded. It is necessary to wait for several minutes for the AC circuit breaker to cool if tripped before restoring operation.
14
• •
Never connect more than one generator to the same circuit. Do not exceed the current limit specified for any one power outlet socket. If an overloaded circuit causes the AC circuit breaker to switch OFF, reduce the electrical load on the circuit, wait a few minutes and then reset the circuit breaker.
STARTING / STOPPING THE ENGINE Starting the engine • • •
Make sure that the AC circuit breaker is in the OFF position. The generator may be hard to start if a load is connected. Turn the fuel tap to the ON position. Move the choke lever to the ON (CLOSED) position, then start the engine.
Fuel Tap The fuel tap is located above the recoil starter. When the fuel tap is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure to turn the fuel tap OFF after stopping the engine, especially during transportation.
Choke ON The choke is used to provide an enriched fuel mixture when starting a cold engine. It is opened and closed by operating the choke lever manually. Move the lever to the “ON” or closed position to enrich the mixture.
15
Â
Key Start
To start, turn the key to the start position When the engine starts, allow the switch to return to the ON position
engine
If required retry starting after 10 second intervals.
Operating the starter motor for more than 3 seconds can overheat and damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operating the starter again. If the speed of the starter motor drops after a period of time, it is an indication that the battery should be recharged.
Recoil Starter (1) (2) (3)
Engage the recoil starter mechanism. Draw out the handle until you feel heavy resistance. Quickly and strongly pull out the recoil rope.
Don’t let the handle fly out of your hands otherwise it may smash into the engine or damage the starter. Slowly and deliberately allow the handle to return to its original position.
16
Choke OFF •
Push the choke lever to the OPEN position as the engine warms up. After starting, let the engine run without load for around 5 seconds before moving the choke lever to the OFF position. Note: Time may vary depending ambient temperature.
on
Colder temperatures will require a longer warm up time.
Stopping the engine In an emergency: •
To stop the engine in an emergency only, move the key switch to the OFF position.
During normal use: •
Turn the AC circuit breaker to the OFF position. (If in use, disconnect the DC battery charging cables).
•
Turn the key switch to the OFF position.
•
Turn the fuel tap to the OFF position.
17
MAINTENANCE Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution. Exhaust gas contains poisonous carbon monoxide. Shut off the engine before performing any maintenance. If the engine must be run, make sure the area is well ventilated. Periodic maintenance and adjustment is necessary to keep the generator in good operating condition. Perform the service and inspection at the intervals shown in the Maintenance schedule below.
MAINTENANCE SCHEDULE 20 hours
100 hours
200 hours
300 hours
Item
Daily
Battery condition - Check
○ Before each operation
Engine oil - Check
○ Before each operation
Leakage Check - oil / fuel
○ Before & after operation
○
○
○
○ 1st time
○ 2nd & Every 100 hr
Air cleaner - Clean / Replace Spark Plug - Clean / Replace Fuel tap sediment cup Clean Engine oil - Replace
Service more frequently in dusty areas
(BPR7ES NGK)
Oil filter - Replace
(620OILFIL)
○ 1st time
○ Every 200 hr
Valve Clearance - Adjust
▲
In-line fuel filter - Replace
○
Muffler spark arrestor Clean Fuel piping - Check / Replace Fuel tank and strainer Clean out
○ Every year
○ Every 2 years
○ Every 2 years
Cylinder head - Wash
○ Every 2 years
The (▲) Mark indicates that special tools and skills are required.
18
Â
Improper maintenance, or failure to correct a problem before operation, can cause a malfunction in which you can be seriously hurt or killed. Always follow the inspection and maintenance recommendations and schedules in this manual. The maintenance schedule applies to normal operating conditions. If you operate your generator under severe conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.
Engine oil / oil filter - Change Drain the oil while the engine is warm to assure complete and rapid draining. 1. Remove the oil filler cap, drain plug and sealing washer, and drain the oil. 2. Unscrew and remove the used oil filter. 3. With new oil filter make sure the contact area is clean and lightly lubricated. 4. Screw on new oil filter, tightening torque is 9 ~ 13 Nm (6.5 ~ 9.5 ftlbs) 5. Reinstall the drain plug and sealing washer. Tighten the plug securely. 6. Refill with the recommended oil and check the oil level.
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. Please dispose of used motor oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local service station or recycling center for reclamation. Do not throw it in the trash or pour it on the ground.
19
Air cleaner service A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the generator in extremely dusty areas. A damaged air filter will allow abrasive particles into the engine and reduce its service life.
Never run the generator without the air cleaner. Rapid engine wear will result.
•
Undo the air cleaner cover screws; pull the air cleaner cover out by its base and lift up to remove.
•
Clean or replace the foam air filter element every 50 to 100 hours (more frequently in dusty conditions).
•
Clean by gently hand washing with detergent and warm water.
•
Inspect the air cleaner element to ensure it is clean and undamaged.
•
Lightly oil the foam and squeeze out any excess,
•
Replace the foam element if it is damaged or distorted in any way.
•
Reposition the foam element in the housing and attach the air cleaner cover, retighten the screws firmly by hand.
20
Spark Plug •
Remove the spark plug cap and HT lead by hand
•
Clean the head area, so no foreign material can fall into the engine once the plug has been removed.
•
Use a tube socket to undo the spark plug.
BPR7ES (NGK) •
Visually inspect the spark plug. Discard if the insulator is cracked or chipped. Clean with a wire brush if it is to be reused.
•
Measure the plug gap with a feeler gauge.
•
The gap should be: 0.70-0.80 mm (0.028-0.031 in).
•
Check that the spark plug washer is in good condition, and thread the spark plug in by hand to prevent cross-threading.
•
After the spark plug is seated, tighten with a spark plug wrench to compress the washer.
•
If installing a new spark plug, tighten l/2 turn after the spark plug seats to compress the washer. If reinstalling a used spark plug, tighten l/8 - l/4 turn after the spark plug seats to compress the washer.
The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and could damage the engine. Never use spark plugs which have an improper heat range. Use only the recommended spark plugs or equivalent.
21
Fuel Tap sediment cup •
Close the fuel valve
•
Use a spanner to undo the sediment cup.
•
Remove the sediment bowl, O-ring and strainer
•
Clean the sediment cup and strainer with high flashpoint solvent.
•
Check the O-ring is not cracked, perished or damaged in any way. If so replace it before assembly.
•
Reassemble the sediment cup, O-ring and strainer
•
Open the fuel tap and inspect for any leakage.
22
Valve Clearance ▲
Special tools and skills are required. •
Inlet Valve: 0.03 ~ 0.05mm
•
Exhaust Valve: 0.05 ~ 0.07mm
Remove the tappet cover and check valve clearance with a feeler gauge •
To be performed every 300 hours of operation.
•
Should be conducted by professional personal
23
DC OPERATION
12 volt DC output socket For convenience the generator is fitted with a cigarette lighter style 12 volt socket. The center terminal is positive (+) and the outer terminals negative (-). •
The DC outlet is an unregulated 12v direct current power source up to a maximum of 8.3amps. It is not suitable for recharging flat car batteries.
•
Should you wish to recharge car batteries use a 240v battery charger plugged into the main generator output.
•
Do not allow the positive and negative leads to contact each other, otherwise it will trip the resettable fuse.
DC Circuit Protector The DC circuit protector (rated current: 10 A) automatically shuts off the DC circuit if there is a short circuit in the connected appliance or the DC current draw becomes excessive. The center button inside the DC circuit protector will pop out to show that the DC circuit protector has tripped. Remove the load or fault that caused the breaker to trip, allow a few minutes to cool, then push the button in, to reset the circuit breaker.
24
Â
TRANSPORTING / STORAGE When transporting the generator, turn the engine switch and the FUEL TAP OFF. Keep the generator level to prevent fuel spillage. Fuel vapor or spilled fuel may ignite. Contact with a hot engine or exhaust system can cause serious burns or fires. Let the engine cool before transporting or storing the generator. Take care not to drop or strike the generator when transporting. Do not place heavy objects on the generator.
Before storing the unit for an extended period: Be sure the storage area is free of excessive humidity and dust. Service according to the table: •
Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed. Storing the engine in this position will help to protect it from internal corrosion.
25
Â
STORAGE TIME
RECOMMENDED SERVICE PROCEDURE TO PREVENT HARD STARTING
Less than 1 month
No preparation required
1 to 2 months
Fill with fresh gasoline and add gasoline conditioner*
2 months to 1 year
Fill with fresh gasoline and add gasoline conditioner* Drain the carburetor float bowl (page 32). Drain the fuel sediment cup (page 26)
1 year or more
Fill with fresh gasoline and add gasoline conditioner* Drain the carburetor float bowl (page 32). Drain the fuel sediment cup (page 26). Remove the spark plug. Put a tablespoon of engine oil into the cylinder. Turn the engine slowly with the pull rope to distribute the oil. Reinstall the spark plug. Leave engine on the compression stroke (both valves closed). Change the engine oil After removal from storage, drain the stored gasoline into a suitable container, and fill with fresh gasoline before starting.
*Use gasoline conditioners that are formulated to extend storage life. Contact your authorized generator dealer for conditioner recommendations.
•
Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container.
Gasoline is extremely flammable and is explosive under certain conditions. Perform this task in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area during this procedure.
26
•
Change the engine oil.
•
Remove the spark plug, and pour about a tablespoon of clean engine oil into the cylinder. Crank the engine several revolutions to distribute the oil, then reinstall the spark plug.
•
Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valves are closed. Storing the engine in this position will help to protect it from internal corrosion.
For all of your repair or servicing requirements Please refer to the below web site.
WWW.PROMAC.COM.AU For details of your nearest service agent.
27
TROUBLESHOOTING When the engine will not start: Is there fuel in the tank?
Refill the fuel tank
NO
YES Is there oil in the engine?
Add the recommended oil.
NO
YES
Is there a spark from the spark plug?
NO
STILL NO SPARK Replace the spark plug.
YES
Be sure there is no spilled fuel around the spark plug. Spilled fuel may ignite. YES
Is the fuel reaching the carburetor? YES If the engine still does not start, take the generator to an authorized generator repairer.
Take the generator to an authorized generator repairer.
To check: 1) Remove the spark plug cap and clean any dirt from around the spark plug. 2) Remove the spark plug and install the spark plug in the plug cap. 3) Set the plug side electrode on the cylinder head. 4) Crank the engine, sparks NO should jump across the gap.
To check: 1) Turn off the fuel tap and loosen the drain screw. 2) Fuel should flow from the drain when the fuel tap is turned on.
Clean the fuel sediment cup
DRAIN SCREW
28
Â
No electrical Output from the AC receptacles:
NO
Is the AC circuit breaker ON
Turn the AC circuit breaker ON
YES NO
Is the RCD breaker ON
Turn the RCD circuit breaker ON
YES NO
Are the push to reset AC circuit breakers ON
Push the reset button for each individual power Outlet.
YES Check the leads and electrical appliance for any defects.
NO DEFECTS
DEFECTS
Take the generator to an authorized generator repairer
Replace the electrical appliance or equipment. Take the electrical appliance or equipment to an electrical shop for repair.
29
Â
WIRING DIAGRAM GT12E
30
SPECIFICATIONS GT12E
Item Engine Type Engine Mode
TR620 Single cylinder, Forced Air Cooling,4-Stroke
Displacement(cc) Engine
Generator
Generator set
622 20 T.C.I. 48 20hr @ 50% load 1.6L 76dBA @ 7 Metres 12(DC) 8.3 3000 50 240 12 9500 8500
Maximum (HP) Igniting Mode Fuel Volume(L) Continuing Time(hr) Oil Volume(L) Noise Charging Voltage(V) Charging Current(A) RPM Rated Frequency(Hz) Rated Voltage(V) Maximum Output(KVA) Maximum Output (Watts) Rated Output (Watts) Length(mm)
850
Width(mm) Height(mm) Net weight(kg)
620 650 143 ●
Large Air Cleaner Large Muffler
Features
●
Extra Large Fuel tank Voltmeter Hour meter Automatic Voltage Regulator
● ● ●
Sine wave output
●
Low oil shut down
●
Non-fuse breaker
●
12v Battery
●
Electric Start
●
Pressure Lubrication System
●
Wheel Kit
●
Remarks: ● means available,
●
- means unavailable
NOTE: Specifications are subject to change without notice.
31
LIMITED WARRANTY POLICY
Limited Warranty Policy This Limited Warranty applies only to new products* distributed by Promac. It is a condition of this Limited Warranty Policy that all servicing requirements are completed as listed in the owner’s manual, (said servicing is at the owner’s expense). We recommend that all servicing is completed by an authorised service agent and that records of said servicing are retained by the purchaser as proof in the event of a warranty claim. The limited warranty period commences from the date of purchase. Promac agrees, subject to the terms and conditions specified below, to repair or replace at Promac’s cost, the product purchased by you when the product does not perform in accordance with its specifications during the limited warranty period, due to any fault in manufacturing, materials and/or workmanship. The purchaser’s attention is drawn to the following • To the extent permitted by law and subject to the Limited Warranty, and as part of the terms of the sale of the equipment or part thereof: Promac shall not be liable for any form of loss, damage, cost, injury or harm of any kind (whether direct, indirect, special or consequential) howsoever arising from the use or supply of the equipment to the purchaser. The Warranty Period • Promac Generators - 12 months Exclusions to Limited Warranty Policy The Limited Warranty will not apply where the equipment or any part thereof: Fails due to an accident (including liquid spillage), abuse, misuse, neglect or normal wear and tear. 1.1 1.2
Has been used in a manner other than for which it was originally designed.
1.3
Has been tampered with or is otherwise than as supplied by Promac.
1.4
Where any damage, malfunction or other failure of the equipment or any part thereof resulted directly or indirectly from unauthorized persons, adjusting or failing to adjust any part requiring normal maintenance and service. (Examples include adjustment of tappets, air filter maintenance, lubrication and tightening of screws nuts and bolts.)
1.5
Malfunctions due to the use of defective or incompatible accessories.
1.6
Is damaged by lightning or thunderstorm activity.
1.7
Has been transported to a country where no authorised Service Agents exist.
Claiming warranty The Warranty may be claimed on in the following manner: In order to make a claim under this warranty, the purchaser must deliver the equipment or any part thereof to a 2.1 repair agent and pay all costs of transportation. 2.2
The purchaser must deliver to the repair agent written reasons why the purchaser considers that the purchaser has a claim under the warranty and must provide all necessary details, including: • • •
2.3
The place, date and from whom the unit or part was purchased. The unit or part involved, Model and Serial Number. The defect, malfunction or failure in respect of which the claim is being made.
If the warranty claim is valid, the repair agent will carry out repairs and return the product at no charge to the purchaser. These repairs are limited to the warranty fault identified and as such will not include any other faults due to misuse, abuse, failure to maintain, fair wear and tear or the replacement of serviceable items such as oil, spark plugs, air filters, fuel etc..
* Torini is a brand name of product distributed by Promac. Note
#
Units which fail to perform in accordance with specifications due to non-warrantable causes will be subject to freight, repair and or quote charges.
32
LIMITED WARRANTY POLICY
36 Month or 3year Limited Extended Engine Warranty: •
The 36 Month, Limited Extended Engine Warranty applies only to the original purchaser of Torini Engines distributed by Promac. The Limited Extended Engine Warranty period commences from the date of purchase and runs in conjunction with the standard 12 months Limited Warranty for the generator. It is a condition of this Limited Extended Engine Warranty Policy that all servicing requirements are completed as listed in the Owners Manual.
•
To the extent permitted by law and subject to the Limited Warranty, and as part of the terms of the sale of the engine or part thereof: Promac shall not be liable for any form of loss, damage, cost, injury or harm of any kind (whether direct, indirect, special or consequential) howsoever arising from the use or supply of the equipment to the purchaser.
Scope of coverage: • •
Torini Engines - 36 Months (3 years)
The Limited Extended Engine Warranty covers the following specific parts only: the cylinder head, cylinder block crankshaft, connecting rods, piston, flywheel, camshaft and timing gears. The Warranty Period for both the standard limited warranty and the limited extended engine warranty begins on the date of purchase to the original retail purchaser and is valid only until the applicable warranted period has passed.
Company responsibilities: • Promac agrees, subject to the terms and conditions specified, to effect warranty repairs within a reasonable amount of time (30 days) at no charge to the owner, the engine purchased by you when the above specified engine components fail to perform in accordance to specifications due to any fault in manufacturing, materials and/or workmanship, during the 36 Month Limited Extended Engine Warranty period.
The owner’s responsibilities: •
As the engine owner, you are required to carryout the maintenance and servicing requirements as listed in your Owners Manual. (said servicing is at the owner’s expense). We recommend that all servicing is completed by an authorised service agent and that records of said servicing and scheduled maintenance are retained by the purchaser as proof in the event of a warranty claim. In the event of a claim, you (the owner) are responsible for presenting your engine to a service dealer for inspection as soon as a problem becomes evident.
Exclusions to Limited Extended Engine Warranty Policy:
This Warranty does not cover the cost of shipping the product to or from the Warranty repair facility. This Warranty does not cover the cost of parts and / or labor necessary to carry out normal servicing or maintenance. The Limited Extended Engine Warranty Policy will not apply where the engine or any part thereof: 1.1 Fails due to an accident (including liquid spillage), abuse, misuse, neglect or normal wear and tear. 1.2 Has been used in a manner other than for which it was originally designed. 1.3 Has been tampered with or is otherwise than as supplied by Promac. 1.4 Where any damage, malfunction or other failure of the equipment or any part thereof resulted directly or indirectly from unauthorized persons, adjusting or failing to adjust any part requiring normal maintenance and service. Examples include adjustment of tappets, air filter maintenance, lubrication and tightening of screws nuts and bolts. 1.5 Malfunctions due to the use of defective or incompatible parts or accessories. 1.6 Is damaged by acts of God, Lightning or thunderstorm activity. 1.7 Has been transported to a country where no authorised Service Agents exist. This Warranty does not cover consumable parts such as, but not limited to, fuel, filters, belts, hoses, lubricants and cleaning fluids.
33
Product Registration
To ensure your warranty is validated please register on line at WWW.PROMAC.COM.AU Click on warranty registration: 1.
Enter your name and address
2.
Phone number
3.
Model
4.
Serial number
5.
Invoice number
6.
Date of purchase
7.
Place of purchase
8.
And return email address
34