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HGI Generators KUMS080HAE1X004 Operation & Maintenance Manual

Fuel proof limited 8.0kva 1500rpm single phase key start diesel generator
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Operation & Maintenance
Fuel Proof Limited
Single Phase Key Start Diesel Generator
Build Code: KUMS080HAE1X004
Manual
8.0kVA 1500rpm
Publication No. 498-141
:: +44 (0)1629 824284
:: +44 (0)1629 824613
F A X
Ravenstor Road
::
Wirkswor th
DERBYSHIRE
DE4 4FY
www.HGIgenerators.com
::
info@HGIgenerators.com
::
Email

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Summary of Contents for HGI Generators KUMS080HAE1X004

  • Page 1 Publication No. 498-141 Operation & Maintenance Manual Fuel Proof Limited 8.0kVA 1500rpm Single Phase Key Start Diesel Generator Build Code: KUMS080HAE1X004 :: +44 (0)1629 824284 :: +44 (0)1629 824613 F A X Ravenstor Road Wirkswor th DERBYSHIRE DE4 4FY www.HGIgenerators.com info@HGIgenerators.com...
  • Page 2 Version Control Harrington Generators International Document Authorisation Name Position Date Originator: M. Crowfoot Technical Department Mar 2012 K. Croft Technical Department Mar 2012 Approved by: Document History Date Version Author Reason for change 08.03.12 Provisional M. Crowfoot Draft for review by C. Coulton 14.03.12 M.

  • Page 3: Table Of Contents

    Contents Harrington Generators International Section Contents Page Certificates and Specification EC Declaration of Conformity Certificate of Conformity Data Plate Specification General Dimensions General Specification Safety General Precautions and Warning Labels Electrical Safety and Earthing Lifting Hazards to Health and Electrocution Electrocution Operation and User’s Instructions Control Panel...

  • Page 4: Ec Declaration Of Conformity

    Wirksworth Derbyshire DE4 4Y Declare that Equipment : Diesel Generator Model name/Number : KUMS080HAE1X004 Electrical Power P 8kVA / 6.4kWe, PF: 0.8 Conforms to the protection requirements of the following EC Council Directives 98/37/EC Machinery Directive 2006/95/EC Low Voltage Directive...

  • Page 5: Certificate Of Conformity

    Customer’s HGI Part No: Description Part No: Ordered Delivered 8kVA V1105 Mec Alte 230V 50Hz KUMS080HAE1X004 Bunded Base HGI’s Serial No(s): 66088 / 01 to 26 We : Harrington Generators International Ltd., Ravenstor Road, Wirksworth, Derbyshire, DE4 4FY. Declare that: The articles have been subjected to and satisfactorily completed the tests defined in the OEM current Specification.

  • Page 6: Data Plate

    Section 1 - Certification Harrington Generators International 1.3 Data Plate Below is a blank copy of the generator’s Data Plate which is located on the base on the service door side. Fill in the data on the blank copy below. There serial number in particular will be needed to order spare parts etc.
  • Page 7 Section 2 - Specification Harrington Generators International 8kVA Diesel Generator 8kVA Diesel Generator Part No: 498-141 Part No: 498-141...

  • Page 8: General Dimensions

    Section 2 - Specification Harrington Generators International 2.1 General Dimensions 8kVA Diesel Generator 8kVA Diesel Generator Part No: 498-141 Part No: 498-141...

  • Page 9: General Specification

    Section 2 - Specification Harrington Generators International 2.2 General Specification Dimensions Power Output Length 1620mm Prime Power 8kVA (6.4kW) Width 796mm Power Factor Height 1131mm Frequency 50Hz Weight 577kgs Voltages 230V AC Engine Fuel Make Kubota Fuel Type Diesel Model D1105 Tank Capacity 62 litres...

  • Page 10: Safety

    Section 3 - Safety Harrington Generators International 3.1 General Precautions The generator is fitted with a number of labels that alert the User to the safe operation and safety re- quirements. A full explanation of these is contained here. If any of the labels are missing or unreadable a duplicate should be obtained and fitted.
  • Page 11 Section 3 - Safety Harrington Generators International On side panel CHECK ENGINE OIL LEVEL DAILY Part of label No: 499-376/11 Check the oil level each day and top up if necessary to the top mark given in the oil level diagram above.
  • Page 12 Section 3 - Safety Harrington Generators International On side panel CHECK THE RADIATOR COOLANT LEVEL AND EXPANSION BOTTLE LEVEL Part of label No: 499-376/11 DAILY WHEN THE ENGINE IS COLD. DO NOT REMOVE PRESSURE CAPS FROM A HOT ENGINE Coolant level should reach the bottom of the radiator filler neck and should be between the level marks on the expansion bottle.
  • Page 13 Section 3 - Safety Harrington Generators International On side panel KEEP CHILDREN AT A SAFE DISTANCE FROM THE Part of label No: 499-376/11 EQUIPMENT AND DO NOT ALLOW THEM TO OPERATE This is a mandatory Health and Safety Requirement for this equipment.
  • Page 14 Section 3 - Safety Harrington Generators International THIS GENERATOR SHOULD On side panel ONLY BE USED TO POWER DOUBLE INSULATED CLASS Part of label No: 499-376/11 II ELECTRICAL EQUIPMENT UNLESS THE OPTIONAL Information: In the UK it is EARTH LEAKAGE TRIP (RCD) currently permissible to use IS FITTED.
  • Page 15 Section 3 - Safety Harrington Generators International On the front of the base. DANGER ELECTRICITY Part of label No: 499-376/06 The battery is 12 V DC and care should be taken not to come into contact with the terminals. On the front of the base. DANGER ACID Part of label No: 499-376/06 The battery contains acid and if any...
  • Page 16 Section 3 - Safety Harrington Generators International On control side access AUTOMATIC MACHINERY – MAY panel START WITHOUT WARNING Label part No: 499-376/32 This is only fitted if the generator is an AMF (automatic mains failure) version intended to start the set automatically if the mains electricity fails OR a Remote Start Version.

  • Page 17: Electrical Safety And Earthing

    Section 3 - Safety Harrington Generators International 3.2 Electrical Safety In addition to the information given previously the generator should be installed, earthed and used with reference to the following available from HMSO:- I.E.E Regulations 17 Edition (BS 7671:2004) 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 Alternatively the HGI Technical Help Line would be pleased to advise on the best measures for your...

  • Page 18: Hazards To Health And Electrocution

    Section 3 - Safety Harrington Generators International 3.4 Hazards to Health A list of the hazards that may affect health are included with safety precautions and first aid instructions Material / Hazard First Aid Measures Location Engine Oil When hot may burn the skin but not Burns: Rinse with clean water, cover with expected to give rise to an acute hazard a sterile pad and obtain medical...
  • Page 19 Section 3 - Safety Harrington Generators International Other No specific hazards under normal use insulation, conditions. gaskets and seals. 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 unidentified organic and inorganic compounds which may be...

  • Page 20: Electrocution

    Section 3 - Safety Harrington Generators International 3.5 Electrocution Electric Assess the situation first. Shock 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.

  • Page 21: Operation And User's Instructions

    Section 4 - Operation and User’s Instructions Harrington Generators International 4.0 Operator and User’s Instructions Switch Position Operation The generator consists of a three-cylinder diesel engine Pre Heat close-coupled to a single phase 16kVA brushless alternator. Run Position The generator set is resiliently mounted within an Engine Crank (Start) acoustically treated housing providing weather protection and noise attenuation.

  • Page 22: Engine Oil And Coolant

    Section 4 - Operation and User’s Instructions Harrington Generators International 4.2 Engine Oil Drain the oil into a suitable waste oil container, and follow HSE recommendations regarding the handling and disposal of contaminated oil products. Information on the Health and Safety aspects of working with oil are Before starting the generator it is important to visually contained in this manual.

  • Page 23: Shutdown Protection Devices

    Section 4 - Operation and User’s Instructions Harrington Generators International 4.7 Fuel Filling Connect the equipment to be powered (load) into the socket outlets on the generator control panel. Operating the generator at low load levels for long The fuel filling point is located externally on the side of periods of time may cause excessive smoking, reduce the and right hand side of the generator (Fig 4.7).

  • Page 24: Fault Finding

    Section 5 - Fault Finding Harrington Generators International 5.1 Engine Fails to Start IMPORTANT: If the following checks and investigations can be completed without the use of tools then the User can safely undertake them. If tools are needed then ONLY trained technicians can undertake the work safely.

  • Page 25: Engine Stops While Running

    Section 5 - Fault Finding Harrington Generators International 5.2 Engine Starts but then Stops Engine starts but then closes down. Check control circuit fuse and MCB. No L.E.D’s are lit on the Control Mod- Check battery charger circuit fuse. ule. Check the 12V DC supplies from the battery and battery charger have not been lost.

  • Page 26: No Electrical Output

    Section 5 - Fault Finding Harrington Generators International 5.4 No Electrical Output Has the electrical output selector switch (if fit- For dual voltage generators there is a choice of ted) been set to the correct position. 115V / OFF / 230V. Choose the correct setting. If fitted has the earth leakage (RCD) unit Before resetting disconnect all equipment plugged tripped.

  • Page 27: Maintenance

    Section 6 - Maintenance Harrington Generators International 6.1 Service Schedule Service intervals will have to be reduced if the generator is operated in dusty or severe conditions. The first service is required after 50 hours from new then as given below. Servicing must be carried out by a competent engineer.

  • Page 28: Engine Oil & Coolant

    Section 6 - Maintenance Harrington Generators International 6.2 Engine Oil & Coolant 6.6 Alternator Ensure that the cooling air vents do not become Check the oil level daily and top up if necessary. Check the oil level when the engine is stationary and blocked by dirt, debris etc.

  • Page 29: Battery Charger

    Section 6 - Maintenance Harrington Generators International 6.9 Battery Charger 6.11 General Inspections If an external mains powered battery charger is Air Filters are subject to the operating environment and installed in an AMF panel isolate it. as such should be inspected daily, cleaned as required and replaced when cleaning becomes ineffective Stop and start the engine a few times if needed to regardless of operating hours.

  • Page 30: Maintenance Record Sheet

    Section 6 - Maintenance Harrington Generators International 6.12 Maintenance Record Sheet Photocopy this page and use it as a service record. WELF-AIR GENERATOR MAINTENANCE RECORD SHEET (for use by owner / service agent) Name of owner: Name of service organisation: Address: Address: Order No:...

  • Page 31: Spares And Service

    Section 7 - Spares and Service Support Harrington Generators International 7.1 - Contact Details General Enquiries and Sales Department Technical Help Line Harrington Generators International Ltd Staffed by Technical Engineers who will advise on Ravenstor Road, Wirksworth, Derbyshire DE4 4FY the correct generator for your power requirements, its application and safe use) Tel: +44 (0)1629 824284...

  • Page 32: Spares List

    Section 7 - Spares and Service Support Harrington Generators International 7.2 - Recommended Parts List Engine Model: Kubota D1105 Engine Type: Diesel Engine Description Part No KU15221-43080 Fuel Filter Element Air Filter Element KU15741-11080 Oil Filter Cartridge KU16271-32090 Fan Belt KU16282-97010 Notes 1.

  • Page 33: Long Term Storage

    Section 8 - Long Term Storage Harrington Generators International 8.1 Long Term Storage Engine 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.

  • Page 34: Warranty Statement

    Standby means a unit that is used only for emergency situations, where the mains has failed and the unit completes less than 50 hours per annum. B) General – All HGI Generators The manufacturer’s warranty will not apply in the following circumstances: If the product has suffered customer or user abuse.

  • Page 35: Notes

    Section 9 - Warranty Harrington Generators International C) Warranty Procedure. Contact HGI for instruction (+44 (0)1629 821647) on an appropriate course of action for equipment fail- ures during the warranty period. This may be one of the following:- Goods to be returned to the local dealer/ supplier (or alternatively a site visit by dealer/ supplier at his option).
  • Page 36 Section 10 - Wiring Diagrams Harrington Generators International 8kVA Diesel Generator 8kVA Diesel Generator Part No: 498-141 Part No: 498-141...
  • Page 37 Section 10 - Wiring Diagrams Harrington Generators International 8kVA Diesel Generator 8kVA Diesel Generator Part No: 498-141 Part No: 498-141...
  • Page 38 Section 11 - Notes / Other Harrington Generators International 498-103 Issue A Page 43...
  • Page 40 HGI Limited, are one of the largest generator manufacturers in the UK, supplying petrol and diesel powered generators from 3kVA - 5000kVA with our range of engine powered Welders, PTO’s and Generators.
  • Page 41 Publication No. 498-141 Important: This manual contains important safety information. If you lose this manual please contact HGI Limited with the Serial Number of your generator and we will send you a replacement free of charge. :: +44 (0)1629 824284 :: +44 (0)1629 824613 F A X Ravenstor Road...

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