10.0kVA Water Cooled Diesel Generator · PDF fileShutdown Protections The generator is ﬁ tted with the following protection devices that will shut down the generator in the event

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

Welf-Air Cube

10.0kVA Water Cooled Diesel Generator

Build No: WA100H

Publication: 498-1058

© 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 Reason for changeJuly 15 Provisional MC Draft for Review by K CroftJuly 15 A MC Issued and Released following reviewJan 17 B MC Upd Warranty Iss F, GA and WD

Harrington Generators International

498-1058Welf-Air 10kVA Cube

Contents

Contents

CERTIFICATION ................................................................................................1

EC Declaration of Conformity .........................................................................1

Data Plate ..........................................................................................................2

SPECIFICATION ................................................................................................3

General Specifi cation .......................................................................................3

General Arrangement and Dimensions ..........................................................5

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

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

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

Precautions .....................................................................................................10

Electrical Safety ..............................................................................................14

Lifting and Moving ..........................................................................................14

Hazards to Health ...........................................................................................15

OPERATION ....................................................................................................17

Generator Layout............................................................................................17

Control Panel .................................................................................................17

Pre-Operation Checks ....................................................................................20

Starting ............................................................................................................21

Stopping ..........................................................................................................22

Stopping and Starting Remotely ...................................................................22

Output Connections .......................................................................................22

Shutdown Protections ...................................................................................23


498-1058 Welf-Air 10kVA Cube

Contents

FAULT FINDING ..............................................................................................24

Engine Fails to Start .......................................................................................24

Engine Starts but then Stops ........................................................................25

Other Faults ....................................................................................................25

No Electrical Output .......................................................................................26

MAINTENANCE ...............................................................................................27

Maintenance Schedule ...................................................................................27

Safety Precautions .........................................................................................28

Maintenance Routine .....................................................................................28

PARTS AND SERVICE ....................................................................................33

Contact Details ...............................................................................................33

Functional Spares ..........................................................................................33

TRANSPORTATION AND STORAGE .............................................................34

WARRANTY STATEMENT ..............................................................................35

WIRING ............................................................................................................37

DATASHEETS AND SPECIFICATIONS ..........................................................38

Engage II Fuel Gauge ....................................................................................39

CN222 Remote Start Controller - programmable ........................................41

MANUFACTURER’S SERVICE AND USER GUIDE LINKS ...........................43

Kubota Engine Operator’s Manuals ..............................................................43

Deep Sea Electonics 3110 User Guide .........................................................43

Sincro SK160 User Manual ...........................................................................43

Welf-Air

CUBE1500 RPMDiesel Generator


1 498-1058Welf-Air 10kVA Cube

Certifi cation

Certifi cationEC Declaration of Conformity

In accordance with ISO/IEC 17050-1:2004 Conformity Assessment - Suppliers’ Declaration of Conformity

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

Declare thatEquipment: Welf-Air Cube Diesel Generator Model: WA100H Electrical Power Pel 10kVA (8.0kW P.F 0.8)

Conforms to the protection requirements of the following EC Council Directives:

2006/42/EC Machinery Directive

2006/95/EC Low Voltage Directive

2014/30/EU EMC Directive

2000/14/EC Noise Emission in the Environment by Equipment for use Outdoors Directive Annex V111 97/68/EC Measures against the emission of gaseous and particulate pollutants from internal combustion engines to be installed in non-road machinery. European level Stage 3A (for engines above the minimum kW power threshold).

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 driven by reciprocating internal combustion engines.

EN60204-1 Safety of machinery. Electrical equipment of machines. General requirements.

EN12601 Reciprocating internal combustion engine driven generating sets. Safety.

BS EN61000-6-1 EMC. Generic Standards. Immunity for residential, commercial and light-industrial environments.

BS EN61000-6-2 EMC. Generic Standards. Immunity for industrial environments.

BS EN61000-6-3 EMC. Generic Standards. Emission standard for residential, commercial and light-industrial environments.

BS EN61000-6-4 EMC. Generic Standards. Emission standard for industrial environments.

BS ISO 3744 Acoustics. Determination of sound power levels of noise sources using sound pressure.

Notifi ed Body for 2000/14/EC Noise HORIBA MIRA UK Emission in the Environment by Watling StreetEquipment for use Outdoors Directive Nuneaton Warwickshire CV10 0UTNotifi ed Body Number: 00888

I declare that as the authorised representative, the above information in relation 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 C. Coulton Jan 2017 Quality Manager


498-1058 2 Welf-Air 10kVA Cube

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: Welf-Air Cube Serial No: 70368899

Build Code: WA100H Year of Manufacture: 2015

Electrical Power: 10.0kVA / 8.0kW PF: 0.8 Frequency: 50 Hz

Voltage Volts: 230V 1 Phase

Current Amps: 43A

Max Altitude: 1000m Max Ambient Temperature: 40°C

Weight Fuel Tank Empty / Full : 443 / 507 kgs

Fuel: Diesel Engine Speed: 1500 rpm Sound Level LwA 88 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. Compact Welf-Air Generator

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 specialist electronic equipment.

Sound Pressure Level: This is the level of sound produced by the generator when running at 75% auxiliary power.

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 cationGeneral Specifi cation

Model WA100H

Rated Output 10kVA / 8.0kW

Frequency: 50 Hz

Voltages: 230V Single Fixed

Socket Confi guration: 2 x 32A 230V

Socket Positiions: 1 x Panel Mounted, 1 x Rear Low Level

Output Protection: 2 pole 32A MCBRCD 30mA

Generator Control System

Starting Method: DSE3110 Control Module on Set for local or remote start

Engine Protection: High engine temperature, Low Oil Pressure, Over/Under speed

Engine Monitoring: Low Fuel with low fuel shut-down, battery voltage, hours run.

Electrical Protection: Over/Under Voltage and Frequency

Electrical Monitoring: Volts, Frequency, AmpsEngineManufacturer: Kubota

Model: D1105Service Interval: 200 hoursCylinders: 3Engine Speed: 1500 rpm

Nominal Power: 9.5kW

Cooling System: Water Cooled

Lowest Starting Temperature: -10°C with standard glow plugs without extra aidsAlternatorManufacturer: Sincro

Model: SK160CA1

Alternator Performance: 12.0 kVA 4-pole Class H with brushless AVR

IP Rating: IP 23

Fuel SystemFuel: Diesel

Fuel Tank: External Fuel Fill

Fuel Filler Cap: Non-locking nominally 2” on alternator end panel in recessed pod.

Fuel Tank Capacity (ltrs) 80

Run Time at 100% load approx. 26.7 hrs. Consumption at 100% load 3.0 l / h



Cont....



Specifi cation

Cont....

Canopy

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

Finish:

Base: Iron phosphate pre-treatment then architectural grade powder coating.

Canopy: Iron phosphate pre-treatment then architectural grade powder coating.

Colour: Base: RAL9005 Jet Black (Semi-Gloss)Canopy: RAL9016 Artic White.

Doors:The main control panel is also a hinged door for improved ser-

vice access.The main side doors are lift off.

Catches: Catches are simple quarter turn.

Lifting:With forklift from below.

With single point lifting beam with 50mm diameter lifting eye.With slings below and a spreader frame above

Fixing Down: Through base using M10 bolts in each corner.

Dimensions LxWxH (mm): 1102 x 822 x 1105

Weight Dry / Full: 430 / 495 kgs

Operating Clearance: The generator is designed to be installed in a Welf-Air cabin or similar with minimal clearances. Consult HGI on the application.

Access for Servicing: Access of 600mm required for single sided servicing through lift-off service access door.

Battery: 12V DC maintenance free. Type 067 68 Ah and 600 CCA.

Battery isolator: Fitted inside canopy.

Battery Charger: Engine DrivenEnvironmentalSound Level LwA 88 dB(A), 63 dB(A) @ 7m Maximum ambient operating temperature: 40°C

Minimum ambient operating temperature: -10°C (using standard diesel fuel)

Maximum altitude above sea level: 1000 m (without affecting performance signifi cantly)

Generator Protections

Fuel Gauge with Low Fuel Indicator and Shutdown

Low Oil Pressure Indicator and Shutdown

High Engine Temperature Indicator and Shutdown

Hours Run Meter

Emergency Stop Button



Specifi cation

General Arrangement and Dimensions



Specifi cation



Specifi cation



Specifi cation



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.

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

DANGERDanger refers to immediate hazards which WILL

result 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.

Welf-Air 10kVA Cube

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 adequate 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 Location / Part No Description

On the fuel tank. Qty 1

Label Part No: 499-367-031

NO OIL IN ENGINE

This generator is generally shipped with oil. Check suffi cient oil in line with engine manufacturer’s guidelines before attempting to start. This label should be removed when oil is added.

On the panel that can be removed to gain access to the oil dip stick. Qty. 1.

Label Part No: 499--376-010

CHECK ENGINE OIL LEVEL DAILY

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



Safety

On the fuel tank. Qty. 1.


DIESEL FUEL ONLY

This generator must only be fi lled with commercial diesel fuel containing up to 5% bio-fuel. If special grades of diesel e.g. 100% Bio-Diesel are to be used consult HGI fi rst to discuss its suitability.

Next to air vents. Qty. 2 off.

Label No: 499-376-004

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.

Next to exhaust outlet. Qty. 1

Label part No: 499-376-002

CAUTION HOT EXHAUST

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

On control panel

Label No: 499-376-008

EARTH POINT

An M8 brass earth stud is supplied next to the output sockets for the external earth connection.

Label Part No:

499-376-023

DANGER MOVING MACHINERY INSIDE DOOR

This label warns operators that there will be moving parts inside the generator when the unit is in a running state.

Inside Service Door near expansion bottle.


HOT WATER UNDER PRESSURECHECK WATER LEVEL DAILY

Coolant must be suffi cient to appear in the fi ller neck.

DO NOT OPEN A HOT RADIATOR



Safety

On the control panel

Label Part No:

499-376-042

12V DC

Advisory circuit breaker reset

On the control panel adjacent to respective output sockets.

Pts 499-376-041

230V Output

Advisory of Voltage Output

On base – front RHS Label No: 499-376-026

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.

On the front panel Label No 499-446

LOW FUEL SHUTDOWN The fuel gauge also incorporates a low fuel shutdown facility. The set will shut down when the level falls to approximately 10-12% of its capacity, thus eliminating the need to bleed the system at restart. Also a note to ad-vise that low oil pressure will also illuminate.

On control side access panel Label part No: 499-376-023

AUTOMATIC MACHINERY – MAY START WITHOUT WARNING This is only fi tted ito the 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.



Safety

Battery Compartment

On front panel over battery compartment

Part of label No: 499-376-011

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

NOTICEThis generator is designed to be installed inside a Welf-Air cabin or similar and not for use outdoors.

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.

Lifting and Moving

This generator is designed to be permanently installed in a Welfare Cabin or similar and it is not designed to be lifted separately apart from when fi rst being installed.

Mechanically Assisted Lifting

The weight has been given previously in this manual but could be 507 kg with a full fuel tank. 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 a fork lift truck with correctly spaced forks.

It is intended that the when lifting from the sides that the forks pass under the base assembly.



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 at the front of the generator

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

Operation

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

The Welf-Air Cube generator is resiliently enclosed within an acoustically treated housing providing noise attenuation. A large access door enables ease of servicing and maintenance in a tight space.

The Welf-Air Cube is confi gured to be operated locally at the set but can be provided with an optional remote start controller.

The At-Set operation utilises a DSE3110 controller that monitors the engine condition and provides warning information about the generator.

If confi gured for remote start stop operation HGI recommend the use of the HGI CN222 remote start controller which has a simple push-button stop / start and programmable timer so that once started the generator will run for a specifi ed period and then shutdown. This is typically set at 1 hour.

NOTICEFor safety reasons, the battery Isolator should be set. It is recommended that this action is repeated when moving the generator or for long term storage.

Generator LayoutControl Panel

The control panel houses the controls for starting the generator, fuel monitoring and socket connectivity.

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

Item Description

1 DSE3110 Control Module2 Control Module MCB3 32A Socket MCB4 Engage II Fuel Gauge5 DC Isolation Switch6 Blue 230V 32A Socket7 Analogue Ammeter 8 Low Fuel Warning Lamp9 Output MCB & RCD

10 Emergency Stop11 Remote Controller Connection Socket

DSE3110 Control Module

The engine module provides engine condition monitoring and status.

(1) (2) (3)

(4) (5) (6) (7) (8)

Lifting EyeExhaust Outlet

CoolantAccess

ControlPanel

FuelFill

ManoeveringHandle

OutletSocket

Service Access Door

EmergencyStop



Operation

Item Description1 Navigation Button

Pressing this button scrolls the display to show the various instruments.

2 Main Status DisplayThis displays the generator instrument and alarm conditions.

3 Common Alarm IndicatorThis illuminates when an alarm is present.

4 Stop/Reset ButtonThis stops the generator and also resets any alarms present (provided the fault has been cleared).

5 Select “Auto” ModeThis places the set in ‘Automatic’ mode allowing the set to be operated automatically and/or remotely.

6 Auto/Remote Indicator7 Start Button

This button starts the engine. Press once ONLY to start the engine. The unit will automatically attempt up to three starts.

8 Run Indicator

The Deep Sea 3110 is the main STOP / START control unit for the generator. The control module allows the user to control the operation of the generator engine and also provides instrumentation for;

• Engine Speed• Generator Voltage• Generator Frequency• Engine Run Time (Hrs)• Battery Volts

The DSE module will go into standby when no com-mon alarms have been triggered after 1 minute of inactivity. If the emergency stop is pressed the DSE module will not go into standby.

NOTICEDo not use Emergency Stop for routine stopping of the generator or the Control Module will not go to low power mode and discharge the battery. Use the control Module “Stop” button to stop the engine and when the engine has stopped turn the control Module isolation switch to OFF.

To activate the control module press the green Start button once.

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.

• Engine speed• Generator volts• Generator frequency• Engine run time• Battery volts

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; also the default instrumentation view that is displayed is the engine speed page.

Indicators

There are 3 indication LED’s (Light Emitting Diodes) on the front of the engine control module;

1. The Started Mode IndicatorThis LED is to the upper-right of the Start button and is illuminated when the engine is in the “Start” mode.

2. The Automatic Mode Indicator This LED is to the upper-right of the Auto button and is illuminated when engine control module is in the “Auto” mode.

3. The Common Alarm IndicatorThe type of common alarm is represented by an Icon that can be seen in the large green LCD on the control module. The Icons and the descrip-tions of the the alarms they represent be seen below:

Icon Alarm / Warning DescriptionBATTERY UNDER VOLTAGE / BATTERY OVER VOLTAGEThe DC supply has fallen below or risen above the low/high volts setting level.



Operation

CHARGE FAILUREThe auxiliary charge alternator voltage is low as measured from the W/L terminal.ENGINE HIGH TEMPERATUREThe module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the “Safety On” timer has expired.LOW FUEL LEVELThe level detected by the fuel level sensor is below the low fuel level setting.LOW OIL PRESSUREThe module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the “Safety On” timer has expired.INTERNAL MEMORY ERROREither the confi guration fi le or engine fi le memory is corrupted. Contact MTC for assistance.GENERATOR OVER VOLTAGEThe generator output voltage has risen above the pre-set pre-alarm setting.GENERATOR UNDER VOLTAGEThe generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.GENERATOR OVER FREQUENCYThe generator output frequency has risen above the pre-set pre-alarm setting.

GENERATOR UNDER FREQUENCYThe generator output frequency has fallen below the pre-set pre-alarm setting after the Safety On timer has expired.FAIL TO STARTThe engine has not fi red after the preset number of start attempts.

FAIL TO STOPThe module has detected a condition that indicates that the engine is running when it has been instructed to stop.NOTE: ‘Fail to Stop’ could indicate a faulty oil pressure sensor – If engine is at rest check oil sensor wiring and confi guration.

Common Alarms

The common alarm indicator will be illuminated when there is a condition with the engine or alternator that requires the operator’s attention. When the common alarm indicator is illuminated one of the following icons will be displayed on the modules LCD.

More information about the DSE3110 control module can be found in Manufacturer’s Service and User Guides section of this manual.

Control Module DC Isolation Switch

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

When switch is turned to the “Off” all functionality is removed from the generator and it is safe to work on. When tuned to “On” and the remote panel inhibit socket is in place the generator can be operated locally.

Turning the Switch to the ON position activates the Deep Sea Electronics 3110 control module.

Engage II Fuel Gauge

Fuel Level

Low Fuel Alert



Operation

More information about the Fuel Gauge can be found in the Datasheets and Specifi cations section of this manual.

Pre-Operation Checks

Engine Oil

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

SAE 10W-30 API grade CD or higher 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.

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) (b)

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.

Max Min

5. If the level is low, remove the oil fi ller cap (b) and top up.

Oil Capacity: 5.1 Litres

Replace the engine oil after the fi rst 50 hours, then every 200. When changing the oil or topping-up, use oil of a grade suitable for the prevailing ambient tem-peratures (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 relieve pressure before removing completely.

The radiator fi ller point is located above the engine.

To check the coolant level:

1. Access the radiator fi ller cap via the service door.

2. Remove the radiator cap after the engine has completely cooled and check to see that coolant reaches the supply port.

(a) (b)

3. If coolant level is low top up with a mixture of Antifreeze and water in 50:50 ratio.



Operation

Coolant Capacity: 3.1 Litres

Also note and maintain the coolant level in the expansion tank between the min and max levels.

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.

To check the fuel level the engine needs to be running to engage the fuel solenoid and provide a reading at the Fuel Gauge. If the fuel is Low the Low Fuel Alarm indicator will be lit.

To refuel.

1. Ensure that the engine is stopped.

2. Locate the fi lling point at the side of the generator

3. Remove the fuel tank cap.

4. Refi ll the fuel tank avoiding spilling fuel.

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.

After refuelling tighten the fuel cap securely.

Fuel Capacity: 80 Litres

Starting

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

1. Review the Safety Precautions.

2. Perform Preoperational checks.

3. Turn the DC Isolation Switch to the ON position.

4. Press the red Reset Button on the Engine Control module.

5. Press the green START button on the DSE3110 controller once. (The run/start indicator will illuminate).

6. Wait approximately 10 seconds while engine preheats.

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

8. Connect the equipment to be powered (load) into the socket outlets on the generator control panel. Check that the total load from all equipment con-nected does not exceed the generator rating.

If the engine fails to start after 3 attempts then initiate 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.



Operation

Stopping

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

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

3. Press the red STOP button.

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 red button, and start the generator by pressing the green Run button.

Stopping and Starting Remotely

To use the generator remotely the third party remote control panel will need to be connected to the Buca-neer 3 way socket on the control panel.

Once connected

1. Press the red Reset Button on the Engine Control module on the generator control panel.

2. Press the white Auto button on the generators DSE3110 control module.

Typically, the remote control panel will have run and stop buttons / switches. If using an HGI CN222 control panel: 3. To start, press the Green Run/Go button on

the remote control.

4. To stop press the Red Stop button on the remote control.

If the remote control panel has a timer facility (as with the HGI CN222) it will, typically, have been programmed to run the generator run for the preset time commencing once the Green button has been pressed.

If you should require generator power after the time has elapsed then press the green button once more to restart the timer.

Should you require to stop the generator from the remote control panel then press the Red button.

Output Connections

The generator is supplied with two 32A 230V output sockets. One is mounted on the control and the other to the rear of the set at panel level.

The generator also has 230V terminals

Connect the equipment to be powered (load) into the socket outlet or terminals. Check that the total load from all equipment connected does not exceed the generator rating.

Each output socket is individually protected by a 30A MCB (miniature circuit breaker). If the current being drawn through the socket exceeds this for a short time the MCB will trip. To reset the MCB when it has tripped remove the load from that socket, wait a few minutes and then reset.

The M10 brass stud next to the output sockets 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.

The RCD should be tested by pressing the TEST button and checking that the RCD trips and has to be reset while the generator is running. This should be done every day.

NOTICEOperating the generator at low load levels for long periods of time may cause excessive smoking, reduce effi ciency due to carbon build-up and cause other engine problems.

Do not overload the generator as this will cause overheating, and shorten the life of the generator.



Operation

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 by LED’s 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 no low oil pressure signal prior to starting.

Low Fuel Level: The fuel gauge also incorporates a low fuel shutdown facility. The set will 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 DSE module.

• Check the DC Isolator on the control panel and the battery isolator are switched on.

• Check the control fuse and 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.

Starter motor did not attempt to turn the engine over and the start fail icon is being displayed on the DSE module.

• Check the Emergency Stop button has not been used.• The control module pulls in a slave relay to put 12V DC onto the

starter motor solenoid.• Check the control module is not faulty by swapping it. Check it is

attempting to pull in the slave relay.• Check the operation of the slave relay.• 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 DSE 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.• Check the fuel level in the tank.

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.(The Start Fail L.E.D should light after 3 attempts to start).Smoke 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 1350 to 1650 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 Faults


Has the miniature circuit breaker (MCB) 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 and reconnect and switch on equipment one piece at a time. 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.

• It is possible to read the 230V output from the Deep Sea Control Module.

• There is a procedure called “alternator fl ashing” which may solve the problem but only trained Technicians may attempt this. Please ring our Technical Helpline for advice.

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



Fault Finding

No Electrical Output


Has the earth leakage (RCD) unit 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 earth leakage unit to trip.

• Reset the trip 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 earth leakage unit repeatedly make sure it cannot be used on another supply by removing the plug and labelling Faulty / Unsafe.

Check the miniature circuit breaker (MCB).

• Each 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.

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, diode or its voltage regulation unit.



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. This will save you money in the long run, as worn items can be spotted sooner, saving further problems.

Servicing must be carried out by a competent engineer. A written record of the service work should be made using the form contained in this manual or similar. The generator must be serviced in accordance with our recommendations for the warranty to be valid.

Maintenance Schedule

Service intervals will have to be reduced if the generator is operated in dusty or severe conditions. The fi rst service is required after 50 hours from new then as given below.

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

Maintenance Schedule Daily Checks

After the fi rst 50

Hrs

Every 3 Months or

200 Hrs

Every 6 Months or

400 Hrs

Every 12 Months or

800 Hrs

Check & replenish fuel

Check & replenish engine oil

Check coolant level

Check fuel fi lter for dirt and water

Check battery

Check for oil and fuel leaks

Check operation of RCD trip.

Check the hours run meter works

Change engine oil

Replace oil fi lter*

Replace fuel fi lter

Check air fi lter & clean

Replace air fi lter

Adjust valve clearances

Replace Coolant

Replace fan belt

Check fan belt tension

Check Oil Breather Clear

Check operation of MCB’s

Control Module Safety Shutdown

Check Alternator

Battery Charger

Canopy

General Inspections

Run on ¼, ½, ¾ full load for 30 mins

If you’d like to make an appointment for HGI to service your generator using our in house 26-point health checker guide for your generator then please contact the Service Department.* The latest kubota guidelines suggest to only replace oil fi lter after every 400 hours but change oil every 200 hours. HGI suggest the fi lter be changed at every oil change.



Maintenance

Safety Precautions

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 serious injury 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

• 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 Fuel

Refer to Pre-Operational Checks to check the fuel level. Replace the fuel fi lter every 6 months or 400hrs.

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.

Check and Replenish Engine Oil

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

Replace the engine oil after the fi rst 50hrs and then every 3 months or 200 hours operation. When changing the oil or topping up, it is recommended to use oil of grade 10W30.

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.



Maintenance

Drain the oil into the suitable container from the oil drain fi tting on the canopy’s base.

Follow HSE recommendations regarding the handling and disposal of contaminated oil products.

Kubota recommend the oil fi lter element is a replacement type, and should be replaced at every oil change (6 months / 200 hours). HGI suggest a change interval every 3 months / 200 hours along with oil change.

Replace components in reverse order.

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

Check Coolant Level

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 cool and stationary and on a level surface.

The radiator should be fi lled to typically 1 cm above the core of the radiators matrix. The expansion bottle’s coolant level should be fi lled as marked on the expansion bottle or label between high and low level marks.

Replace coolant every 12 months or as specifi ed.

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

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 han-dling and disposal of contaminated oil products. Check the radiator and hoses for signs of damage or leaks.

Air FIlter

The Air Filter can be a of single or twin element type.

To clean or replace the air fi lter:

1. Slacken off the two air

(a)

fi lter mounting bolts (a) under the air fi lter housing (do not remove the bolts)

2.

3. Slacken off the hose clamp and remove the inlet hose from the cylinder head manifold .

4. Push the air fi lter housing forward to remove from the slots in the brackets.

5. Remove fi lter from the housing, check and replace in line with engine manufacturers guidelines.

6. Check the hose between the air fi lter and the engine is secure and not damaged.

Fuel Filters

There is a coarse pre-fi lter in a clear plastic cartridge plus a conventional engine mounted fi lter. Check both daily and replace every 6months/400hrs.

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.

Engines Fan and Accessories Drive Belt

Check the fan belt daily and if necessary re-tensionit. Replace if showing signs of wear.

Replace periodically in accordance with the engine manufacturers recommendations.

Engine Oil Breather

Check oil breather is clear and clean and replace as



Maintenance

necessary.

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 is tight and the battery is held fi rmly.

Check RCD Trip The earth leakage unit (RCD) has a self-test button which can be used to apply a fault and to check that the unit trips out when the generator is running.

Check Operation of MCBs

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

Adjust Valve Clearance

Valve Clearances should be checked after the fi rst 12 months or 800hrs 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.

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.

Low Oil Pressure; with the engine off, remove the connection to the normally closed oil pressure switch and attempt to start the engine. The Control Module should see an open circuit representing oil pressure when there should be none and prevent starting.

With the engine running short the oil pressure switch to the generator chassis to simulate loss of oil pres-sure and the module should shut down the engine and show an alarm.

Low Fuel Level; The sensor is connected to the low oil alarm circuit. 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.

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.

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.



Maintenance

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.

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.

Correct sealing / fi tting of exhaust pipe: Remove the top panel and check the exhaust pipe is correctly fi tted and sealed at its mounting fl ange with no signs of blowing.

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 or a similar load like an electric fan heater, 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.



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 / 50hrs / 3mth 200hrs / 6mth 400hrs

General Condition:

Daily Checks:1. Fuel Level Checked2. Oil Level Checked3. Check Coolant4. Battery Check5. Check for oil / fuel leaks6. Check RCD works (if fi tted)7. Check fuel fi lter not contaminated

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

6 month cont....a. Check operation of Control Module

• Hours run meter is running• Low oil pressure shut down

works• Low fuel shut down works

8. Check Canopy• All fi xings secure• Inlet/outlet air louvers clear• Confi rm all seals in the engine

compartment sound and serviceable

9. General checks• Anti vibration mounts are

serviceable• All insulation/seals fi tted &

serviceable• All safety labels are fi tted• All cables and connections

sound• Exhaust system sound and

serviceable• If fi tted lifting beam safe and

serviceable• No signs of over heating• Check fuel cap seals

10. Run at ¼, ½, ¾ and full load

Yes / NoYes / No

Yes / No

Yes / NoYes / NoYes / No

Yes / No

Yes / No

Yes / NoYes / No

Yes / No

Yes / No

Yes / NoYes / NoYes / No

After fi rst 50hrs from new.Every 3 months or 200 hrs1. Complete daily checks2. Change the engine oil3. Clean the oil fi lter4. Check the air fi lter clean5. General inspections6. Run at ¼, ½, ¾ and full load

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

Every 6 month or 400 hrs1. Complete Daily Checks 2. Complete 200 hrs service3. Check battery terminals and fi xing4. Replace fuel fi lter5. Replace air fi lter6. Set engine valve clearances7. Check alternator8. Check alternator vents are clear9. Check operation of all MCB’s10. Check Oil Breather

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

Spare parts used:

Notes:

Signed: Representing: Date:



Parts & Service

Functional Spares

Part Description Part Number

Air fi lter element A1013-024Oil fi lter element A1013-061Fan Belt A1013-063Charge Alternator A1013-040Fuel fi lter element A1013-012In Line Fuel Filter 170-152Fuel Gauge Sender 085-702Fuel Lift Pump A1013-06632A Socket Angled 090-05432A Socket, straight 090-022MCB 30Amp Socket Output 110-030MCB 32A Generator Output 110-232RCD 30mA 110-532Fuse 5A 110-005Fuse 2A 110-002Engage II Hours Run / Fuel Gauge 085-602Ammeter, 0-40A 085-119Slave relay AMF 140-007Battery 12V 120-010Exhaust silencer 180-1033Tail Pipe 180-1035Exhaust Clamp Small 180-714Ant- vibration mount 070-502Safety information label kit (all labels) 499-819Alternator 021-551Starter Motor A1013-075Glow Plug A1013-087Remote Start Controller CN222Engine Oil Breather 170-1050

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



Transportation / Storage

Transportation and Storage

NOTICEDo not lay the generator on its side when moving, storing, or

operating 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. 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.

Flashing the Alternator: if ther is no electrical output after long term storage the alternator may have lost it’s residual magnetism. There is a procedure to re-magnetise 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.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).



Warranty

Warranty Statementa) Customer Responsibilities

The life of a generator depends on the care it receives throughout its lifetime. It is the responsibility of the customer to ensure that servicing and maintenance are performed at the specifi ed period and that the service record is kept safe for future reference. In this way your machine will receive the full benefi t of the HGI Ltd warranty. Regular maintenance is also essential to ensure that your machine operates safely, effi ciently and with the minimum environmental impact. For full terms and conditions and servicing requirements please consult your owners manual. If you are in any doubt regarding the service requirements of your specifi c product please contact your supplying dealer. Alternatively call HGI on +44 (0) 1629 821647.

Please note that your product will require more regular servicing / maintenance if working in very wet, dry, dusty conditions and or in high ambient temperatures.

Warranty Guide

Product Domestic (1) Commercial (2)Petrol 3 Yrs / 1000 Hrs 3 Yrs / 1000 HrsPetrol Standby (3) 5 Yrs / <50 Hrs p.a 3 Yrs / <50 Hrs p.aDiesel 3 Yrs / 2000 Hrs 3 Yrs / 2000 HrsDiesel Standby (3) 5 Yrs / <50 Hrs p.a 3 Yrs / <50 Hrs p.aHSU LPG Briggs Standby 3 Yrs / < 1000 Hrs p.a N/A3E Cabin Unit N/A 2 Yrs/2000 (batteries are not covered

by the warranty)SKD60-I & SKD100-I 2 Yrs / 2000 Hrs 2 Yrs / 2000 HrsLoncin Suitcase Generators 2 Yrs / 1000 Hrs 2 Yrs / 1000 Hrs

Defi nitions:1. Domestic means non-commercial, non-hire, normal domestic applications.2. Commercial means, hire, industrial and any business or professional related use.3. 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.

Some engine manufacturers offer longer warranty terms than those offered above. Examples are Honda 3 years, Yanmar 3 years, Lombardini up to 5 years on standby sets. There may be additional terms and conditions relating to these manufacturer warranty periods which can be provided on application.

b) Warranty Terms

1. HGI warrants that on delivery and during the Warranty Period the Generator shall:a. conform in all material respects with its description and any applicable Specifi cation; andb. be free from material defects in design, material and workmanship.

2. Subject to clause 3, if:a. the Customer gives notice in writing to HGI during the Warranty Period within a reasonable time of discovery that the Generator does not comply with the warranty set out in clause 1 (a “Warranty Claim”); and b. HGI (or its nominated agent or representative) is given a reasonable opportunity of examining the Generator; andc. the Customer (if asked to do so by HGI) returns the Generator to HGI’s place of business at the Customer’s costd. HGI shall, if it accepts the Warranty Claim is valid, at its option repair or replace the defective Generator, or refund the price of the defective Generator in full and, in such circumstances HGI shall reimburse the Customer its reasonable costs of returning the Generator to HGI under clause B.2.

3. HGI shall not be liable for the Generator’s failure to comply with the Warranty if:a. the Customer makes any further use of the Generator after giving notice in accordance with clause B.2.a; orb. the defect arises because the Customer has failed to follow HGI’s oral or written instructions (whether in the owner’s manual or otherwise) as to the storage, commissioning, installation, use, servicing or maintenance of the Generator or (if there are none) good trade practice; orc. the Customer fails to maintain the service record relating to the Generator up to date; ord. the defect arises as a result of HGI following any drawing, design or specifi cation supplied by the Customer; ore. the Customer alters or repairs such Goods without the written consent of HGI or fi ts non-standard parts to the Generator; orf. the defect arises as a result of the ingress of foreign objects including but not limited to the use of incorrect or contaminated fuel or lubricants; org. the defect arises as a result of fair wear and tear, wilful damage, accident and/or collision, neglect, or improper or abnormal storage or working conditions.



Warranty

h. Where a customer has not yet paid for goods and the purchasing company goes into administration, HGI reserve the right to delay any warranty claim until the item is paid for. i. Alternators where the cause is ingress of moisture unless the alternator has been specifi cally treated to prevent the ingress of moisture.j. Failures due to atmospheric conditions e.g. lightning strikes etc.k. On claims where Bio fuels have been used. l. All Welders, where the failure is to the end user exceeding the duty cycle. Your attention is drawn to exceeding duty cycles on welder units. If the duty cycle has been exceeded then the alternator will not be covered in the event of failure. m. All batteries are considered to be service items and are not included in the warranty.

4. This Warranty does not extend to the repair or replacement of expendable or consumable maintenance items after such item’s fi rst scheduled replacement (in accordance with the owner’s manual).

5. Except as provided in this Warranty Statement, HGI shall have no liability to the Customer in respect of the Generator’s failure to comply with the Warranty.

6. These Conditions shall apply to any repaired or replacement Generators supplied by HGI, for a period of 6 months.

c) Warranty Procedure.

Contact HGI for instruction (01629 821647) on an appropriate course of action on equipment failures during the warranty period. A warranty claim form is issued to the customer and this must be completed in all circumstances prior to any warranty claim investigation.

We will then follow one of the procedures below:-1. Goods to be returned to the local dealer/ supplier (or alternatively a site visit by dealer/ supplier at their option). All

warrantable parts etc and full technical support supplied FOC from the factory.or:2. Goods can be returned direct to our factory by the customer. Full parts and labour repairs carried out in our workshops.

Goods returned to customer at our expense. An order number will be required to cover non-warrantable work. A ‘Returns Number’ must be obtained prior to returning product.

or:3. HGI may recommend that the equipment may be repaired by the supplier (or his local agent), on-site or at the local

agent’s premises.

d) Export

All Units are warranted as per the conditions above, but the unit must either be returned to HGI for any warranty claims or we may, at our discretion, assign a local engineer to asses any claim. Any Claim for Export warranty must be made via a the warranty claims form AND a valid Purchase order initially (If you do not have a credit account, then all work must be paid for in advance) and faxed to +44 (0) 1629 821606. If it is found that the warranty does apply, then HGI will issue a credit note or refund as appropriate. All cases are dealt with on an individual basis and we reserve the right to decline any claims based on the Foreign Offi ce website warnings for a particular country, where any action would place HGI personnel or its agents at risk.

e) Notes

The normal process for claiming warranty on parts, is that the customer calls HGI Parts Dept. on 01629 821645 and request a WSR form (Warranty Service Repair form). The customer then completes and returns the form to [email protected] along with an order to purchase a replacement part at the current price. The customer is issued with an RMA number which must be attached to the faulty parts returned to HGI. When it is established that the part has a warrantable fault, the customer account will be credited to the value of the purchased replacement part. Any parts that are supplied FOC (at HGI discretion) are on condition that faulty parts are returned to the factory within 14 days of replacement and subject to factory examination for valid claims.

Equipment supplied for operation outside the UK mainland will normally be dealt as described in d) above.

Limited warranty applies in special circumstances where equipment operates in extreme environmental conditions and/or for extended periods. Consult the factory.

On-site and extended warranty terms are available which include Service Level Agreements for a target response time. Please contact the factory for details.

The Company will not be held responsible for consequential losses, or costs incurred by the customer during a warranty repair. The Company will not accept claims of compensation. The HGI Ltd warranty is provided in lieu of all other warranties, express or implied. HGI Ltd specifi cally disclaims any implied warranties of merchantability or fi tness for a particular purpose, except where such disclaimer is prohibited by law. If such disclaimer is prohibited by law, then implied warranties shall be limited in duration to the life of the Express warranty.

Tel: 01629 821 647 Warranty Statement Issue H 14/03/2016



Wiring

Wiring



Datasheets and Specifi cations

Datasheets and Specifi cationsOther Users and Service Manuals & Datasheets contained within this document are correct at the time of publi-cation and included for reference. Please refer to manufacturer’s website for latest information about their products.

Engage II Hours Run Metre / Fuel GaugeCN222 Remote Start Controller - programmable stop delay




Engage II Fuel Gauge







CN222 Remote Start Controller - programmable






Manufacturer’s Service and User Guides

Manufacturer’s Service and User Guide 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.

Kubota Engine Operator’s Manuals

- http://www.kubota.co.uk/after-sales-support/publication/

Deep Sea Electonics 3110 User Guide

- http://www.deepseaplc.com

Sincro SK160 User Manual

- http://www.sogagroup.com/

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

10.0kVA Water Cooled Diesel Generator · PDF fileShutdown Protections The generator is ﬁ tted with the following protection devices that will shut down the generator in the event

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