BE GX200GEN User manual

Licensed by BE Pressure Supply Inc, Canada
BE-GX200GEN –BE-GX270GEN –BE-GX390 GEN
USER MANUAL
Model shown BE-GX390 GEN
BEFORE USE YOU MUST READ THIS MANUAL COMPLETELY –RETAIN FOR FUTURE USE

Record of Identification Numbers
Generator
If you need to contact your dealer for information or servicing,
please provide the product model and identification numbers.
You will need to locate the model and serial number for the
machine and record the information in the places provided below.
Date of Purchase:
Dealer Name:
Dealer Phone:
Product Identification Numbers;
Model Number:
Serial Number:
Page 2
Ver3

CONTENTS
Section Description
Page No/No’s
RECORD OF IDENTIFICATION NUMBERS
2
4 –7
8
9
9 –11
11 –12
12
13
14
14 - 16
16
17
18
19
1. SAFETY
2. MACHINE LAYOUT
3. PREPARING GENERATOR FOR USE
4. PRE-OPERATION CHECKS
5. STARTING YOUR GENERATOR
6. RCD TESTING –AC USE
7. POWER/WATTAGE INFORMATION
8. STOPPING YOUR GENERATOR
9. TROUBLESHOOTING
10. MAINTENANCE
11. SPECIFICATIONS
12. GENPOWER CONTACT DETAILS
13. DECLARATIONS OF CONFORMITY
Page 3
Ver3

1. SAFETY.
1.1. The operator of the machine;
1.1.1. Is responsible for and has a duty of care in making sure that the machine is operated
safely and in accordance with the instructions in this user manual.
1.1.2. Should never leave it in a condition, which would allow an untrained or unauthorised
person/s to operate this machine.
1.1.3. Take all due care and diligence for the safety of and with regard to those around
whilst using the machine, to include but not limited to;
1.1.3.1. Elderly, children, pets, livestock and property.
1.2. Some or all of the following PPE, warning signs and symbols may appear throughout this
manual and you must adhere to their warning/s. Failure to do so may result in personal
injury.
Warning Signs and Symbols –FOLLOW safety messages to avoid or reduce risk of injury or death.
DANGER - indicates a
hazard, which, if not
avoided, could result in
serious injury or death.
WARNING - indicates a
hazard, which, if not
avoided, could result in
serious injury or death.
CAUTION - indicates a
hazard, which, if not
avoided, might result
in minor or moderate
injury.
NOTE - indicates a
situation that could
easily result in
equipment damage.
READ MANUAL
Personal Protective Equipment (PPE)
Page 4
Ver3

1.3. Carbon monoxide
1.3.1. Carbon monoxide is a colourless and odourless gas. Breathing it can cause death as
well as serious long-term health problems such as brain damage.
1.3.2. The symptoms of carbon monoxide poisoning can include the following;
1.3.2.1. Headaches, Dizziness, Nausea, Breathlessness, Collapsing or Loss of
Consciousness.
1.3.2.2. Carbon monoxide symptoms are similar to flu, food poisoning, viral infections
and simply tiredness. That is why it is quite common for people to mistake this
very dangerous poisoning for something else.
1.3.3. To avoid carbon monoxide poisoning DO NOT use petrol/diesel powered equipment
inside a home or garage even if doors and windows are open.
1.3.4. If you think you or someone around you has been affected by carbon monoxide
poisoning;
1.3.4.1. Leave the affected area and get fresh air immediately.
1.3.4.2. Open doors and windows and turn the machine off.
1.3.4.3. See your doctor immediately or go to hospital - let them know that you
suspect carbon monoxide poisoning.
1.3.5. DO NOT use in an enclosed area or a moving vehicle.
1.4. General fuel safety.
1.4.1. Contact the Health and Safety Executive for additional fuel safety information.
1.4.2. All fuels are Flammable.
1.4.3. Keep away from all ignition sources i.e. Heaters, Lamps, sparks from Grinding or
Welding.
1.4.4. Hot work on tanks that have contained fuel is extremely dangerous.
1.4.5. Keep work area clean and tidy. Clean up all spills promptly using correct methods i.e.
absorbent granules and a lidded bin.
1.4.6. Dispose of waste fuels correctly.
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Ver3

1.4.7. Petrol safety.
1.4.7.1. Always fuel and defuel in well-ventilated area.
1.4.7.2. Always wear correct, suitable and fit for purpose Personal Protective
Equipment (PPE), suggested items are as follows, but are not limited to.
1.4.7.3. Hand protection.
1.4.7.4. Protective clothing.
1.4.7.5. Respiratory protective equipment.
1.4.7.6. When defueling always use a propriety fuel retriever.
1.4.7.7. Always carry fuel in the correct and clearly marked container.
1.4.8. Electrical Safety.
1.4.8.1. Electricity can kill - never work on LIVE/ENERGISED equipment.
1.4.8.2. The generators are fitted with an RCD, which protects against electric shock
hazards. The RCD may not function correctly if the generator is not properly
grounded/earthed. All BE Generators have the neutral internally bonded to the
ground/earth wires.
1.4.8.3. Identify electrical isolation method and always isolate all electrical supplies,
prior to carrying out any maintenance work.
1.4.8.4. Prior to use and with all electrical supplies isolated, check all electrical cables,
plugs and connections for the following;
1.4.8.4.1. Are intact and have no signs of damage, to include but not limited to
bare wires, chaffing, cuts and loose wiring. If there are any signs of damage,
you should stop using the equipment. The damaged item must repaired by
an electrically competent person.
1.4.8.5. To avoid any kind of trip hazard, all trailing cables carefully routed.
1.4.8.6. Never work on or near electricity with wet hands, wet clothing, and wet
gloves.
1.4.9. Batteries.
1.4.9.1. Batteries present a risk if they become damage by the
possible leaking of electrolyte. This electrolyte is an acid and can cause serious
injuries. Take care should when working on or near them.
1.4.9.1.1. Should you come into contact with acid you should;
1.4.9.1.1.1. Remove all clothing contaminated with acid.
1.4.9.1.1.2. Get medical assistance as soon as possible.
1.4.9.1.1.3. Use fresh running water to wash off excess acid, continue this
until medical assistance arrives.
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Ver3

1.4.9.1.1.4. If acid gets into your eyes, you should remove it immediately.
Make sure that you do not wash the acid to another part of the face or
body.
1.4.9.1.1.5. Gasses from charging batteries are highly flammable. You
must charge in well-ventilated areas.
1.4.10. Additional Safety Instructions.
1.4.10.1. Do not enclose or cover the generator. It may become overheated if it is
enclosed. If the generator is covered, make sure to remove it and keep it well
away from the area during generator use.
1.4.10.2. Operate the generator on a level surface. It is not necessary to prepare a
special foundation for the generator. However, the generator will vibrate on an
irregular surface.
1.4.10.3. If the generator is tilted/moved during operation, fuel may spill and/or the
generator may tip over, causing a hazardous situation.
1.4.10.4. If used on a steep incline or slope then proper engine lubrication will not
happen. In such a case, piston seizure may occur even if the oil is above the upper
level.
1.4.10.5. Pay attention to the wiring or extension leads from the generator to the
connected device. If the wire is under the generator or in contact with vibrating
parts it may break and possibly cause a fire, generator burnout, or electric shock
hazard. Replace damaged or worn leads immediately.
1.4.10.6. DO NOT operate in rain, in wet or damp conditions, or with wet hands. The
operator may suffer severe electric shock if the generator is wet due to rain or
snow. If wet, wipe and dry it well before starting. DO NOT pour water directly
over the generator, nor wash it with water.
1.4.10.7. For each use, make sure that the generator has been electrically
grounded/earthed. Failure to do so can be fatal.
1.4.10.8. DO NOT smoke while charging a battery. The battery emits flammable
hydrogen gas, which can explode if exposed to electric arcing or open flame. Keep
the area well ventilated and keep open flames/sparks away when charging a
battery.
1.4.10.9. The engine becomes extremely hot during use and for some time after
operation. Keep combustible materials well away from generator area. Be very
careful not to touch any parts of the hot engine especially the muffler/exhaust
area or serious burns may result.
1.4.10.10. Keep children and all bystanders at a safe distance from work area.
1.4.10.11. It is essential that you know the safe and proper use of the power tool or
appliance that you intend to use. All operators must read, understand and follow
the tool/appliance owners’ manual. Users must make themselves aware of the
tool and appliance applications and limitations. Follow all directions given on
labels and warnings.
1.4.10.12. Use only "LISTED" extension leads. When tools or appliances are
used/operated outside, use only extension leads marked for “Outdoor Use".
Extension leads, when not in use, should be stored in a dry and well-ventilated
area.
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Ver3

1.4.10.13. Always switch off generator's AC circuit breaker and disconnect tools or
appliances when not in use, before servicing, adjusting, or installing accessories
and attachments.
1.4.10.14. Stop the engine before starting any maintenance, servicing or repair.
1.4.10.15. Only allow properly trained personnel to maintain/repair the generator.
2. MACHINE LAYOUT
1
38mm Full Frame Protection
6
Carburettor
11
Low Oil Alert
2
Exhaust –Caution Hot
7
Choke
12
Oil Drain Plug
3
Control Panel and Power
Outlets
8
Recoil Starter Handle
13
Oil Dipstick and Oil Filler
4
Anti-Vibration Mounts
9
Engine
14
Alternator
5
Earth Bonding Strap
10
Main Switch
15
Fuel Tank
Page 8
Ver3

3. PREPARING GENERATOR FOR USE
Incorrect connection of the equipment ground/earth conductor
can result in a risk of electrocution.
Check with a qualified electrician if you are in any doubt.
3.1. Use the ground/earth terminal on the frame to connect the generator to a suitable
ground/earth source. Use a 10mm2wire to connect the ground/earth path. Connect the
grounding/earthing wire securely to the ground terminal. Connect the other end of the
wire securely to a suitable ground/earth point.
3.2. All electrical tools and appliances operated from this generator must be properly
grounded/earthed by use of a third wire or be "Double Insulated".
3.3. It is recommended to:
3.3.1. Use electrical devices with three pin plugs and three core power leads.
3.4. Use an extension cable with a three-pin socket and a three-pin plug at the opposite ends to
ensure continuity of the ground protection from the generator to appliance.
3.5. We strongly recommend that you follow all applicable regulations relating to
grounding/earthing. If in doubt, contact a qualified electrician.
4. PRE-OPERATION CHECKS
4.1. Engine oil.
Always check the level of the engine oil prior to starting the
generator.
Failure to do so could cause the engine to seize if the oil is low or
empty.
4.1.1. Before checking or refilling oil, make sure
generator is located on stable and level surface
with engine stopped.
4.1.2. Remove oil dipstick and check the engine oil
level.
4.1.3. If oil level is below the lower level line, refill
with suitable oil to upper level line. DO NOT
screw in the oil dipstick when checking oil
level.
4.1.4. Change oil if contaminated.
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Ver3

4.2. Fuelling.
Explosive fuel! Petrol is extremely flammable and its vapours can
explode if ignited.
Petrol quality deteriorates over time. Periodically replace with
fresh fuel every three months or add a fuel stabiliser.
4.2.1. DO NOT refuel while smoking or near open flame or other such potential fire
hazards.
4.2.2. Store petrol only in approved containers, in well-ventilated, unoccupied buildings
and away from sparks or flames.
4.2.3. DO NOT fill the tank while the engine is hot or running since spilled fuel could ignite
if it meets hot parts or sparks from ignition.
4.2.4. DO NOT start the engine near spilled fuel.
4.2.5. NEVER use petrol as a cleaning agent.
4.2.6. DO NOT overfill the tank, leave room for the fuel to expand.
4.2.7. If fuel level is low, refill with unleaded petrol.
4.2.8. Check fuel gauge while filling.
4.2.9. When using the generator for the first time or stopping due to the fuel running out,
pull the recoil handle several times after filling the tank.
4.2.10. Purchase petrol in small quantities and store in clean, approved containers.
4.2.11. To minimise gum deposits in your fuel system and for easy starting, DO NOT use
petrol left over from the previous season.
4.2.12. DO NOT add oil to the petrol.
4.2.13. Consider adding fuel stabilizer before running or starting the generator.
4.2.14. For best results use only clean, fresh, unleaded petrol. DO NOT use any other types
of fuel.
4.3. Component check.
4.3.1. Check following items before starting engine;
4.3.1.1. Fuel leakage from fuel hose, etc.
4.3.1.2. Bolts and nuts for looseness.
4.3.1.3. Components for damage or breakage.
4.3.1.4. Generator not resting on or against any adjacent wiring.
4.4. Generator surroundings check.
Keep area clear of flammables or other hazardous materials.
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Ver3

4.4.1. Keep the generator at least 3ft (1m) away from buildings or other structures.
4.4.2. Only operate generators in a dry, well-ventilated area.
4.4.3. Keep exhaust pipe clear of foreign objects.
4.4.4. Keep generator away from open flames. No smoking!
4.4.5. Keep generator on a stable and level surface.
4.4.6. Do not block generator air vents with paper or other materials.
5. STARTING YOUR GENERATOR
When starting the engine with the recoil start, set the toggle
switch in the "ON" position before pulling the starter handle.
5.1. Disconnect all appliances from the generator.
5.2. Move engine choke switch to the START (ON) position. (When the engine is warm or
temperature is high, start engine with the switch in the OFF position).
DO NOT connect appliances with defective power leads and/or
plugs.
Disconnect all appliances before starting the generator. Starting
the generator with an appliance connected could result in damage
to the generator and/or appliances and personal injury.
5.3. Turn on the fuel valve to ‘ON’ position (bottom lever).
5.4. Move the choke lever to the ‘CLOSED’ position (upper lever).
5.5. Turn the engine switch to ‘ON’.
5.6. Pull the recoil starter handle slowly until passing the compression
point (resistance will be felt).
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Ver3

5.7. Return the handle to its original position and then pull briskly.
5.8. After starting, allow the recoil starter handle to return to its original position with the
handle still in your hand.
If the engine fails to start after several attempts, repeat the
starting procedures mentioned above with the engine choke
switch placed in the OFF position.
5.9. After 20 to 30 seconds of warm-up, turn the engine choke switch to "OFF" position.
6. RCD TESTING - AC USE
6.1. To test the RCD receptacle on the unit, apply a test load or lamp to each AC outlet to verify
output. Then push the test button.
6.1.1. The reset button should pop out and there should be no power at the receptacle.
6.1.2. If the reset button does not pop out then you MUST NOT continue to use the
generator.
6.1.3. If the RCD DOES NOT reset properly, do not use the receptacle. See service provider
for service immediately.
6.1.4. If RCD tests correctly, firmly push the reset button to restore power. A distinctive
click should be heard or felt when this is complete.
6.2. You can now continue to apply loads to the unit.
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Ver3

8. POWER/WATTAGE INFORMATION
If an electric motor fails to start or reach running speed, turn off
the appliance or tool immediately to avoid equipment damage.
Always check the requirements of the tool/appliance and compare
to the rated output of the generator.
8.1. Some appliances have a surge of energy when starting. This means that the amount of
electrical power needed to start the appliance may exceed the amount needed to maintain
its use.
8.2. Electrical appliances and tools normally come with a label indicating voltage, frequency,
amperage (amps) and electrical power needed to run the appliance or tool.
8.3. Check with your nearest dealer or service provider with questions regarding power surge of
certain appliances or power tools.
8.4. Electrical loads such as incandescent lamps and hot plates require the same wattage to
start as is needed to maintain use.
8.5. Loads such as fluorescent lamps require 1.2 to 2 times the indicated wattage during start-
up.
8.6. Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.
8.7. Electrical motors require large starting currents. Power requirements depend on the type
of motor and its use. Once enough power is available to start the motor, the appliance will
require only 30% to 50% of the wattage to continue running.
8.8. Most electrical tools require 1.2 to 3 times their wattage for running under load during use.
For example, a 5000-watt generator can power an 1800 to 4000 watt electrical tool.
8.9. Loads such as submersible pumps and air compressors require a very large force to start.
They need 3 to 5 times the normal running wattage in order to start. For example, a 5000-
watt generator would only be able to drive a 1000 to 7000 watt pump.
8.10. To determine the total wattage required to run a particular electrical appliance or
tool, multiply the voltage figure of the appliance/tool by the amperage (amps) figure of it.
The voltage and amperage (amps) information can be found on a nameplate which is
normally attached to electrical appliances and tools.
E.g. 230 Volts, 5 Amps = 230 x 5 = 1150 Watts.
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Ver3

9. STOPPING YOUR GENERATOR
9.1.1. Turn off the power switch of the electric equipment and unplug the leads from the
AC outlets of the generator.
9.1.2. Allow the engine about 3 minutes to cool down without load before stopping.
9.1.3. Push the engine switch to the ‘OFF’position.
9.1.4. Push the main switch to the ‘OFF’position.
9.1.5. Turn the fuel tap to the ‘OFF’ position.
10. TROUBLESHOOTING
10.1. If you are experiencing a problem that is not listed in this chart, or have checked all
possible causes listed and you are still experiencing problems, then contact your local
dealer.
PROBLEM
CAUSE
CORRECTION
Engine will not start
1 Check if engine switch is ‘OFF’.
1 Turn switch to the ‘CHOKE’
position.
2 Fuel tank empty.
Fill with fuel, DO NOT overfill.
3 Check that no appliances are
connected to generator.
3 If appliances connected –turn
‘OFF’ the power switch on the
connected appliance and unplug.
4 Check spark plug for loose spark
plug cap.
4 If loose, tighten and push cap
back into place.
5 Check spark plug for
contamination.
5 Remove spark plug and clean
electrode.
6 Check engine oil level.
If engine oil level low, add oil as
per instructions.
Generator has no
output
1 Check if the DC breaker is in
‘OFF’ position.
Depress or flip circuit breaker to
‘ON’ position.
2 Check AC outlets and DC
terminals for loose connections.
2 Secure connections as required.
3 Check to see if engine starting,
was attempted with appliances
already connected to generator.
3 Turn ‘OFF’ switch on appliances,
and disconnect from the AC outlet.
Reconnect after generator has
been re-started properly.
10.2. Spark arrester.
If the engine has been running, the muffler/exhaust and spark
arrester will be very hot. Allow the muffler/exhaust to cool down
before cleaning.
10.2.1. YOU MUST clean the spark arrester regularly to keep it functioning as designed.
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Ver3

10.2.2. A clogged spark arrester;
10.2.2.1. Prevents the flow of exhaust gases.
10.2.2.2. Reduce engine output.
10.2.2.3. Increases fuel consumption.
10.2.2.4. Makes starting difficult.
10.3. How to remove the spark arrester. (GX200).
10.3.1. Remove the two 4mm screws from the
exhaust deflector and remove the deflector.
10.3.2. Remove the four 5mm screws from the
muffler/exhaust protector; and remove the
muffler/exhaust protector.
10.3.3. Remove the two 4mm screws from the
spark arrestor, and remove the spark arrester
from the muffler/exhaust.
10.4. How to remove the spark arrester. (GX270/GX390).
10.4.1. Remove the two 8mm nuts and remove the
muffler/exhaust from the cylinder.
10.4.2. Remove the three 4mm screws from the
exhaust deflector; and remove the deflector.
10.4.3. Remove the four 5mm screws from the
muffler/exhaust protector; remove the
muffler/exhaust protector.
10.4.4. Remove the 4mm screw from the spark
arrester; and remove the spark arrester from
the muffler/exhaust.
10.5. Clean the spark arrester screen.
10.5.1.1. Use a brush to remove carbon
deposits from the spark arrester screen.
Be careful not to damage the screen.
10.5.1.2. The spark arrester MUST BE free of
breaks/holes. If damaged replace the
spark arrester.
10.5.1.3. Re-fit the spark arrester, and muffler/exhaust cover in reverse order of dis-
assembly.
10.5.1.4. Should you have a problem with this operation contact your local dealer.
10.6. Oil Sensor.
10.6.1. The oil sensor detects a drop in oil level in the crankcase and automatically stops the
engine when the oil level drops below a predetermined level.
DO NOT remove oil sensor probe when refilling with oil.
Remove oil filler cap on the opposite side of carburetor.
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Ver3

10.6.2. When the engine has stopped automatically, turn off the generator, and check the
oil level.
10.6.3. Refill engine oil to the upper level as instructed and restart the engine.
11. MAINTENANCE
11.1. Daily Inspection.
11.1.1. Before running the generator, you should check the following;
11.1.1.1. Make sure that you are using the machine in safe surroundings.
11.1.1.2. Check for any fuel or oil leaks, repair any leaks before use. Clean up all spills
straight away.
11.1.1.3. Check that the oil/fuel levels are correct, if low fill with the required amount,
DO NOT overfill.
11.1.1.4. Check that the fuel is clean.
11.1.1.5. Check AC socket outlets and DC terminals for signs of damage, repair as
required. DO NOT use until all repairs have been carried out.
11.1.1.6. Check for excessive vibration and/or noise. Remedy all before continuing to
use generator.
11.1.1.7. Check for loose or broken nuts, bolts and/or shields. Tighten, replace as
required. DO NOT use until remedied.
11.1.1.8. Check that the air filter element is clean. If dirty, clean and/or replace as
necessary. Avoid using the generator until air filter has been cleaned/replaced
11.2. Periodic maintenance.
Periodic maintenance is vital to safe and efficient operation of
your generator.
11.2.1. For all periodic maintenance, see enclosed engine manual, or view manual on-line at
www.honda-engines-eu.com
MAKE SURE the engine has been stopped before starting any
maintenance, servicing or repair.
YOU MUST wear ear protection when performing operations such
as maintenance and repair of the generator.
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Ver3

12. SPECIFICATIONS
MODEL
BE-GX200GEN
BE-GX270GEN
BE-GX390GEN
Engine Type
Honda GX200 4-
Stroke
Honda GX270 4-
Stroke
Honda GX390 4-
Stroke
Engine Size - cc
196
270
389
Oil Capacity - l
0.6
1.1
1.1
Rated Speed - rpm
3000
3000
3000
Rated Power - kw
2.7
4
5.2
Maximum Power - kw
3.1
4.5
5.5
CE Compliant
Yes
Yes
Yes
Start Method
Recoil
Recoil
Recoil
Fuel Tank Capacity - L
2.5
5.3
6.1
Approximate Run Time Per
Tank - hr
3.5
4
3.5
Voltage - VAC
115/230
115/230
115/230
Socket Type - Current Rating
1x 230v 16A, 2x
115V 16A
2x 230v 16A, 1x 15
16A
1x 230v 16A, 1x 230v
32A, 1x 115 16A, 1x
115v 32A
Alternator Voltage Regulation AVR AVR AVR
Frame 38mm Full Frame
Protection
38mm Full Frame
Protection
38mm Full Frame
Protection
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Ver3

13. GENPOWER CONTACT DETAILS
13.1. Postal address;
Genpower Limited, Isaac Way, Pembroke Dock,
Pembrokeshire, SA72 4RW, UK.
13.2. Telephone and Fax contact numbers;
Office [phone]
13.3. Email contact;
Technical [email protected]
13.4. Web site;
www.bepressure.co.uk
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Ver3

14. DECLARATIONS OF CONFORMITY
14.1. Genpower Ltd confirms that these BE products conform to the following CE
Directives;
14.1.1. 2006/42/EC Machinery Directive
14.1.2. 2004/108/EC EMC Directive
14.1.3. 2000/14/EC Noise Emissions Directive
14.1.4. 97/68/EC NRMM Emissions Directive
14.1.5. 2006/95/EC Low Voltage Directive
Page 19
Ver3

GENPOWER LTD
Isaac Way, Pembroke Dock, Pembrokeshire, UK, SA72 4RW
T: [phone]
F: [phone]
E: [email protected]o.uk
www.bepressure.co.uk