Genpower Gxs14000d ii User manual

Commercial Diesel Generator

User Manual

[Revision 2.0 February 2018]

READ THIS MANUAL CAREFULLY BEFORE USE –FAILURE TO DO SO MAY RESULT IN INJURY, PROPERTY

DAMAGE AND MAY VOID WARRANTY. • KEEP THIS MANUAL FOR FUTURE REFERENCE. • Products covered by

this manual may vary in appearance, assembly, inclusions, specifications, description and packaging.

The product is NOT supplied with engine oil, although traces of oil from the manufacturing

process may be present. It is essential to add adequate engine oil of the correct type to the

engine before use –see Engine Oil. Failure to add engine oil will void the product warranty.

Commercial Diesel Generator

Safety

Safety messages are designed to alert you to possible dangers or hazards that could cause death, injury or

equipment or property damage if not understood or followed. Safety messages have the following symbols:

You WILL be KILLED or

SERIOUSLY INJURED if you

do not follow instructions.

You CAN be KILLED or

SERIOUSLY INJURED if you

do not follow instructions.

You CAN be INJURED if you

do not follow instructions or

equipment damage may occur.

It is vital that you read and understand

this user manual before using the product,

including safety warnings, and any

assembly and operating instructions.

Keep the manual for future reference.

Safety precautions and recommendations

detailed here must be fully understood

and followed to reduce the risk of injury,

fire, explosion, electrical hazard, and/or

property damage.

Safety information presented here is

generic in nature –some advice may not

be applicable to every product. The term

"equipment" refers to the product, be it

electrical mains powered, battery powered

or combustion engine powered.

•Before Use - If you are not familiar with

the safe operation/handling of the

equipment, or are in any way unsure of

any aspect of suitability or correct use

for your application, you should

complete training conducted by a

person or organization qualified in safe

use and operation of this equipment,

including fuel/electrical handling and

safety.

•Do NOT operate the equipment in

flammable or explosive environments,

such as in the presence of flammable

liquids, gases or dust. The equipment

may create sparks or heat that may

ignite flammable substances.

•Keep clear of moving parts.

•Equipment may be a potential source of

electric shock or injury if misused.

•Do NOT operate the equipment if it is

damaged, malfunctioning or is in an

excessively worn state.

•Do NOT allow others to use the

equipment unless they have read this

manual and are adequately trained.

•Keep packaging away from children -

risk of suffocation! Operators must use

the equipment correctly. When using

the equipment, consider conditions and

pay due care to persons and property.

General Work Area Safety

•Work areas should be clean and well it.

•Do not operate the equipment if

bystanders, animals etc are within

operating range of the equipment or the

general work area.

•If devices are provided for connecting

dust extraction / collection facilities,

ensure these are connected and used

properly. Dust collection can reduce

dust-related hazards.

General Personal Safety

•Wear appropriate protective equipment

when operating, servicing, or when in

the operating area of the equipment to

help protect from eye and ear injury,

poisoning, burns, cutting and crush

injuries. Protective equipment such as

safety goggles, respirators, non-slip

safety footwear, hard hat, hearing

protection etc should be used for

appropriate equipment / conditions.

Other people nearby should also wear

appropriate personal protective

equipment. Do not wear loose clothing

or jewellery, which can be caught in

moving parts. Keep hair and clothing

away from the equipment.

•Stay alert and use common sense

when operating the equipment. Do not

over-reach. Always maintain secure

footing and balance.

•Do not use the equipment if tired or

under the influence of drugs, alcohol or

medication.

•This equipment is not intended for use

by persons with reduced physical,

sensory or mental capabilities.

General Fuel Safety

•Petrol/fuel/gasoline is extremely

flammable –keep clear of naked flames

or other ignition sources.

•Do not spill fuel. If you spill fuel, wipe it

off the equipment immediately –if fuel

gets on your clothing, change clothing.

•Do NOT smoke near fuel or when

refuelling.

•Always shut off the engine before

refuelling.

•Do NOT refuel a hot engine.

•Open the fuel cap carefully to allow any

pressure build-up in the tank to release

slowly.

•Always refuel in well ventilated areas.

•Always check for fuel leakage. If fuel

leakage is found, do not start or run the

engine until all leaks are fixed.

General Carbon-Monoxide Safety

•Using a combustion engine indoors

CAN KILL IN MINUTES. Engine

exhaust contains carbon-monoxide –a

poison you cannot smell or see.

•Use combustion engines OUTSIDE

only, and far away from windows, doors

and vents.

General Equipment Use and Care

•The equipment is designed for

domestic use only.

•Handle the equipment safely and

carefully.

•Before use, inspect the equipment for

misalignment or binding of moving

parts, loose components, damage or

any other condition that may affect its

operation. If damaged, have the

equipment repaired by an authorised

service centre or technician before use.

•Prevent unintentional starting of the

equipment - ensure equipment and

power switches are in the OFF position

before connecting or moving

equipment. Do not carry equipment

with hands or fingers touching any

controls. Remove any tools or other

items that are not a part of the

equipment from it before starting or

switching on.

•Do not force the equipment. Use the

correct equipment for your application.

Equipment will perform better and be

safer when used within its design and

usage parameters.

•Use the equipment and accessories

etc. in accordance with these

instructions, considering working

conditions and the work to be

performed. Using the equipment for

operations different from those

intended could result in hazardous

situations.

•Always keep equipment components

(engines, hoses, handles, controls,

frames, housings, guards etc) and

accessories (cutting tools, nozzles, bits

etc) properly maintained. Keep the

equipment clean and, where

applicable, properly lubricated.

•Store the equipment out of reach of

children or untrained persons. To avoid

burns or fire hazards, let the equipment

cool completely before transporting or

storing. Never place or store the

equipment near flammable materials,

combustible gases or liquids etc.

•The equipment is not weather-proof,

and should not be stored in direct

sunlight, at high ambient temperatures

or locations that are damp or humid.

•Do not clean equipment with solvents,

flammable liquids or harsh abrasives.

•For specific equipment safety use and

care, see Equipment Safety.

Commercial Diesel Generator

General Electrical Safety

•Inspect electrical equipment, extension

cords, power bars, and electrical fittings

for damage or wear before each use.

Repair or replace damaged equipment

immediately.

•Ensure all power sources conform to

equipment voltage requirements and

are disconnected before connecting or

disconnecting equipment.

•When wiring electrically powered

equipment, follow all electrical and

safety codes.

•Wherever possible, use a residual

current device (RCD).

•High voltage / high current power lines

may be present. Use extreme caution

to avoid contact or interference with

power lines. Electrical shock can be

fatal.

General Electrical Safety

•Electrically grounded equipment must

have an approved cord and plug and be

connected to a grounded electrical

outlet.

•Do NOT bypass the ON/OFF switch

and operate equipment by connecting

and disconnecting the electrical cord.

•Do NOT use equipment that has

exposed wiring, damaged switches,

covers or guards.

•Do NOT use electrical equipment in wet

conditions or in damp locations.

•Do NOT use electrical cords to lift,

move or carry equipment.

•Do NOT coil or knot electrical cords,

and ensure electrical cords are not trip

hazards.

General Service Information

•The equipment must be serviced or

repaired at authorised service centres

by qualified personnel only.

•Replacement parts must be original

equipment manufacturer (OEM) to

ensure equipment safety is maintained.

•Do NOT attempt any maintenance or

repair work not described in this

manual.

•After use, the equipment and

components may still be hot –allow the

equipment to cool and disconnect

spark plugs and/or electrical power

sources and/or batteries from it before

making adjustments, changing

accessories or performing repair or

maintenance.

•Do NOT make adjustments while the

equipment is running.

•Perform service related activities in

suitable conditions, such as a

workshop.

•Replace worn, damaged or missing

warning/safety labels immediately.

Commercial Diesel Generator

Safety Symbols

The product may have safety warning labels attached to it, explained below. Understand the symbols on

your product and their meanings. If any stickers become unreadable, unattached etc, replace them.

Flammable Material Hazard

Flammable liquids, gases or

substances etc may present.

Avoid ignition sources and

open flames. Danger of fire.

Read User Manual

Read and fully understand

product safety warnings,

operation, procedures etc

before using the product.

Use Hand Protection

Wear appropriate hand

protection and take due care

as the product or use of the

product may present hand

hazards.

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be

fatal.

Electrocution / Electrical

Shock Hazard

High voltage or high current

electricity may be present or

required by the product. Take

due care when handling

electrical products, cables,

plugs and leads. Electrical

shock can be fatal.

Toxic Fumes / Dust Hazard

Using the product or by-

products from use may

produce fumes, smoke or

particles that could be harmful

if inhaled. Wear appropriate

breathing protection and have

adequate ventilation.

Explosive Material Hazard

Combustible liquids, gases or

substances etc may be

present. Avoid ignition sources

and open flames. Danger of

explosion.

Cutting / Amputation Hazard

The product may have blades,

edges or mechanical devices

that can cause severe cut

injury to fingers, limbs etc.

Take due care when handling

and using the product.

Crush Hazard

The product may have blades,

edges or mechanical devices

that can cause severe crush

injury to fingers, limbs etc.

Take due care when handling

and using the product.

Single Operator Only

The product must be operated

by a single person only. More

than one person operating the

product may introduce

additional hazards.

Use Face Protection

Wear appropriate full-face

protection and take due care

as the product or use of the

product may present face and

eye hazards.

Use Foot Protection

Wear appropriate foot

protection and take due care

as the product or use of the

product may present foot

hazards.

Use Eye / Ear / Head

Protection

Wear appropriate eye and / or

ear and / or head protection

and take due care as the

product or use of the product

may present eye, hearing and

head hazards.

Running Hazard

Do not run on or near the

product as doing so may

present a fall hazard.

Diving Hazard

Do not dive into the product as

doing so may present a neck /

head injury hazard.

Adult Supervision Required

Always supervise children and

other users of a product to

prevent drowning or injury.

Skin Penetration / Puncture

Hazard

The product may produce

pressure, emit liquids or

objects that can cause severe

injury to fingers, limbs, blood

etc. Take due care when

handling and using the

product.

Hot Surface Hazard

Be aware that the product may

produce high temperatures

and hot surfaces that can

cause burn injuries.

Flying Debris Hazard

Be aware that the product or

use of the product may

present hazards produced by

flying debris. Wear appropriate

clothing and protectiove

devices.

Moving Parts Hazard

Be aware that the product

contains or uses mechanical

devices that move or rotate.

Always wait for moving parts

to stop fully before handling

the product, adjusting,

maintenence etc.

Commercial Diesel Generator

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be

fatal.

Pull Hazard

Be aware that the product

contains or uses mechanical

devices that can pull in objects

and can cause severe injury to

fingers, limbs etc. Take due

care when handling and using

the product.

Slope / Fall Injury Hazard

Be aware that using the

product on sloping surfaces or

in slippery conditions may

present additional dangers

from falls and contact with

blades, moving parts, hot

surfaces etc.

"Slam Dunk" Warning

Do NOT attempt "slam dunk"

maneouvres as this may result

in severe injury due to falling,

product breakage or collapse

etc.

Electrocution / Electrical

Shock Hazard - Outdoor

High voltage or high current

electricity may be present or

required by the product. Do

NOT use in rain, damp or wet

conditions. Electrical shock

can be fatal.

Electrocution / Electrical

Shock Hazard - Disconnect

High voltage or high current

electricity may be present or

required by the product.

Always disconnect the product

from the electrical supply

before handling the product,

adjusting, maintenence etc.

Power Line Electrocution

Hazard

High voltage / high current

power lines may be present.

Use extreme caution to avoid

contact or interference with

power lines. Electrical shock

can be fatal.

"Kick-Back" Hazard

High level of "kick-back"

hazard that can cause the

machine to suddenly rotate

towards operator. Kick-back

injury can be fatal.

Winch Operator Position

Hazard

Do NOT stand between winch

and load. Do NOT use winch

to move people.

Winch Lift Hazard

Do NOT LIFT load vertically.

Use machine to PULL only.

Cable Hazard

Ensure that load bearing cable

is not kinked or knotted.

Winch Cable Hazard

Ensure that there is a

minimum number of cable

coils on winching mechanism.

Winch Hook Hazard

Carry hook to load –do NOT

throw or run.

Flash / Blinding Hazard

Wear appropriate eye

protection for welding. Direct

exposure to weld arcs may

cause permanent eye injury.

Laser Hazard

Laser may be in use –do NOT

look directly at laser, or allow

others to.

Corrosive Substance Hazard

The product may contain

corrosive substances that can

harm or otherwise cause

damage. Take due care when

handling and using the

product.

Explosion Hazard

The product may contain

substances that can explode

under certain conditions or

misuse. Take due care when

handling and using the

product.

Commercial Diesel Generator

Equipment Safety

Generators can cause serious or fatal injury if proper safety precautions are not followed. It is

extremely important that you read and fully understand the information in this section and all

other safety warnings / recommendations and usage instructions before using the equipment.

Operator

•If you are untrained in the use of a generator, it is highly recommended that you be trained/instructed by

a suitably qualified or experienced person before using the equipment.

•NEVER operate the machine when tired, or under the influence of any substance (medication, alcohol,

drugs etc) that may impair your judgement, alertness, physical strength, vision or dexterity.

•Maintain sure-footing and balance always when using or handling the machine and have full awareness

of your surroundings and any possible hazards.

•Do not operate the equipment with wet hands or clothing.

Work Area Safety

•Be aware of fire risks resulting from machine use. Ensure that the machine exhaust and spark arrestor (if

equipped) is well maintained and that engine is tuned correctly.

•Refuel outdoors only. Avoid fuel spillage. Start the machine at least 3m (10') away from the fuelling

location.

•If the generator is for back-up power to a house etc, it must be connected to the building electrical

system by a qualified electrician and must comply with relevant laws and electrical codes. If not

connected correctly, use of the generator may present electrocution, electric shock, explosion and fire

hazards.

•Operate the generator on solid, level surfaces only, with at least 1m (3') between it and other equipment

or objects.

Operational Safety

•Do NOT use the machine if the throttle or any safety guard or mechanism is not installed or is not

operating correctly –have the machine inspected and repaired at an authorised service centre before

using it again.

•The generator creates high voltage and current electricity. Do not connect incompatible devices.

•Never insert any object other than compatible connectors into any generator output connector.

•When using the generator, ensure to keep it and all connected cables away from other electrical cables.

Transportation Safety

•Always STOP the engine before transporting or working on it (refuelling, adjusting etc).

•When transporting the machine in a vehicle, ensure the engine is OFF, all appliances are disconnected,

and the machine is secured in an upright position to prevent tip-over, machine damage or fuel spills.

Commercial Diesel Generator 
E&OE ©2018 Genpower 7 
Table of Contents 
Safety.................................................................................................................................................................2 
Safety Symbols ............................................................................................................................................4 
Equipment Safety .............................................................................................................................................6 
Applicable Models............................................................................................................................................8 
Parts Identification ...........................................................................................................................................9 
Before Use Checklist......................................................................................................................................10 
Assembly....................................................................................................................................................10 
Engine Oil...................................................................................................................................................10 
Air Filter......................................................................................................................................................10 
Fuel ............................................................................................................................................................11 
Priming the Fuel System .....................................................................................................................11 
Battery........................................................................................................................................................11 
Engine Starting ...............................................................................................................................................13 
Starting.......................................................................................................................................................13 
Jump Starting.............................................................................................................................................13 
Stopping the Engine...................................................................................................................................14 
Environmental Considerations...................................................................................................................14 
Generator Operation.......................................................................................................................................15 
Understanding Rated Output .....................................................................................................................15 
Calculating Generator Load .......................................................................................................................16 
Load Balancing –3-Phase Generators ...............................................................................................16 
Control Panel and Functions......................................................................................................................17 
Grounding the Generator ...........................................................................................................................18 
AC Applications..........................................................................................................................................18 
DC Applications..........................................................................................................................................19 
Battery Charging..................................................................................................................................19 
Maintenance....................................................................................................................................................20 
Maintenance Schedule –Diesel Engines / Machines................................................................................21 
Engine Oil...................................................................................................................................................22 
Checking and Changing Engine Oil.....................................................................................................22 
Oil Strainer...........................................................................................................................................23 
Air Filter......................................................................................................................................................24 
Inspection and Cleaning......................................................................................................................24 
Removal/Installation ............................................................................................................................24 
Fuel Filter ...................................................................................................................................................25 
Inspection and Cleaning......................................................................................................................25 
Removal/Installation –Fuel Filter Internal to Tank..............................................................................25 
Removal/Installation –Fuel Filter External to Tank.............................................................................26 
Battery........................................................................................................................................................27 
Battery Removal/Installation................................................................................................................27 
Transportation and Storage ..........................................................................................................................28 
Preparing for Transport and Storage .........................................................................................................28 
Long Term Storage ....................................................................................................................................28 
Troubleshooting .............................................................................................................................................29 
Specifications .................................................................................................................................................31 
Engine Service and Maintenance Record....................................................................................................32 

Commercial Diesel Generator

Applicable Models

This manual applies to the following generators:

GXS14000D II

GXS14000

TXS14000D III

GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER GENPOWER

Commercial Diesel Generator

Parts Identification

Products detailed in this manual may vary in appearance, inclusions, description and packaging

from those shown or described. This section shows typical major components common to most

diesel powered commercial generators, the position of some components may also vary between models.

No.

Name

No.

Name

1

Control Panel (see Control Panel and Functions)

11

Engine ON / OFF Switch

2

Fuel Filler

12

Accessories / Tools (not all models may include

all or any accessories):

Wheels (some models also have wheel covers)

Wheel Fasteners

Funnel

Engine Spare Parts (technician use only)

Battery Auxiliary Cable

Spanners

Screwdriver

Allen Key

3

Exhaust

4

Engine Access Cover (front)

5

Carry Handle

6

Air Filter Access Cover (filter inside)

7

Engine Access Cover (rear)

8

Fuel Tap (fuel strainer / filter inside tank)

9

Oil Filler/Dipstick

10

Battery

1

3

2

4

6

7

5

11

10

9

12

13

8

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Commercial Diesel Generator

Before Use Checklist

Ensure that you carry out all procedures below before starting the engine or operating the

equipment. All procedures described are generic in nature and slight variations between

different models may exist. Failure to follow the checklist and carry out the procedures correctly may

result in making the product warranty void. The product is NOT supplied with engine oil, although traces

of oil from the manufacturing process may be present. It is essential to add adequate engine oil of the correct

type to the engine before use –see Engine Oil. Failure to add engine oil will void the product warranty.

Assembly

Minor assembly is required to complete the unit, and is generally limited to fitting the wheels or castors. All

necessary parts (wheels and fasteners etc) are supplied with the unit. Suitable tools may be required to lift

the generator sufficiently to install the wheels.

Support the generator with blocks etc so it is safe to work on the wheels.

•For models with wheels, place each wheel on the axle, then secure the wheel by placing a split pin

through the hole in the axle. Bend the legs of the split pins around the axle to prevent them falling out. If

there are wheel covers supplied, attach them to the body of the generator using the supplied fasteners.

•For models with castors, attach each castor (some castors may have brakes) to the underside of the

generator using the 4 supplied fasteners per castor.

Engine Oil

Four-stroke engines require engine oil in the crankcase for lubrication of internal components. Severe or

irreparable damage may occur if the engine is allowed to run without engine oil. The engine oil level requires

regular maintenance. Check the engine oil level and ensure that the oil level is at or just under the maximum

level indicator.

Some machines may feature an oil level sensor that will prevent the engine being started or automatically

stop the engine if the oil level falls below an acceptable level. This system, however, is not to be solely relied

upon. Always check that the engine oil level is at or near the "MAX" indicator before starting the

engine. See Engine Oil.

Air Filter

The air filter is used to prevent dirt and other particles from possibly entering the engine and causing internal

damage to it. The air filter requires regular maintenance.

Always check the air filter before starting the engine. See Air Filter.

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Commercial Diesel Generator

Fuel

Petrol/fuel/gasoline is extremely flammable –keep clear of naked flames or other ignition

sources.

Adequately fill the fuel tank with the correct fuel type.

•Use commercial diesel fuel. Bio-diesel / blended fuels can be used also. Do not use old or contaminated

fuel.

To fill or top up fuel:

1. Place the machine in an upright position on a flat and level surface.

2. Clean the machine around the fuel filler so that no dirt or other material enters the tank when the cap is

removed.

3. Remove (rotate left) the fuel filler cap.

4. Using a funnel, carefully fill the tank with fuel. Do not fill above the top of the strainer (if equipped) or

otherwise overfill the tank.

5. When finished, reinstall (rotate right) the fuel filler cap until firm. Wipe away any residual fuel from the

machine. If fuel has been spilt, move the machine away from the spillage before starting the engine.

Priming the Fuel System

When an engine is new or has been completely run out of fuel it may be necessary to "prime" the fuel system

before attempting to start the engine. This means removing any air from the fuel line. To prime 4-stroke

engines:

1. Fill the fuel tank with fuel.

2. Remove the fuel line (A) from the fuel injector using pliers to loosen

the hose-clamp. Hold a container beneath the fuel line to catch any

spilt fuel.

3. Place the fuel tap in the "ON" position and allow fuel to flow out

(into the container) until no air bubbles can be seen in the fuel

stream.

4. Push the fuel line back onto its connection point and re-fasten the

hose clamp.

5. Clean up any spilled fuel. If fuel has been spilt, move the machine

away from the spillage before starting the engine.

6. Start the engine.

Battery

The engine starting battery is shipped with the unit and comes with the NEGATIVE cable disconnected for

shipping reasons. Complete the battery connection. To connect the battery:

1. Open the front engine access cover (A). Once open, the battery and cables are accessible.

2. Connect the NEGATIVE (-) battery cable (BLACK) to point (X) on the engine.

3. Check that both cable connections at the battery terminals are secure, the protective rubber covers are

protecting the connections, and the battery bracket (B) is secure.

A

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Commercial Diesel Generator

A

X

B

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Commercial Diesel Generator

Engine Starting

Before starting the engine, ensure that you have followed all procedures described in the

Before Use Checklist. The product is NOT supplied with engine oil, although traces of oil

from the manufacturing process may be present. It is essential to add adequate engine oil of the correct type

to the engine before use –see Engine Oil. Failure to add engine oil will void the product warranty. •

Before starting the generator, disconnect all output sockets so that no load is immediately placed on

the generator as it starts up. • The generator may feature in-built protection that will prevent the engine

running if there is insufficient engine oil, the unit is over-temperature or is over-loaded.

The following procedures and images are typical to all models, however, the position or appearance of

controls etc may vary. All major engine controls are identified on the machine by way of stickers or other

markings.

Once the engine is started, the engine speed will automatically regulate depending on connected load. For

example, under high loads, the engine will run at higher speed to maintain the required output.

Starting

Connect the battery before attempting to start the unit. If the battery is flat, charge it before using the

generator, or use the jump-start method. Once the engine is running, it will charge the battery.

1. FUEL –Open the front engine access cover, then place the fuel tap (A) in the "ON" position (rotate the

lever right (clockwise)).

2. THROTTLE –Place the throttle control (B) in the "RUN" position (to the right). Some models may use a

screw to secure the throttle in position –to adjust, loosen the screw and move it to the required position,

then tighten it again. Close the front engine access cover.

3. START –Insert the generator key into the ignition switch (C) on the control panel, then rotate it right to

the "START" position, to engage the starter motor. The engine should start.

4. RUN –Rotate the generator key left to remain in the "ON" position.

If the engine does not start, repeat step 2 onward. If the engine fails to start after several attempts, refer to

Troubleshooting.

Jump Starting

If the battery does not have enough charge to sufficiently crank the engine, the engine can be jump-started.

Use a fully charged battery (the "jump" battery) and suitable jump-starting cables. To jump-start:

1. Ensure the ignition is OFF (for some models, this is the position that allows the key to be removed).

2. Connect the jump battery POSITIVE ("+") terminal to the engine battery POSITIVE ("+") terminal.

3. Connect the jump battery NEGATIVE ("-") terminal to the engine battery NEGATIVE ("-") terminal.

4. Follow the normal start procedure from step 1 onward.

A

C

B

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Commercial Diesel Generator

Stopping the Engine

Stopping in an Emergency

1. To stop the engine immediately, place the generator key in the "OFF" position.

After stopping the engine, it is recommended to follow the normal engine stop procedure (disconnect

connected devices and ignition and fuel OFF).

Stopping in Normal Use

1. OUTPUTS –Turn OFF any connected devices, then unplug them from the

generator.

2. IGNITION –Place the generator key in the "OFF" position. The key can be

removed from the ignition switch when in this position.

3. THROTTLE –Press the throttle stop lever (A) down to release the throttle.

4. FUEL –Place the fuel tap in the "OFF" position (rotate the lever left (anti-

clockwise)).

Environmental Considerations

Altitude –If the engine is being used in altitudes at or above 1500m (approximately 5000'), adjustments to

the engine may be required. This is because there is less oxygen in the air as altitude increases, which

effectively "enriches" the ratio of fuel to air going into the engine and the higher the altitude, the richer the

fuel mixture becomes. If the engine is being permanently operated at high altitude, it is recommended to

have an authorised service centre make the necessary adjustments. If the engine is used occasionally at

altitude (not extreme altitudes), no adjustments should be required, however, a slight decrease in engine

performance can be expected.

Temperature –If the engine is being used in extremely cold

or hot environments; for example, desert or snow conditions,

the type of engine oil may need to be changed to suit

environmental temperatures. Oil thickens as the temperature

decreases and thins as temperature increases, which means

that if the engine oil is not suited to the temperature its ability

to properly lubricate the engine may be affected. Use the

following chart to determine the correct engine oil:

A

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Commercial Diesel Generator

Generator Operation

Allowing the generator to run when being overloaded may permanently damage it

and/or shorten its service life and may void product warranty. • Maximum continuous

run time per day without cool-off is 6 hours @ 50% load, or 4 hours @ 100% load. The manufacturer

recommends that the unit run for no longer than 600 hours per year for optimum machine

performance and to extend generator life. These conditions assume the engine oil level is correct,

servicing is maintained as per the schedule, and conditions are not considered harsh (high

temperature, dust etc). • Ensure that the generator is grounded (earthed) before using it. • Ensure that any

device to be powered by the generator is switched OFF before connecting it to the generator. • Ensure that

all devices that will be powered by the generator are electrically safe and functioning normally. If at any time

a connected device appears to malfunction, stop or slow down etc, immediately switch the generator and

device OFF and disconnect the device. • Do not exceed the rated power output of the generator. Consider

the power rating for all connected devices that will be running simultaneously, both AC and DC, and ensure

that the sum of all power consumption is no more than the generator rated output with consideration given to

actual power output based on altitude and temperature (see Understanding Rated Output). For example, 4 x

1500W devices will be acceptable for a 6.0kW rated output generator, however, will overload a 5.0kW unit. •

Do not exceed the rated current for the output socket. For example, do not connect a device that draws 15A

to a 10A socket. • If using an extension cable, ensure it is an approved type and has a minimum wire gauge

of 1.5mm² up to a cable length of 60m; 2.5mm² up to a cable length of 100m. • For appliances that place

high "inductive" loads when being started or stopped (for example, electric motors), consideration should be

given to the rated output of the generator and the required inductive load capacity. Rated output equates to

approximately 45 to 75% of inductive load capacity. • Do not connect devices in parallel to the generator. •

Devices sensitive to input voltage fluctuation should be connected via a suitable surge protector.

Understanding Rated Output

The "rated output" is described as the maximum power that the generator can consistently and reliably

provide. The rated output of a generator is based around several factors including altitude, ambient

temperature and relative humidity. The specified rated output is calculated at an altitude of 0m, ambient

temperature of 25°C and relative humidity of 30%. Deviations from these values will affect the actual output

capacity of the generator. For example, if the generator is used at high altitude it will produce less power.

Basically, the higher the altitude, the warmer the ambient temperature and the greater the humidity, the less

power can be produced. The following table provides a guideline for calculating actual generator output

based on ambient temperature and altitude [note that humidity is ignored here as it has a marginal effect]:

Ambient Temperature (°C)

25

30

35

40

45

Altitude (m)

Power Output Coefficient

0

1.0

0.98

0.96

0.93

0.90

500

0.93

0.91

0.89

0.87

0.84

1000

0.87

0.85

0.82

0.80

0.78

2000

0.75

0.76

0.71

0.69

0.66

3000

0.64

0.62

0.60

0.58

0.56

4000

0.54

0.52

0.50

0.48

0.46

Examples:

•At an approximate altitude of 1000m and 30°C ambient temperature, the power output coefficient is 0.85.

So, a rated output of 6kW becomes 6.0 x 0.85, which equates to an actual power output of 5.1kW.

•At an approximate altitude of 2000m and 25°C ambient temperature, the power output coefficient is 0.75.

So, a rated output of 6.0kW becomes 6.0 x 0.75, which equates to an actual power output of 4.5kW.

•At an approximate altitude of 3000m and 40°C ambient temperature, the power output coefficient is 0.58.

So, a rated output of 6.0kW becomes 6.0 x 0.58, which equates to an actual power output of 3.48kW.

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Commercial Diesel Generator

Calculating Generator Load

Most electrical devices clearly state the required power, usually in Watts (W). This information is generally

labelled on the device, or listed in its user manual. If a device lists power consumption figures in amperes (A)

only, calculate the wattage by multiplying the ampere rating by the voltage. For example, a 10A device @

240VAC equates to 2400W (10A x 240V). The sum of all devices required to be operating simultaneously

needs to equal or be less than the rated output of the generator.

Many devices require a different load on start-up/shut-down that is often much higher than the actual

continuous running requirements. For example, a water pump may require 2000W to start, and once started,

requires 500W to continue running. When calculating generator load, the start-up requirements need to be

factored in. If the start-up power consumption is not known, the table below lists typical consumption figures

for several device types that may assist in determining how many or which devices may be connected and a

starting order [that is, start the high consumption devices first, followed by devices with no additional start-up

power requirements].

Incandescent

Lamp

Radio

Power Tool

Electric Fan

Water Pump

Fluorescent

Lamp

Start-up Watts

50 to 150

100 to 200

1000 to 1500

600

2500 to 5000

N/A

Running Watts

50 to 150

100 to 200

400 to 600

200

500 to 1000

As Stated

Example (using the typical values above):

•To run a radio, electric fan and 3 power tools requires an approximate running power consumption of

100W (radio) + 200W (fan) + 1800W (power tools) = 2.1kW. However, when factoring in start-up power

requirements, the equation becomes 100W (radio) + 600W (fan) + 4500W (power tools) = 5.2kW.

Many generators have a "maximum" output above that of the rated output, which is allowable for a

short period. This is to allow (up to a point) for increased start-up loads that reduce once connected

devices are running. Using the above example, a generator with a rated output of 3.0kW and maximum

output of 5.2kW would be suitable.

Load Balancing –3-Phase Generators

The following recommendations are applicable to 3-phase capable generators ONLY. • Failure to

correctly "load balance" the outputs on 3-phase generators may damage the unit, and is not

covered by warranty.

•A maximum of one third (33%) of rated generator output ONLY is

available from any 240VAC single-phase output. For example, a 3-

phase generator rated at 3kW is capable of supplying a maximum

1kW (3 ÷ 3) at any one 240VAC outlet.

•When using 240VAC power, it is recommended to use ALL 3

outputs simultaneously as each output uses one phase of the

generator alternator.

•240VAC devices that draw surges of power or have a power

consumption exceeding 1500W should NOT be powered from 3-

phase generators.

•When powering 415V 3-phase and 240VAC single-phase devices

simultaneously, it is recommended to run low power devices from

the single-phase outlets. Note that the 415V 3-phase outlet

maximum current output reduces to 10A.

In the adjacent image, outlets in use are shown as orange; unused

outlets are shown as blue.

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Commercial Diesel Generator

Control Panel and Functions

The generator features a control panel for connecting devices and monitor or understand generator status.

The features vary between models; for example, some models have different numbers of AC connections, 3-

phase connections, RCD etc. The main features of each control panel type are described below.

No.

Description

1

Ignition –Insert generator key and place in the "START" position to start the generator; place in the "ON"

position to run the generator. Place in the "OFF" position to stop the generator.

2

240VAC Output –Used for powering a 240VAC device that connects via a standard 3-pin plug. The

generator may feature several outlets. Lift the cover to access the connector.

3

12VDC Battery Charger Output –Used for charging a 12V battery (charging cable supplied).

4

12VDC Output Protection Reset –Used to reset the 12VDC output over-current protection. If the over-

current protection trips, the button "pops out". Remove the cause for the protection to trip, then press to re-

activate the generator DC output.

5

415V 3-Phase Output –Used for powering a 415V 3-phase device that connects via a standard 4-pin 3-

phase plug (if equipped). The generator may feature more than one socket. Lift the cover to access the

connector. On some models, a lamp indicates that power from the output is in use.

6

Ground Connection –Used to ground the generator –see Grounding the Generator.

7

Low Oil Pressure Indicator –Illuminates red if the engine oil level is inadequate and will automatically stop

the engine. This protection may also prevent the engine being started. If the engine oil level is low, top it up.

8

RCD Protection Reset –Used to reset the residual current device (RCD) protection circuit-breaker (if

equipped). This breaker trips if a ground circuit fault is detected in an attached device. When tripped, the lever

moves to the "OFF" position, and all generator output circuits are automatically cut-off. Remove the cause for

the protection to trip, then move the lever to the "ON" position to reset.

1

3

1

8

6

3

7

11

5

10

2

10

9

7

9

2

11

6

2

12

4

12

4

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Commercial Diesel Generator

No.

Description

9

Output Over-Current Protection Reset –Used to reset the 240VAC (and 415V 3-phase, if equipped) over-

current circuit-breaker. This circuit-breaker trips if the total current draw on the generator (all outputs

combined) is excessive. When tripped, the lever moves to the "OFF" position and all generator output circuits

are automatically cut-off. Remove the cause for the protection to trip, then move the lever to the "ON" position

to reset.

10

Display –Provides generator information:

U–Shows the AC voltage (V) being generated. If the generator is overloaded, this is blank.

F–Shows the voltage frequency (Hz) being generated. If the generator is overloaded, this is blank.

Time –Shows the TOTAL length of the time that the generator has been run for. This is for servicing reasons,

and does not reset to zero when the generator is stopped.

11

Internal 12VDC Circuit Protection Reset –Used to reset the internal 12VDC starter motor circuit over-

current protection. If the over-current protection trips, the button "pops out". Press to re-activate the internal

12VDC circuit.

12

240VAC Output Over-Current Protection Reset –Used to reset the associated 240VAC output over-

current protection. This circuit-breaker trips if the current draw on the associated 240VAC outlet is excessive.

If the protection trips, the button "pops out". Remove the cause for the protection to trip, then press to re-

activate the 240VAC output.

Grounding the Generator

The generator must be properly grounded

before use. Failure to ground the

generator may create a shock or electrocution hazard.

Connect a length of insulated heavy gauge wire (C)

between the generator Ground connector (A) (on the

control panel) and a suitable ground point. You can create

a ground point by driving a metal rod (B) into the ground

and connecting the free end of the cable to it.

AC Applications

Observe the following safety precautions when powering 240VAC devices:

• Connect only devices that have power requirements compatible with the generator. •

Connect only devices that have connectors compatible with the generator output sockets. • Always switch

the connected device OFF before connecting to or disconnecting from the generator. • Do not connect

devices in parallel to the generator. • Devices sensitive to input voltage fluctuation should be connected via a

suitable surge protector. • For 3-phase generators, ensure that the load is balanced across the outlets.

1. Ensure that all circuit-breakers and protection devices are "ON" (not

tripped).

2. Start the generator.

3. Ensure that any device to be connected is switched OFF, then plug the

device into the applicable 240VAC outlet.

4. Switch the connected devices ON, one at a time to help reduce start-up

loads, then operate them as normal.

5. When finished using the device, switch it OFF, then unplug the device from

the generator.

B

A

C

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Commercial Diesel Generator

DC Applications

Observe the following safety precautions when charging batteries:

When connecting a battery to the DC output, ENSURE that the polarity (+to +and –to –) of

connections is correct. Failure to do so may represent an explosion hazard and/or damage the generator

and/or connected battery. • The DC circuit is not monitored and does not automatically switch off or self-

regulate depending on the voltage of the connected battery. This means that you must independently

monitor battery charge status and disconnect the battery before it is over-charged. Over-charging batteries

may present an explosion hazard. • The DC output over-current protection can be tripped in the event of too

much current being drawn (see Specifications for maximum current draw for differing generator models). If

this occurs, the DC protection reset switch (on the control panel) will "pop out". Press the switch to reset the

protection and re-activate the generator DC output. • To prevent sparking near the generator, when

disconnecting a battery, disconnect the battery charging cable from the battery terminals before unplugging it

from the generator DC output socket. Disconnect the negative (-) terminal first, followed by disconnecting

the positive (+) terminal and do not allow the cable ends to touch. • When charging a battery that is mounted

in a vehicle, at the vehicle battery, disconnect the negative (-) terminal first, followed by disconnecting the

positive (+) terminal. Then, proceed to connect the battery charging cable as normal. Ensure that the battery

terminals or charging cable terminals do not make contact with the vehicle chassis as sparking may occur. •

Do not attempt to start a vehicle whilst its battery is connected to the generator, as damage to the generator

may result. • Batteries that are being charged may emit dangerous gases. Batteries being charged should be

in a well ventilated area and a safe distance from any sources of flame, heat, flammable or volatile materials.

•Batteries may contain corrosive substances. Contact with skin or eyes may cause burns –wash with water

immediately (at least 15 minutes if has contacted eyes) and seek professional medical attention. Wear

protective clothing and face mask when handling batteries. • If battery acid is swallowed, administer water or

milk and immediately seek professional medical attention. • All batteries should be kept out of reach of

children.

Battery Charging

Some generators feature a protected 12VDC outlet

that is used for charging suitable batteries (vehicle

batteries etc). Use the supplied cable to connect the

battery to the generator.

1. Connect the battery charging cable (A) to the

battery (B) terminals –RED to the battery

POSITIVE (+) terminal, BLACK to the battery

NEGATIVE (-) terminal. Connect the POSITIVE

(+) terminal first.

2. Connect the battery charging cable to the

generator DC output connectors (C).

3. Start the generator.

4. Switch the 12VDC output ON (D).

When finished using the DC output, switch the 12VDC output OFF, disconnect the BLACK NEGATIVE (-)

battery charging cable from the generator and battery, then disconnect the RED POSITIVE (+) cable from

the generator and battery.

B

C

A

D

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Commercial Diesel Generator

Maintenance

Running combustion engines in confined areas CAN KILL IN MINUTES. Engine exhaust

fumes contain carbon-monoxide –a deadly gas that you cannot smell or see. NEVER run

a combustion engine in confined areas EVEN IF windows and doors are open. ONLY run

combustion engines OUTDOORS and away from doors, windows and vents. • Petrol / fuel

/ gasoline is extremely flammable –keep clear of naked flames or other ignition sources. •

Do not have the engine running during inspection and maintenance unless specifically required. • The engine

should be cool enough to touch before performing maintenance activities. • Some maintenance activities

may be beyond the scope of some users. Do NOT attempt procedures that you are not comfortable with, or

do not have the necessary tools, experience or knowledge for –take the unit to an authorised service centre

or qualified technician for servicing. • Harsh operating environments such as extreme temperatures, dust etc

may necessitate more frequent maintenance. • Failure to follow the maintenance schedule, using

incorrect or non-compatible accessories or replacements parts, or general negligence may result in

making the product warranty void.

To keep the machine performing at optimal efficiency, regular checks and maintenance is required. The

maintenance schedule below specifies preventative maintenance checks and necessary maintenance tasks

and how often they should be performed. The schedule applies to multiple engines; some engines may not

include some components, so maintenance on those components is not applicable.

Maintenance Schedule

Use the following maintenance schedule for a list of regular maintenance tasks and how often they need to

be performed. Maintenance frequency is based on average usage. Be aware of how much the machine is

used and be sure to follow the schedule according to time or usage, whichever comes first.

Towards the end of this document is a form you can use for maintenance record keeping. It is recommended

that you keep a reference of all maintenance.

Major Servicing and "Heavy-Duty" Usage - For engines that are subject to "heavy-duty" use,

which can be defined as being used under loads of 85% or more and / or in use more than

approximately 300 hours per year (for example, generators and water pumps), more frequent "Major

Service" maintenance is required. In addition to normal service requirements, and as with many smaller

machine and off-road bike engines, the following parts (as applicable for petrol, diesel or 2-stroke engines)

may require replacement during a major service:

• Piston rings.

• Big-end bearings.

• Small-end bearings.

•Gudgeon pin.

• Oil rings.

• Gaskets and seals.

• Valve seats.

Inspection of the following items is required:

• Piston for cracks and stress fractures.

• Bore for wear requiring reconditioning.

• Full machine for broken, worn or loose parts.

Failure to follow the maintenance schedule, using incorrect or non-compatible accessories or

replacements parts, or general negligence may result in making the product warranty void.

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GENPOWER GXS14000D II User manual

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