HGI Generators VRP80-TIN12-TL User manual

Ravenstor Road
Wirksworth
Derbyshire
DE4 4FY
ENGLAND
Sales Tel: [phone]
Sales Fax: [phone]
Email: [email protected]
[email protected]
Website: www.hgigenerators.com
Operation and Maintenance Manual
Petrol Generator
8.0 - 9.6 kW Air Cooled
for build numbers:
VRP80-TIN12-TL, VRP96D-TL, VRP96T-TL
Publication No: 498-1019
© 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 change
Jun 15 Provisional MC Draft for Review by Ken Croft
Jun 15 A MC Updated following review and released
Jan 17 B MC Upd Warranty Iss H
Oct 17 C MC Upd Warranty

Harrington Generators International
498-1019Petrol Generator
Contents
Contents
INTRODUCTION............................................................................................. 1
CERTIFICATION............................................................................................. 3
EC Declaration of Conformity ...................................................................... 3
SPECIFICATION............................................................................................. 4
Model Specification....................................................................................... 4
SAFETY .......................................................................................................... 5
A few words about safety ............................................................................. 5
Operator Responsibility................................................................................ 5
Precautions.................................................................................................... 6
Earthing ...................................................................................................... 6
OPERATION ................................................................................................... 7
Generator Layout........................................................................................... 7
Engine Component Identification................................................................ 7
Pre-Operation Checks................................................................................... 8
Starting........................................................................................................... 9
Stopping....................................................................................................... 10
FAULT FINDING ........................................................................................... 12
MAINTENANCE............................................................................................ 13
Maintenance Schedule................................................................................ 13
Safety Precautions...................................................................................... 14
Maintenance Routine .................................................................................. 14

Harrington Generators International
498-1019 Petrol Generator
Contents
PARTS AND SERVICE................................................................................. 17
Contact Details ............................................................................................ 17
Warranty Statement..................................................................................... 17
Functional Spares ....................................................................................... 17
TRANSPORTATION ..................................................................................... 18
STORAGE..................................................................................................... 18
WIRING......................................................................................................... 19
MANUFACTURER’S SERVICE AND USER GUIDES LINKS...................... 20
Vanguard 350000 Series Engine Operators Manual................................. 20
Mecc Alte S20FS/T20F User Manual ......................................................... 20

Harrington Generators International
1 498-1019Petrol Generator
Introduction
Introduction
Thank you for purchasing a quality generator, carefully
manufactured to the highest standards by one of the
World’s leading generator manufacturers, Harington
Generators International (HGI).
This range of Dual Voltage 110V/230V/400V
are generally used for industrial use and are
not CE marked for European Noise Directive.
Before operating the generator, read this manual and
make sure that all personnel who operate the equipment
have access to the manual (and any additional
documentation supplied with it) and are fully aware with
the operation and functionality of the generator prior to
use.
Misuse of the instructions may invalidate the product
warranty and lead to potential accidents.
This manual is an essential part of the generator and
should be kept with the generator at all times. Make
sure that the manual is available to all users throughout
the generator’s life-span.
If in doubt about the functionality of any of the equipment
within this document please contact HGI or seek other
expert advice.
Every effort has been made to ensure that the
information given in this manual is correct at the time of
publishing. However, it may be superseded due to our
continuous improvement processes.
HGI Limited manufacture a wide range of generating
sets and accessories, including generators approved
for use in Telecoms, Railway and Military applications
where quality and reliability are essential. These
include:
• Petrol Generators
• Petrol Welders
• Gas & Water ECE3 (TIN12)
• Trackside
• Tractor PTO
• Super Silent Diesel Generators (3000rpm)
• Super Silent Diesel Generators (1500rpm
• Automatic Mains Failure Control Systems
• Welf-Air Generators
• Compact Welf-Air Generators
• Super Compact Welf-Air Generators
• Super Silent Diesel Welders
For further information call us now on :
[phone]
our experienced and knowledgeable sales staff will be
happy to advise you and provide a detailed quotation
for all your generator requirements or visit our website
www.HGIgenerators.com
VRP96

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498-1019 2 Petrol Generator

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Certification
Certification
EC 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 that
Equipment 110V/230V Dual Voltage or 400V/230V Petrol Generators
Model Name VRP80-TIN12-T VRP96D-TL VRP96T-TL
Electrical Power Pel 8.0 kW e 9.6 kW e 9.6 kW e
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.
Notified Body for 2000/14/EC Noise HORIBA MIRA UK
Emission in the Environment by Watling Street
Equipment for use Outdoors Directive Nuneaton
Warwickshire CV10 0UT
Notified 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

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Specification
Specification
Engine: Nominal Power 12.5kW
Vanguard 350000 Series 570cc
OHV V Twin Cylinder
Engine Speed 3000 rpm
Frame: Mild Steel, Polyester Powder Coat Finish
Trolley Mounted
Dimensions: 1055 x 675 x 755 l x w x h (mm)
Fuel Tank Options: Standard 8.5 litre capacity
Performance Class: ISO 8528 LTP G1 Limited Running hours for general purpose electrical supply
Model Specification
VRP80-TIN12-T
Output: 8.0 kW (10.0 kVA)
Output Voltage: 110V CTE
Alternator: S20FS-160/A - 2-pole brushless, self exciting, capacitor controlled
Weight (kg)1125
Hours Run22.8
VRP96D-TL
Output: 9.6 kW (12.0 kVA)
Output Voltage: 110 / 230V
Alternator: S20FS-160/A - 2-pole brushless, self exciting, capacitor controlled
Weight (kg)1130
Hours Run22.5
VRP96T-TL
Output: 9.6 kW (12.0 kVA)
Output Voltage 230 / 400V
Alternator: T20F-200/A - transformer controlled with brushes
Weight (kg)1138
Hours Run22.5
1Dry Weight approx without fuel and oil
2 Hours Run @ ¾ Load (approximate figures only)

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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 your generator. 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:
DANGER Danger refers to immediate hazards which WILL
result in severe personal injury or death.
WARNING Warning refers to a hazard or unsafe method or practice which
CAN result in severe personal injury or possible death.
CAUTION Caution refers to a hazard or unsafe method or practice
which CAN result in personal injury.
NOTICE Notice 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 qualified technician.

Petrol Generator
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.
- Do not operate the generator in a confined area.
- Ensure that the area surrounding the machine has no restrictions that would prevent an adequate flow
of clean, ambient air.
• The generator should be operated in an open space with free air flow on all sides, at least one
metre from other equipment and buildings. The surrounding area should be clear of any combustible
material.
• Fuel is highly flammable, when refuelling:
- Do not run the engine.
- Do not smoke.
- Avoid overfilling the fuel tank.
- Wipe up any fuel spilt on the machine and move the equipment away from the area where fuel has
been spilt.
- Store fuel in approved containers only and do not expose to direct sunlight.
• 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.
• The throttle control lever is preset to the correct engine speed and must not be adjusted, otherwise
damage to equipment or the generator may be caused and will invalidate the warranty.
• 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.
Earthing
The earth pins of the output socket(s) are electrically connected to the metalwork of the generator.
VRP80-TIN12-TL 110V CTE with centre tap to earth.
VRP96D-TL has the neutral connection floating and not tied to earth.
VRP96T-TL has a star neutral point which is floating and not tied to earth.
Further advice on earthing can be found in the following Health & Safety Executive publications (available from
HMSO):
• GS27 Protection Against Electric Shock
• GS24 Electricity on Construction Site
• PM53 Emergency Private Generation

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Operation
Operation
The guidelines for operating the generator outlined in the section refer to both the standard frame generators
and the trolley mounted generators. However, diagramatically the images refer to the standard frame.
Generator Layout
Engine Component Identification
Muffler
Choke
Lever
Oil Drain Plug
Oil Filler
Air Cleaner
Fuel Tank
Engine
Frame
Auxiliary
Sockets
Alternator
Anti Vibrational Mountings
Tool and
Lead Tray
Control
Panel
Recoil Starter
Air Cleaner
Throttle
Spark
Plug
Engine
Switch Dipstick
Oil Filter
* not exact model shown
for illustration only

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Operation
Pre-Operation Checks
Engine Oil
Check the oil level BEFORE EACH USE with the
generator on a level surface and the engine stopped.
Use 4-stroke fully synthetic motor oil that meets or
exceeds the requirements for API service classification
SF, SG, SH, or SJ or later (or equivalent). Always
check the API SERVICE label on the oil container to
be sure it includes the letter SJ or later (or equivalent).
SAE 10W-30 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. Remove the oil filler cap and wipe the dipstick
clean.
Oil Dip Stick
Oil Fill
2. Insert the dipstick into the oil filler neck but do not
screw it in.
3. If the level is low, fill to the full level mark on the
dipstick
Full
Oil Capacity: 1.4 Litres
Fuel
WARNING
Petrol is highly flammable and explosive.
You can be burned or seriously injured when
handling fuel.
Stop the engine and keep heat, sparks, and flame
away.
Handle fuel only outdoors.
Wipe up spills immediately.
With the engine stopped, remove the fuel tank cap
and check the fuel level.
Refill the fuel tank if the fuel level is low. Refuel care-
fully to avoid spilling fuel.
Do not fill above the bottom of the fuel tank neck.
NOTICE
Fuel can damage paint and plastic. Be careful not to
spill fuel when filling your fuel tank. Damage caused
by spilled fuel is not covered under warranty.
After refuelling tighten the fuel cap securely.

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Operation
NOTICE
If the fuel tank is empty and dry it will take up to
10 minutes for fresh fuel to prime the filters and
carburettor.
Fully fill the tank to speed this up.
Fuel Capacity 8.5 Litres
Throttle
The throttle control lever is preset to the correct engine
speed and must not be adjusted, otherwise damage
to equipment or the generator may be caused and will
invalidate any warranty.
General
Check that the generator is located on level ground
and in an open space with free air flow on all sides, at
least one metre from other equipment and buildings,
and clear of any combustible material.
Starting
WARNING
Please check that all equipment is disconnected
from the generator prior to starting.
WARNING
Carbon monoxide gas is toxic. Breathing it can
cause unconsciousness and even kill. Avoid any
enclosed areas, partially enclosed areas or activities
that may expose you to carbon monoxide.
1. Perform the Pre-Operation Checks.
2. Make sure that all appliances are disconnected
from the output sockets.
3. Turn the fuel shut off valve (located next to the
starter key)to the ON position.
Fuel Shut
Off Valve
Electric
Start Switch
4. Move the choke control to the choke position
NB: The choke may not be required if the engine
is warm or the air temperature is high.
5. Insert the Key and turn the electric start switch
to the START position until the generator starts.
Return the switch to the RUN position.
If the engine failes to start after three attempts
start fault finding procedures.
6. If the choke lever was moved to the choke
position to start the engine, gradually move it to
the RUN position as the engine warms up.
7. Allow the engine to warm up for 1 minute before
connecting any load to the generator output.

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Operation
Output Sockets
The output sockets are located on the Top Box above
the alternator.
The socket arrangement available for connecting load
to is dependant upon the model:
Model Top
Box Sockets
VRP80-TIN12-TL
TB005
110V CTE 2 x 16A,
1 x 32A, 1 x 63A
63A Main MCB
VRP96D-TL TB-
6DV9
110V 2 X 16A, 1 x 32A
230V 2 X 16A, 1 x 32A
32A Main MCB
VRP96T-TL
TB3TP
230V 2 x 16A
3Ph 1 x 32A
10A Main MCB
On VRP80-TIN12-T models earthing of the output is
centre tapped to earth, protected by MCBs. 15A MCBs
protecting 16A sockets and 30A MCBs protecting the
32A sockets.
On VRP96D-TL the neutral is floating.
Select the voltage required using the
voltage selector switch on the top box.
On VRP96T-TL the neutral/star point is floating.
Connect the equipment to be powered (load) into the
socket receptacles on the generator top box.
NOTICE
Do not overload the generator as this will cause
overheating, and shorten the life of the generator.
Check that the total load from all equipment connected
does not exceed the generator rating. The output
may be protected against severe overload by circuit
breakers, when fitted.
There is an M8 brass stud on the frame which 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.
High Altitude Operation
The generator is capable of operating up to 1000m
without significant power reduction.
At higher altitudes, the standard carburettor air-fuel
mixture will be excessively rich. Performance will
decrease, and fuel consumption will increase.
For high altitude operation install a smaller diameter
main fuel jet in the carburettor and readjust the
pilot screw. If you always operate the engine at
high altitudes, have these carburettor modifications
performed by a reputable service company or contact
HGI.
Even with suitable carburettor jetting, engine
horsepower will decrease approximately 3.5% for each
300m increase in altitude. The effect of altitude on
horsepower will be greater than this if no carburettor
modification is made.
NOTICE
Operation of the engine at an altitude lower than
the carburettor is jetted for may result in reduced
performance, overheating, and serious engine
damage caused by an excessively lean air/fuel
mixture.
Stopping
To stop the engine in an emergency, simply turn the
engine key to the OFF position. Under normal condi-
tions, use the following procedure:
1. Switch off and disconnect the load from the
generator’s output sockets.
2. Allow the generator to run off load for 2 minutes to
cool down.
3. Turn the Key switch to the OFF position
4. Move the Fuel Shut Off Valve to the CLOSED
position.
CAUTION
Leaving the fuel shut off valve in the ON position
after stopping can cause the engine to flood and
impair starting.

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Operation
NOTICE
If the fuel shut off valve is left ON for transport the
movement may bounce the carburettor float and
allow fuel to flood the engine.
Always ensure that the fuel shut off valve is turned
to CLOSED when not in use.

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Fault Finding
Fault Finding
IMPORTANT:
If the following checks and investigations can be completed without the use of tools then the User can safely un-
dertake 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 finding.
Symptom Cause and Remedy
Engine will not start • Check the Choke is in the correct position
• Check that there is fuel in the tank
• Blocked Fuel Filters
• Engine Flooded
• Is there enough oil in the engine
• No Spark - incorrectly gapped spark plug
• Blocked Air Filter
• Incorrectly set engine speed.
• Low Oil Level
Engine starts but stops on load • Fuel starvation - check filters
• Choke incorrectly set
• Dirty Air Filter
• Engine Speed incorrectly set
• Low Oil Level
No electrical output • Breakers have been switched off / tripped
• Load is faulty
• Diodes on alternator have failed
• Alternator capacitor has failed
• Alternator has lost magnetism
• Faulty alternator windings
NOTICE FLOODED ENGINES
If the fuel valve is left ON whilst the machine is not in use the engine can flood. If this occurs the following
procedure can alleviate starting problems :
• Turn the Fuel Valve OFF
• Drain the Carburettor bowl
• Remove the Spark Plug and inspect for flooded cylinder - correct if necessary
• Remove Oil Filler Cap (Dipstick) and inspect the oil. Drain oil and refill if necessary.
If in doubt contact HGI Service or consult with your dealer.

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Maintenance
Maintenance
Good maintenance is essential for safe, economical, and trouble free operation. This not only ensures that your
engine is at its optimum in fuel efficiency, 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.
Maintenance Schedule
The maintenance schedule applies to normal operating conditions. If you operate your generator under severe
conditions, such as sustained high-load or high-temperature operation, or use it in unusually dusty conditions,
consult your servicing dealer for recommendations applicable to your individual needs and use.
Service
Period
Item Every 8 hrs
or Daily
Every 25hrs
or Every
Season
50hrs or
Every
Season
100 hrs
or Every
Season Yearly
Check fuel level º
Check oil level º
Change oil º (1) º
Change oil filter (if equipped) º
Service air cleaner pre-cleaner º (2) º
Service air cleaner cartridge º (2)
Clean cooling system º (2)
Clean/replace spark plugs º
Clean/replace in-line fuel filter (if
equipped) º
Check valve clearance º
Alternator Every Year
Battery Every Year
Electrical Every Year
Frame Every Year
1. Change Oil after first 5-8 hours of use and then every 50hrs or season. Change oil every 25hrs if using
under heavy load or in high temperatures.
2. Service more frequently if used in dusty areas.
3. Only by trained personnel.
If you’d like to make an appointment for HGI to service your generator using our in house 26-point health
checker guide then please contact the Service Department.

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498-1019 14 Petrol Generator
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.
WARNING
Failure 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.
• To reduce the possibility of fire or explosion, be
careful when working around petrol. Use only a
nonflammable solvent, not petrol, to clean parts.
Keep cigarettes, sparks, and flames away from all
fuel-related parts.
Maintenance Routine
The following procedures refer to the common mainte-
nance items for servicing your generator.
Fuel Level Check
Refer to Pre-Start Checks.
Oil Level Check
Refer to Pre-Start Checks.
Engine Oil Change
Change Oil after the first 5-8 hours of use and then
every 50hrs or season. Change oil every 25hrs if
using under heavy load or in high temperatures.
Recommended oil of grade 10W30 or better.
Drain the oil in the engine while the engine is warm.
Warm oil drains quickly and completely.
1. Place the generator on a level surface, and place
a suitable container under the drain plug bolt.
2. Disconnect spark plug leads and keep away from
spark plugs. Disconnect battery at the negative
terminal.
3. Remove the oil filler cap, drain plug bolt, and
drain plug washer to drain the oil into the suitable
container.
Oil Drain
Plug
4. Follow HSE recommendations regarding the
handling and disposal of contaminated oil
products.
5. Reinstall drain plug and tighten. Remove oil filler
cap.
6. Fill with recommended oil to the top of the oil filler
neck. Replace oil filler cap.
Change Oil Filter
Change oil filter after every 100 hours or every
season.
1. Drain engine oil and remove oil filter.
2. Before installing new filter, lightly oil filter gasket
with fresh, clean oil.
3. Screw filter on by hand until gasket contacts oil
filter adapter. Tighten 1/2 to 3/4 turn more.
4. Add fresh oil. Fill to FULL line on dipstick.
5. Start and run engine at idle to check for leaks.
6. Stop engine. Re-check oil level. Add oil if required.
Service Air Filter Pre-Cleaner
A dirty air filter will restrict air flow to the carburettor,
reducing engine performance. If the engine is
operated in dusty areas, clean the air cleaner
more often than specified in the MAINTENANCE
SCHEDULE.

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Maintenance
NOTICE
Operating the engine without the air filters or with
the filter installed loosely will allow dirt to enter the
engine, causing rapid engine wear. Install the air
filters securely.
All engines have a round air cleaner cartridge. In
addition, some engines have a pre-cleaner.
To clean pre-cleaner (if equipped), separate it from
cartridge and wash in liquid detergent and water.
Squeeze dry in a clean cloth.
Service Air Cleaner Cartridge
1. Remove knobs and cover.
2. Remove nut, plate and carefully lift air cleaner as-
sembly (pre-cleaner and cartridge) off stud.
3. Reinstall clean (or new) air cleaner assembly
firmly in base. Reinstall plate (top side marked
“UP”) and nut.
4. Reinstall cover. Tighten knobs securely.
Clean Air Cooling System
Debris may clog the engine’s air cooling system.
Remove blower housing and clean area shown to
prevent overheating and engine damage.
NOTICE
Do not use water to clean engine parts.
Water could contaminate fuel system. Use a brush
or dry cloth.
Clean / Replace Spark Plugs
CAUTION
If the engine has been running, the engine will be
very hot. Allow it to cool before proceeding.
Remove the spark plug lead, and then remove the
spark plugs using a spark plug wrench.
Check the spark plug for damage and replace if
necessary, or
Check the gap with a wire gauge. If necessary, reset
the gap.
Re-Install and tighten the spark plug.
PLUG GAP: 0.76 mm (0.03 in)
TORQUE SETTING: 180 lb-in (20 Nm)

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498-1019 16 Petrol Generator
Maintenance
Clean / Replace Inline Fuel Filter
WARNING
Petrol is highly flammable and explosive. You can
be burned or seriously injured when handling fuel.
• Keep heat, sparks, and flame away.
• Handle fuel only outdoors.
• Wipe up spills immediately.
A
C
B
D
B
C
1. Before replacing the fuel filter, if equipped, drain
the fuel tank or close the fuel shut-off valve.
Otherwise, fuel can leak out and cause a fire or
explosion.
2. Clamp hose (D) on either side of the filter.
3. Use pliers to squeeze tabs (B) on the clamps (C),
then slide the clamps away from the fuel filter.
Twist and pull the fuel lines (D) off the fuel filter.
4. Check the fuel lines for cracks or leaks. Replace if
necessary.
5. Replace the fuel filter with an original equipment
replacement filter.
6. Secure the fuel lines with the clamps as shown
and remove the temporary clamps.
Valve Clearance
Valve Clearances should be checked every year. The
clearance should be:
Intake Valve Clearance:
0.004 - 0.006 in (0.10 - 0.15 mm)
Exhaust Valve Clearance:
0.004 - 0.006 in (0.10 - 0.15 mm)
Refit the rocker cover with a new gasket.
Alternator
Ensure that the cooling air vents do not become
blocked by dirt, debris etc.
Check the brushes and slip rings for wear every 12
months or 250/300 hours operation and replace if
worn (brush – type alternators only).
Battery
Electric start models only. 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.
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.
Frame
Check frame for rust and take necessary action if
unsound.
Check security of fixings and fasteners on the
machine.
Ensure earthing point is sound, clean any rust or oil
deposits.
Generally inspect for fuel and oil leaks
Visually inspect anti vibration mounts for signs of
failing or damage and check fixing bolts are secure.
Check wheels and axles for signs of failing.