Itm Construction series User manual

www.itmtools.com.au

Ver: 1.1

OPERATOR’S MANUAL

PETROL GENERATOR

MODELS: TM522-3000 & TM522-6000

TO PREVENT SERIOUS INJURY OR DAMAGE TO YOUR GENERATOR, READ

AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE

! !

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GENERATOR OPERATOR’S MANUAL

LIMITED WARRANTY

Industrial Tool & Machinery Sales (hereinafter referred to as ITMS) will, within twelve (12)

months from the original date of purchase, repair or replace any goods found to be defective

in materials or workmanship.

This warranty is void if the item has been damaged by accident, neglect, improper service or

other causes not arising out of defects in materials or workmanship. This warranty does not

apply to machines and/or components which have been altered, changed, or modified in any

way, or subjected to overloading or use beyond recommended capacities and specifications.

Worn componentry due to normal wear and tear is not a warranty claim. Goods returned

defective shall be returned prepaid freight to ITMS or agreed repair agent, which shall be the

buyer’s sole and exclusive remedy for defective goods. ITMS accepts no additional liability

pursuant to this guarantee for the costs of travelling or transportation of the product or parts to

and from ITMS or the service agent or dealer, such costs are not included in this warranty.

Our goods come with guarantees which cannot be excluded under the Australian Consumer

Law. You are entitled to replacement or refund for a major failure and to compensation

for other reasonably foreseeable loss or damage. You are also entitled to have the goods

repaired or replaced if the goods fail to be of acceptable quality and the failure does not

amount to a major failure.

THE MANUFACTURER RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND

MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE.

PRODUCTS IMPORTED AND DISTRIBUTED NATIONALLY BY:

INDUSTRIAL TOOL & MACHINERY SALES

11 EASTERN SERVICE ROAD, STAPYLTON QLD 4207

T: 07 3287 1114 E: [email protected]

F: 07 3287 1115 W: www.itmtools.com.au

TRADEMASTER

Magnetic Base Drilling Machines

Tools and Machinery

AIR

TABLE OF CONTENTS

Warranty .................................................................................................................. 2

Product Specifications ............................................................................................. 3

Safety Instructions ................................................................................................... 4

Unpacking ................................................................................................................. 6

Assembly .................................................................................................................. 7

Operation .................................................................................................................... 8

Maintenance ............................................................................................................ 19

Trouble Shooting ..................................................................................................... 25

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GENERATOR OPERATOR’S MANUAL

Part Number TM522-3000 TM522-6000

KvA 3.75 7.5

Max Power 3000W 6000W

Rated Power 2800W 5500W

Amps 13 23

Horse Power 6.5HP 13HP

Engine Type Honda GX200 Honda GX390

Fuel Tank (L) 3.6 25

Fuel Type Ron 91 Ron 91

Engine Power cc 196 389

Oil Capacity 0.6L 1.1L

Oil Type 10W-30 10W-30

Running Time 50% Load 4.5 Hours 13 Hours

AC outlets 1 x 15A (IP66) 2 x 15A (IP66)

Start System Recoil Recoil

Alternator AVR* AVR*

Residual Current Device “RCD” Yes Yes

Low Oil Sensor Yes Yes

Wheel & Handle Kit No Yes

Weight 47Kg 80Kg

Thank you for purchasing your ITM Constriction Series Generator. This generator is fitted

with IP66 outlets and RCD meaning it is worksite compliant.

Please read and understand the content of this manual for safety guidelines, start-up,

shutdown, operation, adjustment and maintenance instructions before using this product.

Take all possible precautions to protect your own safety and that of the people in the

immediate vicinity. Save this manual for future reference.

* (Automatic voltage regulator)

PRODUCT SPECIFICATIONS

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GENERATOR OPERATOR’S MANUAL

GENERAL SAFETY RULES FOR OPERATION

Never use the generator in a location that is wet or damp. Never expose the generator to rain,

snow, water spray or standing water while in use. Protect the generator from all hazardous weather

conditions. Moisture or ice can cause a short circuit or other malfunction in the electrical circuit.

Voltage produced by the generator could result in death or serious injury.

• Never operate the generator in rain or a flood plain unless proper precautions are taken to avoid

being subject to rain or a flood.

• Never use worn or damaged extension cords.

• Always have a licensed electrician connect the generator to the utility circuit.

• Never touch an operating generator if the generator is wet or if you have wet hands.

• Never operate the generator in highly conductive areas such as around metal decking or steel

works.

• Always use grounded extension cords. Always use three-wire or double-insulated power tools.

• Never touch live terminals or bare wires while the generator is operating.

• Be sure the generator is properly grounded before operating.

Never modify the generator.

Never operate the generator if it

vibrates at high levels, if engine

speed changes greatly or if the

engine misfires often.

Always disconnect tools or

appliances from the generator

before starting.

Never operate the generator if powered items overheat,

electrical output drops, there is sparking, flames or

smoke coming from the generator, or if the receptacles

are damaged.

Never use the generator to power medical support

equipment.

Always remove any tools or other service equipment

used during maintenance from the generator before

operating.

Petrol and petrol vapors are extremely flammable and explosive under certain conditions.

• Always refuel the generator outdoors, in a well-ventilated area.

• Never remove the fuel cap with the engine running.

• Never refuel the generator while the engine is running. Always turn engine off and allow the

generator to cool before refueling.

• Only fill fuel tank with petrol.

• Keep sparks, open flames or other form of ignition (such as match, cigarette, static electric source

away when refueling.

• Never overfill the fuel tank. Leave room for fuel to expand. Overfilling the fuel tank can result in a

sudden overflow of petrol and result in spilled petrol coming in contact with HOT surfaces. Spilled

fuel can ignite. If fuel is spilled on the generator, wipe up any spills immediately. Dispose of rag

properly. Allow area of spilled fuel to dry before operating the generator.

• Wear eye protection while refueling.

• Never use petrol as a cleaning agent.

• Store any petrol containers in a well-ventilated area, away from any source of ignition.

• Check for fuel leaks after refueling. Never operate the engine if a fuel leak is discovered.

Never operate the generator in an enclosed area. Engine exhaust contains carbon monoxide. Only

operate the generator outside and away from windows, doors and vents.

DANGER

WARNING

WARNING NOTICE

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GENERATOR OPERATOR’S MANUAL

ADDITIONAL SAFETY RULES FOR GENERATORS

Do not force the generator. Use the correct generator for your application. The correct generator will do

the job better and safer at the rate for which it was designed.

Do not use the generator if the engine switch does not turn it on and off. Any generator that cannot be

controlled with the switch is dangerous and must be repaired.

Know exactly how to use the generator correctly. Be thoroughly familiar with proper use of the equipment

and all engine controls, output receptacles, and connections. Know how to stop the engine quickly (see

“Stopping the Generator”).

Instruct operators. The engine owner must instruct all operators in safe engine set-up and operation.

Only trained adults should set up and operate the engine – Do not let children operate.

Intended use. Carefully read about and understand the intended use of this engine. Do not use for other

purposes, as unforeseen hazards or equipment damage may result.

Never operate, or let anyone else operate the generator while under the influence of alcohol, drugs, or

medication.

Do not operate the generator with damaged, missing, or broken parts.

Do not modify the generator in any way. Modifications can create serious safety hazards and will also

void the warranty.

Never attempt to modify the generator speed setting. The generator speed is preset for safe and optimal

performance of the generator. If speed needs adjusting, it must be done by factory authorised personnel.

Never attempt to connect external fuel sources in order to increase generator run time. Larger tank at

pressure or higher elevation will cause to leak from carburetor during operation. Fire or explosion could

result.

Always turn off generator and remove spark plug(s) or spark plug wire(s) before working on the

generator to prevent accidental starting. Always discharge the capacitor before working on the generator

head to prevent electrical shock. (See Maintenance & Repair section of this manual for instructions on

how to do this.)

The running of a generator gives off carbon monoxide, a poisonous gas that can kill you. You CANNOT

smell it, see it, or taste it. Follow all instructions for site selection and positioning the generator, and

avoid inhaling the exhaust. If you start to feel sick, dizzy, or weak while using the generator, shut off the

generator and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

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GENERATOR OPERATOR’S MANUAL

UNPACKING

Always have assistance when lifting the

generator. The generator is heavy; lifting it

could cause bodily harm.

Tools required - box cutter or similar device.

1. Carefully cut the packing tape on top of the

carton.

2. Fold back top flaps to reveal the manual.

3. Remove the Wheel Kit Accessories cardboard

box.

4. Carefully cut two sides of the carton to remove

the generator.

WHAT COMES IN THE BOX

Spark Plug Socket Wrench (1)

Wheel Kit Accessories Box if any

Funnel (1)

WHEEL KIT ACCESSORIES BOX

Open the Wheel Kit Accessories box and verify

the contents against the list right. If any parts are

missing, please locate an authorised.

1. Washer (2 used)

2. Flange Bolt M8 x16mm (4 used)

3. Hairpin Cotter Pin (2 used)

4. Wheel Axle Pin (2)

Wheel and Feet Kit Hardware

Avoid cutting on or near staples to prevent

personal injury.

CAUTION

! !

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GENERATOR OPERATOR’S MANUAL

INSTALLING WHEELS TO FRAME

1. Insert axle pin through washer and wheel.

2. Install the wheel with axle pin through the

axle bracket on the frame. The eye of the

bolt should be facing toward the inside of the

generator.

3. Install the hairpin cotter through the axle pin to

lock it in place.

1 - Axle Bracket

2 - Hairpin Clip

3 - Axle Pin

4. Repeat previous steps on other wheel.

INSTALLING WHEELS AND FEET

BEFORE ASSEMBLING THE

GENERATOR, REVIEW THE SAFETY

SECTION STARTING ON PAGE 5.

CAUTION

Never lift the generator without

assistance. The generator is heavy

and lifting without assistance could

result in personal injury.

Never use the handles as a lifting point

to support the entire weight of the

generator. Only use the handles to move

the generator by lifting the handles and

using the wheels to move the generator.

Use caution when collapsing the

handles. Hands and ngers could get

caught and pinched.

NOTICE

Assembling the generator will require lifting the unit

on one side. Make sure all engine oil and fuel are

drained from the unit prior to assembling. Once

assembled, the wheel kit is not intended for on-

road use. The wheel kit is designed for use on this

generator only.

INSTALLING FEET TO FRAME

1. Place generator on a at surface.

2. Place a piece of cardboard or other soft material to

tip the generator onto, to protect the frame paint and

prevent the generator from sliding. Tip the generator

onto the side.

3. Install the mounting feet to the frame using the M8

ange bolts included.

1 - Mounting Foot

2 - Flange Bolts M8

Figure 1 - Assemble Mounting Feet to Frame

INSTALLING WHEELS TO FRAME

1. Insert axle pin through washer and wheel.

2. Install the wheel with axle pin through the axle

bracket on the frame. The eye of the bolt should be

facing toward the inside of the generator.

Figure 3 - Assemble Wheel to Frame

3. Install the hairpin cotter through the axle pin to lock it

in place.

1 - Axle Bracket

2 - Hairpin Clip

3 - Axle Pin

4. Repeat previous steps on other wheel.

ASSEMBLY

Figure 2 -Wheel Assembly

INSTALLING WHEELS AND FEET

BEFORE ASSEMBLING THE

GENERATOR, REVIEW THE SAFETY

SECTION STARTING ON PAGE 5.

CAUTION

Never lift the generator without

assistance. The generator is heavy

and lifting without assistance could

result in personal injury.

Never use the handles as a lifting point

to support the entire weight of the

generator. Only use the handles to move

the generator by lifting the handles and

using the wheels to move the generator.

Use caution when collapsing the

handles. Hands and ngers could get

caught and pinched.

NOTICE

Assembling the generator will require lifting the unit

on one side. Make sure all engine oil and fuel are

drained from the unit prior to assembling. Once

assembled, the wheel kit is not intended for on-

road use. The wheel kit is designed for use on this

generator only.

INSTALLING FEET TO FRAME

1. Place generator on a at surface.

2. Place a piece of cardboard or other soft material to

tip the generator onto, to protect the frame paint and

prevent the generator from sliding. Tip the generator

onto the side.

3. Install the mounting feet to the frame using the M8

ange bolts included.

1 - Mounting Foot

2 - Flange Bolts M8

Figure 1 - Assemble Mounting Feet to Frame

INSTALLING WHEELS TO FRAME

1. Insert axle pin through washer and wheel.

2. Install the wheel with axle pin through the axle

bracket on the frame. The eye of the bolt should be

facing toward the inside of the generator.

Figure 3 - Assemble Wheel to Frame

3. Install the hairpin cotter through the axle pin to lock it

in place.

1 - Axle Bracket

2 - Hairpin Clip

3 - Axle Pin

4. Repeat previous steps on other wheel.

ASSEMBLY

Figure 2 -Wheel Assembly

INSTALLING WHEELS AND FEET

BEFORE ASSEMBLING THE

GENERATOR, REVIEW THE SAFETY

SECTION STARTING ON PAGE 5.

CAUTION

Never lift the generator without

assistance. The generator is heavy

and lifting without assistance could

result in personal injury.

Never use the handles as a lifting point

to support the entire weight of the

generator. Only use the handles to move

the generator by lifting the handles and

using the wheels to move the generator.

Use caution when collapsing the

handles. Hands and ngers could get

caught and pinched.

NOTICE

Assembling the generator will require lifting the unit

on one side. Make sure all engine oil and fuel are

drained from the unit prior to assembling. Once

assembled, the wheel kit is not intended for on-

road use. The wheel kit is designed for use on this

generator only.

INSTALLING FEET TO FRAME

1. Place generator on a at surface.

2. Place a piece of cardboard or other soft material to

tip the generator onto, to protect the frame paint and

prevent the generator from sliding. Tip the generator

onto the side.

3. Install the mounting feet to the frame using the M8

ange bolts included.

1 - Mounting Foot

2 - Flange Bolts M8

Figure 1 - Assemble Mounting Feet to Frame

INSTALLING WHEELS TO FRAME

1. Insert axle pin through washer and wheel.

2. Install the wheel with axle pin through the axle

bracket on the frame. The eye of the bolt should be

facing toward the inside of the generator.

Figure 3 - Assemble Wheel to Frame

3. Install the hairpin cotter through the axle pin to lock it

in place.

1 - Axle Bracket

2 - Hairpin Clip

3 - Axle Pin

4. Repeat previous steps on other wheel.

ASSEMBLY

Figure 2 -Wheel Assembly

ASSEMBLY

Never lift the generator without assistance.

The generator is heavy and lifting without

assistance could result in personal injury.

Assembling the generator will require lifting

the unit on one side. Make sure all engine

oil and fuel are drained from the unit prior to

assembling. Once assembled, the wheel kit is

not intended for on-road use. The wheel kit is

designed for use on this generator only.

INSTALLING FEET TO FRAME

1. Place generator on a flat surface.

2. Place a piece of cardboard or other soft

material to tip the generator onto, to protect

the frame paint and prevent the generator from

sliding. Tip the generator onto the side.

3. Install the mounting feet to the frame using the

M8 flange bolts included.

1 - Mounting Foot

2 - Flange Bolts M8

Never use the handles as a lifting point to

support the entire weight of the generator.

Only use the handles to move the generator

by lifting the handles and using the wheels to

move the generator.

Use caution when collapsing the handles.

Hands and fingers could get caught and

pinched.

CAUTION

! !

NOTICE

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GENERATOR OPERATOR’S MANUAL

OPERATION

LOCATION SELECTION

Before starting the generator, avoid

exhaust and location hazards by verifying:

• You have selected a location to operate the

generator that is outdoors and well ventilated.

• You have selected a location with a level and

solid surface on which to place the generator.

• You have selected a location that is at least

15 feet (4.5 m) away from any building, other

equipment or combustible material.

• If the generator is located close to a building,

make sure it is not located near any windows,

doors and/or vents. WEATHER

Never operate your generator outdoors during

rain, snow or any combination of weather

conditions that could lead to moisture collecting

on, in or around the generator.

DRY SURFACE

Always operate the generator on a dry surface

free of any moisture.

NO CONNECTED LOADS

Make sure the generator has no connected

loads before starting it. To ensure there are no

connected loads, unplug any electrical extension

cords that are plugged into the control panel

receptacles.

HIGH ALTITUDE OPERATION

Engine power is reduced the higher you

operate above sea level. Output will be reduced

approximately 3.5% for every 1000ft of increased

altitude from sea level. This is a natural

occurrence and cannot be adjusted by engine.

Increased exhaust emissions can also result due

to increased fuel mixture. Other issues include

hard starting, increased fuel consumption and

spark plug fouling.

Always operate the generator on a level

surface. Placing the generator on non level

surfaces can cause the generator to tip over,

causing fuel and oil to spill. Spilled fuel can

ignite if it comes in contact with an ignition

source such as a very hot surface.

Be sure the generator is properly connected to

earth ground before operating. The generator

must be grounded to prevent electrical shock

due to faulty appliances.

DANGER

! !

WARNING

! !

WARNING

! !

Only operate the generator on a solid, level

surface. Operating the generator on a surface

with loose material such as sand or grass

clippings can cause debris to be ingested by

the generator that could:

• Block cooling vents

• Block air intake system

Starting the generator with loads already

applied to it could result in damage to any

appliance being powered off the generator

during the brief start-up period.

NOTICE

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GENERATOR OPERATOR’S MANUAL

OPERATION

CONNECTING THE GENERATOR TO A

BUILDING ELECTRICAL SYSTEM

It is recommended to use a manual transfer switch

when connecting directly to a buildings electrical

system. Connecting a portable generator to a

buildings electrical system must be made in strict

compliance with all national and local electrical

codes and laws, and be completed by a qualified

electrician.doors and/or vents.

ADDING / CHECKING ENGINE

FLUIDS AND FUEL

Before starting the generator, always check the

level of:

• Engine oil

• Petrol in the fuel tank

Once the generator is started and the engine gets

warm, it is not safe to add petrol to the fuel tank or

engine oil to the engine while the engine is running

or the engine and muffler are hot.

CHECKING AND / OR ADDING ENGINE OIL

Internal pressure can build in the engine

crankcase while the engine is running.

Removing the oil fill plug/ dipstick while the

engine is hot can cause extremely hot oil to

spray out of the crankcase and can severely

burn skin. Allow engine oil to cool for several

minutes before removing the oil fill plug/

dipstick.

Filling the fuel tank with petrol while the

generator is running can cause petrol to leak

and come in contact with hot surfaces that can

ignite the petrol.

WARNING

! !

DANGER

! !

The unit as shipped does not contain oil in the

engine. You must add engine oil before starting

the generator for the first time.

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GENERATOR OPERATOR’S MANUAL

OPERATION

ADDING GASOLINE TO THE FUEL TANK

WARNING

Never refuel the generator while the

engine is running.

Always turn the engine o and allow

the generator to cool before refueling.

Required Gasoline – Only use gasoline that meets the

following requirements:

•Unleaded gasoline only

•Gasoline with maximum 10% ethanol added

•Gasoline with an 87 octane rating or higher

Filling the Fuel Tank – Follow the steps below to ll the

fuel tank:

1. Shut o the generator.

2. Allow the generator to cool down so all surface areas

of the muer and engine are cool to the touch.

3. Move the generator to a at surface.

4. Clean area around the fuel cap.

5. Remove the fuel cap by rotating counterclockwise.

6. Slowly add gasoline into the fuel tank. Be very careful

not to overll the tank. The gasoline level should NOT

be higher than the ller neck (see Figure 7).

7. Install the fuel cap by rotating clockwise until

you hear a click, indicating the cap is completely

installed.

Figure 7 - Maximum Gasoline Fill Level

CAUTION

Avoid prolonged skin contact with

gasoline. Avoid prolonged breathing of

gasoline vapors.

BEFORE STARTING THE GENERATOR

BEFORE STARTING THE GENERATOR,

REVIEW SAFETY SECTION STARTING ON

PAGE 5.

Before attempting to start the generator,

verify the following:

•The engine is lled with engine oil. See Checking Engine

Oil on page 24.

•The generator is situated in a proper location (Location

Selection on page 15).

•The generator is on a dry surface (Weather and Dry

Surface on page 15).

•All loads are disconnected from the generator (No

Connected Loads on page 15).

•The generator is properly grounded the Generator

(page 15).

DANGER

Never use the generator in a location

that is wet or damp. Never expose the

generator to rain, snow, water spray or

standing water while in use. Protect the

generator from all hazardous weather

conditions. Moisture or ice can cause a

short circuit or other malfunction in the

electrical circuit.

Never operate the generator in an

enclosed area. Engine exhaust contains

carbon monoxide. Only operate the

generator outside and away from

windows, doors and vents.

NOTICE

The engine is equipped with a low oil shutdown switch. If the

oil level becomes low, the engine may shut down and not start

until the oil is lled to the proper level. Poor oil quality may

interfere with the operation of the low oil shutdown switch.

The owner of the generator is responsible to ensure the proper

oil level is maintained during the operation of the generator.

Failure to maintain the proper oil level can result in engine

damage.

NOTICE

Let engine stabilize and warm up for a few minutes before

adding load.

OPERATION

ADDING PETROL TO THE FUEL TANK

REQUIRED PETROL

Only use petrol that meets the

following requirements:

• Unleaded petrol only

• Petrol with maximum 10% ethanol added

• Petrol with an 87 octane rating or higher

FILLING THE FUEL TANK

Follow the steps below to fill the

fuel tank:

1. Shut off the generator.

2. Allow the generator to cool down so all surface

areas of the muffler and engine are cool to the

touch.

3. Move the generator to a flat surface.

4. Clean area around the fuel cap.

5. Remove the fuel cap by rotating

counterclockwise.

6. Slowly add petrol into the fuel tank. Be very

careful not to overfill the tank. The petrol level

should NOT be higher than the filler neck (see

Figure 7).

7. Install the fuel cap by rotating clockwise

until you hear a click, indicating the cap is

completely installed.

Never refuel the generator while the engine is

running.

Always turn the engine off and allow the

generator to cool before refueling.

WARNING

! ! Before attempting to start the generator,

verify the following:

• The engine is filled with engine oil.

• The generator is situated in a proper location.

• The generator is on a dry surface.

• All loads are disconnected from the generator.

• The generator is properly grounded.

Avoid prolonged skin contact with petrol. Avoid

prolonged breathing of petrol vapors.

CAUTION

! !

Never use the generator in a location that is

wet or damp. Never expose the generator

to rain, snow, water spray or standing water

while in use. Protect the generator from all

hazardous weather conditions. Moisture or ice

can cause a short circuit or other malfunction in

the electrical circuit.

Never operate the generator in an enclosed

area. Engine exhaust contains carbon

monoxide. Only operate the generator outside

and away from windows, doors and vents.

The engine is equipped with a low oil shutdown

switch. If the oil level becomes low, the engine

may shut down and not start until the oil is

filled to the proper level. Poor oil quality may

interfere with the operation of the low oil

shutdown switch.

The owner of the generator is responsible

to ensure the proper oil level is maintained

during the operation of the generator. Failure

to maintain the proper oil level can result in

engine damage.

Let engine stabilize and warm up for a few

minutes before adding load.

DANGER

! !

NOTICE

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GENERATOR OPERATOR’S MANUAL

This generator is fitted with an RCD and if being connected to a transfer switch, the RCD must be

disconnected by a licensed electrician.

Disconnecting the RCD does not then protect the user if being used as a portable power source and

it is highly recommended that the RCD be reconnected after being removed from the main transfer

switch.

CAUTION

! !

OPERATION

GENERATOR SET UP

PLANNING THE POWER LOAD

Plan your power load so that you do not exceed the generator’s rated capacity. To calculate the

running and starting wattage requirements for the devices you will be powering.

SET UP AS A PORTABLE POWER SOURCE

This generator is designed to provide up to its max power (in watts) of electrical power. When

using the generator as a portable power source, you can plug electric devices and appliances

directly into the generator’s electrical outlets. This generator is equipped with two SAA approved IP66

rated socket outlets.

Make sure you plug each electrical device/appliance into the correct generator outlet based on the

device’s plug configuration and voltage/amperage rating. Never exceed the amperage rating of an outlet.

Note: You must not overload the generator. Overloading may cause serious damage to the generator

and attached electrical devices.

SET UP AS A BUILDING BACKUP

For this application, you must arrange for a licensed electrician to connect the generator to your buildings

electrical system via the installation of an approved transfer switch. The transfer switch must be installed

in accordance with building electrical code and guidelines supplied by your power company.

A transfer switch does the following:

• Safely connects the generator to your building’s electrical system by isolating your generator from

your utility company’s power lines.

• Connects your generator to a critical subset of your building’s circuits that are needed for emergency

power needs.

A transfer switch must be installed in order to isolate your generator from the utility power grid. If

your generator is NOT properly isolated from the utility system, serious hazards will arise.

When your generator is running, it’s output will back feed into the utility power line and transformer

that are normally used to provide you with power. The transformer will step up the current to the

normal line voltage. An unsuspecting utility line worker working on what he thinks is a deactivated

line could be electrocuted.

If your generator is connected (running or not) when utility power is restored, your generator will be

destroyed. It could also explode or cause fire.

DANGER

! !

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GENERATOR OPERATOR’S MANUAL

There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations,

local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified

electrician, electrical inspector, or the local agency having jurisdiction.

• In some areas, generators are required to be registered with local utility companies.

• If the generator is used at a construction site, there may be additional regulations that must be

observed.

NOTICE

GROUNDING THE GENERATOR

Standard generators are protected by electrical separators. This equipment has a thermic protection

device and/or a magne to thermic device to protect against a surge of current, overloading and short-

circuiting. In these cases the Generator should under no circumstances be earthed using the terminal

“PE” or with any other part of the generator.

If a licensed electrician installs the generator with a connection to your building’s electrical circuit for use

as a back-up power system, grounding may alternatively be completed through the building’s grounding

system. Ask your electrician.

In order to avoid electrical accidents, all connections to the distribution panel must be carried out by

qualified technicians. Incorrect connections can harm people and damage the generator.

Operating the generator when it’s not properly grounded can result in electrical shock.

Grounding is not required when the generator is used as a portable power source. Below grounding

method is only needed by a qualified electrician if not connecting through your building’s electrical

system.

WARNING

! !

WARNING

! !

OPERATION

Regardless of whether you use your generator as a back-up power source connected to a building

or as a portable power source, you must not overload the generator. Overloading may cause serious

damage to the generator and attached electrical devices.

If your generator will be connected to your building’s electrical system, it MUST ALWAYS be

isolated from the utility power grid with a approved transfer switch installed by a licensed electrician

in compliance with all applicable building and electrical codes and in accordance with guidelines

supplied by your power company. continued over page

NOTICE

12 www.itmtools.com.au

GENERATOR OPERATOR’S MANUAL

If the generator is not grounded through your building’s electricial system, follow the procedure below.

This precedure can only be carried out by a licensed electrician.

1. Drive a 3/4" or 1" copper pipe or rod into the

ground close to the generator. The pipe/rod

must penetrate moist earth - the depth required

will be dictated by local soil conditions.

2. Connect an approved ground clamp to the pipe.

3. Run a 10 gauge wire from the clamp to the

generator grounding post located on the rear of

the generator head.

4. Do not connect the generator grounding post

to a water pipe or a ground used by a radio

system.

15OPERATING MANUAL

! WARNING

Grounding is not required when the generator is used as a portable power source.

Below grounding method is only needed by a qualied electrician if not connecting

through your building’s electrical system.

If the generator is not grounded through your building’s electricial system, follow the

procedure below. This precedure can only be carried out by a licensed electrician.

1. Drive a ¾” or 1” copper pipe or rod into

the ground close to the generator. The

pipe/rod must penetrate moist earth – the

depth required will be dictated by local soil

conditions.

2. Connect an approved ground clamp to the

pipe.

3. Run a 10 gauge wire from the clamp to the

generator grounding post located on the

rear of the generator head.

4. Do not connect the generator grounding

post to a water pipe or a ground used by a radio system.

IMPORTANT!

This generator is tted with a MEN link cable, the neutral is internally bonded to the generator

earth. When a licensed electrician is installing the generator to a building to be used as backup

power the MEN must be removed. The MEN link is located is underneath the alternator end cap

which is labeled to indicate its location. The MEN link cable clearly labeled as “MEN Link”.

EXTENSION CORDS

Extension cords may be used to power devices that are located at a distance from the

generator. However, use only Australian approved outdoor - rated, grounded extension cords.

Locate the generator in a convenient place and where possible avoid long extension leads and

possible damage to leads by pedestrian or vehicular trac.

Extension leads should be heavy duty with at least 1mm, of appropriate current rating and

in any case not less than 1mm cross-section of conductor and must incorporate an earthing

conductor to ensure that there is no voltage dierence between the generater set and any

equipment powered by the generater.

The electrical continuity of the ‘earthing’ core should be checked periodically from pin to socket

to ensure continued electrical safety. Some electrical appliances, e.g. portable drills, are marked

or ‘double insulated’, in which case there should not be an earthing conductor in

its mains lead (even though it may have a three-pin plug).

! WARNING

Use of under sized extension cords can cause electric shock, re, or damage to

connected devices. All extension and appliance cords must be in good condition

and not worn, bare, frayed, or otherwise damaged.

Use of damaged electric cords can cause electric shock or re. Note: If an extension

cord becomes hot to the touch, it is overloaded or damaged and must be replaced.

SABER is NOT responsible for damage or injury resulting from customer use of

inadequate extension cords.

SELECT A SUITABLE SITE

22 GENERATOR

CHARGING A BATTERY

! WARNING

It’s suggested to wear protective clothing, gloves and eye protection when handling

and working with lead acid batteries. For operators with pacemakers or similar

medical devices and conditions, it is recommended not to attempt the following

procedure.

DO NOT attempt to charge a lead acid battery in conned areas. Ensure the charging

process takes place in an area where there is fresh air circulating.

Remove the battery from the car, boat or any other device. The battery MUST be totally isolated

from any other circuitry. After connection to the battery, RECHECK to ensure the connections

are as below.

•Insert the T-shaped plug to the generator with the opposite end of the cable connected to

the battery.

•Connect the positive (+) alligator clip (red) to the positive (+) terminal on the battery.

•Connect the negative (-) alligator clip (black) to the negative (-) terminal on the battery.

•Start the generator and allow the generator to warm up.

•Check the DC reset button is pressed inward (ON position).

The battery charging process is now underway. To disconnect the battery on charge, STOP THE

ENGINE and remove the plug from the generator socket and disconnect the cable clamps from

the battery, in that order.

Note: The battery charging socket should only be used while the 240V AC outlets are NOT

being used. If the battery was originally in a low level of charge, the battery will take many

hours to recharge fully. The time frame will depend on the size of the battery.

! WARNING

DO NOT leave battery charging unattended. Charging battery for a long period of

time can damage the battery once the battery is full.

Over-charging or over-heating can damage the battery, the water and acid solution

can boil and leak out of the battery.

DC OVERLOAD CUT OUT

CAUTION Exceeding the rated capacity of your generator can result in serious damage to your

generator and connected apparatus.

•The DC circuit has a circuit breaker to protect the generator from over loading.

•If the circuit breaker trips, unplug all electrical apparatus from the generator.

•Let the overload cut out switch to cool down and remove the load from the DC circuit.

•Press the DC reset button.

•When re-connecting the DC load, reduce the load which previously overloaded the

generator.

Note: Some batteries, depending on the size, battery condition or level or charge may exceed

the max current output from the generator and trip the overload DC circuit breaker.

EXTENSION CORDS

Use of under sized extension cords can cause electric shock, fire, or damage to connected devices.

All extension and appliance cords must be in good condition and not worn, bare, frayed, or otherwise

damaged.

Use of damaged electric cords can cause electric shock or fire. Note: If an extension cord becomes

hot to the touch, it is overloaded or damaged and must be replaced. ITM is NOT responsible for

damage or injury resulting from customer use of inadequate extension cords.

WARNING

! !

Extension cords may be used to power devices that are located at a distance from the generator.

However, use only Australian approved outdoor - rated, grounded extension cords. Locate the generator

in a convenient place and where possible avoid long extension leads and possible damage to leads by

pedestrian or vehicular traffic.

Extension leads should be heavy duty with at least 1mm, of appropriate current rating and in any case

not less than 1mm cross-section of conductor and must incorporate an earthing conductor to ensure that

there is no voltage difference between the generator set and any equipment powered by the generator.

The electrical continuity of the ‘earthing’ core should be checked periodically from pin to socket to

ensure continued electrical safety. Some electrical appliances, e.g. portable drills, are marked or ‘double

insulated’, in which case there should not be an earthing conductor in its mains lead (even though it may

have a three-pin plug).

OPERATION

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GENERATOR OPERATOR’S MANUAL

ENGINE SPEED

CONNECTING LOADS

240V AC CONNECTION

OPERATION

Engine speed has been factory set to provide safe operation. Tampering with the engine speed

adjustment could result in overheating of attachments and could cause a fire.

You will want to be careful when connecting loads so as not to overload the generator, especially if you

are powering devices with motors that require a higher starting power load.Instructions are provided

below for connecting loads when you are using the generator as a portable power source.

Connect electrical loads one at a time according to the following instructions:

1. Allow engine to reach operating speed by allowing it to warm up for approximately 5 minutes before

connecting electrical devices.

2. Check the devices to be connected is turned “OFF” before connecting them to the AC outlets.

3. After engine is warmed up, begin by connecting the items that require the highest wattage first.

The recommended sequence is as follows:

1. Connect items with motors such as refrigerators, freezers, air conditioners, or small hand tools, one

at a time.

2. Let each motor stabilize before connecting the next device.

3. Connect any lights you are planning on powering.

4. Connect voltage sensitive equipment such as electronics via surge protectors. Plug devices such as

TV’s, computers and microwaves into a voltage surge protector, then plug the surge protector into

the generator.

The generator must be run at the correct speed in order to produce the proper electrical voltage

and frequency. Failure to do so could result in damage to equipment powered by the generator and

possible injury to the individual.

Do not overload generator. Make sure that combined starting and running loads do not exceed rated

capacity of generator. Overloading the generator can cause damage to the generator and attached

electrical devices and may result in fire.

WARNING

! !

WARNING

! !

14 www.itmtools.com.au

GENERATOR OPERATOR’S MANUAL

OPERATION

NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS

DAMAGE to the generator and attached electrical devices and may result in fire.

WARNING

! !

Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage

of the devices you will be powering. Before using your generator, determine the running and starting

wattage requirements of all the electrical devices you will be powering simultaneously. Following below 4

simple steps and example on the right:

Step 1. Determine the tools and appliances you want to power at the

same time

Step 2. List the start up and running power usage (Watts) for each

product

Step 3. Add the total power usage and add 10% as a safety net

Step 4. Choose a generator with a rated and maximum power that equals or exceeds your totals. In

this case a generator with a rated power of at least 3108W and a maximum power output greater than

7233W would be required.

STARTING POWER CONSUMPTION

Electronic appliances and brushed motors generally will not draw more than running Watts at start up.

Induction motors in equipment like air conditioners, welders, water pumps and compressors can draw

2 to 5 times their running power to start. Please consult your equipment’s rating label, manual or the

manufacturer to confirm specific requirement. If only the running wattage is given on the nameplate for

a device with an electric motor, the starting wattage can be approximated to be three to five times the

running wattage. Estimates for the running wattage requirements for common devices are listed in the

table below. Guidance for starting wattages is provided in the table’s footnotes. To size your generator

correctly you need to use Watts - here are some useful calculations:

Watts = Volts x Amps Example 240 Volts x 5 Amps = 1200 Watts

(a) Hard-starting motors require 3-5 times the rated running watts (b) For extremely hard to start loads such as air conditioners and

air compressors, consult the equipment dealer to determine max wattage.

DEVICE RUNNING

WATTS

DEVICE RUNNING

WATTS

DEVICE RUNNING

WATTS

Air conditioner (12.000

BTU)

1700 (a,b) Freezer 800 (b) Oven 4500

Battery charger (20 Amp) 500 Hair dryer 1200 Paint sprayer, Airless (1/3

HP)

600 (a)

Belt sander (3”) 1000 Hand drill (1”) 1100 Paint sprayer, Airless

(handheld)

150

Chain saw 1200 Hand drill (3/8”) 500 Radio 200

Circular saw(6½”) 2000 (a,b) Hedge trimmer 450 Refrigerator 600 (b)

Coffee maker 1800 (a,b) Home computer 150 Slow cooker 200

Compressor (1 HP) 1400 (a,b) Kettle 2400 Submersible pump (1-1/2 HP) 2800 (a)

Compressor (3/4 HP) 1800 (a) Jet pump 800 (a) Submersible pump (1 HP) 2000 (a)

Compressor (1/2 HP) 1400 (a) Lawn mower 1200 Submersible pump (1/2 HP) 1500 (a)

Curling iron 700 Light bulb (100 Watt) 100 Sump pump 600 (a)

Dishwasher 1200 Microwave oven 700 Television 500

Edge trimmer 500 Milk cooler 1100 (a) Toaster 1000

Electric nail gun 1200 Oil burner on furnace 300 Vacuum cleaner 250

Electric range (1 element) 1500 Oil-red space heater (140,000 Btu) 400 Water heater 3000

Electric skillet 1250 Oil-red space heater (85,000 Btu) 225

Furnace fan (1/3 HP) 1200 (a) Oil-red space heater (30,000 Btu) 150

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GENERATOR OPERATOR’S MANUAL

STARTING THE ENGINE

OPERATION

PRE-OPERATION CHECK

1. Check that all shields and covers are in place, and all nuts, bolts, and screws are tightened.

2. Check the engine oil level. Add oil if low. Do not overfill. Running the engine without sufficient oil

can cause unrepairable damage.

3. Check fuel level. Add fuel if low (fresh unleaded RON 91 recommended). Starting with a full tank

will help to eliminate or reduce operating interruptions for refuelling. Check fuel system components

and lines for signs of leak.

19OPERATING MANUAL

STARTING THE ENGINE

PRE-OPERATION CHECK

1. Check that all shields and covers are in place, and all nuts, bolts, and screws are tightened.

2. Check the engine oil level. Add oil if low. Do not overll. Running the engine without

sucient oil can cause unrepairable damage.

3. Check fuel level. Add fuel if low (fresh unleaded RON 91 recommended). Starting with a

full tank will help to eliminate or reduce operating interruptions for refuelling. Check fuel

system components and lines for signs of leak.

4. Check battery level. If the battery level is unable to start the engine, charge it with the 12V

charger included in the package.

RCBO SAFETY CHECK

1. Lift the clear plastic cover on the panel to access the RCBO safety toggle switch.

2. TEST THE RCBO before each and every use by pressing the test button. This will

immediately cause the unit to trip and shut o the power to the socket outlets. If the RCBO

fails to switch OFF after depressing the test button (marked “T”) then the unit should be

immediately taken out of service, tagged appropriately and not be used until repaired by a

qualied electrician.

3. RESET THE RCBO by simply switching the RCBO toggle to ON position.

4. The unit is now ready for operation. No electrical device should be operated or plugged in

prior to checking for physical damage and testing of the RCBO.

Fill oil to the

bottom lip of the

dipstick

18 GENERATOR

! WARNING

NEVER exceed the rated wattage capacity of your generator. OVERLOADING may

cause SERIOUS DAMAGE to the generator and attached electrical devices and may

result in re.

Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering.

Before using your generator, determine the running and starting wattage requirements of all the electrical devices you will be powering

simultaneously. Following below 4 simple steps and example on the right:

Step 1. Determine the tools and appliances you want to power at the same time

Step 2. List the start up and running power usage (Watts) for each product

Step 3. Add the total power usage and add 10% as a safety net

Step 4. Choose a generator with a rated and maximum power that equals or exceeds your totals

In this case a generator with a rated power of at least 3108W and a maximum power output

greater than 7233W would be required.

STARTING POWER CONSUMPTION

Electronic appliances and brushed motors generally will not draw more than running Watts

at start up. Induction motors in equipment like air conditioners, welders, water pumps and

compressors can draw 2 to 5 times their running power to start. Please consult your equipment’s rating label, manual or the manufacturer to

conrm specic requirement. If only the running wattage is given on the nameplate for a device with an electric motor, the starting wattage

can be approximated to be three to ve times the running wattage. Estimates for the running wattage requirements for common devices are

listed in the table below. Guidance for starting wattages is provided in the table’s footnotes.

To size your generator correctly you need to use Watts - here are some useful calculations: Watts = Volts x Amps Example 240 Volts x 5 Amps =

1200 Watts

DEVICE RUNNING WATTS DEVICE RUNNING WATTS

Air conditioner (12.000 BTU) 1700 (a,b) Jet pump 800 (a)

Battery charger (20 Amp) 500 Lawn mower 1200

Belt sander (3”) 1000 Light bulb (100 Watt) 100

Chain saw 1200 Microwave oven 700

Circular saw(6½”) 2000 (a,b) Milk cooler 1100 (a)

Coee maker 1800 (a,b) Oil burner on furnace 300

Compressor (1 HP) 1400 (a,b) Oil-red space heater (140,000 Btu) 400

Compressor (3/4 HP) 1800 (a) Oil-red space heater (85,000 Btu) 225

Compressor (1/2 HP) 1400 (a) Oil-red space heater (30,000 Btu) 150

Curling iron 700 Oven 4500

Dishwasher 1200 Paint sprayer, Airless (1/3 HP) 600 (a)

Edge trimmer 500 Paint sprayer, Airless (handheld) 150

Electric nail gun 1200 Radio 200

Electric range (1 element) 1500 Refrigerator 600 (b)

Electric skillet 1250 Slow cooker 200

Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a)

Freezer 800 (b) Submersible pump (1 HP) 2000 (a)

Hair dryer 1200 Submersible pump (1/2 HP) 1500 (a)

Hand drill (1”) 1100 Sump pump 600 (a)

Hand drill (3/8”) 500 Television 500

Hedge trimmer 450 Toaster 1000

Home computer 150 Vacuum cleaner 250

Kettle 2400 Water heater 3000

(a) Hard-starting motors require 3-5 times the rated running watts (b) For extremely hard to start loads such as air conditioners and air

compressors, consult the equipment dealer to determine max wattage