SIP Medusa Trade T2401 User manual

28
FOR HELP OR ADVISE ON THIS PRODUCT PLEASE CALL OUR
CUSTOMER SERVICE HELP LINE : 01509 500400
Please dispose of packaging for this product in a responsible
manner. It is suitable for recycling. Help to protect the
environment, take the packaging to the local amenity tip and
place into the appropriate recycling bin.
Never dispose of electrical equipment or batteries in with
your domestic waste. If your supplier offers a disposal facil-
ity please use it or alternatively use a recognised re-cycling
agent. This will allow the recycling of raw materials and help
protect the environment.
REF: 070207
1
Please read and fully understand the instruc-
tions in this manual before operation. Keep
this manual safe for future reference.
Medusa
Trade T2401
Generator

2 27
DECLARATION OF CONFORMITY
WE
SIP LTD
GELDERS HALL ROAD
SHEPSHED
LOUGHBOROUGH
LEICESTERSHIRE
LE12 9NH
Declare that the
Medusa Trade T2401 generator SIP pt No: 03921
Complies with the following EEC Directives their supporting Statutory
Instruments and the relevant standard where applicable:
98/37/EC Machinery Directive
EN 12601:2001
73/23/EEC Low Voltage Directive
As amended EN 12601:2001
by 93/68/EEC
89/336/EEC EMC Directive
EN 55014-1/A2:2002
EN 55012:2002
EN 61000-6-1:2001
2000/14/EEC Noise Directive
2002/96/EC WEEE Directive.
As amended by
2003/108/EC
2002/95/EC ROHS Directive.
Signed:
Mr Marco Ippaso
Joint Managing Director
Date: 6th September 2006

26
NOTES
3
CONTENTS
Page 3 Contents
Page 4 General safety instructions
Page 6 Specific Safety Instructions
Page 7 Technical specifications
Page 7 Accessories
Page 8 Getting to know your generator
Page 9 Safety symbols
Page 9 Guarantee
Page 10 Electrical connections
Page 11 Operating instructions
Page 17 Maintenance
Page 19 Troubleshooting
Page 20 Exploded diagram / Parts List (crankcase assembly).
Page 21 Exploded diagram / Parts List (cylinder head / cover assembly).
Page 22 Exploded diagram / Parts List (crankshaft / piston assembly).
Page 22 Exploded diagram / Parts List (starting assembly).
Page 23 Exploded diagram / Parts List (air filter / exhaust assembly).
Page 24 Exploded diagram / Parts List (fuel supply system).
Page 25 Exploded diagram / Parts List (frame / control panel/ alternator).
Page 26 Wiring Diagram
Page 27 Declaration of conformity

4
1. Before starting or servicing any generator, read and understand all instructions.
Failure to follow safety precautions or instructions can cause equipment damage
and/or serious personal injury. Retain all manuals for future reference.
2. Never use this generator for any application other than that specified by the
manufacturer. Never operate this generator under conditions not approved by the
manufacturer.
3. Never attempt to modify this generator to perform in any manner not intended
by the manufacturer.
4. Use only products and parts recommended by the manufacturer For mainte-
nance and repairs.
5. Be sure that the generator is properly grounded to an external ground path prior
to operation. Refer to the section entitled “ Grounding Instructions “ for proper
grounding procedures.
6. Be sure that the generator is operated only by persons who have read and who
understand these instructions.
7. Be sure that the generator is placed on a flat level surface prior to and during
operation. The generator must not slide or shift during operation.
8. Keep all persons away from the generator during operation.
9. Do not allow persons wearing loose clothing or jewellery to start or operate the
generator. Loose clothing or jewellery may become entangled in moving compo-
nents, causing equipment damage and/or personal injury.
10. Be aware of moving parts and hot surfaces that occur during normal operation
of this generator.
11. Be sure all devices are switched off prior to connecting them to the generator.
12. Be sure that all tools and appliances are in good working order and are cor-
rectly grounded.
13. Only use devices that have standard three pin plugs. If an extension cord is
used, be sure that it has three pin plug/socket for proper grounding.
14. Never operate the generator with damaged, broken or missing parts, or with
any guards or covers removed.
15. Do not refill the fuel tank while the engine is running.
16. Be careful to prevent fuel spillage during refills.
17. Be sure the fuel tank cap is securely in place before starting the engine.
18. Allow engine to cool for at least two minutes before refuelling.
19. Never refuel whilst smoking or in the vicinity of a naked flame.
20. Take care not to spill any fuel on the engine, exhaust or any part of the gen-
erator.
GENERAL SAFETY INSTRUCTIONS
Caution: NEVER OPERATE OR ALLOW ANYONE TO OPERATE
THIS GENERATOR UNTIL THIS MANUAL HAS BEEN READ AND
UNDERSTOOD BY ALL.
25
EXPLODED DIAGRAM / PARTS LIST
7. Frame / Control Panel / Alternator.
Ref No. Description Qty Ref No. Description Qty
1. Frame 1 9. Washer (8 mm) 1
2. Anti Vibration Mounts 4 10. Tie Rod 1
3. Flanged Nut (M8) 8 11. End Cover 1
4. Control Board 1 12. Capacitor 1
5. Control Panel 1 13. Alternator Through Bolts 4
6. Flanged Bolt (M6 x 12) 4 14. Cover 1
7. Screw (M6 x 12) 4 15. Rear Cover 1
8. Alternator 1 16. Bolt 7

24
EXPLODED DIAGRAM / PARTS LIST
Ref No. Description Qty Ref No. Description Qty
1. Pipe Clamp 2 11. Fuel Filter 1
2. Fuel Pipe (4.5 x 190) 1 12. Fuel Tank 1
3. Fuel Cock Assembly 1 13. Bolt (M6) 1
4. Bolt (M6 x 20) 4 14. Lock Bolt 1
5. Washer (6 mm) 4 15. Regulating Arm 1
6. Anti Vibration Pad 4 16. Back Spring 1
7. Fuel Gauge Gasket 1 17. Fine Regulating Spring 1
8. Screw (m5 x 8) 2 18. Pull Rod 1
9. Fuel Gauge 1 19. Regulating Control Assembly 1
10. Fuel Tank Cap 1 20. Bolt (M6 x 12) 2
6. Fuel Supply System.
5
21. Should any fuel make contact with your clothes; change and wash them imme-
diately.
22. If any fuel makes contact with your skin wash with soap and water immediately.
23. If you swallow any fuel, inhale any vapour or allow contact with your eyes,
seek medical attention immediately.
24. Be sure to store petrol in clean containers that do not contain water, dirt or rust
because this will reduce the life of the engine.
25. Never operate this generator in an explosive atmosphere or near any flammable
sources.
26. Always operate this generator in a well ventilated area to reduce the risk of suf-
focation.
27. Shut off the generator engine and disconnect the spark plug wire before per-
forming any service or maintenance to the unit.
28. Do not operate this generator on wet surfaces or in the rain.
29. Do not operate the generator or any electrical items with wet hands.
30. Never drag the generator with power cords or by any means to move it; only
move the generator with the carrying handles.
31. Never cover the generator or restrict the exhaust or air flow in any way.
32. Always ensure that the generator is at least 1m (3ft) away from any walls or
buildings to allow correct air flow.
33. Do not connect this generator to a commercial power supply.
34. Do not connect this generator in parallel with any other generator.
GENERAL SAFETY INSTRUCTIONS….cont

6
Electrical current from the generator may "back feed" into the home's electrical system.
It could cause damage or fire to the building, the generator as well as anything con-
nected to it.
Should a generator be required to be connected to any electrical system, it must be
installed by a suitably qualified electrician who can warn you of any dangers that may
occur.
Incorrectly installed generators can also cause personal injury. For example, if a power
company employee is working on an electrical line believing it to be "dead" and current
created by the generator is in the line, shock or electrocution may occur.
The key to better safeguard against these dangers is professional installation by a
qualified electrician and the installation of a generator transfer switch.
Keep in mind a generator burns fuel and must be run in a well ventilated area, it must
not be run in a garage or other outbuilding.
Cords used to connect the generator to the lights and appliances must be correctly
sized to prevent overheating or damage to the equipment as well, again if you are un-
sure ask a suitably qualified electrician.
Grounding instructions:
1. Use the ground terminal (see picture above) on the generator to connect the
unit to a suitable ground source. Securely fasten the end terminal of the ground
wire to the ground terminal on the generator.
2. The ground wire should be made of more than 0.75 square millimetre wire. Too
thin wire may not provide an adequate ground path.
3. The other end of the ground wire must be securely fastened to an approved
ground source. Refer to the local regulations for ground source information. If not
sure of regulations or procedures, obtain assistance from a qualified (licensed or
certified ) electrical technician
SPECIFIC SAFETY INSTRUCTIONS
Caution: Never attempt to connect the generator directly to the electri-
cal system of any building / structure which is connected to the main grid.
Earth point
23
EXPLODED DIAGRAM / PARTS LIST
Ref No. Description Qty Ref No. Description Qty
1. Air Filter Assembly 1 9. Muffler 1
2. Choke Lever 1 10. Nut (M8) 2
3. Gasket 1 11. Exhaust Gasket 1
4. Carburettor 1 12. Cover 1
5. Gasket 1 13. Bolt (M6 x 12) 6
6. Connecting Block 1 14. Bracket 1
7. Inlet Gasket 1 15. Bracket support 1
8. Nut (M6) 4 16. Bolt (M8 x 16) 3
5. Air Filter / Exhaust assembly.

22
EXPLODED DIAGRAM / PARTS LIST
3. Crankshaft / Piston assembly.
Ref No. Description Qty.
1. Piston Ring Set 1
2. Cir-clip 2
3. Piston 1
4. Pin 1
5. Con-Rod Assembly 1
6. Camshaft 1
7. Crankshaft 1
8. Flywheel 1
9. Flywheel Fan 1
10. Starting Flange 1
11. Nut (M14 x 1.5) 1
Ref No. Description Qty.
1. Grommet 1
2. Fan Cover 1
3. Bolt (M6 x 12) 5
4. Bolt (M6 x 8) 4
5. Recoil Starter Assembly 1
6. Clip 1
7. Cover 1
8. Diode 1
9. Oil Sensor 1
10. Bolt (M6 x 14) 2
11. Bolt (M6 x 22) 2
12. Ignition Coil 1
13. Spark Plug (F6RTCU) 1
4. Starting Assembly.
7
Name Medusa Trade T2401
Part number 03921
Engine type 4-stroke, single cylinder, air
cooled, OHV
Engine size 163 cc
Fuel type Unleaded petrol
Rated output (peak) 2400 watts
Rated output (continuous) 2000 watts
AC voltage 230v / 50hz
AC current 8.6 amps (constant)
DC voltage 12v
DC current 8.3 amp
DC output charge capacity 40 A.h battery
Fuel tank capacity 15 litres
Sound power (LwA) 90 dB(A)
Sound pressure 70 dB(A)
Main Generator Unit
Instruction Manual
Box Spanner (for spark plug removal)
12V DC Output lead
If any of these items are missing contact your distributor immedi-
ately.
TECHNICAL SPECIFICATIONS
ACCESSORIES

8
GETTING TO KNOW YOUR GENERATOR
A
B
C
D E F G
H
I
J
K
LMN
Ref: Description Ref: Description
A. Recoil Starter H. AC ~ Overload
B. Air Filter Assembly I. DC Overload
C. Fuel On / Off Tap J. 12v DC Outlet
D. Fuel Cap K. AC ~ 230v Outlets
E. Engine On / Off Switch L. Earth Point
F. Power Indicator Light M. Oil Filler Cap
G. Output Volt meter N. Crankcase Drain Valve
21
EXPLODED DIAGRAM / PARTS LIST
2. Cylinder head / Cylinder cover assembly.
Ref No. Description Qty Ref No. Description Qty
1. Bolt M6 x 12 6 11. Stud 2
2. Cylinder Head Cover 1 12. Cylinder Head Assembly 1
3. Gasket 1 13. Cylinder Head Gasket 1
4. Valve Rocker Assembly 1 14. Set Pin 2
5. Push Guide 1 15. Exhaust Valve 1
6. Cap 1 16. Intake Valve 1
7. Exhaust Spring Seat 1 17. Tappet 2
8. Intake Spring Seat 1 18. Pusher 2
9. Valve Spring 2 19. Stud 2
10. Bolt M8 x 60 4 20. Cover 1

20
EXPLODED DIAGRAM / PARTS LIST
Ref No. Description Qty Ref No. Description Qty
1. Drain Plug 2 9. Snap Ring 1
2. Washer 2 10. Drive Gear Assembly 1
3. Crankcase Oil Seal 2 11. Dipstick inc. O ring 1
4. Crankcase 1 12. Crankcase cover 1
5. Regulating Sway Bar 1 13. Crankcase Gasket 1
6. Washer 1 14. Set Pin (8 14) 2
7. Split Pin 1 15. Bearing (6205) 2
8. Regulating Shaft 1 16. Bolt (M8 x 32 mm) 6
1. Crankcase assembly.
9
Guarantee:
This generator is covered by a 12 month parts and labour warranty covering failure
due to manufacturers defects. This does not cover failure due to misuse or operating
the machine outside the scope of this manual.
In the unlikely event of warranty claims, contact your distributor or contact our help
line on the back page of this manual. Proof of purchase will be required before any
warranty can be honoured.
These generators are powered by air-cooled four-stroke OHV engines and designed to
produce an output rated at 230V +/- 10% / 50hz +/- 3%. The engine is self governed
to give an output of up to 2000 watts (2400 peak) .
A 12V DC output is provided to a enable a battery of up to 40 ah to be charged.
Note: The DC output will not cut out once the battery is charged and so should not be
left unattended for extended periods.
During normal operation certain parts of this generator will be-
come hot. ALWAYS stay alert and be aware of hot components /
surfaces. Allow the engine to cool before attempting to move,
clean or maintain the generator.
SAFETY SYMBOLS
There is a very real risk of electric shock if this generator is not used in
the correct manner. NEVER Use the generator or anything connected to
it in wet conditions.
The fuel used to run this generator (unleaded petrol) is highly flamma-
ble. Never re-fuel the generator whilst it is still running. Store un used
fuel safely and away from children.
Caution: Exhaust fumes are poisonous. Do not operate this generator in
enclosed areas.
GUARANTEE

10
ELECTRICAL CONNECTIONS
Connecting tools etc to the generator:
This generator is fitted with 2 standard 13 amp type sockets. Inspect them, as well as
anything to be connected to the generator, to ensure that no damage is present before
every use. If any damage is visible have the socket / equipment inspected / repaired
by a suitably qualified person.
The wires in the plug are coloured in the following way:
Yellow / green Earth
Blue Neutral
Brown Live
As the colours of the wires may not correspond with the markings in your plug, pro-
ceed as follows: The wire which is coloured blue, must be connected to the terminal
marked with N or coloured black. The wire which is coloured brown, must be con-
nected to the terminal, which is marked L or coloured red. The wire which is coloured
yellow / green should be connected to the terminal which is coloured the same or
marked
Always secure the wires in the plug terminal carefully and tightly. Secure the cable in
the cord grip carefully.
Note: Always make sure that the equipment to be connected is of the cor-
rect voltage (230 v ~ 50hz) and can tolerate fluctuations of 230v +/- 10%
50 hz +/- 3%, if in doubt consult the equipment manufacturer.
Note: If an extension lead is required in order to reach the generator; en-
sure that this too is rated for the correct voltage and current.
Note: The cross section of the extension lead should be checked so that it
is of sufficient size so as to reduce the chances of voltage drops.
Warning: Never connect live or neutral wires to the earth terminal of the
plug. Only fit an approved plug with the correct rated fuse for the equip-
ment. If in doubt consult a qualified electrician.
19
(1) Valve clearance: Intake; 0.15mm - 0.20mm, Exhaust; 0.2 - 0.30mm.
(2) Service more frequently if used in dusty conditions.
Spark plug gap: 0.7mm - 0.8mm (0.028” - 0.031”).
Standard plug type BR5ES (NGK).
TROUBLESHOOTING
Symptom Possible cause (s) Corrective action
No output from the AC ~
sockets.
1. Engine speed is too low.
2. Open or short circuit in wiring.
3. Open or shorted rotor or stator
windings.
4. Open rectifier.
1. Adjust the engine speed.
2. Check wiring and connections.
3. Test winding and replace as
necessary.
4. Test and replace as necessary.
Low output voltage with
no load applied.
1. Engine speed is too slow.
2. Faulty rectifier.
3. Faulty capacitor.
4. Open or shorted rotor or stator
windings.
5. Alternator de-magnetised.
1. Adjust the engine speed.
2. Test and replace as necessary.
3. Test and replace as necessary.
4. Test winding and replace as
necessary.
5. Re-magnetise the alternator.
High output voltage With
no load applied.
1. Faulty capacitor.
2. Engine speed is too fast.
1. Test and replace as necessary.
2. Adjust the engine speed.
Low output voltage whilst
under load.
1. Faulty rectifier.
2. Engine speed is too slow.
3. Excessive load applied.
1. Test and replace as necessary.
2. Adjust the engine speed.
3. Reduce the load.
Erratic output voltage. 1. Dirty / corroded or loose wir-
ing / connector (s).
2. Un-balanced load applied.
1. Check wiring loom and repair /
replace as necessary.
2. Remove all loads; apply each
load individually to determine
which is causing the erratic func-
tion.
Noisy operation. 1. Loose bolts.
2. Short circuit in generator field
or load.
3. Faulty bearing (s).
1. Check and tighten a necessary.
2. Test winding resistance, re-
place as necessary, test applied
loads for short circuit.
3. Locate faulty bearing and re-
place.
Engine will not run. 1. No fuel.
2. Fuel tap in the off position /
faulty.
3. Engine switch is in the “off”
position.
4. Spark plug is dirty / has incor-
rect gap.
5. Low compression inside the
cylinder.
1. Check fuel level and fill as nec-
essary.
2. Check the tap and replace as
necessary.
3. Reset the switch to the “on”
position.
4. Clean the spark plug, adjust
the gap or replace as necessary.
5. Check for leakage from the
cylinder.

18
MAINTENANCE….cont
Cleaning the air filter:
To clean air filter:
•Un-clip the front cover of the air filter; 1 clip at the top and 1 at the bottom (fig.
A).
•Remove the front cover to expose the filter element (Fig. B).
•Pull out the element (Fig. C) and carefully clean it with a mild solvent; squeeze
to remove the excess.
•Pour a small amount of motor oil over the filter element; squeeze to remove the
excess.
Fig. A Fig. B
Fig. C
11
PORTABLE GENERATORS:
FROM COLD STARTING; Allow the generator to reach its operating temperature by
starting and running it with no load connected for approximately 5 minutes.
To avoid damage; always have an additional load plugged into the generator if solid
state equipment (such as television sets) is used. A power line conditioner may be nec-
essary in some applications. i.e. with computers. For further details contact your appli-
ance manufacturer.
IMPORTANT NOTICE: PLEASE READ AND FULLY UNDERSTAND
BEFORE USE.
OPERATING INSTRUCTIONS
CAUTION:
Operating voltages and frequency requirements of all electronic equip-
ment should be checked prior to plugging them into this generator.
Damage may result if the equipment is not designed to operate within
a +/- 10% voltage variation, and +/- 3% frequency variation from the
generator rating.
CAUTION:
Always ensure that the all of the fuel is drained from the tank prior to
transportation. For safety reasons most carriers will not transport such
equipment with fuel still in the tank.
CAUTION:
BEFORE APPLYING ANY LOAD ALWAYS CHECK WITH THE
MANUFACTURER OF THE APPLIANCE TO BE POWERED THAT IT
IS SUITABLE FOR USE WITH A NON-REGULATED GENERATOR
OUTPUT.
Pre operation checks:

12
Pre operation checks….cont:
This generator is shipped from the factory without oil in the engine crank-
case.
•Engine oil is a major factor affecting engine performance and service life. Non-
detergent oils and vegetable oils are not recommended.
•Use premium quality 4-stroke motor oil.
•Do not add commercial additives to the recommended oil and do not mix petrol
with the oil.
•SAE 10W-30 is recommended for general, all-temperature use.
•Other viscosities shown in the chart (below left) may be used when the average
ambient temperature in your area is within the indicated range.
•Check the oil level in the crankcase of the engine before each start.
•The oil level should be positioned between the lower and upper level marks on
the oil filler cap (oil gauge) (see above right).
The Oil capacity is approximately 0.5L.
Filling the crankcase with oil / Checking the oil level:
OPERATING INSTRUCTIONS….cont
CAUTION: Before you operate the generator ALWAYS check that no
damage is present and that everything that should be, is tight and secure.
17
MAINTENANCE
Part Action Before
each use
First
month or
20 hours
Every 3
months
or 50
hours
Every 6
months
or 100
hours
Every 12
months
or 300
hours
Spark
plug
Check con-
dition /gap.
•
Oil Check the
oil level /
condition.
•
Valve
clearance
Check gaps. •
Fuel line Check fuel
line for
cracks /
damage.
•
Exhaust
system
Check for
leaks.
•
Carburet-
tor
Check
choke lever
operation.
•
Cooling
fan
Check for
damage.
•
Starting
system
Check for
correct op-
eration.
•
Air filter Check for
contamina-
tion.
•
Head
bolts etc
Check and
tighten.
•
Caution: Any repairs / adjustments should only be attempted by a suitably
qualified person; if you are unsure call the help-line number on the back
page for your nearest technician

16
Note: BREAKING THE ENGINE IN.
The first 25 hours of operation is considered the break-in period for the en-
gine. During this time operate at less than 75% of the load limit.
Step 5:
Once the engine is running and warm enough,
push the choke lever to the run position
To turn the generator off:
•Remove any loads that may be connected.
•Turn the engine run switch to the off (0) position.
•Turn the fuel tap to the off position.
OPERATING INSTRUCTIONS….cont
Note: Allow the engine to run with no load applied for a few minutes to al-
low the engine to come up to running temperature.
13
Note: Be sure oil level is maintained. Failure to do so will invali-
date any warranty you may have.
Caution: Petrol is highly flammable; never re-fuel the genera-
tor whilst it is running. Do not re-fuel near naked flames or
other possible ignition sources.
OPERATING INSTRUCTIONS….cont
filler cap
(oil gauge)
To fill the crankcase with oil proceed as follows:
•Ensure that the generator is on a flat level surface.
•Remove the filler cap (oil gauge) by turning it anti-clockwise.
•Slowly pour the oil into the crankcase.
•Check the oil level by pushing the filler cap back into its hole up to the bottom of
the threads (do not screw the cap in).
•Once the oil level is between the upper and the lower marks on the oil gauge
(see page 12), replace it and turn clockwise to fully tighten.
The oil level should be checked every 8 hours or daily.
The oil should be changed after the first 8 hours of operation; thereafter change the
oil after 50 hours of operation or less if the generator is operated under constant
heavy loads or in high ambient temperatures.
Fuelling / re-fuelling the generator:

14
The amount of fuel can be checked by the fuel meter
on the top of the tank.
⇒When the tank is empty; the window will be all
white (see top right).
⇒As the tank is filled; the orange indicator will
come across the indicator window (see bottom
right).
Fuel filter
Petrol is highly flammable. Never re-
fuel the generator whilst it is still running;
allow it to cool for a few minutes and avoid
other ignition sources that may be present.
Only re-fuel in a well ventilated area as
petrol fumes can be dangerous if inhaled
or ignited.
To re-fuel the generator:
1. Remove the fuel cap.
2. Carefully pour the petrol into the tank to the desired level and replace the fuel cap.
3. Remove any spilt fuel from the generator and surrounding area to avoid any risk of
fire.
The generator should now be ready to run.
OPERATING INSTRUCTIONS….cont
Never overfill the fuel tank; leave a small
air gap at the top.
Fuel capacity: approx. 15 Litres.
Note: When re-fuelling always ensure that the fuel filter (supplied) is in
place as foreign matter or debris will cause damage to the engine and
greatly reduce the life of the generator.
15
Starting the engine:
Step 1:
Turn the main engine switch to the on (1) position.
Step 2:
Turn the fuel tap to the on position.
Step 3:
Turn the choke lever to the “choke” position.
Note: The choke may not be needed if the engine is
already warm.
Step 4:
Slowly pull the recoil start cord until it engages,
then pull sharply until the engine starts.
Note: it may take a few sharp pulls to get the en-
gine started.
OPERATING INSTRUCTIONS….cont
Caution: Never start the engine with any load connected to the generator.