Medusa Compact T3001 Generator

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1 Please dispose of packaging for the 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 facility please use it or alternatively use a recognised re-cycling agent. This will allow the recycling of raw materials and help protect the environment. Medusa Compact T3001 Generator FOR HELP OR ADVICE ON THIS PRODUCT PLEASE CONTACT YOUR DISTRIBUTOR, OR SIP DIRECTLY ON: TEL: or Ref: Please read and fully understand the instructions in this manual before operation. Keep this manual safe for future reference. 1

2 DECLARATION OF CONFORMITY Declaration of Conformity We SIP (Industrial Products) Ltd Gelders Hall Road Shepshed Loughborough Leicestershire LE12 9NH England As the manufacturer's authorised representative within the EC declare that the Medusa Trade T3001 Generator - SIP Part No Conforms to the requirements of the following directive(s), as indicated. 2006/42/EC 2006/95/EC 2004/108/EC 97/68/EC As Amended By 2012/46/EU 2000/14/EC As Amended By 2005/88/EC 2011/65/EU Machinery Directive Low Voltage Directive EMC Directive Emissions (NRMM) Directive Noise Directive RoHS Directive And the relevant standard(s), including: EN 12601:2010 EN 55012:2007+A1 EN :2007 EN ISO 3744:1995 ISO :1998 Signed:... Mr P. Ippaso - Managing Director - SIP (Industrial Products) Ltd Date: 13/05/

3 NOTES 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 Notes Page 27 Declaration of conformity 26 3

4 GENERAL SAFETY INSTRUCTIONS Caution: NEVER OPERATE OR ALLOW ANYONE TO OPERATE THIS GENER- ATOR UNTIL THIS MANUAL HAS BEEN READ AND UNDERSTOOD BY ALL. EXPLODED DRAWING / PARTS LIST 7. FRAME / CONTROL PANEL / ALTERNATOR 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 maintenance 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 components, 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 correctly 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 generator. Ref No. Description Qty Ref No. Description Qty 1. Frame 1 9. Washer (8 mm) 1 2. Anti Vibration Mounts Tie Rod 1 3. Flanged Nut (M8) End Cover 1 4. Control Board Capacitor 1 5. Control Panel Alternator Through Bolts 4 6. Flanged Bolt (M6 x 12) Cover 1 7. Screw (M6 x 12) Rear Cover 1 8. Alternator Bolt

5 EXPLODED DRAWING / PARTS LIST 6. FUEL SUPPLY SYSTEM GENERAL SAFETY INSTRUCTIONS.cont 21. Should any fuel make contact with your clothes; change and wash them immediately. 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 suffocation. 27. Shut off the generator engine and disconnect the spark plug wire before performing 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. Ref No. Description Qty Ref No. Description Qty 1. Pipe Clamp Fuel Filter 1 2. Fuel Pipe (4.5 x 190) Fuel Tank 1 3. Fuel Cock Assembly Bolt (M6) 1 4. Bolt (M6 x 20) Lock Bolt 1 5. Washer (6 mm) Regulating Arm 1 6. Anti Vibration Pad Back Spring 1 7. Fuel Gauge Gasket Fine Regulating Spring 1 8. Screw (m5 x 8) Pull Rod 1 9. Fuel Gauge Regulating Control Assembly Fuel Tank Cap Bolt (M6 x 12)

6 SPECIFIC SAFETY INSTRUCTIONS Caution: Never attempt to connect the generator directly to the electrical system of any building / structure which is connected to the main grid. EXPLODED DRAWING / PARTS LIST 5. AIR FILTER / EXHAUST ASSEMBLY 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 connected 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 unsure 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 6 Earth point Ref No. Description Qty Ref No. Description Qty 1. Air Filter Assembly 1 9. Muffler 1 2. Choke Lever Nut (M8) 2 3. Gasket Exhaust Gasket 1 4. Carburettor Cover 1 5. Gasket Bolt (M6 x 12) 6 6. Connecting Block Bracket 1 7. Inlet Gasket Bracket support 1 8. Nut (M6) Bolt (M8 x 16) 3 23

7 EXPLODED DRAWING / PARTS LIST TECHNICAL SPECIFICATIONS 3. CRANKSHAFT / PISTON ASSEMBLY 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 Bolt (M6 x 14) Bolt (M6 x 22) Ignition Coil Spark Plug (F6RTCU) 1 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 Starting Flange Nut (M14 x 1.5) 1 4. STARTING ASSEMBLY Name Main Generator Unit Instruction Manual Box Spanner (for spark plug removal) 12V DC Output lead Medusa Trade T3001 Part number Engine type Engine size Fuel type Rated output (peak) Rated output (continuous) AC voltage DC voltage DC current DC output charge capacity Fuel tank capacity Performance class Sound power (LwA) Protection Class ACCESSORIES 4-stroke, single cylinder, air cooled, OHV 210 cc Unleaded petrol 3000 watts 2600 watts 230v / 110v ~ 50hz 12v 8.3 amp 40 A.h battery 15 litres If any of these items are missing contact your distributor immediately. G1 96 db(a) IP23M 22 7

8 GETTING TO KNOW YOUR GENERATOR EXPLODED DRAWING / PARTS LIST D E F G 2. CYLINDER HEAD / CYLINDER COVER ASSEMBLY C H I B J A K L N M 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 Outlet E. Engine On / Off Switch L. AC ~ 110v Outlet F. Power Indicator Light M. Earth Point G. Output Volt meter N. Oil Filler Cap Ref No. Description Qty Ref No. Description Qty 1. Bolt M6 x Stud 2 2. Cylinder Head Cover Cylinder Head Assembly 1 3. Gasket Cylinder Head Gasket 1 4. Valve Rocker Assembly Set Pin 2 5. Push Guide Exhaust Valve 1 6. Cap Intake Valve 1 7. Exhaust Spring Seat Tappet 2 8. Intake Spring Seat Pusher 2 9. Valve Spring Stud Bolt M8 x Cover

9 EXPLODED DRAWING / PARTS LIST SAFETY INSTRUCTIONS 1. CRANKCASE ASSEMBLY During normal operation certain parts of this generator will become 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. 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 flammable. 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 Ref No. Description Qty Ref No. Description Qty 1. Drain Plug 2 9. Snap Ring 1 2. Washer Drive Gear Assembly 1 3. Crankcase Oil Seal Dipstick inc. O ring 1 4. Crankcase Crankcase cover 1 5. Regulating Sway Bar Crankcase Gasket 1 6. Washer Bearing (6205) 2 7. Split Pin Set pin (8 14) 2 8. Regulating Shaft Bolt (M8 x 32 mm) 6 20 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. 9

10 ELECTRICAL CONNECTIONS Connecting tools etc. to the generator: This generator is fitted with 2 standard 16 amp type sockets (1 x 110V & 1 x 230V~). 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 Blue Brown Earth Neutral Live As the colours of the wires may not correspond with the markings in your plug, proceed 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 connected 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. 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 equipment. If in doubt consult a qualified electrician. Note: Always make sure that the equipment to be connected is of the correct 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; ensure 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. TROUBLESHOOTING Symptom Possible cause (s) Corrective action No output from the AC ~ sockets. Low output voltage with no load applied. High output voltage With no load applied. Low output voltage whilst under load. 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. Engine speed is too slow. 2. Faulty rectifier. 3. Faulty capacitor. 4. Open or shorted rotor or stator windings. 5. Alternator de-magnetised. 1. Faulty capacitor. 2. Engine speed is too fast. 1. Faulty rectifier. 2. Engine speed is too slow. 3. Excessive load applied. Erratic output voltage. 1. Dirty / corroded or loose wiring / connector (s). 2. Un-balanced load applied. Noisy operation. Engine will not run. 1. Loose bolts. 2. Short circuit in generator field or load. 3. Faulty bearing (s). 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 incorrect gap. 5. Low compression inside the cylinder. (1) Valve clearance: Intake; 0.15mm mm, Exhaust; mm. (2) Service more frequently if used in dusty conditions. Spark plug gap: 0.7mm - 0.8mm ( ). Standard plug type BR5ES (NGK). 1. Adjust the engine speed. 2. Check wiring and connections. 3. Test winding and replace as necessary. 4. Test and replace as necessary. 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. 1. Test and replace as necessary. 2. Adjust the engine speed. 1. Test and replace as necessary. 2. Adjust the engine speed. 3. Reduce the load. 1. Check wiring loom and repair / replace as necessary. 2. Remove all loads; apply each load individually to determine which is causing the erratic function. 1. Check and tighten a necessary. 2. Test winding resistance, replace as necessary, test applied loads for short circuit. 3. Locate faulty bearing and replace. 1. Check fuel level and fill as necessary. 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

11 MAINTENANCE.cont CLEANING THE AIR FILTER To clean the air filter element: OPERATING INSTRUCTIONS PRE OPERATION CHECKS IMPORTANT NOTICE: PLEASE READ AND FULLY UNDERSTAND BEFORE USE. 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. Follow these instructions in reverse to refit the element / cover etc. 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. CAUTION: Operating voltages and frequency requirements of all electronic equipment 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. Fig. A Fig. B 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 necessary in some applications. i.e. with computers. For further details contact your appliance manufacturer. 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. Fig. C 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

12 OPERATING INSTRUCTIONS.cont MAINTENANCE CAUTION: Before you operate the generator ALWAYS check that no damage is present and that everything that should be, is tight and secure. 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 FILLING THE CRANKCASE WITH OIL / CHECKING THE OIL LEVEL This generator is shipped from the factory without oil in the engine crankcase. Engine oil is a major factor affecting engine performance and service life. Nondetergent 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. Spark plug Oil Valve clearance Fuel line Exhaust system Check condition /gap. Check the oil level / condition. Check gaps. Check fuel line for cracks / damage. Check for leaks. Carburettor Check choke lever operation. Cooling fan Starting system Check for damage. Check for correct operation. 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. Air filter Head bolts etc Check for contamination. 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

13 OPERATING INSTRUCTIONS.cont OPERATING INSTRUCTIONS.cont Step 5: Note: Be sure oil level is maintained. Failure to do so will invalidate any warranty you may have. Once the engine is running and warm enough, push the choke lever to the run position. filler cap (oil gauge) Note: Allow the engine to run with no load applied for a few minutes to allow the engine to come up to running temperature. Note: Breaking the engine in. The first 25 hours of operation is considered the break-in period for the engine. During this time operate at less than 75% of the load limit. 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. 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 Caution: Petrol is highly flammable; never re-fuel the generator whilst it is running. Do not re-fuel near naked flames or other possible ignition sources

14 OPERATING INSTRUCTIONS.cont 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). Never overfill the fuel tank; leave a small air gap at the top. Fuel capacity: approx. 15 Litres. 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. OPERATING INSTRUCTIONS.cont STARTING THE ENGINE Step 1: Caution: Never start the engine with any load connected to the generator. Turn the main engine switch to the on (1) position. Engine ON/OFF switch Step 2: Turn the fuel tap to the on position. 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. Step 3: Turn the choke lever to the choke position. Fuel filter Note: The choke may not be needed if the engine is already warm. 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. 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 engine started

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