Operation and Maintenance Manual: 40kVA 3 Phase Diesel Generator

Ravenstor Road
Wirksworth
Derbyshire
DE4 4FY
ENGLAND
Sales Tel: +44 (0) 1629 824 284

Sales Fax: +44 (0) 1629 824 613
Email: info@hgigenerators.com
sales@hgigenerators.com
Website: www.hgigenerators.com
Operation and Maintenance Manual
40kVA 3 Phase Diesel Generator

Build No: HRD400T-AD-SP, HRD400T-AP-S
Publication No: 498-1073
© Harrington Generators International Limited

All rights reserved. No part of this publication may be reproduced in any material form (including photography or storing in
any medium by electronic means or other) without the written permission of the copyright holder except in accordance with
the provisions of the Copyright, Designs and Patents Act 1988.
Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to
Harrington Generators International Limited at the address above.
Any reference to trademarked product names used within this publication is owned by their respective companies.
Harrington Generators International Limited reserves the right to change the contents of this document without prior notice.
Change Control
Date Version Author Reason for change

Jan 17 Prov MC Draft for Review by A Palmer
Jan 17 A MC Updated and released following review
Sept 17 B MC Warranty Iss I, Wiring Schematic Updated,
Declaration of Conformance Update
Harrington Generators International Contents
Contents
INTRODUCTION ............................................................................................. 1
Declaration of Conformity ............................................................................ 2
Data Plate ....................................................................................................... 3
SPECIFICATION ............................................................................................. 4
SAFETY .......................................................................................................... 8
A few words about safety ............................................................................. 8
Operator Responsibility ................................................................................ 8
Precautions .................................................................................................... 8
Electrical Safety ........................................................................................... 17
Lifting and Moving....................................................................................... 17
Hazards to Health ........................................................................................ 18
OPERATION ................................................................................................. 20
Generator Layout......................................................................................... 20
Output Panel (Typical)................................................................................. 20
Control Panel (Typical)................................................................................ 21
Terminal Output Pod ................................................................................... 23
Remote Connection Socket ........................................................................ 23
Installations.................................................................................................. 23
Pre-Operation Checks ................................................................................. 24
Starting ........................................................................................................ 26
Stopping ....................................................................................................... 27
Shutdown Protections ................................................................................ 27
HRD Diesel Generator 498-1073

Contents Harrington Generators International
FAULT FINDING ........................................................................................... 28

Engine Fails to Start .................................................................................... 28
Engine Starts but then Stops ..................................................................... 29
Other Generator Faults ............................................................................... 29
No Electrical Output .................................................................................... 30
MAINTENANCE ............................................................................................ 31
Maintenance Schedule ................................................................................ 31
Maintenance Safety ..................................................................................... 32
Maintenance Routine .................................................................................. 32
PARTS AND SERVICE ................................................................................. 39
Contact Details ............................................................................................ 39
Warranty Statement ..................................................................................... 39
Functional Spares ....................................................................................... 39
TRANSPORTATION AND STORAGE .......................................................... 40
WIRING ......................................................................................................... 41
WD-HRD400T1-AD-SP ................................................................................. 41
WD-HRD400T1-AP-S.................................................................................... 42
DATASHEETS AND SPECIFICATIONS ....................................................... 43
Vigirex Adjustable RCD............................................................................... 43
MANUFACTURER’S SERVICE AND USER GUIDES LINKS ...................... 44
Perkins Operators and Maintenance Manual ........................................... 44
Deep Sea 7310 User Guide ........................................................................ 44
Sincro SK160 User Manual ........................................................................ 44
498-1073 HRD Diesel Generator

40kVA
1500 RPM
Diesel Generator
*Illustration only
Harrington Generators International Introduction
Introduction
Thank you for purchasing a quality generator, carefully Every effort has been made to ensure that the
manufactured to the highest standards by one of information given in this manual is correct at the time of
the World’s leading generator manufacturers, HGI publishing. However, it may be superseded due to our
International. continuous improvement processes.
The HRD Events 1500rpm range of generators have HGI Limited manufacture a wide range of generating
been specifically designed for the most demanding sets and accessories, including generators approved
jobs and ultimate long-term performance. The design for use in Telecoms, Railway and Military applications
encompasses a single sided service access, large fully where quality and reliability are essential. These
bunded fuel tank and noise and vibration attenuation. include:
These facilitate ease of operation and maintenance,
and considerate working environment. • Petrol Generators
• Petrol Welders
Before operating the generator, read this manual and • Gas & Water ECE3 (TIN12)
make sure that all personnel who operate the equipment • Trackside
have access to the manual (and any additional • Tractor PTO
documentation supplied with it) and are fully aware with • Super Silent Diesel Generators (3000rpm)
the operation and functionality of the generator prior to • Super Silent Diesel Generators (1500rpm
use. • Automatic Mains Failure Control Systems
• Welf-Air Generators
Misuse of the instructions may invalidate the product • Compact Welf-Air Generators
warranty and lead to potential accidents. • Super Compact Welf-Air Generators
• Super Silent Diesel Welders
This manual is an essential part of the generator and
should be kept with the generator at all times. There For further information call us now on :
is a convenient document holder located on the inside
of the service side door to store the manual and other +44 (0)1629 824 284
documents in. Make sure that the manual is available to
all users throughout the generator’s life-span. our experienced and knowledgeable sales staff will be
happy to advise you and provide a detailed quotation
If in doubt about the functionality of any of the equipment for all your generator requirements or visit our website
within this document please contact HGI or seek other www.HGIgenerators.com
expert advice.
HRD Diesel Generator 1 498-1073

Certification Harrington Generators International
In accordance with ISO/IEC 17050-1:2010 Conformity Assessment - Suppliers’ Declaration of Conformity

Declaration of Conformity
EU DECLARATION OF CONFORMITY
We: HGI Harrington Generators International Ltd.
Ravenstor Road Wirksworth, Derbyshire DE4 4FY
Declare that Equipment : Diesel Generator
Model name /Number : HRD400 range
Electrical Power Pel : 32 kW e
Measured Sound Power Level: 88 dB(A)
Guaranteed Sound Power Level 90 dB(A)
Conforms to the protection requirements of the following EC Council Directives:
2006/42/EC Machinery Directive
2014/35/EU Low Voltage Directive
2014/30/EU EMC Directive
2000/14/EC Noise Emission in the Environment by Equipment for use Outdoors Directive Annex VIII
And has been designed and manufactured to the following Standards:

BS5000 Part 3 Rotating electrical machines of particular types or for particular applications. Generators to be
driven by reciprocating internal combustion engines.
EN60204-1 Safety of machinery. Electrical equipment of machines. General requirements
EN12601 Reciprocating internal combustion engine driven generating sets. Safety
BS EN 61000-6-1 EMC. Generic standards. Immunity for residential, commercial and light-industrial envi-
ronments.
BS EN 61000-6-2 EMC. Generic standards. Immunity for industrial environments
BS EN 61000-6-3 EMC. Generic standards. Emission standard for residential, commercial and light-industrial
environments
BS EN 61000-6-4 EMC. Generic standards. Emission standard for industrial environments
BS ISO 3744 Acoustics. Determination of sound power levels of noise sources using sound pressure.
Notified Body for 2000/14/EC Noise Emis- HORIBA MIRA UK

sion in the Environment by Equipment for Watling Street
use Outdoors Directive Nuneaton
Warwickshire CV10 0UT
Notified Body Number : 0888
I declare that as the authorised representative, the above information in relation to the supply and manufacture of
this product is in conformity with the stated standards and other related documents following the provision of the
above EC Directives.
Signed: Date: 20/06/17
Printed: D.C.Coulton Position: Head of Systems
498-1073 2 HRD Diesel Generator

Harrington Generators International Certification
Data Plate
Each generator supplied will have a data plate attached to the canopy of the set. Below is an exemplar data
plate with notes to help understand the terminology and information supplied on the data plate of your machine.
Harrington Generators International Ltd

Ravenstor Road Wirksworth Derbyshire, DE4 4FY
Tel: +44(0)1629 824284 Fax +44(0)1629 824613
www.hgigenerators.com info@harringtongen.co.uk
Generating Set ISO 8528 PRP Class G2

Model: HRD Serial No: 70183626
Build Code: HRD400T-AP-S Year of Manufacture: 2016
Electrical Power: 40kVA / 32.0kW PF: 0.8 Frequency: 50 Hz
Voltage Volts: 400V 230V 110V
Current Amps: 58 3off 58
Max Altitude: 1000m Max Ambient Temperature: 40°C
Weight Fuel Tank Empty / Full: 1150 / 1308 kgs
Fuel: Diesel Engine Speed: 1500 rpm Sound Level LwA 90 dB(A)
This is the “CE” mark and indicates that the generator complies
with the European Directives as detailed in the Certificate of
Conformance
Model: This is the build model of the machine e.g. HRD
This is a code number, which tells us the exact build standard to
Build Code: which the generator was built. This is important when ordering
spares or contacting our Technical Help Line
This is a unique number, which identifies the generator. This is
Serial No: important when ordering spares or contacting our Technical Help
Line
Year of Manufacture: Year of Manufacture e.g. 2016
Electrical Power: This is the power in kVA and kW, the power factor and frequency
Voltage: This is the nominal voltage e.g. 400V, 230V or 110V
Current Amps: This is the nominal electrical current of the principal voltage
G2 provides steady state voltage deviation ± 2.5% for use with
Performance Class
standard electronic equipment.
This is the level of sound produced by the generator when running at
Sound Pressure Level: 75% auxiliary power. This generator complies with the CE Directive
on sound levels
Maximum Altitude / These are given and if the generator is to be used at higher altitudes
Ambient Temperature: or at higher ambient temperatures HGI should be consulted
Weight: This provides weights including and excluding a full tank of fuel
Only commercially available diesel fuel can be used. If a special
Fuel: type of diesel is to be used please consult HGI first to discuss its
suitability

Specification Harrington Generators International
Specification
General Specification
Canopied set with integral bunded 190 Litre fuel tank.
With local or remote starting using DeepSea 7310 module.
400V 3 Phase 230V Single Phase Fixed Voltage Output
Model HRD400T-AD-SP HRD400T-AP-S

400V 3 Ph 40.0 kVA/32.0 kW PF 0.8
Rated Output:
3x 230V 1 Ph 13.3 kVA/10.6kW PF 0.8 on different phases
Temperature range: -10°C ( without additional starting aids ) to +40°C
Environment:
Relative Humidity: 10% to 90%
Prime Power “PRP” Electrical Class G2
Performance Class ISO 8528:
Steady state voltage: +/- 2.5% Frequency droop < 5%
Dimensions L x W x H Approx. 2120 x 950 x 1643mm
Operating Clearance: Minimum of 1000mm all around and above.
Access for Servicing: Access of 850 mm required both sides to open doors.
Weight – fuel tank empty: Approx. 1150 kgs
Weight – fuel tank full: Approx. 1308 kgs
Fuel: Commercial diesel with up to 10% bio-diesel .i.e. B10 blend.
Output
Output Type: Fixed Voltages
Frequency: 50 Hz
Voltages: 230/400V
Starting System: Electric Start via Control Module as local or remote start.
Output Configuration: Sockets and Terminal Output
230V 6 x 32A 230V 3 x 32A
Socket Arrangement:
400V 1 x 32A 400V 1 x 63A, 1x 125A
Terminals: 400V 3 Phase terminals in terminal compartment.
3 pole main MCB
3 pole main MCB
Output Protection: RCDs on Sockets ≤ 32A
RCDs on Sockets ≤ 32A
Adjustable RCD on Sockets ≥ 32A
Generator Control System
Starting Method: Electric Start via Control Module as local or remote start.
Control Module: Deep Sea Electronics 7310 Engine and Generator Control Module
Engine Protection: High engine temperature, Low Oil Pressure, Over/Under speed
Engine Monitoring: Low Fuel, RPM, battery voltage, hours run.
Electrical Protection: Over/Under Voltage and Frequency
Electrical Monitoring: Volts, Frequency, Amps
Alarms: Bund Alarm
Safety Switch: Fitted to door over terminal compartment.
Battery
Battery: 12V DC maintenance free 70 Ah.
Battery isolator: Fitted inside canopy.
Cont....

Harrington Generators International Specification
Engine
Engine model: Perkins 1103C-33TG3
Service Interval: 500 hours
Engine Speed: 1500 rpm
Engine Cooling: Water cooled
Starting Method: Electric Start
Specific Fuel Consumption 219 g / kW h
Electrical System: 12V DC system
HGI hve received a FLEX certificate and use a European Stage 2 engine
Emissions Level:
for Stage 3A mobile applications
Lowest starting temperature: -10°C with standard glow plugs without extra aids
Alternator
Alternator Model: Sincro SK160-WB SAE 3
Alternator Performance: 40kVA 4-pole Class H with AVR
Fuel System
Fuel Tank Capacity: 190 litres
Fuel Tank Bund: Yes
Run Time at 100 load – approx. 18.0 hrs Consumption at 100% load 10.7 l / hr
Run Time at 75% load - approx. 22.0 hrs Consumption at 75% load 8.6 / hr
Run Time at 50% load - approx. 36.0 hrs Consumption at 50% load 5.3 l / hr
Canopy
Canopy Type: Canopied set with integral bunded fuel tank.
Base: Structural Steel.
Material:
Canopy: Smooth galvanised steel.
Base: Iron phosphate pre-treatment, zinc rich primer then architectural
grade powder coating.
Finish:
Canopy: Iron phosphate pre-treatment then architectural grade powder
coating.
Base: RAL9005 Jet Black (Semi-Gloss)
Colour: Canopy: RAL5013 Cobalt Blue* or RAL9016 Artic White
Panel: RAL5013 Cobalt Blue* or RAL9005 Jet Black
Doors: Hinged doors
Catches have keyed locks (but locks do not have to be used).
Catches:
Catches have hasps for padlocks.
With forklift from below using integral fork lift pods.
Lifting: With single point lifting beam with concealed lifting eye.
With slings below and a spreader frame above.
Fixing Down: Through skid tubes underneath the base.
Towing: Towing tube for final adjustment on site
Other: Remote Start and USB Controller Program Socket on Control Panel.
*Older Models

Specification Harrington Generators International
*Illustration Only Typical of

all models

Harrington Generators International Specification
*Illustration Only Typical of

all models

Safety Harrington Generators International
Safety Operator Responsibility
• Know how to stop the generator quickly in case of

A few words about safety
emergency.
Your safety and the safety of others are very important • Understand the use of all generator controls,
and using this generator safely is an important output sockets, and connections.
responsibility. • Be sure that anyone who operates the generator
receives proper instruction.
HGI have designed this generator to give safe and
dependable service if operated in accordance to If you have any doubts about the safe operation of
these instructions. Please ensure that you read this this equipment, please contact HGI or a competent
owner’s manual and understand the functionality of operator or qualified technician.
the generator before using. You can help prevent
accidents and harm to yourself and nearby personnel
Precautions
by being familiar with the controls, and by observing
safe operating procedures.
The generator can constitute a hazard to users,
The warnings and safety instructions appearing in this nearby personnel and property unless the following
guide are not meant to cover every eventuality and precautions are observed during operation:
hazards associated with operating or maintaining a
generator. You must use your own good judgement,
care and caution. • Ensure that you know how to stop the engine in
an emergency.
This is the safety alert symbol. It is used to • Exhaust fumes are poisonous and can kill.
alert you to potential hazards. Obey all safety • Ensure that the area surrounding the machine
messages that follow this symbol to avoid possible has no restrictions that would prevent an ad-
injury or death. equate flow of clean, ambient air.
• Fuel is highly flammable, when refuelling:
here are four types of safety alert messages used in • Do not run the engine.
this manual: • Do not smoke.
• Avoid overfilling the fuel tank.
• Wipe up any fuel spilt on the machine and
DANGER move the equipment away from the area where
Danger refers to immediate hazards which WILL fuel has been spilt.
result in severe personal injury or death. • Parts of the engine, and particularly the exhaust
system will get very hot during use, and will
remain hot for some time after the generator has
WARNING
stopped.
Warning refers to a hazard or unsafe method or • Do not use the equipment with loose or missing
practice which CAN result in severe personal injury
components or guards.
or possible death.
• Additional care should be applied if using the
generator in damp or wet conditions.
CAUTION • Regularly inspect the condition of trailing cables
Caution refers to a hazard or unsafe method or and integrity of connectors. Only use correctly
practice which CAN result in personal injury. rated cable and standard plugs of suitable
capacity for the application.
NOTICE • During servicing, follow HSE recommendations
regarding the handling and disposal of
Notice refers to a method or practice which can
result in product damage, or to draw attention to contaminated oil products.
additional information or explanations.

Harrington Generators International Safety
The generator is fitted with a number of labels that alert the user to the safe operation and safety requirements.
A full explanation of these is contained here. If any of the labels are missing or unreadable a duplicate should be
obtained and fitted.
Label Part No, Qty, Location Description

Pt No. 499-945-002 CAUTION HOT EXHAUST
Qty 1 The exhaust pipe is shielded as much as

is practical but the final outlet is hot.
Roof Panel Side Next to Exhaust
Pt No. 499-945-003 DIESEL FUEL ONLY
Qty 1 This generator must only be filled with

commercial diesel fuel containing up to
On Filler Cap 10% bio-fuel. If special grades of diesel
e.g. 100% Bio-Diesel are to be used
consult HGI first to discuss its suitability.
Pt No. 499-945-004 INLET AND OUTLET VENTS TO BE

KEPT CLEAR
Qty 2
These must be kept free from obstructions
Next to Inlet Outlet Vents to allow a free flow of cooling air or the
engine and alternator could over heat.
Pt No. 499-945-005 NO STEP
Qty 1 The generator should not be used as a

step.
On Roof
Pt No. 499-945-015 FUSE IDENTIFICATION
Qty 1 Informational label advising the Identity of

the Fuse.
On Control Panel 3 phase
Generators
Pt No. 499-945-008 EARTH POINT
Qty 1 An M10 brass earth stud is supplied next

to the output sockets for the external earth
Inside Terminal Pod connection.

Pt No. 499-945-009 FORK LIFT POINT
Qty 4 The generator can be lifted from the sides

or from the front or rear using a fork lift
Above Fork Lift Pockets truck with correctly spaced forks.
It is intended that when lifting from the

sides, that one fork passes through the
part of the frame that forms a loop and
foot.
Pt No. 499-945-010 CHECK ENGINE OIL LEVEL DAILY
Qty 1 The oil level should be seen on the oil dip

stick as per the diagram on the label.
On Lifting Beam Dipstick Side
Pt No 499-945-011 ELECTRICITY IS DANGEROUS
On side panel: If in doubt about the correct use consult

a qualified electrician or contact our
Technical Help Line.
Pt No 499-945-011 CHECK ENGINE OIL LEVEL DAILY
On side panel: Check the oil level each day and top up if
necessary to the top mark given in the oil
level diagram above. If oil consumption is
excessive investigate further.
Pt No 499-945-011 LOW LOAD RUNNING:
On side panel: Operating the generator at low load

levels for extended periods can result
in high levels of carbon build up in the
engine and exhaust system which can
lead to excessive smoking, reduced
efficiency and overheating.
If the generator is not required switch it

off and avoid running with light or no load
wherever possible. Also see Maintenance
Section.
Pt No 499-945-011 ENSURE Generator IS AT LEAST 1
METRE AWAY FROM BUILDINGS,
On side panel: VEHICLES etc. WHEN IN USE.
This is to ensure a free flow of cooling

air to the generator and that the exhaust
from the generator does not affect other
items.

Pt No 499-945-011 KEEP FLAMMABLE MATERIAL AWAY

FROM THE GENERATOR
On side panel:
The exhaust and some surfaces are hot
and flammable material should not be
allowed near the generator.
Pt No 499-945-011 OPERATE ONLY IN WELL VENTILATED
AREAS. EXHAUST FUMES CAN KILL.
On side panel:
Generally the generator will be installed
outside. If the generator is to be installed
inside a building please consult the
Technical Help Line.
Pt No 499-945-011 STOP ENGINE AND ALLOW TO COOL
DOWN FOR A FEW MINUTES BEFORE
On side panel: REFUELLING.
In addition DO NOT SMOKE while

refuelling, use a funnel or similar to
prevent fuel spillage, avoid over filling the
fuel tank and wipe up any spilt fuel. Avoid
contact of fuel with skin.
Pt No 499-945-011 DO NOT SPILL FUEL ONTO HOT
SURFACES
On side panel:
The exhaust outlet and the area around it
in particular are hot.
Pt No 499-945-011 DO NOT ADJUST THE SPEED OF THE

ENGINE UNLESS YOU HAVE BEEN
On side panel: TRAINED TO DO SO
If the generator is not producing enough

power for the application or you suspect
a problem do not adjust the engine
speed. This may damage the engine,
alternator and any power equipment
plugged into the generator.
Pt No 499-945-011 KEEP CHILDREN AT A SAFE
DISTANCE FROM THE EQUIPMENT
On side panel: AND DO NOT ALLOW THEM TO
OPERATE IT
This is a mandatory Health and Safety

Requirement for this equipment. A
version with a key switch is available if
required.

Pt No 499-945-011 DO NOT OPERATE WITH ANY

COVERS OPEN
On side panel:
If covers are open (or missing) the
generator will exceed the European
Noise Regulations and the cooling of the
engine and alternator will be affected
which could cause damage to them.
Pt No 499-945-011 ONLY OPERATE ON A LEVEL
SURFACE
On side panel:
Generally the generator will only be
used on a level surface. It can be
used on small inclines as given in the
Specification as given previously but
additional precautions may be needed to
stop it moving due to vibration.
Pt No 499-945-011 AN EARTH LEAKAGE TRIP (RCD) IS
FITTED THE GENERATOR’S BRASS
On side panel: EARTH STUD SHOULD BE CONNECT-
ED TO AN EXTERNAL EARTH. THIS
EXTERNAL EARTH CAN BE AN EARTH
SPIKE OR ANY SUITABLE EARTH
POINT. THE RCD SHOULD BE TESTED
DAILY BY PRESSING THE TEST BUT-
TON AND CHECKING IT DOES TRIP.
If the generator is to be used for a fixed

installation or installed on the same site
for a long period it should be installed by
a competent person. The User should be
shown where the TEST button is located
and shown how to use it. An earth spike
kit is available as an optional extra.
Pt No. 499-945-012 DC ISOLATOR IDENTIFICATION
Qty 1 Informational label showing the ON / OFF

positions of the switch.
On Control Panel around the DC
Isolator Switch
Pt No. 499-945-013 EXTERNAL INTERNAL FUEL SWITCH

IDENTIFICATION
Qty 1
Informational Label showing the positions
On Fuel Switch Bracket of the Fuel Lever and the Fuel Toggle
switch to use Internal or External Fuel
supply

Pt No. 499-945-014 MCB1 IDENTIFICATION
Qty 1 Informational label showing position of

MCB1.
On Control Panel for DC MCB
Pt No. 499-945-019 3 PhaseTERMINALS
Qty 1 Informational label showing terminal posi-

tions.
Below Terminals in Terminal Pod
of 3 Phase Generators
Pt No. 499-945-017 BATTERY ISOLATOR
Qty 1 Identification label showing the ON / OFF

position of the Battery Isolator.
On Battery Isolator Bracket
Pt No. 499-945-018 SAFETY SWITCH
Qty 1 Informational label advising that the gen-

erator will automatically shut down should
On Terminal Pod Safety Cover the Terminal Pod Cover be opened whilst
the generator is running.
Pt No. 499-945-020 EXTERNAL FUEL SUPPLY
Qty 1
Below Snap Connectors Information label showing the positions of
the snap connectors when using an ex-
ternal fuel supply. Label also advises that
Diesel Only should be used.
Pt No. 499-945-021 230V OUTPUT
Qty 1 Advisory label showing voltage of the

generator
On Control Panel Dual Voltage
Generators
Pt No. 499-945-022 400V OUTPUT
Qty 1 Advisory label showing voltage of the

generator
On Control Panel Dual Voltage
Generators

Pt No. 499-945-023 AUTOMATIC MACHINERY – MAY START

WITHOUT WARNING
Qty 2
This is only fitted if the generator is an
One per Service Access Door AMF (automatic mains failure) version in-
tended to start the set automatically if the
mains electricity fails OR a Remote Start
Version.
While checking the oil level or doing any

type of maintenance on this generator it
should be made safe so it cannot start
automatically by removing the control fuse
or using the Emergency Stop button.
Pt No. 499-945-024 USB PORT
Qty 1 Information label advising position of USB

Port.
On Control Panel below the USB
Port
Pt No. 499-945-025 RADIATOR DRAIN
Qty 1 Advisory label showing the position of the

Radiator Drain Point
On Bottom of Radiator next to
Drain Point
Pt No. 499-945-026 ENGINE OIL DRAIN
Qty 1 Engine oil is drained by removing the cap

on the front RHS of the base. The oil will
Base of Generator next to Drain drain easier from a warm engine. Observe
Point correct disposal practices.
Pt No. 499-945-049 HOT WATER UNDER PRESSURE
Qty 1 CHECK COOLANT LEVEL DAILY
On lifting Beam Service Access Coolant level must be sufficient to appear

Side in the filler neck.
DO NOT OPEN A HOT RADIATOR

Pt No. 499-945-035 EXPANSION BOTTLE
Qty 1 Coolant level should reach the bottom

of the radiator filler neck and should be
On lifting Beam Expansion Bottle between the level marks on the expansion
Side bottle.
Filling the expansion bottle does NOT refill

the cooling system.

Pt No. 499-945-028 DANGER 400V
Qty 1 Alerting to voltages behind cover
On Terminal Pod Cover
Pt No. 499-945-037 DANGER ELECTRICITY
Qty 1 The battery is 12 V DC and care should

be taken not to come into contact with the
On the DC box inside the genera- terminals.
tor
Pt No. 499-945-040 400V
Qty 1 Advisory of voltage on socket output
On Top of the Top 400V Socket if

used
Pt No. 499-945-041 230V
Qty 1 Advisory of voltage on socket output.
On Top of the Top 230V Sockets

if used
Pt No. 499-945-042 12 V DC
Qty 1 Advisory of the battery voltages and care

should be taken not to come into contact
On the DC box inside the genera- with the terminals.
tor
Pt No. 499-945-043 ELECTRICITY IS DANGEROUS
Qty 1 Warning about the danger or using Elec-

trical equipment and the difference in
On the Terminal Box Cover top phases.
right, close to Sockets
Pt No. 499-945-044 HIGH LEVEL
Qty 1 Informational to denote the High Level

mark on the expansion bottle.
On High Mark Level of Expansion
Bottle if not embossed on bottle
Pt No. 499-945-045 LOW LEVEL
Qty 1 Informational to denote the Low Level

mark on the expansion bottle.
On Low Mark Level of Expansion
Bottle if not embossed on bottle

Battery Compartment
On front panel over battery DANGER ELECTRICITY
compartment
The battery is 12 V DC and care should
Part of label be taken not to come into contact with the
No: 499-945-006 terminals.
On front panel over battery DANGER ACID

compartment
The battery contains acid and if any liquid is
Part of label seen check the source, but assume first that
No: 499-945-006 it is acid. Care should be taken in cleaning up
acid.
On front panel over battery WARNING EXPLOSIVE MATERIAL
compartment
The battery can under certain conditions give
Part of label off small quantities of hydrogen gas. Do not
No: 499-945-006 smoke or use naked flames while working on
a battery. NEVER attempt to burn a battery
as a method of disposal.
On front panel over battery DISCONNECT NEGATIVE LEAD FIRST
compartment AND RECONNECT LAST
Part of label This is to ensure that if a spanner slips you

No: 499-945-006 cannot create a circuit from the live battery
post to the generator chassis.
On front panel over battery NO SMOKING OR NAKED LIGHTS
compartment
The battery can under certain conditions give
Part of label off small quantities of hydrogen gas. Do not
No: 499-945-006 smoke or use naked flames while working on
a battery.
On front panel over battery RECYCLE
compartment
The battery contains lead and sulphuric acid
Part of label and should be recycled at an approved facil-
No: 499-945-006 ity only and not put into a dust bin.

Electrical Safety • Visibly marked with any appropriate information

to be taken into account for its safe use, e.g. safe
In addition to the information given previously the- working loads.
generator should be installed, earthed and used with • Accessories, e.g. slings, clamps etc. should be
reference to the following:- similarly marked.
• I.E.E Regulations 17th Edition (BS 7671:2008) You must ensure that a lifting operation must be
• Health and Safety Executive Publications GS27 planned, supervised and carried out in a safe manner
Protection Against Electric Shock by people who are competent.
• Health and Safety Executive Publications GS24
Electricity On Construction Sites No personnel should be present in an area where a
• Health and Safety Executive Publications PM53 mechanical lifting operation is taking place.
Emergency Private Generation
Lifting by Fork Lift Truck
available from HMSO. Alternatively the HGI Technical
Help Line would be pleased to advise you on the best The generator can be lifted from the sides using the
measures for your particular application. pockets integrated into the base, and a fork lift truck
with correctly spaced forks.
NOTICE Lifting Beam
We would NOT recommend operating hand held The generator can be lifted using a single point lifting
electrical equipment in light rain or snow. beam. This can be accessed via the cover on the
DO NOT use a pressure washer to clean the roof of the generator. The fixing of this beam should
generator as high pressure water may enter the be inspected to make sure that no fixing bolts have
electrical system. been removed or loosened and that it has not been
damaged.
Lifting and Moving
In addition to the information given previously the

following apply:-
Mechanically Assisted Lifting
In Great Britain all assisted lifting is governed by:-
• Lifting Operations & Lifting Equipment Regulations Lifting Plate (where fitted)
1998 (LOLER) SI 1998 No: 2307
(1) (2) (3) (4)
and the following publication should be observed:-
• HSE ACoP publication L113 Safe Use of Lifting

Equipment, Lifting Operations and Lifting
Equipment Regulations.
As a guide line only you should ensure that all lifting

equipment is:-
Some models come complete with a lifting plate (3),
where this is fitted use of the lifting beam will require
• Sufficiently strong, stable and suitable for the the lifting plate to be secured. This is done by aligning
proposed use. the plate (3) or with the hole in the lifting beam (1) and
• The load and anything attached must be suitable pinning the plate and beam in together using the lifting
to be lifted. pin (2) and split pin (4). Ensure both pins are in place
and that the lifting pin (2) cannot be dislodged prior to
• Positioned or installed to prevent the risk of injury, conducting any lifting.
e.g. from the equipment or the load falling or
striking people.

Hazards to Health
A list of the hazards that may affect health are included with safety precautions and first aid instructions.
Material / Hazard First Aid Measures

Location
Engine Oil When hot may burn the skin but not Burns: Rinse with clean water, cover with a ster-
expected to give rise to an acute hazard ile pad and obtain medical assistance.
under normal conditions of use. May Skin Contact: Remove contaminated clothing
cause an allergic skin reaction in sensitive and wash thoroughly with soap and water. If per-
individuals. Continuous skin exposure sistent irritation occurs obtain medical attention.
may give rise to dermatitis. If the material is injected under high pressure into
the body obtain medical assistance immediately.
Gloves, overalls and eye protection Inhalation: In the unlikely event of inhalation of
should be worn when handling this fumes if dizziness or nausea occurs move the
product. individual to fresh air. If symptoms persist, obtain
medical attention. If difficulties are experienced
Do not burn old oil as a method of with breathing a qualified person should admin-
disposal as combustion is likely to ister oxygen. If breathing stops give artificial
give rise to a complex mixture of respiration.
airborne solids, liquid particulates and Eyes: In the unlikely event that the material
gases including carbon monoxide and enters the eye flush with copious quantities of
unidentified organic and inorganic clean water. If persistent irritation occurs obtain
compounds . medical attention.
Old engine oil has potential health Ingestion: In the unlikely event that ingestion
implications and should not come into occurs, wash out the mouth with water and seek
contact with the skin. medical attention. Do not induce vomiting.
Diesel May cause skin irritation. As for engine oil above.

Fuel Gloves, overalls and eye protection
should be worn when handling this
product.
Fibre The User will not normally come into Skin Contact: Remove contaminated clothing
Glass contact with this material but Service and wash thoroughly with soap and water. If per-
Insulation Technicians may. sistent irritation occurs obtain medical attention.
(over If the material is injected under high pressure into
exhaust May cause skin and respiratory tract the body obtain medical assistance immediately.
pipe duct irritation. Inhalation: In the unlikely event of inhalation of
and lining fumes if dizziness or nausea occurs move the
exhaust Gloves, overalls, dust mask and eye individual to fresh air. If symptoms persist, obtain
pipe box) protection should be worn when handling medical attention. If difficulties are experienced
this product. with breathing a qualified person should admin-
ister oxygen. If breathing stops give artificial
respiration.
Eyes: In the unlikely event that the material
enters the eye flush with copious quantities of
clean water. If persistent irritation occurs obtain
medical attention.
Other No specific hazards under normal use N/A
insulation, conditions.
gaskets
and seals DO NOT burn as a method of disposal
as combustion is likely to give rise to a
complex mixture of airborne solids, liquid
particulates and gases including carbon
monoxide and unidentified organic and
inorganic compounds which may be haz-
ardous to health.

Asbestos This generator is asbestos free. N/A

Battery The User and Service Technicians will not Skin Contact: Remove contaminated clothing
Acid normally come into contact with acid. and wash thoroughly with soap and water.
If persistent irritation occurs obtain medical
Battery is Battery contains acid electrolyte which is attention. If the material is injected under high
located in absorbed in the separator glass mat ma- pressure into the body obtain medical assistance
the battery terial. If battery case is punctured, com- immediately.
box in the pletely flush any released material from Inhalation: In the unlikely event of inhalation
engine skin or eyes with water. of fumes if dizziness or nausea occurs move
canopy the individual to fresh air. If symptoms persist,
Battery posts, terminals and related obtain medical attention. If difficulties are
accessories contain lead and lead com- experienced with breathing a qualified person
pounds which have been known to cause should administer oxygen. If breathing stops give
cancer and reproductive harm. Batter- artificial respiration.
ies also contain other chemicals which Eyes: In the unlikely event that the material
have been known to cause cancer. Wash enters the eye flush with copious quantities of
hands after handling. clean water. If persistent irritation occurs obtain
medical attention.
Avoid contact with acid materials. Use Ingestion: In the unlikely event that ingestion
soda ash or lime to neutralize material occurs, wash out the mouth with water and seek
released or spilled: Flush with copious medical attention. Do not induce vomiting.
amounts of water.
Exhaust Exhaust fumes are very hot and con- Skin Contact: Remove contaminated clothing
Fumes tain carbon monoxide which can cause and wash thoroughly with soap and water.
unconsciousness and death in humans If persistent irritation occurs obtain medical
and animals. It is odourless and tasteless attention. If the material is injected under high
but diesel exhaust fumes contain other pressure into the body obtain medical assistance
chemicals and soot which will irritate the immediately.
eyes and breathing and will usually alert Inhalation: In the unlikely event of inhalation
the user to the presence of fumes. of fumes if dizziness or nausea occurs move
the individual to fresh air. If symptoms persist,
Symptoms of carbon monoxide poisoning obtain medical attention. If difficulties are
are dizziness, nausea, fatigue and vertigo. experienced with breathing a qualified person
should administer oxygen. If breathing stops give
artificial respiration.
Eyes: In the unlikely event that the material
enters the eye flush with copious quantities of
clean water. If persistent irritation occurs obtain
medical attention.
Electric • Assess the situation first.
Shock • DO NOT touch the person until it is safe for you to do so.
• Identify where the electricity is coming from. DO NOT assume it is the generator
• Turn off the electricity at the source.
• To stop generators in an emergency press the RED stop button on the generator control
panel or remove the plug from the socket. On Automatic Mains Failure Units (AMF) press
the emergency stop button on the main control panel.
• If necessary check patients air ways, administer artificial resuscitation, move the person to
the recovery position.
• Even if the person remains conscious anticipate that they will pass into shock.
• Local burns where contact was made should be covered by a sterile dressing.
• Obtain medical attention immediately.

Operation Harrington Generators International
Generator Layout
NOTICE
Lifting Beam Output
For safety reasons, the battery isolator will be turned
Access Panel
off prior to delivery. It is recommended that this
action is repeated when moving the generator or for Radiator
long term storage. Access
Exhaust
Operation
The guidelines for operating the generator are outlined
in the section.
The HRD 1500rpm range of generators are resiliently

enclosed within an acoustically treated housing
providing noise attenuation. Large access doors on
both sides enable ease of servicing and maintenance
in a tight space.
Emergency
The HRD range utilises a standard control panel using Stop
a Deep Sea Electronics 7310 (DSE7310) controller.
The Deep Sea controller can be configured for local Service Access Fork Lift
and remote operation. Door Pockets
When configured for local operation the operator

NB Layout may vary depending upon model please
can stop and start the set and monitor the generator
refer to General Arrangement Diagrams.
and engine condition at the set using the green start
and red stop buttons and instrument panel on the
DSE7310 control module. Output Panel (Typical)
When configured for remote start the output terminal

pod on the output panel is used to connect the set
(1)
to a remote Automatic Mains Failure (AMF) panel or (6)
timer volt free switch. The switched connection can
then transmit a start and stop signal to the DSE7310
to initiate the generator’s start up or shutdown
procedure. In order to action this signal the DSE7310 (2) (7)
will need to be placed in AUTO mode.
(3)
(8)
(4)
Output
Panel
Remote
Control /
(5) (9)
Output
Terminal Panel
Pod
400/230V
3Ph Output
Item Description
1 Control Panel
Generator
2 400V RCD Panel
3 230V RCBO Panel
*Schematic for illustration only. 4 400V 63A Socket
5 400V 125A Socket

Harrington Generators International Operation
6 Control Panel Key Lock Control Button Descriptions:
7 Emergency Stop
Item Description
8 Terminal Output Pod
This button allows you to STOP the
9 230V 32A Sockets
unit or reset any cleared alarms.
Control Panel (Typical) By selecting this button you can place

the unit into manual mode a LED will
The control panel is accessed via the lockable control illuminate, this now allow the unit to
panel door. be started when the button is
pressed.
(1) (2) (3) Selecting this button places the unit
into AUTO mode and will automatically
start when the mains fails or the unit
receives a remote start signal.
This button places the module into its
‘Test’ mode. This allows an on load test
of the generator.
Alarm cancel button and lamp test
Press this button to start the generator

(Used in conjunction with the manual
start control button)
(4) (5) When the unit is in manual mode this
button closes a control contactor or
Item motorised breaker when fitted. (May be
Description
disabled if manual MCCB fitted)
1 DSE7310 Control Module
When the unit is in manual mode this
2 USB Controller Program Socket button opens a control contactor or
3 Fuses: 20mm 5 Amp Glass type motorised breaker when fitted. (May be
4 DC Isolation Switch disabled if manual MCCB fitted)
5 Control Module Protection MCB
Menu scroll keys left and right
DSE7310 Control Module
The control panel has a Deep Sea Electronics 7310

engine and generator management system which
combines engine management, condition monitoring Menu scroll keys up and down
and general operational control of the machine. It is
designed for ease of use and provides information
via a large LCD display which is accessed through a
simple scroll menu system.
Accept or OK button to enter different
menus levels
The DSE7310 control module allows the user to con-

trol the operation of the generator engine.

The DSE7310 also provides instrumentation for;

This USB connection can be used to
install and modify the DSE7310
• Engine Speed • Generator kW generator control module programme.
• Generator Voltage • Generator kVA
• Generator Current • Alarm messages
• Generator Frequency • Mains Voltage and Emergency Stop
• Engine Run Time frequency
• Battery Volts Pressing the emergency stop
pushbutton will immediately stop
The DSE7310 module will go into standby when no the engine and prevent it from
common alarms have been triggered after 1 minute of restarting.
inactivity. When the emergency stop is pressed in the
DSE7310 module will not go into standby, so while the The emergency stop button must
generator is in storage ensure that it is on charge us- only be used to stop the machine
ing the appliance plug. in an emergency and not to stop the set during normal
operation.
Instrumentation
To restart the generator, release the emergency stop
To access various instrumentation displays you will button by twisting clockwise, reset the control module
need to press the “page” button on the engine control by pressing the Fault Reset button, and start the
module. Each “page” of instrumentation can be ac- generator by pressing the green Run button.
cessed sequentially in this order.
400V RCD Panel & 230V RCBO Panel (Typical)
• Status
• Engine (1)
• Generator
• Mains
• Alarms
If an alarm is raised while an instrumentation view is

being displayed the instrumentation view is changed
to the alarm page. The alarm page is only available
when an alarm has been raised.
(2)
The configuration settings for the DSE7310 can be
found later in this document.
DC Isolator Switch
Item Description
1 Single Phase RCBO 30mA
The DC Isolator Switch enables
2 Three Phase RCD 100mA
operation of the generator. It is a
simple ON / OFF switch.
The RCDs should be tested by pressing the TEST
Turning the Switch to the ON buttons and checking that the RCD trips and has to be
position activates the Deep Sea reset while the generator is running. This should be
Electronics 7310 control module. done every day.
Adjustable RCD (where fitted)
NOTICE Please refer to the Datasheet at the back of the

manual for operation of the RCD.
When generator not required switch off to minimise
battery drain.
USB Controller Programme Socket

Terminal Output Pod Remote Connection Socket
WARNING
Risk of Electrocution. Disconnect Power before
making electrical connections.
Terminal connections should be made by qualified
personnel only.
NOTICE This can be used to connect the set to a remote

If the Terminal Box Cover is open the set will not Automatic Mains Failure (AMF) panel, remote
run. An emergency stop alarm will appear in the control panel or timer volt free switch. The switched
DSE7310. connection can then transmit a start and stop signal
to the DSE7310 to initiate the generator start up or
The Terminal Output Pod can be accessed by shutdown procedure.
removing the Terminal Output cover’s wingnuts. The
cover is hinged from the bottom and folds down to Please contact HGI sales to discuss any requirement
reveal the terminals. to extend the generator functionality for remote
connectivity.
Earth Stud
The M10 brass stud in the terminal pod should be

connected to an external earth point or to an earth
spike. An earth spike can be supplied as an optional
extra and should be driven at least 600 mm into soil.
Installations
Installation of the generator is to be made by qualified

If the set has been configure to provide terminal personnel in accordance with appropriate regulations
output supply and or remote control, the electrical e.g., Electricity Safety, Quality and Continuity
connections from the generator will have been made Regulations 2002 (S.I. 2002/2665), and Electrical
and tested during installation. All cables connecting Safety regulations cited previously in this document.
to external panels and output will have been passed
through the cable gland opening.
Three Phase Terminal Connections
Ensure that the connections are secure and correctly

sequenced. Please refer to the wirring diagram later in
this manual.

Pre-Operation Checks
Engine Oil
Check the oil level BEFORE EACH USE with the

generator on a level surface and the engine stopped.
Engine oil should have properties of API classification

CH grade or higher. SAE10W-30 is recommended
for general, all temperature use. Other viscosities
shown in the chart may be used when the average
temperature in your area is within the indicated range.
5. If the level is low, remove the oil filler cap located
Oil Viscosity on the rocker cover and top up.
EMA LRG-1 Ambient Temperature
API CH-4
Viscosity Grade Min Max
SAE 0W20 -40°C (-40°F) 10°C (50°F)
SAE 0W30 -40°C (-40°F) 30°C (86°F)
SAE 0W40 -40°C (-40°F) 40°C (104°F)
SAE 5W30 -30°C (-22°F) 30°C (86°F)
SAE 5W40 -30°C (-22°F) 40°C (104°F)
SAE 10W30 -20°C (-4°F) 40°C (104°F) Replace the engine oil every 500hrs or yearly. When
SAE 15W40 -10°C (14°F) 50°C (122°F) changing the oil or topping-up, use oil of a grade
suitable for the prevailing ambient temperatures (see
* Please refer to engine manufacture’s O&M for full table in engine handbook).
details of operational oil grade requirements.
Coolant Level Check
To check the oil level:
1. If the generator has been running then wait for 10 WARNING

minutes to allow the oil to drain back into the oil
Explosive release of fluids from pressurised cooling
pan.
systems can cause serious burns. Only remove
filler cap when engine is cold or when cool enough
2. Access the engine via Service Access doors
to touch with bare hands. Slowly loosen cap to first
stop to relieve pressure before removing completely.
3. Remove the dipstick (a) and wipe the dipstick
clean.
The radiator filler point is located at the front of the set.
To check the coolant level:
1. Access the radiator filler cap via

the cover on the roof of the
generator. Turn the cover anti-
clockwise to open.
(a)
2. Remove the radiator cap after the engine has
completely cooled and check to see that coolant
reaches the bottom of the neck.
4. Insert the dipstick back into the dip tube and then
remove again, checking where the oil level lies on
between the minimum and maximum positions on
the dip stick.

(a) (b) Some generators have an option to have fuel sourced

either by using the on-board fuel tank or by using
an external fuel tank connected using the snap
connectors on the front left side of the generator base.
On these the respective fuel source must be selected

prior to use.
To select the fuel source:

3. If coolant level is low top up. Refer to Engine
Manufacturer’s Operation and Maintenance 1. Open the Left Hand Service Access Door.
Manual for details of Coolant Mix (www.perkins. 2. Locate the fuel lever mounted on a bracket from
com). the base of the generator.
Coolant Capacity 10.2 litres
NOTICE
DO NOT use the expansion bottle as indicator of
coolant level.
NOTICE COOLANTS
3. To use the internal tank the lever must be
Organic Acid technology (OAT), Hybrid organic positioned to the left (as shown above). To use
acid technology (HOAT) and G5 antifreeze coolants an external fuel supply then move the lever to the
offer exceptionally long service life compared to right.
glycol antifreeze. It is recommend that OAT, HOAT
and G5 coolants are not mixed with each other or Fuel Prime Switch
any other type of coolant. Where possible always
use the same type as that supplied with your new
generator.
G05 is a low-silicate HOAT derivative, phosphate
free formula that includes the benzoate inhibitor.
WARRANTY CLAIMS will be rejected where it
is found that coolant types have been mixed and
contributes to generator failure.
Fuel There is a fuel priming switch that is spring loaded.

When used this will energise the electric fuel pump
and solenoid to prime the system.
WARNING
Diesel is highly flammable and explosive. To operate the fuel prime switch.
You can be burned or seriously injured when
handling fuel. Stop the engine and keep heat, 1. Open the Left Hand Service Access Door.
sparks, and flame away. Handle fuel only outdoors. 2. Locate the fuel prime switch mounted on the back
Wipe up spills immediately. of the control panel.
3. Move the toggle switch to the left to engage fuel
priming.
Fuel Source
4. Return the switch to the right after priming.
The generator uses Commercial diesel with up to 10%
Prime the fuel after switching fuel source or after
bio-diesel .i.e. B10 blend.
routine maintenance involving the fuel system.
The fuel is stored in an on-board bunded fuel tank
within the base of the generator. The tank has a
capacity of 190 Litres.

Fuel Level Starting

If an external tank is used please refer to the
manufacturers instructions for checking the fuel and WARNING
ensure that sufficient fuel is available prior to using the
generator. Please check that all equipment is disconnected
from the generator prior to starting.
If the internal tank is being
used then the fuel level Local Operation
can be checked using the
sight level in the base of the 1. Perform the Pre-Operation Checks.
generator.
2. Check MCB and RCD are in the OFF positions.
If the engine is running the fuel level can be
checked at the DSE7310 control module. If the fuel 3. Turn the DC ISolation Switch to the “ON” position.
is low the Low Fuel Alarm indicator will be lit and the
generator will shutdown to prevent air locking in the
fuel system. This functionality is only available when 4. Press the Red Stop/Reset button once.
using the internal tank.
5. Press the Green Run/Start pushbutton once
To refuel the internal tank only and engine will pre-heat and the starter motor
will turn and the engine will crank.
Ensure that there is sufficient fuel in the tank.
To check the fuel: If the engine fails to start within 10 seconds, the
control module will pause and attempt 3 cranks.
1. Open the Left Hand Service Access Door
6. After Starting, allow the engine to warm up for
2. Locate the Fuel Level Sight 1 minute before setting the MCBs and RCDs to
Glass located on the base of the ON position and connecting any load to the
the generator next to the fuel generator output.
filller cap.
Remote Operation
3. If the gauge is low top up with fuel. Locate the
For remote starting the generator needs to be
filling point located inside the generator on the
prepared at the set:
base next to the fuel supply switching lever.
4. Remove the fuel tank cap. 1. Perform the Pre-Operation Checks.
2. Check MCB and RCD are in the ON positions.
3. Turn the DC ISolation Switch to the “ON” position.
4. Press the Red Stop/Reset button once.
5. Refill the fuel tank avoiding spilling fuel. 5. Ensure that the remote panel/timer is plugged in
using the 3 way socket.
6. Do not over fill.
6. Press the White Auto button.
NOTICE
7. The generator will now start upon the Start signal
Fuel can damage paint and plastic. Be careful not to being received from the remote panel/timer.
spill fuel when filling your fuel tank. Damage caused
by spilled fuel is not covered under warranty.
7. After refuelling tighten the fuel cap securely.
Fuel Capacity: 190 Litres

Shutdown Protections
CAUTION
The generator is fitted with the following protection
Generator can now start automatically devices that will shut down the generator in the event
of a fault. They are indicated on the engine control
module.
If the engine fails to start after 3 attempts then inititate
fault finding to rectify the problem. Charge Fail: Operates if the battery is not charging,
this could be caused by parasitic drain (leaving engine
control module illuminated), generator inactivity, or
NOTICE faulty alternator charging.
If the generator is not required switch it off and avoid
running with light or no load wherever possible. Also Low Oil Pressure: This operates if the oil pressure
see Maintenance Section. falls below a safe level. This can be caused by a lack
of oil, wrong type of oil or high temperature. Check
and top up the oil level as necessary. During starting,
Stopping the alarm is held off for 10 seconds to allow the oil
pressure to build up to normal running level. The
1. Switch off the electrical output and disconnect the engine will not crank if there is a false oil pressure
load from the generator’s output sockets. signal prior to starting.
2. Allow the generator to run off load for 2 minutes to Low Fuel Level: The fuel gauge also incorporates
cool down. a low fuel shutdown facility. The set will give a
warning and then shut down when the level falls to
3. Press the red stop/reset button on the approximately 10-12% of its capacity, thus eliminating
DSE7310 moudle or if being operated remotely the need to bleed the system at restart.
the Stop signal will be transmitted to the DSE7310
High Engine Temperature: If the temperature is
4. The engine will then stop after the shutdown out side the value programmed into the controller the
process and cool down period is competed. generator will close down.

Fault Finding Harrington Generators International
Fault Finding
IMPORTANT:
If the following checks and investigations can be completed without the use of tools then the operator can
safely undertake them. If tools are needed then ONLY trained technicians can undertake the work safely. Wiring
diagrams can be obtained from HGI to help with electrical fault finding.
Engine Fails to Start
Symptom Cause and Remedy

Starter motor did not attempt to • Check the BatteryI solator is OFF
turn the engine over and no fault • Check the emergency stop button is not pressed IN.
icons are displayed on the engine • Check the control fuse or MCB has not failed.
module. • Flat battery or wrong polarity from battery.
• Check that the battery is producing over 12V DC from the positive
terminal relative to the chassis of the generator.
• Check the connections to the control module.
• Check the operation of the slave relay, module and its fuses.
• Check the connections to the starter motor.
• Check the operation of the starter motor by making a temporary
connection to its solenoid.
Starter motor did not attempt to • The control module believes that oil pressure is present when the
turn the engine over and the oil engine is off.
pressure icon is displayed on the • Check the oil pressure switch has not gone faulty.
Engine module. • Check the control module has not gone faulty by swapping it.
• If running off local internal tank check fuel in tank, check 3 way valve
set to internal tank. If running from external tank, check the fuel in
tank, connections are made, check 3 way valve set to external tank
and fuel transfer pump is set to on.
Engine turns over but will not • Check that the fuel filter is not blocked or full of water.
start. • Check there is a 12V DC supply to the fuel solenoid valve.
• Check* fuel is getting past the fuel solenoid valve.
No smoke seen from exhaust • Check* fuel is flowing at high pressure out of the fuel pump located
pipe. next to the fuel solenoid.
• Suspect the fuel system is air locked or there is contamination
blocking the fuel system or injector.
Engine turns over but will not • Suspect faulty fuel supply as above.
start after 3 attempts to start). • Suspect faulty fuel injector nozzle.
“Start Fail” will be displayed on • Suspect contaminated / unsuitable fuel.
control module • Suspect starter motor is not turning engine over quickly enough
Smoke seen from exhaust pipe. particularly if the temperature is too low.
• Suspect serious fault with the engine.
* Care should be taken while working on the fuel system particularly when fuel is under high pressure.

Harrington Generators International Fault Finding
Engine Starts but then Stops

Engine starts but then closes • Check control circuit fuse and MCB.
down. No alarm message • Check battery charger circuit fuse.
• Check the 12V DC supply from the battery and battery charger has
not been lost.
• Suspect faulty control module. Swap it to check it.
Engine starts but then closes • Check the fuel level and that the fuel system is not blocked or air
down. locked.
Common alarm on the control • Then check for faulty fuel level switch.
module triggered. • Check oil level then check for faulty oil pressure switch.
• Check the fuel solenoid valve has not closed prematurely.
• Check the fuel system has not become contaminated or defective as
given previously.
Engine starts but then closes • Speed Fault - If the engine does not run at 1500 rpm it will close
down on Speed Fault on the down. The most common cause of incorrect speed is air or
Control Module. contamination in the fuel system. Bleed the system and try starting
again
Other Generator Faults

Has the miniature circuit • Before resetting disconnect all equipment plugged into the sockets
breaker (MCB) tripped or pop- or wired into the terminals. Look for any obvious reasons or faults as
out breaker tripped. to why the equipment has caused the unit to trip.
Reset the MCB and reconnect and switch on equipment one piece
at a time. Do not hold the suspect equipment and use the selector
switch on the generator to turn the supply ON to the suspect equip-
ment. If a piece of equipment trips the MCB repeatedly make sure
it cannot be used again by removing the plug and labelling faulty/
unsafe.
The miniature circuit breakers • Connect another piece of electrical equipment that is not faulty to
have not tripped. confirm that the generator is faulty.
• Suspect a major fault with the alternator or its voltage regulation unit.

Fault Finding Harrington Generators International
No Electrical Output

Check the phase rotation. • For three phase generators ensure that the phase rotation of the
load is correct.
• Swap phases if necessary.
Has the earth leakage (RCD) • Before resetting disconnect all equipment plugged into the sockets
unit tripped. or wired into the terminals. Look for any obvious reasons or faults as
to why the equipment has caused the earth leakage unit to trip.
• Reset the trip and reconnect and switch on equipment one piece at
a time. Do not hold the suspect equipment and use the MCB on the
generator to turn the supply ON to the suspect equipment. If a piece
of equipment trips the earth leakage unit repeatedly make sure it
cannot be used on another supply by removing the plug and labelling
Faulty / Unsafe.
Check the miniature circuit • Each 230V/400V output socket has its own MCB to prevent
breaker (MCB). excessive electrical load being taken through that socket. Check
if the miniature circuit breaker (MCB) has tripped or 3-pole circuit
breakers have been set to OFF.
The earth leakage unit has not • Connect another piece of electrical equipment that is not faulty to
tripped, the miniature circuit confirm that the generator is faulty.
breakers have not tripped, and • Suspect a major fault with the alternator or its voltage regulation unit.
the voltage selector switch is • The voltage can also be read on the Deep Sea Module if present.
in the correct position.

Harrington Generators International Maintenance
Maintenance
Good maintenance is essential for safe, economical, and trouble free operation. This not only ensures that your
engine is at its optimum in fuel efficiency, but maintains the engine in order to minimize the risk of breakdowns.
Maintenance Schedule
Service intervals will have to be reduced if the generator is operated in dusty or severe conditions.
Servicing must be carried out by a competent engineer. A written record of the service work should be made.
The generator must be serviced in accordance with our recommendations for the warranty to be valid. Please
refer to the Engine Manufacturer’s Operation and Maintenance Manual for full servicing requirements.
DO NOT use a pressure washer to clean the welder-generator as high pressure water may enter the electrical
system. Use a damp cloth or similar.
PERIODICITY (HOURS)
OPERATION DESCRIPTION
Daily 500 1000 2000 3000 6000 12000
Check and Replenish Engine Oil º º º º º º º
Coolant Level Check º º º º º º º
General Inspection º º º º º º º
RCD Test º º º º º º º
Engine Air Cleaner Service Indicator Check º º º º º º º
Alternator Belt Tension Check and Adjust º º º º º º º
Radiator º º º º º º
Engine Air Cleaner Check/Clean/Replace º º º º º º
Run on ¼, ½, ¾ full load for 30 mins º º º º º º
Canopy Checks º º º º º º
Electrical Checks º º º º º º
Battery Check º º º º º º
Control Module Checks º º º º º º
Engine Oil Replace º º º º º º
Oil Filter Cartridge Replace º º º º º º
Primary Fuel Filter Replace º º º º º º
Secondary Fuel Filter Replace º º º º º º
Exhaust System º º º º º º
Battery Charger º º º º º º
Glow Plugs Check / Replace º º º º º º
Engine Valve Lash Inspect/Replace º º º º º
Canopy º º º º º
Starter Motor Check º º º º
Alternator Check º º º º
Cooling System Coolant Change º º º
Coolng System Coolant Extender (ELC) Add º
Cooling System Coolant (ELC) Change º
If you’d like to make an appointment for HGI to service your generator using our in house 26-point health
checker guide then please contact the Service Department.

Maintenance Harrington Generators International
Maintenance Safety Follow HSE recommendations regarding the handling

and disposal of contaminated oil products.
Some of the most important safety precautions follow.
However, we cannot warn you of every conceivable The oil filter element is a replacement type, and
hazard that can arise in performing maintenance. Only should be replaced in line with the procedure below
you can decide whether or not you should perform a
given task. Replace components in reverse order.
Fill with recommended oil to the max level shown on

WARNING the dipstick.
Failure to properly follow maintenance instructions
and precautions can cause you to be seriously hurt Coolant Level Check
or death.
Always follow the procedures and precautions in the Check the coolant level daily and top up if necessary.
operations’ manual. Where third party equipment is
incorporated into the generator always refer to their Check the radiator and hoses for signs of damage or
guides for familiarisation and information. leaks. Check the cap and seal for signs of damage.
Clean the radiator matrix of leaves or similar debris.
Safety Precautions
Check the coolant level when the engine is stationary
• Make sure the engine is off and cannot and on a level surface.
be remotely started before you begin any
maintenance or repairs. This will eliminate several The radiator should be filled to typically 1 cm above
potential hazards: the core of the radiators matrix. If the engine has an
expansion bottle the coolant level should be filled as
• Read the instructions before you begin, and make marked on the expansion bottle or label.
sure you have the tools and skills required.
Top or change with a Coolant Mixture in line with the
Engine manufacturers guidelines. Never use neat
Maintenance Routine
antifreeze.
The following procedures refer to the common
If fitted, DO NOT use the expansion bottle to decide if
maintenance items for servicing your generator.
the radiator needs topping up.
Check and Replenish Engine Oil
Drain the waste fluids into suitable waste containers,
and follow HSE recommendations regarding the
Refer to Pre-Operational Checks to check the engine
handling and disposal of contaminated oil products.
oil level and replenish.
Check the radiator and hoses for signs of damage or
Replace the engine oil after 500 hours operation.
leaks.
When changing the oil or topping up, it is
recommended to use oil of grade SAE10W-30.
Cooling System Coolant Change
Use the Eazy-Drain system to drain
Clean the cooling system and flush the cooling
the oil in the engine while the engine
system as per engine manufacturer’s Operation and
is warm. Warm oil drains quickly and
Maintenance Manual (www.perkins.com).
completely.
Drain
Place the generator on a level
surface, and place a suitable
1. Stop the engine and allow the engine to cool.
container under the generator at the
Loosen the cooling system filler cap slowly in
service access panel side of the generator.
order to relieve any pressure. Remove the cooling
system filler cap.
Remove the oil filler cap / dipstick.
Drain the oil into the suitable container.

2. Fill the cooling system with an approriate mix of

antifreeze and water for the respective ambient
operating conditions. Do not install the cooling
system filler cap. Refer to Engine Manufacturer’s
Operation and Maintenance Manual for details of
Coolant Mix.
3. Start and run the engine for one minute in order to
purge the air from the cavities of the engine block.
Stop the engine.
4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level in the
2. Open the drain cock or remove the drain plug (1) expansion bottle (if equipped) at the correct level.
on the engine. Open the drain cock or remove 5. Clean the cooling system filler cap. Inspect the
the drain plug on the radiator. Allow the coolant to gasket that is on the cooling system filler cap. If
drain. the gasket that is on the cooling system filler cap
3. Dispose of used engine coolant or recycle in local is damaged, discard the old cooling system filler
with local HSE regulations. cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap
Flush is not damaged, use a suitable pressurizing pump
in order to pressure test the cooling system filler
1. Flush the cooling system with clean water in order cap. The correct pressure for the cooling system
to remove any debris. filler cap is stamped on the face of the cooling
2. Close the drain cock or install the drain plug in the system filler cap. If the cooling system filler cap
engine. Close the drain cock or install the drain does not retain the correct pressure, install a new
plug on the radiator. cooling system filler cap.
6. Start the engine. Inspect the cooling system for
NOTICE Do not fill the cooling system faster than leaks and for correct operating temperature.
5 L per minute to avoid air locks. Cooling system
air locks may result in engine damage. Primary Fuel Filter Replace
3. Fill the cooling system with clean water. Install the

cooling system filler cap.
4. Start and run the engine at low power until the
temperature reaches 49 to 66 °C (120 to 150 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain cock or remove
the drain plug on the engine. Open the drain cock
or remove the drain plug on the radiator. Allow
the water to drain. Flush the cooling system with
clean water.
Fill
1. Close the drain cock or install the drain plug on

the engine. Close the drain cock or install the
drain plug on the radiator.
NOTICE Do not fill the cooling system faster than

5 L per minute to avoid air locks. Cooling syste-
mair locks may result in engine damage
. 1. Turn the fuel supply valve (if equipped) to the OFF

position. filter (2) from the fuel priming pump (1).

2. Place a suitable container under the water 4. Ensure that the fuel drain (3) on the new spin-on
separator. Clean the outside of the water filter is closed.
separator. 5. Lubricate the sealing ring with clean fuel oil.
3. Open the drain (5). Allow the fluid to drain into the 6. Install the spin-on filter (2) into the top of the fuel
container. priming pump (1).
4. Tighten the drain (5) by hand pressure only. 7. Tighten the spin-on filter by hand until the sealing
5. Hold the element (2) and remove the screw (1). ring contacts the fuel priming pump. Rotate the
Remove the element and the glass bowl (3) from spin-on filter through 90 degrees.
the base. Discard the old element. 8. Prime the fuel system by using the Fuel Prime
6. Clean the glass bowl (4). Clean the bottom cover Toggle Switch to run the electric pump located
(6). next to the fuel snap connectors.
7. Install the new O ring seal. Install the bottom
cover onto the new element. Install the assembly Drain Fuel Tank
onto the base.
8. Install the screw (1) and tighten the screw to a Drain and flush the fuel tank periodically to prevent
torque of 8 N·m (6 lb ft). the build-up of contaminants, particularly when the
9. Remove the container and dispose of the fuel generator has operated in high humidity and dusty
safely. environments.
10. Open the fuel supply valve.
11. Prime the fuel system. Refer to the Engine Change the Oil Filter
Manufacturer’s O&M Manual.
1. Replace the oil filter cartridge every 500 hours
Secondary Fuel Filter Replace thereafter.
2. Remove the old oil filter cartridge with a filter
wrench.
3. Apply a film of oil to the gasket for the new
cartridge.
4. Screw in the cartridge by hand. When the gasket
contacts the seal surface, tighten the cartridge
enough by hand. Because, if you tighten the
cartridge with a wrench, it could be tightened too
much.
5. After the new cartridge has been replaced, the
engine oil level normally decreases a little. Thus,
run the engine for a while and check for oil leaks
through the seal before checking the engine oil
level. Add oil if necessary.
Battery
The battery is a maintenance free unit and should not

require the electrolyte being topped up.
Check that the positive and negative terminals are

tight and secure, and free from corrosion. Lightly coat
them with petroleum jelly or similar to protect from
corrosion.
Check that the battery securing strap is tight and the

1. Turn the valves for the fuel lines (if equipped)
battery is held firmly.
to the OFF position before performing this
maintenance.
2. Clean the outside of the fuel filter assembly. Open
the fuel drain (3) and drain the fuel into a suitable
container.
3. Use a suitable tool in order to remove the spin-on

Engine Air Cleaner Service Indicator Check Engine Air Cleaner Check/Replace
The differential gauge for inlet air The Air Cleaner has a Dual Element filtering system.
pressure displays the difference
in the pressure that is measured If the air cleaner element becomes blocked, the air
before the air cleaner element pressure can split the material of the air cleaner
and the pressure that is element. Unfiltered air will drastically accelerate
measured after the air cleaner internal engine wear.
element. As the air cleaner
element becomes dirty, the pressure differential rises. • Check the precleaner (if equipped) and the dust
bowl regularly for accumulation of dirt and debris.
The service indicator is mounted on the air cleaner Remove any dirt and debris, as needed.
element or in a remote location. The air cleaner • Operating conditions (dust, dirt and debris) may
element should be cleaned or the air cleaner element require more frequent service of the air cleaner
should be replaced when one of the following element.
conditions occur: • The air cleaner element should be replaced
at least one time per year. This replacement
• The yellow diaphragm enters the red zone. should be performed regardless of the number of
• The red piston locks in the visible position. cleanings.
Refer to Engine Manufacturer’s O&M for full Replace the dirty air cleaner elements with clean air
information about checking the Service Indicator. cleaner elements.
Engines Glow Plugs The primary air cleaner element can be cleaned and
(where fitted) used for up to six times
With the engine starting normally measure the
current being drawn by each glow plug or heater
to confirm operational.
Replace them periodically as recommended in the

engine manufacturer’s manual.
Check Operation of MCBs
No maintenance can be carried out on MCBs other

than a physical check to ensure the MCB latches in
the On position and no sign of external damage can
be seen.
Alternator Fan Belt Check and Adjust

1. Remove the cover. Remove the primary air
To maximize the engine performance, inspect the cleaner element.
belts for wear and for cracking. Replace belts that are 2. The secondary air cleaner element should be
worn or damaged. Refer to Engine Manufacturer’s removed and discarded for every three cleanings
O&M for full information about checking and adjusting of the primary air cleaner element.
the Fan Belt. 3. Clean the primary element by using pressurised
air or a vacuum cleaner.
Radiator 4. Cover the air inlet with tape in order to keep dirt
out.
Inspect the radiator for these items: Damaged fins, 5. Clean the inside of the air cleaner cover and body
corrosion, dirt, grease, insects, leaves, oil, and other with a clean, dry cloth.
debris. Clean the radiator, if necessary. 6. Remove the tape for the air inlet. Install the sec-
ondary air cleaner element. Install a primary air
cleaner element that is new or cleaned.
7. Install the air cleaner cover.
8. Reset the air cleaner service indicator.

Adjust Valve Clearance of the exhaust. Care should be taken that hot soot
does not land on combustible material.
Valve Clearances should be checked after the first
12 months or 1000hrs and reset in accordance with Canopy
the engine manufacutrer’s guidelines. Refit the rocker
cover with a new gasket. Check security of fixings and fasteners on the
machine. Lubricate hinges and latches with light
Alternator machine oil.
Ensure that the cooling air vents do not become Ensure that the inlet and outlet louvres are kept clean
blocked by dirt, debris etc. and that the cooling fan is and unimpeded at all times. Check that no sound
not damaged. Service in line with alternator manufac- insulation has become loose and obstructed them.
turer’s guidelines.
General Inspections
Control Module Safety Shut Down
Inspect generally for:-
This module will prevent the generator from starting or
shut it down if faults occur. Check the following:- Fuel and Oil Leaks: Look for excessive oil in the base
tray. Look for weeps from fuel hoses and connections.
Hours Run Counter; confirm counter is working. Check the insulation is dry and not contaminated with
fuel or oil.
Emergency Stop: with the engine running use the
E-Stop Button. The engine should stop and the E-Stop Worn or Failed Anti Vibration Mounts: When the
alarm should be seen. side panels are removed rock the engine and check all
four anti vibration mounts are flexing slightly and have
Low Fuel Level; With the engine running allow the not failed or broken up.
fuel tank to run out of fuel and the engine should stop
and the Low Oil alarm should be seen. Refill with fuel Damaged or missing insulation and seals:
and the engine should start and run normally. Generally look at the sound insulation and seals and
check it is still securely fitted and has not deteriorated.
Battery Charger
Hoses and Clamps: Inspect all hoses for leaks that
Stop and start the engine a few times if needed to are caused by the following conditions:
draw off the battery. • Cracking
• Softness
Start the engine and allow running for 5 minutes, then • Loose clamps
checking that the battery charger is delivering at least
13.2V DC into the battery. Replace hoses that are cracked or soft. Tighten any
loose clamps.
Starter Motor
Missing Safety Labels: These labels are a
These are normally sealed for life but should be mandatory safety requirement and if any are missing
inspected and serviced in accordance with the engine or not easy to read they should be replaced. Full
manufacturers instructions. details of all labels are contained in this manual. A
replacement label kit is available.
Exhaust System
Chaffing or Stretching of Cables: Inspect all cables
Inspect the exhaust system and silencer at the flexible and connections and look for obvious signs of wear or
sections and joints in particular. damage.
Check the exhaust is adequately supported and Lifting Points: Inspect the lifting points for obvious
secured. Check for leaks and signs of burning of the signs of wear, damage or distortion.
insulation. Replace insulation if necessary.
Signs of Over Heating: Look for obvious deterioration
If the engine has run on low load for a considerable due to heat and investigate the cause and rectify as
period the exhaust may be sooted up. Run the engine necessary.
on low load for 10 minutes and gradually increase to
full load for 30 minutes to blow and burn any soot out

Fuel Cap: Check the cap seals correctly. Check for 4. Clean the cooling system filler cap and inspect the
obvious signs of fuel spillage. gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
Electrical: is not damaged, use a suitable pressurising pump
• Inspect sockets, and replace if damaged or in order to pressure test the filler cap. The correct
contact pins are burnt. pressure is stamped on the face of the filler cap. If
• Check all wiring is secure and not damaged. the filler cap does not retain the correct pressure,
install a new filler cap.
• Check the output voltage and frequency are
correct.
Cooling System Coolant Extender (ELC) Change
• Check the earth continuity between the socket
earth pins and the generator frame. Refer to changing the standard Cooling System
Change. When refilling use the Perkins Extended Life
Run on ¼, ½, ¾ then full load Coolant.
Operating the generator at low load levels for

extended periods can result in high levels of carbon
build up in the engine and exhaust system which can
lead to excessive smoking, reduced efficiency and
overheating. Looking at the silencer’s outlet will give
some indication this has happened.
After each service the generator should be run first

on ¼, then ½, then ¾ and finally full load using a load
bank to burn out any deposits of soot in the engine
and silencer.
Each level of load should be applied for at least

10 minutes or until the exhaust is clear of soot and
smoke. If you suspect the engine is badly sooted, DO
NOT apply full load but build the load up gradually.
It should be anticipated that hot soot will be expelled

from the engine during this procedure and it should be
done in a safe place away from combustible material
and under supervision at all times.
Cooling System Coolant Extender (ELC) Add
The Perkins Extended Life Coolant (ELC) does not

need the frequent addition of Supplemental Coolant
Additives (SCA) that are associated with conventional
coolants. The Extender only needs to be added once.
Check the cooling system only when the engine is

stopped and cool.
1. Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant from

the cooling system in order to add the Extender.
3. Add Extender according to the requirements for

your engine’s cooling system capacity.

Maintenance Record Sheet (for use by owner / service agent)

Name of Owner: Name of Service Organisation:
Address: Address:
Order No: Job No:

Generator Details (from Data Plate) Date of Service:
Model:
Serial No: Hours Run meter reading: (hrs)
Build Code:
Service Interval:
Year of Manufacture:
Daily / 500 / 1000 / 2000 / 3000 / 6000 / 12000
Rated Power:
Power Factor PF: General Condition:
Voltage (Current):
Fuel Type
Daily Checks: After 1000hrs:
1. Fuel Level Checked Yes / No 1. Complete 500hrs check Yes / No
2. Oil Level Checked Yes / No 2. Canopy checked Yes / No
3. Coolant Checked Yes / No 3. Engine Valve Inspect / Lash / Yes / No
4. Battery Checked Yes / No Replace
5. Check for oil / fuel leaks Yes / No
After 2000hrs:
6. MCB/RCD/RCBOs checked Yes / No
7. Check fuel filter not contaminated Yes / No 1. Complete 1000hrs check Yes / No
2. Starter Motor checked Yes / No
After 500hrs: 3. Alternator checked Yes / No
1. Complete daily checks Yes / No 4. Turbocharger inspect Yes / No
2. Check Radiator Yes / No
3. Change the engine oil Yes / No After 3000hrs:
4. Change the oil filter Yes / No 1. Cooling System Change Yes / No
5. Check the air filter clean Yes / No 2. Alternator Belt Tension check / Yes / No
6. Electrical checks Yes / No Adjust
7. Control Module checks Yes / No
After 6000hrs:
8. Primary Fuel Filter replace Yes / No
9. Secondary Fuel Fileter replace Yes / No 1. Complete 2000 & 3000hrs check Yes / No
10. Run at ¼, ½, ¾ and full load Yes / No 2. Coolant Extender (ELC) Add Yes / No
11. Exhaust System check Yes / No
After 12000hrs:
12. Battery Charger Yes / No
13. Glow Plugs Yes / No 1. Complete 6000hrs check Yes / No
14. ............................................... Yes / No 2. Coolant Extender(ELC) Change Yes / No
Spare parts used:
Notes:
Signed: Representing: Date:
498-1073 38
Harrington Generators International Parts & Service
Parts and Service
Contact Details
Parts Department Technical Help Line
Tel: +44 (0) 1629 821 645 Staffed by friendly Technical Engineers who will
Fax: +44 (0) 1629 821 606 advise on the correct generator for your power
email: parts@hgigenerators.com requirements, its application and safe use.
Website: www.hgiparts.com
Tel: +44 (0) 1629 821 614 or 821 652
Service Department
Tel: +44 (0) 1629 821 647

Email: service@hgigenerators.com
Warranty Statement
See HGI Website for latest warranty statement
https://www.hgigenerators.com/warranty-statement-2.html
Functional Spares
Description Part Number

Engine Parts
Oil Filter A1003-086
Air Filter A1003-087
Fuel Filter A1003-058
Fan Belt A1003-056
Glow Plug Call
Rocker Cover Joint A1003-064
Generator Parts
DSE7310 Controller 125-080
3 Phase 3 pole 50A MCB 110-350
32A RCBO 30mA 1 Phase 110-525
4 Pole RCD Merlin Vigi 110-968
MG 4P MCB Trip 110-020
25A MCB 1 Pole Push Button 110-025
Fuse 2A 20mm 100-002
Fuse 5A 20mm 100-005
Fuse 10A 20mm 110-006
Socket 32A 230V 2P+E IP67 090-022
Socket 63A 3P+N+E IP67 090-252
Socket 125A 3P+N+E IP67 090-248
Socket 32A 3P+N+E IP44 090-032
Socket, straight 32A 2P+E IP44 090-022

Transportation / Storage Harrington Generators International
Transportation and Storage

Do not lay the generator on its side when moving, storing, or operat-
NOTICE ing it. Oil may leak and damage the engine or your property
If the generator has been used, allow it cool for at least 15 minutes before loading the generator on the transport
vehicle. A hot engine and exhaust system can burn you and can ignite some material. To prevent fuel spillage
when transporting, the generator should be secured upright in its normal operating position, with the engine
Control Module switched OFF.
Take care not to drop or strike the generator when transporting. Do not place heavy objects on the generator.
Item Description
Engine: Turn the Engine Control Module “OFF”
Short Term typically up to 6 months:
Do not run the generator out of fuel. If the engine runs out of fuel the fuel system will
become air locked and will have to be bled before the engine will restart. Leave a
small quantity of fuel in the fuel tank. Drain any water from the water separator / filter.
Run the engine for a few minutes and drain the warm oil and fill with new oil as for a
normal service. Turn battery isolator off. Disconnect battery and grease terminals with
petroleum jelly.
Long Term over 6 months:
For long term storage each engine manufacturer will have their own recommendations
typically:
1. Replace engine oil with a special inhibiting oil.

2. Flush through fuel system and leave full with a special inhibiting compound.
3. Spray connectors in the loom and plug in sensors with Vaporol Inhibitor or similar.
Please contact HGI for further details.

Alternator: No special requirements other than store in a dry well ventilated place.
If the generator has been stored for a considerable period of time e.g. several years
the alternator insulation winding resistance should be checked as they can absorb
moisture. The insulation resistance must be at least 2 MΏ (2 mega ohms). If it is
less than this then the alternator windings can be dried out by placing the alternator
in an oven at 60-70°C for a few hours with plenty of air movement. Generally if this
procedure is required consider replacing the alternator.
Please contact HGI for details.

Electrical : No special requirements other than store in a dry well ventilated place.
General: Store in dry, well ventilated and dust free place.
Whilst in storage it is recommended that the battery is trickle charged via the 3-pin
socket (buccaneer) on the control panel.
If the generator is to be stored long term it would be beneficial to start and run the
generator under electrical load for half an hour every three months and then store as
above ( but no need to change the oil).

Harrington Generators International Wiring
Wiring
WD-HRD400T1-AD-SP

Wiring Harrington Generators International
WD-HRD400T1-AP-S

Harrington Generators International Datasheets and Specifications
Datasheets and Specifications
Vigirex Adjustable RCD

Manufacturer’s Service and User Guides Harrington Generators International
Manufacturer’s Service and User Guides Links

Every effort is made to ensure that the manufacturer’s user and service guides contained in this manual are the
latest available at the time of publication. If in doubt about the recency of the documents then please contact the
manufacturer or visit their website for the latest information.
Perkins Operators and Maintenance Manual
- http://www.perkins.com/Manuals
Deep Sea 7310 User Guide
- http://www.deepseaplc.com/products/dse-genset
Sincro SK160 User Manual
- http://www.sincro.com.au/shop/generators/4-pole-alternators
If you are still unsure then please contact HGI Technical Helpline: +44 (0) 1629 821 614 or 821 652

Operation and Maintenance Manual: 40kVA 3 Phase Diesel Generator

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Ravenstor Road

Sales Tel: +44 (0) 1629 824 284

Operation and Maintenance Manual

40kVA 3 Phase Diesel Generator

Publication No: 498-1073

© Harrington Generators International Limited

Date Version Author Reason for change

HRD Diesel Generator 498-1073

FAULT FINDING ........................................................................................... 28

498-1073 HRD Diesel Generator

HRD Diesel Generator 1 498-1073

In accordance with ISO/IEC 17050-1:2010 Conformity Assessment - Suppliers’ Declaration of Conformity

And has been designed and manufactured to the following Standards:

Notified Body for 2000/14/EC Noise Emis- HORIBA MIRA UK

Signed: Date: 20/06/17

Printed: D.C.Coulton Position: Head of Systems

498-1073 2 HRD Diesel Generator

Harrington Generators International Ltd

Generating Set ISO 8528 PRP Class G2

HRD Diesel Generator 3 498-1073

Model HRD400T-AD-SP HRD400T-AP-S

498-1073 4 HRD Diesel Generator

HRD Diesel Generator 5 498-1073

*Illustration Only Typical of

498-1073 6 HRD Diesel Generator

*Illustration Only Typical of

HRD Diesel Generator 7 498-1073

Safety Operator Responsibility

• Know how to stop the generator quickly in case of

498-1073 8 HRD Diesel Generator

Label Part No, Qty, Location Description

Qty 1 The exhaust pipe is shielded as much as

Pt No. 499-945-003 DIESEL FUEL ONLY

Qty 1 This generator must only be filled with

Pt No. 499-945-004 INLET AND OUTLET VENTS TO BE

Pt No. 499-945-005 NO STEP

Qty 1 The generator should not be used as a

Pt No. 499-945-015 FUSE IDENTIFICATION

Qty 1 Informational label advising the Identity of

Qty 1 An M10 brass earth stud is supplied next

HRD Diesel Generator 9 498-1073

Pt No. 499-945-009 FORK LIFT POINT

Qty 4 The generator can be lifted from the sides

It is intended that when lifting from the

Qty 1 The oil level should be seen on the oil dip

Pt No 499-945-011 ELECTRICITY IS DANGEROUS

On side panel: If in doubt about the correct use consult

Pt No 499-945-011 CHECK ENGINE OIL LEVEL DAILY

On side panel: Operating the generator at low load

If the generator is not required switch it

This is to ensure a free flow of cooling

498-1073 10 HRD Diesel Generator

Pt No 499-945-011 KEEP FLAMMABLE MATERIAL AWAY

In addition DO NOT SMOKE while

Pt No 499-945-011 DO NOT ADJUST THE SPEED OF THE

If the generator is not producing enough

This is a mandatory Health and Safety

HRD Diesel Generator 11 498-1073

Pt No 499-945-011 DO NOT OPERATE WITH ANY

If the generator is to be used for a fixed

Qty 1 Informational label showing the ON / OFF

Pt No. 499-945-013 EXTERNAL INTERNAL FUEL SWITCH

498-1073 12 HRD Diesel Generator