What are the precautions for portable generators

Portable generators are widely used in outdoor operations, emergency power supply, camping and other scenarios due to their portability and flexibility. However, if used improperly, it may cause safety hazards or damage to the equipment. The following are the key precautions for using portable generators, covering safe operation, maintenance and compliance requirements:

I. Safety Operation Specifications

1. Fuel and exhaust safety

Keep away from fire sources: When refueling, the machine must be shut down and cooled for at least 10 minutes (to prevent fuel vapor from exploding upon contact with open flames). It is strictly forbidden to add fuel when the generator is in operation.

Ventilation requirements: Do not operate the generator indoors, in a closed garage or near doors and Windows to prevent carbon monoxide (CO) poisoning (exposure to 50ppm CO for one hour can cause headaches).

Fuel storage: Use dedicated metal fuel drums to store gasoline. Keep away from direct sunlight, fire sources and children. The storage volume should not exceed the daily usage (usually ≤20L).

2. Electrical connection safety

Grounding protection: The generator casing must be connected to a reliable grounding electrode through a grounding wire (copper wire with a cross-sectional area of ≥4mm²) to prevent leakage and electric shock.

Load matching

Calculate the total load power (for example, 100W for lighting + 500W for electric drill =600W), ensuring it does not exceed 80% of the generator's rated power (leaving a 20% margin to deal with start-up shock).

Avoid starting multiple high-power devices (such as air conditioners and welding machines) simultaneously to prevent voltage drops from damaging electrical appliances.

Anti-reverse power supply

It is prohibited to directly connect generators to the household power grid (which may cause "reverse power supply" and endanger the safety of power grid maintenance personnel).

If it is necessary to supply power to buildings where the municipal power supply is cut off, a double-transfer switch or an automatic transfer switch (ATS) must be installed.

3. The operating environment is safe

Rain and moisture protection: When used in rainy weather, a rain shelter (with a height of ≥1.5m) should be built to prevent rainwater from entering the exhaust vent or control panel.

Dust and sand prevention: When used in deserts or construction sites, cover the air intake with a dust cover and clean the dust on the heat sink in time after operation.

Anti-tilt: Ensure that the generator is placed on a level ground (with an tilt Angle of no more than 15°) to prevent fuel leakage or insufficient oil lubrication.

Ii. Precautions for Startup and Shutdown

1. Check before startup

Fuel inspection: Confirm that the fuel level in the fuel tank is above 1/2 and there is no leakage in the fuel line (apply soapy water to the joint to check for bubbles).

Engine oil check: Check the oil level through the dipstick (it should be between the upper and lower marks). A low oil level can cause the engine to pull cylinders.

Air filter: Tap the filter element gently to remove dust. Replace it immediately if it is damaged (to prevent impurities from entering the cylinder and wearing the piston).

2. Start the operation

Cold start

Turn off all load switches;

Place the damper pull rod in the "closed" position (to reduce the intake volume and increase the starting concentration);

Pull the start rope or press the electric start button. After starting, immediately push the air door back to the "open" position.

Hot start: If the generator has just been shut down, you can directly set the damper to the "Open" position to start it.

3. Shutdown specifications

Normal shutdown

First, turn off all load switches;

Run the engine idle for 3 to 5 minutes (to allow the engine to cool down and prevent the turbocharger bearings from lacking oil);

Press the stop button or turn off the fuel switch.

Emergency stop: In case of abnormal situations (such as severe vibration or black smoke), immediately press the red emergency stop button.

Iii. Key Points for Monitoring during Operation

1. Instrument parameters

Voltage: Measure the output voltage with a multimeter (for a 220V single-phase generator, the fluctuation range is ±5%, that is, 209 to 231V).

Frequency: Detected by a frequency meter (the fluctuation range of a 50Hz generator is ±0.5Hz, that is, 49.5 to 50.5Hz).

Oil pressure: Small generators usually do not have an oil pressure gauge, but it can be determined by the engine sound (there will be a "click" sound when the oil pressure is low).

Water temperature: For air-cooled models, it can be judged by the temperature of the heat sink (if the touch can stay for 3 seconds, it is normal). For water-cooled models, the water temperature gauge (≤95℃) needs to be observed.

2. Abnormal phenomenon handling

Unstable voltage

Check whether the load is overloaded;

Adjust the AVR(Automatic Voltage Regulator) knob (if any);

Replace the carbon brushes (wear and tear can cause poor contact).

Engine shaking

Check the carbon deposits on the spark plugs (clean the electrodes with sandpaper);

Adjust the valve clearances (0.15 to 0.20mm for intake valves and 0.20 to 0.25mm for exhaust valves when the machine is cold).

Black smoke comes out of the exhaust

Clean the air filter;

Adjust the carburetor mixture ratio (tightening the mixture ratio screw clockwise can reduce the fuel consumption).

Iv. Maintenance and Servicing Cycle

1. Daily maintenance

Clean the body of the generator: Wipe the dust on the surface of the generator with a dry cloth to prevent the heat dissipation holes from being blocked.

Check the fasteners: Use a wrench to check if the engine bolts and control panel screws are loose.

Run the test without load for 10 minutes and observe if there are any abnormal sounds or oil leaks.

2. Maintenance is required every 50 hours of operation

Change the engine oil: Drain the old engine oil (collect the waste oil in a container and hand it over to a professional institution for treatment), and add new engine oil (10W-30 mineral oil is suitable for environments ranging from -5℃ to 40℃).

Clean the spark plugs: Use a wire brush to remove carbon deposits and adjust the electrode gap to 0.7 to 0.8mm.

Check the fuel pipe: Use compressed air (pressure ≤0.2MPa) to blow through the fuel filter.

3. Maintenance is required every 100 hours of operation

Clean the carburetor: Disassemble the carburetor and soak the float chamber and fuel injectors in carburetor cleaner.

Check the muffler: Tap the muffler to listen for any debris sounds (the internal insulation cotton has fallen off and needs to be replaced).

Lubricating the bearings: Add 2 to 3 drops of lubricating oil (such as No. 3 lithium-based grease) to the bearings of the generator fan.

V. Storage and Transportation Specifications

Long-term storage (≥30 days)

Fuel treatment: Drain the gasoline from the fuel tank and carburetor (to prevent gum sedimentation from blocking the fuel passage).

Anti-corrosion treatment: Spray a small amount of engine oil into the cylinder and rotate the engine 2 to 3 times to make the oil adhere to the cylinder wall.

Storage environment: Keep in a dry and well-ventilated place, cover with a dust cover, and avoid direct sunlight and moisture.

2. Transportation requirements

Secure firmly: Use a dedicated transport box or straps to secure the generator in the vehicle to prevent damage from jolts.

Vertical placement: Keep the generator vertical during transportation (with an inclination Angle of no more than 15°) to prevent fuel leakage.

Avoid collision: Keep away from hard and sharp objects to prevent deformation of the casing or heat sink.