Guide to Gasoline Generator Essential Safety & Operation

In today's society, the stability of electricity supply is crucial for both daily life and work. However, natural disasters, power grid failures, or special event needs make gasoline generators an indispensable backup power source. Yet, safety and proper operation are of utmost importance when using gasoline generators. This article will provide you with a comprehensive guide on the use and maintenance of gasoline generators, helping you to operate them safely and efficiently.

Safety Precautions for Using Gasoline Generators

Safety is always the primary consideration when using gasoline generators. Here are several key safety points.

1. Exhaust and Ventilation

The exhaust from gasoline generators is toxic and can cause unconsciousness or even death in a short period. Therefore, never use the generator in an enclosed space. It is essential to choose a well-ventilated area to ensure that harmful gases can be quickly expelled, safeguarding the safety of the operator and those around them.

2. Fuel Safety

Gasoline is a highly flammable and toxic substance. When refueling, the generator must be turned off to avoid sparks or flames that could cause a fire. Additionally, prevent fuel from spilling or leaking onto the engine and muffler to avoid fires or equipment damage. Moreover, tilting the generator can cause fuel to leak from the carburetor and fuel tank, so it is important to keep the generator upright during operation or movement.

3. Equipment Placement and Protection

The engine and muffler generate heat during operation, so the generator should be placed out of reach of passersby and children to prevent burns. Also, do not place any flammable materials near the exhaust outlet to avoid fires. The distance between the generator and buildings or other devices should be more than 1 meter; otherwise, the generator may overheat. Furthermore, do not cover the generator with a dust cover while it is running, as this can affect heat dissipation.

4. Weather and Environment

Never use the generator in the rain or snow. Touching the generator with wet hands can lead to electric shock. Ensure that the operating environment is dry to avoid safety issues caused by dampness.

5. Grounding and Electrical Safety

It is imperative to properly connect the grounding wire, using a conductor with a cross-sectional area of more than 4mm². Grounding can effectively prevent electric shock accidents. Additionally, do not connect the generator to commercial power outlets, nor should it be connected to other generators. The switching between utility power, generator power, and load should be done using an interlocking switch to ensure safety.

6. Fuel Selection

The fuel must be unleaded gasoline with an octane rating of 90 or higher. High-quality fuel can ensure the performance and longevity of the generator while reducing the emission of harmful gases.

Use and Maintenance of Gasoline Generator Batteries

The battery is an essential component of the gasoline generator, and its proper use and maintenance directly affect the generator's starting performance and service life.

1. Battery Connection

When starting the battery, connect the red wire to the positive terminal of the starting battery and the green wire to the negative terminal, tightening the terminals to ensure good contact. Be cautious not to cause a short circuit with the tools used during battery connection. Do not remove the power cable while the generator is running, and never connect the positive terminal of the battery cable to the negative terminal, as this can damage the charging coil.

2. Safety Precautions for Batteries

The electrolyte is toxic and extremely hazardous, potentially causing burns and other accidents. Since it contains sulfuric acid, avoid contact with skin, eyes, and clothing. Batteries can produce explosive gases, so keep them away from lightning, flames, and cigarettes. Ensure proper ventilation when using or charging batteries in confined spaces. Protect your eyes when approaching the battery and keep children away from it.

Fuel and Oil Filling for Gasoline Generators

Ensuring the correct filling and inspection of fuel and oil is a crucial step in guaranteeing the safe operation of gasoline generators. Next, we will detail how to properly fill and inspect fuel and oil to ensure the efficient and safe operation of the generator.

1. Gasoline Generator Fuel Filling

When filling the fuel tank, remove the fuel cap by rotating it counterclockwise and observe the fuel level gauge on the tank. Do not remove the fuel filter mesh from the filler opening to prevent impurities from entering the tank. During fueling, the engine must be stopped, and be very cautious of any sparks or flames around. Do not fill the fuel tank while the engine is running or not yet cooled down. Before fueling, the fuel line switch must be turned off. Also, avoid mixing dust, dirt, water, and other external impurities into the gasoline. If gasoline spills, it must be wiped off before starting the engine.

2. Gasoline Generator Oil Filling

The quality standard for engine oil should be SJ or SG grade or higher. Pull out the dipstick to check the oil level, which should be within the mesh grid on the dipstick, ideally slightly above the middle. To fill the oil, rotate the gray filler cap counterclockwise to remove it and pour the oil in. After one minute, check the oil level again to ensure it is appropriate. The engine has an oil pressure sensor, and the generator cannot operate normally if the oil is insufficient or excessive. If there is too much oil, it can be drained through the oil drain plug. The generator does not come with engine oil when it leaves the factory, and it must be filled with oil before use.

Starting and Running of Gasoline Generators

This section will guide you on how to safely and effectively start a gasoline generator and pay attention to key points during operation to ensure the stable running of the equipment and the safety of the operator.

1. Pre-Start Preparation

Before starting the generator, make sure to set the output AC switch to the OFF position; otherwise, it may damage the generator. Turn on the fuel switch (to the ON position) and gently pull out the choke with your finger. For manual start models, slowly pull the recoil starter until it engages, and then pull it forcefully. For electric start models, adjust the start switch to the ON running position and rotate the start switch to the START position for 10 seconds. If the start is unsuccessful, wait for ten seconds before trying again until it starts successfully.

2. Initial Use and Warm-Up

When using a newly purchased unit for the first time, it may need to be started 2-3 times to succeed. For electric start models, the interval between each start should be more than ten seconds to avoid over-discharging the battery or damaging the starter motor due to overheating. If the unit fails to start after five attempts, check for any faults. After starting at normal temperature, the generator should run for 1-2 minutes to warm up. In cold weather, extend the warm-up time to 3-5 minutes. Starting with a load immediately after starting may cause the generator to shut down suddenly. If connecting a load, it should be correctly connected to the generator's output terminals before starting the generator, and then the output switch should be closed after the warm-up.

3. Precautions During Operation

The generator should not be overloaded. Long-term operation with a load should not exceed 80% of the rated power. For three-phase models, the three-phase loads should be balanced, with no phase difference exceeding 30%, otherwise, the generator is prone to damage. The cable size connecting the generator and the load should comply with the relevant national technical specifications (1 mm²/4A). To avoid personal injury, operation must be carried out by professional technicians. The generator should be monitored by a dedicated person during operation, regularly observing the voltage and current of the generator. If any abnormal phenomena occur, stop the machine immediately for inspection. During operation, the muffler and exhaust pipe will be very hot and must not be touched, as this could cause severe burns.

Shutdown and Maintenance of Gasoline Generators

After the generator has completed its operating task, proper shutdown and regular maintenance are essential to ensure the long-term stable operation of the equipment. The following content will detail how to safely shut down the generator and how to perform routine maintenance to extend the service life of the generator and maintain its optimal performance.

1. Gasoline Generator Shutdown Procedure

The shutdown of the generator should be carried out in the correct sequence. First, turn off the load, then disconnect the generator's output switch. Run the generator without load for 2-3 minutes, then turn the start switch to the STOP position. Turn the fuel switch to the STOP position. If the generator is not going to be used for a long time, the following shutdown method should be used: first, turn the fuel to the OFF position and let the generator run until the fuel is exhausted and it stops automatically. After shutdown, turn the start switch to the STOP position. This shutdown method can prevent residual fuel in the carburetor from deteriorating due to long-term disuse, clogging the carburetor, and causing the generator to fail to start.

2. Gasoline Generator Routine Inspection

Before each use of the generator, the following checks should be performed to ensure the safe and normal operation of the generator:

Check if there is sufficient gasoline in the fuel tank.

Check for any fuel leakage or seepage in the fuel line switch and fuel supply lines.

Check if the engine oil level is within the mesh grid on the dipstick and observe the oil quality to determine if a change is needed.

Check if the starting battery voltage is above 12V and observe if there is any damage or leakage on the battery's appearance. If the generator is not used for a long time (more than one month), the starting battery will lose power due to self-discharge. In this case, use an external charger to charge the battery.

3. Gasoline Generator Maintenance

Maintenance is the key to ensuring the long-term stable operation of the generator. Original factory parts must be used, otherwise, the warranty will not be honored. Maintenance must be carried out by professional technicians. Here are the specific maintenance steps:

Place the generator on a flat surface and start the engine for a few minutes to raise the engine oil temperature, then stop the engine. Remove the oil fill bolt (i.e., the dipstick).

Place an oil pan under the engine, remove the drain plug, and the engine oil will drain from the crankcase.

Inspect the drain plug, seal ring, and rubber ring. If any damage is found, replace them immediately.

Reinstall the drain plug and tighten it. Fill the engine oil to the upper part of the mesh grid on the dipstick.

The generator should have its engine oil changed immediately after the first 20 hours (or one month) of use. After that, the oil must be changed every 100 hours (or six months). In harsh environments, the frequency of oil changes should be increased. It is recommended to use clean engine oil with a viscosity of SAE10W30 and an API grade of SG, SH, SJ, or higher.

The air filter should be cleaned every 50 hours (or three months) of generator use. In harsh environments, the cleaning frequency should be increased, and replacement should be done when necessary. Remove the air filter cover and filter element, clean the filter element with a solvent, and dry it. Apply oil to the filter element and squeeze out any excess oil. The filter element should be wet but not dripping oil. Insert the filter element into the air filter. Do not twist the sponge forcefully to avoid damage. Do not start the engine without the air filter installed to prevent excessive toxic gas production and cylinder wear.

Conclusion

Gasoline generators are highly practical backup power devices, but strict adherence to safety operating procedures is essential during use. From exhaust and ventilation, fuel and oil filling, starting and running, shutdown and maintenance, to battery use and maintenance, every step is crucial. Only through correct operation and regular maintenance can the safety and efficient operation of the generator be ensured, and its service life extended. It is hoped that this comprehensive guide provided in this article will help you better use and maintain your gasoline generator.