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USER MANUAL PLEASE READ THIS MANUAL CAREFULLY. IT CONTAINS IMPORTANT SAFETY INFORMATION. ITEM # DIES5500 DIESEL GENERATOR PREFACE Thank you for purchasing a - - diesel generating set. This operation manual will tell you how to operate and service your set correctly. - - generation Please read this manual before using the generating set to ensure the proper operation. Follow the instructions to keep your generating set in the best working condition and extend the life of it. If you have any commends or problem, please contact with our sales company or the authorized agent. This manual deals with the general items of the - - diesel generating set.However the manual may vary with the development of the products in the future. Please give special attentions to warnings and cautions. WARNING Indicates that the severe personal injury even death will result if the instructions are not followed. CAUTION Indicates that the serious personal injury or equipment damage will result if the instructions are not followed. -diesel generating set will meet your requirement if you operate it according to the manual instruction. Otherwise serious personal injury and equipment damage will result. So, - - reconfirms that you must to read and understand this manual before operating the generating set. WARNING: 1. TO PREVENT THE FIRE Never add fuel to the fuel tank while the engine is running, Wipe off the overflowed fuel oil with a clean cloth. Keep explosives and other flammable products and from the generating set. To prevent the fire and to provide adequate ventilation, keep the generating set at least one meter away from buildings and other equipment during operation. Operate the generating set on a level surface. Do not put the generating set indoors while the engine is hot. 1. To PREVENT FROM INHALING THE EXHAUST Exhaust gas contains poisonous carbon monoxide,which is harnful to the health. Never use the generating set at the confined places or poor ventilated locations. If it’s necessary to run the generating set indoors, be sure to provide the adequate ventilation . 3. Danger: SCALDING can accure The muffler and the engine body are very hot while the engine is running or just after running, do not touch these parts to prevent from being scalded. 4. ELECTRIC SHOCKS, SHORT CIRCUITS To avoid electric shocks or short circuits, do not touch the generating set when your hands are wet.This generating set is not waterproof, so it should not be used in a place exposed to rain snow or water sprays. Use of the generating set tor in a wet place can cause short circuits and electric shocks during operation. The generating set should be grounded to prevent electrical shocks from faulty appliances. Connect a length of heavy wires between the generating sets ground terminal and an external ground source. Do not hook up tools or other apparatus to generating set rator before it has been started. If equipment is attached, generator starting may cause sudden movements of the equipment and result in injuries and accidents. Be sure to disconnect any apparatus from the generating set or prior to starting. CAUTION Most appliance motors require more than their rated wattage for start-up. Do not exceed the the specified current limit of any socket. Do not connect the generating set to a household circuit. This could cause damage to the generating set and to electrical appliances in the house. 5. WHEN CHARGING THE BATTERY Battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. In case of contact, flush thoroughly with water and get prompt medical attention, especially if your eyes are affected. Batteries generate hydrogen gas, which can be highly explosive. Do not smoke or allow flames or sparks near a battery, especially during charging. Charge the battery in a fully ventilated place. 6. PLEASE KEEP THE CHILDREN FROM THE GENERATOR A generating set may cause hazards that are not recognized by the layman and especially not recognized by children. Protect children by keeping them at a safe distance from the generating set. 7. IN USING Advice on the need of personal protection equipment, e. g. hearing protection where the application is known. CONTENTS 1. Main Technical Specifications and Date …............................1 2. Configurating ………………………………………………...3 3. Preparation for Starting ……………………………………..6 4. Start the Generating Set …………………………………….10 5. Operate the Generating Set …………………………………15 6. Load …………………………………………………………...16 7. Stop the Generating Set ……………………………………...18 8. Periodic Checks and Service ………………………………...19 9. Long-term Storage ……………………………………………20 10. Troubleshooting and Remedy ………………………………25 11. Noise………………………………………………………..…26 air-cool genset is cooling by air . if altitude is more than 1000m , air will be rarefaction , so the effect will be not good . In case overheating , for gensets which are using in high altitude (more than 1000m) , it should be running in low load . Also it dosent mean that gensets can be overload if altitude is less than 1000m . 2.1 Part name (LDE series T type) 2.1 Control Panel 3. PREPARATION FOR STARTING 3.1 Selection and handling of the fule oil Selection of fule oil. Only use the light diesel, which is most suitable for the engine. Keep dust and water out of the fule When filling the fule tank from druns, make sure that no dust or water is mixed in the fule. Otherwise the serious fule injection pump and nozzle problems will result. Do not overfill Overfilling is very dangerous. Do not fill the tank beyond the top of the red plug inside the fule oil filter. WARNING Refuel in a well-ventilated area with engine stopped. Do not smoke or allow flames or sparks in the area where the engine is refueled or where the fule oill stored. Do not overfill the tank, make sure the filler cap is securely closed after refueling. Be careful not to spill fuel when refueling. If any fuel is spilled, make sure the area is dry before starting the engine. 3.2 Check and refill the engine oil WARNING Always check the engine oill level with the generating set on a level surface before starting and refill if necessary. The engine may be damaged if operated with insufficient engine oil, it is also dangerous to refill too much engine oill as sudden increase in engine speed may be caused by its combustion. CAUTION: LDE series generating set are equipped with low oil warning system. This system will stops the engine automatically when the oil level falls below the lower level. This prevents accidents such as bearing seizures, etc. Select the most applicable engine oil It is very important to select the applicable engine oil for keep up the performance and life of the generating set. If inferior engine oil is used, or if your engine oil is not replaced periodically, the risk of piston seizure, piston ring sticking and accelerated wear of the cylinder liner, bearing and other moving components increases significantly. So the generating set life will be shortened. - recommends CC/CD oil classified by APL.Choose the applicable viscosity oil according to the local ambient temperature. 3.3 Service the air cleaner 1. Screw off the wing nut, remove the air cleaner cover and take out the element CAUTION: Do not wash the element with detergent. Replace the element when its output decrease or a bad exhaust color is noticed. Never run the generating set without the element, otherwise the rapid engine wear will result. 2. Reattach the air cleaner cover and screw on the wing nut. 3.4 Check the generating set 1. Turn off the main switch and any other loads. WARNING: Be sure to turn off the main switch before starting. The generating set should be earthed to prevent electric shocks. WARNING: The generating set should be earthed to prevent electric shocks. Protection against electrical shock depends on circuit breakers specially matched to the generating set. If the circuit breakers require replacement they must be replaced with a circuit breaker having identical ratings and performance characteristics. 2. Handling of dual voltage type generating sets Be sure to place the changeover switch in the correct position for the rated volttage of the working instrument. CAUTION The main switch should always be kept in the “ON” position during operation. Before starting the engine, be sure to turn the switches of the working instrument (lighting apparatus, motor, etc.) to their “OFF” position. If the switches are not “OFF”, the sudden application of load when the engine is started could be very dangerous. 3.5 How to open the cabinet door and covers of - - LDE series generating set 1. Open the cabinet door for daily inspection. Turn the lever counterclockwise and raise the door 2. Loosen the bolt of the air cleaner check port cover to check the air cleaner. 3. Screw off the wing nut to open the cover. then check the nozzle cover. 3.6 Break-in period operation The first 20hrs are the break-in period of the engine, the operator must obey to following items: Warm up the engine 5 minutes after the initial starting. Run the engine at low speed and zero load before the engine becomes warm. Avoid applying any heavy loads during the break-in period.- - recommends to run the engine at 3000r/min with 50% load in break-in period. Replace the engine oil on time. Replace the engine oil while the engine is warm after 20-hours-running, the old engine oil will be drained out completely. Approx. one month or 20hours Every 3 months or 100 hours 4. START THE GENERATING SET WARNING Do not hook up tools or other apparatus to the generating set before starting. 4-1 Recoil starting Start the engine according to the following procedures: 1. Open the fule cock. 2. Set the engine speed lever at the RUN position. 3. Pull out the recoil starter handle. Pull out the handle until you feel the resistance, then return it back to the initial position. Press down the decompression lever. It will return automaticallly when the recoil starter is pulled. Pull out the recoil starter handle briskly with both hands. CAUTION Do not hook up tools or other apparatus to the generating set before starting. Do not allow the handle grip to snap back against the engine. Return it gently to prevent damage to the starter. When the engine is difficult to start in cold weather, remove the screw plug from the cylinder head cover and add 2cc engine oil. CAUTION Always screw on the screw plug on the cylinder head cover except filling. to prevent the rain and dirty flowing into the engine body. Otherwise the quick wear of the internal parts and other serious problems will result. Recoil starting Recoil starting 4.2 Electric starting 1. Starting (The preparations for electric starting are the same as for the recoil starting.) Open the fule cock. Set the engine speed lever at “RUN” position. Turn the starting key clockwise to “START” position. Remove your hand from the key as soon as the engine starts. If the starting motor does not start after 10 seconds, wait 15 seconds before starting it again. CAUTION Run the starting motor for long time will cost the battery power greatly even burn out the motor Always leave the starting key at “ON” position while the engine is running. 2. Battery Check the battery electrolyte level every month. Refill the distilled water until the upper limits if the electroly dropped to the lower limits. CAUTION If the electrolyte level is too low, the engine may fail to start because there is not sufficient power. On the other side, if the electrolyte level is too high, the fluid will corrode the surrounding parts. Do keep the electrolyte level between the upper and lower limits. 5. OPERATE THE GENERATING SET 5.1 Operate the generating set 1. Warm up the engine without load three minutes. 2. Concerning the generating set with Low Oil Warning System, check that the Oil Alarm Lamp is not lit. CAUTION For the generating set Low Oil Warning System, the Oil Alarm Lamp will activated by low oil pressure or engine oil shortage, simultaneously, the engine will stop. The engine will stop immediately if restarted without refilling the engine oil. Check the oil level and refil. Do not loosen or readjust either the engine speed limiting bolt or fuel injection limiting bolt, otherwise, otherwise, the performance will be affected. 5.2 Checks during the running 1. Whether there is abnormal sound or vibration; 2. Whether the engine misfires or runs rough; 3. Check the color of the exhaust.(Is it black or too white?) If you notice any of the above-mentioned phenomenon happened, stop the engine and find out the fault cause or contact with - - agent. CAUTION If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler. Never refill the fule tank while the engine is running. 6.LOAD CAUTION Do not startn 2 or more machines simultaneously. Start them one by one. Do not use floodlights together with other machines. CAUTION The generating set must not be connected to other power sources, such as the power company supply mains. In special cases where stand-by connection to existing electrical systems is intended, it shall only be performed by a qualified electrician who has to consider the differences between operating equipment using the public electrical supply network and operating the generating set. When using extension lines or mobile distribution networks the total length of lines for a cross section of 1.5 mm2 should not exceed 60m; for a cross section of 2.5mm2 this should not exceed 100m. 6.1 AC application 1. Be sure to run the generating set at rated speed, otherwise AVR(Automatic Voltage Regulator ) will produce the forced excitation. If the running is for a long time under such condition, AVR will be burned out. 2. After switching on the switch, observe the voltmeter on the panel of the control cabinet, the voltmeter should point to 230V±5%(50HZ)for single-phase generating set; 400V ± 5% ( 50HZ ) for three-phase generating set,then the loading can be carried out. 3. When the double voltage generating set changes over the voltage, the air switch should be set at“OFF” postion. Otherwise the generating set and electric devices will be burned out and damaged. 4. Connect the equipment to the generating set in order. For the matter of the motor load, firstly the heavy-duty motor should be connected, then the light-duty motors. If the operation is false , the generating set will lag or stop suddenly. It is necessary to unload the generating set immediately and turn off the main switch and do checks. 5. Three-phase generating set Balance three phases during the operation. Stop the engine for check if the tolerance exceed 20%. Be sure to keep the tolerance among three phases less than 20%. The load for each phase must below the rated load as well as the current must less than rated current. A,B,C,D(or U,V,W,N) phase arrangement should be from left to right, or clockwise. Concerning starting the three phase asynchronous motors, first start the heavyduty motors, then start the light-duty motors. NOTE If coverloading of the circuit trips the AC circuit protector, reduce the electrical load on the circuit, and wait a few minutes before resuming operation. 6.2 DC applicetion 1. DC terminals are only for charging 12V battery. 2. Set the air switch at “OFF” position while charging. On the 12V output terminals, a charge switch can be connected so the switch can be used for on-and-off purpose. 3. Concerning the automatic type battery with the leads, be sure to disconnect the negative leads of the battery while charging. CAUTION Connect the positive and negative poles of the battery with the positive and negative poles of DC terminals separately. Do not confuse them, otherwise the battery and generating set will burn out. Do not connect the positive pole of the battery with its negative pole, otherwise the battery damage will result. Do not connect the positive pole of the DC terminal with its negative pole, otherwise the generating set damage will result. When a large capacity battery is charged, excessive current flows, the fuse for the direct current will burn out. Do not run the generating set while it is still connected with the battery. Do not use DC 12V and AC at the same time. CAUTION Battery exhausts explosive gas. Keep sparks, flames, and cigarettes away from the battery. To prevent from creating a spark near the battery, always connect the charging cables to the battery first and only then to the generating set. When disconnecting, you should disconnect the cables at the generating set first. Charge the battery at a well-ventilated place. Before charging, remove the cap from each cell of the battery. ℃ Stop charging if the electrolyte temperature exceed 45 . 6.3 Electrical appliance particularly motor-driven equipment will produce very high current while starting, the below table provides the reference for connecting these apparatus to the generator set. 7. STOP YOUR GENERATING SET 1. Disconnect the load from the generating set. 2. Turn off the air switch of the generating set, 3. Set the speed lever at “RUN” position, run the generating set without load for about 3 minutes. Do not stop the engine suddenly, otherwise the temperature will increase abnormally, the nozzle will blocked and the generating set will be damaged. Press down the stop lever. Concerning the electric starter, turn the key to “OFF”. Turn the fuel cock lever to “S” position. Pull out the recoil starter handle until you feel resistance (at this position, both intake/exhaust valve are closed. ) and leave the handle in this position. This prevents the engine from rust. WARNING If the engine keep on running even after the speed lever is placed at the “STOP” position, either turn the fule cock to the “CLOSE” position or loosen the nut of high pressure fule pipe on the pump side to stop the engine. Do not stop the engine with the decompression lever. Do not stop the generating set with load. Stop it after the load removed 8. PERIODIC CHECK AND SERVICE Periodic check and service are very important for keeping the engine in good condi- tion and durable. The chart below indicates what checks to make and when to make them. WARNING Shut off the engine before performing any service. If the engine must be run, make sure the area is well ventilated. The exhaust contains poisonous carbon monoxide gas. After the generating set has been used, clean it immediately with a cloth to prevent corrosion and to remove sediment. 8.1 Replace engine oil Remove the oil filler cap. Remove the drain plug and drain the old oil while the engine is still warm. The pulg is located on the bottom of the cylinder block. Tighten the drain plug and refill with the recommended oil. 8.2 Clean the engine oil filter Cleaning Time every 6 months or 500 hours Replace if necssary 8.3 Replace the air cleaner element Do not clean the air cleaner element with detergent. Replace time Every 6 months or 500 hours CAUTION Never run the engine without the element or with a defective element. 8.4 Clean and replance fule oil filter The fuel oil filter also has to be cleaned regularly to insure maximum engine output. Clean time Every 6 months or 500 hrs Replace time Every year or 1000 hrs 1. Drain out the fule from the fule tank. 2. Drain out the fule from the fule tank. Screw off the small screw of the fule cock and pull out the filter from the filler port. 3. Wash the filter thoroughly with diesel fule. Loosen the fastening mut, bottom cover and delivery discs for cleaning the deposit carbon. 8.5 Tighten cylinder head bolt Tightening the cylinder head bolt requires a special tool. Do not try yourself. Contanct with - - agent. 8.6 Check the injection nozzle and fule injection pump 1. Adjust the clearance of the intake/exhaust valves. 2. Grind the intake/exhaust valves. 3. Replance the piston ring. All these operation require special tools and skills, contact with your - - agent. WARNING Do not perform the injection nozzle test near an open fire or any other kind of fire. The fule spray may ignite. Do not expose bare skin to the fule spray. The fule may penetrate the skin and cause injury to the body. Always keep your body away from the nozzle. 8.7 Check and refill the battery electrolyte and charge the battery The diesel uses a 12V battery. Battery electrolyte will be lost through continuous charging and discharging. Before starting, check for physical damage to the battery and also the electrolyte levels, and refill the distilled water till to the upper level if necessary. When actual damage is discovered, replace the battery. Check the battery electrolyte monthly. WARNING The battery electrolyte contains sulfuric acid. Protect your eyes, skil and clothing. In case of contact, flush thoroughly with water and get prompt medical attention, especially if your eyes are affected. The battery exhaust hydrogen gas, which can be highly explosive. Do not smoke or allow flames or sparks near the battery, especially during charging. 8.8 Check the generating set carbon brush slip ring Often check the generating set carbon brush slip ring. Readjust if there is spark. 9. LONG-TERM STORAGE If store the generating set for long periods, make the following preparation. 1. 2. 3. 4 Operate the engine for about 3 minutes and then stop. Stop the engine. Drain the engine oil while the engine is still warm and fill fresh oil. Remove the screw plug on the cylinder head cover and refill 2cc engine oil, then put the plug in place. Recoil starting: Push the decompression lever down(Non-compression position) and hold it while you pull the recoil starter2~3times.(Do not start the engine.) Electric starting: Turn the engine 2~3 seconds with the decompression lever set at the non-compression position, and the starting key at the “START” position.(Do not start the engine.) 5 6 Pull the decompression lever up. Pull the recoil starter slowly. Stop when you feel resistance.( at this position, both intake/exhaust values are closed to prevent the engine from the rust.) Wipe off the oil and dirt from the engine and store in a dry place. WARNING Indication that the installation and major repair work shall be carried out only by specifically trained personnel. The diesel engine can not start CAUTION Replace the AVR. AVR is damaged Charge it or replace it with a new one. The battery has no electricity. Adjust it according to the requirements. Start the enging according to the start procedures included in this book. The speed and force to pull the recoil starter are not enough. The rated speed can not attached. Clean the nozzle The nozzle has dirty. Adjust the socket. The specified oil level should be between the upper level and lower lever Check the engine oil level. The contact of the socket is not good. Set the lever to START position The governor lever is not at START position. Replace the carbon brush. Remove the nozzle and repair it at test table Fuel injection pump and nozzle do not delivery the fuel or delivery insufficient fuel. The carbon brush already worn. Turn it START position Fuel cock is not at START position Turn the main switch to ON position. Refill the fuel oil Fuel oil is not sufficient Main switch not be turned on. Remedy Fault Cause 10. TROUBLESHOOTING AND REMEDY The generating set can not generate The installation and major repair work shall be carried out only by specifically trained personnel. 11. Noise The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of work-force include the characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent processes, and the length of time for which an operator is exposed to the noise. Also the permissible exposure level can vary from country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk 74. 1dB 77. 2dB 79. 8dB 3M 5M 7M 87. 6dB Electric Wiring Diagram for All Types of the Set 85. 4dB <1> C type electric wiring diagram <2> X type electric wiring diagram (single voltage output) <3> X type electric wiring diagram (double voltage output) <4> E type electric wiring diagram (single voltage output) <5> E type electric wiring diagram (double voltage output) <6> E type electric wiring diagram <7> X3, E3 type electric principle diagram Description: For set X3 type, the components in the two –point-and-line box are not mounted. <8> T3 type electric principle diagram CALL FOR SERVICE 866-797-2738 PST) (8am to 5pm
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