USER MANUAL

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USER MANUAL | Manualzz
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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