Diesel Generator Set Shop Manual

MODEL: KDE19EA
KDE19EA KDE1
19EA，KDE19EA3
9EA3,, KDE1
KDE19EA3 9STA
KDE19 TA,, KDE19STA3
KDE19STA3
 Preface

This manual contains KDE19EA ， KDE19EA3, KDE19STA, KDE19STA3 generator types, which
written by KIPOR POWER CO.,LTD. It mainly guides KIPOR’S dealers and it’s eligible repairmen how
to properly operate and maintain KIPOR generator set . The manual doesn’t cover all the maintaining
knowledge of generator set. Therefore, the maintainers should have basic knowledge and skill in
generator maintenance technique. If not, but trying to maintain above-mentioned generator types will
cause damage and safe accident. To avoid this happening, please contact with KIPOR POWER CO.,
LTD. or agents in time. If you have any suggestions or requests，please contact us.
The manual is about universal item of KIPOR generator set, with the company’s improvement and
development, maybe the practical product content of generator set is inconsistent with maintenance
service manual, please follow the shop random manual. If the procedure has any modification or any
other important change, KIPOR will inform all the authorized agents and revise the content in the new
edition manual.
 Content

1. Safety
1.1 Attentions
1.2 Install, move and transport genset
1.3 Fire prevention and explosion prevention
1.4 Protection
1.5 Chemical
1.6 Electric equipment
Warning labels and position
1.8 Rescue the injured hurt by electricity
Lifting, installation and deposit
2.1 Lifting
2.2 Installation
2.3 Deposit
3. Technical parameters
3.1 Main technical parameters of generator set
3.2 Maintenance parameters of generator set
3.3 Maintenance parameters of generator set
3.4 Electrical systematic elementary diagram
3.5 Fastening torque values
4. General explanation
4.1 Shape and structure of generator set
4.2 Electric cabinet
4.3 Diesel engine
4.4 AC brushless four poles synchronous generator
4.5 Genset fuel supply system
4.6 Genset structure air dust cooled system and water cooled system
5. Handling instruction of electric control parts
5.1 Operation panel
5.2 Operation of digital display controller function
5.3 ATS connects with generator set
5.4 Connection of load
6. Daily inspection and regular inspection
6.1 Regular inspection procedure
7. Operation indication
7.1 Fuel lubrication water cooled
7.2 Battery cell operation
7.3 Preparation before operation
7.4 Used method
8. Maintenance and repair of electrical system
8.1 Starting electrical motor
8.2 Charging generator
8.3 Generator
9. Maintenance and repair of engine
9.1 Installation drawing and some parts names
9.2 Engine disassembly and assembly
9.3 Engine check and maintenance
10. Failure and resolution
10.1 Doesn’t generate power or generate power abnormally
10.2 Digital panel electrical system
10.3 Warning system failure
10.4 Starting failure
10.5 Engine rotation speed unsteady
10.6 Exhaust color anomaly
10.7 Engine under-power
10.8 Fluctuation of service
10.9 Engine overheat
10.10 Hard shutdown
10.11 Abnormal sound while engine operating
1.Safety
1.1 Attentions
Thank you for purchasing KIPOR generator set.
Please carefully read and thoroughly understand this introduction and precautions and attentions
marked on the machine prior to operation, check and maintenance. Then official operation is allowed.
Please carefully read the following safety indications for avoiding unexpected accidents and damages.
This manual identifies conditions of risks and damages if operation is incorrect with following.

The sign shows that if not obey the indication will lead to serious injury and
death accident.

Danger

Indicates the potential risk should be noted, if not obey the indication will lead
to serious injury and death accident.

Warning

The sign shows that if not obey the indication might lead to mild injury
and damage.

Attended
●To get the best efficiency and ensure the longest life of generator set, must do preventative
maintenance in accordance with this manual. If generator set operates in bad status condition, it will
shorter duration of some parts.
● Be sure all the servicemen have professionary training.
● However, it is impossible for our company to expect all risks concerning conditions of
operation, check and maintenance. Therefore warnings contained in the introduction and identified on
the machine are exclusive and complete. User shall take own responsibility for safety if user does
operation, check and maintenance not mentioned herein.

Install,, move and transport genset

1.2 Install

For safety, please observe following matters needing attention.

Warning
 ● According to correlative standard, norm and other requests containing earth connection and
creepage fault to connect wire.
● Do not lift the machine at non-designated positions because of insufficient lifting strength.
Otherwise falling machine leads to mechanical damage or human injury.
● Upon lifting the machine, please use the designated metal hook in the center of engine cover.
● Do not stand under lifted machine.

● Do not lift the machine when engine runs or don’t run engine when lift the machine.
● Incorrect overlapping-storage may cause falling and overturn of machine and mechanical
damage.
● Place the machine on the flat and solid ground. Keep machines level. Ensure that ground can
bear overlapping weight.
Max two layers of overlapping storage are allowed.

● Check if machine bolts are loose or missing.

● Separate machines with wooden lumps. Keep all wooden lumps bearing same weight.
● Do not run overlapped machines. Otherwise it may cause overturn and falling.
1.3 Fire prevention and explosion prevention

The fuel and exhaust-smoke of the generator are easily ignited and
explosive. Carefully deal with these matters and nip them in the bud. The BC
and ABC fire extinguishers in the machinery room should be in good condition.
Users must know how to use the fire extinguishers.
 Danger

Ensure the ventilation is enough in the machinery room.

Ensure the machinery room, floor and generator surface are clean, if the fuel, battery solution or
refrigerating fluid leak out, please clear them up immediately.
Don’t put inflammables near by generator set.
Put the oily rag into the metal container with cover.
Smoking, sparking or other open flame action near by the battery and fuel are not allowed.
Because the volatile gas from fuel and the hydrogen from battery charging will cause explosion by
open flame.
Cut off the power supply of battery charger before connecting or shut-off battery.
The conducting objects like metal tool should be away from exposed live part(like output
electrode), prevent the arc-spark and fuel or gas explosion caused by arc-spark.
Don’t fill fuel when the generator set is working.
Don’t start the generator in the condition of the fuel leaked.
Start the generator repeatedly, check valve and heat machine stops will cause excess unburned
gas in the exhaust system. Please be very careful by now, there is potential explosion danger. You
should start generator set after exhausting gas.

1.4 Protection

The safety cover is installed on the rotating place of the generator set, be
careful all the risks of moving parts to people when the generator set starts.

Danger

When the safety cover is took apart, don’t start the generator set. When the generator set is
running, don’t reach under or nearby the safety cover to maintain.
When maintaining, the worker should wear work clothes, gloves and hat.
Palm, arm, long hair, loose-fitting clothes and jewelry should keep away from the moving or
rotating parts of generator set.
Don’t touch high temperature parts before generator cooling.

1.5 Chemical

The fuel, oil and battery solution belong to product of chemical industry, if
improperly used or managed them, it is harm to human body.

Warning

Don’t swallow or let skin touch harmful chemicals like fuel, oil, battery solution. If swallowing them
by careless, you should see a doctor in time, if the skin touches them, you should wash your eyes with
soap and clean water.
 Don’t wear clothes stained by fuel, lubricant and battery solution.
When dealing with battery, please wear acid-proof apron, face shield or eye protector, once the
body is stained by acid liquor, wash it immediately with abundant water. If the acid liquor splashes into
eyes, please wash your eyes with clean water or 10% dilute boric acid solution, and see a doctor in
time.
1.6 Electric equipment

Correct installation, operation and maintenance can make sure the electric
equipment work efficiently and safely. If not, the injury even death is very likely
to occur.

Danger

Generator set must be connected load by qualified or experienced electrician, connected load
must conform to relevant electrical rules, standards and norms.
Ensure the earth specification of generator set conforms to local safety rules and standards of
electric.
Don’t stand in the water or humid ground to connect or dismantle load.
When the generator set generates electricity, human body or metallic object without insulation
protection doesn’t touch with live parts of generator set or power supply wire.
After connecting or disassembling load, please reset distribution cabinet cover immediately. Don’t
start generator set at open distribution cabinet cover.
The load or electric system supplied power by this generator set must consist with electrical
character of this generator set. And the power should be in the range of capacity of this generator set.
When maintaining the generator set, make sure you remember to cut off all the external power.
Keep all the electric equipments dry and clean. Please replace wire and insulator immediately if
they are any cracking, laceration or wearing. Keep wire and connection pole clean and close connected.
Ensure all the electric parts and power connection of generator set have proper protection.
Only BC or ABC grade fire extinguisher can be used for electric equipment fire fighting.
When connecting into battery, keep positive pole and negative pole upright, otherwise it may
cause serious damage to electric equipment.
1.7 Warning labels and position
1.7.1 Lab le position
Lable
 4
7
3
2
6 1
5

10
11
12

8 9

1. Attention 2. Pay attention to exhaust 3. Pay attention to scalding 4. Pay attention to high
temperature 5. Lifting position 6. Prevent flame and fire 7. Forbid lifting the machine 8. Pay
attention to handling of storage battery 9. Avoid being involved in the running machine 10. Low oil
pressure warning 11. Pay attention to electric shock 12. Attended operations
.7.2 Warning label
1.7.2
1. Pay attention to 2. Pay attention to exhaust 3. Pay attention to scalding

Check the engine while it is in
the cooling state. Check the
engine after it stopped. Be
care not to be scalded by
muffler and exhaust pipe.
Danger
The exhaust is harmful to the
health. Do not run the unit in
doors or in poor ventilated
area.
Don’t touch the water tank,
while it’s too hot to prevent
from the scalding.

4. Pay attention to high

5. Hooking position 6. No Smoking
temperature
 Don’t open the water tank
while high temperature.
You may be scalded due to
the hot water.
Hooking position Smoking or spark is
forbidden near to the filling
port. Otherwise the fire will
be happened.
Be sure to refuel the unit
after the engine is stopped.

9. Avoid being involved in

7. Hooking is forbidden. 8. Pay attention to not move battery
the running machine

Hooking is forbidden. Don’t move the battery when the Don’t put the hand or
generator is running. fingers into the machine
while running. Otherwise
injury may be happened.

11. Pay attention to

10. Low oil warning
electric shock

Don’t run engine without checking oil level in case of

auto stop or lighting of oil pressure alert lamp. Check
engine oil before each start. Be sure to use SEA 10W30
grade CC.
 12： Attended operations

◎ Please read the user manual carefully and operate the unit safely
Please read the user manual carefully before operation.
If the user manual and safety label are broken, please order from Kipor.
◎There is possibility of electric shook and fire. Don’t connect the unit to the utility lines or
home wirings.
◎Refuel the unit after the engine stopped to prevent the fire.
◎There is danger of electric shock and injury. Before starting, please firstly confirm that the
breaker is on the position of OFF.
◎Don’t move the unit while running to prevent from the injury.
◎Please operate by professional man with rich technology.
◎safety information:
There is high-voltage part, rotation part and high-temperature part. Do run the engine after
closing the lid.
◎Check and service the unit after the engine is completely stopped.

1.8 Rescue the casualties shocked by electricity

If electric shock occurs, cut off switch, shut down generator set emergently. If the power supply can not
be cut off, please separate the casualties shocked by electricity from the conductive matters as quickly
as you can. Avoid to directly touch with the conductive matters and the casualties shocked by electricity,,
please remove the casualties shocked by electricity with dry batten or dry clothings or other insulating
material
If the injured was in a coma, give rescue breathing immediately according to the needs. Otherwise, the
injured will die. When the heart has stopped, do cardiac massage.
2. Lifting and transportation, installation and storage
2.1 Lifting and transportation
2.1.1 Lifting
 ●Lift generator with the lifting hook on the top of cover. Do not stand under the
lifted generator. If the generator falls down, it may cause hurt.

Warning

● If lifting the generator with transportation hook or other parts, there is the risk of mechanical damage
or falling-down.

● Do not lift or move the running generator. Some irrevocable errors like fan damage may occur.
● Don’t run the lifted machine.
2.1.2 Transportation
● If shipping with the truck, please fix the generator on the loading table in the truck for safety concern.

● Bind the generator with ropes at left and right hands indicated on below drawings after loading.
2.2 Installation

Please work the machine in the well-ventilated place. Bad

ventilation causes breath of waste gas thus to death.

Danger

●Do not work the generator in the building or place with cover, bad ventilation or static exhaust.
●Do not work the generator in the place with bad ventilation such as inside stockroom, tunnel, cabin or
enclosure channel.
●If it is necessary to run the machine on mentioned conditions, necessarily extend exhaust pipe outside
of room and provide proper ventilation device to ensure sufficient ventilation.
●Prevent exhaust vent direct to passerby or other's family.

2.2.1 Pay attention to vibration

Running machine produces vibration as inside engine is working.
Please observe the following requirements upon installation.
1)Place the generator on the solid ground and keep it level.
Abnormal vibration may occur if generator runs on the uneven ground.
2) If there is uptown around, residents may complain about noise. Therefore please install the
generator after solid foundation is completely finished. Consult local sales department of KAMA for
detailed information concerning vibration specification and foundation project.

2.2.2 Pay attention to noise

There is great noise if operator opens the side door as inside engine is working.
In addition, there is still certain noise even if side door is close.
1）Close the side door after machine is installed.
2 ） If there is uptown around, residents may complain about noise. Therefore please take additional
measures against noise. Consult local sales department for detailed information concerning noise
specification.

2.2.3 Pay attention to installation

This generator is portable and used as main or auxiliary power supply for outside work. Installation shall
consider below requirements.
1）Please install the machine on the flat and solid ground. Make sure bottom of the generator contacts
ground evenly. Error may occur due to generator vibration.
2）If it is necessary to run the machine on the inclined ground, make sure the side with radiator upward
and inclination angle within 10°. Engine may face over-heat due to bad working of water temperature
switch, air into cooling water pipe and etc.
3）Keep machine at least 200-300mm away from walls upon installation. Keep air vent of radiator and
suction inlet and exhaust vent of engine upward. Prevent them from any jam. Otherwise temperature
rise or reduction of cooling airflow may cause over-heat of engine or reduction of rotation. In addition,
temperature of exhaust or increase of load also may lead to shorter duration.

4）Run the machine in the place free of moisture, dust and rubbish and with fresh air.
Electricity leakage causes electric shock. If air vent of radiator is jammed, over-heat of engine may
occur.
5）Place the generator near to working equipments like motor, lamps and etc.
Long line reduces efficiency because of large resistance and electricity loss. And electricity fee turns
more.
6 ） When the generator loads down, please pay special attention to impact load and release loads
gradually and evenly.

2.3 Storage
Please store generators as following if two-layers storage is required.
●Check if generator hood is damaged or screw is loose or released.
●Check if the ground is flat and solid and can bear static weight of overlapped generators.
●Place the wooden lumps between generators.
●Prevent generators in the upper layer from inclination.
●Prevent generators in the upper layer heavier than those in the lower layer.
●Do not run the generator at the status of storage.

2.3.1 Long-term storage

Please implement following maintenance for the generator idle for long-term.
● Drain off cooling water in cold season or at the status of long-term storage.
(Mentioned action is no need if anti-freezing liquid is used.)
1）Take off upper hood and open radiator cover.
2）Take off drainage plug of cooling water in the frame of generator to drain inside water.
3）Loosen the drainage plug at the side of cylinder and drain out the water.
4）Close radiator cover, hood and drainage plug after drainage finishes.

It is necessary to drain off cooling water. Otherwise rest cooling water in the
engine may freeze and expand thus to damage the machine

Attention

●Please clean mud, dust and oil remained on the machine surface.
●Must finish periodic check prior to maintenance.
●In order to prevent dew concentration in the fuel tank. Drain off fuel or fill fuel completely.
●Disconnect cable of storage battery with (-) pole.
●Apply lubricant to operating devices and relevant connections.
●Please cover the plastic hood and similar parts in order to prevent water or dust into control box,
radiator and muffle of exhaust pipe.
●Store the machine in the place without moisture or dust and with good ventilation.
●Please charge the storage battery once per month to resolve intrinsic shelf depreciation during
machine storage.
●Please do no-load running for short time and at low speed if machine is idle for long term and prior to
load running.
 3.Technical parameters
3.1Main technical parameters of generator set
3.1.1Overall dimension

Model KDE19STA /3 KDE19EA/3

Overall length 1540mm 1210mm

Width 700mm 850mm

Height 810mm 785mm

3.1.2Main technical parameters(single-phase generator set)

Model KDE19EA KDE19STA

Rated frequency Hz 50 60 50 60
Rated output capacity KVA 14.4 17 14.4 17
Max. output KVA 16.7 18.7 16.7 18.7
Rated voltage V 115/230 120/240 115/230 120/240
Rated current A 125/62.6 142/70.8 125/62.6 142/70.8
Generator

Rated rotation speed rpm 3000 3600 3000 3600

Circuit mode Single-phase and three circuits
Power factor 0.9(LOG)
Insulation grade F
Steady-state voltage
≤2.5
deviation (%)
Frequency step down (%) ≤0.5
Air circuit breaker(selected
63A 75A 63A 700A
value)
Pole number 2
Excitation mode self-excitation and constant voltage
 （with AVR）
Panel type Digital panel
Output Voltage V 115/230 120/240 115/230 120/240
Receptacle Two single phase receptacles
Connection pole With
DC12V output Without
Fuel tank capacity L 38 38
Set

Continuous running time h 7 6 7 6

Overall dimension: LXWXH mm 1210X850X785 1540X700X810
Net weight Kg 320 442
Noise level (7m) dB(A) 90 72
Structure type Open frame Ultra silent

3.1.3 Main technical parameters of three-phase generator set

Model KDE19EA3 KDE19STA3

Rated frequency Hz 50 60 50 60
Rated output capacity KVA 16.25 19 16.25 19
Max. output KVA 18.75 21 18.75 21
Rated voltage V 230/400 240/416 230/400 240/416
Rated current A 23.5 26.4 23.5 26.4
Generator

Rated rotation speed rpm 3000 3600 3000 3600

Circuit mode Three phase, four lines, Y connection
Factor power 0.8(lag) 0.8(lag)
Insulation grade F
Steady-state voltage
≤2.5
deviation (%)
Frequency step down (%) ≤0.5
Air circuit
25A 30A 25A 30A
breaker(selected value)
Pole number 4
Excitation mode self-excitation and constant voltage
 （with AVR）
Panel type Digital panel
Voltage V 230/400 240/416 230/400 240/416

Output
Receptacle Two single phase receptacles
Connection pole With
DC12V output Without
Fuel tank capacity L 38
Set

Continuous running time h 6 7 6

Overall dimension:
mm 1210X850X785 1540X700X810
LXWXH
Net weight Kg 320 442
Noise level (7m) dB(A) 90
Structure type Open frame Ultra silent

3.2 Maintenance parameter of generator

3.2
3.2.1 Main parts maintenance detecting parameter of single-phase generator and generator set
3.2
Generator set model KDE19EA KDE19STA
Generator model KT19 KF19
Frequency 50 60 50 60
Each winding When main winding is
1.2 1.15 1.2 1.15
resistance measuring 230V：L1L2+R1R2
condition of generator:
The ambient
temperature of is
20℃±2℃ Main winding of rotor 45 45
The measured value
deviation on the right
form isΩ±10%
The measuring
Sampling voltage V 115 115
conditions of resistance
voltage and current:
Exciter full field voltage V 115 115
Rated output voltage is
230V, frequency is
50Hz,rated power,
ambient temperature
Exciter full field current A 1.30 1.30
20℃±2%, the deviation
is V±0.1%

3.2..2. Main parts maintenance detecting parameter of three-phase generator and generator set
3.2

Generator set model KDE19EA3 KDE19SAT3

Generator model KTS19 KFTS19
Frequency 50 60 50 60
Each winding U-N（O） 0.9 0.6 0.9 0.6
Main
resistance measuring V-N（O） 0.9 0.6 0.9 0.6
winding
condition of generator: W-N（O） 0.9 0.6 0.9 0.6
The ambient
temperature of is
20℃±2℃
Main winding of rotor 45 45
The measured value
deviation on the right
form isΩ±10%
The measuring
Sampling voltage V 200 200
conditions of resistance
voltage and current:
Exciter full field voltageV 115 115
Rated output voltage is
230V, frequency is
50Hz, rated power,
ambient temperature Exciter full field current A 1.30 1.30
20℃±2%, the deviation
is V±0.1%

3.4 Principle diagram of electrical system

3.4.1 Single-phase univoltage output
3.4.2 Three-phase voltage output
3.4.2
4. General explanation
4.1 Outlook and structure of generator set
4.2 Diese
4.2 Diesell engine
Diesel multi-cylinder engine adopts KD376 engine of KIPOR and consists of three-cylinder, vertical and
four-stroke piston-rod, the burning type is whirlpool injection, the lubricate system is pressure and
splash mixing; the diesel multi-cylinder engine uses forced circulation cooling system made up of
radiator and fan and pump, it has auxiliary functions of electric starter, air heater and charging genertrix.
The function of diesel engine is to convert heat produced by diesel oil consumption into mechanical
energy. (see KM 376engine service manual)
4.3 two
4.3 two– –pole synchronous alternator
KIPOR company uses KT series synchronous alternator with rotor exciting dynamo self-excitation and
stator sampling and sub winding, the alternator supplies exciting current to rotor main winding by AVR
self-excitation and control and adjust the generator output voltage. It makes the generator voltage
output smoothly. The function of the generator is to convert mechanical energy output by generator into
electric energy.
4.5 Fuel supply system of generator set
Generator set uses electric pump fuel supply, The way is that generator own fuel tank passes the
electric pump fuel supply to fuel pump of engine, by electric pump fuel supply, which ensures
unimpeded flow of fuel supply.
4.6 Air dust cooled system and water cooled sy
sysstem of generator set structure
Generator set uses enclosed silent housing construction that makes radiant heat and running noise
produced by running engine reduce, it becomes the real silent generator set.

5. Handling instruction of electric control parts

5.1 Operation panel
Opera
It contains intelligent display controller, breaker, , starter, emergency stop button and power supply
indicator lamp.
The intelligent display is made up of display panel, module control panel, ATS control panel, only the
display panel is on the operation panel, module is installed in the machine cabinet. The ATS control
panel is installed in the outside control box of ATS, you can select to use or not. All the functions can be
operated on the display panel. ( this is Select Configure for ATS Function , May have no such function
on other units )
5.1.1 Starter
5.1.1
Work start, running and stop.

Take out the start key and keep in the proper place if generator is not used.

Attention

●OFF
Indicate that start key is taken out and engine stops.
Intelligent indication lamps are all off.

●ON
Keep the position when machine works.

●START
Indicate start position of engine. In the case that starter is turned to this position, machine is
preheated and starts. If operator releases the start key, starter returns to ON automatically.

●Pre-heating (HEAT)
Automatically start pre-heating upon start of intelligent panel controller. Operator can define
preheating time.
When intelligent display shows PRE-H, machine is preheated. After preheating, machine
automatically enters into start procedure. When intelligent display shows START, machine is running.

5.1.2Bre
5.1.2 aker
Brea
To supply power produced by generator to main switch of 3-phase joint of output terminal block
Automatically cut off the switch when loading equipment is at short-circuit or over-load. Protect the
generator.

Do not operate loading equipment ON/OFF with the breaker. If user requires
ON/OFF function, add Load ON/ OFF switch between 3-phase joint and
loading equipment. Otherwise there are some errors of breaker.
 Attention

●It is at OFF when engine starts. It is at ON when power is used.

●If there is over current, regulating handle of breaker maintains between ON

and OFF when breaker is cutoff. This condition is named tripping. By then turn
regulating handle downward to OFF. If regulating handle does not return to
original position, it is not allowed to turn regulating handle to ON.

5.1.3 Voltage regulator

5.1.3
It is used to regulate output voltage. If turn it right, voltage rises. If turn it left, voltage falls down.
The adjustment potentiometer on the AVR. You can to turn the volt potentiometer only ,don’t to turn the
other two

●Voltage regulation range

this is Single-phase AVR

AVR frequency regulation:

AVR will enter into
protection function if the
frequency changes too
much. It has already
been set when leaving
factory, so you don’t need
to regulate it any more.

Regulate output voltage of stator．when AVR output voltage regulation: Regulate the
The output rated voltage（sine wave crest） AVR controlling feedback time. It has already
is up and down undulation and then been set when leaving factory, so you don’t
regulate it ． It was able to get rated need to regulate it any more.
voltage ． It is used change by
user’s．
 this is three-phase AVR
AVR output voltage regulation: Regulate the
AVR controlling feedback time. It has already
been set when leaving factory, so you don’t
need to regulate it any more.

Regulate output voltage of stator ． when The
output rated voltage（sine wave crest）is up and down
undulation and then regulate it ．It was able to get
rated voltage．It is used change by user’s．
AVR frequency regulation: AVR will
enter into protection function if the
frequency changes too much. It has
already been set when leaving
factory, so you don’t need to regulate
it any more.
5.1.5 Intelligent display controller
The intelligent display controller uses one-chip microprocessor to check and monitor the operating
conditions of engine, such as oil pressure, cooled temperature, and charging voltage parameter. The
engine running trouble will be displayed by code. And it can check and display the output frequency,
output voltage, output current(three-phase) or power (single-phase), running time, battery voltage. The
intelligent display controller controls the start and stop of generator set through one-single
microprocessor. When setting up ATS, it will monitor and judge the utility power, and realize the
conversion between utility power and generation power. The intelligent display controller can be used
absolutely to combine into common generator set, also be used for ATS generator set which transforms
between utility power and electric power generation.

5.1.5.1 Running electric parameter display function

(1) Indicate output voltage;

(2) Indicate output current;
(3) Indicate output frequency;
(4) Indicate running time;
(5) Indicate battery voltage;
(6) Indicate voltage of utility electric network (available just with ATS)

5.1.5.2 Warning indication & protection function

(1) Low and over voltage protection
(2) Low and over frequency protection
(3) Over current protection
(4) Engine oil pressure warning
(5) Overheat warning (special units)
(6) Charging motor fault warning
(7) Emergency stops warning indication
(8) AVR protection indication

5.1.5.3 Starting function

(1) Preheat start (special unit)
(2) Direct startup (common units)

5.1.5.4 The stop of the unit and troubleshooting function

5.1.5.5 Supply transfer function and ATS function
5.2 The operation of the display panel functions
5.2.1 Knob Function-setting Function

●While the control panel with ATS function, the system will supply two setting parameter to the user:
1. Push down the "Supply switch" and "Automatic/manual " for 2 second after starting the generator 10
s and under stand-by, it enters to user parameter functions;
2. Push down the "item" key to choose function-set item. These are 2 functions to choose for the
consumer:
(1)” Real time clock” setting;
(2)” Auto startup time” setting;
3. Push down the "phase sequence switch" key to affirm the parameter set.
4. Push down "start" key, "stop/clear" key and "supply transfer" key to set up and down parameter.
The details of the setting are as followed:

(1) Clock (hour, minute) setting:

(2) When the screen displays “SETT” (setup timer), push down “supply transfer” key to choose “hour”
and “minute”.
a. When choose to set “hour”, two last digital diodes start glittering at left. Push down “start” or
“stop/clear” to set “hour”. The clock will increase or decrease1h by pushing down “start” or “stop/clear”
key each time.
b. When choose to set “minute”, two last digital diodes start glittering at right. Push down “start” or
“stop/clear” to set “minute”. The Clock will increase or decrease1m by pushing down “start” or
“stop/clear” key each time. Then you should push down “phase sequence switch” to affirm what your
choose.
●Time parameter setting for auto startup of inspection machine (just for ATS):
After entering setting function, push down the “item” key.
When the screen displays “SEAST” (Setup automatic start time), push down “supply transfer” key to
choose “intervals of automatic inspection in day”, “startup time (hour, minute)” and “automatic running
time”.
a. When choose to set “intervals of automatic inspection in day”, the screen displays “DAYXX” (X
indicates value, DAY indicates interval of automatic inspection, XX=0 indicates automatic start time of
inspection is invalid). Push down “start” or “stop/clear” to set “intervals of automatic inspection in day.”
The one-day will be increased or decreased by pushing down “start” or “stop/clear” key each time.
b. When choose to set “startup time (hour, minute)”, the screen displays “XX=XX”. Push down “supply
transfer” key to choose “hour” and “minute”.
When choose to set “hour”, two last digital diodes start glittering at left. Push down “start” or “stop/clear”
to set “hour”. “The Start time” will increase or decrease1h by pushing down “start” or “stop/clear” key
each time.
When choose to set “minute”, two last digital diodes start glittering at right. Push down “start” or
“stop/clear” to set “minute”. “The Start time” will increase or decrease1m by pushing down “start” or
“stop/clear” key each time.
c. When choose to set “Automatic start running time”, the screen displays “rt XX” (X indicates value, rt
indicates automatic start running time). Push down “start” or “stop/clear” to set “automatic start running
time”. “The Automatic start running time” will increase or decrease1m by pushing down “start” or
“stop/clear” key each time. Then you should push down “phase sequence switch” to affirm what your
choose.

●Exit the setting function:

Pushing down the “Supply transfer” and “Auto/manual” key simultaneously for 2s, it will exist setting
function and return electrical parameter indication state.

5.2.2
5.2.2Running Indication Function
Push down the “item” key to choose the display parameter.
item”
1. Display output voltage
When output voltage indicating lamp lights, digital diode displays: (unit: V)
“XXXX.X”
XXXX.X” Single-phase output indication
Dual-phases (any phase) output indication
“AXXX X”
AXXX．X Display output voltage of phase A
“BXXX X”
BXXX．X Display output voltage of phase B Dual phase output simultaneously
“CXXX X”
CXXX．X Display output voltage of phase C

“AXXX X”
AXXX．X Display output voltage of phase A
“BXXX X”
BXXX．X Display output voltage of phase B
“CXXX X”
CXXX．X Display output voltage of phase C Three-phase output voltage display
“ABXXX”
ABXXX” Display voltage of wire AB
 “BCXXX”
BCXXX” Display voltage of wire BC
“CAXXX”
CAXXX” Display voltage of wire CA
It can switch to display the different phase voltage and line voltage by pushing down the “phase
sequence switch” key.
2. Display output current or output apparent power
The digital diode indication information is as followed, when indicating lamp is got on. (Unit: A or VA)
“XXXXX”
XXXXX” Single-phase output current display. VA
“XXXXX”
XXXXX” Dual-phase output current display. VA
“XXXXX”
XXXXX” Display dual-phase output current display at the same time
“AXXX X”
AXXX．X
“BXXX X”
BXXX．X Three-phase output phase current display.
“CXXX
CXXX．X X”
It can switch to display the different phase current by pushing down the “phase sequence switch” key,
when it is in the state of displaying output current.
3.The output frequency display
The digital diode displays “XX.XX” (Hz), when output frequency indicating lamp lights.
4. The running time display
The digital diode displays “XXXX.X” (hours), when running indicating lamp lights.
For example: 0.1 hour means 6 minutes. It will log the running time every 6 minutes.
5. The battery voltage display
The digital diode displays “XXX.X” (V), when battery voltage indicating lamp lights.
6. Voltage of power network display
a. If insert ATS control panel as machine is energized, then ATS function is available. If voltage of
power network is normal, indication light of normal voltage will be on and digital diode displays “XXX.X”
(V). If voltage of power network is abnormal, indication light will be glittering and digital diode displays
“XXX.X” (V).
b. If ATS control panel is not been inserted, ATS function is valid and voltage of power network does not
display.

5.2.3Starting Function
1. Push down the “start” key or turn on “electric door lock” directly to start the unit when there is no fault
of the unit. The preheat time is varied from the ambient temperature. It will connect the starter motor
automatically after preheating successfully.
2. When the unit is in warning state, you should push down the “stop/clear” key to eliminate the fault
before starting the unit.
Note: If voltage of power network is normal and push down “start” key, machine cannot start provided
that ATS is effective and under Auto. Then choose “manual” or “semi-auto” to set ATS working condition
to start machine.
3. If digital diode displays “Pre-H”, it means that machine is under preheating as to start preheating. If
digital diode displays “Start”, it means that starter motor has been connected as to connect starter
motor.

5.2.4Stop Function
1. When unit is starting or preheated, you can push down the “stop/clear” key to stop the unit.
2. When the unit is running or starting, you can push down the “stop/clear” key to stop the unit.
3. Delay stopping unit in relation with “delay stop for protection functions” when unit enters into “warning
protection”. Push down “stop/clear” key to stop unit if unit enters into protected stop delay.
4. To unit with ATS, unit delays stop according to normal delay setting when ATS' power supply
transfers from generator to power network.
5. To unit with ATS, running unit automatically stops with respect to inspection running time setting
when ATS is at working condition of automatic inspection unit.

5.2.5Troubleshooting and Clear Function

When there is some fault of the unit, the corresponding warning indicating lamp will light.
Push down the “Item” key to observe the information of the electrical parameter when the unit stops for
the fault.
Push down the “stop/clear” key to clear the fault state, making unit stay at the pre-start state and fault
warning light off.

5.2.6Fault Warning and Protection Function

1. Engine oil pressure is not enough:
When the unit detects that the engine oil pressure isn't enough lasting for 5s, the unit will stop and start
stop protection after 1s delay. The low oil pressure-indicating lamp will glitter. Digital diode displays fault
code “P-01”, warning lower engine oil pressure.
2.Over-heat warning:
When the unit detects overheat signal, fault indicating lamp will glitter. Digital diode displays “P-08”,
meaning too hot water in unit. The unit will stop and start stop protection after 10s delay after mentioned
indications last for 10s.
3. Charging motor fault warning:
When the unit detects fault signal of the charging motor, fault indicating lamp will glitter. Digital diode
displays “P-07”, meaning unit-charging fault. There is no protection for charging fault.
4. Over/low voltage protection warning
(1). If the output frequency is set as 50Hz but it is over 55Hz, over/low protection indicating lamp will
glitter and digital diode displays “P-02” warning over/ low frequency for 3 seconds later with the unit
stops.

(2). If the output frequency is set as 60Hz but it is over 65Hz, over/low protection indicating lamp will

glitter and digital diode displays “P-02” warning over/ low frequency for 3 seconds later with the unit

stops.

(3). If output voltage is 110% set voltage, fault indicating lamp will glitter and digital diode displays “P-
03” warning overpressure for 3s later with the unit stops and over/low protection light will be on.
5. Overload protection
(1).When the single-phase current, delivered by the dual-phase circuit simultaneously, is 100%～110%
of the set current the fault indicating lamp will glitter and digital diode displays “P-04” warning overload.
Then large unit will cut off the air switch but not enter into stop protection, while small unit will enter into
stop protection an hour later.
When single-phase current is over 110% of the set current, the fault indicating lamp will glitter and
digital diode displays “P-04” warning overload. Then large unit will cut off the air switch but not enter
into stop protection 60 second later, while small unit will enter into stop protection.
(2) Three-phase unit:
When the current of any phase reaches the 100 ～ 110% of the set current, fault indicating lamp will
glitter and digital diode displays “P-04” warning overload. Large unit will cut off air switch but not enter
into stop protection 1hour later. When the current of any phase is over the 110% of the set current, fault
indicating lamp glittering and digital diode displays “P-04” warning overload for 60s, large unit will cut off
air switch but not enter into stop protection, while small unit will enter into stop protection.
(3). Dual-phase selectively output unit:
When to choose “230V” or “240V” for output voltage, fault-indicating lamp will glitter and digital diode
displays “P-04” warning overload provided that unit current reaches the 100%-110% of set current.
Large unit will cut off air switch but not enter into stop protection 1hour later, while small unit will enter
into stop protection. When the current is over the 110% of the set current, fault indicating lamp glittering
and digital diode displays “P-04” warning overload for 60s, large unit will cut off air switch but not enter
into stop protection, while small unit will enter into stop protection.
When to choose 115V or 120V for output voltage, fault-indicating lamp will glitter and digital diode
displays “P-04” warning overload provided that unit current reaches the 200%-220% of set current.
Large unit will cut off air switch but not enter into stop protection 1hour later, while small unit will enter
into stop protection. When the current is over the 220% of the set current, fault indicating lamp glittering
and digital diode displays “P-04” warning overload for 60s, large unit will cut off air switch but not enter
into stop protection, while small unit will enter into stop protection.

(4) Dual output-voltage simultaneity unit:

Error indicating light glitters when unit current reaches to 100%-110% setting current under voltage of
230V or 240V. And digital diode shows P-04, indicating overload alarming. One hour later, large unit
shuts down without stop protection while small unit with stop protection, while small unit will enter into
stop protection. Error indicating light glitters when unit current is over 110% setting current. And digital
diode shows P-04, indicating overload alarming. 60 seconds later, large unit shuts down without stop
protection while small unit with stop protection, while small unit will enter into stop protection.
Error indicating light glitters when unit current reaches to 100%-110% setting current under output
voltage of 115V or 120V. And digital diode shows P-04, indicating overload alarming. One hour later,
large unit shuts down without stop protection while small unit with stop protection. Error indicating light
glitters when unit current is over 110% setting current. And digital diode shows P-04, indicating
overload alarming. 60 seconds later, large unit shuts down without stop protection while small unit with
stop protection.
6. Start fault warning：
If the unit doesn't start successfully in 8 second after the unit is connected to starter motor, it will cut off
the starter motor relay automatically and digital diode displays P-05 warning start fault.
7. Emergency stop indication:
If the unit detects the signal of the emergency stop continuously, emergency stop indicating lamp will
glitter and digital diode displays P-06 meaning unit emergency stop 0.3 seconds later. If unit is on
condition of running, unit will stop and will not be able to start only if emergency stop keeps effective.
5.2.7 Supply Transfer Function, ATS function and Automatic Start Inspection Function
1. Identification of ATS control panel connection
Effective identification of ATS function is available when to connect ATS control panel with plug on
digital panel.
a. Light indicating lamp to set working conditions by system when unit starts and identifies connection
with ATS control panel. And indicating lamp of network power will be on, meaning effective ATS
function.
b. Black out indicating lamps for automatic, manual, network power and unit power when unit does not
identify connection with ATS control panel, meaning invalid ATS function.
2. Supply transfer function
a. Supply transfer function will be invalid in accompany with invalid ATS function.
b. Push down “supply transfer” key to change supply between network and unit when effective ATS
works at “manual” or “semi-automatic” condition. Indicating lamp for network power will light on when
power is supplied by power network. Indicating lamp for unit power will light on when power is supplied
by unit itself.
c. When ATS is operative in Auto state; “Power Switch” key is not available.
3. ATS working state option
a. In case that ATS loses its function, ATS working state option and its switch are all invalid.
b. When ATS is operative, push down “Manual/Auto” key to change its working state. When ATS
operates in Auto state, the auto indicating light is on. Likewise, the manual indicating light is on when
ATS operates in Manual state. While ATS operates in Semi-auto state, both indicating lights are on.
c. In any cases, push down “Stop/clear” key to convert ATS into “Manual” state.
4. Automatic transfer switch
a. When ATS is operative as well as in “Network Power” state, the system checks voltage every one
second. Once continuously for 3 seconds check the voltage exceeding ±10% of pre-set voltage, it
indicates abnormal voltage and lights the indicating light as well. Unit is then started and the system
makes time delayed according to pre-set power switch and checks voltage and frequency of unit. Once
voltage of unit reaches up to ±5% of pre-set voltage and frequency recovers, the unit is allowed to be
connected to power supply with indicating light of Unit Power Supply on, while the indicating light of
Network Power is off.

b. When ATS is operative as well as in “Unit Power Supply” state, the system checks voltage every one

second. Once continuously for 6 seconds check the voltage exceeding ±10% of pre-set voltage, it

indicates normal voltage and stop the indicating light as well. The system makes time delayed

according to pre-set power switch and converts to electric network supply. Indicating light of Electric

Network Supply is on and time-delayed stopping procedure is started.

5. Self-start check
When ATS is operative, comparing reading of current time with self-start check time, which matches
and the unit is self-started.

a. Provided that the unit starts successfully, it operates for some time with pre-set self-start check on.
Once all checked states are normal, the unit stops.

b. Provided that the unit cannot start, it delays for a while and restarts. In case that the unit cannot start
for 3 times, it gives off fault alarming and the self-start check is failed as well.

5.2.8 Cycling Display Setup For Various Electric Parameters

1. Push down “Start” key to enter into display of various electric parameters as unit is running.
2. Push down “Start” key to exist display of various electric parameters as unit is displaying parameters.
Kinds of code list ：P-01
P-01 oil pressure alarm
P-02 over/low frequency alarm
P-03 over/low voltage alarm
P-04 unit overload alarm
P-05 starting trouble alarm
P-06 emergency stop alarm
P-07 charging faulty alarm
P-08 unit overheat alarm
PRE-H unit preheating indication

5.3 The connection of ATS and generator set

5.4 Connection of load
5.4.1 Capacity of motor
If select the motor with improper capacity, it is impossible to start the motor.
Decide the capacity of motor as per followings:
●According to type, application, start method, quantity and operating power of motor, features of
generator, type of auto voltage regulator, starting capacity of generator is different.
Upon starting motor, its current is 5-8times of rated current. Its rapid rise of starting current causes
instant overload of generator. Then voltage of generator falls down rapidly. Therefore sometimes it is
difficult to start the motor.
It is recommended to discuss with manufacturer of motor upon decision of capacity. User can
calculate the capacity simply with below formulas.
1)Input power of squirrel-cage asynchronous motor (kVA)
Rated power of motor (kW)
Input power (kVA)=
Motor efficiency x Power factor

Power factor of motor: 0.8 Motor efficiency: 0.8

Input power (kVA)=1.56x rated power of motor (kW)
2)Direct-starting squirrel-cage asynchronous motor (with knife switch)
Generator capacity = 2x input power of motor
3)Direct-starting squirrel-cage motor (with contactor)
Generator capacity = 3x input power of motor
4)Star/ triangular-starting squirrel-cage motor
Generator capacity = 1.2~1.5x input power of motor
●It is required to balance the load if more than one AC electric welder is used.
Therefore user shall distribute phases equally as per following:

The input power of one electric welder should be adjusted below 1/3 of generator’s output. If it is
overload, the generator is possibly to be burnt out.
5.4.2 Selection of 3-phase cable

Please select the cable with proper diameter after taking into account tolerable current of cable and
distance from generator to loading equipments.
If load current exceeds tolerable current, lead is burnt to damage due to over-heat. In addition, following
conditions also can cause lead damage such as too long cable, super-small diameter, excessively large
voltage-drop of lead, reduction of input voltage of loading equipments, or reduction of efficiency of
loading equipments.

5.4.3 Connection of loading equipment

Please notice the following safe matters for security, otherwise it will cause
death.
 Danger

●Touching output terminal of running machine may cause electric shock even death risk, particularly
when hands are wet.
●Start connection work after cut off breaker and stop running machine.
●Application of damaged cable may cause electric shock. Forbid using such cable.
●Laws forbid connecting power supply of generator with inside distributing line (common distributing
line accepting power from the power company).
●If connection with inside distributing line, there is over-current of inside distributing line and generator
thus to cause fire or electric shock accident.
●Please do not connect the machine with inside distributing line.
5.4.4 3-phase power supply
●Connect cable with 3-phase joint of output terminal block.

● If 3-phase motor rotates in the reverse direction, please exchange any two lines of three terminals.

U
V M
W
N

5.4.5 Single-phase power supply (120V/240V)

There are two connection methods for single-phase power supply, i.e. single-phase socket and 3-phase
joint as indicated in the below drawing.
Please select proper connection method.
Socket and breaker are two 15A circuits (W-phase use). 3-phase joint combines N-phase with U, V
and W-phase. Regulate the voltage with voltage regulator.
Tolerable current of generator takes single-phase and 3-phase into account. If select single-phase
output, output of single-phase is only 1/3 of 3-phase output (unit: KW).If use single-phase and 3-phase
at the same time, please limit output of each phase below 1/3 rated power (unit: kw).
●Check AC current instrument on the operation panel is up to or over rated current.
●As use N terminal with U, V and W terminals, in order to keep phase balance, please equally use
output of generator, i.e. 1/3 rated power. If unbalance load is necessary, difference between 3-phase
shall be within 20%.
●For single-phase socket or VN, WN. Prevent overload of generator.

●For single-phase socket

Turn the single-phase breaker to ON to energize socket.
●There are two single-phase sockets (below 15A) on the panel.
●Prevent overload of generator if single-phase power is used via single-phase socket or VN, WN.

5.4.6 Connect loading equipment

●Add Load ON/ OFF switch between wiring terminal of generator and loading equipments.
If breaker of generator is also used as load switch of loading equipments, error is possible for breaker
due to frequent start and stop.
●Turn the breaker at side of generator to OFF upon connecting cable. And connect the cable when
engine stops for safety concern.
●Do not connect cable with joints at other phases.
●Close cover of output terminal block and screw down holding screws upon finish of cable connection.
●Using load with other generators may cause error of generators.
5.4.7 Low-load operation
Prevent low-load operation for long term.
●Long-term operation is allowed when load exceeds 1/4.
●Operation period shall be no longer than 5hours if load is within the scope of 1/8-1/4.
If run the machine at low-load, carbon collects on the engine and exhaust pipe. Engine works badly.

5.4.8
5.4.8Earth
Provide reliable earth to generator and loading equipments.

If no reliable earth, electrical leakage may flow through human body and cause
serious injury.

Danger

Decide diameter of earth line as per technical specifications of electrical facilities. Select the size with
proper load capacity. Please use earth pole in compliance with following earth resistance.
●Earth resistance of loading equipment shall be below 500Ω.
● Information of common earth
Implement earth of outside box and loading equipments independently. However common earth is
acceptable if independent earth is difficult on site.
1） Select the maximum value for diameter of common earth cable in accordance with respective
requirements.
2） Select the minimum value for earth resistance of common earth cable in accordance with
respective requirements.
3） Reliably screw down terminals.
● Handling attentions for earth project
1）Earth pole shall be placed in the shady and wet place. Upper part shall be in the soil.
2）If earth pole is placed in the place where there is a lot of passerby, please carefully fix it to avoid
blocking passerby.
3）Connect lead extension as following
Weld lead extension or use proper sleeve. Meanwhile cover connection part with insulation tape. In
addition, connection part shall on the ground.
4）Do not place the earth pole of the machine within 2m away from earth for lightening rod.
5）Not allow using the same earth line with telephone.
6）Not allow using the same earth line with others.
6. Daily and periodic check
Due to the bad condition and extension work time, the capability of the engine will become worsen.
Such as: increase the consumption of the fuel and oil, and increase the harmful matter of the exhaust,
increase the vibration and noise, and then shorten the life of the engine. Reinforce the maintenance,
daily and periodic check, you can keep the unit’s efficiency and prevent the fault.
Check
Daily check and periodic check
Daily check: You should do the daily check before starting the engine every day, and perform it as a
regulation.
Periodic check: Advise you make a running diary, note every day’s running and checking result, add up
the
 unit’s work time, make periodic check and maintenance according to the following table.

Start
System Check 50h 250h 500h 1000h 2000h
check
Check and fill fuel level in the fuel
○
tank
Fuel leakage check ○
Fuel Drain off water from fuel tank or oil
○
water separator
Replace filter element of fuel ◎
Washing of filter ○
Check and fill lubricant level ○
Lubricant leakage check ○
Lubricant Replace lubricant ◎After
◎First
first
Replace filter element of lubricant time
time
Check and fill cooling water ○
Clean the element of radiator ○
Replace cooling water ◎
Cooling Clean and repair cooling-water
●
water system
Water leakage check ○
○First
Cooling fan belt check ○
time
Rubber Replace fuel pipe and cooling water
○ ◎
pipe pipe
Operation Speed regulator operation ○
system Idle speed adjustment ●
Air intake
Clean and replace air filter element ○Clean ◎
system
Check alarm system ○
Electrical Check electrolyte fluid level and
○
equipmen battery charge
t Check working conditions of
○ ●
instruments and fuse
○Afte
Adjustment of inlet/exhaust valve ○First
Cylinder r first
clearance time
cover time
Wearing of inlet/exhaust seal ring ●
Fuel Check and adjustment of injection
○
injector pressure
and Check and adjustment of injection
○
injection p timing
 Repair fuel injector and injection
ump ●
pump
Confirm movements of breaker and
○ ●
digital panel executive components
Check protective earth ○ ●
Check if panel and terminals are
○ ●
loose
Generator
Measure insulation resistance or
○ ●
withstand voltage
Check if circuit connections and
cable surface insulation are friction ○ ○
or scuffing
Check if any screw or nut is loose ○
2
years
Check if all rubber hoses and materials of vent-
○ ○ ● or
pipe are distortion
every
400h
Check the air dust ports of each machine cabinet
○ ○ ●
and anti-vibration and sound-proof material
Periodic check is divided into several intervals like 50hours, 250hours, 500hours, 1000hours and
2000hours.
The time interval of the periodic check can ahead or delay according to engine’s use, loading
conditions, quality of fuel and lubricant and other conditions. See table
○：Check ◎：Replace ●： Consulting agent or dealer

6.1 Periodic checking routine

6.1.1 The first 50 running hours:
Because the engine just start running, the inside running parts abrasion each other, the lubricant will be
polluted soon. You should replace the lubricant and oil filter element. It is easier and quicker to drain the
lubricant, when the engine is still hot.

When drain the hot oil, be care of scalded. Do not make the hot oil splash to
you. Make sure the screw is tightened, if not, it will result in severe accident.

Warning

Drain the lubricant: Prepare a pot to keep the oil; Loose the screw with a spanner, start to drain the
oil; After drain out the oil, be sure to tighten the screw
2）Replace the oil filter element: Screw off the filter element wider shins with a
spanner; Clean the filter seat; Install a new element, wipe a thin flat of lubricant
in the sealed gasket, tighten it by clockwise, then use the spanner to screw
down 3/4 circle. (tighten torque 20～23N·m)
Replace the oil filter element
3）Add new oil about 6.9L
Running the engine about 5 minutes to preheat the unit, and check the leakage. After stopping the
running 10minutes, and then check the oil level of the oil bottom cover, and supply to the upper limit.
After the first maintenance, you should replace the engine oil and filter element every 250 hours.

6.1.2 Check for every 50hours

1）Drain out the fuel tank empty: Prepare a basin to keep the oil; Screw down the plug, drain out the
water and dirt empty; Fit on the plug and tighten it, check oil leakage.
2）Check the battery:
When check the electrical system, please break off the cathode grounding lead, short circuit will
produce fire, it may cause fire disaster;
Be sure to provide adequate ventilation, it will produce hydrogen gas during charging, the hydrogen gas
will be burned by any fire source;
Check the level of the electrolyte, if the level close to the lower limit, supply oil to the upper limit. if the
electrolyte is over low, it will shorten the service life of the battery, even explode if the temperature is
too high, the oil level decline quickly in summer, and you should check and supply the distilled water
frequently;
When start the engine, if the crankshaft speed is lower than normal, and the starting is failed, recharge
the battery. If it still fails, you should replace the battery.
3）Check the air cleaner: Air cleaner element is easy to be polluted by the dust, oil mist, steam. It will
increase the enter resistance, and the air will decrease, the engine will produce smoke. You should
clean and check frequently, even replace it. When the engine work in the dusty place(stone pit, coal
field, building field), even clean the element more frequently,
clean out the impurity. Take out the element from the air cleaner
shell, blow the inside with the compress air, and blow out the dust.
If the paper element is damaged, please change it. Clean the
grease in the air cleaner shell, cover the intake with cloth, prevent
the rubbish drop into the intake pipe.
Clear the air filter
4) Install the air cleaner, keep the element and rubber tube sealed, avoid air enter into the cylinder not
through the cleaner element.
5）Drainage and cleaning of water oil separator, drain depositional water and

rubbish in the filter.

① Open check side door, put oil holder below the drain port of filter of water

oil separator.

②Loose drain plug, let out depositional water and rubbish in the filter.

③If you can not drain of the intermixing water, please loose exhaust plug.

④Please exhaust air after water drainage.

⑤Please close check side door.

6.1.3 Check for every 250hours

1）Change the lubricant and oil filter element, replace it every 250hours from the second time.
2) Check and clean the radiator chip:
The dust and dirt adhered to the radiator chip will reduce
the cooling capability, make the engine over hot, according
to the situation, you can clean it ahead, even clean it
every day;
Blow out the dirt and dust with 196kPa（2kgf/cm 2 ）or less
pressure compressed air, if it is still dirty, you should use
cleanser and water to wash thoroughly;
Before using the compressed air, please wear the
protection glass to protect your eyes. Prevent the
dust or float pieces hurt your eyes;
Do not use the high-pressure tap and high-pressure air to wash by force,
Clear the radiator
do not use the brush to scrub, or the radiator chip will be damaged.
element
3）Replace the air cleaner element: The damaged air cleaner element will make the air into the cylinder
not through the air cleaner element, it will damage the valve, cylinder, piston, piston ring quickly.
If the element is plastered with dust, it will be hard to start the engine, the power will drop, and there will
be black smoke. Replace the element terminally, and clean the shell, it’s benefit to the engine.
6.1.4 Check for every 500hours
1）Replace the fuel filter: Replace the diesel filter element terminally, before it choked by the grease.
① Turn off the switch of the fuel tank, disassemble the oil pipe, take off the element, then clean the oil
filter seat
② Replace a new diesel element, install the fuel filter, pay attention to the sealed terminal cover of the
filter element, prevent the un-filtration fuel enter into the fuel injection pump.
③ Install in and out fuel pipe, turn on the switch of the fuel tank, advert drain out the air empty.
Otherwise the diesel engine will be hard to start or stop running after starting.
2 ） Replace the cooling water: After the cooling water is not hot, drain it, avoid the splash hot water
scalding people.
① If the cooling water or cooling liquid contain the rust and scale, the cooling effection will be
depressed.
② The cooling water should be replaced once a year at least. Drain the cooling water, and then add
cleanly soft water.
3）Check and adjust the valve clearance:
Make sure the valve is closed before adjusting the gap, there will be clearance.
Note: The 1-cylinder, 2-cylinder, 3-cylinder of engine is marked from flywheel end to gear room, which
is different from the general method. There are top dead center reticules of each cylinder, you can look
at it from dead center view port（φ30）of flywheel cover, the top dead center reticule of 1-cylinder is
marked on the belt wheel.
① Single cylinder method of adjusting valve clearance
a) Make sure the first cylinder piston locate in compression top dead center, then you can adjust the
clearance between the intake and exhaust valve (0.1～0.15)mm of 1-cylinder
b) Turn the flywheel about 240°by counterclockwise, and then adjust clearance between the intake and
exhaust valve of 3-cylinder
c) Turn the flywheel about 240°by counterclockwise, last adjust clearance between the intake and
exhaust valve of 2-cylinder
Note: After all above, make sure put the adjusting bolt cap together tight, or it will become loose, result
in the unit can not work normally.
② Valve clearance adjustment at twice method:
a) Put the 1-cylinder piston on compression top dead center, you can adjust the following clearance,
see table 6
Table 6 Valve clearance adjustment at first time
Cylinder order 1-cylinder 2-cylinder 3-cylinder
Adjustable valve Intake Exhaust Intake ○ ○ ○
b) Rotate the flywheel about 240°by counterclockwise(rotary direction of the engine), make the piston
of 3-cylinder locate in compression top dead center, then adjust the other valve gap which is not
adjusted, see table 7.
Table 7 Valve clearance adjustment at second time
Cylinder order 1-cylinder 2-cylinder 3-cylinder
Adjustable valve ○ ○ ○ Exhaust Intake Exhaust
4）Check and adjust the injector: Check and adjust the injection pressure and quality of the spray on the
test-bed.
If the injection pressure is incorrectly, you can screw down the injector shell, replace the different
thickness adjusting gasket, make the pressure reach the right value. （20±0.5）MPa。
Check injector
 Replace and adjust gasket

The injection pressure is right, but the quality of the spray is bad. You can clean the injector orifice or
replace the injector element.
③ Put the injector into the cylinder cover, the gasket should be original, to make sure the unit’s
extended distance (2.2 ～ 2.3)mm. If the warp of the extended distance is too large, the power, fuel
consume, exhaust smoke of the diesel engine, will be affected greatly.

6.1.5 Check for every 1000hours

1）Check and adjust of injection advance angle(The adjust need special tool, special knowledge and
skill, you should ask a respected professional person do it. )
①Concrete steps (PL plunger pump)
a）Loose the two-end nut of 1-cylinder high pressure oil pipe, take off the high pressure oil pipe, mount
the tube union of the side oil supply advance angle , swing the flywheel repeatedly around the
compression top dead center 90°range, until the diesel oil spreads out from tube union .

b）Withdraw flywheel to the top dead center about60°, then turn the flywheel anticlockwise (or turn the
crankshaft belt wheel clockwise with sleeve and torque spanner), stare oil face wave of tube union,
once oil face wave, stop it immediately.

c）Check the flywheel upper scale mark, the scale in front of the top dead center 16°±1°is on the
sight hole centerline of top dead center of flywheel cover. Please adjust the advance angle of oil
supply, if there is extraordinary disparity, the methods as following:

d）Loose the６-M8×16 bolt of the tight small circle cover board on gear room cover, take off the small
circle cover board.

e）Relax the４-M8×20 bolt of tighten oil supply gear (Don’t take it off, if only there is relative movement
between the oil supply gear and contact flange of oil pump).

f) Turn the camshaft of injection pump with sleeve and connecting rod as crankshaft rotation direction
(clockwise), the director angle of oil supply will increase, otherwise, reduce.

g)Screw up the oil supply gear after adjusting; Put back the small circle cover board and screw it.
② Concrete steps (VE injection pump)
a）Remove all high-pressure oil pipes and boil cap, install a micrometer in
the hole of bolt cap. Press the meter into 2mm. See right fig.
b ） Turn the crankshaft to put the 1-cylinder piston in front of the top
dead center about 30°～40°, adjust the micrometer to zero. Wave the belt
wheel, and check the reading of the micrometer. See right fig.
c ） Turn the crankshaft as crankshaft rotation direction: as clockwise
rotation the belt wheel, and align the oil supply scale mark （16°）on belt
wheel with ▼(top dead center)on gear room cover. See right fig.
The reading of the micrometer is 0.5mm. If not, the oil supply
timing is wrong, need adjust it.
The adjust method is:
Loose the three fixing nut of injection pump and the fixing bolt of
injection pump bracket, adjust the injection timing by changing
the angle of injection pump installation. See right fig.
d）If the reading is greater than 0.5mm, pull the oil pump shell
upside(away from engine). Reduce the reading to the standard
value; if the reading is smaller than 0.5mm, push the oil pump
shell upside(near engine). Increase the reading to standard
value.
e） Screw up the fixing nut of injection pump and fixing bolt of
injection pump bracket after adjusting.
f） Remove the micrometer, install bolt cover.
g） Install high pressure oil pipe of 3 or 4 cylinder in turn.

2）Clean the scale and iron rust of cooling system

There will be much iron rust and scale in the radiator after
running 1000hours; it will make the cooling water deterioration, reduce the radiating effection, rise the
cooling water temperature. You should clean it at this time. The work need special knowledge and skill,
you should ask a respected professional person do it.
6.1.6 Check after running 2000hours
1）Check and replace fuel, lubricating oil, cooling water, rubber hose.
Check rubber hose at time, if it is broken
2）Check and lap the seal band of inlet and exhaust valve .
The work need special knowledge and skill, you should ask a respected professional person do it.
Check the sealability of valve, the subquality product of the valve, the width of seal band and the
clearance between the valve stem and valve guide.
3）Check the performance of the injection pump.
The job needs oil pump test bed adjusted by professional staff. Check oil supply quality of rated spot,
the starting-up oil mass, the uniformity of each cylinder, the flexibility of each part of speed regulator,
the highest and lowest rotation speed limit and so on.

7. The indication of running and operation

Fuel·· Lubricati
7.1 Fuel ng oil
Lubricating oil·· Cooling water
7.1.1 Fuel
● Please use the right light diesel to the engine performance. If not, the engine performance can’t be
exerting, or the parts may produce fault.
The ambient temperature is the standard; choose the fuel base on the following condition.
Standard Choosing method
GB 252-1994 Light diesel, summer 0#, winter -10#, -20#
JISK2204 2#（Above -5℃）， 3#（Above-25℃）

● The usage of fuel

Please keep the fuel away from the rain and rubbish.
(1) If there is water or rubbish in the fuel, the engine can’t run well. Please use the clean container to
keep the fuel.
(2）If there is water or rubbish in the fuel, don’t move the container, put it for several hours silently,
deposit the water and rubbish to the bottom, suck the clean fuel through the pump.

7.1.2 Lubricating oil

Lubricating
●The choice of the lubricating oil
Use the best oil (CD grade) 10W-30, 15W-40

● The use of the lubricating oil

1）While keeping and using the lubricating oil, don’t let the rubbish and dust into the oil. While adding the
oil, please clean the small dust round the oil filling oil.
2）Don’t use the different kinds mixing lubricating oil, avoid reducing the lubricating performance.
7.1.3 Cooling water
●The daily manage of the engine cooling water is very important.
You must use clean soft water (tap water) for cooling water.
● While using the cooling water, you must add the antifreeze with antirust function. The cooling water
will freeze in the cold winter, will frost crack the parts of the cooling water system. Besides, the clean
water can rust easily; it may result in bad cooling. As though, using in the warm area, it can avoid
rusting.
● If there is little antifreeze, while the temperature falls down, will destroy the cooling or rusting.
If there is too much antifreeze, the cooling status will not be good.
Antifreeze
1 ） The antifreeze have the anti-rust function, you needn’t add antirusting agent. Besides, the
antifreeze can use for one year. The mixing ratio is between 30% and 50%.
 The lowest
Below -15 -20 -25
temperature ℃
The mixing ratio % 30 35 40

2 ） You should choose the antifreeze with anti-rust function. Please follow the mixing ratio of the
manufacture. Please change it by one year.

7.2
The operation of the battery

Because the battery may produce the explosion hazard gas, It may bring
explosion or injury.

Warning

●Charging in the ventilated place. Or there will be the danger of the combustion and explosion.
● No smoking, spark or other fire while charging.
● While connecting the battery cable, don’t contact the “+” end with “-” end.
● Don’t connect wrong, produce the spark, it may have flammable air, result in explosion.

There is weak sulphuric acid in the electrolyte. If operation is wrong, you may
have bad injury.

Danger

● While the cloth or skin is wet by electrolyte, please clean it with plenty of water. If the electrolyte
goes into the eyes, clean the eyes with water at once or take care of the doctor.

7.2.1The attention of battery charging

●While charging the battery.
1) Take down the wire of the battery, and charging.
2）Take down all bolts while charging.
3）First take down the grounding wire and then remove the wire of the battery end.
（If there is other tools between (+) end and the generator, it may result electric spark, so it is danger.）
While install the wire of the battery end, connect the grounding wire at last.
4）Scavenging fully while charging.
It will produce flammable air while charging, it may result in explosion, so don’t approach the spark.
5）While the battery is too hot ( over 45℃）, stop for a while, and then charging.
6）After charging fully, you should stop charging at once.
There will be some defect, if charging again after charging fully.
①The battery is too hot.
②The quantity of the electrolyte reduces.
③The battery is abnormal.
7 ） While connecting the battery wire, please connect the “+” wire, and then connect the “-”wire.
Connecting the wire in reverse will damage the generator, please take attention.

7.3 Preparations before starting

7.3.1 Fill fuel

Fill the proper fuel. Improper fuel may lead to risk of fire. Please confirm the
type of fuel in advance. Clean any overflowed fuel.

Danger

● Fuel tank is provided with lock. Open the lock and take off the cover of fuel tank. Fill clean and
clear fuel without water and foreign matters into fuel tank. (open frame no have lock )

● In order to prevent any overflow when machine is running, fill-in amount shall be approximately
90% of tank volume.

Volume of fuel tank: 38L

7.3.2 Fill lubricant
7.3.2

Keep lubricant level between upper and lower scale marks. Lubricant level
shall not exceed the upper mark. Ejection of lubricant from the breather hole
may cause engine errors.

Attention

1）Keep engine level upon lubricant fill-in.

2）Take off the yellow cover of lubricant inlet on the top of gear chamber. Add recommended diesel oil

up to the upper mark of oil gauge.

3）Measure the lubricant with oil gauge. In order to get correct level, please clean the oil gauge before
inserting it into lubricant. Lubricant trace remained on the oil gauge indicates measurement.
Re-confirm it after 3-5min running.

7.3.4 Fill cooling water

● Add cooling water as per following procedures. Please add anti-freezing liquid into cooling water.

● Fill water into radiator

1）Turn the cover of radiator towards left side and take it off.
2）Add the cooling water till it overflows from water inlet of radiator. Slowly fill cooling water to avoid
 any foam.
3）Close the cover of radiator tightly to prevent any water leakage. Direct the inside clip towards notch
of water inlet. Then press down the cover and turn the cover towards right side for 1/3 cycle to close the
cover.

● Fill water into overflow bucket of auxiliary tank

1 ） Please take off the cover of water inlet of auxiliary tank. Add cooling water up to the upper scale
mark. Then re-mount the cover.
2 ） Check if joints of rubber hoses connecting auxiliary tank and radiator are loose, released or
damaged. If any, auxiliary tank cannot work.
3) Check the rubber pipe of the auxiliary tank for disconnection, loosen or damage. If the rubber pipe is
not at good condition, don’t use the auxiliary tank.

Volume of cooling water is :

Radiator

7.3.5 Trial running

● Run the generator that is new or idle for long-term at low speed and without load for short term
before load running. Deliver the lubricant to all abrasion parts. If start the load running without
mentioned operation, it may cause abnormal abrasion or damage to piston, cylinder sleeve, crank shaft,
bearing and other parts.

1） Turn the breaker of generator to OFF.

2） Insert the start key and turn it to ON. Then engine starts. Run the engine for about 5min to
check if any abnormal sound and leakage of water, oil and gas.
3） Turn the key to OFF and stop engine.
7.3.6 Quantity re-confirmation of lubricant and cooling water

Please re-confirm the quantity of lubricant and cooling water after 5-minute trial running, if lubricant or
cooling water is filled into for the first time or is replaced.
Trial running distributes lubricant and cooling water around the machine. During re-check level of
lubricant and cooling water shall be lower. By then, please make up insufficiency.

7.4 Operation
Following parts in the running generator are extremely dangerous, such as
radiator fan, belt and other rotation parts, engine, cylinder hood, exhaust pipe,
muffle and other parts at high temperature and high voltage.
 Danger

●Close the side door of running machine.

●Stop running machine before check and maintenance.

●Carry on following checks prior to each start.

1. Remove foreign matters in the generator

●Check if there is any tool or rag in the generator.
●Check if there is any rubbish or inflammable matter around muffler or engine. If any, remove it away
immediately.
●Check if suction inlet and exhaust vent of generator is jammed by rubbish or rag. If any, remove it
away immediately.

2.
2.Check in the generator
①Any oil leakage in the engine
②Any fuel leakage in the fuel system
③Any water leakage in cooling water system
④Broken distribution line, short circuit or loose joint
⑤Check if any screw is loose or released.
Do not run the machine before eliminating any founded abnormality.
3. Check and fill fuel

Regularly check rest fuel level in the fuel tank and add recommended fuel on the basis of need.
4.
4.Check and fill lubricant
①Check lubricant level with oil dipstick.
②Add recommended engine oil from oil-inlet of gear case when oil level is insufficient.
Check the lubricant with oil dipstick. Add lubricant up to upper scale mark with check
5. Check and fill cooling water

Generator is still hot when machine is running or after machine stops. In such
case, do not open the cover of water inlet of radiator because ejected steam
and hot water are extremely dangerous. As temperature falls down, envelop
the cover of water inlet of radiator with cloth. Then open the cover. Close
radiator cover tightly after checking.
Warning
1）Check and add cooling water before machine is running and when engine is cold.

2）Confirm and check the quantity of cooling water by level in the auxiliary tank.
If water level is between the upper and lower scale marks, it means normal.
Check if there is any change on water level before or after using machine once a week.
●Normal change on water level

Prior to running (cold status): low level

After stop (high-temperature status): upper level
(Note) Open the radiator cover. Check and add cooling water if there is no change on water level after
running compared to that prior to running. In addition, check rubber hoses connecting radiator cover
and auxiliary tank; confirm if any connection is released, loose or broken.

7.4.1 Keynote for no-load start

If the breaker at side of generator and loading equipments

is at ON, please do not start the machine. Power is
supplied to loading equipments and runs machine
suddenly when engine starts, which leads to damage.
And it may cause electric shock or errors of loading
equipments.
Danger

1) Start
Start the machine in the following order.

①Confirm breaker at side of generator and loading equipments is at OFF

②Insert the start key and turn it to ON. Indication lamp of intelligent display is on. Please confirm it.
③Turn the key to START then release it. Key returns to ON automatically. Engine is pre-heated and
starts.

●Check that intelligent display shows no error code when engine starts.
●Repeat start operations. Carry on start operations after engine stops running completely.
Operation on the running machine causes errors of starter and damages start motor.

2）Adjustment of frequency and voltage

Make adjustment after machine is heated and runs.
Heat the machine for about 5 minutes (no-load).
①Adjust the regulating screw rod of fuel-pump rotation speed till frequency is up to rated value
(at the fuel pump ).
②Adjust the voltage with voltage adjuster as per specifications
( at the AVR).
7.4.2 Keynote for load running
1）Pre-running check
① Confirm that voltage, current and frequency shown in the intelligent panel are normal.
② Check if fuel switch of outside fuel tank is at the correct position.
③ Check the environment of engine.
④ If color of exhaust is normal or not
Colorless or light gray: Normal
Black: Abnormal (insufficient combustion)
Blue: Abnormal (Combustion of lubricant)
White: Abnormal (No combustion of fuel or too much water contained in the fuel)
⑤ If any sound is abnormal, or running is stable, or there is any abnormal vibration or not
⑥ If there is any leakage of fuel, lubricant and cooling water
⑦ Check if breaker at the side of loading equipments is at OFF.
⑧ Turn the single-phase and three-phase breaker of generator to OFF.
2）Load conditions

Forbid increasing or reducing speed rapidly, over-load or other unreasonable

operations during the first 50hours for new engine.

Attention

①Turn the breaker (single-phase/ 3-phase) of generator to ON

②Turn the breaker at the side of loading equipments to ON

3）Adjustment during running

Adjust the rotation, frequency and voltage according to load.

4）Checks during running

If generator produces any abnormal sound, please stop running it immediately

for check and repair. If continue running machine at abnormal status,
unexpected serious accidents may occur.

Warning

Check if there is any abnormality of generator, or below conditions occur for running generator.

① Check all instruments and central indication lamps

Check voltage, current and frequency in accordance with specifications. Check if indication lamps are
on.
② If color of exhaust is normal or not
Colorless or light gray: Normal
Black: Abnormal (insufficient combustion)
Blue: Abnormal (Combustion of lubricant)
③ If there is any abnormal sound and vibration
④ If there is any leakage of fuel, lubricant or cooling water
⑤ If rest fuel is sufficient
If fuel supply is interrupted during machine runs, please eliminate air remained in the fuel pipe after fuel
fill-in.

5）Stop the machine

Stop the machine in the following order.
1）Turn the breaker at the side of loading equipments to OFF.
2）Turn the breaker (single-phase/ 3-phase) of generator to OFF
3）Please run the machine at cold status for about 5minutes (no-load)

Do not stop the machine suddenly if load running starts. Otherwise

temperature of engine parts rises rapidly, leading to blow engine or cylinder
scoring.

Warning

4）Turn the start key to OFF to stop running machine.

5）Take off the key and keep it properly

7.4.3 Running on the automobile

●If run the machine temporarily on the automobile, please do not block or cover the air inlet or exhaust
vent of generator.

●If place materials around the breather hole of machine and run the machine, machine may face to
over-heat.

●Keep the gap between driver seat and machine within 200-300mm to the least extent. Meanwhile
there is no any blockage around the breather hole of machine. Then start the machine.

8. Maintenance service of electrical system

8.1 Start motor
8.1.1 Disassembly
Motor disassembly
（1）Disassembly the leading-out wire terminal of winding from magnet switch wiring terminal.
（2）Loose the transfixion bolt and the setscrew of carbon brush holder
（3）Take off the back-end shield, stator, carbon brush holder, armature in turn.
(4）Assemble sequence and disassemble sequence are opposite, smear lubricant grease on the end B
of armature spline while assembling.
1. electromagnetic switch 2.armature 3.leading-out wire terminal of winding 4.stator
5. carbon brush holder 6.back-end shield 7.transfixion screw 8. setscrew of carbon brush

Electromagnetic switch disassembly

（1）Loose the three bolts of end cover
（2）Take off end cover and magnet iron core.

Reducer /clutch disassembly

（1）Loose three bolts of tightened driving shell ,(two are outside of motor, one is inside of motor),
（2）Take off driving shell, clutch subassembly, steel ball, return spring and drive gear in turn.
(3）When assembling, please smear new lubricant grease.

1. driving shell 2.decelerating clutch 3.steel ball 4. return spring

5. electromagnetic switch 6.driving gear 7.idler gear 8. driving gea

8.1.2 Inspection and maintenance of starter motor

Motor inspection
1) Disassemble the motor excitation and armature winding output wire
from C connector.
2) Connect the motor positive terminal with the battery positive
connector
3) Connect the motor out shell with the battery negative connector.
The motor should rotate, if no rotation please check the two windings of motor.

Electromagnetic switch inspection

1) Disassemble the starting motor from the motor seat and
prepare a 6V battery.
2) Connect the electromagnetic switch out shell and C connector
with the battery negative connector by two wires.
 3) Connect the battery positive pole with S receptacle by a wire, and the gear shaft should jump out
suddenly. If the C connector is disconnected, the gear shaft should remain at the extend position, which
indicates tha the electromagnetic switch is normal.
4) Pay special attention that the connection time is only 3 to 5 seconds, otherwise the winding will be
burnt and damaged.

Commutator inspection and maintenance

（1）Check the commutator for wear, if slightly worn, burnish and polish with fine rubber
（ 2 ） Measure diameter of commutator with outside micrometer, if diameter dimension is small than
limiting size, please change armature.

(3）If there is much difference between excircle wire harness of commutator and axes parallelism, but
the diameter of axle minimum limit of size is in the allowable value. And please correct to the specified
value on the lathe. Fig (a) is good, Fig (b) is bad.

Check the electric brush for wear

（1）If there is soil and dust on the wearing surface, please burnish with abrasive cloth.
(2）Measure the carbon brush height A with vernier caliper. If it wears heavily, which indicats small size
of A, please replace the carbon brush.

Check the electric brush bracket

Check the insulating performance between the insulating electric brush bracket and supporting plate, if
it is current conducting, please replace electric brush bracket.
Check the armature
Measure the electric conductivity of commutator copper sheet , armature core and armature winding
with ohmmeter:
(1）If the commutator copper sheet and armature core is current conducting, please replace armature.
（ 2 ） If commutator copper sheet and armature winding are not current conducting, please replace
armature.
(3）If the commutator copper sheet is current conducting, please replace armature.

Check the stator winding

(1) Test electric conductivity of stator winding output wire with an ohmmeter, if no conductivity, please
replace stator. Refer to Fig. a
(2) Test insulativity between stator winding coil and stator shell with an ohmmeter, if conductivity,
please replace stator. Refer to Fig. b.

图a 图b

Check the armature rolling bearing

If swing the rolling bearing, there should be small radial and axial clearance, smooth running. If swing
heavily, clagging or damage will happen, and please replace the rolling bearing.

Check the decelerating cluth

(1) Check all gears of decelarating clutch for damage or wea, if severely worn or
damaged, please replace decelerating clutch or related gear.
(2) Check flexibility of decelarating clutch. Smooth radial operation and rotation
must be secured. No skid when given a force, normal performance maintained, otherwise please
replace.

Check the electromagnetic swith

Test the electric conductivity of contact disc in electromagnetic switch. Hold
magnetic core with your thumb. Test electric conductivity between connector C
and B. If no conductivity, please check contacting and fastening between the two
connectors and inner copper sheet.

8.2 Generator
8.2.1 Generator disassembly
Generator rotor assembly

Rotor fan
The fuction is to rotate the fan by rotor, take off the motor energy and cool the motor rotor and
stator winding.
Rotor winging

This is collecting ring

that consists DC
current from the AVR

Fen

Exciter rotor
 It consists of AVR output of exciter and rotor winding, its function is to exciter from AVR DC
current into magnetic field by rotor winding, so that to provide the rotation magnetic field and
generate electricity for stator.
8.2.2 Inspection
Rotor winding inspection
The function of rotor winding and also the electricity generating principle is that the rotor winding
inverts the excitation DC current into current magnetic field, the stator winding generates induced
electric potential by means of engine rotation and rotation magnetic field. If the generator doesn’t
generate electricity, it is possibly caused by no output of generator. Generally speaking, such faults
usually occur in case of long time operation, long time max power output, high working temperature or
big no power consumption. And these faults will result in inner temperature of rotor winding rises,
insulation performance of lacquered wire reduces, short circuit among wires and finally the motor rotor
is burnt and damaged. Main faults are: output voltage reduces after the generator set runs at the
related power, AVR voltage potentiometer regulation doesn’t work or the AVR fuse splits. To avoid such
faults, please check the rotor commucator, the resistance of motor rotor winding, the motor appearance
and winding color, if the winding splits, you should replace the rotor assembly.
THE resistance
Value 45 Ω

Possible fault of rotor

1) Rotor metal core and stator inner ring wear: the location of motor two ends changes
① The engine rotation shaft and side cover location hole wear.
② The motor bearing wears
2) The rotor winding frame splits: the rotor winding is heated to high temperature and inflates, so that
the fame splits. Please avoid high temperature or long time conntinuly working under no power load
condition.
3) The exciter rotor winding changes color or is burnt:: the rotor winding may be short circuit so that the
winding changes color. But this kind of fault is not normal, as there equipped with current protection and
quick fuse protection in AVR. This fault occurs only when the fuse changed or protection current
increases.
4) The bearing out ring location groove splits or wears: this kind of fault occurs mainly in case of long
time running. The reason is that the material structure distorts after long time wear and heat. However,
the occurance probability is very little, it usually occurs in the end of generator operation period.

Check the generator stator winding

The function of generator stator winding is to invert the excitation DC current into magnetic force
line so that to generate electricity. The electricity generating principle is that the stator winding
generates induced electric potential by means of engine rotation and rotation magnetic field. If the
generator doesn’t generate electricity, it is possibly caused by no output of generator resulted by open
circui or short circuit of stator winding, or caused by generator stator fault. Generally speaking, such
faults usually occur in case of long time operation, long time max power output, high working
temperature or big no power consumption. And these faults will result in inner temperature of stator
winding rises, insulation performance of lacquered wire reduces, short circuit among wires and finally
the stator winding is burnt and damaged. Main faults are: output voltage reduces after the generator set
runs at the related power, AVR voltage potentiometer regulation doesn’t work or the surface
temperature of motor is high. To avoid such faults, please check the resistance of motor stator winding,
the motor appearance and winding color, if the winding splits, you should replace the rotor assembly.
Refer to 3.3 Generator maintenance data for detail maintenance data.

By Resistance Measuring
Meter to check the value for
each phase
The resistance value should
be consistent with 1.3-1.6Ω

Measure the rotor insulation pressure-proof

To avoid personal damage caused by high voltage of dielectric strength tester,

please put on the insulation gloves, insulation protection shoes and lay an
insulation mat on the workplace before testing. Refer to the operating
instruction of dielectric strength tester for detail operation.
Danger
Testing conditions: testing voltage 750V, drain current ＜10mA
Testing method: connect the grounding terminal of dielectric strength tester with the metal core of motor
rotor, and connect the high pressure output terminal with any terminal of rotor winding output wire. Turn
on the dielectric strength tester for measurement. If the drain current exceeds the prescribed value,
please check the rotor for insulation or replace the rotor.
Measure the rotor insulation pressure-proof

To avoid personal damage caused by high voltage of dielectric strength tester,

please put on the insulation gloves, insulation protection shoes and lay an
insulation mat on the workplace before testing. Refer to the operating
instruction of dielectric strength tester for detail operation.
Danger

Testing conditions: testing voltage 1500V, drain current ＜10mA

Testing method: connect the grounding terminal of dielectric strength tester with the out shell of motor
stator, and connect the high pressure output terminal with any terminal of stator winding output wire.
Turn on the dielectric strength tester for measurement. If the drain current exceeds the prescribed value,
please check the stator for insulation or replace the stator.

9.1General Troubleshooting
 Fault Reason Troubleshooting
Disassemble to check whether it is open circuit, the
1. The air breaker fails
resistence should be '0'
Control 2. The connection wire of control panel
Check the wiring harness
panel looses
3. The receptacle connector looses or
Check or replace the receptacle
melts
1. The outlet terminal of motor stator
Check the wiring harness
looses
2. The connection terminal of motor stator
Check or replace the connection terminal
crazes or melts
Check the resistence of connection terminal,
3. Break circuit of motor main winding coil
reconnect or replace the stator
Check the resistence of connection terminal,
4. Short circuit of motor main winding coil
reconnect or replace the stator
5. Open circuit of motor exciter winding Check the resistence of secondary winding insert,
coil reconnect or replace the stator
6. Open circuit of motor sampling winding Check the resistence of sampling winding insert,
coil reconnect or replace the stator
Check the motor temperature and resistence, or
7. Short circuit of motor main winding coil
replace the stator
8. Open (break) circuit of motor rotor Check the resistance of rotor exciter, reconnect or
winding coil replace the rotor
Check the resistance of rotor exciter, reconnect or
9. Short circuit of motor rotor winding coil
replace the rotor
Motor 10. The motor rotor exciter loses Check the voltage of stator coil of rotor exciter or
fault excitation AVR output terminal
11. Short circuit of motor rotor collection check the resistance of collection ring, reconnect or
ring replace the rotor
12. The motor rotor connection shaft Check the motor noise when starting and the
looses resistance, replace the front end cover
Check the motor temperature and resistance, or
13. Short circuit of motor stator /rotor
replace the stator or rotor
14. Motor fault caused by engine output Check the engine noise when starting or motor
shaft wearing temperature, replace the engine
Check the motor noise when starting or motor
15. The motor fan crazes
temperature, replace the rotor
Check the motor noise when starting and the
16. The motor bearing is worn
resistance, replace the front end cover
17. The motor stator or rotor is Check the motor temperature and resistance, or
overheated replace the stator or rotor
18. Short circuit of interturn or the stator
Check the wire color of stator or rotor winding
/rotor coil changes color
19. The generator insulation resistance Check the insulation resistance of stator /rotor with
decreases piezometer, or replace the motor staor /rotor
1. The adjusting potentiometer fails, can't
AVR fault Check the output voltage, adjust or replace AVR
regulate the voltage
 Check the output voltage or adjust AVR, check the
2. The voltage deviates
connection wiring harness
3. The generator set stops automatically,
Check the output power, adjust or replace AVR
wrong current setting
4. The electrical apparatus element fails Replace AVR
5. No excitation output after inputting the Check AVR excitation output voltage, adjust or
sampling signal replace AVR
6. Insufficient excitation voltage of exciter
Chekc the magnetic steel of motor exciter
magnetic steel
7. Outout increases and AVR
Check the load
consumption increases
8. Deviation between full load and zero Check AVR and motor temperature, replace motor
load is too big or AVR
Check or decrease the load, check the voltage of
9. The voltage increases too much
AVR secondary winding, or replace AVR
10. The excitation connection wire is
Modify the connection wire
mistaken
Control 1. No displaying
Check the 12V electric power, and the connection
panel 2. Error displaying
wire, or replace the display
fault 3. Fail to start

9.2 Digital panel electrical system

Fault Reason Troubleshooting

1. The fuse on the panel breaks
2. The electric starting switch fails or
No display
poor connection
3. Poor connection of inserter
1. Insufficient oil quantity
2. The lubrication system is faulty
P-01 3. The low oil pressure switch fails
4. Short circuit of low oil pressure
switch
P-02 1. Sampling wire disconnects
Replace the fuse
Check or replace the electric starting switch
Check moduel No.9, PIN inserter and data wire
Refill in oil
Check the lubrication system
Replace the low oil pressure switch of the same
model
Check the circuit
Check the sampling wiring harness, there should
be no voltage or frequency display on the panel

2. Abnormal frequency (Too high or
too low)
3. Abnormal fuel system, the engine
rotating speed is unstable
1. The sampling wire disconnects
2. Abnormal voltage (too high or too
P-03
low)
3. Open circuit of excitation circuit
4. AVR or motor fails
P-04 1. Overload
1. Fuse of starting circuit disconnects
2. Starting circuit disconnects or poor
P-05 connection of inserter
3. The starting motor fails
4. The charging motor fails
P-06 1. The emergent stopping button fails
P-07 1. Open circuit of charging circuit
2. Charging motor fault
1. The temperature of cooling water is
too high
2. Insufficient water in the water tank
P-08
3. Short circuit of water temperature
switch
4. The water temperature switch fails
Check the output frequency with multimeter, the
displaying value should be the same with the real
value. Adjust the engine rotating speed, set the
output frequency the same with the factory setting
Check the fuel system
Check the voltage sampling wiring harness, there
should be no voltage or frequency display
Check the output voltage with multimeter, the
displaying value should be the same with the real
value. Adjust AVR, set the output voltage the
same with the related value
Check the excitation wire and carbon brush
Replace AVR or motor of the same type
Decrease load less than the related load, turn on
the brealer
Replace the fuse of the same type
Check the circuit and inserter
Replace the starting motor
No input of starting signal
Replace the emergent stopping button
Check the charging generator AC signal wire and
inserter
Replace the charging geberator of the same model
Disconnect the breaker, stop the generatot set
after running with zero load for a while. Restart the
generator when the water temperature decreases
Refill in cooling water
Check the circuit
Replace the water temperature switch of the same
type

9.3 Alarm system fault

Fault Reason Troubleshooting

1. Insufficient oil Refill in oil
Lubricant alarms
2. The oil filter is blocked Replace the filter element
1. Insufficient cooling water in Refill in cooling water
radiator
Cooling water
2. The radiator element is dirty Clean the radiator element
temperature
indicator light 3. Cooling water leaks, the Check the leaking parts, clean or replace
cooling water pipe is polluted the cooling water pipe
4. The fan and driving V strip of Tighten or replace
 water pump loose
5. Cooling water pump fault Maintain or replace the water pump
1. Battery fault Check the electrolyte and recharge, or
Charging indictor replace the battery
light 2. Circuit fault Check, repair or replace
3. AC generator fault Repair or replace the generator
Insufficient inlet Air filter element is dirty Clean the filter element with
pressure indicator
compression air or replace it
light

9.4 Fail to start

Fault Reason Troubleshooting

 1. No fuel in the fuel tank Refill in fuel
2. Air mixed in the fuel system Drain out air
3. The electromagnetic valve is off Check the electromagnetic valve, repair or replace
4. The fuel is not qualified Use the correct type of fule
5. The air filter element is dirty Replace the filter element
6. The circumstance temperature is Use the air heater
low

Suppl 7. The fuel filter element is blocked Replace the diesel filter element
ying 8. The oil supplying timing is Check and adjust the oil supplying advanced angle
syste incorrect
m 9. The fuel injector is blocked Check or replace the nozzle parts
fault 10. Incorrect inlet /exhaust valve Check and adjust the valve clearance
clearance
11. Cylinder compression is poor Check the cylinder compression pressure, standard
value is 3.1 Mpa, and the minium value is 2.2 Mpa
(1) The valve leaks gas Check and grind the valve
(2) The cylinder, piston and piston Maintain by professional
ring are severely worn
12. The starting oil quantity of oil Check and adjust on the test desk
injection pump is too little
1. Insufficient battery electric Check the connector or the electrolyte level and
quantity or the connector looses proportation and recharge
2. The engine rotates with no load Check or replace the engine
Circuit
3. Hard to mesh Adjust the relative position between engine and
fault
flywheel gear ring end
4. Low rotating speed Voltage drops greatly in winter or battery guide wire is
slender

9.5 Instable engine rotating speed

Fault Reason Troubleshooting

Insufficient oil supplying Adjust or clean

Instabl
Oil supplying angle of oil pump is
e Check the oil pump or replace the nozzle
incorrect or nozzle is faulty
engine
Generator is over load or short circuit Check the load or check the output current
rotating
Insufficient cooling water, or high Check the water level of water tank after
speed,
temperature caused by fan belt skiding stopping the engine and check the fan belt
too
Insufficient oil pump pressure caused by
high or
oil leakage or inlet /exhaust valve Check the inlet /exhaust valve clearance
too low
clearance leaks gas

9.6 Abnormal color of exhaust smoke

 Fault Reason
1. The engine is overload
2. The air filter element is blocked
3. The fuel is not qualified
4. The valve clearance is too big
5. The fuel injector is blocked or leaks
oil
Black smoke
6. The oil supplying timing is incorrect
7. The valve is not sealing
8. The cylinder, piston and piston ring
are over worn
1. The oil level is too high
2. Too much spray of respirator
3. The valve oil seal fails to work or
Blue smoke
valve rod clearance is too big
4. The inlined ring is installed
mistakenly (the 2nd ring)
1. Temperature in winter is low, so it is
normal for white smoke after starting,
the white smoke will disappear when
temperature rises
2. Much water mixed in the fuel, the
water vapor drains out
White smoke
3. The fuel fails to pulverizate, the oil
vapor drains out
4. The fuel injection advanced angle is
too late, oil vapor drains out
5. The cylinder, cylinder cover and
cylinder gasket leak
9.7 Insufficient engine power
Fault Reason
1. The air filter element is dirty, air
Isufficient
inlet is not fluent
engine power
2. The fuel filter element is dirty, oil inl
Troubleshooting
Reduce load
Clean or replace the air fileter element
Use the correct type of fuel
Check and adjust the valve clearance
Checl the fuel pressure and spray
quality
Check and adjust the oil supplying
advanced angle
Check, repair and grind the sealing ring
strip
Repair or replace
Check the oil level in the crankcase oil
tray with oil rule and drain oil
Check the sealing of respirator valve
and fluent of oil return hole
Replace the valve oil seal or repair the
valve and guide pipe
Check and repair (the oil stripper is at
the bottom side)
Drain out oil and water
Check the fuel injection pressure and
spray quality
Check and adjust the oil supplying
advance angle
Check why the cooling water inleaks in
the cylinder and mend it
Troubleshooting
Clean or replace the filter element
Clean or replace the filter element
 et is not fluent
3. Fuel duct is blocked, oil supplying
is not fluent
4. Air sucked into the oil suction pipe
connector
5. The speed adjusting spring softs,
rotating speed reduces
6. The oil quantity limitation level is
too little, insufficient oil supplying
7. The oil supplying quantity of oil
supplying pump is too little
8. The oil supplying advanced angle is
wrong
9. The oil injection pressue and spray
are poor
10. The valve clearance is incorrect
11. The oil quality is poor
12. The ventilation hole of fuel tank
cover is blocked
13. The cylinder compression Check
pressure is insufficient
(1) The valve leaks gas
(2) The cylinder gasket leaks gas
(3) The cylinder, piston and piston
ring wears
(4) The installation hole of fuel
injector leaks gas
9.8 Instable running
Fault Reason
1. Air mixed in the fuel system
Instable running
Check and clean or replace the oil pipe
Check for leakage and air exhausting
Check and adjust the engine rotating
speed
Enlarge the oil quantity limation level
Check the oil supplying of oil supplying
pump
Check and adjust
Check and adjust
Check and adjust
Use the correct type of fuel
Check and dredge
the cylinder compression
pressure is 3.1 Mpa
Check and grind the valve or replace
the valve and valve washer
Tightent the cylinder cover bolt or
replace the cylinder gasket
Replace the relevant parts
Tighten or replace the fuel injector
washer
Troubleshooting
Drain out air, check the leakage of oil
suction pipe connector
 2. The accelerator pulling rod is not Operate on the oil pump test desk
flexible or clearance is too big
3. Speed adjusting is not flexible Operate on the oil pump test desk
4. Oil supplying of each cylinder of Operate on the oil pump test desk
fuel injection pump is not uniform
5. The spray quality of fuel injector is Operate on the oil pump test desk
poor

9.9 The engine is overheated

Fault Reason Troubleshooting

1. Insufficient cooling water in the Refill in cooling water
water tank
2. Air resistance in the cooling water Refill in water or drain out air
tank
3. The engine is overload Reduce load
4. The fan belt looses and rotating Tighten or replace the belt
speed reduces
5. The cooling water pipe is blocked Check or replace
6. The fuel injection is too late Adjust the oil supplying advanced
Outlet water
angle
temperature is
too high 7. Abnormal combustion Check the spray quality
8. The surface of water tank is too Wash the heat dissipation chip of
dirty water tank
9. The cooling system is incrusted Wash the incrustation and iron rust
severely professionally
10. The thermostat is damaged Replace the thermostat
11. The water pump is faulty, Check, repair ot replace the water
abnormal water pumping pump
12. The water temperature gauge is Replace
faulty, wrong reaction
1. Too much or too little oil Check the oil level with oil gauge
Oil temperature 2. The oil quality is too bad Use the correct type of oil
is too high 3. The gas blowby of piston ring is too Check the damage of cylinder and
much piston ring, scuffing and clipping of
 cylinder
4. The cooling water temperature is Eliminates according to above
too high mentioned
5. The engine is overload Reduce the load
6. The oil temperature gauge is Replace
damaged

9.10 Suddenly stop

Fault Reason Troubleshooting

1. No fuel in the fuel tank
2. Fuel piep leaks, air sucked into the oil
duct
3. Fuel filter element is blocked
4. The electromagnetic valve of oil pump
is powered off, cutting off the fuel
supplying
5. Fuel supplying pump fails to pump
6. Fuel injection pump damages, fails to
Suddenly
pump
stop
7. The crankshaft fails to rotate
(1) Scuffing and clipping of cylinder
(2) The oil pressure is too low or lack of
oil
(3) The oil pump is damaged and fails to
pump
(4) The valve hits the piston, cylinder
sheath and cylinder cover
Refill in fuel
Check for leakage; drain out air
Replace the fuel filter element
Check the electric circuit and
electromagnetic valve
Replace the oil supplying pump
Replace the oil injection pump
Disassemble the engine and find out the
reason
Maintain by professional
Maintain by professional
Maintain by professional
Maintain by professional

9.11 Abnormal noise during running

Fault Reason Troubleshooting

 1. Valve clearance is too big, sound of Check and adjust the valve clearance
shocking
2. Cleanrance between piston and Check and rereplace the worn parts,
cylinder is too big, sound of shocking keep the correct clearance
3. Axial clearance between main bushing Check the crankshaft neck journal,
and connection rod bushing is too big, replace the bushing
sound of shocking
4. Clearance between piston pin and Check and replace the connection rod
connection rod small head bushing is too bushing and piston pin
Abnormal
big
noise
5. Clearance between piston ring and ring Replace the piston and piston ring
during
running groove is too big
6. Crankshaft axial clearance is too big Replace the thrust
7. The valve hits the piston Check the valve clearance, valve
distribution phase and cylinder
compression clearance
8. Gear clearance is too big, sound of Replace the gear
shocking
9. Fuel injection is too early, sound of Check and adjust the oil supplying timing
cylinder hitting
10. The fuel injector parts are seized Clean or replace the nozzle parts
Jingyi Road Beside, Three Period, Industry Kit
Park Wangzhuang, National High and NEW Technique
Industry Development Area, Wuxi, Jiangsu, P.R.China
Tel: 0086-510-85205041
Fax: 0086-510-85203796
E-mail: kipor@kipor.com