OPERATION & MAINTENANCE

MANUAL
DIESEL LIGHT TOWER
 FOREWORD

Thank you for purchasing our diesel light tower.

This manual covers the correct operation and maintenance of the light tower and important
parts.
This manual also contains important information about safety, installation and trouble-
shooting guidelines. Please always keep this manual with the equipment. Please operate this
equipment after thoroughly reviewing and understanding the contents of this manual.
The contents of this manual are applicable to the genset in the production of sales. We
reserve the right to make changes at any time without notice and without incurring any obligation.
Without express written permission from us, any part of this manual cannot be reproduced in any
form or by any means.

SAFETY INFORMATION

All below are the safety alert symbols. It is used to alert you to potential personal injury
hazards. Please obey all safety messages and follow this symbol to avoid possible injury or
death. Otherwise, failure to properly follow these precautions can result in property damage,
serious injury or DEATH! Read these manual carefully. It is essential that you read the manual
and safety regulations before you attempt to use this unit. All the installation, operation,
maintenance and repair work must be performed by a qualified professional personnel !

WARNING

It indicates a strong possibility of severe personal injury or even death if instructions are not
followed.

CAUTION

It indicates a possibility of minor or moderate injury if instructions are not followed.

It indicates a possibility of potential hazards if instructions are not followed.

 CONTENTS
1.Production Introduction ............................................................................................................. 1
2. Security Guidelines .................................................................................................................. 3
3. Correct operation procedures and specifications of Lighthouse............................................... 7
4. Operations and precautions for Lighthouse transport ............................................................ 14
5. Electrical System Description ................................................................................................. 15
6. Introduction on engine performance and use requirements ................................................... 19
7. Introduction on generator principle and use requirements ..................................................... 24
8. Maintenance specifications .................................................................................................... 32
9. General troubleshooting ......................................................................................................... 36
10. Diagram and list of main parts.............................................................................................. 40
 1. Product Introduction

1.1 Product characteristics.

Mobile light tower is a high-performance product with good function of lighting and extra
power output. And the design of this product is based on the market demands, excellent
experience of marketing development and the advanced technology.
This illumination device can be rotated 359 °and manually lift. The generator set with good
performance is designed by us and the trailed chassis with good driving performance makes
sure the performance is reliable and it can be towed flexibly.
The performance parameters of the pole height , maximum working height, lighting distance
and lighting range, chassis driving performance, ability to resist shake and natural wind are at the
forefront of the same products currently. Conclusively, the characteristics of mobile lighthouse
are good performance , reliability, adaptability and wide working range

1.2 Appearance Specifications

1.2.1 Appearance Parameters On Working State

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1.2.2 Appearance Parameters On Moving State

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 2.Security Guidelines

Before operating the unit, please read the safety guidelines, and learn the local safety
standards or related specifications, to minimize personal injury or damage to the machine.
Incorrect operations are very dangerous ! If you realize the machine is in unsafe situation,
DONNOT trying to start and operate the unit ! All installation, connection, operation, maintenance
and repair work must be performed by a professional person with relevant qualifications. Users
have the responsibility to keep the unit in a good and safe working state.
Please read all safety labels carefully and follow all safety instructions.

2.1 Security Warning

We have fully considered the safety factors and the impact on human health in the design
and manufacturing process, all users must carefully read the instructions before operation to
ensure the equipment and personal safety, and personal health. Our company will not take
responsibility in reason of security incidents or damage on human health caused by an illegal
operation .
1). When the generator works, children are not allowed to play or stay near the operating
area
2). The diesel engine puts off exhaust gas all the time which is harmful to personal health
when it works , so users need to maintain good ventilation in the workplace. If you use this unit in
an enclosed space, make sure there is good ventilation to put the engine exhaust gas away from
working area. In addition, the exhaust pipes and other high-temperature parts should be kept
away from flammable substances, and you should also ensure the engine exhaust gas would not
become public nuisance.
3). The unit load connection must be performed by a qualified and experienced electrician,
it must comply with the relevant electrical regulations and standards.
4). Before starting the engine, all of the insulating connector should meet the requirements,
and you should make sure that there are no omissions.
5). Make sure all the ground wires connect to the ground reliably.
6). Check the engine oil, coolant and fuel to ensure there is no leakage.
7).Check the engine oil level, fuel level and coolant level to ensure they meet requirements.

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 8). Maintenance procedures maybe involve heavy parts or life-threatening electrical
equipment, therefore, the operator must go through qualifying training, DONOT operate the
equipment alone , and there must be an companion for you to prevent accidents .
9). Before maintenance, please cut off the connection between the engine starter motor
and battery negative to ensure the starter motor will not work to prevent accidents.
2.2 Pay attention to risk of electric shock
Before taking in external loads, please make sure all load equipments qualified, otherwise
they will cause serious damage to equipment and personnel.
In an emergency, the operator must be able to use the correct treatment methods of electric
shock.
Connect or disconnect the circuit in the operating state of any part must use insulated tools.
Before switching on or off the circuit, please ensure the circuit safety .
It does not allow metal objects resting on the battery which supply power to engine starter
motor or staying on the terminals.
When a strong current flows to the battery terminals, incorrect connection can cause the
metal stream. Any wire from the battery positive must firstly through safety devices (excluding
starter motor’s and battery charger’s wires), and then be directed to control devices, or if a short
circuit happens, it will cause serious consequences.
Please comply with all electrical regulations, the installation and maintenance of electrical
equipment must be carried out by a qualified electrician.
The sizes of wires used connection must meet relevant requirements.
2.3 Pay attention to toxic gas
There should be enough space to make the exhaust gas diffuse to avoid damage to human
body. When the unit works in a relatively closed or small space, users should open the doors or
windows firstly to diffuse all exhaust gas to prevent carbon monoxide poisoning people.

2.4 Pay attention to working safety

DONOT use the unit in the environment of explosives.

Approaching to the running engine is very dangerous. Loose clothing, hair and tools falling
will maybe cause significant accidents to personal or equipment. Please keep away from partial
nudity pipes in a high temperature to prevent burns when the generator set is running.

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2.5 Fire Prevention

Metal objects will cause a short circuit and possibly cause fires.
Please keep the engine clean. Excessive oil may lead to engine overheating and causing
economic losses, damage or fires directly.
Please place a number of dry powder or carbon dioxide fire extinguisher nearby the unit
working area.

2.6 Starting Safety

In extremely cold environment, the starter needs preheating device. DONOT use flame to
bake parts. The installation of the water heater jacket can help you start this set easily and
quickly.
The normal temperature of the battery working should be maintained at above 10 ℃,
otherwise it will not provide enough power .

Warning

DONOT use fluid or similar items to help you start the unit.

2.7 Safety of using fuel and lubricants

Fuel and lubricants will stimulate the skin. If your skin contact to the oil, please wash them
promptly and thoroughly with clean water and gel. People whose skin allergies or having got
injured should wear protective gloves before touching the oil.

2.8 Safe of using coolant

Before starting unit in any temperature, please add enough coolant to the cooling system to
prevent freezing and rust.
When the cooling system has not enough coolant while the engine is running, the user shall
not start the heater, otherwise it will cause damage.
High-temperature cooling water can cause serious burns. When the engine is hot, please do
not open the tank cover with high heat and high pressure cooling water in closed cooling system,
and plugs of water pipes.
2.9 Unit safety of connecting to ground
The point used to connect to ground is arranged on the side of the unit chassis, please stick
the metal deflector into the underground reliably before the unit working.

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 Grounding system is a vital system, which can prevent damage caused by the abuse of
power or power failures, users must ensure all the Internal neutral wires are connected to
ground.

Warning

Users have the responsibility of maintaining equipment grounding effectively. The

maintenance of grounding system should be operated as the instructions requires strictly. Our
company and its agents are not liable for the accident caused by the unit being not grounded or
being grounded failure.

2.10 Items about safety during maintenance

All maintenance and repair works must be carried out with the engine shutting off.
After this unit stops working, please cut off the main power switch and battery switch, and
disconnecting the wire out from battery negative is necessary.

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 3.Correct operation procedures and specifications of Lighthouse

3.1 Environmental requirements of using Lighthouse

Altitude ≤1000m

Environment temperature ＜50℃

Earthquake resistance level ＜Class 6

Natural wind resistance level ≤Class 7 (16m/s)

弹簧销“E”
Spring pin "E" winch
绞盘“B”"B" steel
钢丝绳 cable

锁紧销“D”
Locking pin "D"
steel cable
钢丝绳
Parking brake handler

驻车手柄 Outrigge
支撑腿
绞盘“A”
winch 锁紧销“C”
"A" Locking r
pin "C" 支撑腿
Outrigge
r

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3.2 Preparation before using Lighthouse
3.2.1 Items to check before starting
Make sure there is no obstacle
within 40 feet on the top of unit

Please try to choose

a flat place to put unit

1.Please choose a good place where the ground is flat.

2.Check cables and lamps bolts to ensure they are connected reliably.
3.Make sure there is no obstacle within 40 feet on the top of unit.
4.Check lamps to ensure they are connected reliably.
5.Make sure exhaust pipe in the tail is not blocked.
6.Check engine fuel reserves to ensure there is adequate fuel supply to the engine working .
7.Check engine oil level to ensure the oil level is between the high and low oil dipstick .
8.Check the coolant level.
9.Check the engine oil pipes to ensure they are connected stably.
10.Check the wires out from battery positive and negative to ensure the battery current
inputs and outputs correctly.

3.2.2 Standing lamps pole up

1. Extend four outrigger beams fully and insert the spring pins, and then rotate the handles
of outriggers to support the whole unit, while ensuring outriggers and the ground connect stably.

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 2. Users should try to place the unit flatly by adjusting outriggers, but also should note that the
tires cannot be out of contact with the ground.
3. After connecting the metal rod to unit, then stud the metal rod into the ground firmly to avoid
injury or electric shock .

This bolt is used to grounding

4. Pull out the locking pin "D"

Locking pin "D"

5. Rotate the handle of winch "A" to make pole perpendicular to the ground.

6. Pulled out the locking pin "C"from hole " a ", then rotate the handle of winch "A" slowly to
help the locking pin "C" penetrate to hole" b" freely . Finally, the pole will be in the state of being

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locked and perpendicular to the ground.

3.2.3 Extend and retract the pole

1. After the pole standing up, pull the spring pin "E" out, then the pole can be rotated to the
desired angle. After stopping rotating, the user can insert spring pin "E" to lock the pole.

2.Users can extend or retract the pole to reach the desired height in the vertical direction by
rotating the winch "B". When pole is extended, DON’T exceed pole over the marked position (red
zone).

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 G
G
局部视图
Partial view

winch "B"
When the pole is up
to this position, stop
rotating winch "B".

3.3 Starting unit

1.Before starting, please ensure the output switches are in the state of being off, and then turn
on the battery switch and the knob switch on control panel counter.
2. Make sure the emergency button is in the state of being reset (OFF).
3. After the controller interface being lit up, press the button "MAN" key firstly, then press the
"START" button, then the controller interface will display related parameters and it will start the
unit automatically after a few seconds.
4.Keep the engine idling running 2-3 minutes, then observe whether the parameters displayed
by the controller interface are in stable state or not. If the buzzer alarm does not sound , it
indicates the unit is running normally; if the buzzer alarm sound ,please record the parameters
displayed on the interface of controller ,and immediately stop this unit, then according to the
chapter 9 " general troubleshooting methods "in this manual, shoot all troubles rapidly to ensure
this unit can work normally.

Warning In this process, please pay attention to protect yourself safety, and avoid burns,

crush, electric shock and other injuries;

5. After the engine is running stably, user can turn on the lamps according to need, or take
power by putting the plug supplied with this unit into the corresponding socket. But please make
sure all the output, including the four lamps, should not be over the max.power;
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 6. If user needs to light lamps up, please turn on the lamps switches one by one according to
the symbol on the control counter board. After a period of time to warm, lamps will brighten
slowly until brighten completely. In order to prevent wires burning out, DON’T turn on four lamps
at the same time.
7. If taking power from the unit, firstly please access the extra load equipment to the unit
safely, secondly turn on the socket switches according to the symbol on the control counter
board, then the extra load equipment can work well.

3.4 Stopping unit

1. After the work is completed, close the all (lamps, sockets) switches on the control counter
board, then turned off lamps or unplug the external load to cut off the power output.
2. After the unit running for 3-5 minutes without load , please press the "STOP" button for
several seconds, then the controller will display stopping tips and automatically shut off after
several seconds.
3.Ensure four illumination lamps to cool down for 5-10 minutes
4.Retract the pole by rotating the winch "B".
5.Pull out the spring pin "E", rotate pole to take the arrows to positive location.
6.Insert the spring pin "E" and lock it.
7.Pull out the locking pin "C" and put it into the hole "a".
8.Slow down the pole to the lowest level position by rotating the winch "A";
9.Insert the locking pin "D" to keep the pole in the state of being locked.
10.Back up the four vertical outriggers to ensure two tires are in full contact with the ground.
11.Rotate the handles of vertical outriggers to take the four outriggers back, and then lock
them in fixed positions.
12. After pulling out the locking spring-pins, slid four outriggers horizontally to the tube, then
insert locking spring-pins.
13.Pull out the metal deflector rod ,and unscrew the grounding nut , and then put the metal rod
into the fixed position Internally.
14.Adjust the guide wheel in the front to make the drawbar be close to a horizontal position.

3.5 Attention

1. When the pole is in extended state, DONOT move the unit !

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 2. When the unit is on the 5 °ramp or above, DONOT lift the pole!
3. If high-voltage wires appear in the work area, please keep the unit being in a safety
distance with the high-voltage lines .
4. When the wind speed exceeds over 16m / s. (DONOT lift the pole when you face the
wirerope!)
5. DONOT use the unit outdoor in the thunderstorm weather.
6. If the unit is used indoor in rainy weather, please pay attention to protection against the
electrical shock.
7. After the lamps lighting up, don’t touch the surfaces of lamps to avoid burns caused by the
heat.
8. After the lamps shutting off, DONOT start them again before the lamps completely
cooled .
9. Pay attention to smearing grease lubrication regularly to protect the nylon slides and
cables.

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 4.Operations and precautions for Lighthouse transport

4.1 Procedures for Lighthouse transport

1.Make sure the power is turned off and all the poles and outriggers are back in the fixed
places and in the locked state.
2.Close and lock-up all doors, then remove the keys and keep them.
3.Check the tires pressure to ensure that the unit can be towed normally.
4.Import tractor, and pull the collar of this unit into the tractor drawbar.
5.Open the protection cover on the towing device.

6. Tract the unit normally under the speed of 30km / h.

4.2 Precautions

1.Please keep the speed under 40km/h while the unit is towed.
2.When the unit is pulled in the winding road, please control the traveling speed in 15km / h,
otherwise there is danger of tipping.

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 5.Electrical System Description

5.1 Summary

The electrical part of this generator set consists of following components:

DC system consists of batteries, charging generator.
AC system consists of alternator.
Control system consists of the functions of detection on starting, stopping, running
status, and fault warning and protection, parameters displaying and so on.
Illumination system consists of lamps, ballasts, explosion-proof capacitors and
associated circuit breakers and other components with control functions
The DC power consists of a maintenance-free battery, and it provides power to starter motor and
the unit control system.
5.1.1 Voltage and capacity
The voltage of maintenance-free battery is DC12V, battery capacity expressed in ampere
hours (Ah). Greater the power of this generator set is, more number of battery to be configured,
and the capacity is also greater. All above have been equipped according to the requirements in
our factory, users do not need to consider it.

Warning Free to change the configuration of the battery may cause failure to start the unit or

serious damage!
5.1. 2 Battery wire connection
Battery wires must be connected reliably, because the instantaneous current is very large
at the moment of starter motor starting. Any unreliable connection will lead to the increase of the
starting circuit voltage drop, and the unit cannot be started. Generally, in a DC12V battery system,
the line voltage drop is less than 1V when starting.

Warning If the battery wires are loose, damage to the control module and motor and other

serious accidents can be caused.

5.1. 3 Battery charging
Alternator will charge the battery during the unit normal working.

Warning Please ensure the battery has sufficient power at any time. DO NOT try to sconnect

the wires between the alternator and battery except for maintenance !
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5.2 Alternator
Generally , the alternator in this Lighthouse Unit is exciter quadrupole generator. The
frequency is 50Hz at the speed of 1500 rpm / min, and the frequency is 60Hz at the speed of
1800 rpm / min.
5.2.2 Protection by grounding
Users should connect the grounding wire reliably according to regulations.
A good protection of grounding will mitigate damage to equipment and personal at the time
of power failure and illegal operation. And the Internal neutral wires must be connected to ground
directly as the generator is the only power.

Warning There are current transformers used to detect current in the box of generator,

DONOT start the unit while the current transformers are being in open state, otherwise it will
endanger the equipment and personal !
For more information on the generator, please refer to chapter 7 of this manual .
5.3 Control Box
The electrical control box is mounted on the side of unit, its main functions are:
Control the unit starting and stopping.
Fault detection, alarm and shutdown protection.
Control and display the operating parameters.
Take control of illuminating system and output to other load.
5.4 Illuminating system
This system consists of four sets of metal halide lamps, ballasts, explosion-proof capacitors
and associated circuit breakers with controlling functions etc., and the power of a single lamp is
1000W.

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5.4.1 Lamps

1 Power of a single lamp 1000W 5 Color temperature 5000K

2 Maximum voltage allowed 263V 6 CRI 70

3 Maximum current allowed 4.1A 7 Protection class IP54

4 Initial light effect 1m/w 11000 8 Weight 6.5kg

5.4.2 Ballasts

1 Voltage 220～240V 50Hz

2 Working current ≤5.5A

3 Starting current ≤4.8A

4 Weight 9.7Kg

5.4.3 Explosion-proof capacitor

1 Rated capacitance 28μF

2 Working temperature -40～105℃

3 Rated voltage 120～540VAC

4 Capacitance range 3～100μF

5 Working frequency 50/60Hz

5.5 Metal halides Installation precautions

1.You should wear gloves to avoid stains and other pollution while installing, otherwise they will
cause damage to the lamp bulbs during the lighting by high temperature.
2. When the lamp is installed, please make sure there is no contact between the lamp, lamp bulb,
reflector, and glass, otherwise the installation method is wrong.
3. To prevent halide consolidation at both ends, the igniting test time must be more than 10
minutes so that ensure the halide in the tank will be fully boil; if the arc discharge lamp has not
fully set up , then turn off the lights, the two electrodes of the lamp arc tube will be black, and
these will cause difficult to start lamps again. If failed to start again, please choose the right
ignitor to auxiliary start , after waiting for lights burning out normally and stably, this black
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phenomenon will disappear.
4. After the lamps burning out ,users should avoid touching them .Otherwise, it will lead to loose
bulbs or cracking ,and it also will lead to burns to human body by the high temperature .
5. After the lamps extinguishing, DO NOT re-start the lamps before they cooled down completely.
In the circuit equipped with triggers, if bulbs are damaged or fail to ignite, the user should turn off
the power immediately, do not keep the circuit working without load.
6. It needs about 10 minutes to be up to the halide maximum luminous flux. After 10 minutes ,
they will achieve the stable state. DO NOT switch frequently to prevent the bad affect to the
lamps life .
7. As the metal halide characteristics, please wait for 5 to 15 minutes to cool lamps enough after
the lamps extinguishing . And the ballasts will take control of this process automatically, in the
meantime, do not open ballasts again and again to prevent the damage to the lamps life .

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 6.Introduction on engine performance and use requirements

In order to ensure the diesel engine work safely and reliably, and to extend its life , please
use engine rationally, and make maintenance Regularly.
In this chapter, contents about the engine performance, structure and requirements of
maintenance and operation will be presented.

6.1 Usage Tips

6.1.1 Cautionary Tips

1) It is strictly forbidden to use inferior and dirty diesel fuel or lube oil. Please choose to use fuel
and lube oil with stipulated number according to the instruction.
2) It is strictly forbidden to leak out from an intake system (air filter, pipelines and connecting
components)
3) It is strictly forbidden to have hard water (well water or spring water)as cooling water, if
necessary to apply the hard(water),soften it first.
4) It is strictly forbidden to start under the circumstances of lack of lube oil or water
5) It is strictly forbidden to operate at overload or under other conditions against the rules
6) It is strictly forbidden to regulate the fuel injection pump at will
7) It is strictly forbidden to change the diameter of the pulley
8)To control the starting time(less than 15 seconds) and the starting interval(more than 2
minutes)strictly
9) It’s must to maintain the diesel engine technically in the allotted time
10) Ambient temperature under 0℃, discharge all the coolant to prevent frostbite after stop
11) All the filters (include air pump filter) maintain, repair or instead according to the provision

6.2 Notice of winter

Make sure the usual running of engine in winter; please pay attention on the items as

following:

1. Please choose high-quality diesel fuel based on related information in Chapter 8

2. Please use Class CC or CD 10W/30 or 5w/30 diesel fuel, and the Class CD diesel fuel for

Turbo-charger.
3. Make sure the connecting reliable and available between battery and start motor

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 4. Battery capacity should be conform to specification of manual

The total length of front line, ground line should less than 2 meters, and area more than 50 mm2

The total length of front line, ground line should more than 2 meters, and area more than 70 mm2

5. The temperature starting should be below -5℃,and add hot water and fuel

6. Eliminate the air of fuel system

7. Check if the pulverization of injector is normal or no

6.3 Safety requirements for diesel engine
1.Diesel engine workplace must be well-ventilated , whenever possible accumulation of
flammable, toxic or asphyxiated gas in place, should be installed ventilation facilities.
2. The Diesel Engine operation place must have non-slip cover.
3. The engine when is working, need to equipped with water temperature meter, oil pressure
meter and instructions system.
4. When engine is in operation of adjustment, and there is abnormal sound, running away or
lubrication failure or the environment when used in the combustible exhaust temperature
exceeds the limit, we should promptly cut off fuel (put handle off, cut off the fuel line method) and
air (blocked) inlet or adopt other effective measures to stop the engine quickly.
5. The inlet of fuel tank and the outlet of air flow should far away from the surface of high
temperature and the electronic equipment. Make sure the fixing bolt of fuel tank is well fixed to
allow the fuel tank without leakage.
6. When locate the heat changer should put at eye-catching place with warning mark. And
make a caution to operator that shouldn’t open the cover of heat changer immediately to prevent
burn injury.
7. The air outlet of diesel engine and silencer are the surface of high temperature. Operator
should not touch the surface under the operation state of diesel engine. If the user takes the
insulation material as a protection, make sure the fuel oil not into it to prevent fire.
6.4 Maintenance
To make engine work reliably, lower abrasion parts, extend service life, make sure the
regular maintenance for the engine system according to the following technology rules.
6.4.1 Routine maintenance

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 1.Check the oil level is under the gauge rated range. New machine or long time no used
machine should stop after five～ten minute low speed running when gas. Then use gauge
measure the oil level.
2.Check the water level of heat changer
3.Check the oil level on the oil pump of the governor whether if at rated level.
4.Exclude the leakage situation of water, oil and gas on the diesel engine.
5.Check the fasten class and the layout correction of parts on the diesel engine.
6.Check every holding parts and connectors whether if connect well.
7.Pretend the clear of diesel engine. Use the duster that soaked some gas to clear oil, water,
and dust especially make sure the clear and dry of electronic equipment, also clear the
dust of the heat sink on the water tank
8.Should replace the oil at the oil house, oil pump and governor at once after the 50 hours
running, and wash clear the oil filter, the oil house and the oil filter net.
9.Eliminate all faulty and unmoral situations.
6.4.2 Maintenance after 100 accumulated operating hours
Except the daily maintenance, make sure to do the following as well:
1.Replace the sump oil.
2.Clean or replace oil filters.
3.Clean or replace diesel filter (after working continuously 200 hours).
4.Check the bolt firmness of cylinder
5.Check Valve Gap to measure up, adjusted it if necessary.
6.Check fan belt tension extent, adjust it if necessary.
7.Oil ZG-4 lubricant into the water pump bearing with grease gun.
8.Clean the dust accumulated in the air inlet pipe, dust pan of the air filter and on the surface
of paper filtering core, and remove the dust inside the air exhaust pipe and the muffler.
9.After 200 hours running in total, check the oil injection pressure and the injection status.
Clean the needle valve parts if necessary, and re-adjust the oil injection pressure.
10.Tear off the tape on the hole, add the electrolyzed liquid to “Max” level (when the air
temperature is 20℃, liquid proportion shall be 1.28). Screw the vent hole and check the
voltage, then standing it for 20 minutes to use it. (if the temperature is lower than 15℃, it
needs longer time)

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 11. Components disassembled due to maintenance work shall be cleaned before
re-assembly, and the installation position shall be guaranteed correctly. Then start the
diesel engine and check its operation. Remove errors and abnormal phenomena found.
6.4.3 The maintenance after 500 hours’ operation
Besides the items in “maintenance after 100 hours’ operation”, the following jobs shall be
added as well:
1.Check the oil injection pressure of the injector and observe the pulverization quality of oil
injection. Clean the needle valve parts and re-adjust the oil injection pressure if necessary.
2.Check the working conditions and the oil supply advanced angle of the oil injection pump,
re-adjust if necessary. Re-adjust the oil supply to the oil pump on the oil pump test bench if
conditions allow.
3.Check the sealing condition of air inlet and exhaust valve and the air valve stand. Grand
and rectify if necessary, and re-adjust the clearance between the air valves.
4. Check the fixing status of connection rod bolt, main bearing bolt and flywheel bolt.
5.Re-fasten the bolt of cylinder cover, and adjust the clearance between the air valves
according the regulations.
6.Clean or change the filtering core of the air filter.
7.Clean the cooling system, the detergent comprised by 150g NaOH and 1L water.
Discharge the water in cooling system before cleaning, and then fill full it with detergent. Start
the diesel engine after reserving the detergent for 8~12 hours. and stop when the water
temperature reaches the working temperature. Discharge the detergent immediately to avoid
the furring deposit. Clean the cooling system with water at last.
8.Check the working conditions of the thermostat, and check the water prop inside the water
discharging hole in the water pump. If water drop is serious, replace the water seal.
9.Check the joints of the electric circuits of the electric equipment are firm or not, and the
lead contact is good or not. If there is burning mark found, clean it immediately.
10.After 1000 hours of working accumulatively, add the following work:
(1) Generally inspect the parts of the diesel engine, and carry out necessary repair and
adjustment.
(2) Dismantle the generator and the motor to clean the old butter on the bearing and
replace new butter, meanwhile check the gears on the driving motor.
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 11. After 1500 hours of working accumulatively, add the following work:
(1) Dismantle the cylinder cover; check other parts between air valve and air valve stand and
cylinder cover set.
(2) Remove the deposited carbon on such parts as cylinder lid, cylinder cover, piston and
piston ring, and clean thoroughly.
(3) Check and measure the abrasion of piston and piston ring.
(4) Check and measure the abrasion of internal holes of cylinder cover.
(5) Check and measure the abrasion of crank necks.
(6) Check and measure the abrasion of main shafting and connection rod shaft.
(7) Clean the oil tunnels inside the engine and change oil.

6.5 Preservation and storage of engine

When the diesel engine is to be stopped for a long time, the following methods can be taken
for sealing and preservation.
1. After stopping the engine, discharge oil, coolant and fuel thoroughly when they are hot.
Clean the oil sump and the filter.
2. Clean the dust and oil on the surface. Apply anti-rust oil onto the parts that without paint.
No oil shall be supplied onto rubber and plastic products.
3, Heat the filtered oil to 110~120℃, until foams disappear totally. Then fill the dehydrated oil
to the oil sump until it reaches the upper scale of the oil gauge and turn the crank to make the
whole lubrication system full of oil.
4, Add some dehydrated oil to the cylinder from the oil injector installation hole on the
cylinder lid and then turn the crank to make the oil adhere onto piston, piston ring, cylinder
cover and air valve sealed surface.
5, The mouths of air inlet and exhaust pipes(muffler) shall be blocked with wood lid or plastic
cloth to avoid immunities enter.
6, Diesel engine shall be placed in dry and clean location with good ventilation. It shall be
covered to avoid dust drop. It is prohibited to pile chemical products near the diesel engine.
The aforesaid oil sealing method can be used to preserve the machine for 3 months. When
exceeding such time limit, re-seal it with oil.

23
 7.Introduction on generator principle and use requirements

7.1 Use conditions and requirements of generator

Generator is suitable for ambient temperature 40 ℃, altitude 1000 m or less (in accordance
with BS5000 standards and China standard GB755).

Notice

If the ambient temperature exceeds 40 ℃, and the altitude is more than 1000m , generator is
permitted to use, but rated power will decrease. If users need to use the generator with the
ambient temperature being over the value on the nameplate (40 ℃) or the altitude being over
1000m, please revise the rated power . The revise factor is:
Ambient temperature Revise factor
45℃ 0.97
50℃ 0.94
55℃ 0.91
60℃ 0.88
Altitude (m) Revise factor
1500 0.97
2000 0.94
2500 0.91
3000 0.88
3500 0.85
As the louvers structure, if the user wants to place the generator in a sealed cover shed,
please ensure the temperature of cooling air will not exceed the value on nameplate.

Warning Cooling airflow reducing or inadequate protection of the generator will lead to

damage to the windings and / or malfunction.

Generator rotor has been tested to get a good balancing efficacy at the time of manufacture in
accordance with China GB755 and BS6861 first part by the 2.5 precision, and the vibration limits
of the generator is in line with China GB10038.
The main vibration frequencies produced by the generator are:
Grade 4 1800rpm 30HZ
However, the vibration induced by the generator is complex, which contains basic vibration
frequency of 1.5 times, 3 times, 5 times or more multiples. These frequencies will result in
vibration level is higher than the generator vibration from itself. FG164DX generator has been
designed to meet the requirements of IS08528-9 (IS08528-3 requires to detect the entire
24
frequency band)
7.3 Generator installation
7.3.1 Lifting generator
For the transport safety, a shaft card has been mounted at the end of driving-shaft extension.
If the card is removed and after connecting of the generator and engine, the rotor can rotate
freely in the cradle. User should pay attention to ensure the seat remains level in the cooperation
and alignment process.

Warning Incorrect lifting or insufficient lifting capacity will cause serious personal injury or

damage to the equipment. The minimum lifting capacity required has been noted
on the lifting tag . And the lifting ring on the generator shall not be used to lift the
entire group.
7.3.2 Connection between the generator and engine
In the connection of the generator and engine, firstly, please pair carefully, then rotate the
generator rotor, engine crankshaft assembly. In this process, please complete the positioning
screw connection, insert and tighten.
In the process of connecting the single bearing generator to engine, you need to connect the
generator flange holes and the holes on the engine flywheel, we recommend you firstly place two
studs into two symmetrical holes on the flywheel, then the generator flange disk can be easily
slid into the engine flywheel. Before you tighten all connecting screws, pins must be removed
and instead by connecting screws . In this process, you must rotate the engine crankshaft ---
generator rotor assembly . During rotation, you should be careful and use the correct way to
ensure safe, and to avoid component damage .
Generator manufacturer will provide suitable tools used to rotate the crankshaft assembly ,
you must use the tools during the installation.

Notice In the connection process, you must be carefully to lock the entire rotating assembly

before internal operation of the generator.

In order to transport and storage, the generator casing and flange have been coated with
rust layer , you can use Toluene to clean the surface to remove rust layer.

Notice After washing, your skin must be cleaned.

Generator moderate is very critical, if necessary, please use cushion sheet at the foot of
25
generator to ensure the moderate of machined surface.
Connection of engine and alternator:
1. Check the distance between the engine flywheel mating face and the flywheel housing mating
face , the value of distance should be within 0.5mm , otherwise, the generator bearing or
engine bearing will be affected by lateral thrust.
2. Make sure the bolts between the disc and the flange hub have been fixed .
3. Remove the stencil at the position of generator drive end and the transition nipple bolts. In
addition , please ensure the surface is clean without lubricant.
4. Make sure the flange disc and transition nipple spigot is concentric; you can adjust the
concentricity by padding wedge-shaped pieces of wood between the fan and the transition
nipple, or lift the rotor by sling.
5. Move the generator to engine ,and pay attention to closing the flange and flywheel cover .
Then move the generator closer to engine until the flange and flywheel cover contact well.

Notice Incorrect installation of transition nipple protector will lead to serious personal injury

or equipment damage.
7.3.3 Grounding
Generator seats should be fixed firmly in the public chassis , if installing damping device
between the generator and the public chassis, there must be a suitable grounding conductor (the
cable cross-sectional area is generally half of the main cable) to connect the generator and
public chassis.

Warning Please ground properly according to local regulations

7.3.4 Check items before running

1.Check the insulation properties
（1）New generator
The generator insulation resistance, along with many other critical factors, will have been
measured during the alternator manufacturing process. The generator will have been
transported with an appropriate packaging suitable for the method of delivery to the Generating
Set assemblers works. Where we expect it to be stored in a suitable location protected from
adverse conditions. However, absolute assurance that generator will arrive at the Gen-set
production line with IR values still at the factory test levels of above 100MΩ cannot be
guaranteed.

26
（2）At Generating Set Manufacturers Works
The generator should have been transported and stored such that it will be de livered to the
assembly area in a clean dry condition. If held in appropriate storage conditions the generator IR
value should typically be 25MΩ
If the unused/new generator’s IR values fall below 10MΩ , then a drying out procedure
should be implemented before it being dispatched to the end customer’s site. The dryingmethod
please refer to the Section 7.4.

（3）Generator in maintenance
It is known that a generator will give reliable service with an IR value of just 1.0MΩ. If the IR
value is lower than 1.0MΩ, it may be caused by inappropriate operating or storage conditions.
Any temporary reduction in IR values can be restored to expected values by drying out.

2.Direction of rotation
The standard direction of rotation is clockwise, as viewed from the drive end.
3.Phase sequence
The phase sequence is U.V.W. while the rotation is clockwise, as viewed from the drive end.
4.Voltage and frequency
Check the voltage and frequency values required on the nameplate to make sure they meet
requirements of the work site.
5. AVR settings
Remove the AVR cover , and then refer to the type of AVR , user can read the contents in
this specification. Most of the AVR have been set well in factory to give satisfactory performance
during initial running tests. And the user can adjust it during normal operation, in order to obtain
the best operating performance.

7.3.5 Generator testing

Before the test, cables or wires should be connected with a terminal or connector type of
alligator clips.

Warning

(1)During the test, it may be necessary to remove covers to adjust controller, and maybe
some terminals or components will expose. Only the professional electrician will be allowed to
carry out the test.
(2) When fitting power cables for load testing purposes, ensure cable voltage rating is at
27
least equal to the generator rated voltage. The load cable termination should be placed on top of
the winding lead termination and clamped between the two nuts provided.
(3) Check that all wiring terminations for internal or external wiring are secure, and fit all
terminal box covers and guard. Failure to secure wiring and/or covers may result in personal
injury and/or equipment failure.
7.3.6 Initial startup requirements
On completion of generating set assembly and before starting the generating set ,please
ensure all engine manufacturer’s pre-running procedures have been completed , and adjust the
engine governor to make sure the generator speed will be in excess of 125% of the rated speed.

Warning The over speed caused by the improper engine governor settings will cause

damage to the generator rotating parts.

Warning Do not increase the voltage above the rated generator voltage.

Warning During the test, it may be necessary to remove covers to adjust controller,

and maybe some terminals or components will expose, only the professional electrician will be
allowed to carry out the test. Please cover it again after the test.
7.4 Generator Maintenance
7.4.1 Winding condition
Typical Insulation Resistance [IR] Values
New generator
The generator insulation resistance, along with many other critical factors, will have been
measured during the alternator manufacturing process. The generator will have been
transported with an appropriate packaging suitable for the method of delivery to the Generating
Set assemblers’ works, where we expect it to be stored in a suitable location protected from
adverse conditions. However, absolute assurance that generator will arrive at the Gen-set
production line with IR values still at the factory test levels of above 100MΩ cannot be
guaranteed.
At Generating Set Manufacturers Works
The generator should have been transported and stored such that it will be de livered to the
assembly area in a clean dry condition. If held in appropriate storage conditions the generator IR
value should typically be 25MΩ
If the unused/new generator’s IR values fall below 10MΩ , then a drying out procedure
should be implemented before it being dispatched to the end customer’s site. The drying method
28
please refer to the Section 7.4.

Generator in maintenance
It is known that a generator will give reliable service with an IR value of just 1.0MΩ. If the IR
value is lower than 1.0MΩ, it may be caused by inappropriate operating or storage conditions.
Any temporary reduction in IR values can be restored to expected values by drying out.

Warning Service and fault procedures can result in hazards. Only the professional

electrician will be allowed to carry out the procedures. Please ensure the engine start circuits are
disabled to start and isolate the anti-condensation heater switch before maintenance.
7.4.2 Winding condition assessment
The condition of the windings can be assessed by measurement of insulation resistance (IR)
between phase to phase, and phase to earth . Measurement of winding insulation should be
carried out:-
1. As part of a periodic maintenance plan.
2. After prolong periods of shutdown.
3. When low insulation is suspected, e.g. Damp or wet windings.
Care should be taken when dealing with winding that are suspected of being excessively
damp or dirty. The initial measurement of the [IR] insulation Resistance should be established
using a low voltage (500V) megger type instrument. If manually powered the handle should
initially be turned slowly so that the full test voltage will not be applied, and only applied for long
enough to very quickly assess the situation if low values are suspected or immediately indicated.
Full voltage megger tests or other forms of high voltage test should be carried out after
winding drying

Procedures for insulation testing

Disconnect all electronic components, such as AVR, electronic protection equipment etc.
Ground the [RTD’S] Resistance Temperature Detection devices if fitted. And short out the diodes
on the rotating diode assembly.
Be aware of all components connected to the system under test that could cause false
readings or be damaged by the test voltage.
The measure value of insulation resistance for all windings to earth and phase to phase
should be compared with the guidance given above for the various ‘life stages’ of a generator.
Then minimum acceptable value is 1.0MΩ。

29
7.4.3 Drying method
1).Cold running
Providing a generator in good condition but has not been run for some time. It is possible
that simply running the genset ,without excitation , will raise the IR sufficiently (greater than
1.0MΩ) to allow the unit to be put into service. Run the generator for approximately 10 minutes
with , AVR terminals K1 and K2 open. Visually check that the windings appear dry and carry out
an insulation resistance test to prove that the minimum (1.0MΩ) insulation value has been
achieved. If this method fails, use one of the traditional methods outlined below.
2). Blown air drying
Remove the covers from all apertures to allow the escape of the water-laden air. During
drying, air must be able to flow freely through the generator in order to carry off the moisture.
Direct hot air form two electrical fan heaters of around 1-3 KW into the generator air inlet
apertures. Ensure the heat source is at least 300mm away from the windings to avoid
overheating and damage to the insulation.
Apply the heat and plot the insulation value at half hourly intervals. The process is complete
when the parameters covered in the section entitled ‘Typical Drying Out Curve’ are met. Remove
the heaters, replace all covers and re-commission as appropriate.

If the set is not to be run immediately ensure that the anti-condensation heaters are
energized, and retest prior to running.

Typical drying out curve

Whichever method is used to dry out the generator the resistance should be measured
every half-hour and a curve plotted as shown.

The picture shows a typical curve for a machine that has absorbed a considerable amount of
moisture. The curve indicates a temporary increase in resistance, a fall and the a gradual rise to
a steady state. Point ‘A’, the steady state, must be greater than 1.0MΩ. (If the windings are only
slightly damp the dotted portion of the curve may not appear).For general guidance expect that
the typical time to reach point ‘A’ will be approximately 3 hours for a LV 6 generator. Drying

30
should be continued after point “A” has been reached for at least one hour.
It should be noted that as winding temperature increases, values of insulation resistance
may significantly reduce. Therefore, the reference values for insulation resistance can only be
established with windings at a temperature of approximately 20℃。
After drying out , the insulation resistances should be rechecked to verify minimum
resistances quoted above are achieved. On re-testing it is recommended that the main stator
insulation resistance is checked as follows:
Separate the neutral leads.
Ground V and W phase and megger U phase to ground
Ground U and W phase and megger V phase to ground
Ground U and V phase and megger W phase to ground
If the minimum value of 1.0 MΩ is not obtained, drying out must be continued and the test
repeated.

7.4.4 Bearing maintenance

All bearings have been pre-loaded with grease. Closed-end bearings are completely closed,
there is no need to add Lubricants to them .
Precautions

(1) The bearing life and working conditions have a direct relationship with the environment.

Vibration of the engine is too large or the bearing is subjected to lateral force caused by the poor
case of installation, will reduce the bearing life. And If the vibration exceeds the predetermined
value in ISO8528-9 or BS5000-3, the bearing life will also be reduced.
(2) If the generator is stored in long-term vibration environment, the generator will be forced

to vibrate together , and it will produce an effect called Brinell ball effect, namely the vibration will
force the ball to be deformed and dent in the raceway, which can cause damage.
(3) Humid climates or moisture can emulsify the grease causing corrosion and premature
bearing damage.
Bearing condition monitoring
It is recommended to check the bearing condition by monitoring devices. The best way is to
take the initial value as a reference, then check bearings regularly to realize the wearing trend.
If the generator vibration exceeds the predetermined value in ISO8528-9 or BS5000-3,
please contact the generator manufacturer to review the design to minimize vibration.

31
 8.Maintenance specifications

8.1 Lubrication oil

The correct selection of lubricant to is very important for engine working normally and
extending the engine life.
Lubricant selection mainly based API (American Petroleum Institute) quality grades and
SAE (Society of Automotive Engineers) viscosity grade classification. The engine lubricant
quality should meet CD, CE level (API). The grade of lubricant adapts to the international SAE
standard. For example, the grade of lubricant SAE5W / 30 adapts to environment temperature
-30 ℃ ~ + 25 ℃. Using the multi-engine lubricant will extend the cycle of changing lubricant.
There is an affect on the cold starting performance of the engine if the ambient temperature is
lower the extreme operating temperature, and if the ambient temperature is higher than the
extreme operating temperature, it will cause early damage to the engine.

The relationship between temperature and lubricant viscosity

8.2 Engine coolant

User should choose soft water (PH=6-8) with adding a certain percentage of antifreeze to be
the cooling medium for cooling system . Using soft water for the cooling system is to prevent the
formation of scale, and guarantee the cooling effect. Generally, the drinking water can meet
requirements.
Adding antifreeze to the cooling system can protect the engine from damage in low
temperature, and It can also play a role to prevent corrosion.

32
 In the area not required adding antifreeze, user should add preservative to the coolant to
reduce the liners corrosion. But user should not join much more preservative to the coolant that
has been equipped with preservative already, otherwise it will generate a lot of foam and affect
the cooling effect
8.3 Fuel choice
User should choose the superior or first grade diesel fuel in accordance with international
standards.
The main indicators of the diesel fuel quality is the sulfur content . If the sulfur content is
more than 0.5%, there will be a great impact on engine life, and the cycle of changing oil will be
shortened. Using inferior fuel will cause the phenomenon of power lack, instability speed, black
smoke, serious knock etc..
Diesel fuel is often chosen based on ambient temperature. In cold region, inappropriate
choice of fuel will cause the engine running hardly.
Relations between the grades of light diesel fuel and ambient temperature

Ambient temperature ℃ >12 4～12 -5～4 -14～-5 -29～-14 -44～-29

Grades of light diesel fuel 10 0 -10 -20 -35 -50

Diesel fuel should be precipitated for a period of time before injected to fuel tank (generally
more than 48 hours), and then choose the upper diesel fuel to inject into fuel tank. Filtering the
diesel fuel with gauze will extend the life of the fuel pump and injector.
8.4 Daily inspection and maintenance
Routine inspection and maintenance should be performed according to the instructions and
cycle specified by the engine and generator manufacturer. All the work will be :
8.4.1 Lubricity system
(1) The cycle of changing the lubrication should be based on the usage and the quality of the
engine oil. The details please refer to the chapter introduced the engine: such as the sulfur
proportion in diesel is in the range of 0.5% to 1.0%, or the ambient temperature is below 0 ℃,
the cycle of changing the lubrication should be shortened by half.
(2) It is very necessary to replace Oil filter or cartridge to ensure good performance of the unit,
and its cycle can be synchronized with the cycle of changing engine oil.
8.4.2 Fuel system
Diesel before entering the pump must be filtered to avoid the damage to high-precision and
33
high-pressure pumps. Diesel filter should be replaced when the engine is working 200 to 250
hours, and the user should clean the coarse screen. Of course, replacing the fuel filter in
advance depending on the circumstances is also suitable.
8.4.3 Cooling system
(1) The cycle of cleaning cooler and radiator should be determined according to working
environment. Generally , the time range is from 1500 to 2000 hours. Please clean the interior
of cooler and radiator with neutral detergent and clean water , and check them regularly .
(2) Please replace all the coolant in the cooling system after flushing.
8.4.4 Intake system
Maintenance of intake system is mainly to check the air filter, dust and replace the filter. The
air resistance indicator of air cleaner should be checked during engine operation, if there is a red
tag appearing ,the user should replace the air filter. Replacing the air filter should be carried out
at the time of engine being in stop. After replacing, please press the button on the blocking
indicator to reset it (as below picture).
Do not use the air filter replaced after being washed .
8.5 Maintenance schedule
When the unit fails to work, please refer to the following troubleshooting guide.
Keeping the unit at level, the parts clean and tighten the battery connections, and keeping
the unit running normally will help engine reduce faults.
Please contact us if you need complex repairs or replacement parts.

Waring

Troubleshooting should be completed by the personnel with relevant qualifications .

Please stop the engine and wait until the engine has cooled completely to avoid burns
Before troubleshooting

34
Maintenance schedule Per. day Per.100 Per.250 Per.500 Per.150 Per.
or Per. hours hours hours 0 hours Year
week
Lubrication ● ● ● ● ●
Check the fuel tank, and add the ● ● ● ● ●
diesel fuel with appropriate rade
according to the environmental
conditions
Check leakage ● ● ●
Replace Oil filter ● ● ●
Oil ● ●
Check Coolant level ● ●
Leakage ● ●
Radiator resistance, ● ●
external pipes, window
Tension of cooling belt ● ●
Replace Add clean water after
flushing (if necessary,
add antifreeze)
Fuel system ● ● ● ● ●
Washing Fuel prefilter ● ● ● ●
Replace Fuel Filter
Intake system ● ● ● ● ●
Check Leakage ● ● ● ●
Blockage
Crankcase ventilation ● ● ● ● ●
state
Replace Air filter ● ● ● ● ●
Exhaust system ● ● ●
Check Leakage ● ● ●
Exhaust back pressure
Fuel tank ● ● ● ● ●
Check Fuel level, leakage ● ● ●
Starting system
Check Battery level, charging ● ● ● ● ●
status
Wiring is reliable or not ● ● ● ● ●

35
 9.General troubleshooting
Troubles
Engine fails to start or starts difficultly
Engine cannot reach the maximum speed or sudden flameout after starting
Engine is idling or not fired while being heated
The speed of engine is unstable during operation
The output power does not meet requirements
The coolant losses by the high temperature
The pressure of lubricant is lower
The pressure of lubricant is higher
Black smoke and power loss
Blue smoke
White smoke
Engine knocking
Engine noise is too big
Reasons for above
phenomenon
● Fuel tank is empty
● Fuel plug is closed
● ● ● ● ● Air mixed with the fuel system
● ● ● ● ● Fuel pre-filter / prefilter is
clogged
● Fuel mixed with water
● ● ● ● Air filter is clogged
● Circuit is interrupted
● Battery power is lower
● Starter / solenoid switch failure
● ● ● ● ● Began to supply incorrectly/
set up wrong
● Nozzles are clogged
● Raining in the inside of engine
(piston is stuck, probably due
to water being maxed into the
fuel)
● ● ● The fuel quality does not meet
standards, or fuel is seriously
contaminated
● Low idle is set too low
● ● ● ● Incorrect valve clearance
36
 ● Nozzle leaks
● Fuel shortage
● Tachometer failure
● ● ● Nozzle failure or being
carbonized
Troubles
Engine fails to start or starts difficultly
Engine cannot reach the maximum speed or sudden flameout after starting
Engine is idling or not fired while being heated
The speed of engine is unstable during operation
The output power does not meet requirements
The coolant losses by the high temperature
The pressure of lubricant is lower
The pressure of lubricant is higher
Black smoke and power loss
Blue smoke
White smoke
Engine knocking
Engine noise is too big
Reasons for above
phenomenon
Engine is overused

Fuel supply failure, the fuel

temperature is too high

● Engine oil level is too high

Rated speed is unreasonable

● The coolant level is too low

● Air maxes into the coolant

● Radiator is dirty

● Pump belt tension is incorrect

(slip)

● The bonnet cover of expansion

tank / radiator shows fault or
leakage
● Thermometer with fault

● Coolant pipe is leaking, blocked

37
 or twisted

● Engine oil level is too low

● Engine temperature is too high

● Oil filter is clogged

● ● Oil pressure gauge is in fault

● ● The oil viscosity is not suitable

for the ambient temperature(Oil
is too thin)
● Oil is too thin (water or gas
mixes into the fuel)
● Engine temperature is too low

Troubles
Engine fails to start or starts difficultly
Engine starts, but fail to get the highest speed or suddenly power off
Engine is idling or not fired while being heated
The speed of engine is unstable during operation
The output power does not meet requirements
The coolant losses by the high temperature
The pressure of lubricant is lower
The pressure of lubricant is higher
Black smoke and power loss
Blue smoke
White smoke
Engine knocking
Engine noise is too big
Reasons for above
phenomenon
● ● Engine, coolant or intaking air
temperature is too low
● Lubricant comes into the
combustion chamber (worn
piston or piston ring wears out
or tears out)
● The pressure of crankcase is
too low (crankcase exhaust
pipe is blocked)
● Operated with low-load for

38
 long time
● Coolant comes into the
combustion chamber (cylinder
head, gasket leaks)
● Engine operating temperature
is not correct
● Intake or exhaust pipe leaks

39
 10.Diagram and list of main parts

10.1 Main parts

19 18 17 15（15） 16 15（15）

20
14

21
13

12

11

6（6）

1 2 3 4 5（5） 6（6） 7、8 9、10 5（5）

Diagram 1

22、23、24 25 26 27 28

22、23、24

Diagram 2（The case assembly, front /rear seat assembly, pole assembly and lamps are removed
away）

40
 31、32、33

29（29） 30 29（29）

Diagram 3（The case assembly, front /rear seat assembly, pole assembly and lamps are removed
away）

List of main parts

NO. Name Quantity Unit Parameter Remark

1 Guide wheel 1

2 Winch 1 1700N-4500N

3 Brake handle 1
4 Frame assembly 1

5 Outrigger assembly 4 460-680mm

6 Spring pin 4

7 Travel system 1 Exploded View

8 Damping block 2

9 Left fender 1

10 Right fender 1
11 Muffler cover assembly 1

12 Exhaust system 1
13 Case assembly 1 Exploded View

14 Rear seat assembly 1

16 Waterproof box 1

41
17 Pole assembly 1

18 Rotation pin 1
Front seat assembly
19 1

20 Wirerope 1
21 Traction device 1

22 Ballast installation parts 2

23 Ballast 4

24 Explosion-proof capacitor 4
Control cabinet assembly
25 1

26 Alternator parts 1
27 Engine parts 1

28 Radiator parts 1
29 Cushion 4

30 Fuel tank assembly 1

31 Maintenance-free battery 1 60AH

32 Battery fixed support 1

33 Bolt 2
34 Accessories 1

42
10.2.3 Exploded view and list of Travel System

3 2 4 4

1 2 3

List of Travel System

NO Series no. Name Qty Remark
1 451714010 Axle assembly 1
Rims
2 451714011 2
PCD5-114.3-84-0 3/5
Tires
3 451724000 2
185R14C/LT GB9744-2007
Leaf spring assembly Including 2 sets of square
4 451714012 2
（820x110mm） boards, U screws and steel
plate pins
43
10.2.4 Exploded view and list of Case assembly

11 10 9 9 3 8 7 1 1
3

8 2

7
1
1

1 2 1 3 4 5 6

List of Case assembly

No. Series No. Name Qty. Remark
1 401711272 Exposed hinges 6
2 401711280 Locks 2
3 401711281 Gas Springs 4
4 451414004-02 The right side plate 1
Sealing plate assembly
5 451414004-03 1
in the front
6 451414004-01 The left side plate assembly 1
7 451414004-05 Door Components 2
8 401720038 Door seals φ16mm 2
9 934000091 Radiator covers 2
10 451414004-04 The cover assembly 1
11 451414004-06 The plate assembly in the rear 1
44
45