Installation and Operating Manual

-Diesel Generating Set

Preface.........................................................................................................................................................3

2. Safety Regulations....................................................................................................................................4

2.1 Safety instructions for lifting, movement and transport..................................................................5

2.2...........................Safety instructions for installation and prestart operation 5

2.3............................................ Safety instructions for operating 5

2.4................................................. Fire and explosion safety 6

2.5............................................................ Chemicals 7

2.6............................................Electricity and protection facility 7

2.7 Give first aid to electric shock injured people...............................................................................8

2.8............................................. Description for safety marking 9

3............................................................ Product instruction 11

3.1........................................................Product features 12

3.2.............................................Outside shape of generating set 13

3.3..............................................Instructions for generating set 13

4. Installation..............................................................................................................................................15

4.1........................................................... installation 15

4.2.........................................................City electricity 21

4.3....................................................... Load connection 21

4.4......................................................Ground connection 22

4.5........................................................ATS connection 22

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 4.6......................................................Battery connection 23

4.7.....................................................Fuel box connection 23

5..............................................................Prestart checking 24

5.1...................................................... Routine inspection 24

5.2................................................. Engine oil level checking 25

5.3..................................................... Fuel level checking 26

5.4 Check the coolant level................................................................................................................26

6. Operation............................................................................................................................................... 28

6.1 Operation of the common control system...................................................................................28

6.2 Automation HGM6120/6110control system operation（Module details refer to HGM61XX user
manual）........................................................................................................................................... 31

6.3 Four protection control system operation（Details please refer to 1780 controller direction）..38

7. maintenance and service........................................................................................................................ 44

7.1 maintenance and service periodic chart......................................................................................44

7.2 Maintenance and maintenance of the generator set..................................................................... 45

7.3 Air filter......................................................................................................................................46

7.4 Replace the engine coolant..........................................................................................................46

7.5..................................................................Oil and oil

filter.............................................................................................................................................47

7.6 Fuel filter....................................................................................................................................48

7.7 Oil-water separator...................................................................................................................... 49

7.8..................................................................Devannin
g、Moving、Hoisting..............................................................................................................50

7.9 Storage of the generator.............................................................................................................. 51

7.10 Fault treatment...........................................................................................................................51

8. Factory warranty.................................................................................................................................... 55

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8.1 Factory warranty...................................................................................................................... 55

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Preface
Thanks for you to choose our diesel generating set. We prepare this manual,in order to help you and
other engineers to finding out the structure, installation and operation method of diesel generating set.

This manual include installation,application instruction,maintenance and operation methods.Please read

it carefully before start the generator.Keep it safe in order to use it anytime when you need it.In order to
ensure the generator operate in the long term and efficiently,the
generator set should be operated and maintained according to this manual and other related manual,such
as diesel engine user manual,alternator user manual and operator manual.In addition,The generator set
should be maintained frequently for operating well when use it in duty or dusty environment.

The charts and instructions provided in this manual can instruct operators to check,
start,operate and maintain the generator correctly.

Some pictorial parts and accessories many differ from your generator.For illustrative
purpose,the baffle and cover board in the following picture may have been removed.

As there are many new products go to the market every year,I’m afraid that we will not inform you the
change of its technical data,color parts and accessories. If you have any questions,Please get in touch
with our company and its local agent for more information.

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2. Safety Regulations
Before operation, please read the safety regulations carefully and learn to know the local safety
standards and regulations,in order to reduce the injury to operator and the damage to generating set. All
operations include installation,operation and maintenance should be operated by professionals and
qualified operators.

There have some specific warning signs on generating set. What follows introduce the meaning of its
signs. Please take some time to be familiar with it.

Make sure you can read all warning signs. If you can not read warning words or see warning pictures,
please clean it or replace a new sign. When clean the signs,Please use cloth,water and soap,solvent and
gasoline is not allowed.

It must be replaced when the signs is damaged,missing or illegible. Make sure mark a new sign on
the replacement, if you replace the part marked with signs. For more information about new signs,please
get in touch with related agent company .

It indicates there will be potential injury to people.

It indicates there will be a grave danger. If not avoided, it will result in serious injury
,even death.

It indicates there will be a grave danger.If not avoided, it will result in serious injury
,even death.

It indicates there will be a greater danger. If not avoided, it will result in a mild or
moderate injury.

Do not operate the generator when you not read and understand the operating manual.
Incorrect operation is very dangerous,even results in personal injury. If you do not
understand how to operate it, please get in touch with its agent company or
headquarters for correct instructions.

! Do not start and operate the generator when you know it is unsafe environment.

! Please make a mark on the generator and cut the connection of the battery to stop its
starting when you know the existence of hidden dangers. Connect the connection when it
get right.

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 ! Follow the operating manual , relevant national standards,norms and other
requirements when install and operate the generators.

2.1 Safety instructions for lifting, movement and transport

! Do not use the lifting lug on the diesel engine or alternator to lift the generator. Use the separate lifting
lug based on generating set to lift it.

! Make sure the lifting lug and holder have been installed firmly and connected correctly. The load
bearing capacity of the lifting equipment is bigger than the weight of generator.

! Stay away from the generator when it has been lifted.

! Make sure the diesel engine has been stopped when transport.

! Do not install and operate the generator in the place where store dangerous goods.

! Follow the local standards,norms and traffic rules including the maximum and minimum speed and
good brake system, when use portable generators.

! Do not allow people to ride, stand or walk on the portable generator.

2.2 Safety instructions for installation and prestart operation

! Do not allow children approach operating area when generator works.

! Exhaust gas discharged by diesel engine do harm to human body. The generator should be installed in
the place where is well ventilated. If you start generator in closed-in spaces,make sure there is good
ventilation, so that the exhaust gas can be drained away.Make sure the exhaust pipe and silencer keep
away from flammable substance. Ensure the gas discharged not become social pollution.

! The load connection should be performed by qualified and experienced electrician. It must follow
relevant electrical standards and other norms.

! Make sure all insulation joints and ground joints meet the requirements and there is no
omission.

! Check if there is a leakage about engine oil,coolant and fuel.

! Check if the coolant level and fuel level meet the requirements.

2.3 Safety instructions for operating

! When generator works,operators should wear ear protection equipment to avoid damaging eardrum
by long time noise.

! Make sure cut the circuit breaker before starting.

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! Do not touch the electrical connections when the generator is operating because they are charged
and have the danger of getting electric shock.

! Do not connect or disconnect the load when the generator is operating because there is a high voltage in
the line and has danger of electric shock. The load should be connected before starting the generator.

! Do not touch the engine, radiator and exhaust port when the generating is operating because there have
an extremely high temperature on its surface and have danger of scald.

! Do not move the generator when it is operating unless it is stopped.

! Do not smoke or use open flame nearby generator when the generator is operating because the engine
fuel ignition point is low and it is easy to be fired, then causing a fire.

! Do not press emergency stop button when the generator is operating. The button can only be used in
emergency.

! When the generator has a breakdown and stopped. First, check the generator and remove the
troubles,then restart the generator.

! Stop the generator and wait until the engine has been completely cooled when maintain the
generator.

2.4 Fire and explosion safety

! The fuel used and smoke discharged from the generator have the danger of flammability and
explosion. Handle the fuel and smoke carefully can avoid danger. In addition, generator room should be
equipped with good condition BC and ABC fire extinguisher for safety and users must know how to use
it.

! All fuels and most lubricants and many chemicals are flammable. Read and follow the
instructions on the package.

! Make sure diesel engine has been cooled when work on the fuel system.It can cause a fire if the fuel
spill on hot surfaces or electrical components.

! The fuel-soaked rags and other flammable materials should store in fireproof place.

! Do not smoke when fill the fuel or lubricating oil or at the gas station or near engine room.

! Batteries contain and release hydrogen gas, especially during charging, the gas is easy to
explosion.

! In any case, do not smoke or use open flame near battery or battery room.

! Do not use starting fluid or similar products to start the engine equipping with air preheating
equipment (glow plug / preheater). Otherwise, the preheater could cause an explosion in the intake
manifold, causing personal injury.

! When working on a hot engine, there will be a risk of burns. Pay attention to the hot surface,for
example: the exhaust pipe, turbocharger, oil pan, charge air pipe, heater, hot coolant and lubricant in
lubricating pipe.

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2.5 Chemicals

! The fuel, engine oil, coolant, lubricants and battery electrolyte used in the generator are
commonly used in the industry. However, it will harm to human when used it improper.

! Do not swallow or touch fuel, oil, coolant, lubricants or battery electrolyte with skin. If swallow it
incautiously,go to a doctor immediately. If touch the skin,wash it immediately with soap and water.

! Wear anti-acid aprons,masks or goggles when handling batteries. Rinse with water
immediately,once you stain battery liquor.

2.6 Electricity and protection facility

! If the generator connect to public distribution system, you must adopt the following methods to
separate it.

A switch off the main switch when light generator connect to the system temporary. B Switch off the
bilateral(conversion) switch when it connect to the system permanently. If you do not follow the above
methods, it can cause person injury accident. The above warning does not apply,when the generator and
the public distribution system is designed and approved by the utility company and allowed it operate in
parallel.

! Stop the generator and break the negative electrode (-) of the battery,before connect or
disconnect the load.

! Do not connect or disconnect the load standing in water or on the wet ground.

! Do not touch the live equipment or power cord with human body or insulated metal object when generate
electricity.

! Recover the electronic box cover, after connect or disconnect the load. Do not operate the
generator when the electronic box cover is open.

! The load or power system powered by the generator must be compatible with the generator, and
should be within the capacity of the generator.

! Switch off all the electric powers when maintain the generator.

! Keep all electrical equipment dry or clean.When there is any crack, cut or fray on insulated
wire,replace it immediately. Keep the wiring terminals clean and tight.

! Make sure there are some insulated equipment on all power connections or power wires
dismantled.

! Only BC or ABC fire extinguisher is allowed to put out a fire.

! Do not start the generator when the fan guard or other safety protective cover is open. Do not hand out
your hands approaching the protection equipment to repair it when the generator is working.

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! Make your hands, arms, long hair, loose clothing and gloves stay away from belts and other rotating
parts.

! Pay attention to the hot oil, hot coolant, hot exhaust gas, and hot surfaces.

! Wear overalls, gloves and hats when you work nearing the generator.

! Do not unscrew the radiator’s cover when the coolant is not completely cooled. Once the coolant is
cooled, firstly unscrew the cover a little, so that the inside pressure can released, then unscrew the
cap completely.

2.7 Give first aid to electric shock injured

people.

Warning

! Do not touch injured people when the power has not been cut off.

! If it possible, cut off the power, then unplug the power plug or pull the wire from
the injured body.

! If you can not follow the above measures, stand on dry insulated ground using
insulated tool, such as a dry stick, pushed the injured body from live conductors.

! If the person go into a coma, give the body mouth-to-mouth breathing

immediately as need.

Clear the airway

1. Tip person’s head back and hold up his jaw.

2. Take out the stemming (including dentures, cigarettes)gagged in his mouth or throat.

Breathing

1. Judge whether the person can breathe by observing,listening and touching.

Circulatory system

1.Check the carotid to judge whether there is a pulse. If

there is a pulse but no breath

1. Pinch the nose firmly.

2. Take a deep breath,and then mouth to mouth

3. Blow into injury’s mouth slowing until the chest up,then stop

4. blowing making chest down. Repeat this cycle. It can give 10

5. times mouth to mouth resuscitation per minutes.

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6. If there is no other helper and need to transport the injury to

7. other place,you should give 10 times mouth to mouth ,and

8. continue to give mouth to mouth when you back from seeking help.

9. Check the pulse per10 times mouth to mouth .

10. When the person get his breath again, recover his body position as the
following ways.

If there is no breath and pulse

1. Call an ambulance immediately.

2. Give mouth to mouth twice and press his chest as the following ways.

3. Put a hand pressing on the section where second down to the rib cavity / bone
junction,and put another hand on top making fingers interlocked .

4. Keep your arms straight; press 4-5CM (1.5-2 inch),press 15 times at a frequency of 80 per
minutes.

5. Repeat it( mouth to mouth twice,press 15 times) until rescue workers come.

6. If injured person get better, and have a pulse, give him mouth to mouth and check the pulse every 10
times breaths;

11. When the person get his breath again, recover his body position as the following ways.

Recover body position

1. Lie the injury on side as the picture.

2. Tilt his head to keep trachea fluently.

3. Make sure the body will not scroll forward or backward

4. Check his breath and pulse regularly. If one of them stop, give a first aid following the above
methods immediately.

Warning

Do not give him drinking water or other beverages, if the injury has not regain his
consciousness.

2.8 Description for safety marking

Label Description

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Lifting position indicator, please lifting referring
lifting instructions.

Diesel fuel filling position.

In case of splash

Read operation manual carefully before operating. No

detaching privately.

Please wear earplugs.

No open fires.

Do not lift the whole generator set.

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 Please read lifting instructions.

Ground connection indicator.Make sure the generator

earthed.

In case of electric shock .

Key points of operation.

L1，L2，L3,L4 load connection position，please connect in

series order

Oil filling

3. Product instruction

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3.1 Product features

3.1.1 Application: Diesel generating set is one of the type of AC-power equipment. It is an independent
generating equipment using internal-combustion engine as its power,which drive synchronous alternator
to generate electricity. As electricity supply equipment, it mainly used for the two purpose:

①Daily use: Generate electricity and provide energy for lighting, heat energy, etc.

②Standby service: On many occasions, such as hospitals, factories, airports, etc., when energy is
interrupted, there may bring an adverse impact on all aspects of life. Generating set can solve the problem
of energy crisis.

3.1.2 Main features

! High reliability : The core components of the generator choose high-performance diesel engines and
brushless copper alternator,which makes the generator have good reliability and good performance.

! Easy for operation: The generator’s control system adopts advanced control module. Operator can
operate by control panel or remote control equipment. Various keys are designed with an intuitive
symbols which make it easy to operate. In addition, the control system have the function of automatic
alarm and emergency stop protection. When there is something wrong with the generator, it will promptly
send alarm signals and display the faults. When the faults is series, it will stop the generator to protect it.

! The rational design on intake and exhaust system and the cooling fan reduce the operating
temperature effectively,which increases work efficiency.

! The use of rubber absorbers when install engines and alternators reduce the vibration of
generator greatly when it operate.

! The fasteners and locks exposed are made of stainless steels, which have a good performance of anti-
causticity.

! The generating set is equipped with ground protection, emergency stop button, the base fuel tank (full
load operation for 8 hours ), optional power connections, 24 hours fuel tank.

! Easy to maintain. Unique open design bring great convenience for engines, alternators, control systems,
service and maintenance to maintain.

3.1.3 Application environment

! Installation Location: Indoor (well ventilated)

! Ambient temperature: -15 ℃ to 35 ℃

! Humidity: less than 80%

! Altitude: below 1000 meters sea level

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3.2 Outside shape of generating set

3.3 Instructions for generating set

Diesel generator is a small electricity equipment, which use diesel as fuel, diesel engine as power to
driven alternator generating electricity. The generator is mainly made up of three parts:

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diesel engine (engine), alternator (bulb) and control systems. Diesel engine is the engine power driving
the whole generator. Alternator is used to generate electricity. Control system is used to control the
start,operation and stop of the generator. It also include control cabinet (panel),
switch cabinet, radiator, coupling, fuel tank,battery, protecting equipment, silencer and common
foundation.

① Diesel engine: The power of diesel engine. The quality of the engine mostly determine the
generating performance of the generator. The engine is designed with the advantages of low
fuel consumption, high power, long life performance and good reliability.

② Cooling system: Cooling system of engine include a radiator, an axial-flow fan and
a thermostat. Alternator has independent fan to cool its components. Air flow is being pushed through
the radiator. Cooling air flow is first through alternator,then through diesel engine,finally through
radiator.

③ Engine electric system: Electric system of engine is 12V(or 24V) negative ground direct current. It
also include a starting dynamo,battery holder and battery charger (optional). The positive pole of the
battery connect the starting dynamo,and negative connect the power switch.

④ Fuel tank and common foundation: Diesel engine and alternator is installed on the common
foundation. Common foundation equips a fuel tank,which can operate 8 hours (or 24 hours) with full
load.

⑤ Absorber: There equip absorber on the common foundation which can reduce the shock in operating.
The absorber is installed between engine/alternator and common foundation.

⑥ Alternator: We mainly use Stamford series brushless alternator,which have reliable

performance, H level insulation class and stable voltage. Excitation mode is brushless
self-excitation. The alternator is equipped with protection shield. Power connection cabinet is on the top
of the alternator. Customers can choose other brand alternator according their need.

⑦Control system: There are many types of control system: for example, common
control,GU3303，HGM61xx，DSE73xx,etc. One of them is equipped with the generator to control the
operation and output. When there is something wrong with the generator, it can give out a warning or
even stop the generator, which can protect the generator. Control system with control panel is equipped
with liquid crystal display, a variety of gauges and warning lights to indicate the operation of the
generator.The operating buttons have different images to make the operation easier.

Note: The relationship between apparent power, active power, prime power, maximum power and
economic power.

! Apparent power is also called total power,its unit is kva.

! Active power is also called prime power,its unit is kw.

! The prime power of generating set refers to the continuous operating power in 12 hours.

! Maximum power is 1.1 times bigger than prime power. But it only can operate 1 hour within 12 hours.

! Economic power is 0.75 times bigger than prime. It is the output power without time limit. Operating
with this power,it have the advantages of taking least fuel,discharging least pollution

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and going wrong least.

4. Installation
When you receive the generator, please check the generator shipping list in detail. If you have questions,
please contact relevant agent or headquarters. In addition,check if there is a damage on the generator.
Open type generator can only be used indoors unless install rainproof equipment.

4.1 installation

4.1.1 When there need install the generator indoors, machine room designed should take lighting
protection, Sound insulation, fire protection, lighting, heating, cooling and pollution into consideration.

① General requirement

! There should have one or two entrance,one of them should meet the requirements of transport the
generator,which can make installation and maintenance convenient.

! There should set trench in machine room to lay cable and water and oil pipes.Trench slope and drainage
measures should not be less than 1%. Trench cover should adopt steel or fire-treated wood cover or
reinforced concrete cover.

! Machine room with control room should set observation window on the wall between control room
and machine room.The door of the machine room and control room should be fireproof door opening
outward. The door between machine room and control room should be fireproof and insulated door
opening inward.

! Machine room together with main buildings should adopt high-density (areal density of 700kg / m2)
materials on wall and roof. Doors and windows use encryption seals and double glazing.

! The ground of the machine room usually use calender cement floor. If possible, use terrazzo or quarry-
tile floor in case of the oil seeping into the ground.

! The installation base of the generator should bigger enough to reduce vibration. Sewage trenches
and floor drain should be set up to eliminate the accumulated oil on the surface.

! The position should close transformer room and distribution room.

! Machine should not close staff-intensive place or the entrance in 6 o'clock position. Thermal exhaust
port and the exhaust port should not toward staff-intensive place or main road. If it toward the main
window of the residential buildings, the pitch must be at least 8 meters. Air intake and exhaust vent
should not set near a conference room and other quiet place.

! Machine room should be well ventilated and have clean environment. Goods can produce acid, alkali
and other corrosive gases are not allowed placing in machine room. There is no conductive dust in
machine room.

② Lighting protection and anti-static requirements

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! Machine rooms set lighting measures according to three classes. If the machine room build under other
buildings in the basement, the lighting protection class should the same as the class of the building itself.

! If the fuel used in generator is carried by pipe in the buildings, the fuel pipe should set anti-static
ground.

③ Grounding requirements

The following conductivity metal should make equipotential bonding:

! The foundation of the generator;

! Metal pipes, such as water pipes, heating pipes and ventilation tubes;

! Steel door (window) box, shutters, and other non-ferrous metal frame, steel construction steel column
(if available);

! Distribution system PE line

! Cable tray, wiring pipes, fixed appliances

④ Fire protection requirements

! There must have fire protection equipment.

! Automatic fire alarm system and automatic fire extinguishing system should be installed in
machine room.

! The lighting sub between machine room and control room should connect fire distribution
circuits.

! When the generator is not set in high buildings, fire endurance rating in generator room and daily
used oil room should be first class.

! Generator can place in high buildings, first floor or basement, but it must conforms with
the following regulations:

‹ The machine should be separated by walls(fire endurance≥2h) and doors(fire

endurance≥1.5h).

‹ Machine room should have oil storage room in high buildings. The total amount of oil should not
exceed 2h requirement, or daily fuel tank capacity is not greater than 1m3. Oil storage room should be
separated by firewall from generator. When it is necessary to open the door on the firewall, you should
set an automatic class fire door.

4.1.2 Installation foundation

① Basic requirement

z There should not have rigid connection between installation foundation and machine room
construction.

z On the surface of the foundation, it should have water and oil proof and drainage measures.

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z If there is a need to set generator on the floor, the bearing capacity of the floor should meet the
dynamic load bearing and static load bearing when operating. And it should reserve some safety factor.

z The installation place should be flat, solid and preferably have reinforced concrete. Guarantee the
capacity of geologic materials exceed the capacity of installation basement when choose installation
basement. Please refer to the following formulas and tables.

Geologic materials Safety load capacity(kg/m2)

Adamant-granite 244000-977000

Mediate adamant-oil shale 98000-146000

Hard rock origin 78000-98000

Soft rock 49000-98000

Gravel 49000-59000

Stiff clay,scree and grit 39000-49000

Aeration, medium-coarse,and silver 28900-39000

sand

Medium hard clay 20000-39000

loose fine sand 10000-20000

Soft clay ＜10000

② Size of installation basement (for reference)

installation basement
Length（mm） Width（mm） Depth（mm） Above ground level
（mm）
length+300 width+300 ≥200 ≥150

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4.1.3 The fixation of generating set

The generator is fixed on steeled chassis. In order the reduce the shock, absorbers is equipped between
engine and chassis, and alternator and chassis before leave the factory. Uses can fix the generator on
installation basement directly.

The fixation between basement and chassis use anchor bolts. The

number and size of the anchor bolt is subject to the number and size on the chassis. 4.1.4The

installation of generating set

In order to operate and maintain,machine room should have reasonable size, good ventilation and well
smoke discharging conditions. As shown below (H represent high,W represent width)

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① Smoke discharging system

The smoke and exhaust gas discharged by engine do harm to human body. It must discharged to a
certain level by exhaust system and reduce noise. In addition, the smoke and exhaust gas discharged
must meet local environment requirements.

z The thickness of all exhaust pipe must be 3mm at least.

z The first stage pipes discharged from engine exhaust pipe must have flexible pipes and
bellows,in order to reduce the shock produced by engine.

z When the exhaust pipe need through the wall, retardant jacket sleeve or wall board should be equipped
to prevent fire and shock. It also can avoid cracking due to excessive heat.

z If the end of exhaust pipe is horizontal, the ends should be cut at 60 °. If vertical, it should be fitted
with rain cap to prevent rain and snow entering the exhaust system.

z If there equip absorbers in the generator, all connections, such as the exhaust pipe, tubing, pipes, etc.
must adopt flexible connections. Do not use flexible connection of exhaust pipe as elbow and
compensate the error of pipe installation.

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z If there is a high requirements of silencer, a second stage silencer can be install behind the first stage
silencer.

z Exhaust system should be short and straight. The less elbow is used,the better. The flow is very
instability when discharge exhaust gas. If the flow direction change sharply, it will increase the back
pressure in exhaust system, which can affect the exhaust gas leading to the loss of power.
Therefore,reduce the back pressure as much as possible. If there must bend, labyrinth must be at least 1.5
times bigger as the inside diameter of the pipe. When there is a need to increase the length of exhaust
system, pipe’s diameter should increase accordingly. The size of exhaust pipe is recommended as
follows:

Exhaust port Exhaust pipe size

size
Less than 6m 6-12m 12-18m 18-24m
mm (in) mm (in) mm (in) mm (in) mm (in)
50（2） 50（2） 63（2.5） 76（3） 76（3）
76（3） 76（3） 89（3.5） 100（4） 100（4）
89（3.5） 89（3.5） 100（4） 100（4） 100（4）
100（4） 100（4） 127（5） 127（5） 150（6）
127（5） 127（5） 150（6） 150（6） 200（8）
150（6） 150（6） 150（6） 200（8） 200（8）
200（8） 200（8） 200（8） 254（10） 254（10）
254（10） 254（10） 254（10） 305（12） 305（12）
Note: The size in the table is just for reference, actual size must refer to the technical
specifications and silencer instruction manual.

② Make sure there is enough air through the machine room,when the intake and exhaust system become
work. Part of the air is used for engine combustion. They must me clean and lower temperature. Part of
them is used for cooling alternator,engine and radiator. The are enter from air inlet through
alternator,engine and radiator,then exhaust to outdoors by a detachable exhaust duct . The following
questions must be considered about the design of exhaust and intake system:

Z If there is a high requirement of noise, silencer can be set on intake duct and exhaust duct.

Z Louver is suggested to set in air inlet and outlet to protect the generator. The battens can be fixed and
move. When the weather is cool, the battens can be shut to keep the room warm, which can make it east
to start the generator.

Z The inlet and outlet of air should be big enough to through the air freely. The flow area of air inlet
should be 1.5-1.8 times than radiator’s frontal area. The flow area of the air output should be 1.25-1.5
times bigger than radiator’s frontal area.

Intake and exhaust area estimate for typical diesel generator room (for reference)

Output supply air Intake area Exhaust Engine air Exhaust

power(kW) volume area inflow displacem
3
m /min m2 3
ent m3/min
m /min
m2

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 100 215 2 1.4 7.8 22.6
200 370 2.5 2 14.3 38.8
400 726 5 4 31.9 86
800 1510 10 7 68.4 184
1000 1962 13 10 92.7 254
Z The machine room not only can accommodate the generator and all accessories, and also have
enough space as air passage and maintenance and operation passage.

Z The smoke and exhaust gas enter into the end of the smoke vent by exhaust pipe and silencer. In
addition, the air cool the alternator and radiator carrying away a lot of heating. Finally,it enter into the
exhaust pipe lying the right of the generator,then exhaust outdoors. The smoke and exhaust gas must meet
the requirement of local environment.

4.2 City electricity

When the generator stop working, city electricity provide power to the key electric appliance,such as
battery, preheating device (jacket water heaters, oil heaters), etc, which keep the normal performance of
electric appliance.

4.3 Load connection

① The cable chosen must accord with the voltage and current output by generator. Diameter and length
must suitable. In addition,the following two points must take into account:

Z The permit current of the cable

Z The distance between generator and load.Power loss in cable must take into consideration.Usually,
there will be maximum 5% voltage drop between generator and load.

Z If the load current exceed the cable capacity,the cable will be overheating and burn out.

Z If the cable is too long or too thin,it will produce big voltage drop. This will lower the voltage on load,
which make the load can not work normally.

② Connect the load

There equip load binding post in the switch cabinet. User can connect directly the load cable to the
corresponding binding post. Tighten the bolts by wrench. Make the phase,neutral and ground line one-to-
one correspondence. Do not connect wrong.

Make sure the balance of each phase. Any phase can not exceed another,otherwise it will cause alternator
coil overheating. The unbalance among phase can also damage the three phase equipment in load.

The cable should set in pipe or trunking. Do not fix the trunking on the generator. In addition, do not set
the DC cable and AC cable in the same pipe.

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z The load cable connection must operate by professional electrician.

z The battery switch should turn to “OFF” position before connect the load. z

The start key should on the position of”OFF” before connect the load.

4.4 Ground connection

The components of the generator must connect ground. If the mental parts is directly exposed,it can cause
charging and electric shock to operator.

The generator and all electric equipment are equipped with ground terminal. The connect the copper in
the control cabinet. The copper is connected to the earth stud on the generator. Before using, the earth
stud should connect to the ground steel angle, then insert the ground steel angle into the ground.

When connect to the ground steel angle,the minimum cross-sectional area is16mm2. Galvanized steel is
the best choice for ground steel angle. The size is number 5.The underside is made into sharp in order to
insert into the ground.

z If the ground wire of electric equipment disconnect or connect wrong, it will cause electric
leakage.

The current will pass directly into the human body and cause great danger. z

All load should set ground connection.

z All ground connection work should be finished before generator operating.

4.5 ATS connection

ATS is also called Automatic Transfer Switch,mainly used in emergency

power supply system. It automatic transfer load circuit from one
switch to another standby switch to confirm the load operate
reliable.

As the picture shows the common ATS: it has rows of terminal block
labeling A, B, LOAD (C). LOAD is used to connect load,A is used to
connect generator which is usually finished before leave factory(When A
is not connect the generator,it is used to connect city electricity). B is used
to connect city electricity,and it is usually empty except 1.5mm² signal
line(when there have cable on B row,it indicate this row is used as
generator outlet. Please connect city electricity to the empty row).

z ATS connection should operate after the generator stop operating.

z Each binding post should be one-one correspondence.

If ATS has been connected,control system will monitor the public grid signals from ATS interface. For
example,when public grid is normal,control panel will send signals to ATS interface. Then

2
transfer the load to the public grid by ATS while the generator stop automatically. To the contrary, when
public grid is abnormal,such as over-voltage, low-voltage, over-frequency or low frequency,ATS will
transfer the power to generator, which make generator operating automatically and provide electricity to
load.

4.6 Battery connection

When there is a need to transport or store generator long time,please cut the negative cable of the
battery(or turn the power switch on “OFF”position).Connect them before start.

The red cable is connect to positive pole (generator starter). The black

cable is connect to negative pole (engine power switch)

Do not put the battery into fire,otherwise it will explode.If it explode,the electrolyte will be injected into
all directions.

Battery electrolyte is corrosive. It can cause burns, and even cause blindness, if it spray onto the human
body. If you or your eyes touch this electrolyte,you should wash with water and go to the doctor
immediately.

4.7 Fuel box connection

Daily fuel box can be fixed on the floor indoors or outdoors,or underground. Base fuel tank is a
common equipment,which is set on the bottom of the generator. Generators provides by company need
to indicate individually whether there need to carry base fuel tank.

The bottom of the fuel tank should have oil drain holes and cocks,in order to clean the tank
discharging the water and impurities thoroughly.

Some generators are equipped with main fuel tank besides daily fuel tank. Main fuel tank must have air
port to let the air and other gases out. The air port should resist dust,pollution and moisture to enter into
the fuel tank. Oil fuel pipe should be away from oil outlet pipe,otherwise, bubbles carried by oil return
pipe can be sucked into oil inlet pipe causing the instability of engine. In addition,return oil is heated by
engine.When the temperature of return oil is high enough,it will lower the power of the generator. There
must have at least 5% expansion space in fuel tank. If the fuel tank is installed too high, oil calve should be
installed to avoid blockage or overflow caused by high oil pressure.

Fuel pipe adopt 4# black iron or copper pipe.Fuel tank can not be made by indium phosphide
or aluminum.The inner surface can not be galvanized or painted.These may produce a chemical reaction
producing impurities in oil, which eventually clog fuel injectors.Diesel systems can not use galvanized
pipe, fittings and tanks. It is because diesel fuel can react to zinc clogging the filter or damaging the fuel
injection device.

There must have at least two pipes: one for provide oil,one for return oil.The oil provided to pump is
always much than burning need. So the spare oil can return to the tank.the size of return oil pipe is the
same as oil inlet pipe. There can not have stopper and short enough,returning to tank

2
in f gravity way.

Fuel overheating must be avoided. The better temperature is 25℃，never exceed 60℃. On the condition
of 25℃ room temperature,6℃ increase on fuel temperature will reduce 1% output power of engine.
High oil temperature may cause vaporization of fuel,producing air resistance in pipe which can make the
pump can not supply oil.Therefore, the fuel tank should not be placed in a position near heat sources,
such as: heater.

Sometimes,it is difficult to let fuel return to the tank by gravity. When design providing system,when
it occurs pressure on return oil, consult the supplier and implement it when you confirm.

5. Prestart checking
5.1 Routine inspection

In order to start the generator currently and quickly,check the following situations carefully before start.

z Check if there is a leakage on oil pipe,fuel pipe,coolant pipe and pipe joints. If you find any
leakage on generator, do not use generator. Tighten the fittings, if necessary, replace the damaged pipe.

z Check radiator and fan surface to confirm there is no debris or other sundries clogging them. z Check

air filter,silencer and exhaust pipe to confirm there is no debris stop the generator

z Check the connection of all components in switch cabinet and control cabinet. Check the wiring
is not broken or loose, and all switches and circuit breakers are in the "OFF" position.

z Check the battery to confirm the screw on binding post has been tighten. z

Check the fan pulleys to confirm the belts is tight.

z Check the load connection to confirm load connection meet the requirements.

z Check the ground connection to confirm the ground connection meet the requirements in accord
with local standards.

z Check the fixation and installation of generator to confirm it will not pollute the environment. z

Refer to the safety regulations in section two and follow it.

2
z If you do not follow the above requirements,it may do harm to human or damage the generator.
Operators should have specialized training or have corresponding qualifications.

z Operators should wear protective clothing and gloves when the generator is operating.

5.2 Engine oil level checking

The generator must remain level when you check oil level.Insert the oil level indicator on the generator
side into oil tank,then pull out checking the oil level. The correct level should between the upper limit
and lower limit.

‹ You need to fill oil when oil level lower than lower limit. Ø

Choose the right number of oil:

API CF4 class or more higher class Ø

Loosen the oil cover on the side.

Ø Take the oil cover down,then fill new oil by external oil filter. Check if the oil level os on the
position between the upper limit and lower limit.

Ø Tighten the oil cover.

‹ Oil selection notes:

API is the abbreviation of American Petroleum Institute. API class represent the class of engine oil. “C”
series represent engine oil. The letter after C means:from “CA” to “CL”. Every one unit increase in
letters, the quality of oil is better than the former,which indicates there are more addictive in the oil to
protect the engine.

z If the generator is not in the level position,the oil level checked is not accurate.

z Oil can not exceed the upper limit level,otherwise,it is easy to damage the generator. z Do

not smoke or use open fire near the generator when fill the oil.

z Clean the oil around the engine to protect environment.

2
5.3 Fuel level checking

Loosen fuel cover and check the level of fuel tank.

‹ Fill the fuel when oil level is less then 20%. Ø

Choose the right number of fuel.

Ø Open the fuel cover by key.

Ø Fill fuel from fuel port until the lever in fuel tank is slightly lower than fuel port. Ø

Lock the fuel cover.

‹ Fuel selection notes: When engine speed exceed 1000r/min,use light diesel oil. According to the
standard of GB252, diesel class is divided based on the freezing point of fuel. This standard divide fuel
into 10#,5#,0#,-10#,-20#,-35#,-50#. When you choose fuel, local temperature and cold filter plugging
point of fuel should be considered. Cold filter plugging point is an important indicator to measure the low
temperature performance of light diesel fuel. It can reflect the actual use performance of diesel fuel.

Please refer to the following form when you choose diesel fuel:

No. Diesel Cold filter plugging point The lowest temperature of

Grade （℃） applicable environment（℃）
1 10 / Suitable for engine with
preheating
2 5 8 8
3 0 4 4
4 -10 -5 -5
5 -20 -14 -14
6 -35 -29 -29
7 -50 -44 -44

z When adding fuel, smoking and using fire is not allowed in the vicinity.
z After refueling, the fuel left around should be wiped clean, so as not to pollute the
environment.

5.4 Check the coolant level

Remove the cap on the radiator Check the

coolant level inside radiator

2
 ‹ When the level is below the mark inside tank mouth , add coolant Ø
Choose the right type of coolant：（Recommended）Shell -45℃. Ø
Turn and take off the cap of radiator.
Ø Fill with coolant as specified .
Ø Put on the cap and turn tighten .
‹ Selection and use of coolant Caution ：
Cooling fluid full name is antifreeze coolant，Winter antifreeze，To prevent water tank splitting
because of the ice；Anti-prickly heat in summer，To protect the engine .
Cooling system can promote heat dissipation and improve the efficiency of the engine working.

The basic indicators of Coolant is freezing point and boiling point. Freezing point of water is 0
℃，Ordinary type of coolant can reach -40 ℃，The high quality coolant should be able to reach -
60 ℃ ， Usually ， Coolant selected freezing point should be lower than the local minimum
temperature of 10 ℃ or more，in case of sudden change in weather；The boiling point of water is
100 ℃，for coolant at least should be 108℃.The lower of freezing point，The higher of boiling
point，temperature difference is bigger ，it means the quality is better.what’s more ， coolant is
required with good anti-corrosion and anti- scaling performance。

When using the coolant, mainly pay attention to the following two points：

z Try to use the same brand of coolant, production formula of different brands may vary, if
mixed, it is likely to occur chemical reaction between the various additives , resulting in additive
failure.

z Avoid watered, if coolant is water, when the engine temperature reaches 100 ℃
water will "boil", In addition, the water is corrosive and will have fouling in cooling effect.

2
6. Operation

6.1 Operation of the common control system No. Description

1 Voltmeter
6.1.1 Control cabinet and switch cabinet 2 Oil manometer
3 Coolant temperature gauge
Control Panel
4 Frequency meter
5 The charging current meter
6 Amperemeter
7 Run time meter
8 Three-phase voltage switch
9 Emergency stop

10 Electric lock (stop - run - start position)

11 Three phase current switch

A Main circuit breaker
B Terminal Blocks

Switch Cabinet

2
6.1.2 Main electric components

①Current, voltage, frequency meter

Ammeter, voltmeter, frequency table used to detect the current, voltage and
frequency of the generator set.If the voltage and frequency is lower than the
minimum load equipment, do not switch when the voltage
and frequency！！The ammeter displays the
current load current value, please do not make current is larger than the rated current of the
unit.

②Emergency stop
Generator is configured with a red stop button, located on the surface of the
control cabinet..Press the button (to the medial position then release)， The main
circuit breaker disconnect (when equipped with electric switch operation)，Engine
fuel system will be electricity outage, button will remain in the inside
position.Then, rotate the button, it will automatically pop up reset.

③Terminal Blocks

Generator is configured with terminal blocks，Located in the switch cabinet， Can

be connected to external load.Various terminals with under labeling， Indicate
the corresponding fire line , zero line and grounding line .When connecting, make
bolts tighten to cable connection by wrench.

④ Main circuit breaker

Main circuit breaker is used to control the generator main circuit.It has two
position ：“ON”（closing）and“OFF”（separating），can manually switch，
Also can control the corresponding button on the control panel （ In the normal
operation of the process and form a complete set of electric switch unit）.When
the main current in the circuit exceeds its rating, the breaker will automatically
switch to "OFF" position, disconnect the main circuit, and cut off the main
terminal and the load connection.

Warning:
Before shut down the generator，Or to make any maintenance ，To confirm the
main circuit breaker in the "OFF" position.

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 ⑤ Key switch

The power of the generator set control module is controlled by the key
switch，As the key to "ON" position, the control module get power , all the
buttons ON the control panel can be operated.

⑥ Oil manometer, water temperature meter, charging current meter, Run

time meter

Is mainly used to display the current oil pressure, water temperature, charging
current, total running time.
Attention: observe the oil manometer before loading , oil pressure is larger than 103
kpa.

6.1.3 Manual starting and stopping operation

‹ Start
Attention：please follow the instructions in chapter 5 check on the generator before start
① All switches and circuit breaker of load turn to "OFF" position.
②The generator main breaker and other circuit breaker turn to "OFF" position.
③ Turn the engine battery power switch to "ON" position, if with.
④ Switch key to "ON" position, then clockwise key to start generating set, loosen the key after
a successful start.
⑤If the first did not start successfully, please wait for at least 30 seconds before the
restart.After the engine the successfully starting, idle run 5 minutes to warm up.If continuous start
more than five times unsuccessfully, please wait at least 10 minutes to let the start motor cooling.
⑥Regulate generator frequency and voltage conforms to the rated working conditions ， Then
let main breaker switch to "ON" position。
⑦ The circuit breaker of the load switch to "ON" position, make the power output to the load
side.Power loading sequence is: from large to small in turn .

Danger：
z All of the load connection to the generator is done before operation，worker must
have the related electrician certificate .
z Before the main circuit breaker get through, make sure all the load circuit breaker and
switch on "OFF" position, otherwise might cause electric shock to the operator.
z When the generator is running, don't touch the cables connected to the generator, because
they are electriferous .

‹ Shut down
① Disconnect all of the load switch and circuit breaker。Power Unloading sequence is: from
small to large in turn .
② Make the generator main breaker and other all circuit breaker switch to "OFF"
position.
③ After unloading, keep unit running 2 minutes before stop the generator.
④ Switch the key to "OFF" position.
⑤ Turn the engine battery power switch to "OFF" position.

3
6.2 Automation HGM6120 / 6110control system operation（Module details refer
to HGM61XX user manual）

6.2.1 Controller switch cabinet NO

Description
.
1 Operation Tips
2 Controller
3 Buzzer alarm
4 The power switch of control panel
5 Emergency stop
6 Idle - high speed switch
b Alarm indicator
c Normal running indicator
Controller cabinet d Display screen
e Power close-break button
f Load position
g The mains close-break button
h Page button
i OK Button
k Stop button
l Generator normal indicator
m Manual mode button
controller
n Power ready for loading indicator
o Automatic mode button
p Test mode button
q Setup
r Mains loading
s Start button
t Mains normal instructor
A Main circuit breaker
B Terminal Blocks

Switch Cabinet

3
6.2.2 Main electric components

①Control module
Generator control module 6120/6110 integrates digital, intelligent, network
technology,Used for diesel generator automation and
monitoring system，To realize automatic starting/stopping of the unit，
precisely measuring various parameters, setting the adjustment value,real-time
monitoring water temperature, engine oil pressure, fuel level，And alarm
protecting function.On the self-starting control function increases the mains
power monitoring and mains/generator automatic switching control
function.Controller use the large LCD screen , simple interface,it is easy to
operation, reliable in operation.

②Emergency stop
Generator is configured with a red stop button, located on the surface of the
control cabinet..Press the button (to the medial position then release)， The main
circuit breaker disconnect (when equipped with electric switch operation)，Engine
fuel system will be electricity outage, button will remain in the inside
position.Then, rotate the button, it will automatically pop up reset.

③Terminal Blocks

Generator is configured with terminal blocks，Located in the switch cabinet， Can

be connected to external load.Various terminals with under labeling， Indicate
the corresponding fire line , zero line and grounding line .When connecting, make
bolts tighten to cable connection by wrench.

④ Main circuit breaker

Main circuit breaker is used to control the generator main circuit.It has two
position ：“ON”（closing）and“OFF”（separating），can manually switch，
Also can control the corresponding button on the control panel （ In the normal
operation of the process and form a complete set of electric switch unit）.When
the main current in the circuit exceeds its rating, the breaker will automatically
switch to "OFF" position, disconnect the main circuit, and cut off the main
terminal and the load connection.

Warning:
Before shut down the generator，Or to make any maintenance ，To confirm the
main circuit breaker in the "OFF" position.

⑤Key switch

The power of the generator set control module is controlled by the key

3
 switch，As the key to "ON" position, the control module get power , all the
buttons ON the control panel can be operated.

⑥ATS Automatic transfer switch

ATS main assure power switch between mains supply and generator, when
manually switch to A position, A row of terminals and C load terminals is
conducted, A row on the terminal supply power,while switch to B ,the B line
terminals is connected to supply the power .

6.2.3 Manually starting and stopping operation

‹ Start
①All switches and circuit breaker of load turn to "OFF" position.
②The generator main breaker and other circuit breaker turn to "OFF" position.
③Turn the engine battery power switch to "ON" position.

④Turn the power switch to“ON”position .

⑤Push the manual key ，the above indicator will light.

⑥Push the start key ,fuel solenoid valve is electrified

，after 1 second delay ，start motor will run and drive the engine crankshaft.
⑦If the engine can't successfully ignite in the setting times ，The control system will alarm.If
you want to restart, it is recommended that at least 30 seconds later.After the engine the successfully
starting, idle run 5 minutes to warm up.If continuous start more than five times unsuccessfully,
please wait at least 10 minutes to let the start motor cooling.

⑧Control module will check the output voltage and frequency data automatically，If it is
different with the setting numerical, control system will alarm。If it is same，generator
operation indicator (c) and the normal indicator(l) will light up,switch the main breaker
to“ON”position this time .

⑨Switching the circuit breaker of the load to "ON" position, transfer the power output to the
load side. loading sequence is: from big to small in turn .

Danger：
z All of the load connection to the generator is done before operation，worker must have the
related electrician certificate .
z Before the main circuit breaker get through, make sure all the load circuit breaker and
switch on "OFF" position, otherwise might cause electric shock to the operator.
z When the generator is running, don't touch the cables connected to the generator, because
they are electriferous .

‹ Shut down
① Disconnect all of the load switch and circuit breaker。Power Unloading sequence is: from
small to large in turn .
② Make the generator main breaker, other all circuit breaker and ATS switch to "OFF"

3
position.
③ Push stop button (e) ,generator will keep running 1 minutes after

unloading to cool down .then stop automatically .

④ Switch the key to "OFF" position.

⑤ Turn the engine battery power switch to "OFF" position.

6.2.4 Automatic start and stop operation

‹ Start
① According to the starting part of the front section 6.2.3 ① to ④ step to operate.

② Press the automatic operation key ，它 The indicator above will be light，

And then control module can carry out automatic starting procedure .

③If the unit is connected the ATS (automatic transfer switch) equipment，The operator should
put the ATS switch to "ON" position，Control module of the unit will inspect public power
supply input signals, if public power supply is normal, it will be as the load power supply,
and the generator will not start.conversely ，If public power supply is abnormal, such as:
over voltage, low voltage, over frequency and low frequency, control module will perform
automatic starting procedure,and supply power for the load .If the unit is connected with the
remote controller, let operator close remote control switch，automatic starting procedure
will be performed while control module detecting remote start input single .

④After control module performs automatic starting procedure, engine will start
automatically .If successfully start, idle running 0 to 1000 minutes preheat
engine(idle time can be set freely according to the customer,default for 30
seconds) .If the engine can’t ignite successfully within the set of starting times not , the
control system will alarm.。
⑤If the output voltage and frequency values is different with setting , control system
will alarm. If the value is same, unit operation indicator (c) and the power normal
indicator (l) will light up.This time the generator main breaker will automatically switch
to "ON" position.

⑥Switching the circuit breaker of the load to "ON" position, transfer the power output to the load
side. loading sequence is: from big to small in turn .
Tips：If you need to use the ATS equipment or remote controller, it must be connected to the unit
well before start.
‹ Shut Down
①If the unit is equipped with the ATS, when the generator is running, control module will
automatically monitor the input signal of public power supply, if it back to normal, the
control system will automatically start the shutdown procedure.First generator main circuit
breaker will automatically switch to "OFF" position, and then the mains switch will
automatically switching,public grid will be as the load power supply.Unit operation indicator
(j) and run normal indicator (k) will be extinguished, The mains state indicator (c) and mains
supplying indicator (d) will light up.

②If the unit is equipped remote controller, operator should disconnect the remote control
switch, the generator control module detects the remote input signal is invalid, then will
begin to implement automatic stop procedure, main circuit breaker will automatically
switch to "OFF" position.

3
③Engine idle speed run about 1 minute to cool.After the delay time, fuel solenoid valve power
is off, engine shutdown.

④Turn the key switch to“OFF”position.

⑤Turn the engine battery power switch to "OFF" position.

6.2.5 The inspection items of operation

z View the LCD screen , through turn key operation，Check the voltage, current and frequency
of reading is normal by key ， They should be consistent with the
setting value.
z Check the oil , coolant and fuel level on screen.
z Check oil pressure and coolant temperature reading on screen. z
Check the alarm information or alarm indicator on the Screen. z
Check the coolant, engine oil and fuel whether have leak.
z Check whether there is any abnormal vibration or noise on unit. z
Check engine exhaust whether have unusual color, usually,
smoke is colorless, or with light blue.
Z If engine speed is unstable or with poor oil absorption, need to vent air
from the fuel pipe.Can repeatedly squeeze manual oil pump
(installed on the fuel inlet pump)，as diagram：

Ø Loosen the exhaust bolt on the fuel filter.

Ø Discharge the air in the fuel pipe, about 30 seconds. Ø
Tighten vent bolt.

z If the generator is configured with water heater,

engine can start quickly at low temperature or cold
environment .Water heater is installed on the
engine side, power supplied by the battery，When
the engine power switch to "ON" position, heater
starts to work and heating . when the temperature
of the engine body reaches 40-50 ℃ , the water
heater will
automatically stop heating.we Suggest that the
user add water heater if their ambient temperature
lower than 0 ℃. as diagram：the ball valve on the
heater is in the connected state.

Attention：
z If occur an emergency or serious fault, you must shut down the unit, please press the red
"stop button" on control panel , unit will stop immediately.
z Fault handling please refer to section 7.10. If can't handle fault, please consult to our
authorized agents or after-sales service department.

6.2.6 The control system protection function

‹ Alarm information display

When occur abnormal situation, control system have two ways to show alarm information.
① Alarm lamp light up：B - alarm indicator on the control panel light on , and the buzzer rang.
② Shown on LCD screen：The screen can display specific alarm information content。

‹ Warning/Alert

3
 When the control module detected warning/early warning signal，It will send out alarm
signal，warning information is shown as black text on the first line of screen.Generator not
stop at this moment, but alert the operator machine exist hidden trouble or failure， Operators
according to the actual situation make analysis, and decide immediately stop, or can be dealt
with after work is completed.

No. Warning item Description

1 High water temperature The water temperature over the setting warning
values
2 Low oil pressure Oil pressure is lower than the setting warning values

3 Generator over speed The speed of the generator over setting warning
threshold
4 Generator under speed The speed of the generator is under setting warning
threshold
5 The speed signal loss The speed of the generator is zero
6 Over frequency Generator frequency over the setting warning
threshold
7 Under frequency Generator frequency is under the setting warning
threshold
8 Over voltage The generator voltage over the setting warning
thresholds
9 Under voltage The generator voltage is under the setting warning
thresholds
10 Over current The generator current over the setting warning
thresholds
11 Stop Failure When stop delay time is over，generator still output
power
12 Low fuel level Generator fuel level value is less than the setting
threshold（10%）
13 Charge Failure Generator battery charger voltage is under the
setting threshold
14 Battery under voltage The battery voltage value is smaller than the setting
threshold
15 Battery under voltage The battery voltage value is larger than the setting
threshold
16 Auxiliary input port Auxiliary input port of control module has warned
warning input

As the follow , when the battery undervoltage warnings, stop failure warning，Control module
LCD will show the following information：Battery under voltage warning stop failure warning

‹ Shut down alarm

Control system is with functions of automatic stop alarm protection，When the stop alarm
signal is detected，It wil stop genset Immediately，disconnect the main circuit breaker of the
generator set to separate with load, and display warning information first line on the LCD by
black text.

3
 No. Warning item Description

1 Emergency stop Operators press the red stop button to urgently stop

2 High water/cylinder Water/cylinder temperature value over the setting

temperature
3 Low oil pressure Oil pressure is lower than the shutdown setting
values
4 Generator over speed The speed of the generator over shutdown setting
threshold
5 Generator under speed The speed of the generator under shutdown setting
threshold
6 The speed signal loss The speed of the generator is zero
7 Over frequency Generator frequency over the shutdown setting
threshold
8 Under frequency Generator frequency under the shutdown setting
threshold
9 Under voltage The generator voltage over the shutdown setting
thresholds
10 Under voltage The generator voltage under the shutdown setting
thresholds
11 Over current The generator current over the shutdown setting
thresholds
12 Start Failure Generator did not start successfully within the setting
time
13 Oil pressure sensor open Oil pressure sensor is disconnected

14 Auxiliary input port Auxiliary input port of control module has shutdown
warning warned input

As following figure, when emergency stop alarm, the control module LCD will show the following
information：Emergency stop alarm

NO. Description
6.3 Four protection control system
operation（Details please refer to
1780
controller direction）
1 Voltmeter
2 The charging current meter
3 Frequency meter
4 1780 controller
5 Control cabinet power switch

6.2.1Control and switch cabinet 6 Ampere meter

7 Emergency Stop
8 Rheotrope
9 The unit closing instruction
10 Unit Generating instruction
11 Voltmeter commutator switch
a Display screen
b alarm indication
c Page button
d Start button (Up)
Control Panel e Manual Button
f Auto button
g Stop button (Down)
A Main circuit breaker
B Terminal Blocks

Controller

Terminal switch cabinet

3
4
6.3.2 Main electric components

①Control module

The generator control module PLC-1780 ， it is a kind of four

protection module ， can be added self-launch
function.Generator set can be started manually by press the button
on the panel, Also can be started automatically by the remote
input signal.The module can disconnected the fuel relay
automatically when detecting the fault(low oil
pressure,high water /cylinder temperature ,external alarm, over
speed) ， At the same time stop magnet electrified and
actuation .The alarm indicator on the panel display on failure
state，providing real and effective fault alarm signal.

② Rheotrope

When generating unit normal operation, by switching rheotrope , above

ammeter shows the corresponding current value of each phase.

③ Voltmeter commutator switch

When generating unit normal operation, by switching Voltmeter commutator

switch, above voltmeter shows the corresponding voltage value

of each phase and line.

⑥ Main circuit breaker

Main circuit breaker is used to control the generator main

circuit.It has two position ：“ON（” closing）and“OFF（” separating），
can manually switch，Also can control the corresponding button
on the control pane（l In the normal operation of the process and
form a complete set of electric switch unit）.When the main current
in the circuit exceeds its rating, the breaker will automatically switch
to "OFF" position, disconnect the main circuit, and cut off the main
terminal and the load connection.

4
 Warning:
Before shut down the generator，Or to make any maintenance
，To confirm the main circuit breaker in the "OFF" position.

6.3.3 Manually starting and stopping operation

‹ Start
① Turn all switches and circuit breaker of load to "OFF" position.
② Turn generator main breaker and other circuit breakers to "OFF" position.
③ Turn the engine battery power switch to "ON" position.

④ Press the manual key ，the above indicator will light.

⑤ Press the start key to start the generator.

⑥If the engine can't successful ignition in the setting times，The control
system will alarm.If you want to restart, it is recommended at least 30
seconds later.After the engine the successfully starting, idle run 5 minutes to
warm up.

⑦ After generator running，turning voltmeter commutator switch，Checking

voltmeter and frequency meter，If the value conform to the setting，turn the
generator main breaker switch to "ON" position.

⑧Switching the circuit breaker of the load to "ON" position, transfer the power
output to the load side. loading sequence is: from big to small in turn .

Danger：
z All of the load connection to the generator is done before operation， worker
must have the related electrician certificate .
z Before the main circuit breaker get through, make sure all the load circuit breaker
and switch on "OFF" position, otherwise might cause electric shock to
the operator.
z When the generator is running, don't touch the cables connected to the
generator, because they are electriferous .

‹ Shutdown

①Disconnect all of the load switch and circuit breaker。Power Unloading sequence
is: from small to large in turn .
②Turn the generator main breaker, other all circuit breaker switch to "OFF"
position.

4
③Press stop button (g)，generator will keep running 1 minutes after
unloading to cool down .then stop automatically .

④Turn the engine battery power switch to "OFF" position.

6.3.4 Automatic start and stop operation

‹ Start
① According to the starting part of the front section 6.2.3 ① to ③ step operate.

② Pressing the automatic operation key， the indicator above will be

light.

③ If the unit is connected with the remote controller, let operator close remote
control switch ， then automatic starting procedure will be performed while
control module detecting remote start single input .

④ After engine automatic starting successfully，Idling run 5 minutes to

preheated .If the engine can't successfully ignite in the setting times ,The
control system will alarm.If you want to restart, it is recommended that at
least 30 seconds later.
⑤If the output voltage and frequency are in conformity with setting values,
generator main circuit breaker will automatically switch to "ON" position. （ If
equipped with automatic breakers，Otherwise need to switch manually）

⑥Switching the circuit breaker of the load to "ON" position, transfer the power
output to the load side. loading sequence is: from big to small in turn .
Tips：If you need to use the remote controller, it must be connected to the unit well
before start.

‹ Shutdown
① Disconnect all of the load switches and circuit breakers.Power Unloading
sequence is: from small to large in turn .

② If the unit is equipped remote controller, operator should disconnect the

remote control switch. the generator control module detects the remote input
signal is invalid, then will begin to implement automatic stop procedure.
③ The main circuit breaker will automatically switch to "OFF" position.
（If equipped with automatic breakers，Otherwise need to break manually）。
④ Engine idling run about 1 minute to cool down.After the delay time over, fuel
solenoid valve power is off, engine shut down.
⑤ Turn the engine battery power switch to "OFF" position.

6.3.5 The inspection items of operation

4
 z Check the frequency 、voltage and current value，They should be
consistent with the setting value.
z Check the oil , coolant and fuel level is normal or not. z
Check the battery voltage is normal or not.

Attention：

z Fault handling please refer to section 7.10.If can't handle fault, please
consult to our authorized agents or after-sales service department.

6.3.6 Control system protection function

Control system is with functions of automatic stop and alarm protection，

When the control module detected stop alarm signal，The corresponding alarm
indicator on the control panel will light up, and immediately stop.

NO. Alert Item Description

1 High water temperature The water temperature over the setting warning
values
2 Low oil pressure Oil pressure is lower than the setting warning values

3 Over speed The speed of the generator over setting warning

threshold
4 Charging failure Generator battery charger voltage is under the
setting threshold

4
7.maintenance and service

z Before any maintenance or service operation, be sure to shut down the engine, and
remove the starting key of the control system.
z About details of the engine maintenance, please refer to the engine operating
manual provided.

7.1 maintenance and service periodic chart

Every 6 Every
Every Every Every 2
Every months year or
day or week or month or years or
Item or
running running runing running
running
8 hrs 50 hrs 100 hrs running 500hrs 1000hrs
250 hrs
Check all meters and alarm
●
indicator
Check the level of oil, fuel and ●
the coolant
Check the oil, fuel and coolant ●
leakage

Replace engine oil ●

●
First
time
Check the battery liquid level ●
and charging system
Release the water and sediment ●
inside fuel-water separator

Release the water and sediment ●

inside fuel filter
Release the water and sediment ●
inside fuel tank
Fasten all the electric fitting ●

Replace oil filter ●

Replace fuel filter ●

4
Replace the filter mesh of ●
fuel-water separator

Clean or replace air filters ● ●

Clean Replace

Clean the cooling system ●

Check the pulley fastening ●
degree
Replace engine oil and fuel pipe ●

Replace the coolant ●

Clean bottom of the fuel tank ●

7.2 Maintenance and maintenance of the generator set

A good maintenance is the key to ensure generating set longevity.Repair and

maintenance should be carried out by qualified technical personnel.the maintenance
should be recorded, this will help to arrange maintenance procedures in the future.
Generator set should be kept clean, do not leave liquid such as fuel or lubricating
oil on any surface or the surrounding of the unit.clean the surface of the machine by
using industrial water solvent , can't using flammable solution .
Due to the generator configuration is different,therefore maintenance requirements
is not same . in addition to the requirements in the table section 7.1, the below listed is
regular maintenance and maintenance requirements of the unit :
Z Everyday：check the unit around with eyes every day before operation.
（For standby generator set, these steps can be conducted once a week）.
Z Every 2 weeks：Checking those standby units have never been operated , start
and run the machine for 5 minutes.
Z Every month ： Checking those standby units have never been loaded ， start
and run the machine with 50% loading for 1-2hours.
Z Every 6 months ： Check all control system fault protection devices through
simulating electric fault. Clean all the battery cover vent.
Tighten all the exhaust pipe interface.Tighten all electrical connectors.To start the
machine, observe whether control screen all meters is operating normally.

4
7.3 Air filter

7.3.1 Clean the filter screen

①Loosen the clamp on the air filter，Remove the dust cap.

②Take out the filter screen
③Blow the filter screen from inside to outside by compressed air.
④Wipe the the seal face and pipe inside of filter with a clean cloth .
⑤Reinstall the filter.

7.3.2 Replace the filter screen

①Loosen the
clamp on the
air filter，
Remove the
dust cap.
②Take out the filter screen
③Replace a new filter screen
④Reinstall the filter.

Warning：
z Can’t take out the filter in machine working or shutdown immediately,It
could easily lead to scalding.
z Can't start the generator under the condition of filter is taken out ，the
tempering of engine can cause serious burn.

7.4 Replace the engine coolant

①Open the ball valve on radiator bottom，

release all of the coolant.

②After release all coolant ，close the valve

③Take off the cap of the radiator.

4
 ④Filling with the new coolant, until the
liquid level close to the top to the
entrance .（About the coolant
instructions, please refer to section
5.4）
⑤Remount on the radiator cap and tighten.

Warning：
z When replacing cooling fluid, wear protective gloves and goggles.
z When machine at run or just stop, don't refill or replace coolant in case burn
or damage.

7.5 Oil and oil filter

7.5.1 Replace the oil

①Open the ball valve on engine

oil pan ,release all oil from
discharge mouth .
②After release out, close the ball
valve.

③Taking the oil mouth cap, fill with

new oil through an external oil
filter，，And check oil liquid
level by gauge until to the
position between limit up and
down.
（About the engine oil
specification, please refer to
section 5.2）
④Tighten the oil mouth cap.

7.5.2 Replace engine oil filter

①Discharge all the oil, the method is as

mentioned in 7.5.1.

②Take the oil filter down with special

wrench.

③Replace the new filter, and add up the oil.

4
 ④Daub right amount oil on the rubber seal of the
new filter.

⑤Install the new filter and and

tighten until the rubber ring
sticking closely to sealing
surface, then wrench filter
screw 1 more round.
⑥Add oil, the method is as mentioned in 7.5.1

Warning：
z When replace the oil,should wear protective gloves, goggles, and
protective clothing.
z When machine at run or just stop，Don’t replace oil or take down the filter.

z When replace the engine oil, place a plastic bucket or box under the
discharge port to collect waste oil.
handling of waste oil should be
accordance with local environmental
protection requirements.

7.6 Fuel filter

7.6.1 Release water and sediment

①Loosen the drain plug.

②Discharge the water and sediment in filter, until
there are fresh oil stream out .

③Tighten the drain plug.

7.6.2 Replace the fuel filter

① Loosen the drain plug and release the water and fuel until the filter is empty.
②Take down the cup under filter with special wrench，then take the filter.
③Replace the fuel filter, and fill it up with fuel.
④Daub right amount fuel on the rubber seal of the new filter .

⑤Install the new filter in the original position ，and tighten until the rubber ring
sticking closely to sealing surface, then wrench filter screw 1 more round.

4
 Warning：
z Not allowed smoking and using fire near the engine or fuel tank in case cause
fire .

z When replace the fuel filter, should wear protective gloves, goggles, and
protective clothing.beside,collecting waste fuel in plastic bucket or box,the
handling of waste oil should be accordance with local environmental
protection requirements.

7.7 Oil-water separator

7.7.1 Discharge of water and sediment

①Loosen the drain screw plug.

②Loosen the exhaust bolt.
③Discharge the water and sediment in oil-
water
Separator until there are fresh oil stream out .

④Tighten the drain screw plug and exhaust

bolt.

7.7.2 Clean the filter screen

①Loosen the drain screw plug and exhaust bolt,and discharge the water and
sediment in oil-water Separator until no more fuel come out.then tighten the drain
screw plug and exhaust bolt.
②Loosen the mounting bolt of the top to take down the separator.
③Take out the filter screen from the cup.
④Clean the filter screen with diesel.
⑤After cleaning, put the filter screen back to cup and install with the bottom
cover,then add fuel to the cup until full.

⑥Daub right amount fuel on the rubber seal of the separator.

⑦Install the separator in original place and tighten mounting bolts.

Warning：
z Not allowed smoking and using fire near the engine or fuel tank in case cause
fire .

5
 z When clean the separator, should wear protective gloves, goggles, and
protective clothing.beside,collecting waste fuel in plastic bucket or box,the
handling of waste oil should be accordance with local environmental protection
requirements.

7.8 Devanning、Moving、
Hoisting

7.8.1 Devanning of diesel generator

Before stripping of diesel generator ， the box should be checked whether the
packing of unit was damaged and be opened, if damaged or opened,we shall
immediately notify the transportation part and shipper, to confirm whether the unite
damaged or missing parts and so on .
When we strip the generator case ,should be careful for not to hurt the generator
and parts .After devanning,check the coolant,lubricant,fuel’s injecting mouth ,if is open
or fall into foreign bodies ,if so ,we should clean it out .Check the unit if have
damage,check attachment,tool along with the unit is confirm to the packing list ,if not
,should contact the supplier promptly.
7.8.2 There are two hoisting rings on the both side of the public chassis of unit for
listing the generator. If using wrong handling method,that will seriously damage the
generator parts .When move the generator by forklift，should lifting slowly or focus on
the chassis pushing or pulling carefully.When pull or push the unit ,it must be placed
wood between the forklift and the unit chassis to prevent collision and disperse weight
.If generator need to be moved frequently,
Unite can be mounted with “oil-filled slide
rail ”,there is hoisting hole and groove for
forklift.
Graph7.1 The correct lifting
unit method is demonstrated

Warning※
！Don’t lift generator on the ring of engine or alternator.
！Check if the hanging equipment and support is in good condition,and check the
hanging equipment load ability is OK .
！When unit is lifting , anybody is not allowed to close to.The standard model of
silent type generator is equipped with a single point suspension device.

Large silent generator hoisting point is the hole in four corners of the
shell .Make sure the canopy is firmly connected with the chassis before lifting generator.

5
 As to install to lift the generator ,unit chassis is specially designed for hanging
hole.Hanging the hole on the chassis around with wire rope, check if it hang firmly ，
the welding spot if have cracks ,if screw is tightening and so on.Using whippletree to
prevent collisions between sling and the unit(See figure 7.1).Hoisting points should fall
in the center of gravity (close to the engine), not the center of the unit, so can vertical
lift.Once the unit up from the ground,With guide line to prevent kink or swing .Don't lift
unit in the strong wind.The unit should be placed in the place where flat and can bear its
weight .

7.9 Storage of the generator

For short-term storage,take starting key and lock the control cabinet and switch
cabinet. If the unit is not needed more than two months or need storage longer,Operation
according to the following method：
z taking starting key and lock the control cabinet and switch cabinet,Turning the
engine power switch to "OFF" position.
z Place unit to a clean, dry place.
z Refer to the engine manufacturer's Suggestions, comply the regulations and
rules engine long stored.

Attention：
z Unit can not be stored in low-lying place, in case the water will flow
backward into the unit inside in rain day.

7.10 Fault treatment

When unit occurs failure, please refer to the below fault excluding guide.If still
can't handle failure, please contact our authorized agent or service department in time.

Fault Reason Solution

feature
1.The oil is not enough
2.The oil pipe or connector leaks
Low engine oil pressure
3.The oil filter clogging
4.The oil type is not correct
1.The coolant is not enough
1.Add oil
2.Replace the oil pipe or tight joint
3.Replace the oil filter
4.Change to the right type oil
1.Add coolant

5

High water temperature
Low fuel level
The unit circuit breaker
can’t switch to "ON"
position
Fault
feature
Control module can not run
Unit voltage drop quickly
after connected to the load.
The output Engine speed
2.The radiator pipe or connector
leaks
3.Belt of Cooling fan is loose
4.Radiator have inside blockage
5.Water temperature sensor is not
sensitive
6.The thermostat of engine is
broken
1.Fuel is not enough
2.Fuel pipe or joint leaks
3.Fuel tank have leaks
4.The fuel filter is blocked
5.Fuel level sensor is insensitive
1.Breaker stay in the middle of the
"ON" and "OFF"
2.Load short-cireuit
Reason
1.The control module power line
is break
2.Battery lack voltage
3.Dc circuit fuse is burned
1.The total load current is over
rated
2.The load is unbalanced
1.Fuel is not enough
2.Fuel filter is too dirty, fuel
injection quantity is not enough
5
2.Replace pipe or tight joint
3.Tighten the cooling fan belt
4.Cleaning the radiator inside
5.Repair or replace the water
temperature sensor
6.Repair or replace the engine
thermostat
1.Add fuel
2.Replace the fuel pipe or tight
joint
3.Repair or replace the fuel tank
4.Discharge the water and
sediment in the filter
5.Repair or replace the fuel level
sensor
1.First, turn the circuit breaker to
"OFF" position, then to "ON"
position.
2.Repair or replace the load circuit
Solution
1. Connect the control module
power line .
2.Charging battery with the mains
power
3.Replace the burnt fuse
1.Reduce the load to matching
the unit output
2.Balance each load
1.Add fuel
2.Replace the fuel filter
frequency of is unstable
the unit is
unstable
Alternator
speed is
unstable
Stable frequency ，Unstable
voltage
Connecting with load，Unit
frequency ,voltage is
stable ，Current is unstable
After a period of time, Unit
work well, but the power is
decreased
grounded metal parts is
electrified
Electric meter no reading
Circuit connect point is
overheating
Low insulation resistance
Generator not work or lack
3.There is air in fuel system
4.Fuel injector have wear or
failure
1.AVR（automatic voltage
regulator）Fault
1.Alternator AVR Fault
1.Terminal load is unstable
1.Air filter is dirty, air intake not
enough
2.Fuel filter was too dirty, fuel
injection quantity is not enough
3. Engine ignition timing is not
straight
1.Unwell contact and low
insulation resistance
2.Grounded wire is unwell ， lead
wire from alternator is connected to 2.Keep the lead line and circuit in
the chassis or ground
1.Meter damage
2.Power circuit is break
1. Joint is loose
2.connect point is burnt
1.Wires and insulation
components is damaged and
touch the ground
2.Alternator coil get damp
1.Broken coil lead to circuit break
5
3.Exhaust air of fuel system, and
check if leaks for fuel pipe and joint
4.Check or replace the fuel
injector
1.Check or replace AVR
1.Check or replace AVR
1.Check and adjust the load
1.Clean or replace air filters
2.Replace the fuel filter
3.Adjust the engine ignition time
1.Test insulation resistance by 500V
tramegger ,it should not be smaller
than 0.5M ohm,otherwise will
baking the alternator
good insulation
1.Repair ,replace damaged meter
2.Find out the fault point and
reconnected
1.Check and connect solidly
2.Wipe connector With NO：00
#
1.Find the broken part and
change it .
2.Baking the alternator coil
1.Twist and weld the broken part
with soldering tin，then wrap with
insulation tap .outside
 voltage 2.Connection part get loose 2.Clean the wire head and
connect tighten .
3.Low speed 3.Keep the speed as rated
1.Over loading 1.Reduce the load not more than
Generator is overheating rating.
2.ventilatting duct is obstructed 2.Blowing the inside completely
clean.

Fault Reason Solution

feature
Starting motor 1.Battery power switch is off 1.Open the power switch
can not drive, or 2.Battery power is insufficient 2.Charging for the battery
driving speed is
too low The battery electrolyte is 3.Replace the battery
metamorphic
The
4.Battery connection terminal get 4.Tighten the battery terminals
engine loose
can not Starting motor 1.Fuel insufficient 1.Add fuel
start drive normally, 2.Fuel pipe or joint leakage 2.Replace the fuel pipe or tight
but the engine joint
can not start
3.Fuel filter is blocked 3.Discharge the water and
sediment in the filter
4.Oil-water separator filter is 4.Clean or replace filter
blocked
5.The fuel system within air 5.Discharge the air in the fuel
system
1.Fuel pipe or joint leakage 1.Replace the fuel pipe or tight
joint
2.Fuel filter is blocked 2.Discharge the water and
Engine shut down sediment in the filter
immediately after start 3.Oil-water separator filter is 3.Clean or replace filter
blocked
4.The engine oil is not enough 4.Add engine oil
5.The fuel system within air 5.Discharge the air in the fuel
system
6.Air filter blocked 6.Clean or replace the air filter
screen
1.Use wrong model fuel 1.Change to the correct model
Engine exhaust black
2.Air filter is blocked 2.Clean or replace the air filter
smoke
screen

！The synchronous alternator fault and solve method refer to《Three phase synchronous
alternator operating instructions》

5
！The diesel engine fault and solve method refer to《Diesel engine operation instruction》
！The generator control cabinet fault and solve method refer to《Control panel instructions》

8. Factory warranty

8.1 Factory warranty

On the condition of user comply with “User maintenance manuals”，Within 12 months

or running 1500 hrs, whichever comes first,If machine is damaged because of produce problem
and have record for checking, The factory will repair or replace the damaged parts free of
charge.If the machine failure is caused by improper use,The factory not bear the
compensation.But should provide with the technical service and components needed to help
solving in time.

Product information table：

Engine
Model

Alternator
Model

5
 Maintenance record
Maintenance Maintenance
Date Item

5
Maintenance Maintenance
Date Item

5
5