TABLE OF CONTENTS

1 Safety Information........................................................................................................................................ 1
1.1 Safe Operation....................................................................................................................................1
1.2 Safety Labels...................................................................................................................................... 3
1.3 First Aid................................................................................................................................................ 8
2 Generator Set Introduction....................................................................................................................... 10
2.1 Specifications....................................................................................................................................10
2.2 General Description......................................................................................................................... 11
3. InstaIlation.................................................................................................................................................. 13
3.1 General.............................................................................................................................................. 13
3.2 Outdoor Installation..........................................................................................................................13
3.3 Indoor Installation.............................................................................................................................13
3.4 Utility Power...................................................................................................................................... 18
3.5 Load Connections............................................................................................................................ 18
3.6 Battery Connections........................................................................................................................ 19
3.7 Water Jacket Preheat Connections...............................................................................................19
4. Pre-Check Before Starting.......................................................................................................................20
4.1 Generator Pre-check....................................................................................................................... 20
4.2 Checking Engine Oil Level............................................................................................................. 20
4.3 Checking Fuel Level........................................................................................................................ 21
4.4 Checking Coolant Level.................................................................................................................. 21
5. Operation....................................................................................................................................................22
5.1 Main Electrical components ......................................................................................................... 22
5.2 Operation...........................................................................................................................................24
5.3 During Operation..............................................................................................................................27
5.4 Protection.......................................................................................................................................... 27
6 Maintenance.............................................................................................................................................28
6.1 General.............................................................................................................................................. 28
6.2 Periodic Maintenance Schedule.................................................................................................... 28
6.3 Generator Set Maintaining..............................................................................................................29
6.4 Air Cleaner........................................................................................................................................ 30
6.5 Engine Coolant.................................................................................................................................30
6.6 Engine Oil and Oil Filter.................................................................................................................. 31
6.7 Fuel Filter.......................................................................................................................................... 32
6.8 Oil-water Separator (lf Equipped)..................................................................................................32
6.9 Battery Maintenance........................................................................................................................33
6.10 Overnight Storage..........................................................................................................................34
6.11 Long-term Storage.........................................................................................................................34
7 Troubleshooting.......................................................................................................................................... 35
7.1 General.............................................................................................................................................. 35
7.2 Generator Set Trouble.....................................................................................................................35
7.3 control System Trouble................................................................................................................... 36
7.4 Engine Trouble................................................................................................................................. 37
7.5 Alternator Trouble.............................................................................................................................39
7.6 Battery Charge Trouble...................................................................................................................40
1 Safety Information
1.1 Safe Operation
Before operating the machine, read the following safety regulations carefully and find out about the
local requirements in safety. It can reduce the possibility of personal injury, damage to the equipment,
or improper service.
The operation, maintenance and repairs must be carried out only by authorized and competent
personnel. The owner is responsible for maintaining the genset in good safety conditions.
Read carefully the safety symbols attached on the genset and obey all messages that follow the
symbols to avoid possible injury or death.

General Safety Precautions

● Check that all necessary or available guards are correctly fitted.
It is forbidden to dismantle or disable any safety devices.
● Check the genset is securely mounted.
● Check all the mechanical connections are satisfactory.
Check all electrical connections are correct, safely insulated and
suitably earthed.
Check service and maintenance persons are competent and
adequately trained.
● Keep the genset clean and the genset house tidy.
● Always disconnect starter battery before commencing maintenance
operations.
● Do not approach the genset if you are wearing loose clothes or objects
that may be attracted by the airflow or by the mobile parts of the engine.
It is forbidden to lean on the genset or to leave objects on it.

Safety During Operation

● Do not allow children or animals to access the operating area of the genset.
● Always wear ear protections to avoid ear damage when genset is in operation.
● Before operating the genset, make sure that it has been connected to
a good earthen ground for proper operating safety.
● Before starting the engine, turn off the connected load and set all circuit
breakers to“OFF” position.
● Do not operate the genset in poorly ventilated area, because the exhaust
fume from the engine contains many harmful elements to human.
● Do not touch wires and connections to the alternator when the genset is
operating, because they are live.
● Do not touch any parts in motion, until the genset has stopped completely.
● Do not move the genset when it is running.
● Do not connect or disconnect loads during [Link] voltage is
present whenever the engine is [Link] shock can cause
serious or fatal injury. Loads should be connected correctly before
starting the engine.
● Do not smoke near the genset during operation or close to fuel source.
lt may cause fire, explosions, injury or death.
● Do not point the exhaust fume toward person or building.
● When working with the parts that may be live,make sure that your hands and feet are dry.
● Use the emergency stop button only in an actual [Link] not restart the engine
until the cause of the trouble has been checked out and fixed

1
Safety during InstalIation and lnitial Start-up
● lnstallation and repair procedures require specialized skills
with eIectrical generating equipment and small engine systems.
Any person that instalIs or performs repairs must have these
specialized skills to ensure that the genset is safe to operate.
●lnstallation of the genset must be reliable. You must be familiar with
emergency procedures concerning installation to be followed.
● Always wear a safety helmet, footwear, gloves, protections
goggles and dry, tight clothes.
●Do not modify the original protections, located on all rotary parts
on display, hot surfaces, air intake, belts and live parts.
●Do not leave any flammable liquids or rags soaked in flammable
liquids near the genset, electrical devices or any other parts of
the electrical installation.
●Take extreme caution to avoid risks of fulguration, make sure
there is a grounding installation and that it has been fitted
according to the regulations.
●lnsulate all connections and wires that are disconnected.
Do not leave any terminals of the genset unprotected.
● Plug all connection points concerning the genset and its
accessories into the grounding installations.
●Verity and make sure the electrical power connections and the
auxiliary services connections are correctly made.
● Check that the cyclical direction of the phases matches the
one of the power supply.
●Check the correct ventilation of the premises so that the
exhaust gas can be released to the atmosphere, to the exterior
of the premises, and verity that they are in a safe position
away from doors, windows and air intakes.
● Make sure there are no losses or leaks in the oil and fuel pipes.
●Single out the sources of dangers, such as fuel leaks, lubricant oil,
acid solutions, condensed drippings, high pressures and other dangers
● Never stand under or close to an object that is being hoisted or lift into position.
if the object falls or tips over, you or someone else could be crushed by the weight
of the object. It may cause severe injury or death to yourself for others. Always
remain a safe distance from the object and always wear protective head gear(hard hat)

Safety during Using Diesel Engine

● Do not operate the engine when the air cleaner is removed. An engine backfire can cause serious
burns.
● Do not open the radiator cap during operation or just after stopping the [Link] radiator fluid is
hot and under pressure and may cause serious burns.
● Do not add coolant, oil or fuel to a hot [Link] the engine to cool down firstly.
● Do not touch the engine and muffler during operation or just after the engine stops, because the
temperature can reach extremeIy high.
● Do not smoke or make light fires during the engine oil and fuel supply.
● Do not smoke during the fuel replacement, and be careful not to spill fuel on the genset.
● Check the exhaust circuit, and in the event that any eventual gas leaks are detected, repair
immediately. These are possible fire sources.

2
1.2 Safety Labels

Label No.BSL01 Operating Instructions

Before starting:
[Link] Operator’s Manual.
[Link] level unit.
[Link] ground unit.
[Link] all fluid levels.
[Link] engine cooling fan and rap degree of
tightness.
[Link] all pipes to ensure no leakage.
[Link] battery pole to ensure no cauterization.

Manual starting (for key start panel):

[Link] all external loads.
[Link] on the power.
[Link] the key.
[Link]-heat the machine.
[Link] Emergency Stop button to “ON” position.
[Link] the key to “ON” position.

Automatic start and remote start:

Read Operator’s Manual.

Stopping:
[Link] all external loads.
[Link] the key to “OFF” position,for automatic
start or remote start machine,press the “STOP”
button.
[Link] fuel tank.

Label No.BSL02 Label No.BSL04

Label No.BSL03

WARNING
CRUSH HAZARD
Withdraw your hand,
While operating.

3
 Label No.BSL05

WARNING
SAFETY INSTRUCTIONS
ENGINE EXHAUST can cause serious
Improper operation of this machine injury or even death.
can cause serious injury or even death. ●Use only in open,well ventilated areas
Read Operator’s Manual carefully before or vent exhaust outside.
operating or servicing.
This machine should only be operated by a WARNING
person with sufficient knowledge and skill to ELECTRIC SHOCK HAZARD
ensure safe operation. ●Do not touch internal wiring or connections
High voltage circuits are located inside the output while this machine operating.
terminals and control panel. ●Turn power off before servicing.
●The cover and control panel should be closed
before operating. WARNING
●The movable parts and hot surfaces should ●Before connecting this generator to any
be isolated within the enclosure. buildings electrical system, anisolation
●All the doors should be closed and locked (transfer) switch must be installed by
before operating. a licensed electrician.
●Serious injuty or even death may result
without this transfer switch.

Label No.BSL06
BATTERY VOLTAGE ALARM
THE GENERATOR WHICH DO NOT
RUN PASSED 3 MONTHS,SHOULD
CHECK THE BATTERY VOLTAGE
FIRST; IF THE BATTERY VOLTAGE
LOWER THAN 12V, SHOULD
RECHARGE THE BATTERY,OR ELSE
START THE MOTOR UNDER LOW
PRESSURE, WOULD DAMAGE THE
STARTING MOTOR.

4
Label No.BSL07
OIL FILTER CARTRIDGE
1 Replace the oil filter cartridge every 500 hours
of operation.
2 Apply a film of oil to the gasket for the new cartridge.
3 Screw in the cartridge enough by hand.
4 When the cartridge is removed,the oil level lowers. Be
sure to check for oil [Link] the engine oil level
and add oil up to the prescribed level after operating the
engine for a few minutes.
FUEL FILTER CARTRIDGE
[Link] the fuel filter cartridge every 500 hours
of use.
[Link] the cartridge by using ring spanner.
[Link] it securely by hand.
[Link] replacement of the fuel filter cartridge,
airbleed the fuel system.

AIR CLEANER
[Link] the air cleaner regularly according to
Operator’s Manual.
[Link] the evacuator valve once a week
under ordinary conditions.
[Link] air cleaner element should be cleaned
every 250 hours of operation.
[Link] the element every year or every 6 cleanings.

Label No.BSL08

CAUTION
Hot surface.

Do not touch.

Label No.BSL09

5
 Label No.BSL10 Label No.BSL11

Label No.BSL12 Label No.BSL13

DIESEL FUEL ONLY

ATTENTION:Be careful burn DO NOT USE GASOLINE

Label No.BSL14

● LIVE WIRE TERMINALS(U,V,W)

● NEUTRALWIRE TERMINAL(N)

Label No.BSL15 Label No.BSL16 Label No.BSL17

6
Label No.BSL18

7
1.3 First Aid

1) Emergency
A worker gets an electric shock by accident
and laying on the ground.
First aid in the right way is prerequisite.

2) Get the victim rid of electricity

First the rescuer needs to turn off all the
power if it is possible and then use some
special devices to get the victim off the
power and moves him far away the electricity

3) Open the air way

Tilt the victim's head back and lift chin with
fingers under bony part of jaw and take
the external things out of the victim's mouth
to keep the air way unblocked

4) Prepare for CPR

First check the victim for breathlessness by
looking, listening, and feeling for breathing
for 3 to 5 seconds.
Secondly pinch nose, seal your lips tightly
around the victim's mouth and give 2 full
breaths for 1 to 2 seconds each

8
5) Cardiopulmonary Recovery
lf the victim gets heart stoppage,
please take this way. Press on the victim's
chest 80 times per minute to stimulate the
action of the victim's heart and do the artificial
respiration twice after every 15 times of
cardiopulmonary recovery.

6) lf the breath recovers

Roll the victim to get him/her lateral
to keep his/her air way open.
Check the victim's breath and pulse
frequently to make sure if it is
working order

7) lf the breath can't recover

Send someone to call an ambulance
for help, send the second person if
possible to give location of emergency
and condition of the victim.

8) Before the ambulance comes

Keep head tilted back, pinch nose,
give 1 breath every 5 seconds. Look
listen and feel for breathing between
breaths

Check carotid pulse for 5 to10 seconds

If victim has pulse but no breathing,
continue rescue breathing.

9
2 Generator Set Introduction
● Convenient: Wide doors are design to allow
2.1 Specifications easy access for cleaning and repairing.
2.1.1 Use ● Super quiet performance: Use oversized
Generator set is one type of AC power supply muffler and absorbent cotton installed inside
equipment, which is driven by diesel engine and to minimize noise.
drive the alternator to generate electricity. The ● Designed with safe earth leakage protection
genset is used as power supply for emergency stop button, muffler, outer fuel
three main types of services. inlet and base fuel tank (with a capacity of
(1) Continuous service approximately 8/24 hours operation at full
Used as main power supply to generate load)
electricity for several purposes: motion force, 2.1.3 InstalIation Place
lighting, heating,etc. The genset can continue The genset is soundproof type, which can be
running and allow 10% overload for 1 used indoors(well ventilated) or outdoors.
hour per 12 hours under variable load, which is 2.1.4 Ambient Condition
used for remote area. ●Temperature:-25℃ to 45℃ (use the water
(2) Standby service jacket preheat unit below 5℃)
Used as standby power supply to provide ●Humidity: Less than 80%
continue electric power for non-invariable loads. ●Altitude: Less than one thousand (1000)
The genset is suitable for the area where must meters above sea Level
ensure continue power supply, such as hospitals, 2.1.5 Power Derating
industrial facilities, airports etc. Keep the genset For environmental conditions of installation and
standby state at any time and start to run when operation different from those above specified, it
the mains supply is abnormal. is necessary to foresee an eventual loss of
(3) Emergency service power, or derating, not only in the engine, but
Used as auxiliary power supply to solve energy also in the generator that is fitted into it, and
interruptions that may cause serious problems to therefore, in the electric power provided by the
people, physical and/or financial damage or to genset
face consumption peaks. The genset can start in The user/customer must clearly establish the
short time to provide steady electric power for effective environment conditions in which the
the loads when the mains supply happen genset will operate when placing the order.
abnormity, and switch to stop after the mains Therefore, the derating must be fixed at the time
supply becomes normal. Generally the genset of signing the agreement, so that both the engine
continues working for several hours and the alternator are correctly sized.
2.1.2 Main Specifications Particularly, the user/customer must report on
●High reliable performance:Use powerful the following environmental conditions in which
Engine(Cummins,Perkins,lsuzu,Volvo,Kubota, the genset will operate:
etc) and reliable Alternator (Stamford parts, ●The upper and lower room temperature
Leroy somer, Marathon etc.) limits.
●Ease of operation: Use advanced control ●The altitude above sea level or, preferably the
module, which makes operation very easy and minimum and maximum values of barometric
convenient by PC or front control panel. In pressure in the installation area.
addition, it will perform automatic shutdown on ●The humidity values in relation to the
fault condition. temperature and air pressure within the
●Specially designed cooling system helps installation,paying special attention to the
decrease the temperature humidity value with respect to the maximum
●Installation of engine and alternator use temperature.
isolators to reduce vibration greatly. ●Any other environmental conditions that may
●High anti-corrosion performance:All fasteners require special solutions or shorter
maintenance cycle, such as: dusty and/or
and locks used are stainless.

10
sandy environments, maritime environments, (6) Alternator
environments with the possibility of chemical The alternator producing output electrical power
pollution, operating conditions with the presence has been chosen for its superior performance
of great vibration (e.g. earthquake-prone areas, and reliability. All the standard alternator are the
or subject to external vibrations caused by machines without slip rings and revolving field
nearby machines.) brushes, wound as “2/3 pitch”, with Class H
[Link] apply STAMFORD or LEROY
2.2 General Description SOMER or other brand according to the
Modern generator set is a mini power station customer's requirement.
which is driven by the diesel engine. General (7) Control System
speaking, it contains the diesel engine, alternator There are three kinds of control system, one of
and control system. The engine drives the which is equipped for the genset to control the
alternator to produce output electrical power operation and output, and protect the machine
while the control system controls the operation from possible malfunctions.
and output of the genset and protects the a) BS1.0 Standard Control system: This control
machine from possible malfunctions. Besides, system is equipped with voltage meter,
the genset also includes accessories such as the current meter, frequency meter, water
control panel, switch cabinet, radiator, fuel tank, temperature meter, oil pressure meter, phase
battery, protective device, muffler and base switch, time counter, shut down switch, start
frame. key indicator light, etc.
(1) Diesel Engine b) BS1.0 plus protection controller: This kind of
The diesel engine powering the generator set system not only include the a/m meters, but
has been chosen for its superior performance also include one protection controller which
and reliability and the fact that it has been can indicate the stop of genset when
specifically designed for powering the generator the speed oil pressure, water temperature
set. and current run abnormally.
(2) Cooling system c) BS2.0 ATS Control System: is comprised with
The engine cooling system is either air cooled or LCD control panel, Automatic Transfer
water cooled. The air cooled system consists of Switch,,Switch cabinet and electric relay. lt
high capacity fan to pull cool air across engine to can achieve the transfer automatically
cool it. The water cooled system is comprised of between main power and genset power.
radiator, fan and a thermostat. The alternator When main power failure,the switch cabinet
cooling system is air cooled which consists of a will send a short circuit signal to genset, the
fan to pull cool air across alternator to cool it. genset will supply the power to Ioads in few
(3) Engine Electrical System seconds after receive the signal; conversely,
The engine electrical system is 12 (or 24) volt when the main power recover, the genset will
DC electricity, which consists of the start motor, shut down in few second after receiving the
battery and charger. signal from the switch cabinet.
(4) Fuel Tank & Base Frame The control panel includes LCD, indicator
The engine and alternator are coupled together light,start key and shut down button, which
and mounted on a heavy duty steel base frame. have the function of digitally showing the
This base frame includes a fuel tank with a presenting all output values and various
capacity of approximately 8 hours(or 24 hours) alarms information in four languages,
operation at full load. automaticaIly shutting down the engine
(5) Vibration Isolator when the genset run abnormally. We supply
The generator set is fitted with vibration isolators different brands of ATS control panel, such
which are designed to reduce engine vibration as Smartgen, Deepsea,Comap, etc.
being transmitted to the foundation on which the
generator set is mounted.
These vibration isolators are fitted between the
engine/alternator feet and the base frame

11
Control System:
Standard Control Panel--BS1.0

Model BS1.0
Voltage Meter √
Frequency Meter √
Current Meter √
Water [Link] √
AMP Meter √
Voltage Phase Switch √
Hour Meter Optional
Current Phase Switch √
Oil Pressure Meter √
Fuel Meter √
[Link] Indicator √
AVR √
[Link] √
Key Start √
Emergency Stop Switch √
4 protection function Optional

ATS (Automatic Transfer Switch) Control Panel--BS2.0

Main Features HGM6120U

Display LCD
Hours √
Plug-pull terminal √
Com port Link
Fix Input 1
Config Input 2
Fix Output 2
Config output 4
Analog Input 3
HGM6120U ATS Control Panel
Generator Data √
Engine Data √
Fuel Level √
Over Speed √
High engine Temp. √
Low oil pressure √
Fail to start √
Over voltage √
Under voltage √
Over current √
Short ciucuit √
Switch Cabinet
Idle control √
12
3. InstaIlation
3.3 Indoor Installation
3.1 General
When the genset is delivered, it is advisable to
3.3.1 Room Requirements
check that the received machine matches the
The lightning protection,Ventilation, fire
order, and to compare it with the delivery note.
Also, check that the machine is not [Link] protection lighting, and environment protection
any flaw is detected, you must contact the should be carefully evaluated when the genset is
shipping company immediately in order to report installed indoors.
the incident to the insurance company.
(1)Generator Requirements
3.2 Outdoor Installation
●Assure the genset room has 1 or 2 doors. At
The genset should be installed in an area that is
protected from direct harmful gases or liquids, least one of the door is big enough to
dust, metallic particles, shock, vibration. transporting the machine.
The soundproof type and container type genset ●The channel equipped with drainage should
can be installed outdoors. There should not be a be designed in the room for laying cables
cooling [Link] factory installed enclosure or ducting. The channel should be covered
is designs to keep out undesirable weather
by steel pad or concrete pad.
elements while providing cooling and ventilation.
●lf the genset room is coupled with control
ln addition, several other factors should be
carefully considered when selecting a location room, observational window should be set in
for installation. the wall between the two rooms. The doors
Access must be provides to allow the soundproof of genset room and control room should be
bonnet or control cabinet to be opened or fire-soundproof and opened outside, while
removed for service and maintenance. the door between the two rooms shouId be
Installation should prevent water level from
opened towards the genset room.
reaching the genset. Drainage must be adequate
to keep concrete pad free from standing water. ●lf genset room is located in the main
Installation should prevent obstructions by building, the wall and roof should be built
buildup leaves, grass, sand, snow, ect. If these with high density material (at least 700kg/m²)
items pose a problem, consider building a small and the windows should be double-gIass.
fence or other break to protect the unit from ●Usually the ground is polishing concrete and
accumulation of debris.
it could prevent oil infiltrating.
At least 1.2 meters(47.5 inches) clearance must
●The genset room should be near the
be provided on all side for air flow. And be careful,
the exhaust gas pipe and hot air exhaust pipe distribution management location.
can't face the doors or windows of the buildings. ●The genset room should not be located in
For effective cooling and maintenance, the living area or building that are located by
generator set should be mounted on a flat, people or animals. Never allow exhaust gas
smooth, noncombustible level surface. A to be directed towards any opening or air
concrete pad is ideal and provides a secure
entry routes(doors, windows, vents etc) of an
installation.
The safe loading capability of the geological occupied building.
material should be carefully evaluated when ●The genset room should be clear and
seIecting a location for install. ventilated, which never be used for storage.

13
(2) Lightning& Electrostatic Protection ●The surface of the foundation should be
[Link] safe loading capability of the
●The lightning protection should be carefully geological material should be carefully
evaluated when the genset room is designed. evaluated when selecting the foundation for
lf the room is located in the building, the installing. We advise adopting concrete as
lightning protection rating should be equal to the material of foundation.
the main building.
●lf the genset use external fuel transported of 9.81TW
the genset use external fuel transported by SBL=
pipelines, the fuel lines should be grounded. L×W

(3) Grounding Protection SBL--Weight of the load on the foundation(kg)

● Metal parts of installation or structures of the TW--Weight of the genset and foundation(kg)
genset room which are exposed to human L--Length of the foundation(m)
contact, and due to an insulation flaw or other W--Width of the foundation(m)
reason, may get in contact which voltage,
must be connected to the ground. Geological Material Max Load(kg/m2)
Granite 244000-977000
(4) Fire Protective Oil shale 98000-146000
The genset room should be provided with the fire Rock 78000-146000
extinguisher. Recommend the room is equipped Soft Rock 49000-59000
with automatic fire alarm system& automatic fire Tamping gravel 49000-59000
protection system. Pebble and gravel 39000-49000
Tamping sandy clay 28900-39000
3.3.2 lnstallation Foundation Sandy clay 20000-39000
●Never use rigid connection between the Sandy 10000-20000
foundation and genset room Soft clay 10000
●The surface of the foundation should be
oil-water proof, and equipped with drainage.
● If the genset is set on the floor, the load
carrying capacity of the floor should be fitted
to the static load and dynamic load of the
genset.

14
3.3.3 Foundation Dimensions

① Generator Set ⑥ Wicket

② Concrete ⑦ Air inlet

③ Gravel ⑧ Gate

④ Air outlet ⑨ lnstallation foundation

⑤ Observational window

15
 Foundation
Length Width Depth Height
(mm) (mm) (m) (mm)
Genset Genset
Length Width B ≥150
+300 +300

2M
B=
W×L×p

B- Depth of foundation(m)
M- Weight of genset(kg)
p-- Density of concrete(2322 kg/m3)
L- Length of foundation(m)
W- Width of foundation(m)

3.3.4 Generator Set Fixation

The engine and alternator are coupled together 3.3.5 Generator Set Installation
and mounted on the steel base frame. ln order to
reduce vibration transmitted to the foundation The soundproof genset is equipped with the
while running, the genset is equipped with exhaust pipeline and muffler, and its bonnet is
isolators between the engine/alternator and the designed with air intakes and air outlet. So the
base frame. machine has the performance of reducing noise
Fix the base frame of the genset with foundation and good ventilation function. The size of room
bolts before using the machine. and chimney should be carefully considered
Each foundation bolt needs to use a hexagonal when the genset is installed indoors.
nut, flat washer and spring washer. The amount ●'H' and'W' refer to the genset technical
and dimension of foundation bolts should be data for the height and width.
decided by the installation hole of the base ●Enough space must be provided to allow
frame. the access door or control cabinet to be
opened or removed for service and
maintenance in the room.
●Make sure enough cool air flows through
the genset, many of which is supplied to
the engine for combustion, and the rest is
used to cool the alternator, engine and
radiator.
●The exhaust gas and smoke produced by
the engine pass through the muffler and
enter the chimney. Make sure the exhaust
gas and smoke comply with the
requirement of the local laws.

16
① Air outlet ④ Air inlet ⑦ Gate

② Air and exhaust gas outlet pipe ⑤ Wicket

③ Generator set ⑥ Foundation

17
3.4 Utility Power 3.5.2 Connecting Load Cable

Utility can provide power to critical components The genset is ready for user connections. The
on the genset, like battery charge, block heater, user load cable(U,V,W,N) should be connected
water jacket, oil heater and other devices. to the corresponding wire terminal which is
The battery naturally discharges while it is stored located inside the control cabinet or switch
or not running. To maintain the genset in a good cabinet, then use a wrench to tighten cable
capability of starting, recharge it once a month in connections and fix them.
summer, and every 2 months in winter. The user Power cables must be placed in suitable
can charge the battery through ATS equipment, channel,tunnels or protective conduct-
or by connecting utility wirings to terminals of the holder. Do not include AC and DC cables in the
battery charge (refer to the genset circuit same channeling.
diagram). The charge indicator on the control
panel will illuminate when charging and put out
after finishing the charge.
The engine will be hard to start in the cold
environment. lt is recommended to equip
appropriate heater unit. Connect wirings of the
heater to utility before starting the engine. Turn
on the utility switch, the heater unit starts to work.
When the temperature reaches the preset value
or the engine has started the heater unit will stop
working automatically.

3.5 Load Connections

3.5.1 Select Load Cable
Select Load Cable with proper diameter, based
on its allowable amperage and the distance
between the genset and the load.
Recommend to select the proper diameter and  
length of cable. There is maximum 5% marginal
drop only for the rated voltage between the
terminals of loads and genset via the cables. lt ① Live wire terminal (U,V,W)
should be considered while selecting the cable. ② Neutral wire terminal (N)

……………………Warning ………………… …………………Warning …………………

◆ If load exceeds allowable amperage, the ◆Connection must be carried out only
cable may be damaged in overheating. by a licensed electrician
◆ If the cable is either too long or too ◆ Battery must be disconnected, and
small, there will be greater voltage drop the start key switch must be set
between cables which bring voltage "OFF" position.
drop to [Link] may result in reduced
performance in the connected loads.
…………………………………………………… ………………………………………………

18
3.6 Battery Connections 3.7 Water Jacket Preheat Connections
(Optional)
The battery cables should be disconnected to The water jacket preheat unit(optional) can make
the posts when the genset is required to the engine start up quickly in the cold
transport or store for long term. Before running environment. It is supplied power by the utility.
the machine, connect the battery cables.
Connect wirings of the heater to the utility before
Connect the red cable to the positive(+) post,
starting the engine. Once turn on the utility
and the black cable to the negative(-) post.
switch, the preheat unit starts to work and heats
the engine water jacket. It will stop working
automatically when the engine temperature
reaches 40-50℃ or the engine has started.

……………………Warning …………………
◆Do not dispose of battery in a fire. The
battery is capable of exploding. If it ① Ball valve
explodes, electrolyte solution will be ② Water jacket prehaet unit
released in all directions. Battery ③ Wiring terminals
electrolyte solution is caustic and
can cause severe burns and blindness.
If electrolyte contact skin or eyes,
immediately flush the area with water
and seek medical attention quickly.
…………………………………………………

19
4. Pre-Check Before Starting 4.2 Checking Engine Oil Level
Keep the genset level when checking engine oil,
4.1 Generator Pre-check insert the oil gauge all the way in. The
Before starting the genset, check each item appropriate level should be between the lower
below to make sure that the machine can be limit and upper on the oil gauge.
started up properly and reduce possible
problem.
●Check engine oil, fuel and coolant leakage at
the hose connections.
……………………Warning …………………
◆Do not use the machine when any leak
is found. Repair it first of all. Tighten or
change the connection hose if
necessary.
…………………………………………………

●Check to make sure no debris has lodged ① Oil gaude ② Upper limit
in vents, near radiator or around fan. ③ Lower limit
●Check to make sure that nothing is
touching the muffler or exhaust pipes. Add the engine oil if the level is below the lower
●Check that genset is grounded to a good limit.
earthen ground per local regulations. 1) Select the proper engine engine oil:
●Make correct terminal connections. (recommended) 15W-40.
●Check that all electrical connections were 2) Loose the oil inlet cap and remove it
made in compliance with local regulations 3) Fill engine oil into the oil inlet through an oil
and NEC standards. filter until the level is slightly less than the
●Check to make sure that fan belt and upper limit by checking the oil gauge.
hoses on engine have no loose 4) Tighten the oil inlet cap.
connections or fraying. Tighten or replace
as required.
●Check to make sure that the battery cables
are firmly secured to the posts. Tighten the
clamps more if necessary.
●Close and secure access doors, control
cabinet and switch cabinet doors.
●Review and follow safety instructions in
the front of this manual.

……………………Warning …………………
◆Failure to follow the procedures listed
may cause injuiry to personnel or
damage to the [Link] certain that all
persons setting up the genset are
certified or fully trained on the
installation of the genset.
◆Always wear protective gloves and ① Oil inlet cap ② Oil inlet
clothes during operation. ③ Oil gauge
…………………………………………………

20
…………………Warning ………………… 4.4 Checking Coolant Level
◆A single or multigrade oil must be used
which conforms to API-CG4/CH4 or Remove the coolant inlet cap and radiator cap,
ACEA-E3/E5. check coolant level in the [Link] coolant in
◆lf the genset is not level when check case of shortage
the engine oil,you can not obtain
1) Select the proper coolant: (recommended)
accurate oil level.
Shell long life-OAT-45℃
◆Do not overfill the engine oil. The
level can not exceed the upper limit 2) Remove the coolant inlet cap.
because the excessive amount of 3) Remove the radiator cap.
engine oil may damage the engine. 4) Fill coolant up to the radiator inlet top.
◆Do not smoke or make light fires near 5) Tighten the radiator cap and coolant inlet
the genset when filling the engine oil. cap.
◆Do not leave oil everywhere for
environmental [Link] off oil
residue on the engine after adding.
…………………………………………………
4.3 Checking Fuel Level

Remove the fuel cap, check the level in the tank.

Add fuel in case of shortage.
1) Select the proper fuel:0# /ATSM2.
2) Loosen the fuel cap and remove it.
3) Fill the fuel through the inlet until the fuel is
slightly less than the full tank level.
4) Tighten the fuel cap.

…………………Warning …………………
◆Do not open the radiator cap while
operating the genset or just immediately
after stopping the machine, because that
may cause burns from hot vapour or
coolant.
◆Do not leave coolant everywhere. Wipe
off coolant residue on the genset after
adding.
…………………………………………………

21
5. Operation
Emergency Stop Button
5.1 Main Electrical components

Control Model

◆The genset is equipped with one red

emergency stop button. By pushing the
red button in, the engine stops. Closing
◆HGM6120 is an automatic mains failure the emergency stop button opens the
control module. lt is used to monitor the main circuit breaker and the fuel solenoid,
mains supply and automatically start and and results in the engine shutting down.
When rotating the button,it will pop out
stop the engine. The module indicates the
automatically. The switch will remain
operational status and fault conditions,
closed until the button is rotated.
automatically shutting down the engine
and indicating engine failure on the LCD.

Auto Transfer Switch (Optional)

Main Circuit Breaker

◆The genset is equipped with an automatic

transfer switch in the control [Link] can
transfer automatically power supply
◆Main circuit breaker is located in the between the genset and the mains supply.
middle of the switch [Link] the ◆Main Wiring terminals for outside load
current in the main circuit is above its connection. A label which is attached upon
rated value,it will turn to the “OFF” the terminals shows the correct
position automatically and interrupt connections for power cables. Use a
main circuit power. wrench to tighten cable connections in
place.

22
 Main Wiring Terminals ATS Control Receptacle (Optional)

◆The genset is equipped with an

◆ The genset provides wiring terminals for automatic transfer switch receptacle in
outside load connection. A label which is the control cabinet, which is used for
attached upon the terminals shows the connecting the genset to ATS. lf the
correct connections for power [Link] customer connects an ATS equipment, it
a wrench to tighten cable connections in can transfer automatically power supply
place. between the genset and the mains
supply.

Key Switch
Charge Indicator

◆ Only if the key switch is turned to the

“ON” position,could the control module ◆The indicator will bright when the storage
be powered. battery is changed by the utility power.

Alarm Reset Button Alarm Indicator

◆The reset button can make the alarm ◆The alarm indicator will illuminate when a
indicator return the original condition. fault occurs during the genset running.

23
5.2 Operation
5.2.1 Control Cabinet and Control Panel

Ref. Description
1 Control Panel
2 Key Switch
3 Genset Indicator
4 Circuit breaker

a Alarm
b Running
c Genset Available LED
d Stop Mode
e Stop/Reset
f Up
g Set/Confirm
h Down
i Close/Open
j Mains Available LED
k Mains On-load
l Start Key
Manual Mode/Manual
m
Key
n Gens On-load
o Auto Mode
p Auto Key
q Test Mode
r Test On-load Key
s Menu Key
t LCD Display

24
5.2.2 Manual Start-up and Stop
…………………Warning …………………
(1) Start- up ◆Before turning the main circuit breaker
to"ON" to send power to the load,
make sure any circuit breaker and
1) Set every circuit breaker and switch of loads switch of loads are positioned to
to"OFF" position. "OFF". Otherwise,it may cause electric
2) Turn the Genset Main Circuit Breaker and shock to the operator.
◆Do not touch wires and connections to
other circuit breakers to the "OFF" position.
the alternator when the genset is
3) Turn on the engine battery switch. running,because they are live.
4) Turn the Key Switch to the "ON" position. …………………………………………………
5) Press the Manual mode Key(m), then the
LED above the button will illuminate.
6) Press the Start Key (l), then the fuel solenoid (2) Stop
is energised, and after 1 second delay the starter
motor is run to make the engine crank for the 1) Turn off every switch and circuit breaker
duration of the crank timer. of loads (from light to heavy load in sequence).
7) lf the engine could not fire during the pre-set 2) Turn the Genset Main Circuit Breaker and
number of attempts to start, the control module other circuit breaker to the "OFF" position.
would alarm. lf you need to restart, wait at least 3) Press the Stop Key (e) to make the engine
30 seconds. After the engine starts stop.
successfully, allow the engine to warm up for 4) Keep the engine idle for about 1 minute to
about 5 minutes. allow it cool down.
8) Checking the LCD reading of output voltage 5) Turn off the Key Switch
and frequency, the control module would alarm if 6) Turn off the engine battery switch.
the values are not the same with that of the
pre-set. Once the genset is running at the correct
voltage and frequency, the Genset Available Note: (e) refers to the illustration of HGM6120
LED (c) will illuminate. Turn the Genset Main control panel.
Circuit Breaker to "ON", the Genset On Load
LED (n) will illuminate.
9)Turn on every switch or circuit breaker of
loads(from heavy to light load in sequence),
send power to the load side.

Note: (m), (l), (c), (n) refer to the illustration of

HGM6120 control panel.

25
5.2.3 Auto Start-up and Stop
(1) Start-up (2) Stop
1) Set every circuit breaker and switch of loads
to "OFF" position. 1) If the genset is connected to the ATS
2)Turn the Genset Main Circuit Breaker and equipment, the module will monitor the incoming
other circuit breaker to the "OFF" position. AC mains supply when running. Once the mains
3) Turn on the engine battery switch. supply becomes normal, the module would
4) Turn the Key Switch to the"ON" position. proceed with its auto stop sequence. The
5)Press the Auto Mode key(p), then the LED Genset Main Circuit Breaker will be
above the button will illuminate. The module will automatically turned to the "OFF" position. Then
proceed with its auto start sequence. the mains supply circuit breaker will be turned to
6)If the genset is connected to the ATS the "ON" position and supply power for the loads.
equipment (automatic transfer switch), the The Genset Available LED (c) and Genset On
module will monitor the incoming AC mains Load LED(n) will put out, and the Mains
supply. lf the mains supply is normal, it will Available LED (j) and Mains On Load LED (k)
become power for loads and the genset does not will illuminate.
run. On the contrary the module will perform the 2) lf the genset is connected to the remote
auto start sequence and supply power if the controller, turn the start switch to the "OFF"
mains supply is abnormal (like over-voltage, position. When the module monitors that the
over-frequency, under-frequency, etc.) remote start signal is removed, it will perform the
7)If the genset is connected to the remote auto stop sequence. The Genset Main Circuit
controller, turn the start switch to the"ON" Breaker will be automatically turned to the
position. When the module monitors that the "OFF" position.
remote start signal is active, it will perform the 3) The engine will idle for about 1 minute to allow
auto start sequence. it cool down. After the pre-set delay, the fuel
8) The engine will start automatically. After it solenoid will be de-energized, and the engine will
starts successfully, it will warm up for about 5 stop.
minutes. lf it could not fire during the pre-set 4) Turn off the Key Switch.
numbers of attempts to start, the control module 5) Turn off the engine battery switch.
would alarm.
9) The control module would alarm if the values Note: (c), (n), (j), (k) referto the illustration of
of output voltage and frequency are not the HGM6120 control Panel.
same with that of the pre-set. Once the genset is
running at the correct voltage and frequency, the
Genset Available LED(c) will illuminate and
automatically turned to the "ON" position. Then
the Genset On Load LED (n) will illuminate.
10)Turn on every switch or circuit breaker of
loads(from heavy to light load in sequence), the
genset will supply power to the loads.
Note:
●If you want to use ATS or remote
controller, connect it to the genset before
starting.
●(p), (c), (n) refer to the illustration of
HGM6120 control panel.

26
 5.3 During Operation
●Check the LCD reading of voltage, 5.4 Protection
current,frequency by using the Scroll [Link]
Button,which should be desired. Warn are non-critical alarm conditions and do
●Check the LCD reading of engine oil,
not affect the operation of the generator system,
coolant and fuel levels.
they serve to draw the operator attention to an
●Check the LCD reading of engine oil
undesirable condition.
pressure and coolant temperature.
●Check any alarm signal on the LCD or In the event of a warn, the module will display at
alarm LED. the last screen of LCD.
●Check for any leakage of coolant, oil, fuel. Warn is shown as below:
●Check for any unusual vibration or noise. √ High engine temperature
●Check for any unusual colour from the √ Low oil pressure
[Link] normal condition, the √ Loss of speed signal
exhaust gas has no colour or light bluish √ Generator over current
colour. √ Fail to stop
●If engine speed is not stable or engine can √ Battery high voltage
not run because of no fuel, extract the air √ Battery low voltage
in the fuel system. The operator can √ Auxiliary inputs
extrude the manual fuel pump(optional) in √ Low level warn
the fuel inlet line, or press the air release
√ Fail to charge warn
bolt( if equipped) on the side of the engine,
or operate the air release bolt on the fuel
5.4.2. Shutdown Alarm
filter.
1)Loosen air release bolt on the fuel filter. Shutdowns are latching and stop the generator.
2)Extract the air in the fuel system about The alarm must be cleared, and the fault
30 seconds. removed to reset the module.
3)Tighten the bolt. Note: The alarm condition must be rectified
before a reset take place. lf the alarm condition
remains it will not be possible to reset the unit
(The exception of this is the low oil pressure
alarm, as the oil pressure will below with the
engine at rest).
√ Emergency stop
√ High engine temperature
√ Low oil pressure
√ Over speed
√ Under speed
√ Loss of speed signal
√ Generator over frequency
√ Generator under frequency
√ Generator over voltage
…………………Warning ………………… √ Generator under voltage
◆Press the emergency stop button if an √ Generator over current
emergency occurs and the genset √ Fail to start
must be stopped immediately √ Auxiliary inputs
◆Repair the machine according to
troubleshooting guidelines. Please
consult with our authorized distributor
or our engineening section if you could
not deal with.
…………………………………………………

27
6 Maintenance
…………………Warning …………………
6.1 General
◆Accidental starting of the machine
●Before performing any check or during maintenance can cause severe
maintenance, stop the engine and personal injury or [Link]
remove the start key both genset starting battery cables
●For detailed maintenance procedures before performing maintenance, and
on the engine, refer to engine operator's remove negative (-) cable first to reduce
manual. the risk of arcing.
●Following the maintenance schedule ◆Maintenance should be performed by a
and using the machine properly will licensed engineer.
result in loge genset lift, better …………………………………………………
performance, and safer operation.
Perform each maintenance procedure
at the time period indicated or after the
number of operating hours indicated,
whichever comes first.
●In hot and dusty environments
maintenance procedure of changing
engine oil and oil filter should be
performed more frequently.

6.2 Periodic Maintenance Schedule

Weekly Monthly 6 Months 1 Year 2 Years

Daily or
Service items or after or after or after or after or after
after 8th
100 h 100 h 250 h 500 h 1000 h
Check various meters and alarm
●
lamps
Check engine oil,fuel and coolant
●
level
Check engine (oil, fuel and
●
coolant)
First
Change engine oil ●
50th
Check battery charging system ●
Drain water/sediment in oil-water
●
separator
Drain water/sediment in fuel filter ●
Drain water/sediment in fuel tank ●
Change engine oil filter ●
Change fuel filter ●
Clean gauze filter in oil-water
●
separator
Clean or change air filter element
clean change
if the clog indicator is on
Check cooling system ●
Check drive belt tension ●
Change oil and fuel pipes ●
Change coolant ●
Clean inside fuel tank ●

28
6.3 Generator Set Maintaining …………………Warning …………………
Inspect the genset daiIy or after every eight ◆Inhalation of exhaust gases can result
hours of operation,whichever comes first. Check in severe personal injury or even
the mechanical, exhaust, fuel, and DC electrical [Link] exhaust system audibly
systems as described below. and visually for leaks [Link] all
(1)New Machines leaks immediately.
●Run the genset at least 60-100% of …………………………………………………
continuous load for the first 100 hours. (4) Fuel System
●Change engine oil and replace oil filter Start the genset, inspect the fuel supply lines,
after the first 50 hours return lines, filters, and fittings for cuts, cracks
(2)Mechanical System and abrasions. Make sure that the fuel lines do
Inspect any signs of mechanical damage. Start not rub against anything that could break them.
the genset and listen for any unusual noises, Replace worn fuel line components if necessary
which may indicate mechanical problems. Repair before leaks occur.
them immediately.
Inspect the mounting fasteners to make sure the …………………Warning …………………
genset is secure in its [Link] use an ◆Fuel leakage will cause a fire hazard
under-floor housing, make sure that the genset is which can result in severe personal
secured to the housing. injury or even death if ignited. When
Check the genset air inlet and outlet areas, make checking for leaks, do not smoke or
sure that they are not blocked with debris. allow any spark, flame,pilot light or
Clean the machine whenever dust and dirt begin other ignition source in the area, lf any
to accumulate. Usually remove dust and dirt with leaks are found out, repair them
a damp cloth. immediately.
…………………Warning ………………… …………………………………………………
◆Do not clean the genset when the
engine is running. (5) DC Electrical system
◆Protect the alternator, air cleaner, Inspect the battery terminals for clean and tight
control panel and electrical connections with the genset [Link] or
connections from cleaning solvents, corroded connections cause resistance which
because cleaning solvents can damage can impede starting. Clean and reconnect loose
electrical connectors. battery cables if necessary.
………………………………………………… In order to reduce the possibiIity of arcing,
always disconnect the negative (-) battery cable
(3) Exhaust System first and connect it last.
Start the genset, inspect the entire exhaust
system including the exhaust manifold, exhaust …………………Warning …………………
elbow, muffler and exhaust pipe during the ◆Ignition of explosive battery gases can
machine running. create severe personal injury.
Visually and audibly check for leaks at all ◆Wear goggles, protective rubber gloves
connections, welds, gaskets, and joints. and apron and do not smoke while
lf any leaks are found out, shut down the servicing batteries.
machine and do not operate until corrected. …………………………………………………
Replace corroded exhaust components if
necessary before leaks occur.

29
6.4 Air Cleaner 6.5 Engine Coolant
6.4.1 Clean air filter element
1) Loosen clips in the air cleaner and remove the Change coolant
dust cap. 1) Turn on the radiator drain ball value,and drain
2) Remove the air filter element coolant.
3) Blast the compressed air to the air filter 2) After draining, turn off the drain ball valve.
element from inside. 3) Remove the coolant inlet cap.
4) Use a clean cloth to wipe the filter sealing 4) Remove the radiator cap.
surface and the inside of the outlet tube. 5) Fill new coolant into the radiator up to the
5) Reinstall the air cleaner in the reverse order. radiator inlet top.
6) Close the radiator cap and coolant inlet cap.
6.4.2 Change air filter element

1) Loosen clips in the air cleaner and remove the

dust cap
2) Remove the air filter element.
3) Change a new air filter element.
4) Reinstall the air cleaner in the reverse order

① Coolant inlet cap ③ Radiator cap

② Coolant inlet ④ Radiator
① Dust cap ⑤ Air inlet cap
② Clip ⑥ Clog indicator
③ Air cleaner housing
④ Clamp ⑦ Air filter element
…………………Warning …………………
◆Wear protective gloves, goggles and
clothes when changing coolant
◆Do not change coolant while operating
the genset or immediately after
…………………Warning …………………
stopping the machine, because that
◆Do not remove the air cleaner while
may cause burns from hot vapour or
operation the genset or immediately
coolant
after stopping the machine.
………………………………………………
◆Do not start the engine after the air
cleaner is removed. The backfire can
cause serious burns.
………………………………………………

30
6.6 Engine Oil and Oil Filter
6.6.1 Change engine oil
6.6.2 Change oil filter

1) Turn on the oil drain ball valve on the side of

1) Drain engine oil fully
the base frame.
2) Loosen and remove the oil filter by using an oil
2) Open the access door
filter wrench.
3) Turn on the oil pump ball valve which is under
3) Add engine oil into a new oil filter and fill it up.
the oil pan or oil pump.
4) Smear a little engine oil on the rubber gasket
4) Twitch the oil pump or handle the level on the
of the new oil filter.
oil pump to drain engine oil.
5) Screw the new filter into place and tighten it
5)After draining,turn off the oil drain ball valve
until the gasket conditional 1 turn by using the oil
and oil pump ball valve.
filter wrench.
6) Loosen and remove the oil inlet cap, add oil
6) Supply engine oil.
into the oil inlet through an outside oil filter until
the level is slightly less than the upper limit by
checking the oil level on the oil gauge.
7) Tighten the oil inlet cap and close the access
door.

① Oil filter ② Gasket

…………………Warning ……………………
◆Wear protective gloves, goggles and
clothes when changing the engine oil.
◆Do not remove the oil filter or change
① Fuel filter ④ Oil inlet engine oil while operating the genset or
immediately after stopping the machine.
② Oil pump ⑤ Radiator
◆Take a plastic sheet and a container
③ Oil Gauge
under the oil drain outlet to protect
[Link] of the waste liquid
in accordance with environmental
protection legislation.
…………………………………………………

31
6.7 Fuel Filter

6.7.1 Drain water/sediment in the fuel filter 6.8 Oil-water Separator (lf Equipped)

1) Loosen the drain plug. 6.8.1 Drain water in the oil-water separator
2) Drain water and sediment until fuel inside
starts to come out. 1) Loosen the drain plug
3) Tighten the plug. 2) Loosen the air release bolt.
3) Drain water or other sediment until the fuel
starts to come out. Tighten the drain plug and air
release bolt.

① Mounting bolt ④ Cup

① Fuel filter ② Drain plug ③ Gasket
② Air release bolt ⑤ Bottom cover
6.7.2 Change fuel filter ③ Gauze filter ⑥ Drain plug
1) Loosen the drain plug to drain water and fuel
until the inside does not come out from the plug.
6.8.2 Clean gauze filter in oil-water separator
2) Loosen the bowl by using the filter wrench.
Remove the fuel filter.
1) Loosen the drain plug and air release bolt,
3)Add fuel into a new filter and fill it up.
drain water and fuel until the fuel does not
4) Smear a little fuel on the rubber gasket of the
come out from the plug. Then tighten the
new fuel filter.
drain plug and air release bolt.
5) Screw the bowl and the new filter into place
2) Loosen the mounting bolt on the top cover to
and tighten it until the gasket contacts the seal
remove the oil-water separator.
level. Then, give it additional 1 turn by using the
3) Remove the gauze filter from the cap
filter wrench.
4) Wash the gauze filter in Diesel fuel.
…………………Warning …………………………
5) After washing, place it back and add fuel to
◆Do not smoke near the engine or fuel
fill the oil-water separator up.
resource, it may cause fire.
6) Reinstall the oil-water separator in the
◆Wear protective gloves, goggles and
reverse order
clothes when changing the fuel filter. ln
addition, the waste fuel should be collected
in a container for environmental protective.
………………………………………………………

32
6.9 Battery Maintenance

Mishandling of the battery will shorten the 4) Quick recharging charges the battery at a high
service life and add to maintenance costs. To get rate in a short time. This is only for emergencies.
the maximum performance and longest life of the 5) Recharge the battery as possible, or battery
battery, the user should handle properly and with life will be extremely shortened.
care.
Engine starting will be very difficult if battery …………………Warning ………………………
charge is low. Recharge it in time before it is too ◆When disconnect the cable from the
late. battery, start with the negative post first.
6.9.1 Battery charging when connecting the cable to the battery,
1) Remove the battery vent plug, make sure start with the postive post first. The
each electrolyte level is to the bottom of vent contact of tools on the battery may cause
wells. If necessary, add only distilled water in a a short if reversed.
well-ventilated place. ◆Remove the battery vent plugs when
charging the battery.
◆When the battery is being activated,
hydrogen and oxygen gases in the
battery are extremely explosive. Keep
open sparks and flames away from the
battery at all time, especially when
charging the battery.
◆Do not check the battery charge by
placing a metal object across the post.
Use a voltmeter or hydrometer.
◆Be careful not to let the battery electrolyte
contact your skin or eyes. If it occurs,
flush the area with running water
Battey electrolyte level
A: Too low immediately and seek medical attention
B: Proper quickly.
C: Too high ◆Do not use or charge the battery if its fluid
level stands below the lower mark.
2) Connect the charge to the proper mains ……………………………………………………
supply.
3) Connect the charger to the battery. Connect
the charger positive terminal to the battery
positive(+) post, and the negative to the
battery negative(-) post.

① Battery vent plug

33
6.9.2 Battery long-term storage 6.11 Long-term Storage

When storing the engine for long periods of time: lf the genset would not be used for more than
1) Remove the battery and adjust the two months, perform the following procedures to
electrolyte to the proper level, store it in a
store it.
dry and dark place.
1) Make sure the engine battery switch and
2) The battery naturally discharges while it is
stored. Recharge it once a month in all genset circuit breakers are placed
summer, and every 2 months in winter. "OFF" position.
…………………Warning …………………… 2) Close and padlock the control cabinet
◆Damaged wiring will reduce the and access doors. Remove the start key.
capacity of electrical parts. Change of 3) Turn off the fuel supply valve(if equipped)
repair damaged wiring immediately. 4) Disconnect the battery cables(negative「-」
◆Check to see if electric cables and
cable first) from the starting battery and
wiring are swollen,hardened or cracked.
store the battery.
Change of repair damaged wiring
immediately. 5) Change the engine oil and attach a tag
◆Keep dust and water away from all indicating the oil viscosity.
power connections. Loose wiring 6) Store the genset where dust and
terminal parts make bad connections. humidity are less as possible.
Make sure to repair them before starting
the engine.
…………………………………………………

6.10 Overnight Storage

Proper operation is essential for preserving top

genset performance and reliability when storing
the genset overnight.
1)Check and make sure the engine battery
switch and all genset circuit breakers are
placed "OFF" position.
2)Make sure that the control cabinet and
access doors are closed and padlocked.
3)Turn off the fuel supply valve(if equipped)

…………………Warning ……………………
◆Do not store if overnight in a low lying
area that might fill with water during a
heavy storm.
…………………………………………………

34
7 Troubleshooting …………………Warning ……………………
◆Performing troubleshooting should be
7.1 General carried out by a licensed engineer.
◆Before performing any troubleshooting
When performing any troubleshooting, follow
stop engine and remove the start key,
the guideline below.
and always allow engine to cool
For detailed troubleshooting procedures
because hot engine parts can cause
about engine/alternator, refer to engine
severe burns.
operator's manual.
…………………………………………………
Keeping engine oil level,making battery
connections clean and tight, checking fuel
level, not overloading ect, will prevent most
shutdowns.
Contact our authorized distributor to ask for
help for complicated maintaining and
replacing operation.

7.2 Generator Set Trouble

Trouble Cause Remedies

1. Lubricant oil is insufficient [Link] lubricant oil
Low engine oil 2. Oil hose has leak [Link] or change oil hose
pressure [Link] filter is clogged [Link] oil filter
4. Wrong oil is used 4. Change to proper kind oil
[Link] is insufficient 1. Add coolant
[Link] pipe has leak [Link] or change coolant pipe
[Link] belt is loose [Link] the belt
High coolant
temperature [Link] core is clogged [Link] radiator core
[Link] temp sensor is defective [Link] or change the sensor
[Link] or change the
[Link] thermostat is defective
thermostat
[Link] is insufficient [Link] fuel
[Link] hose has leak [Link] or change fuel hose
Low fuel level [Link] tank has leak [Link] or change fuel hose
[Link] water/sediment or
[Link] filter is clogged
change fuel filter
[Link] level sensor is defective [Link] or change the sensor
[Link] filter element is clogged, and [Link] or change air filter
air is insufficient element
Power drops after
[Link] filter is clogged, and fuel is [Link] water/sediment or
running a period of
insufficient change fuel filter
time
[Link] the ignition time as
[Link] ignition time is incorrect
required
[Link] connection is defective [Link] ground wiring
Ground metal part is
[Link] insulating resistance,
electriferous [Link] resistance is too low
change if necessary

35
7.3 control System Trouble

Trouble Cause Remedies

[Link] main breaker position is [Link] turn the breaker to
Main breaker cannot be turn to between on and off off, turn it to on
on [Link] and repair the load
[Link] circuit on the load
circuit
[Link] module cable is [Link] the module cable
disconnected to the battery to the battery
Control module cannot run [Link] the battery with the
[Link] power is insufficient
utility power
[Link] DV fuse is damaged [Link] the DV fuse
[Link] total exceeds the [Link] the loads to meet
rated current the rated output
[Link] sharing to each [Link] the loads sharing
Voltage drops quickly when terminal is unbalanced to each terminal
connecting to the load [Link] of alternator is [Link] AVR,and change it if
defective necessary
[Link] the frequency to the
[Link] wrong frequency
load frequency
Frequency is stable, but 1. AVR of alternator is [Link] AVR,and change it if
voltage is unstable defective necessary
After connecting to the load,
[Link] and adjust the
voltage and frequency is [Link] load is unstable
customer load
stable, but current is unstable
[Link] of alternator is [Link] AVR,and change it if
Voltage cannot go up to the defective necessary
rated value [Link] frequency as
[Link] is low
required
Voltage exceeds the rated [Link] of alternator is [Link] AVR,and change it if
value defective necessary
[Link] the meter,and
[Link] meter is defective
change if necessary
Electric meter has no reading
[Link] is disconnected,or [Link] the cut position and
terminal is loose connect again

36
 7.4 Engine Trouble

Trouble Causes Remedies

[Link] switch is off [Link] the switch to on
Starter motor
[Link] output is weak [Link] the battery
cannot drive or
[Link] is deteriorated [Link] the battery
speed to low
[Link] terminal is loose [Link] the terminal
[Link] fuel system,and add
Engine [Link] is insufficient
fuel if necessary
cannot start Starter motor
[Link] filter is leak [Link] or change gauze
drives, but
[Link] water/sediment or
engine cannot [Link] filter is clogged
change fuel filter
start
[Link] filter is clogged [Link] or change fuel hose
[Link] is mixed in fuel line [Link] the air
[Link] hose has leak [Link] or change fuel hose
[Link] water/sediment or
[Link] filter is clogged
change fuel filter
[Link] or change gauze
[Link] filter is clogged
filter
Engine starts but stalls at once
[Link] oil level, add oil as
[Link] oil is insufficient
required
[Link] is mixed in fuel line [Link] the air
[Link] filter element is [Link] or change air filter
clogged element
[Link] fuel system,and add
[Link] is insufficient
fuel if necessary
[Link] of moving [Link] to see if lubricating
parts oil filter is working properly
[Link] or change air filter
Output is insufficient [Link] filter element is dirty
element
[Link] the fuel injection
pump element and delivery
[Link] pump wear
valve assembly,replace if
necessary
[Link] is of very poor
[Link] good quality fuel
quality
[Link] filter element is [Link] or change air filter
clogged element
[Link] total exceeds the [Link] the loads to meet the
Muffler releases black smoke
rated current rated output
[Link] of gas
carbon is high on the
[Link] out gas carbon
exhaust pipes and
muffler

37
 Trouble Causes Remedies
[Link] oil level,add oil as
[Link] oil is insufficient
required
[Link] belt or adjust belt
[Link] belt broken or elongated
tension
[Link] insufficient [Link] coolant
[Link] net or radiator fin
[Link] net or fin carefully
clogged with dust
[Link] of radiator or coolant [Link] or replace radiator and
flow route corroded parts
Engine overheats [Link] or radiator or radiator cap
[Link] defective part
is defective
[Link] thermostat and replace
[Link] is defective
if necessary
[Link] temperature with
[Link] gauge or sensor
thermometer and repalce if
is defective
necessary
[Link] running [Link] load
[Link] injection timing [Link] to proper timing
[Link] fuel is used [Link] suitable fuel
[Link] the solenoid is not being
energized by a short in the
wiring. Check the linkage to the
[Link] or manual fuel
shutoff lever for [Link]
shutoff not closing
Engine will not shut off for the ability of the spring in the
solenoid to move the lever to the
shutoff position
[Link] running on fumes [Link] and isolate the source
drawn into air intake of fumes
[Link] is insufficient [Link] fuel
[Link] the air in fuel system
[Link] is mixed in fuel line
and check for suction leaks
Engine surges at idle [Link] and adjust low idle
[Link] speed is set too low
screw
[Link] water/sediment or
[Link] filter is clogged
change fuel filter

38
7.5 Alternator Trouble

Trouble Causes Remedies

[Link] the cut winding
[Link] is cut
and weld firmly
[Link] terminal is loose [Link] the wiring terminal
No voltage or voltage is
[Link] terminal is [Link] or replace the
insufficient while genset running
defective defective terminal
[Link] the speed and keep
[Link] is too low
the rated speed
[Link] is unstable [Link] the rated speed
Voltage is unstable [Link] AVR,and change if
[Link] is defective
necessary
[Link] runnig [Link] load
Alternator overheats [Link]-pipe inside the
[Link] and clean the inner
alternator is clogged
[Link] is too high [Link] the rated speed
Voltage is too high [Link] AVR,and change if
[Link] is defective
necessary
[Link] is too low [Link] the rated speed
Voltage is too low while running
[Link] AVR,and change if
without load [Link] is defective
necessary
[Link] setting is [Link] and adjust the
incorrect speed
Voltage is too low while running [Link] resistance of the
[Link] circuit on the rotor
without load circuit
[Link] of excitation [Link] resistance of the
is defective circuit
[Link] of magnetic field [Link] the cut winding,
is cut intertwist and weld firmly
Voltage disappears while [Link] of excitation is [Link] rotor,repair it and
running defective change if necessary
[Link] AVR,and change if
[Link] is defective
necessary

39
7.6 Battery Charge Trouble

Trouble Causes Remedies

[Link] post is defective [Link],or clean the post
[Link] post is connected
[Link] the connection post
incorrectly
No charge current
[Link] the wiring to the
[Link] mains supply
charger from mains supply
[Link] fuse is bad [Link] the fuse
Display nothing on the [Link] the current with
[Link] meter is bad
charge current meter the standard ampere meter
[Link] supply power is low [Link] mains supply
[Link] of the charge
transformer does not match [Link] to the plug of charger
Charge rate is too low
with the mains supply transformer
voltage
[Link] post is loose [Link] the battery post
[Link] of the fuse does not
[Link] the proper fuse
Fuse of mains supply is match
burned-out again [Link] and connect all
[Link] is short
wiring
[Link] post is defective [Link],or clean the post
Charge clip heats
[Link] of the clip is loose [Link] and tighten the bolt
[Link] is deteriorated [Link] the battery
Charge power does not
[Link] the battery, and
decrease [Link] has been damaged
change it if necessary

40
 FOREWORD

Thank you for purchasing our diesel generator set.

This manual contains information for the correct operation and maintenance of your genset. lt
also contains important safety and installation information,troubleshooting guidelines. Please
always keep this manual with the equipment.

Please operate this equipment after thoroughly reviewing and understanding the contents of
this manual.

This manual does not cover diesel engine and alternator maintenance procedures. Please
consult the engine and the alternator operation and maintenance manuals if necessary.

The information contained in this manual was based on the genset in production at the time of
publication. We reserve the right to change any portion of this information without notice.

Without express written permission from us, any part of this manual can not be reproduced in
any form or by any means.

△
! SAFETY SYMBOL
This symbol, the industry's "safety Alert Symbol", is used throughout this manual and on labels
on the machine itself to warn of the possibility of personal injury. Read these instructions
carefully. lt is essential that you read the instructions and safety regulation before you attempt
to assemble or use this unit.

△
It indicates a hazardous situation,which if not avoided,will
! DANGER result inserious injury or even death.

△
! WARNING
It indicates a hazardous situation ,which,if not avoided, could
result in serious injury or even death.

△ ! CAUTION
It indicates a hazardous situation,which if not avoided, could
result in minor or moderate injury.

△
! It indicates potential hazards which can cause injury.

It indicates additional information which is important to a

NOTE procedure.

41