ALLPOWER APG3201 User manual

6500WATTAIR-COOLED
DIESELGENERATOR

AIR-COOLED DIESEL GENERATOR
TABLE OF CONTENTS
Page number
Chapter 1 Technical Specifications and Data .......................................... 3
1-1 Technical specifications and data.................................................3
1-2 Basic operating instruction,s............................................................5
1-3 General dimensions and overview of generator ....................5
Chapter 2 Operating the Diesel Generator. .............................................7
2-1 Main points of safety during operation of the generator ...... 7
2-2 Preparation before operation .........................................................9
2-3 Checking the operation of the diesel engine ............................12
2-4 Starting the generator ......................................................................12
2-5 Procedures for starting the generator .......................................15
2-6 Proper operation of the generator ...............................................17
2-7 Loading ................................................................................................17
2-8 Stopping the generator ....................................................................19
Chapter 3 Maintenance ...................................................................................20
3-1 Maintenance schedules ...................................................................20
3-2 Storing for a long period of time ................................................22
Chapter 4 Troubleshooting .............................................................................23
4-1 troubleshooting procedures ...........................................................23
4-2 Questions and concerns .................................................................24
Chapter 5 Generator Parts Diagrams and Listings ............................24
Limited Warranty ...................................................................... 31
2

AIR-COOLED DIESEL GENERATOR
CHAPTER 1. TECHNICAL SPECIFICATIONS AND DATA
1-1 Technical specifications and data
CHANGFA Single-cylinder diesel generator
CFA6500CL_E_/CF
Rated frequency (Hz)
Rated voltage (V)
Rated output power
(kVA)
Max output power
(kVA)
Rated rotation speed
(rpm)
Power factor cos
Phase number
Pole number
Excitation
Transistorized
ATS type
Structure type
Fuel
consumption(g/kw.h)
Fuel tank capacity(L)
Continuour running
time(hr)(at rated
power)
Noise level
[dBA/7m](zero
load_full load)
Net weight (kg)
Overall dimension
(L_W_H)
A6500CX_E_
60
220_230_240_110
/220_115/230_120/2
40
4.5
5
3600
Single
2
self-excitation,
Brushless
without ATS
Open-frame
CFA6500CL_E_S
/CFA6500CX_E_S
60
380/220_400/230_420/240
4.5
5
3600
12.5 12.5
7.5 7.5
75 -79 75 -79
L_X:95; E:100 L_X:95_ E3:100
29" 19" 26.25" 29" 19" 26.25"
340340
Three
2
self-excitation constant voltage
(AVR)
without ATS
Open-frame

OWNER'S MANUAL
Starter system
Fuel type
Lube oil
Engine model
Engine type
Bore stroke(mm)
Displacement(cm3)
Compression ratio
Rated power [kW/rpm]
Rotation direction(from
the flywheel)
C: recoil starter
E: recoil starter/electric
0# (summer),_l 0#
(winter), _35#(chill
cold) diesel
SAE 15W 40
L_X:CFA186F
E:CFA186FE
Single-cylinder,4-
stroke,air-
cooled,vertical,diesel
engine 86 72
0.418
19_1
6.3/3600
clockwise
C: recoil starter
E: recoil starter/electric starter
0# (summer),_10# (winter),
_35#(chill cold) diesel
SAE 15W 40
L_X3:CFA186F
E3:CFA186FE
Single-cylinder,4 -stroke, air-
cooled,vertical,diesel engine
86 72
0.418
19_1
6.3/3600
clockwise
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OWNER'S MANUAL
1-2 Basic operating instructions
1-2.1 Under the given conditions, the generator will output the specified power in the table
listed below.
Table 1.
o
Height above sea level (ft) Ambient temperature (F) RH
o
0 +60 (+20 C) 60%
1-2.1 Under the given conditions, the generator will output the approximate
power in the table listed below.
Table 2
o
Height above sea level (ft) Ambient temperature (F) RH
<3280.8 (<1000 m) 41-104 (5-40 °C) 90%
1-3 General dimensions and overview of the generators
1-3.1 G CFA6500CL(X)E/CFA6500CL(X)ES
dimensions of the series generators
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OWNER'S MANUAL
CHAPTER 2 OPERATING THE DIESEL GENERATOR
2-1 General main points of safety during operation of the generator set.
In order to operate the generator set safely, please follow all the instructions provided
in this manual carefully. Doing so otherwise may lead to accidents and or equipment
damage.
2-1.1 Fire prevention
The proper fuel for the diesel generator set is light diesel fuel. Do not use gasoline,
kerosene and or other fuels other than light diesel fuel. Keep all flammable fuels
away from the generator as the generator may spark and ignite these gases. In order
to prevent fires from occurring and to provide enough ventilation for people and the
machine, keep the diesel generator at least 1.5 meters away from buildings and or
other equipment. Always operate your diesel generator on a level site. If the
generator is operated on an incline, the lubricating system within the engine will not
perform well and may lead to failure of the engine.
2-1.2 Prevention from inhaling exhaust gases
Never inhale exhaust gases emitted by the engine. The exhaust gases contain toxic
carbon monoxide. Never operate your generator in places with poor ventilation. In
order to operate this machinery indoors, a suitable ventilation system for the building
is required to draw the poisonous exhaust gases out.
2-1.3 Prevention from accidental burns
Never touch the muffler and its cover when the diesel engine is running. Never touch
the muffler and cover after the diesel engine has been used, as the muffler remains hot
for a long period of time.
2-1.4 Electric shock and short circuits
Never touch the generator if the generator is wet. Also never touch the generator if
your hand is wet. Never operate your generator if the weather conditions call for any
type of precipitation such as rain, snow, or fog. To prevent electrical shocks, the
generator should be grounded. Use a lead to connect the grounding end of the
generator to the grounding surface of choice. Please refer to Fig. 2-1 before
beginning to use the electric generator.
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OWNER'S MANUAL
Note: When connecting devices to the generator, make sure all other devices are
rated lower than the generators output. Any generator socket should not be
overloaded over its regulated limit
2-1.5 Other safety points
Before operating this generator, all operators should have a good knowledge of how
to break the circuit if any accidents occur. Also, all operators should be familiar with
all the switches and functions of the generator before using this machine. While
operating the generator, wear safe shoes and suitable clothes during operation.
Always keep children and animals away from the generator.
2-1.6 Battery
The electrolytic liquid of the battery also known as battery acid contains sulfuric acid.
In order to protect your eyes, skin, and clothing, wear protective gear when working
with the battery. If you come in contact with the electrolytic liquid, wash it
immediately with clean water. Also, if the electrolytic liquid comes in contact with
your eyes, see a doctor immediately.
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OWNER'S MANUAL
2-2 Preparation before operation
2-2.1 Fuel choices and fuel treatment
Fuel tank
Use only light diesel fuel. The fuel should be filtered clean. Never let dust and
water mix with fuel in the fuel tank. Otherwise it will clog the fuel lines and oil
nozzles. It may also damage your pressure pump.
Note: It is dangerous to overfill the fuel tank. Never exceed the red piston in the
filter.
Type
The effective volume
tank:(L)
(US gal)
CFA6500
APG3201 CXES
of fuel 12.5
3.3 12.5 3.3
a. After purchasing fuel, put it into a
drum and let it sit for 3-4 days.
b. 3-4 days later, insert half of the fuel
siphon into the drum, (water and
impurities stay in the lower portion
of the drum) b
Air filter element
Do not wash the air filter. The element is made of dry material, which does not
permit washing. When the output of the diesel engine is bad or the color of the
exhaust gas is abnormal, replace the air filter element. Never start the diesel engine
without the air filter.
staR:/run
Note:
Never smoke near the opening of the fuel tank.
Do not let sparks get near the fuel or fuel tank
and do not overfill tank. After filling, tighten the
fuel cap.
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OWNER'S MANUAL
2-2.2 Filling engine oil
Remove the dipstick from the engine
Make sure the generator is on level ground, and fill the engine with 15W40 engine oil.
Put the dipstick back into the hole to check the engine oil level.
it(H)
_t(L)
_ 45 _ _ _8_ii'_
2_NN
CFA186F Ciass fication of ma*n_e_mr_ce ![o ARk diesel
en_{_e
I_r,_'_v_oW Be sure _o u_ oil GRADE CD or be_ter tnar_
CD
Engine oil is the most important factor in determining the life of your generator
engine. If you use poor engine oil or if you don't change the oil regularly, the piston
and cylinder will wear easily or seize up. Also, the life of the other parts in your
engine such as bearings, and other rotating parts will shorten considerably.
FIRST USE
eve_ 3 r_hs o_ 2_]houts
IntervsI of Oha_i_g Machine Oi_
Although there is an oil sensor that checks for low oil pressure, it is always a good
idea to check the amount of oil inside the engine. If the oil level is low, fill it before
starting the engine. A good time to drain the oil from the engine is when the diesel
engine is warm. If the engine is fully cooled, it is more difficult to drain all the oil out
or some impurities will remain in the engine.
bot[ 1odrain abrica_ing oil bol_ to drain tubricatir_g o,il
[Warning: Don't fill engine oi_when diese_ is operating, ]
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OWNER'S MANUAL
2-2.3 Checking the air filter
fiRercore
(1) Loosen the butterfly nut, take the cover of the air
filter off and take the air filter element out.
Do not wash the air filter element.
When the performance of the engine decreases or
when the color of the exhaust gases is bad, exchange
the filter element. Never start the engine without the
air filter as foreign objects may enter the intake and damage the engine.
Use dry compressed air (with pressure about 28 PSI to blow the dust out in
the electric control cabinet and at the surface of the generator. Check to see
how clean the surface of the sliding ring is. Check the pressure of the carbon
brush. Also, check whether the position of the carbon brush at the slide rig is
correct and the fixture is reliable with a good contact.
2-2.5 The fuel and oil in a new engine is drained before sold. Before you start the
engine, please fill the fuel tank and engine oil first.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure oil switch.
CF diesel engines have a low-pressure sensor system where if the oil pressure
drops too low, the sensor will shut the engine off. The purpose of having this
system is to ensure that the engine does not seize up. If there is not enough oil
in the engine, the temperature of the oil will be raised too high. On the
contrary, if there is too much oil in the engine, the engine oil can slow the
engine down considerably.
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OWNER'S MANUAL
2-3.3 Engine break in
When you purchase a brand new engine, the engine must be properly broken
in. The break in period is about 20 hours.
(1) Avoid overloading the engine when brand new
(2) Change the engine oil according to specifications. An oil change for a
brand new engine is about 20 hours or every month, an older engine, the
oil change is about 100 hours or three months.
2-4 Starting the generator set
2-4.1 Manual starting.
Start the engine in accordance with procedures below:
(1) Put the fuel switch in the "On" position.
(2) Turn the handle of the engine to the
"RUN" position. _p_e_
(3) Pull the recoil starter handle out until
you feel resistance. It will reset to its original
automatically. The handle
should be reset into its recoil device slowly to
prolong the life of the engine starter.
(4) In cold climate, it is difficult to start the engine. Rubberplu9,
To remedy this, pull the rubber plug out from the
rocker of the diesel engine and fill 1/2 a cap full of engine
oil. Before starting, put the rubber plug back in
place. If you don't put the rubber plug back in place,
position
rain, dust and other dirt can enter into the diesel engine. It will cause the parts inside the
diesel engine to wear quickly and lead to engine failure.
2-4.2 Electric starting
The procedures for preparing to start the engine are the same as the manual starting
engine. 2-4.3 Battery
1. Insert key into ignition and put it in the "off" position.
2. Put the speed handle in the "Run" position.
3. Turn the start switch clockwise to the "START" position; to set the silent
type, first turn it clockwise to the "RUN" (ON) position for 1-2 seconds.
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OWNER'S MANUAL
The electromagnetic iron will be triggered, now turn it clockwise to the "START"
position.
4. After the diesel engine is started, remove your hand from the switch handle; the
switch will automatically reset itself to the "ON" position.
5. If the engine is not starting after 10 seconds of cranking, wait about 15 seconds
before trying it again. If you crank to long, the voltage of the battery will drop. This
can lead to improper ignition. When the diesel engine is operating, let the ignition
retain on the "ON" position.
Note:
If you crank the starter to long, the battery may be drained too much to provide
enough energy for proper engine ignition. Also, when the diesel engine is
operating, let the key retain in the "ON" position.
Important Notice:
All of our units come with a dry battery for shipping
safety purposes. In order to get your generator started
for the first time; the battery must be filled with
battery acid which can be purchased at a local
automotive supply store and slowly charged (trickle
charged) for a day.
To properly maintain your battery; check the height of the battery acid once a month.
If the level of the liquid drops too low, fill it with distilled water until it reaches the
high mark. If there is not enough battery acid, then the diesel engine cannot be
started. It is important to keep the liquid level between the high and low limits.
If the level in the battery is to high, the liquid may flow out and end up on
surrounding parts resulting in corrosion of these parts.
Note: Avoid too much or too little of battery acid. Check and fill it once a month
if necessary.
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OWNER'S MANUAL
2-5 Procedures for starting the generator
This procedure applies to the CF series recoil starting style models.
Open the fuel valve I
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OWNER'S MANUAL
]4

OWNER'S MANUAL
2-6 Proper operation of the generator
2-6.1 Operating the diesel engine
1. Pre-heat the diesel engine for 3
minutes under no load conditions.
.
.
First check the height of the
lubricating oil level, if it is
low, refill it. Our diesel
engines are equipped with
an oil switch that will
notify you if the oil pressure
is too low. The system will
shut down the engine if the oil
pressures too low.
Fuel adjustment bolt SD:ed handle
Do not adjust the speed limit
regulation bolt or the fuel adjustment
bolt.These bolts have been set by the |tigh_pressurefuel Fueladjusm_entbolt
factory already, changing them will affect the properties of the engine
performance.
2-6.2 Checks during engine operation
1. Check to see if there are abnormal noises.
2. Check to see if the performance is good or bad
3. Check the color of the exhaust gases (whether it is too black or too white).
If any of these conditions exist, stop the engine and find the cause of the
problem. If no problems are found, please contact your local dealer or our
nearest company branch.
2-7 Loading
2-7.1 Load conditions
Exert loads in accordance with the specified parameters.
2-7.2 Output of electricity
1. Raise the revolutions per minute (turn the speed handle to the max setting) of the
generator to get the maximum power out of the generator. If not, the
automatic voltage regulator device will excite and doing this for long periods of time
will cause the AVR to burn. For the rated speed of the generator, please refer to
Chapter 1, item 1-1 technical specification and data.
2. Observe the pointer of the voltmeter, it should point to 240 (60Hz). Meanwhile
put the switch in the GEN (generator) position. The AC voltage from the socket of
the power supply can be output.
3. When connecting devices to the generator, make sure to connect these devices in order.
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OWNER'S MANUAL
Connect the large loads onto the generator first. If everything is functional, smaller loads can then
be added. If the generator shuts off, it may be because the load being drawn by all the various
devices are too high. In this event, decrease the number of small devices until everything is
functional. The total drawn power should not exceed the maximum output power of the generator.
Please see Table 1-1 for technical specifications of what the generator can output. In order to reset
the generator after overdrawn power, let it sit for several minutes. If the indication of the
voltmeter is too high or too low, adjust the speed accordingly. If there are problems, stop the
generator immediately and fix the issue.
4. During operation, the generator should be in a place that has very good ventilation.
Never cover the engine to solve a ventilation problem, as this will damage your
equipment.
Note: Do not start more than two devices simultaneously. Each device should be
started one by one to prevent overloading the generator.
The generator should be running at 3600 revolutions per minute in order to
achieve the (60 Hz) frequency. The speed of the engine can be adjusted from the
speed governor.
2-7.3 Charging the battery
1. For the electric starter on the generator sets, the 12V battery is automatically
charged through the regulator on the side of the engine when it is running.
2. If the generator is not used for long periods of time, the battery should be
disconnected to avoid energy loss from the battery.
3. Do not connect the negative and positive terminals of the battery together at any
time. Doing so will cause the battery to explode and cause serious injuries.
4. Do not reverse the polarities when attaching the battery cables to the battery.
Doing so will damage both the battery and the electric starter.
5. When charging the battery, the battery produces flammable gases. Do only on well
ventilated area.
Do not smoke, let flames, and sparks get near the battery while it is charging as
this may cause a fire.
To avoid sparking while connecting the cables to the battery, first, connect the cables
to the battery then to the motor. To disconnect battery cables, first disconnect the
motor end of the cable.
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OWNER'S MANUAL
2-8 Stopping the generator
1. Take the electrical load of f the
generator
2. Put the speed handle in the "RUN"
position and let the engine run for 3
minutes after unloading. Do not stop the
engine immediately let it warm down.
Stopping the diesel engine suddenly may
the temperature of the engine abnormally
lock the nozzle and damage the diesel
engine.
ft_÷H switch
1. If the speed handle is in the "Stop position and the engine is still running, turn the
fuel switch to the "OFF" position or loosen the high pressure oil pipe nut. The engine
could be stopped more than one-wayother than the speed handle way.
2. If you cannot stop the engine with a load on it, then remove the load first than stop
the engine.
3. Press down on the brake handle
4. If equipped with an electric starter, turn the key to the "Of t7'position
5. Put the fuel handle to the "S" position
6. Finally, pull slowly on the recoil handle until you feel resistance (this is when the
piston is on the compression stroke, where the intake and exhaust valves are closed).
What this does is prevent the engine from rusting when not in use.
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OWNER'S MANUAL
CHAPTER 3 MAINTENANCE
3-1 Maintenance schedules
Keeping your generator well maintained will prolong the life of your generator. Everything needs to be
checked including the diesel engine, generator, control cabinet, and frame.
Betbre starting the maintenance, make sure the diesel engine is off:
Please refer to the Table 3-1 for the proper maintenance schedule.
lteli1
Check the fuel level and
refill
Drain the fuel tank
Check and fill enough
engine oil
Clean the fuel filter
Check fuel oil leakage
Check and screw each
fastered part
Check iniector
Check iniection pump
Cheak fuel pipe
Check the lube. oil level in
the oil pan and refill
Replace the lube. oil
Clean lube. Oil filter
Check the air cleaner
element
Chan_e the core of air filter
Check the battery liquid
level and refill
Adjusting the intake and
exhaust valve clearance
Grind air intake and air
exhausted _ate
Exchange piston rin_
Check electric brush and
slide rin_
Check insulation resistance
Everyday
Before
startin_
after every
operatin_
before
startin_
After 1 month
or 50hours
the first time
the first time
the first time
Every 3 month or
200 hours
the second time and
afterward
the second time and
afterward
the second time and
afterward
If damaged or smeary, chan_e it in time
Every 6 month or 400
hours
screw the bolt of
cylinder head firmly
If necessary exchange
it
the second time and
the first time afterward
The time of stop is over 10 days
Every lyear or
1000 hours
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OWNER'S MANUAL
3-1.1 Changing the engine oil (every 200 hours)
High-pressure fuel pipe bol
Oil drain bolt
Take the oil cover off. Remove the oil
drain plug when the diesel engine is still
hot. Be careful of hot oil and hot engine
as you may get burned. The bolt is
located at the bottom of the cylinder.
Dipstick After draining the oil, put the bolt back
and tighten it. Then fill with the proper
engine oil to the proper level.
3-1.2 Air filter maintenance schedule
1. Clean air-filter every 6 months or 400 hours of operation.
2. If necessary, exchange it.
Note: 3. Do not use detergent to clean air filter element.
Never start the engine without the air filter
This can cause serious damage to the engine if
foreign objects enter the intake system.
Always change the air filter on time.
3-1.3 Fuel filter maintenance
1. The fuel filter should be cleaned often to keep the engine running at maximum
performance.
2. The recommended time period for cleaning the fuel filter is 6 months or 400
hours of operation.
a. To do this, first drain the fuel from the fuel tank.
b. Loosen the small screws on the fuel switch and remove the fuel filter
form the port. Use diesel fuel to clean the fuel filter. Also, remove the
fuel injector and clean the carbon deposit around it. The recommended
time period for this is 3 months or 200 hours.
3-1.4 Cylinder head bolt tensions
The cylinder head bolts should be tightened to specifications please refer to the
diesel engine manual for specifications and the special tools required to do
this.
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OWNER'S MANUAL
3-1.5 Battery check
Make sure the battery acid is full. The engine uses a 12V battery. Due to
numerous starting cycles, the battery acid may be used up. Also, before
filling, verify that the battery is not damaged in any way. Add distilled water
to the battery when filling. Perform checks on the battery once a month.
3-2 Storing for long periods of time
If your generator needs to be stored for long periods of time, the following
preparations should be made.
1. Start the diesel engine for 3 minutes then stop it.
2. When the engine is still warm, change the engine oil with new engine oil of the
proper grade.
3. Pull the rubber plug out of the cylinder head cover and put 2CC of lubricating
oil in it, then cover the plughole up again.
4. For manual starting generator welders, press the decompression handle down
and pull the recoil handle 2 or 3 times. This pushes the intake out. (Do not
start the engine)
5. For electric started generator welders, press the decompression handle down
and crank the engine for 2-3 seconds. To do this, put the starter switch in the
"Start" position. (Do not start the diesel engine)
6. Finally, pull the recoil starter until you feel resistance; this is when the piston is
on the compression stroke where the intake and exhaust valves are closed.
Having the intake and exhaust valves closed will prevent rust, as moisture
cannot get inside the combustion chamber.
7. Clean the engine and store it in a dry place.
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