Daewoo DDAE6000XE User manual
Manufactured under license of Daewoo International Corporation, Korea
www.daewoopowerproducts.com
USER'S MANUAL
DDAE6000XE
Diesel generator
INDEX
1. TECHNICAL SPECIFICATIONS AND DATA
.......................................................................................... 3
2. OPERATING THE DIESEL GENERATOR
............................................................................................... 4
3. MAINTENANCE
................................................................................................................................... 14
4. TROUBLESHOOTING
........................................................................................................................... 17
5. PART LISTINGS
.................................................................................................................................... 18
6. REMOTE CONTROL INSTRUCTIONS
................................................................................................. 23
WARRANTY ............................................................................................................................................... 24
1
EN
The following manual is only a guide to assist you and is not a complete or comprehensive manual
of ali aspects of maintaining and repairing your generator. The equipment you have purchas d is a
complex piece of machinery. We recommend that you consult with a dealer if you have doubts or
concerns as to your experience or ability to properly maintain or repair your equipment. You will
save time and the inconvenience of having to go back to the store if you choose to write or call us
concerning missing parts, service question ,operating ad vice, and/or assembly questions.
Our air-cooled diese) generators have sorne of the following feature:
• Lightweight construction
• Air cooled
• Four-stroke diesel internal combustion engine
• Direct fuel injection system
• Recoil starter or an optional electric starter
• Large fuel tank
• Automatic voltage stabilizer
• NFB circuit protector
• AC and DC outputs
• Low oil pressure sensor
The air-cooled diese! generators are widely used when electrical power is scarce. Our generators
provide a portable mobile solution in supplying power for field operations during project construc-
tion. Sorne other known applications include pipeline construction and metal welding when electri-
cal power is not available.
This manual will explain how to operate and service your generator set.
lf you have any questions or suggestions about this manual. please contact your local dealer or us
directly. Consumers should notice that this manual might differ slightly from the actual product as
more improvements are made to our products. Some of the pictures in this manual may differ slight-
ly Jrom the actual product as well. We reserves the right to make changes at any time without notice
and without incurring any obligation.
1. TECHNICAL SPECIFICATIONS AND DATA
Engine Type: Single cylinder, Vertical, 4 Stroke, Direct injection, Air-cooled
Displacement: 418 cc
Max power: 5.5 kW
Rated power: 5.0 kW
Engine power: 10 hp / 3000 rpm
Speed: 3000 rpm
Bore×stroke: 86×72 mm
Fuel tank capacity: 13.5 L
Oil tank capacity: 1.65 L
Compression ratio: 19:01
Starting system: Recoil + Electric Start
Starting motor capacity: 12 V - 0.8 kW
Charging generator capacity: 12 V - 8.3 A
Battery capacity: 12 V - 30 Ah
Fuel consumption: 370 g/kW.h
Continuous running time: 5.5 hr
Noise level (7m): 77 dB(A)
Insulation grade: F
1-2 Basic parameters
1-2.1 Under the given conditions, the generator will output the specified power in the table listed
below.
Table 1. The generator should output its rated power under these conditions
Height above sea level(in) Ambient temperature (F) Relative humidity (%)
o +60 (+20 °C) 60%
Table 2. The generator should output reliable work and its stipulated power
Altitude height (in) Ambient temperature (F) Relative humidity (%)
< 39370.08 ( 1000m) 41-104 (5-40 °C) 90%
1-3 General dimensions and overview of the generators
1-3.1 General dimensions of the of the DDAEXE series generators
2
The following manual is only a guide to assist you and is not a complete or comprehensive manual
of ali aspects of maintaining and repairing your generator. The equipment you have purchas d is a
complex piece of machinery. We recommend that you consult with a dealer if you have doubts or
concerns as to your experience or ability to properly maintain or repair your equipment. You will
save time and the inconvenience of having to go back to the store if you choose to write or call us
concerning missing parts, service question ,operating ad vice, and/or assembly questions.
Our air-cooled diese) generators have sorne of the following feature:
• Lightweight construction
• Air cooled
• Four-stroke diesel internal combustion engine
• Direct fuel injection system
• Recoil starter or an optional electric starter
• Large fuel tank
• Automatic voltage stabilizer
• NFB circuit protector
• AC and DC outputs
• Low oil pressure sensor
The air-cooled diese! generators are widely used when electrical power is scarce. Our generators
provide a portable mobile solution in supplying power for field operations during project construc-
tion. Sorne other known applications include pipeline construction and metal welding when electri-
cal power is not available.
This manual will explain how to operate and service your generator set.
lf you have any questions or suggestions about this manual. please contact your local dealer or us
directly. Consumers should notice that this manual might differ slightly from the actual product as
more improvements are made to our products. Some of the pictures in this manual may differ slight-
ly Jrom the actual product as well. We reserves the right to make changes at any time without notice
and without incurring any obligation.
1. TECHNICAL SPECIFICATIONS AND DATA
Engine Type: Single cylinder, Vertical, 4 Stroke, Direct injection, Air-cooled
Displacement: 418 cc
Max power: 5.5 kW
Rated power: 5.0 kW
Engine power: 10 hp / 3000 rpm
Speed: 3000 rpm
Bore×stroke: 86×72 mm
Fuel tank capacity: 13.5 L
Oil tank capacity: 1.65 L
Compression ratio: 19:01
Starting system: Recoil + Electric Start
Starting motor capacity: 12 V - 0.8 kW
Charging generator capacity: 12 V - 8.3 A
Battery capacity: 12 V - 30 Ah
Fuel consumption: 370 g/kW.h
Continuous running time: 5.5 hr
Noise level (7m): 77 dB(A)
Insulation grade: F
1-2 Basic parameters
1-2.1 Under the given conditions, the generator will output the specified power in the table listed
below.
Table 1. The generator should output its rated power under these conditions
Height above sea level(in) Ambient temperature (F) Relative humidity (%)
o +60 (+20 °C) 60%
Table 2. The generator should output reliable work and its stipulated power
Altitude height (in) Ambient temperature (F) Relative humidity (%)
< 39370.08 ( 1000m) 41-104 (5-40 °C) 90%
1-3 General dimensions and overview of the generators
1-3.1 General dimensions of the of the DDAEXE series generators
3
EN
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 a11 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 l .5meters 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 monoxi-
de.Never operate your generator in places with poor ventilation.ln 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 bums
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 good 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. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
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, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions 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 elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
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.
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 sucker into the drum (water and impurities stay in the lower
portion of the drum).
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.
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.
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining 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 part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING: Don't fill engine oil when diesel is operating.
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to 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.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )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
Fig. 2-1 Fig. 2-2
4
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 MΩmeter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 MΩ. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to 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.
2-3.2 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 oíl 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.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, 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 eh 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. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf 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: Ali 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 filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you 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.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
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 a11 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 l .5meters 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 monoxi-
de.Never operate your generator in places with poor ventilation.ln 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 bums
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 good 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. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
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, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions 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 elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
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.
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 sucker into the drum (water and impurities stay in the lower
portion of the drum).
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.
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.
2000
Series
3000
Series
6000
Series
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining 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 part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING: Don't fill engine oil when diesel is operating.
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to 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.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )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
a
Gearlever
Stop Start/run
b
5
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 MΩmeter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 MΩ. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to 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.
2-3.2 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 oíl 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.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, 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 eh 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. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf 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: Ali 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 filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you 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.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
EN
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 a11 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 l .5meters 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 monoxi-
de.Never operate your generator in places with poor ventilation.ln 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 bums
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 good 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. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
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, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions 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 elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
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.
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 sucker into the drum (water and impurities stay in the lower
portion of the drum).
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.
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.
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining 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 part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING: Don't fill engine oil when diesel is operating.
Time to change engine oil
Every 3 months or 1000 hoursAbout 1 month or 20 hours
6000 Series3000 Series2000 Series
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to 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.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )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
High limit (H)
Low limit (H)
Applicable limit
Recommended value
Working temperature
Dipstick
Dipstick
Bolt to drain lubricating oil Bolt to drain lubricating oil
6
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 MΩmeter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 MΩ. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to 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.
2-3.2 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 oíl 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.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, 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 eh 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. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf 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: Ali 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 filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you 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.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
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 a11 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 l .5meters 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 monoxi-
de.Never operate your generator in places with poor ventilation.ln 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 bums
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 good 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. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
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, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions 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 elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
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.
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 sucker into the drum (water and impurities stay in the lower
portion of the drum).
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.
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.
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining 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 part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING: Don't fill engine oil when diesel is operating.
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to 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.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )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
Indicating Hours Automatic air
AC output socket
Fuse
DC
7
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 MΩmeter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 MΩ. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to 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.
2-3.2 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 oíl 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.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, 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 eh 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. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf 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: Ali 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 filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you 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.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
EN
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 a11 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 l .5meters 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 monoxi-
de.Never operate your generator in places with poor ventilation.ln 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 bums
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 good 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. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
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, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions 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 elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
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.
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 sucker into the drum (water and impurities stay in the lower
portion of the drum).
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.
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.
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining 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 part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING: Don't fill engine oil when diesel is operating.
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to 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.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )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
8
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 MΩmeter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 MΩ. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to 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.
2-3.2 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 oíl 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.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, 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 eh 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. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf 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: Ali 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 filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you 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.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
Fuel switch
Speed handle
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 a11 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 l .5meters 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 monoxi-
de.Never operate your generator in places with poor ventilation.ln 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 bums
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 good 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. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
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, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions 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 elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
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.
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 sucker into the drum (water and impurities stay in the lower
portion of the drum).
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.
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.
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining 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 part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING: Don't fill engine oil when diesel is operating.
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to 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.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )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
9
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 MΩmeter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 MΩ. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to 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.
2-3.2 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 oíl 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.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, 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 eh 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. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf 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: Ali 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 filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you 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.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
Speed handle
High limit of liquid level
EN
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 a11 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 l .5meters 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 monoxi-
de.Never operate your generator in places with poor ventilation.ln 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 bums
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 good 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. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
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, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions 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 elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
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.
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 sucker into the drum (water and impurities stay in the lower
portion of the drum).
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.
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.
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining 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 part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING: Don't fill engine oil when diesel is operating.
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to 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.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )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
10
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 MΩmeter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 MΩ. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to 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.
2-3.2 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 oíl 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.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, 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 eh 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. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf 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: Ali 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 filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you 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.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
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 a11 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 l .5meters 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 monoxi-
de.Never operate your generator in places with poor ventilation.ln 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 bums
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 good 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. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
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, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions 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 elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
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.
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 sucker into the drum (water and impurities stay in the lower
portion of the drum).
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.
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.
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining 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 part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING: Don't fill engine oil when diesel is operating.
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to 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.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )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
11
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 MΩmeter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 MΩ. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to 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.
2-3.2 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 oíl 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.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, 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 eh 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. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf 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: Ali 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 filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you 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.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
EN
12
2-6 Proper operation of the generator set
2-6. 1 Operating the diesel engine
1. Pre-heat the diesel engine for 3 minutes under no load conditions.
2. Pirst check the height of the Iubricating oil l vel, if it is low, refill it. Our diese! engines are equi-
pped with an alarm system that will notify you if the oil pressure is to low. The alarm system will shut
down the engine if the oil pressure is too low.
3. Do not adjust the speed limit regulation bolt or the fuel adjustment bolt. These bolts have been
set by the factory airead y, changing them will affect the porperties 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 condi-
tions exist, stop the engine and find the cause of the problem. lf 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. lf not, the automatic voltage regulator device will excite
and doing this for long periods of time will cause the capacitor to bum. For the rated speed of the
generator, please refer to Chapter 1, item 1-1 technical specification and data. Observe the pointer
of the voltmeter, it should poin t to 230V ± 5%
2. (50 Hz). (For 60 Hz set, it will be 240V ± 5%). 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. 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 ali 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, Jet it sit for severa} 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.
Table 2-1
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 (60Hz)
frequenty. The speed of the engine can be adjusted from the speed governor.
2-7 .3 Charging the battery
l. For the electric starter on the generator, 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 damage the battery.
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 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.
2-8 Stopping the generator
1. Take the electrical load off 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 diesel engine immediately let it warm down. Stopping the diesel engine suddenly
may raise the temperature of the engine abnormally and lock the nozzle and damage the diesel
engine. Press down on the brake handle.
NOTE: 1. If the speed handle is in the "Stop" position and the engine is switch running, tum the fuel
sitch to the "OFF" position or loosen the high pressure oil pipe nut. The engine could be stopped
more than one-way other than the speed handle way.
2. lf you cannot stop the engine with a load on it, then remove the load first than stop the engine.
3. If equipped with an electric starter, turn
4. the key to the "Off' position. Put the fuel handle to the "S" position.
5. Finally, pull slowly on the recoil handle
6. Until you feel resistance (this is when the piston is on the compression stroke, where the intake
and exhaust val ves are closed). What this does is prevent the engine from rusting when not in use.
3. MAINTENANCE
3-1 Maintenance schedules
Kepping your generator well maintained will prolong the life of your generator. Everything needs to
be checked including the diesel engine, welder, generator, control cabinet, and frame. For overhau-
ling procedures, please refer to the instruction manual of the relative subassembly. If you need
these manuals, plsaes call our company and we will send you one.
Before starting the maintenance, make sure the diesel engine is off.
Pleaes refer to the Table 3-1 for the proper maintenance schedule.
Table 3-1. Maintenance schedulefor diesel generator set.
Note: "• "mark indicates that it needs special wrench, please contact with dealer.
3- l .1 Changing the engine oil (every 100 hours)
Take the oil cover out.Remove the oil drain plug when the diesel engine is still hot. Be careful of hot
oil and hot engine as you may get bumed. The bolt i located at the bottom of the cylinder. After
draining the oil, put the bolt back and tighten it. Then fill with the proper engine oil to the proper
level.
Fuel adjustment bolt
Fuel adjustment bolt
Fuel adjustment bolt
High-pressure
fuel pipe nut
Speed limit bolt
13
2-6 Proper operation of the generator set
2-6. 1 Operating the diesel engine
1. Pre-heat the diesel engine for 3 minutes under no load conditions.
2. Pirst check the height of the Iubricating oil l vel, if it is low, refill it. Our diese! engines are equi-
pped with an alarm system that will notify you if the oil pressure is to low. The alarm system will shut
down the engine if the oil pressure is too low.
3. Do not adjust the speed limit regulation bolt or the fuel adjustment bolt. These bolts have been
set by the factory airead y, changing them will affect the porperties 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 condi-
tions exist, stop the engine and find the cause of the problem. lf 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. lf not, the automatic voltage regulator device will excite
and doing this for long periods of time will cause the capacitor to bum. For the rated speed of the
generator, please refer to Chapter 1, item 1-1 technical specification and data. Observe the pointer
of the voltmeter, it should poin t to 230V ± 5%
2. (50 Hz). (For 60 Hz set, it will be 240V ± 5%). 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. 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 ali 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, Jet it sit for severa} 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.
Table 2-1
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 (60Hz)
frequenty. The speed of the engine can be adjusted from the speed governor.
2-7 .3 Charging the battery
l. For the electric starter on the generator, 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 damage the battery.
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 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.
2-8 Stopping the generator
1. Take the electrical load off 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 diesel engine immediately let it warm down. Stopping the diesel engine suddenly
may raise the temperature of the engine abnormally and lock the nozzle and damage the diesel
engine. Press down on the brake handle.
NOTE: 1. If the speed handle is in the "Stop" position and the engine is switch running, tum the fuel
sitch to the "OFF" position or loosen the high pressure oil pipe nut. The engine could be stopped
more than one-way other than the speed handle way.
2. lf you cannot stop the engine with a load on it, then remove the load first than stop the engine.
3. If equipped with an electric starter, turn
4. the key to the "Off' position. Put the fuel handle to the "S" position.
5. Finally, pull slowly on the recoil handle
6. Until you feel resistance (this is when the piston is on the compression stroke, where the intake
and exhaust val ves are closed). What this does is prevent the engine from rusting when not in use.
3. MAINTENANCE
3-1 Maintenance schedules
Kepping your generator well maintained will prolong the life of your generator. Everything needs to
be checked including the diesel engine, welder, generator, control cabinet, and frame. For overhau-
ling procedures, please refer to the instruction manual of the relative subassembly. If you need
these manuals, plsaes call our company and we will send you one.
Before starting the maintenance, make sure the diesel engine is off.
Pleaes refer to the Table 3-1 for the proper maintenance schedule.
Table 3-1. Maintenance schedulefor diesel generator set.
Note: "• "mark indicates that it needs special wrench, please contact with dealer.
3- l .1 Changing the engine oil (every 100 hours)
Take the oil cover out.Remove the oil drain plug when the diesel engine is still hot. Be careful of hot
oil and hot engine as you may get bumed. The bolt i located at the bottom of the cylinder. After
draining the oil, put the bolt back and tighten it. Then fill with the proper engine oil to the proper
level.
Speed handle
EN
14
2-6 Proper operation of the generator set
2-6. 1 Operating the diesel engine
1. Pre-heat the diesel engine for 3 minutes under no load conditions.
2. Pirst check the height of the Iubricating oil l vel, if it is low, refill it. Our diese! engines are equi-
pped with an alarm system that will notify you if the oil pressure is to low. The alarm system will shut
down the engine if the oil pressure is too low.
3. Do not adjust the speed limit regulation bolt or the fuel adjustment bolt. These bolts have been
set by the factory airead y, changing them will affect the porperties 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 condi-
tions exist, stop the engine and find the cause of the problem. lf 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. lf not, the automatic voltage regulator device will excite
and doing this for long periods of time will cause the capacitor to bum. For the rated speed of the
generator, please refer to Chapter 1, item 1-1 technical specification and data. Observe the pointer
of the voltmeter, it should poin t to 230V ± 5%
2. (50 Hz). (For 60 Hz set, it will be 240V ± 5%). 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. 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 ali 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, Jet it sit for severa} 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.
Table 2-1
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 (60Hz)
frequenty. The speed of the engine can be adjusted from the speed governor.
2-7 .3 Charging the battery
l. For the electric starter on the generator, 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 damage the battery.
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 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.
2-8 Stopping the generator
1. Take the electrical load off 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 diesel engine immediately let it warm down. Stopping the diesel engine suddenly
may raise the temperature of the engine abnormally and lock the nozzle and damage the diesel
engine. Press down on the brake handle.
NOTE: 1. If the speed handle is in the "Stop" position and the engine is switch running, tum the fuel
sitch to the "OFF" position or loosen the high pressure oil pipe nut. The engine could be stopped
more than one-way other than the speed handle way.
2. lf you cannot stop the engine with a load on it, then remove the load first than stop the engine.
3. If equipped with an electric starter, turn
4. the key to the "Off' position. Put the fuel handle to the "S" position.
5. Finally, pull slowly on the recoil handle
6. Until you feel resistance (this is when the piston is on the compression stroke, where the intake
and exhaust val ves are closed). What this does is prevent the engine from rusting when not in use.
3. MAINTENANCE
3-1 Maintenance schedules
Kepping your generator well maintained will prolong the life of your generator. Everything needs to
be checked including the diesel engine, welder, generator, control cabinet, and frame. For overhau-
ling procedures, please refer to the instruction manual of the relative subassembly. If you need
these manuals, plsaes call our company and we will send you one.
Before starting the maintenance, make sure the diesel engine is off.
Pleaes refer to the Table 3-1 for the proper maintenance schedule.
Table 3-1. Maintenance schedulefor diesel generator set.
Note: "• "mark indicates that it needs special wrench, please contact with dealer.
3- l .1 Changing the engine oil (every 100 hours)
Take the oil cover out.Remove the oil drain plug when the diesel engine is still hot. Be careful of hot
oil and hot engine as you may get bumed. The bolt i located at the bottom of the cylinder. After
draining the oil, put the bolt back and tighten it. Then fill with the proper engine oil to the proper
level.
Fuel switch
Fuel switch
Loose the nut
(nut of high pressure
oil pipe)
15
2-6 Proper operation of the generator set
2-6. 1 Operating the diesel engine
1. Pre-heat the diesel engine for 3 minutes under no load conditions.
2. Pirst check the height of the Iubricating oil l vel, if it is low, refill it. Our diese! engines are equi-
pped with an alarm system that will notify you if the oil pressure is to low. The alarm system will shut
down the engine if the oil pressure is too low.
3. Do not adjust the speed limit regulation bolt or the fuel adjustment bolt. These bolts have been
set by the factory airead y, changing them will affect the porperties 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 condi-
tions exist, stop the engine and find the cause of the problem. lf 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. lf not, the automatic voltage regulator device will excite
and doing this for long periods of time will cause the capacitor to bum. For the rated speed of the
generator, please refer to Chapter 1, item 1-1 technical specification and data. Observe the pointer
of the voltmeter, it should poin t to 230V ± 5%
2. (50 Hz). (For 60 Hz set, it will be 240V ± 5%). 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. 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 ali 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, Jet it sit for severa} 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.
Table 2-1
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 (60Hz)
frequenty. The speed of the engine can be adjusted from the speed governor.
2-7 .3 Charging the battery
l. For the electric starter on the generator, 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 damage the battery.
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 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.
2-8 Stopping the generator
1. Take the electrical load off 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 diesel engine immediately let it warm down. Stopping the diesel engine suddenly
may raise the temperature of the engine abnormally and lock the nozzle and damage the diesel
engine. Press down on the brake handle.
NOTE: 1. If the speed handle is in the "Stop" position and the engine is switch running, tum the fuel
sitch to the "OFF" position or loosen the high pressure oil pipe nut. The engine could be stopped
more than one-way other than the speed handle way.
2. lf you cannot stop the engine with a load on it, then remove the load first than stop the engine.
3. If equipped with an electric starter, turn
4. the key to the "Off' position. Put the fuel handle to the "S" position.
5. Finally, pull slowly on the recoil handle
6. Until you feel resistance (this is when the piston is on the compression stroke, where the intake
and exhaust val ves are closed). What this does is prevent the engine from rusting when not in use.
3. MAINTENANCE
3-1 Maintenance schedules
Kepping your generator well maintained will prolong the life of your generator. Everything needs to
be checked including the diesel engine, welder, generator, control cabinet, and frame. For overhau-
ling procedures, please refer to the instruction manual of the relative subassembly. If you need
these manuals, plsaes call our company and we will send you one.
Before starting the maintenance, make sure the diesel engine is off.
Pleaes refer to the Table 3-1 for the proper maintenance schedule.
Table 3-1. Maintenance schedulefor diesel generator set.
Note: "• "mark indicates that it needs special wrench, please contact with dealer.
3- l .1 Changing the engine oil (every 100 hours)
Take the oil cover out.Remove the oil drain plug when the diesel engine is still hot. Be careful of hot
oil and hot engine as you may get bumed. The bolt i located at the bottom of the cylinder. After
draining the oil, put the bolt back and tighten it. Then fill with the proper engine oil to the proper
level.
EN
16
3-1.2 Air filter maintenance schedule
l. Clean air-filter every 6 months or 500 hours of operation.
2. lf necessary, exchange it.
3. Do not use detergent to clean air filter element.
NOTE: Never start the engine without t he air filter. This can cause erious damage to the engine if
foreign objects enter the intake system. Always change the air filter on time.
3-1.3 Fuel filter maintenance
l .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 500 hours of operation.
a. To do this, first drain the fule 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 100 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 reuired to do this.
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.
l. Start the diese} engine for 3 minutes then stop it.
2. When the engine is still hot, 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, 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 compres-
sion 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.
4. TROUBLESHOOTING
4-1 Troubleshooting procedures
lf you are still having trouble, please contact with your nearest dealer or with our company directly
if necessary.
4-2 Questions and doubts
If you do not understand anything or have any questions, please feel free to contact your local
dealer or with our company directly. Below is a list of sorne information you should have ready
before contacting your local dealer or us.
1. Model of diesel engine generator and engine model number.
2. State of residency
3. Number of hours of operating equipment along with the problem that occurred.
4. A detailed condition and time when the problem occurred, in other words, climate and atmosphe-
re.
5. PART LISTINGS
Overall view of engine generator assembly
Number Part Description Quantity
1 Series diesl engine 1
2 Starter Motor 1
3 Flywheel generator 1
4 Bolt 2
5 Voltage Regulator 1
6 Battery Cable(red,black) 2
7 Battery 1
8 Oíl level sensor 1
9 Generator 1
10 Output panel assembly 1
11 Throttle cable 8
12 Spring washer 10 2
13 Capacitor 1
14 Bolt 2
15 Voltage Regulator Bracket 1
16 Bolt 2
Exploded view of frame assembly
Number Part Description Quantity
1 Left frame 1
2 Right frame 1
3 Board connected 4
4 Output panel bracket 1
5 Back board 1
6 Battery tray 1
7 Axle 2
8 Handrail 1
9 Carrier frame 1
10 Rubber mount 4
11 Washer 10 8
12 Spring washer 10 8
13 Nut M10 8
14 Nut M6 8
15 Spring washer 6 8
16 Washer 6 8
17 U bolt 4
18 Nylon nut M8 8
19 Nylon washer 8 9
20 Hexagon socket head cap screw 8
21 Hexagon socket head cap screw 1
22 Nylon washer 6 1
23 Nylon nnut M6 1
24 Nylon nnut M6 1
25 Nylon washer 6 1
26 Hexagon socket head cap screw 1
27 Bolt 1
28 Washer 10 1
29 Spring washer 10 1
30 Nut M10 1
31 Hexagon socket head cap screw 1
32 Spring washer 6 1
33 Steel tube 1
34 Nylon nut 6 1
35 Bolt 4
37 Flat washer M6 4
37 Shock absorber 4
38 Washer 6 4
39 Nut M6 4
40 Rubber cover 1
41 Decorative cover 1
42 Rubber absorber 1
43 Plate connecting engine and frame 1
44 Flat washer 4
45 Split pin 4
46 Wheel 4
47 Bolt 1
48 Magnet bracket 1
49 Magnet 1
50 Magnet cable bolts 1
51 Throttle cable 2
52 Bolt 2
Electric panel parts drawing
Number Part Description Quantity
1 Positive DC port 1
2 Negative DC port 1
3 Grounded bolt 1
4 Bolt 2
5 Large nut 1
6 Bolt 2
7 Bolt 2
8 3 Prong socket 1
9 Current adjusting switch 1
10 Bolt 6
11 Electric panel bolt 6
12 Electric panel 1
13 Starter switch 1
14 Large nut 6
15 Oil alert lamp 1
16 Hour meter 1
17 Hour meter bolts 2
18 DC fuse 1
19 Voltmeter 1
20 Nut 2
21 4 prong socket 1
22 Breaker bracket 1
23 Nut 2
24 Breaker 1
25 Wiring harness 1
26 Electrical box 1
Generator head assembly
Dipstick
Oil drain bolt
High-pressure fuel pipe bolt
17
3-1.2 Air filter maintenance schedule
l. Clean air-filter every 6 months or 500 hours of operation.
2. lf necessary, exchange it.
3. Do not use detergent to clean air filter element.
NOTE: Never start the engine without t he air filter. This can cause erious damage to the engine if
foreign objects enter the intake system. Always change the air filter on time.
3-1.3 Fuel filter maintenance
l .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 500 hours of operation.
a. To do this, first drain the fule 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 100 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 reuired to do this.
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.
l. Start the diese} engine for 3 minutes then stop it.
2. When the engine is still hot, 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, 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 compres-
sion 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.
4. TROUBLESHOOTING
4-1 Troubleshooting procedures
lf you are still having trouble, please contact with your nearest dealer or with our company directly
if necessary.
4-2 Questions and doubts
If you do not understand anything or have any questions, please feel free to contact your local
dealer or with our company directly. Below is a list of sorne information you should have ready
before contacting your local dealer or us.
1. Model of diesel engine generator and engine model number.
2. State of residency
3. Number of hours of operating equipment along with the problem that occurred.
4. A detailed condition and time when the problem occurred, in other words, climate and atmosphe-
re.
5. PART LISTINGS
Overall view of engine generator assembly
Number Part Description Quantity
1 Series diesl engine 1
2 Starter Motor 1
3 Flywheel generator 1
4 Bolt 2
5 Voltage Regulator 1
6 Battery Cable(red,black) 2
7 Battery 1
8 Oíl level sensor 1
9 Generator 1
10 Output panel assembly 1
11 Throttle cable 8
12 Spring washer 10 2
13 Capacitor 1
14 Bolt 2
15 Voltage Regulator Bracket 1
16 Bolt 2
Exploded view of frame assembly
Number Part Description Quantity
1 Left frame 1
2 Right frame 1
3 Board connected 4
4 Output panel bracket 1
5 Back board 1
6 Battery tray 1
7 Axle 2
8 Handrail 1
9 Carrier frame 1
10 Rubber mount 4
11 Washer 10 8
12 Spring washer 10 8
13 Nut M10 8
14 Nut M6 8
15 Spring washer 6 8
16 Washer 6 8
17 U bolt 4
18 Nylon nut M8 8
19 Nylon washer 8 9
20 Hexagon socket head cap screw 8
21 Hexagon socket head cap screw 1
22 Nylon washer 6 1
23 Nylon nnut M6 1
24 Nylon nnut M6 1
25 Nylon washer 6 1
26 Hexagon socket head cap screw 1
27 Bolt 1
28 Washer 10 1
29 Spring washer 10 1
30 Nut M10 1
31 Hexagon socket head cap screw 1
32 Spring washer 6 1
33 Steel tube 1
34 Nylon nut 6 1
35 Bolt 4
37 Flat washer M6 4
37 Shock absorber 4
38 Washer 6 4
39 Nut M6 4
40 Rubber cover 1
41 Decorative cover 1
42 Rubber absorber 1
43 Plate connecting engine and frame 1
44 Flat washer 4
45 Split pin 4
46 Wheel 4
47 Bolt 1
48 Magnet bracket 1
49 Magnet 1
50 Magnet cable bolts 1
51 Throttle cable 2
52 Bolt 2
Electric panel parts drawing
Number Part Description Quantity
1 Positive DC port 1
2 Negative DC port 1
3 Grounded bolt 1
4 Bolt 2
5 Large nut 1
6 Bolt 2
7 Bolt 2
8 3 Prong socket 1
9 Current adjusting switch 1
10 Bolt 6
11 Electric panel bolt 6
12 Electric panel 1
13 Starter switch 1
14 Large nut 6
15 Oil alert lamp 1
16 Hour meter 1
17 Hour meter bolts 2
18 DC fuse 1
19 Voltmeter 1
20 Nut 2
21 4 prong socket 1
22 Breaker bracket 1
23 Nut 2
24 Breaker 1
25 Wiring harness 1
26 Electrical box 1
Generator head assembly
EN
18
3-1.2 Air filter maintenance schedule
l. Clean air-filter every 6 months or 500 hours of operation.
2. lf necessary, exchange it.
3. Do not use detergent to clean air filter element.
NOTE: Never start the engine without t he air filter. This can cause erious damage to the engine if
foreign objects enter the intake system. Always change the air filter on time.
3-1.3 Fuel filter maintenance
l .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 500 hours of operation.
a. To do this, first drain the fule 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 100 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 reuired to do this.
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.
l. Start the diese} engine for 3 minutes then stop it.
2. When the engine is still hot, 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, 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 compres-
sion 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.
4. TROUBLESHOOTING
4-1 Troubleshooting procedures
lf you are still having trouble, please contact with your nearest dealer or with our company directly
if necessary.
4-2 Questions and doubts
If you do not understand anything or have any questions, please feel free to contact your local
dealer or with our company directly. Below is a list of sorne information you should have ready
before contacting your local dealer or us.
1. Model of diesel engine generator and engine model number.
2. State of residency
3. Number of hours of operating equipment along with the problem that occurred.
4. A detailed condition and time when the problem occurred, in other words, climate and atmosphe-
re.
5. PART LISTINGS
Overall view of engine generator assembly
Number Part Description Quantity
1 Series diesl engine 1
2 Starter Motor 1
3 Flywheel generator 1
4 Bolt 2
5 Voltage Regulator 1
6 Battery Cable(red,black) 2
7 Battery 1
8 Oíl level sensor 1
9 Generator 1
10 Output panel assembly 1
11 Throttle cable 8
12 Spring washer 10 2
13 Capacitor 1
14 Bolt 2
15 Voltage Regulator Bracket 1
16 Bolt 2
Exploded view of frame assembly
Number Part Description Quantity
1 Left frame 1
2 Right frame 1
3 Board connected 4
4 Output panel bracket 1
5 Back board 1
6 Battery tray 1
7 Axle 2
8 Handrail 1
9 Carrier frame 1
10 Rubber mount 4
11 Washer 10 8
12 Spring washer 10 8
13 Nut M10 8
14 Nut M6 8
15 Spring washer 6 8
16 Washer 6 8
17 U bolt 4
18 Nylon nut M8 8
19 Nylon washer 8 9
20 Hexagon socket head cap screw 8
21 Hexagon socket head cap screw 1
22 Nylon washer 6 1
23 Nylon nnut M6 1
24 Nylon nnut M6 1
25 Nylon washer 6 1
26 Hexagon socket head cap screw 1
27 Bolt 1
28 Washer 10 1
29 Spring washer 10 1
30 Nut M10 1
31 Hexagon socket head cap screw 1
32 Spring washer 6 1
33 Steel tube 1
34 Nylon nut 6 1
35 Bolt 4
37 Flat washer M6 4
37 Shock absorber 4
38 Washer 6 4
39 Nut M6 4
40 Rubber cover 1
41 Decorative cover 1
42 Rubber absorber 1
43 Plate connecting engine and frame 1
44 Flat washer 4
45 Split pin 4
46 Wheel 4
47 Bolt 1
48 Magnet bracket 1
49 Magnet 1
50 Magnet cable bolts 1
51 Throttle cable 2
52 Bolt 2
Electric panel parts drawing
Number Part Description Quantity
1 Positive DC port 1
2 Negative DC port 1
3 Grounded bolt 1
4 Bolt 2
5 Large nut 1
6 Bolt 2
7 Bolt 2
8 3 Prong socket 1
9 Current adjusting switch 1
10 Bolt 6
11 Electric panel bolt 6
12 Electric panel 1
13 Starter switch 1
14 Large nut 6
15 Oil alert lamp 1
16 Hour meter 1
17 Hour meter bolts 2
18 DC fuse 1
19 Voltmeter 1
20 Nut 2
21 4 prong socket 1
22 Breaker bracket 1
23 Nut 2
24 Breaker 1
25 Wiring harness 1
26 Electrical box 1
Generator head assembly
19
3-1.2 Air filter maintenance schedule
l. Clean air-filter every 6 months or 500 hours of operation.
2. lf necessary, exchange it.
3. Do not use detergent to clean air filter element.
NOTE: Never start the engine without t he air filter. This can cause erious damage to the engine if
foreign objects enter the intake system. Always change the air filter on time.
3-1.3 Fuel filter maintenance
l .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 500 hours of operation.
a. To do this, first drain the fule 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 100 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 reuired to do this.
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.
l. Start the diese} engine for 3 minutes then stop it.
2. When the engine is still hot, 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, 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 compres-
sion 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.
4. TROUBLESHOOTING
4-1 Troubleshooting procedures
lf you are still having trouble, please contact with your nearest dealer or with our company directly
if necessary.
4-2 Questions and doubts
If you do not understand anything or have any questions, please feel free to contact your local
dealer or with our company directly. Below is a list of sorne information you should have ready
before contacting your local dealer or us.
1. Model of diesel engine generator and engine model number.
2. State of residency
3. Number of hours of operating equipment along with the problem that occurred.
4. A detailed condition and time when the problem occurred, in other words, climate and atmosphe-
re.
5. PART LISTINGS
Overall view of engine generator assembly
Number Part Description Quantity
1 Series diesl engine 1
2 Starter Motor 1
3 Flywheel generator 1
4 Bolt 2
5 Voltage Regulator 1
6 Battery Cable(red,black) 2
7 Battery 1
8 Oíl level sensor 1
9 Generator 1
10 Output panel assembly 1
11 Throttle cable 8
12 Spring washer 10 2
13 Capacitor 1
14 Bolt 2
15 Voltage Regulator Bracket 1
16 Bolt 2
Exploded view of frame assembly
Number Part Description Quantity
1 Left frame 1
2 Right frame 1
3 Board connected 4
4 Output panel bracket 1
5 Back board 1
6 Battery tray 1
7 Axle 2
8 Handrail 1
9 Carrier frame 1
10 Rubber mount 4
11 Washer 10 8
12 Spring washer 10 8
13 Nut M10 8
14 Nut M6 8
15 Spring washer 6 8
16 Washer 6 8
17 U bolt 4
18 Nylon nut M8 8
19 Nylon washer 8 9
20 Hexagon socket head cap screw 8
21 Hexagon socket head cap screw 1
22 Nylon washer 6 1
23 Nylon nnut M6 1
24 Nylon nnut M6 1
25 Nylon washer 6 1
26 Hexagon socket head cap screw 1
27 Bolt 1
28 Washer 10 1
29 Spring washer 10 1
30 Nut M10 1
31 Hexagon socket head cap screw 1
32 Spring washer 6 1
33 Steel tube 1
34 Nylon nut 6 1
35 Bolt 4
37 Flat washer M6 4
37 Shock absorber 4
38 Washer 6 4
39 Nut M6 4
40 Rubber cover 1
41 Decorative cover 1
42 Rubber absorber 1
43 Plate connecting engine and frame 1
44 Flat washer 4
45 Split pin 4
46 Wheel 4
47 Bolt 1
48 Magnet bracket 1
49 Magnet 1
50 Magnet cable bolts 1
51 Throttle cable 2
52 Bolt 2
Electric panel parts drawing
Number Part Description Quantity
1 Positive DC port 1
2 Negative DC port 1
3 Grounded bolt 1
4 Bolt 2
5 Large nut 1
6 Bolt 2
7 Bolt 2
8 3 Prong socket 1
9 Current adjusting switch 1
10 Bolt 6
11 Electric panel bolt 6
12 Electric panel 1
13 Starter switch 1
14 Large nut 6
15 Oil alert lamp 1
16 Hour meter 1
17 Hour meter bolts 2
18 DC fuse 1
19 Voltmeter 1
20 Nut 2
21 4 prong socket 1
22 Breaker bracket 1
23 Nut 2
24 Breaker 1
25 Wiring harness 1
26 Electrical box 1
Generator head assembly
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2
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