Firman SDG2500CL User manual

Diesel Generator
D0128008
D0128008

Operation Manual of Diesel Generator
FOREWORD
Thank you very much for purchasing our products.
This operation manual is intended for proper handling and minor checking and maintenance of
the generator. Before operating the generator, please read these instructions completely and
carefully in order to make the best use of it as well as operate safely.
Due to constant efforts to improve our products, certain procedures and specifications are
subject to change without notice, if you have any question, please contact your dealer.
Contents
1. Safety Precautions .......................................................................................... 2
2. Name of Parts.................................................................................................. 4
3. Specifications.................................................................................................. 5
3-1 Main technical specifications................................................................... 5
3-2 Basic parameters........................................................................................ 5
4. Before Starting ................................................................................................. 6
4-1 Handling your engine oil......................................................................... 6
5. Starting .................................................................................................................. 8
5-1 Recoil starting........................................................................................... 8
5-2 Electric starting......................................................................................... 8
6. Operating Your Generator Set.......................................................................... 10
6-1 Operating your generator..................................................................... 10
6-2 Checks during operation ...................................................................... 10
6-3 Load......................................................................................................... 10
7. Stopping Your Generator Set ............................................................................ 11
8. Periodic Checks and Maintenance................................................................. 12
8-1 Periodic checks and maintenance........................................................ 12
8-2 Long term storage .................................................................................... 13
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Operation Manual of Diesel Generator
1. Safety Precautions
The electric power generated by the diesel engine of the generator can be used for many
kinds of electric appliances. When handling it, please keep to the following matters. Please
make sure you review each precaution carefully.
WARNING “WARNING” indicates a strong possibility of severe personal injury or
loss of life if instructions are not followed.
WARNING EXHAUST PRECAUTIONS
Never inhale exhaust gasses.
They contain carbon monoxide, a colorless, odorless and extremely dangerous gas which
can cause unconsciousness or death.
Never operate the generator indoor or in a poorly ventilated area, such as tunnel, cave,
etc.
Exercise extreme care when operating the generator near people or animals.
Keep the exhaust pipe free of foreign objects.
WARNING REFUELING PRECAUTIONS
Do not refuel indoors or in a poorly ventilated area.
Be sure to stop the generator prior to refueling.
Do not overfill the tank.
If fuel is spilt, wipe it away carefully before starting the engine.
WARNING WHEN CHARGING THE BATTERY
Battery electrolyte contains sulphuric acid. Be careful of your eyes, skin and clothing. Flush
thoroughly with water and get prompt medical attention in case of contacts, especially if
your eyes are affected.
Charge the battery in a fully ventilated place.
Be sure to confirm battery polarity.
WARNING OTHER SAFETY PRECAUTIONS
Be careful of hot parts.
The muffler and other engine parts become very hot while the engine is running or just after
it has stopped. Operate the engine in a safe area and keep children away from the
running engine.
Where to use the generator
Do not use it near flammables.
Use it more than 1 meter away from buildings or any other facilities.
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Operation Manual of Diesel Generator
When using the generator
Do not tip or move.
Do not cover it with a box or fence it around.
Never unscrew the dipstick when using the generator set, or else scald will be caused by
ejective oil. Do not touch the generator in the rain. And also do not splash water or touch
with wet hand.
To avoid an electric shock, ground the generator from the ground terminal.
Avoid using generator at the place where the ground is not firm.
Never connect generator to the wiring of a power company.
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Operation Manual of Diesel Generator
2. Name of Parts
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Operation Manual of Diesel Generator
3. Specifications
3-1 Main technical specifications
Model
Item
SDG2500CL
SDG2500CLE
SDG2500CX
SDG2500CXE
SDG4000CL
SDG4000CLE
SDG2500CX
SDG2500CXE
SDG5500CL
SDG5500CLE
SDG5500CX
SDG5500CXE
SDG3500SE SDG5000SE
Type 2 electrode single-phase alternating current generator
Excitation system Self-excitation system
Voltage adjusting system Condenser compensating system
Frequency (Hz) 50 60 50 60 50 60 50 60 50 60
Rated output (KVA) 1.8 2.0 2.8 3.0 4.5 5.0 2.8 3.0 4.2 4.5
Max. output (KVA) 2.0 2.2 3.0 3.3 4.8 5.3 3.0 3.3 4.5 4.8
Rated Voltage (V) 110,115,120,220,230,240,110/220,115/230,120,240
Power factor (cos Φ) 1
generator
DC output (V-A) 12 – 8.3
Model SDE170 SDE178 SDE186 SDE178 SDE186
Type Air-cooled 4-cycle Diesel Engine
Displacement (cc) 219 306 418 306 418
Continuous rated output
(kw/rpm)
2.5/
3000
2.8/
3600
3.7/
3000
4.0/
3600
5.7/
3000
6.3/
3600
3.7/
3000
4.0/
3600
5.7/
3000
6.3/
3600
Fuel Diesel light oil
Fuel tank capacity (L) 10 13
Continuous running time
(at the rated output) 11 9.6 7.7 7.0 5.1 4.5 10.0 9.1 6.6 5.9
Lube oil capacity (L) 0.80 1.10 1.65 1.10 1.65
engine
Starting system Recoil start/electric start Electric start
Protective system
of low oil pressure CX,CXE type have have
Dimensions ( L X W X H ) 625X455X520
690X455X545 700X465X600 840X530X740 910X530X740
set
Net weight (KG) 54/58(E) 64/68(E) 98/102(E) 127 154
3-2 Basic parameters
3-2.1 Under the following conditions, the generator set should output the rated power:
Altitude height (m) Ambient temperature (℃) Relative humidity (%)
0 20 60
3-2.2 Under the following conditions, the generator set should output the stipulated power and
work reliably:
Altitude height (m) Ambient temperature (℃) Relative humidity (%)
<1000 5~40 90
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Operation Manual of Diesel Generator
4.Before Starting
Before starting the engine, check the generator set on the place where it is flat by placing it
horizontally.
4-1 Handling your engine oil
WARNING
The engine may be damaged if operated with insufficient lube oil. It is also dangerous to
supply too much lube oil to the engine because a sudden increase in engine rpm could be
caused by its combustion. Always check the lube oil level before starting the engine and
refill if necessary.
Use proper lube oil preserves your engine
ENGINEOIL
We recommend A.P.I engine service classification of CC or CD.
Always use the oil with the right viscosity for the ambient temperature in which your engine is
being operated. Use the chart
right side for choosing your engine
oil.
2500series 4000series
3500SE
5500series
5000SE
Lube oil capacity(L) 0.80 1.1 1.65
CAUTION:
When checking the oil level, make sure your engine is sitting level. If it is tilted, you may add
either too much or too little oil. If you overfill, your engine will consume too much oil and the
oil temperature will become dangerously high; if you do not add enough oil, your engine
could seize up.
When checking the oil, simply dip the dipstick into the oil pan. Do not screw in the dipstick.
Be sure to check the engine on a level surface with the engine stopped.
4-2 Selection and handling of fuel oil
Only use diesel light oil.
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Operation Manual of Diesel Generator
When filling the fuel tank from drums, make sure that no dust or water are mixed in the fuel. This
may lead to serious fuel-injection pump and nozzle problems.
CAUTION:
Only use the recommended diesel fuel oil.
Use of non-recommended fuel may cause the engine damage.
Fuel should have a cetane value of more than 45 in order to prevent difficult starting,
misfiring, and white exhaust smoke.
Diesel fuel oil substitutes are not recommended; they may be harmful to the fuel system
components.
Fuel should be free of water or dust because these cause trouble in the fuel injection pump
and nozzle.
Afterpurchasingfuel:Allowdrumtostand3~4days.
After 3~4 days: Put a suction pipe halfway into the
drum.(Water and dust accumulate in the lower position of
the drum.)
WARNING
Refuel in a well ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the area where the engine is refueled or where
gasoline is stored.
Do not overfill the tank and make sure the filter cap is securely closed after refueling.
Be careful not to spill fuel when refueling . if any fuel is spilled, make sure the area is dry
before starting the engine.
Overfill is dangerous. Do not fill the tank beyond the
top of the red plug inside the fuel tank filter.
2500 series, 4000 series
5500 series 3500SE, 5000SE
Fuel tank capacity
(L) 10 13
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Operation Manual of Diesel Generator
5. Starting
5-1 Recoil starting
(1) Set the fuel cock at the “O”(Open) position.
(2) Set the engine speed lever to “RUN” position.
(3) Pull out the recoil starting handle.
a. Pull out the handle to the point where you feel
strong resistance, and then return it to the initial
position.
b. Push down the decompression lever. It will return automatically when the recoil starter is
pulled.
c. Pull out the recoil starting handle briskly with both
hands.
d. In cold weather, when your engine is hard to start,
remove the oil screw plug of the cylinder head
bonnet and add 2cc of engine lube oil before
starting. (Only 2500 series/4000 series)
WARNING
Never use any volatile liquid or gas such as gasoline to cold starting the machine, or else,
severe damage will occur.
CAUTION
Keep the oil screw plug in the bonnet except adding oil. If the plug is not in place, rain dirt
and other contaminants may enter the engine and cause accelerated wear out (abrasion)
of internal parts. This can cause serious problems.
5-2 Electric starting
(1) Starting
a. Open the fuel cock.
b. Set the engine speed lever to “RUN” position.
c. Turn the starting key clockwise to “START” position.
d. Remove your hand from the key as soon as the engine starts.
e. If the engine does not start after 10 seconds, wait a while (for about 15 seconds) before
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Operation Manual of Diesel Generator
attempting to start again.
CAUTION
If the starting motor is working for too long, the battery will go flat and motor seize up will
occur. Always leave the starting key turned on, at the “ON” position, while the engine is
running.
(2) Battery
Check the level of the fluid in the battery every
month. When the level has dropped to the lower
mark, replenish with distilled water up to the upper
mark.
CAUTION
If the battery fluid is short, the engine may not start because too little electricity is reaching
the starter motor. Always keep the fluid level between the upper and lower limits.
If too much battery fluid is supplied, the fluid may spill and corrode the surrounding parts.
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Operation Manual of Diesel Generator
6. Operating Your Generator Set
6-1 Operating your generator
(1) Warm up the engine without load for 3 minutes.
(2) CX series generator is equipped with low oil warning system. The engine will stop
automatically in case of low oil pressure or a lubrication oil shortage. The engine will stop
immediately without a lubrication oil refill. Check the oil level and refill.
(3) Do not loosen or readjust either the engine speed limiting bolt or fuel injection limiting bolt
(They had been already well adjusted before leaving factory), otherwise performance may
be affected.
6-2 Checks during operation
(1) Any abnormal sound or vibration?
(2) The engine misfiring or running rough?
(3) What about the color of the exhaust gas? (Is it black or too white?).
If you notice any situation mentioned above, please contact your dealer.
6-3 Load
To add load according to specified parameter.
A.C application
(1) Set AC breaker to “ON”. Pilot lamp will illuminate, the speed of generator must reach rated
speed (lever at top).
(2) Insert the receptacle with the plugs of electric instruments to be connected, keep the
switches of the connected electric instruments to “OFF”.
CAUTION
The instruments which require much starting current and some kinds of motors may be
unable to be use even if they are within the applicable scope.
The circuit breaker turns “OFF” when the current exceeding the applicable scope is used or
when the applied instrument is defective.
The current of the instruments which should not exceed the rated current showed on the
socket, or else it may damage the machine.
DC application
(1) When the instruments connect with the DC terminal, please make sure to the positive
polarity.
(2) DC output 12V 8.3A – 100W.
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Operation Manual of Diesel Generator
7. Stopping Your Generator Set
(1) Set the AC breaker to “OFF”
(2) Pull out the plug of an electric appliance from the receptacle
(3) Move the engine speed lever to low speed, and run the engine for about 3 minutes with no
load.
(4) Return the engine speed lever to the “STOP” position
(5) In electric-start models, return the starter key to the “OFF” position
(6) Set the fuel chock lever to “S”(closed) position
(7) Slowly pull out the recoil handle until pressure is felt (that is, to the point in the compression
stroke where the intake and exhaust valves are closed), and leave the handle in this
position this prevents rust from forming while the engine is not in use.
WARNING
If the engine keeps on running even after the
speed lever is placed at “STOP” position, stop
the engine either by closing the fuel cock(“S”
position) or by loosening the nut of the high
pressure fuel pipe on the pump side.
CAUTION
When stopping the engine, reduce the load slowly. Do not stop the engine suddenly since
it may cause the temperature to rise abnormally.
Do not stop the engine with the decompression lever.
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Operation Manual of Diesel Generator
8. Periodic Checks and Maintenance
8-1 Periodic checks and maintenance
Periodic checks and maintenance are very important for keeping the engine in good
condition and durable. The mark (●) indicates that special tools and skills are required, you
have to contact your dealer.
WARNING
Shut off the engine before performing any maintenance. If the engine must run, make sure the
area is well ventilated. The exhaust contains poisonous carbon monoxide gas.
Maintenance schedule
First
month Every 3 months Every 6 months Every
year or
Operation hours
Item
Daily
or 20Hrs
or 100Hrs or 300Hrs Every
1000Hrs
Check and tighten bolts
and nuts
○
Check and resupply
engine oil
○
Replace engine oil
○ 1st
time
○2nd time and
thereafter
Clean and replace oil
filter ○● Replace if
necessary
Check oil leakage ○
Replace air cleaner
element Service more frequently
when used in dusty areas
○
Drain the fuel tank Monthly
Clean and replace fuel
filter ○ Clean ○ Replace
Check fuel injection
nozzle ●
Check fuel injection
pump ●
Check fuel piping
○ Replace if
necessary
Adjust intake/exhaust
valves head clearance
○ 1 st
time ○
Check and lap intake/exhaust
valve seat ●
Replace piston rings ●
Check battery liquid Monthly
8-1.1 Changing engine oil
Remove the oil filler cap, remove the drain plug and drain the used oil while the engine is still
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Operation Manual of Diesel Generator
warm. The plug is located on the bottom of the cylinder block. Tighten the drain plug and refill
with the recommended oil.
8-1.2 Cleaning the oil filter
Loosen the fixing bolt and then pull out the oil filter
Clean Every 3months or 100 hours
8-1.3 Changing the air cleaner element
Do not wash the air cleaner element with detergent because this is a wet type element.
Change Every 6months or 300 hours(or earlier if dirty)
CAUTION
Never run the engine without the element or with a defective element.
8-1.4 Cleaning and replacing the fuel filter
The fuel filter also has to be cleaned regularly to insure maximum engine output.
Clean Every 3months or 100 hours
Replace Every 6months or 300 hours
8-1.5 Checking the injection nozzle injection pump etc
This requires special tools and skills, so contact your dealer.
8-1.6 Replacing piston ring
This requires special tools and skills, so contact your dealer.
8-2 Long term storage
If your generator set should be stored for a long time, the following preparation should be
made:
(1) Operate the diesel engine about 3 minutes, and stop it
(2) Stop the engine. Drain the engine lube oil while the engine is still warm and fill with new oil
(3) Remove the oil screw plug of the cylinder head bonnet and add 2c of engine lube oil. Put
back to the place.(2500 series, 4000 series)
(4) Recoil starting
Push the decompression lever down (non- compression position) and hold it while you pull
the recoil starter 2 or 3 times. (Do not start the engine)
Electric starting
Turn the engine for 2~3 seconds with decompression. Lever set at the non-compression
position, and the starter key at the “START” position. (Do not start the engine)
(5) Pull the decompression lever up. Pull the recoil starter slowly. Stop when it feels tight. This
closes the intake and exhaust valves in compression position and helps prevent rust from
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Operation Manual of Diesel Generator
forming
(6) Clean and store it in a dry place.
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