HOWIN 9600i User manual

V201708
SILENT DIESEL
INVERTER GENERATOR
9600i
OPERATION MANUAL
PLEASE READ THIS MANUAL CAREFULLY.
IT CONTAINS IMPORTANT SAFETY INFORMATION.

PREFACE
Thank you for purchasing a HOWIN generator.
This manual covers the operation and preventive maintenance of
the 9600i generator sets. This manual is primarily concerned
with the generator specifications, function, troubleshooting and
repair.
All information in this publication is based on the latest product
information available at the time of approval for printing.
No part of this publication may be reproduced without written
permission.
If a problem should arise or if you have any questions about the
generator, consult an authorized HOWIN service center.
Our generators are designed to give safe and dependable service
if operated according to instructions. Read and understand the
operation manual before operating the generator. Failure to do so
could result in personal injury or equipment damage.
Several preventive maintenance procedures require background
knowledge in diesel engines. Be sure to consult an authorized
service center when necessary.
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CHARGING THE BATTERY
Do not charge the battery connected. The diodes will be
damaged by the high voltage.
Connect the (+) lead of the charger to the (+) terminal of the
battery, and the (–) lead to the (–) terminal. Reversed polarity will
damage the charger rectifier or the battery.
After charging is completed, connect the battery cables correctly
to the battery. Reversed polarity wiring will damage the diodes.
Quick-charging should only be done in an emergency; slow
charging is recommended.
1. Disconnect the battery cables from the battery.
2. Clean terminals on the battery and clamps on the end of the
cables.
3. Connect the positive (+) clamp from the charger to the positive
(+) terminal on the battery.
4. Connect the negative (–) clamp from the charger to the
negative (–) terminal on the battery.
5. When finished charging the battery, unplug the charger before
disconnecting clamps from the battery.

- 31 -
9. LONG TERM STORAGE
BEFORE YOU PLACE THE GENERATOR IN LONG TERM
STORAGE
EXPLOSION HAZARD!
NEVER check the remaining battery charge by shorting out the
terminals. This will result in a spark and may cause an explosion
or fire. Use a hydrometer to check the remaining battery charge.
If the electrolyte is frozen, slowly warm the battery before you
recharge it.
Failure to comply will result in death or serious injury.
1. Start the engine. Allow the engine to run without load for
approximately five minutes and then stop the engine.
2. Drain the engine oil while the engine is still warm and fill with
new oil.
3. Drain the fuel tank or make sure it is completely full.
4. Protect the air cleaner, muffler and electrical components
(dynamo, starter motor, switches) from water and dust.
5. Disconnect the negative (-) battery cable to prevent the battery
from discharging.
6. Charge the battery once a month during storage.
7. Clean the generator and store it in a dry place.
RETURNING THE ENGINE TO SERVICE
1. Perform the Daily Checks.
2. Start the engine. Allow the engine to run without load for
approximately 5 to 10 minutes while you check for:
(a) abnormal noises or vibration
(b) fuel and engine oil leaks.
3. Avoid prolonged operation at maximum load for the remainder of
the first hour of operation.
CONTENT
1. SAFETY INFORMATION …………….…………………. 1
2. COMPONENT IDENTIFICATION …………………...…… 5
3. PREPARATION FOR STARTING …………………….... 10
4. STARTING THE GENERATOR ……………………….... 14
5. OPERATING THE GENERATOR …………………….... 18
6. STOPPING THE GENERATOR ………………………… 22
7. PERIODIC MAINTENANCE ……………………………. 23
8. TROUBLESHOOTING …………………….…………... 29
9. LONG TERM STORAGE …………….………………….. 31

- 1 -
1. SAFETY INFORMATION
Failure to properly follow these precautions can result in property
damage, serious injury or DEATH!
Read all labels and the owner's manual before operating this
generator.
Operate only in well ventilated areas. Exhaust gas contains
carbon monoxide, a poisonous, colorless, odorless gas and can
be deadly.
Always stop the engine before refueling. Wait 5 minutes before
restarting.
Check for spilled fuel or leaks. Clean and/or repair before use.
Keep any source of combustion away from fuel tank at all times.
Do not operate near flammable materials or in an explosive
atmosphere.
Do not operate this unit in wet conditions or with wet hands. Use
of a generator in rain, snow or near water can result in
electrocution.
Keep the generator dry at all times. The LG9600i comes with a
weather resistant, not weatherproof enclosure.
Connections for standby power to a building's electrical system
must be made by a qualified electrician and must comply with all
applicable laws and electrical codes. Improper connections can
allow electrical current from the generator to back feed into the
utility lines. Such back feed may electrocute utility company
workers or others who contact the lines during a power outage
and when utility power is being restored; the generator may
explode, burn, or cause fires in the building’s electrical system.
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Black exhaust smoke
Trouble Diagnose Correction
Engine overloaded Reduce load
Clogged air cleaner element Clean element or replace
Improper diesel fuel Replace with recommended
diesel fuel
Faulty spraying of fuel
injection See authorized dealer or distributor
Excessive intake / exhaust valve
clearance
White exhaust smoke
Trouble Diagnose Correction
Improper diesel fuel Replace with recommended diesel
fuel
Faulty spray pattern of fuel
injection See authorized dealer or distributor
Fuel injection timing delay
Engine burning oil
NO POWER FROM THE AC RECEPTACLES
Trouble Diagnose Correction
Output switch is OFF. Turn output switch ON.
Equipment incorrectly connected
to generator. Connect the equipment correctly.
Electrical load too high Reduce electrical load and restart
the generator.
Receptacle is defective Check wiring and check or replace
receptacle
Defective stator
See authorized dealer or distributor
Defective rotor
Engine not running properly
Defective inverter unit

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8. TROUBLESHOOTING
If a problem occurs, stop the engine immediately.
Refer to the SYMPTOM column in the Troubleshooting Chart to
identify the problem.
The diesel engine will not start or is difficult to start
Trouble Diagnose Correction
Deteriorated diesel fuel in the tank Drain the tank and refuel with fresh
diesel fuel
Fuel filter is clogged Clean or replace fuel filter
Fuel Cock is not in the Start
position. Turn it to the START position
The governor lever of the engine
throttle is not in the start position Switch to the start position
Oil filter is clogged causing low oil
pressure switch to activate Clean or replace oil filter
Low oil pressure switch failure Check wiring and replace switch as
necessary
Air in the fuel lines (often occurs
after running out of fuel)
Consult the service manual for
bleeding procedure
Valves out of adjustment Check valve adjustment and reset as
necessary (refer to service manual)
Insufficient battery voltage to
energize starter and/or fuel
solenoid valve
Check battery state and terminals
and cables
Engine speed is unstable, too high or too low
Trouble Diagnose Correction
Engine governor spring is
defective Replace governor spring
Valves out of adjustment Check valve adjustment and reset as
necessary (refer to service manual)
Governor out of adjustment Adjust governor (refer to service
manual)
- 2 -
TO PREVENT FIRE
Never add fuel to the fuel tank while the engine is running.
Wipe off any overflow of diesel fuel with a clean cloth. Keep
explosives and other flammable products away from the
generator set.
To prevent fire and to provide adequate ventilation, keep the
generator at least three feet (one meter) away from buildings
and other equipment during operation.
Operate the generator on a level surface.
Do not put the generator indoors while the engine is hot.
TO PREVENT EXHAUST INHALATION
Exhaust gas contains poisonous carbon monoxide which is harmful to
your health and possibly fatal. Never use the generating set in
confined spaces or poorly ventilated areas.
AVOID BURN INJURIES
The muffler and the engine body are very hot while the engine is
running and remains so for a time after the generator has been shut off.
Do not touch these parts to prevent possible severe burns.
ELECTRIC SHOCKS
To avoid electric shocks or short circuits, do not touch the generating
set when your hands are wet. The generator is not waterproof so it
should not be used in a place exposed to rain, snow or water spray.
Use of the generator in a wet location can cause short circuits and
electrical shocks during operation.
The generator should be grounded to prevent electrical shocks
from faulty loads. Connect a length of heavy wire between the
generator set ground terminal (on the control panel) and an
external ground source.

- 3 -
Do not hook up tools or other appliances to the generator before it
has been started. If equipment is plugged in and the circuit
breakers are on, the generator starting motion may cause sudden
movements of the equipment and possibly result in injuries. Be
sure to disconnect any tool or appliance from the generator prior to
starting.
Most appliance motors require more than their rated current for
start-up.
Do not exceed the specified current limit of any receptacle.
Do not connect the generator set to a household circuit without an
approved transfer switch. This could cause damage to the
generating set and to electrical appliances in the house.
WHEN CHARGING THE BATTERY
Your generator is equipped with a wet acid style battery. Leakage
of battery electrolyte is possible if the case is penetrated or the
battery is upended. Battery electrolyte contains sulfuric acid.
Protect your eyes, skin and clothing. In case of contact, flush
thoroughly with water and get prompt medical attention. Batteries
generate hydrogen gas which can be highly explosive. Do not
smoke or allow flames or sparks near a battery at any time. Charge
the battery only in a well-ventilated area.
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1) Clean the area around the fuel cap.
2) Remove the fuel cap from the fuel tank.
3) Lift out the inlet fuel screen.
4) Clean the inlet fuel screen or replace if damaged.
5) Inspect fuel cap gasket and replace if damaged.
6) Reinstall the inlet fuel screen.
7) Reinstall the fuel cap and hand tighten.
Overtightening the fuel cap will damage it.
7.5 Drain the Fuel Tank and Replace Outlet Fuel Filter
FIRE AND EXPLOSION HAZARD!
Diesel fuel is extremely flammable and explosive under certain
conditions.
When you remove any fuel system component to perform
maintenance (such as changing the fuel filter) place an approved
container under the opening to catch the fuel.
NEVER use a shop rag to catch the fuel. Vapors from the rag are
extremely flammable and explosive.
Wipe up any spills immediately.
Wear eye protection. The fuel system is under pressure and fuel
could spray out when you remove any fuel system component.
Failure to comply will result in death or serious injury.
1) Place a suitable container under the fuel filter to collect the
remaining fuel. The fuel can be used again later.
2) Pull the fuel line off of the fuel filter on both sides and insert a
new filter.
3) Fill the fuel tank with diesel fuel. The fuel system is bled
automatically.
4) Check the fuel filter and lines for tightness after a brief trial run.

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1) Remove the wing nut.
2) Remove the air cleaner cover.
3) Remove the air cleaner element and outer foam element.
4) Blow air through both elements using 42-71psi (0.29−0.49 MPa,
3.0−5.0kgf/cm2) compressed air to remove the particulates. Use
the lowest possible air pressure to remove the dust without
damaging the elements.
5) Wash foam element with warm soapy water and allow it to dry
completely. Inspect element.
6) If either element is damaged replace both of them.
7) Clean the inside of the air cleaner cover.
8) Reinstall the air cleaner element into the air cleaner case.
9) Slide the outer foam element over the air cleaner element.
10) Reinstall the air cleaner cover.
11) Reinstall the wing nut.
Overtightening the wing nut will damage the air cleaner
assembly.
7.3 Clean Inlet Fuel Screen
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MAIN TECHNICAL SPECIFICATIONS AND DATA
Model
Item LG9600i
Generating set
Rated frequency (Hz) 50
Max power (kVA) 6.0
Rated power (kVA) 5.5
Rated voltage (AC) 220
Rated current (AC) 25
Rated speed (rpm) 3600
Phase Single phase
Power factor 1.0
Gross weight (kg) 140
Dimensions (L×W×H) (mm) 940×540×750
Engine
Model LG190FGE
Type
Vertical, 4-stroke,
single-cylinder, air-cooled,
direct injection diesel engine
Continuous output (kW/rpm) 7.5
Max. Power (kW/rpm) 8.3
Bore x stroke in. (mm) 90×70
Displacement (cc) 420
Cooling system Forced air-cooled system
Lubricating system Pressure splash combined
type
Lube oil capacity (L) 1.65
Starting system Electric starter
Fuel Diesel
Fuel capacity (L) 16
Low oil pressure alarm with

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2. COMPONENT IDENTIFICATION
2.1 Component Location
○
1Fuel Tank Cap
○
2Engine Access Panel
○
3Control Panel
○
4Wheel
○
5Air Filter Cover
○
1
○
2○
3 ○
4
○
5
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10) Recheck the engine oil level by fully inserting, but not screwing
in the oil filler cap.
11) Add engine oil as needed until the level is between the upper
and lower lines on the oil filler cap.
12) Replace the oil filler cap and tighten by hand. Over-tightening
may damage the cap. If any engine oil is spilled, wipe it up with
a clean cloth.
7.3 Clean Air Cleaner Element
The engine performance is adversely affected when the air cleaner
element is clogged with dust.
Be sure to clean the air filter element periodically.

- 25 -
7.2 Clean / Inspect Engine Oil Filter
* Every 6 months or 500 hours
Clean / inspect the engine oil filter as follows:
1) Remove the oil filter retaining bolt.
2) Pull the oil filter cap out and remove the oil filter.
3) Clean the oil filter or replace if damaged.
4) Reinstall the oil filter.
5) Make sure the oil filter cap is fully seated.
6) Reinstall and tighten the oil filter retaining bolt.
7) Add new engine oil to the engine as specified.
NEVER overfill the engine with engine oil.
ALWAYS keep the oil level between the upper and lower lines on
the oil filler cap.
8) Warm up the engine by running it for five minutes and check for
any engine oil leaks.
9) After engine is warm, shut it off and let it sit for 10 minutes.
- 6 -
○
1Exhaust outlet
○
2Outlet for cooling fan
○
2
○
1

- 7 -
2.2 Control Panel
1. Voltmeter
2. Engine Switch - Used to start or stop the generator.
3. AC Receptacle - Used to supply electrical power for the operation
of 230 Volt AC, 50 Hz loads requiring up to 16 Amps or 3500 Watts
of power.
4. Ground Terminal - The generator ground terminal is connected to
the frame of the generator, and the ground terminals of each
receptacle.
5. INDICATOR - RUN, ALERT and LOW OIL indicator.
6. Output Switch - Used to switch the generator power ON or OFF.
7. DC Receptacle - The DC receptacle should ONLY be used for
charging 12 volt automotive type batteries.
8. DC Circuit Protector - The DC circuit protector automatically
shuts off the DC battery charging circuit when the DC charging
circuit is overloaded.
○
1
○
2
○
3
○
4
○
5
○
6
○
7
○
8
- 24 -
7.1 Changing the engine oil
The engine oil on a new engine becomes contaminated from the initial
break-in of internal parts. The initial 20 hour oil change and filter
cleaning is very important.
Drain the engine oil as follows:
1) Make sure the engine is level.
2) Start the engine and bring it up to operating temperature.
3) Stop the engine.
4) Remove the oil filler cap to allow the engine oil to drain more easily.
5) Position a container under the engine to collect waste oil.
Note: There is an oil drain plug located on each side of the engine.
6) Remove the drain plug located on the bottom of the cylinder
block. Allow oil to drain.
7) After all oil has been drained from the engine, reinstall the drain
plug.
8) Refill with the recommended oil.
9) Dispose of used oil properly.