ITC Power DG2500L User manual

DIESEL GENERATOR SET USER’S MANUAL
Chapter 2 Use for the Generator Set
2.1 Use Essentials and Cautions
In order to ensure that you safely operate the generator set, be sure that you read and
understand the operation manual. Especial attention should be paid to the use of main points
listed below. Otherwise personal accidents and the equipment damages may be caused.
2.1.1 Fire prevention
The combustion oil used in the diesel engine is light diesel oil. Gasoline, kerosene and
other oils must not be used.
Use a clean cloth to wipe off the overflowed oil. Gasoline, kerosene, match or other
inflammable and explosive matters should not be place near the set because the
temperature for the place around the exhaust is very high while the diesel engine is running
and can cause explosion .
For the purpose to prevent the fire and to supply the sufficient ventilation condition, during
the operation, at least 1.5m distance between the set and the building or other equipment
must be kept.
Operating the welder and generator set should be carried out on a flat floor. If the set is
oblique, the oil can overflow.
2.1.2 Prevent the suction of the exhausted gas.
At the places with poor ventilation, the welder and generator set should not be used. If it is
necessary to operate the set indoors, a suitable ventilation
condition should be supplied to prevent the personnel and
livestock from the affection of carbon monoxide of burning.
2.1.3 Prevent of burning.
When the diesel engine is running and is hot, it is not
allowed to touch the noise suppressor and its housing.
2.1.4 Electric shock and short-circuit.
In order to avoid the electric shock or the short-circuit, when
the welder and generator set is wet or when your hand is wet, contacting the welder and
generator set is not allowed. This welder and generator set is not waterproof so that it
should not be used at the places in rain, snow and water mist.
In order to prevent the electric shock, the welder and generator set should be grounded.
Connect the grounding terminal of the generator with the external grounding device by
using a conductor. Don’t connect the other equipment with the welder and generator set.
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DIESEL GENERATOR SET USER’S MANUAL
2.1.5 Other safety main points.
In order to know how to quickly stop the set, the operators should be familiar with
operating all the switches. Anyone without passing through the correct guidance should not
carry out the operation. The operators should wear the safety shoes and the suitable clothes.
The children and livestock should be kept far from the welder and generator set.
2.1.6 Charge the battery.
The electrolyte of the battery contains sulphuric acid. In order to protect your eyes, skin
and clothes, if you touch it, it is necessary to use water for wash. If your eyes touch it, you
should go to a clinic for wash.
The hydrogen produced from the battery is an explosive gas. Don’t smoke particularly at
the charge time.Any spark should not be splashed to the places near the battery.
Charge the battery at the places with good ventilation.
2.2 Preparation before the Start
2.2.1 Select and treat with the combustion oil.
Only use the light diesel oil. The combustion oil should filtered cleanly. Attention should be
paid so don’t let any dust and water to be mixed into the combustion oil and the oil tank.
Otherwise the High-pressure pump and the oil nozzle may be blocked up.
ATTENTION:
zOverflowing the oil is very dangerous. Filling the oil
into the oil tank should not exceed the top of the red
cock inside the filler.
zAt the places of filling the oil into the diesel engine or of
storing the diesel oil, don’t smoke. Don’t let any spark
go into this area. At the time of filling the oil, the oil
should not be overflowed. After the oil filling, be sure
fastening the cover nut on the oil inlet.
2.2.2 Filling the Machinery Oil
Put the generator set in a level state. Fill the oil into the oil-filling inlet. At the time of
checking the oil level, it is necessary only to lightly insert the oil ruler. Please pay attention to
that you should not rotate the oil ruler.
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DIESEL GENERATOR SET USER’S MANUAL
Type D200 D300 D400 D500
Volume (L) 0.8 1.1 1.65 1.65
A.P.I. Diesel engine maintenance classification.
The lubrication oil should be CC or CD grade.
The factor of the affection, to the performance and reliability of the diesel engine, caused by
your lubrication oil, is bigger than other factors. If you use any poor quality machinery oil or if
you do not change the oil for your diesel engine according to the stipulation, it is easy to block up
the piston. It is also to quicken the wearing of the cylinder, bearings, and other moving
components so that the life of your diesel engine is reduced.
Although there are the low oil pressure alarm system-the stop device. At the time of starting
the set, it is necessary to check the oil quantity is not sufficient, please add some oil. Discharging
the machinery oil should be carried out while the diesel engine is hot. After the cooling, it is very
difficult to discharge the oil cleanly.
WARNING!
Don’t fill the machinery oil into the diesel engine when the diesel engine is running
2.2.3 Check the air filter
Unfasten the butterfly nut, open the filter cover, and take out the filter core. Never wash the
filter core by using any detergents. When the output is reduced or the color of the
exhausted gas is not good, change the filter core. Never start the generator set without the
air filter core. Otherwise the diesel engine will soon be worn out.
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DIESEL GENERATOR SET USER’S MANUAL
After mounting the filter core, cover the air filter housing and fasten the butterfly nut.
2.2.4 Inspection for the generator set
Before starting the set, be sure that the air switch should be turned to “OFF” state. If the
switch is not turned to “OFF” state, when starting the diesel engine, suddenly loading is
very dangerous.
The generator should be grounded to prevent the electric shock.
Blow the dust out of the generator control box inside and surface by using dry compressed
air (air pressure should be less than 1.96×105Pa) or manual. Check the clean condition on
the slide rings, check the carbon brush pressure, check whether the position on the slide
rings are correctly fitted. Check whether the fixing is reliable and whether the contact is
good.
According to the electric wiring diagram, check whether the wiring lines are correct and
whether the connection joints are firm.
2.2.5 Before delivering the diesel engine from the factory, the fuel oil and the machinery oil
had been discharged.
Before filling the fuel oil and starting the diesel engine, it is necessary to check whether
there is any air mixed into the oil circuit. If there is any, the air should be discharged. The
concrete method is to unfasten the connecting nut between the oil injection pump and the
oil transmission pipe so discharge the air in the fuel oil until no air bubble appear. Then
faster the connecting nut again.
2.3 Inspection and Operation of the Diesel Engine
2.3.1 Low oil pressure alarm system/ breaking device
Diesel engine possesses the low oil pressure alarm system/breaking device. When the oil
pressure goes down, the device will automatically stop the diesel engine to avoid the
blocking-up of the diesel engine because the oil pressure is too low and the lubrication is
insufficient.
If the diesel engine is running under the condition that the lubrication oil is insufficient, the
oil temperature will go up too high. On the other hand, it is also dangerous if there is too
much oil. Because the machinery oil may be burned, this will make that the revolution
speed of the engine increases suddenly and results in “abnormal fast running”. For this
purpose, it is necessary to check the machinery oil and the oil level reach the stipulated
lever.
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DIESEL GENERATOR SET USER’S MANUAL
2.3.2 Trial run operation
When your diesel engine is a new set, a large loading will reduce the engine’s life. Within the
first 20 hours, it is necessary to carry out the trial run.
Avoid the overload. During the trial run stage, it is necessary to avoid the large load. It uses
only 75% of the rated load.
Change the machinery oil of the engine according to the stipulation. At the beginning of the
use, change the oil once each 20-hours or once a month. After this, change the oil once
each 3-months or once for each 100-hours.
2.4 Starting the Generator Set
2.4.1 Recoil start (manual start)
Start the engine according to the following procedures:
(1) Switch on the fuel oil switch (in “ON” position).
(2) Set the speed handle of the engine at “run” position.
(3) Draw out the buffer start handle.
Draw out the handle till you feel your hand has the resistance
force. Then relieve it and let it restore to the initial position.
Press down the pressure reduction handle (when the buffer
starter is drawn, it will automatically be restored.).
Quickly draw out the buffer start handle by two hands. While operating (or after the start),
don’t let the handle fly out of your hand to avoid that it smashes onto the diesel engine.
Slowly and lightly let the handle return its position to avoid damaging the starter.
CAUTION:
When the diesel engine is running, never draw out the start handle otherwise it will damage
the diesel engine.
In the cold days, when it is difficult to start the diesel engine, unplug the rubber cock on the
rocker arm of the diesel engine and fill in 2ml machinery oil.
Plug the rubber cock before the start.
The rubber cock should be plugged except filling in the oil. Otherwise the rain, water, dust
and other dirt may enter into the diesel engine to cause the fast wearing of the inside components.
This will result in serious problem.
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DIESEL GENERATOR SET USER’S MANUAL
2.4.2 Electric start
1. Start (The preparation for this start is the same as the hand start.)
Insert the electric door key and make it in “OFF” position.
Set the speed handle of the diesel engine in “RUN” position.
Turn the start switch to “START” position .
After the diesel engine starts, your hand should relieve the switch handle. Let the switch
restore to “ON” position automatically.
If the diesel engine doesn’t start after 10 seconds, please wait for anther 15 seconds and
make the start again.
CAUTION:
zIf the start motor rotates for a long time and the voltage of the battery will go down to
cause the start motor running hysteresis.
zWhen the diesel engine is in operation, always leave the start key in “ON” position.
2. Battery
Check the electrolyte level height of the battery once a month. When the liquid level goes
down to a lower mark, add some distilled water to make that the liquid level goes up to the
higher mark.
If the electrolyte in the battery is too less, the diesel engine will not start. Because the
electric power is insufficient at this time, it is necessary to keep the liquid is at a place
between the higher limit and the lower limit.
If the electrolyte in the battery is too much, the liquid may overflow and this may corrode
its surrounding components.
Attention should be paid to avoiding that the electrolyte is too much or is too less.
Charge the battery once a month.
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DIESEL GENERATOR SET USER’S MANUAL
2.5. Operation Procedure for Starting the Generator Set
This operation procedure is suitable series recoil hand drawing start mode.
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DIESEL GENERATOR SET USER’S MANUAL
2.6. How to Operate the Welder and Generator Set
2.6.1 Operating the Diesel Engine
Preheat the diesel engine for three minutes under the condition without any load.
For the diesel engine having the low oil pressure alarm system, it is necessary to check
whether the oil pressure signal indicator lights up. For the diesel engine having the low oil
pressure alarm system, the lubrication oil alarm indicator will light up when the oil
pressure is low or the lubrication oil is insufficient, and the diesel engine will stop
automatically. If no lubrication oil is added and you do not make a restart, the diesel engine
will still stop immediately. It is necessary to check the oil height and add some oil.
Do not unfasten the adjustment bolt used for adjusting the speed limit of the diesel engine
or do not unfasten the high-pressure pump limit bolt (They were adjusted well when
delivered from the factory.). otherwise their performance will be affected.
2.6.2 Inspection during the Operation
Check whether there is any abnormal sound or vibration.
Check whether the diesel engine does not start or the operation is not good.
Check the exhausted gas color (Is it black or is it too white?). If you find one of the
above-mentioned phenomena, it is necessary to brake the set, to find out the trouble cause
and shoot the trouble. If the settlement can not be made, please contact agency of our
company nearby, or contact our company directly.
2.7. Loading
2.7.1 Load
Load according to the stipulated parameters. For the electric principle diagram of the
generator set, please see the following figure.
2.7.2 AC Application
Be sure that the revolution speed of the generator set be increased to the rated speed (the
speed handle of the diesel engine should be turned to the top.). please see Main Technical
Specifications and Data in Chapter 1.
After switching on the air switch, observe the voltmeter on the panel of the control cabinet
and the voltmeter should point to the single phase set 220V±5% (50Hz), then the loading
can be carried out.
When the double voltage generator set charges over the voltage, the air switch should be
set at “OFF” state. Otherwise the generator set and the electric devices may be burned out
and damaged.
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DIESEL GENERATOR SET USER’S MANUAL
CAUTION：
Do not start more than two machines at the same time. The machines should be started one
by one. Do not use the floodlight at the same time of using other machines.
At the time of connecting with the generator, all kinds of equipment should be connected in
order. For the matter of the motor load, firstly the large power motors should be connected.
After the operation is normal, then the small power motors can be connected. If the
operation is incorrect, the generator will cause the running hysteresis or will brake suddenly.
It is necessary to unload immediately and to turn off the generator switch. Check where the
trouble appears.
If the circuit overload makes that the air switch of AC circuit trips, it is necessary to reduce
the circuit load. It is not allowed that the set runs under the overload condition. Maximum output
power of the generation for the set should not exceed the stipulation .It is necessary to wait for
several minutes before restoring the operation. If the indication on the voltmeter is too low or too
high, the revolution speed can be adjusted. If there is any trouble and any abnormal running
condition, it is necessary to stop the generator for check.
2.7.3 DC application
DC terminals are used only for charging 12V battery.
At the time of using 12Vfor charge, the air switch should be set at “OFF” state. On the
12Voutput terminals, a charge switch can be connected so the switch can be used for
on-and-off purpose.
At the time of using the automatic type battery with the battery conductors, be sure that the
battery negative conductor should be disconnected at the time of charge.
Connect the positive and negative poles of the battery with the positive and negative poles
of DC terminals separately. Do not misconnect the positive and negative poles of the
battery. Otherwise it will damage the generator and the battery.
Do not connect the positive pole of the battery with its negative pole. Otherwise it will
damage the battery.
Do not let the positive and negative poles of the DC contact to each other. Otherwise it will
damage the generator.
At the time of charging the large capacity battery, because the current is too big (the charge
current should not be more than 10A). Otherwise the fuse of the DC power supply will be
burned off and broken easily.
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DIESEL GENERATOR SET USER’S MANUAL
Charging the battery will produce the flammable gas. Do not let any spark, flame and
cigarette approaching the place. In order to avoid producing the spark near the battery.
Firstly connect the charging conductors with the battery, then with the generator. At the
time of disconnection, firstly disconnect the motor cable.
Charging the battery should be at a place with good ventilation. Before turning on, open the
battery cover. If the electrolyte temperature exceeds 45℃, terminate the charge.
In order to protect the motor, at the terminals of the generator, the generator set has a fuse.
When the user find that the circuit is normal and there is no DC output, please open the
back cover of the motor. If the fuse is burned out, please check whether the
rectification-bridge is normal and change the fuse in time. If the generator set is not in use
for a time, the battery connection lines should be removed to prevent the electric leakage of
the battery.
2.8 Braking the Generator Set
2.8.1 Remove the load of the generator set.
2.8.2 Turn off the air switch of the generator set.
2.8.3 Set the speed handle of the engine to “RUN” position. Carry out the unload operation of the
diesel engine for 3 minutes. Do not brake the diesel engine suddenly because this may make that
the temperature goes up abnormally and cause the blocking-up of the oil nozzle and the damage
of the diesel engine.
Press the braking handle downwards.
When using the electric starter ,turn the key to “OFF”
Set the fuel switch handle to “S” position.
Slowly draw out the recoil handle till you feel the pressure (i.e., at this point of the
compression stroke, the suction and exhaust valves are close.). Stop the handle at this
position. In such a way, when the engine is not in use, the rusting can be prevented.
CAUTION:
zWhen the speed handle is set at “STOP” position and the diesel engine is still in operation,
it is possible to stop the diesel engine either by setting the fuel switch to “OFF” position or
by unfastening the high pressure oil pipe nut. Do not brake the diesel engine by using the
pressure reduction handle.
zIt is not allowed that the set stops with load. It is necessary to firstly remove the load and
then stop the set.
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DIESEL GENERATOR SET USER’S MANUAL
Chapter 3 Maintenance of the Generator Set
3.1 Regular Maintenance
Serviceperiod
regular
Item
Daily
check
First month
or 20 Hrs
Every 3
months or
100 Hrs
Every 6
months or
500 Hrs
Every year
or 1000 Hrs
Check and replenish fuel
○
Drain fuel from F.O. tank
○
Check and replenish lube oil
○
Check for oil leakage
○
Check and tighten each parts
engine
○
●
tighten head bolts
Chang lube oil
○
1st time
○
2nd and thereafter
Clean oil filter
○
(replace if
necessary)
Air cleaner element
replacement (Service more frequently when used in dusty areas)
○
(replace)
Clean fuel filter
○
●
(replace)
Check fuel injection pump
●
Check fuel injection nozzle
●
Check fuel pipe
●
(replace if
necessary)
Adjust valve clearance for
intake and exhaust valves
●
(1st time)
●
Lap intake and exhaust valves
●
Replace piston rings
●
Check battery fluid (monthly)
“●” The chart above indicates which checks to make and when to make them, the mark (●)
Indicates that special tools and skills one required, consult your dealer.
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DIESEL GENERATOR SET USER’S MANUAL
In order to keep the welder and generator sets in a good state, the regular inspection and
maintenance is very important. The set is composed of the diesel engine, welder generator,
control cabinet, frame and so on. For the details about the inspection and maintenance, please
read the operation and maintenance manual for each assembling section.
Before carrying out the maintenance to the set, please turn off the diesel engine. If it is
necessary to run the diesel engine, its surrounding should be in good ventilation to discharge the
gas that contains the poison carbon monoxide.
After using the set, it is necessary to wipe off dirt by using a clean cloth to prevent the
corrosion and remove the sink materials.
3.1.1 Changing engine oil (every 100Hrs)
Remove the oil filler cap. Remove the drain plug and drain the old oil while the engine is still
warm. The plug is located on the bottom of the cylinder block. Tighten the drain plug and refill
with recommended oil.
3.1.2 Cleaning the oil filter
Clean Every 6 months or 500 hours.
Replace Replace if necessary.
3.1.3 Changing the air cleaner element
Do not wash the air cleaner element with detergent because this is a wet type element.
Change
Every 6 months or 500 hours. (or earlier if dirty)
CAUTION:
Never start the engine without the element, or with a defective element. Change the element
in time.
3.1.4 Cleaning and replacing the fuel filter
The fuel filter also has to be cleaned regularly to insure maximum engine output.
Clean Every 6 months or 500 hours.
Replace Every year or 1000 hours.
Drain the fuel oil from the fuel tank.
Loosen the small screws of the fuel cock and pull out the filter from the F.O. tank. Wash
the filter thoroughly with diesel fuel.
Remove the lock nut, end cap and diffuser discs and clean the carbon deposit.
Clean time Every 3 months or 100 hours.
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DIESEL GENERATOR SET USER’S MANUAL
3.1.5 Tightening cylinder head bolts (refer to the manual of diesel engine) requires a special
tool. Don’t try it yourself.
3.1.6 Checking the injection nozzle, injection pump, etc.
Adjusting the valve head clearance for the intake and exhaust valves.
Lapping of intake and exhaust valves.
Replacing piston ring.
All these require special tools and skills. Do not perform the injection nozzle test near an
open fire or any other kind of fire. The fuel spray may ignite. Do not expose bare skin to the fuel
spray. The fuel may penetrate the skin and cause injury to the body. Always keep your body away
from the nozzle.
3.1.7 Checking and replenishing battery fluid and charging the battery.
This diesel engine uses a 12V battery. The battery fluid will be lost through continuous
charging and discharging.
Before starting, check for physical damage to the battery and also the electrolyte level, and
replenish with distilled water up to the upper mark if necessary, when actual damage is
discovered, replace the battery.
Battery fluid check monthly
3.2 Maintenance for a long time storage
If your generator should be storage in a long time, the following preparation should be made:
3.2.1 Operate the diesel engine about 3 minutes, the stop it.
3.2.2 Close the diesel engine when the diesel engine is still hot, drain old lubricate of diesel
engine oil out, then refill new one.
3.2.3 Pull out the rubber plug at the cover of diesel engine and add 2ml of lubricate in
cylinder, and finally put the plug on its original place.
3.2.4 Maintenance of starting position.
Manual starting
Press the pressure-reduce handle (non-compression position), pull the recoil handle 2~3
times. (Don’t start the diesel engine).
Electric starting
When the starting handle is in the position of non-compression position, operate the diesel
engine 2~3 seconds. When the switch is in the position of start, don’t start the diesel
engine.
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DIESEL GENERATOR SET USER’S MANUAL
3.2.5 Pull the pressure-reduce handle out, pull the recoil starter slowly.
When full it is fasten, then stop. (At this time the intake and drain valve is at the status of
close, it is suitable to prevent from rust.).
3.2.6 Clean and store it in a dry place.
Chapter 4 Maintenance and remedy of generator set
Cause Remedy
Oil fuel is not enough Add oil fuel
The switch is not at “ON” position Turn it to “ON” position
The pump of high pressure and oil
nozzle can not inject oil or the oil
amount is not enough
Remove the oil nozzle out and repair it
at test table
The control lever of speed is not at
“RUN” position Put the control level to “RUN” position
Check the level of lubricant The specified oil level should be between upper level “H” and lower
level “L”
The speed and force to pull the recoil
starter is not enough
Start the diesel engine according to the
requirements of operating procedure of
start
The oil nozzle has dirty Clean the nozzle
The diesel
engine can
no start
The battery has no electricity Charge it or replace it with a new one
Main switch (AC SW) is not closed Put the main switch to the “ON” position
Capacitor damage Change capacitor
The contact of socket is not closed Adjust the feet of socket
The
generator
can not
generate The rated speed of generator can not
be reached Adjust it according to the requirement
If electricity is still not generated, take the generator to a dealer.
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