Powermate PMD5000s User manual

OWNER’S MANUAL
AIR-COOLED DIESEL SILENT GENERATORS
MANUALE D’ISTRUZIONI
GENERATORE DIESEL SILENZIOSO RAFFREDDATO AD ARIA
MANUAL DEL USUARIO
GENERADORES DIESEL SILENCIOSOS REFRIGERADOS POR AIRE
MODE D’EMPLOI DE L’USAGER
GROUPES ELECTROGENES SILENCIEUX REFROIDIS A AIR
PMD5000s / PMD5050s
1

PREFACE
PREFACE
Thank you for purchasing products from our company.
The manuals will help you to operate and maintain the machines rightly.
Please make sure to read the manuals carefully before the operating the
machines. Then the generators can work in the best condition and prolong
the life.
.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 slightly from the actual
product as well. The manufacturer reserves the right to make changes
at any time without notice and without incurring any obligation.
Please notice the following warning.
If you will not operate the machines according to the manuals, there may
be body injury and dead.
So you MUST operate the machines after the fully understanding of the
manuals.
2
PR INDUSTRIAL s.r.l.
Loc. Il Piano
CAP 53031, Casole D’Elsa (SI)
ITALIA

TABLE OF CONTENTS
TABLE OF CONTENTS
Chapter 1 Technical Specifications and Data………………….1
1-1 Technical specifications and data……………………………………1
1-2 Basic operating parameters…………………………………………..2
1-3 General dimensions and overview of the generators………………2
1-4 Parts name and control panel………………………………………….3
Chapter 2 Operating the Diesel Generator……………………….....4
2-1 Main points of safety during operation of the generator…………..4
2-2 Preparation before operation…………………………………………5
2-3 Checking the operation of the diesel engine………………………..8
2-4 Starting the generator set……………………………………………..8
2-5 Proper operation of the generator set………………………………..9
2-6 Loading…………………………………………………………………10
2-7 Stopping the generator………………………………………………11
Chapter 3 Maintenance……………………………………………………..12
3-1 Maintenance schedules……………………………………………...12
3-2 Storing for long periods of time……………………………………...13
Chapter 4 Troubleshooting……………………………………………….14
4-1 Troubleshooting procedures………………………………………...14
4-2 Questions and doubts…………………………………………….….14
Chapter 5 Circuit diagram………………………………………………….15
Appendix ⅠType of socket……………………………………………………..18
Appendix ⅡGeneral power list of appliance…………………………………20
3

TECHNICAL SPECIFICATIONS AND DATA
1
CHAPTER 1 TECHNICAL
SPECIFICATIONS AND DATA
1-1 Technical specifications and data
Type
Item
PMD 5000s
PMD 5000s
Generator
Kind
Single phase
Three phase
Frequency(Hz)
50
60
50
60
Rated power (KVA)
4.2
4.5
4.2
4.5
Voltage (A.C)(V)
220V,230V,240V,110/220V,120/240V,
115/230V
400/230V,420/240V,380/220V,
127/200V
Excitation mode
Self-excitation brushless or
Self-excitation constant voltage(AVR)
Self-excitation constant
voltage(AVR)
Revolution (r/min)
3000
3600
3000
3600
Voltage (D.C)(V)
12
Current (D.C)(A)
7
Noise level dB(A)/7m
(0-100%load)
70-74
Power factor cosφ
1
0.8
Insulation grade
F
B
Diesel engine
Model of power
CF186F (E)
Kind
4-stroke single-cylinder air cooled direct injection
Max power (kW/rpm)
6.5
8.6
6.5
8.6
Bore ×stroke (mm)
86×70
Cylinder displacement
(ml)
406
Cooling system
Force air-cooled
Lubricating system
Pressure splash, duplex type lubrication
Volume of lube oil (L)
1.65
Start system
Electric start
Fuel
Diesel fuel
Set
Fuel tank volume (L)
14.5
Low oil pressure
protection
Have
Total weight (kg)
186
Overall dimensions
(mm)
920×520×700
Note: Get this power only after 30 hours’ initial run.
4

TECHNICAL SPECIFICATIONS AND DATA
1-2 Basic operating parameters
1-2.1 Under the given conditions, the generator will output
the specified power in the table listed below.
Table 1
Height above sea level (ft)
Ambient temperature
RH
0
+60°F (+20°C)
60%
<3280.8 ft (<1000 m)
41~104°F (5-40°C)
90%
1-3 General dimensions and overview of the
generators
Please refer to the specification for the right dimension for
different models.
5

TECHNICAL SPECIFICATIONS AND DATA
1-4 Parts name and control panel
1-4.1 Parts Name
Cover of fuel tank
Label
Muffler
(inside)
Battery
(inside)
Door
Wheel
Engine
(inside)
Control Panel
6

OPERATING THE DIESEL GENERATOR
1-4.2 control panel
Single phase Control Panel
Three Phase Control Panel
Low oil protection
indicating lamp (12V)
Voltmeter
99T1-300V
2P support for
breaker
Fuse10 A
Red wire
holder (107)
Black wire
holder (107)
Bolt to the
grounded
Socket SCHUKO
230V 16A
Socket 2P+T
CEE 230V 16A
Electric start switch
Connector
7 contacts
Low oil protection
indicating lamp (12V)
Voltmeter
99T1-300V
2P support for
breaker
Fuse10 A
Red wire
holder (107)
Black wire
holder (107)
Bolt to the
grounded
Socket 2P+T
400V 16A
Socket 2P+T
CEE 230V 16A
Electric start switch
Connector
7 contacts
7

OPERATING THE DIESEL GENERATOR
CHAPTER 2 OPERATING THE DIESEL
GENERATOR
2-1 General main points of safety during
operation of the generator set.
In order to operate the generator set safely, please follow all the
instructions provided in this manual carefully. Doing so otherwise may lead to
accidents and or equipment damage.
2-1.1 Fire prevention
Do not use gasoline, kerosene or other fuels other than light diesel fuel.
Keep all flammable fuels away from the generator as the generator may
spark and ignite these gases.
Keep the diesel generator at least 1.5 meters away from buildings and or
other equipment.
Always operate your diesel generator on a level site.
2-1.2 Prevention from inhaling exhaust gases.
Never inhales exhaust gases emitted by the engine. The exhaust gases
contain toxic carbon monoxide.
Never operate your generator in places with poor ventilation. In order to
operate this machinery indoors, a suitable ventilation system for the building is
required to draw the poisonous exhaust gases out.
2-1.3 Prevention from accidental burns
Never touch the muffler and its cover when the diesel engine is running.
Never touch the muffler and cover after the diesel engine has been used,
as the muffler remains hot for a 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. Please
refer to Fig. 2-1 before beginning to use the electric generator.
Fig. 2-1
8

OPERATING THE DIESEL 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, all operators
should have a good knowledge of how to break
the circuit if any accidents occur. Also, all operators should be familiar with all
the switches and functions of the generator before using this machine. While
operating the generator, wear safe shoes and suitable clothes during operation.
Always keep children and animals away from the generator.
2-1.6 Battery
Wear protective gear when working with the battery to protect your eyes, skin,
and clothing,. If you come in contact with the electrolytic liquid, wash it
immediately with clean water. Also, if the electrolytic liquid comes in contact
with your eyes, see a doctor immediately.
2-2 Preparation before operation
2-2.1 Fuel choices and fuel treatment
Use only light diesel fuel. Otherwise it will be difficult to start the generator.
The fuel should be filtered clean. Never let dust and water mix with fuel in
the fuel tank. Otherwise it will clog the fuel lines and oil nozzles. It may
also damage your pressure pump.
Note
It is dangerous to overfill the fuel tank. Never exceed the red piston in the filter.
Type
PMD 5000s
The effective volume of fuel tank:
14.5L
a. After purchasing fuel, put it into a drum and let it sit for 3-4 days.
Otherwise it contains granule, which will result to clog the fuel lines.
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) .Otherwise they will be taken in.
Contaminated fuel will cause accelerated wear to fuel system part.
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.
9

OPERATING THE DIESEL GENERATOR
2-2.2 Check and fill engine oil
Make sure the generator is on level ground and
remove the dipstick from the engines. if not, the
oil level of the engine which show us are wrong.
Check if the oil level is between the high limit
and low limit. If the engine is new or oil is not
enough, fill the engine with the right engine
oil(10W30).
Put the dipstick back into the hole to check the
engine oil level.
Choose the right engine oil
Engine oil is the most important factor in determining the life of your generator
engine. If you use poor engine oil or if you don’t change the oil regularly, the
piston and cylinder will wear easily or seize up. Also, the life of the other parts
in your engine such as bearings, and other rotating parts will shorten
considerably.
NOTE
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 level is low, fill
it before starting the engine.
A good time to drain the oil from the engine is when the diesel engine is still hot.
If the engine is fully cooled, it is more difficult to drain all the oil out or some
impurities will remain in the engine.
WARNING
Oil dipstick
10

OPERATING THE DIESEL GENERATOR
DO NOT fill engine oil when the machines are running.
2-2.3 Checking the air filter
(1) Open the cover of generators, you will
see the air filter assembly.
(2) Loosen the butterfly nut of air filter,
take the cover of the air filter off and take
the air filter element out.
NOTE
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.
(3) After replacing the air filter element, replace the cover and tighten the
butterfly nut firmly.
If not replace the air filter immediately, the dust in the air will not be adsorbed.
In that case, it stands a good chance to block the air way.
2-2.4 Check the oil way
The fuel and oil in a new engine is drained before sold. Before you start the
engine, please fill the fuel tank and engine oil first. Then, check to see if there
are air bubbles in the engine. If 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.
2-2.5 Check the generators
(1) Close the power switch and disconnect from any load. Otherwise it may
cause electric shock. Even make injures or death.
WARNING
Make sure to close the power switch.
Make sure to ground the generators.
(2) How to use double voltage generators
Push the voltage switch to the right voltage you will use.
WARNING
Make sure to disconnect any load before starting the generators. It is very
dangerous if not.
Air filter cover
11

OPERATING THE DIESEL GENERATOR
Knob handle
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
Diesel engines have a low-pressure sensor system where if the oil pressure
drops too low, the sensor will shut the engine off. The purpose of having this
system is to ensure that the engine does not seize up. If there is not enough oil
in the engine, the temperature of the oil will be raised too high. On the contrary,
if there is too much oil in the engine, the engine oil can slow the engine down
considerably.
2-3.2 How to open the case door/cover
(1) Open the case door: Pull the handle outward and open the door. Do these
checks daily.
(2) Loosen the outer cover bolt of the air filter
and outer cover of the oil nozzle, and then
check the air filter.
(3) Check the outer cover of the oil nozzle.
Loosen the butterfly nut and open the outer
cover.
2-3.3 Engine break in
When you purchase a brand new engine, the engine must be properly broken
in. The break in period is about 20 hours.
(1) Avoid overloading the engine when brand new
(2) Change the engine oil according to specifications. An oil change for a brand
new engine is about 20 hours or every month, an older engine, the oil change
is about 100 hours or three months.
If not breaking in, it will reduce the serving life, reliability and cost performance
of the engine. At last, the life of the generator also be shortened.
2-4 Starting the generator set
2-4.1 Starting.
(1) Make certain the generator is on a " FLAT " or " LEVEL SURFACE ". If the
engine is tilled, fuel spillage may result.
(2) Disconnect all electrical loads from the generator. Never start and stop the
generator with electrical devices plugged in or turned on. Otherwise it will result
to short circuit, even break down the starter motor.
(3) Turn the Fuel Valve to the " ON " position. Otherwise fuel will be not enough
to start the generator.
(4). Push the speed level to " run " Position. If do not so, the start of generator
will be fail.
(5) Insert the ignition key to the “off ”position.
(6) Electric Start: Turn the ignition key to the " Start " position and hold until
12

OPERATING THE DIESEL GENERATOR
engine starts. Otherwise it will be abnormal to electrify. ( If the engine fails to
start within five seconds, release the key and wait at least ten seconds before
attempting to start the engine again. If holding on starting, it will heat up motor.)
(7) As engine warms up, move the ignition key to " on " position. Otherwise the
fuel way will cause serious trouble.
2-4.2 Battery
NOTE
If you crank the starter too 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 NOTE
All of our units come with a maintenance free battery. You do not need to add
any battery acid.
2-5 Proper operation of the generator set
2-5.1 Operating the diesel engine
1. Pre-heat the diesel engine for 3 minutes under no load conditions.
2. First check the low oil pressure indication light in the panel. If the light is red,
please fill into enough oil.
3. Do not adjust the speed limit regulation bolt or the fuel adjustment bolt.
These bolts have been set by the factory already, changing them will affect the
properties of the engine performance.
2-5.2 Checks during engine operation
1. Check to see if there are abnormal noises. Check the joint of oil passages,
fuel passages, water passages and air passages frequently to find out whether
there is any leakage. If any, remove at once. Otherwise serious troubles may
be caused.
2. Check to see if the performance is good or bad.
3. Check the color of the exhaust gases (whether it is too black or too white).
If any of these conditions exist, stop the engine and find the cause of the
problem. If no problems are found, please contact your local dealer or our
nearest company branch.
13

OPERATING THE DIESEL GENERATOR
2-6 Loading
2-6.1 Connecting Electrical Loads:
1. Let the engine stably and warm up for a few minutes after starting.
2. Plug in and turn on the desired VOLTAGE AC Output with electrical loads.
IMPORTANT NOTE
DO NOT connect 3-phase loads to SINGLE PHASE Diesel Generator.
DO NOT overload this generator.
To prolong the life of your generator and properly connect your appliances,
please follow these steps to add electrical load:
3. Start the generator with NO ELECTRICAL LOAD ATTACHED.
4. Allow the engine to run for several minutes to STABILIZE.
5. Plug in and turn on the first item. It is best to attached the item with the
LARGEST LOAD first.
6. Allow the engine to stabilize.
7. Plug in and turn on the next item.
8. Allow the engine to STABILIZE.
9. Repeat step 4-5 for each capacity when adding loads.
2-6.2 Output of electricity
1. Raise the revolutions per minute (turn the speed handle to the max setting)
of the generator to get the maximum power out of the generator. If not, the
automatic voltage regulator device will excite and doing this for long periods
of time will cause the AVR to burn. For the rated speed of the generator,
please refer to Chapter 1, item 1-1 technical specification and data.
2. Observe the pointer of the voltmeter, it should point to the voltage you need
5%. Meanwhile put the switch in the GEN (generator) position. The AC
voltage from the socket of the power supply can be output.
2-6.3 Charging the battery
1. For the electric starter on the generator sets, the 12V battery is automatically
charged through the regulator on the side of the engine when it is running.
2. If the generator is not used for long periods of time, the battery should be
disconnected to avoid energy loss from the battery.
3. Do not connect the negative and positive terminals of the battery together at
any time. Doing so will damage the battery and cause serious injuries.
4. Do not reverse the polarities when attaching the battery cables to the battery.
NOTE
Do not start more than two devices simultaneously. Each device should be
started one by one to prevent overloading the generator.
The generator should be running at 3600 revolutions per minute in order to
achieve the (60 Hz) frequency. The speed of the engine can be adjusted from
the speed governor.
14

OPERATING THE DIESEL GENERATOR
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.
2-7 Stopping the generator
1. Take the electrical load off the generator, when you want to stop the
generators.
2. Move the air switch to “off”position. If not, the short circuit will appear.
3. 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.
NOTE
1. If you cannot stop the engine with a
load on it, then remove the load first
than stop the engine.
2. Press down on the brake handle.
3. If equipped with an electric starter,
turn the key to the “Off” position.
4. Put the fuel handle to the “S”
position.
4. Put the ignition key to “off”position. Then the generators will stop.
5. Move the speed level to “stop”position, which make sure to cut off the fuel
way.
6. Close the fuel valve. But don’t stall the generator by turning off the cock of
the fuel tank in case air enters fuel passages to cause difficult starting next
time.
Speed
handle
15

MAINTENANCE
CHAPTER 3 MAINTENANCE
3-1 Maintenance schedules
Keeping your generator well maintained will prolong the life of your generator.
Everything needs to be checked including the diesel engine, generator, control
cabinet, and frame. For overhauling procedures, please refer to the instruction
manual of the relative subassembly. If you need these manuals, please call our
company and we will send you one.
Before starting the maintenance, make sure the diesel engine is off.
Please refer to the Table 3-1 for the proper maintenance schedule.
Table 3-1. Maintenance schedule for diesel generator set
Time
Item
Everyday
After 1
month or
50hours
Every 3 month
or 200 hours
Every 6 month
or 400 hours
Every 1year
or 1000 hours
Check the fuel
level and refill
○Before
starting
Drain the fuel tank
○
Check and fill
enough engine oil
○
Clean the fuel
filter
○
Check fuel oil
leakage
○after
every
operating
Check and screw
each fastened part
○
●screw the bolt of
cylinder head firmly
Check injector
●
Checkinjectionpump
●
Check fuel pipe
●If necessary
exchange it
Checkthelube.oillevelin
theoilpanandrefill
○before
starting
Replace the lube.
oil
○the first
time
○the second time
and afterward
Clean lube. Oil
filter
○the first
time
○the second time
and afterward
Check the air
cleaner element
○the first
time
○the second time
and afterward
Change the core
of air filter
If damaged or smeary , change it in time
Check the battery
liquid level and
refill
○
Adjusting the intake
and exhaust valve
clearance
●the first
time
●the second
time and
afterward
Grind air intake and
air exhausted gate
●
Exchangepistonring
●
Check electric brush
and slide ring
●
Check insulation
resistance
The time of stop is over 10 days ○
Note: the quality period of the injector and injection pump is 1500 hours
or two years. There into,●means it should operate with special
tools, or can be checked by dealer.
16

MAINTENANCE
Dipstick
Oildrainbolt
3-1.1 Changing the engine oil (every 100 hours)
Take the oil cover off. Remove the oil drain plug
when the diesel engine is still hot. Be careful of
hot oil and hot engine as you may get burned. The
bolt is located at the bottom of the cylinder. After
draining the oil, put the bolt back and tighten it.
Then fill with the proper engine oil to the proper
level.
3-1.2 Air filter maintenance schedule
1. Clean air-filter every 6 months or 500 hours of operation.
2. If necessary, exchange it.
3. Do not use detergent to clean air filter element.
NOTE
Never start the engine without the air filter. This can cause serious damage to
the engine if foreign objects enter the intake system. Always change the air
filter on time.
3-1.3 Fuel filter maintenance
1. The fuel filter should be cleaned often to keep the engine running at
maximum performance.
2. The recommended time period for cleaning the fuel filter is 6 months or 500
hours of operation.
a. To do this, first drain the fuel from the fuel tank.
b. Loosen the small screws on the fuel switch and remove the fuel filter form
the port. Use diesel fuel to clean the fuel filter. Also, remove the fuel injector
and clean the carbon deposit around it. The recommended time period for this
is 3 months or 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 required 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.
1. Start the diesel 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. 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)
4. Clean the engine and store it in a dry place.
17

TROUBLESHOOTING
CHAPTER 4 TROUBLESHOOTING
4-1 Troubleshooting procedures
Causes of malfunction
Remedy
Diesel cannot be started.
Not enough fuel
Add enough fuel
The switch of fuel is not at
“OPEN” position.
Turn the switch of fuel to “OPEN”
position.
High-pressure pump and nozzle
do not inject fuel or the injected
amount is less.
Disassemble the nozzle and adjust it
at test table.
Speed control lever is not at
“RUN” position.
Turn speed control lever to “RUN”
position.
Check level of lubrication oil.
The standard oil amount of
lubricating oil should be between
high graduation “H” and low
graduation “L”.
It is not quick and powerful to pull
reactive starter.
Start diesel engine in accordance
with the requirements of “start
operation procedures”.
Nozzle exist dirt.
Clean the nozzle.
Accumulator has not electricity.
Charge the accumulator or
exchange it.
Generator cannot generate electricity
and has not welding voltage
Master switch (NFB) is not be
switched on.
Turn master switch handle to “ON”
position.
Carbon brush of generator was
worn. The contact is bad.
Exchange the carbon brush.
The contact of socket is bad.
Adjust the contact feet of socket.
The rated revolution of engine
cannot be reached.
Make it reach to the rated revolution
in accordance with the
requirements.
AVR automatic governor is
damaged.
Exchange it.
The potentiometer of current
regulation for electric welding is
damaged.
Exchange it.
If you are still having trouble, please contact with your nearest dealer or with
our company directly if necessary.
4-2 Questions and doubts
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 atmosphere.
18

CIRCUIT DIAGRAM
CHAPTER 5 CIRCUIT DIAGRAM
Figure 5-1 single-phase double voltage circuit diagram
19

CIRCUIT DIAGRAM
Figure 5-2 single-phase single voltage circuit diagram
20