Neilsen BDE3500E, BDE5000E, BDE2200E, BDE6700T, BDE6500T Original Instructions Manual

...

Download

DIESEL GENERATOR

SINGLE PHASE:

BDE2200E

BDE3500E

BDE5000E

BDE6500TW

BDE6700T

BDE6500T

BDE6700TN

BDE6500TW3

BDE6700T3

BDE6500T3

BDE6700TN3

PLEASE READ THIS MANUAL CAREFULLY. IT CONTAINS IMPORTANT SAFETY INFORMATION.

ORIGINAL INSTRUCTIONS

EC DECLARATION OF CONFORMITY

We CANNON TOOLS LTD 20 Station road, Rowley Regis, West Midlands,B65 0JU.U.K.

Declare that the following machine complies with the appropriate basic safety and health requirements of the EC Directive based on its design and type, as brought into circulation by us.

In case of alteration of the machine, not agreed upon by us, this declaration will lose its validity. Product description: Diesel Generator Model:

CT2020 CT1848

CT1788 CT0405

CT3998

CT0012

CT3999

BDE2200E BDE3500E BDE5000E BDE6500TW BDE6700T BDE6500T BDE6700TN BDE6500TW3 BDE6700T3 BDE6500T3 BDE6700TN3

Appropriate EC directives:

- EC-Machinery Directive 2006/42/EC

- EC-EMC Directive 2014/30/EU

Applicable Harmonized Standards: EN12601, EN60204, EN55012

20 Station Road, Rowley Regis, West Midlands, B65 0JU.U.K. Mr. Gurcharan Tony Singh Sanghera Managing Director

CANNON TOOLS LTD

2015-12-04

Symbols used in this manual

General safety warnings

The generator may only be used in well ventilated areas.

The rated power of a connected power consuming load must not exceed the generator’s rating.

Overloading the generator poses a risk and can lead to serious damage and/or injury. Disconnect the generator before carrying out any kind of maintenance. Let the engine reach full speed before connecting a power consuming load. Always start the engine before connecting consumers to the outputs. Check the generator for signs of damage before attempting to use. Stay clear of moving parts during operation.

Never allow children or animals near the generator at least 5m. Do not allow the generator to run out of fuel when a load is connected. During operation voltage fluctuations may occur. Sensitive electronic devices like television sets or computers may only be operated in conjunction with a surge protector. Do not interfere with the internal wiring. Never climb or stand on the generator. To prevent the risk of burns do not touch the engine, alternator or exhaust. These parts become extremely hot during operation.

Operational safety warnings

To prevent overheating of the engine keep a distance of at least 1M from buildings or other objects when operating the generator. Ensure that the generator is standing level on a flat, solid surface. Ensure that the surrounding area is free from flammable materials or objects that can be damaged by heat. Never move or tilt the generator during operation.

HANDLING & STORAGE

CAUTION: Always use and store this generator correctly, never use or store this generator on it’s side as oil or fuel may leak and damage the generator or your property. If the generator has been used always allow it to cool for at least 30 minutes before transporting the generator and ensure that the generator has fully cooled before returning it to storage as a hot engine and exhaust system could cause personal injury or ignite some materials. To prevent fuel/oil spillage when transporting, the generator should be secured upright in it’s normal operating position with the engine switch in the off position. Take care not to drop or strike the generator when transporting. Never cover the generator when in use. Before starting the generator for a long period: Be sure that the storage area is free of excessive humidity and dust. Drain the fuel, storage procedure below. Unscrew the fuel tank cap, remove the filter screen and empty the fuel tank into an approved diesel container using a commercially available hand siphon, re-install the filter screen and fuel tank cap. Loosen the carburetor drain screw and drain the carburetor into a suitable container.

Remove the spark plug maintenance cover and remove the spark plug cap. Turn the engine switch to the OFF position. Pull the starter cord 3 or 4 times to empty the fuel pump of diesel, into a suitable container. Turn the engine switch to the OFF position and tighten the carburetor drain screw.

Work area safety

a) Among engine exhaust emissions, there is Toxic CO, so never use in an enclosed room

without good ventilation. Use the generator in closed environment will cause CO poisoning.

b) For afraid of Fire, never use in a place where keeping in flammable and explosive

dangerous, never forward the vent-pipe to Buildings and Equipments, Filling before stalling engine is forbidden

Oil use safety

a) USE FRESH UNLEADED GASOLINE ONLY. Any other oil may hurt will damage the

machine. b) TANK CAPACITY: 18L. The maximum capacity of the generator is 18L. c) Check if there is any fuel spilling or leakage. Any fuel spilling may cause a fire disaster. d) No refueling when the engine is working. Refueling the generator when it is working will

cause a fire. e) Be sure wipe out the spilling oil for afraid of Fire. Spilling oil will increase the risk of fire.

Fire hazard

The extreme flammability and potential explosiveness of diesel and its fumes must be considered in all assessment of risk by the operator. The engine must be OFF when refilling the tank. Refill the tank away from all sources of direct or convectional heat. Refill the tank only in well ventilated areas. Do not overfill the tank. Do not smoke or allow flames or sparks where the generator is refuelled or the fuel is stored. Do not start the engine if there is a fuel spillage. Spillages must be wiped away immediately and the generator allowed to dry out completely before starting the engine. Parts of the generator become extremely hot during operation. Keep a safe distance of at least one metre from buildings, other objects or flammable materials when working with the enerator. Let the generator cool down completely before storage.

Dry chemical fire extinguisher to be used.

Electric hazard

Do not operate the generator near water, in damp or wet conditions. Do not touch the generator with wet hands. Do not clean the generator with water. The generator must not be connected to a mains supply or any other electrical source. If an extension cable is required, ensure that the conductors are of sufficient diameter to carry the current drawn by any power consuming device connected. The rated power of a connected load must not exceed the generator’s rating.

Fumes hazard

Fuel fumes are poisonous. Do not inhale. Exhaust fumes contain carbon monoxide. Carbon monoxide can be extremely dangerous or even fatal. Never run the generator indoors. Only operate the machine in well ventilated areas. The exhaust fumes produced can be very hot. Stay clear of the exhaust system and never cover the generator during operation.

Anyone who operates or services the machine must be familiar with these instructions and must be aware of possible dangers. This product may only be used by a competent person in case of doubt seek training or advice from an expert. Any applicable health and safety regulations must be followed.

NOTE! Major repair works shall be carried out only by specifically trained personnel (see items prefix with ☆ in Table of 8. PERIODIC CHECK AND SERVICE). Maintenance space needs at least 1.5m

Maintenance

Good maintenance is essential for safe, economical, and trouble-free operation, It will also help reduce air pollution. Exhaust gas contains poisonous carbon monoxide. Shut off the engine before performing any maintenance. If the engine must be run, make sure the area is well ventilated.

Periodic maintenance and adjustment is necessary to keep the generator in good operating condition. Perform the service and inspection at the intervals shown in the Maintenance schedule below:

(1) Service more frequently when used in dusty areas. (2) These items should be serviced by an authorized generator dealer. (3) When more often use, only servicing according to above correct intervals can insure the

generator set long-term use.

1. MAIN TECHNICAL SPECIFICATIONS AND DATA

1.1 Main Technical Specifications and Data

BDE6500TW3

BDE6500T3

BDE6700T3

BDE6700TN3

5.0 416/240

8.7

3600

Three phases

0.8(lag)

Controlled silicon self excitation constant voltage

12V/8.3A

12 hour continuous running E: Frame type T:Hand cart type

Transmission rigid connection

170

E:720X480X645

T:910X520X740

4.6 230/380

7.9/8.7

3000

BDE6500TW

BDE6500T

BDE6700T

BDE6700TN

5.0 240/120

20.8/41.7

3600

Single phase

1 12V/8.3A

170/190 E:720X480X645

T:910X520X740

4.6 230/115

20/40

3000

BDE5000E

5 240/120

20.8/41.7

3600

Single phase

1 12V/8.3A

139

E:720X480X645

T:910X520X740

4.2 230/115

18.3

3000

BDE3500E

3.0 240/120

13.8/27.5

3600

E640x480x530

T:830x520x740

2.8 230/115

12/24

3000

BDE2200E

2.0 240/120

8.3/16.7

3600

575x400x500 50

1.8 230/115

7.8

3000

Model

Item

Rated frequency(Hz)

Rated power (kW)

Rated Voltage (V)

Rated current (A)

Rated revolution

speed(r/min)

Phase No.

Power factor(cosφ )

Excitation mode

DCoutput

Operation mode

Structure mode

Coupling method

Gross weight(kg)

Overall dimensions

(LXWXH)(mm)

Generating set

Sound pressure level LpA: 75.1 dB(A) Sound power level LwA: 95.1 dB(A) Guaranteed sound power level LwA: 97 dB(A)

Note: A is intelligent control panel

BDE6500TW3

BDE6500T3

BDE6700T3

BDE6700TN3

186

4-stroke, single-cylinder, air-cooled, direct injection diesel engine

6.25

6.88

86 x 72

418

Forced air-cooled system

20:1

1.65

CX:Recoil starter E.T:Electric starter

Diesel 0#(summer)-10#(winter)

15/30

With

5.7

6.25

BDE6500TW

BDE6500T

BDE6700T

BDE6700TN

186

6.25

6.88

86 x 72

406

1.65

15/30

5.7

6.25 BDE5000E

186

6.3

6.6

86 x 70

406

1.65

CX:Recoil starter T.E:Electric starter

Diesel oil

5.7

6.3 BDE3500E

178

4.0

3.75

78 x 62

296

1.1

3.7

3.5 BDE2200E

170

2.5

2.75

70 x 55

211

0.75

2.2

2.5

Model

Item

Model

Type

Rated power kW)

Max. Power(kW)

Bore x stroke(mm)

Displacement (CC)

Cooling system

Compression ratio

Lube oil capacity(L)

Starting system

Fuel oil

Fuel tank volume (L)

Low oil alarm

system

Engine

Proper use

The device is designed for applications operated with 230 V and 115V alternating current source. Be sure to observe the restrictions in the safety instructions. The generator is intended to provide electric tools and light sources with electricity. When using the device with household appliances, please check their suitability in accordance with the relevant manufacturer’s instructions. In case of doubt, ask an authorized dealer of the respective appliance. The machine is to be used only for its prescribed purpose. Any other use is deemed to be a case of misuse. The user / operator and not the manufacturer will be liable for any damage or injuries of any kind caused as a result of this. Please note that our equipment has not been designed for use in commercial, trade or industrial applications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.

Before putting the machine into operation

1. Electrical safety: Electric supply cables and connected equipment must be in perfect condition. The generator is to be operated only with equipment whose voltage specifications conform with the generator's output voltage. Never connect the generator to the power supply (socket-outlet). Keep the cable length to the consumer as short as possible.

2. Environmental protection Dispose of soiled maintenance material and operating materials at the appropriate collection point. Recycle packaging material, metal and plastics.

3. Connecting to earth The housing is allowed to be connected to earth in order to discharge static electricity. To do this, connect one end of a cable to the earth connection on the generator (Fig. 4) and the other end to an external earth (for example an earthing rod).

Operation

Important! You must fill up with engine oil (approx. 0.6 l) and fuel before you can start the engine. Check the fuel level and top it up if necessary Make sure that the generator has sufficient ventilation Make sure that the ignition cable is secured to the spark plug Inspect the immediate vicinity of the generator Disconnect any electrical equipment which may already be connected to the generator

1. Starting the engine Open the diesel cock by turning it down Move the ON/OFF switch to position "ON” with the key. Move the choke lever to position IØI. Start the engine with the reversing starter by pulling the handle forcefully. If the engine does not start, pull the handle again. Push the choke lever back again after the engine has started.

Important!

When starting with the reserve starter, the motor may recoil suddenly as it starts up, resulting in hand injuries. Wear protective gloves when starting the equipment.

2. Connecting consumers to the generator Connect the equipment you want to use to the 230 V and 115V~sockets (3) Important: These sockets may be loaded continuously (S1) with 2600W and temporarily (S2) for a maximum of 2 minutes with 2800W. The generator is suitable for 230 V and 115V~ AC appliances. Do not connect the generator to the domestic power network as this may result in damage to the generator itself or to other electrical appliances in your home. Note: Some electrical appliances (power jigsaws, drills, etc.) may have a higher level of power consumption when used in difficult conditions.

3. Switching off the engine Before you switch off the generator, allow it to run briefly with no consumers so that it can "cool

down” Move the ON/OFF switch to position "OFF” with the key.

Close the diesel cock

2.1 Parts name(BDE series E/X type)

2.1 Parts name(BDE series T type)

2.2 Control panel

C type panel E type panel

E model receptacle panel

E3 type three-phase panel EW welding panel

E type basic model panel E type panel A model double voltage panel

Intelligent control panel

3. PREPARATION FOR STARTING

3.1 Selection and handling of the fuel oil

 Selection of fuel oil

Only use the light diesel, which is most suitable for the engine.

 Keep dust and water out of the fuel

When filling the fuel tank from drums, make sure that no dust or water is mixed in the fuel. Otherwise the serious fuel injection pump and nozzle problems will result.

 Do not overfill

Overfilling is very dangerous.Do not fill the tank beyond the top of the red plug inside the fuel oil filter.

 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 the fuel oil stored.

 Do not overfill the tank,make sure the filler 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.

3.2 Check and refill the engine oil

 Always check the engine oil level with the generating set on a level surface before

starting and refill if necessary.

 The engine may be damaged if operated with insufficient engine oil, it is also

dangerous to refill too much engine oil as sudden increase in engine speed may be caused by its combustion.

WARNING

CAUTION:

OUR series generating set are equipped with low oil warning system. This system will stops the engine automatically when the oil level falls below the lower level. This prevents accidents such as bearing seizures, etc.

 Select the most applicable engine oil

It is very important to select the applicable engine oil for keep up the performance and life of the generating set. If inferior engine oil is used, or if your engine oil is not replaced periodically, the risk of piston seizure, piston ring sticking and accelerated wear of the cylinder liner, bearing and other moving components increases significantly. So the generating set life will be shortened. Recommends CC/CD oil classified by API. Choose the applicable viscosity oil according to the local ambient temperature.

3.3 Service the air cleaner

1. Screw off the wing nut, remove the air cleaner cover and take out the element.

CAUTION:

 Do not wash the element with detergent.  Replace the element when its output

decrease or a bad exhaust color is noticed.

 Never run the generating set without

the element, otherwise the rapid engine wear will result.

Air cleaner

X/E type

Air cleaner inspection port cover

2. Reattach the air cleaner cover and screw on the wing nut.

3.4 Check the generating set

1. Turn off the main switch and any other

Loads.

WARNING:

 Be sure to turn off the main switch

before starting.

 The generating set should be earthed

to prevent electric shocks.

WARNING:

 The generating set should be earthed

to prevent electric shocks.

AC Output receptacle

Ground terminal

Element

2. Handling of dual voltage type generating

sets. Be sure to place the changeover switch in the correct position for the rated voltage of the working instrument.

 The main switch should always be kept in the “ON” position during operation.  Before starting the engine, be sure to turn the switches of the working instrument

(lighting apparatus, motor, etc.) to their “OFF” position. If the switches are not “OFF”, the sudden application of load when the engine is started could be very dangerous.

3.5 How to open the cabinet door and covers of LDE series generating set

1. Open the cabinet door for daily inspection. Turn the lever counterclockwise and Raise the door.

2. Loosen the bolt of the air cleaner Check port cover to check the air cleaner.

3. Screw off the wing nut to open the cover, the check the nozzle cover.

3.6 Break-in period operation

The first 20hrs are the break-in period of the engine, the operator must obey to following

items:

 Warm up the engine 5 minutes after the initial starting. Run the engine at low

speed and zero load before the engine becomes warm.

CAUTION

 Avoid applying any heavy loads during the break-in period. Recommends to

run the engine at 3000r/min with 50% load in break-in period. Replace the engine oil on time.

 Replace the engine oil while the engine is warm after 20-hours-running, the

old engine oil will be drained out completely.

4. START THE GENERATING SET

 Do not hook up tools or other apparatus to the generating set before starting.

4.1 Recoil starting

Start the engine according to the following procedures:

1. Open the fuel cock.

WARNING

Photo shows open position

2. Set the engine speed lever at the position.

3. Pull out the recoil starter handle.

 Pull out the handle until you feel the

resistance, then return it back to the initial position.

 Press down the decompression lever.

It will return automatically when the recoil starter is pulled.

 Pull out the recoil starter handle briskly

with both hands.

 Do not allow the handle grip to snap back against the engine. Return it gently to

prevent damage to the starter.

 When the engine is difficult to start in cold weather, remove the screw plug from the

cylinder head cover and add 2cc engine oil.

 Always screw on the screw plug on the cylinder head cover except filling,

to prevent the rain and dirty flowing into the engine body. Otherwise the quick wear of the internal parts and other serious problems will result.

Engine speed lever

Photo shows RUN position

Decompression lever

CAUTION

4.2 Electric starting

1. Starting (The preparations for electric

starting are the same as for the recoil Starting.)

 Open the fuel cock.

 Set the engine speed lever at

“RUN” position.

 Turn the starting key clockwise to

“START” position. Remove your hand from the key as soon as the engine starts. If the starting motor doer not start after 10 seconds, wait 15 seconds before starting it again.

 Run the starting motor for long time will cost the battery power greatly even burn out

the motor.

 Always leave the starting key at “ON” position while the engine is running.

Engine speed lever

Photo shows RUN position

Engine starter key

CAUTION

2. Battery

Check the battery electrolyte level every month. Refill the distilled water until the upper limits if the electrolyte dropped to the lower limits.

 If the electrolyte level is too low, the engine may fail to start because

there is not sufficient power.On the other side if the electrolyte level is too high,the fluid will corrode the surrounding parts. Do keep the electrolyte level between the upper and lower limits.

5. OPERATE THE GENERATING SET

5.1 Operate the generating set

1. Warm up the engine without load three

Minutes.

2. Concerning the generating set with Low

Oil Warning System, check that the Oil Alarm Lamp is not lit.

CAUTION

Fuel injection limiting bolt

 For the generating set with Low Oil Warning System, the Oil Alarm Lamp

will activated by low oil pressure or engine oil shortage, simultaneously, the engine will stop. The engine will stop immediately if restarted without refilling the engine oil. Check the oil level and refill.

 Do not loosen or readjust either the engine speed limiting bolt or fuel injection bolt,

otherwise , the performance will be affected.

5.2 Checks during the running

1. Whether there is abnormal sound or vibration;

2. Whether the engine misfires or runs rough;

3. Check the color of the exhaust.(Is it black or too white?)

If you notice any of the above-mentioned phenomenon happened, stop the engine and find

out the fault cause or contact with agent.

 If the engine has been running, the muffler will be vary hot. Be careful not to touch the

muffler.

 Never refill the fuel tank while the engine is running.

6. LOAD

 Do not start 2 or more machines simultaneously. Start them one by one.  Do not use floodlights together with other machines.

CAUTION

6.1 AC application

1. Be sure to run the generating set at rated speed, otherwise AVR(Automatic Voltage

Regulator) will produce the forced excitation. If the running is for a long time unser such condition,AVR will be burned out.

2. After switching on the air switch, observe the voltmeter on the panel of the control cabinet,

the voltmeter should point to 230V±5%(50Hz) for single-phase generating set;400V± 5%(50Hz) for three-phase generating set, then the loading can be carried out.

3. When the double voltage generating set changes over the voltage, the air switch should be

set at “OFF” position. Otherwise the generating set and electric devices will be burned out and damaged.

4. Connect the equipment to the generating set in order. For the matter of the motor load, firstly

the heavy-duty motor should be connected, then the light-duty motors. If the operation is false, the generating set will lag or stop suddenly. It is necessary to unload the generating set immediately and turn off the main switch and do checks.

5. Three-phase generating set

 Balance three phase during the operation. Stop the engine for check if the tolerance exceed

20%.Be sure to keep the tolerance among three phases less than 20%.

 The load for each phase must below the rated load as well as the current must less than

rated current. A,B,C,D(or U,V,W,N) phase arrangement should be from left to right, or clockwise.

 Concerning starting the three phase asynchronous motors, first start the heavy-duty motors,

then start the light-duty motors.

 If overloading of the circuit trips the AC circuit protector, reduce the

electrical load on the circuit, and wait a few minutes before resuming operation.

NOTE

6.2 DC application

1. DC terminals are only for charging 12V battery.

2. Set the air switch at “OFF” position while charging. On the 12V output terminals, a charge

switch can be connected so the switch can be used for on-and-off purpose.

3. Concerning the automatic type battery with the leads, be sure to disconnect the negative

leads of the battery while charging.

 Connect the positive and negative poles of the battery with the positive and negative

poles of DC terminals separately. Do not confuse them, otherwise the battery and generating set will burn out.

 Do not connect the positive pole of the battery with its negative pole, otherwise the

battery damage will result.

 Do not connect the positive pole of the DC terminal with its negative pole, otherwise

the generating set damage will result.

 When a large capacity battery is charged, excessive current flows, the fuse for the

direct current will burn out.

 Do not run the generating set while it is still connected with the battery.  Do not use DC12V and AC at the same time.

 Battery exhausts explosive gas. Keep sparks, flames, and cigarettes away from the

battery. To prevent from creating a spark near the battery, always connect the charging cables to the battery first and only then to the generating set. When disconnecting, you should disconnect the cables at the generating set first.

 Charge the battery at a well-ventilated place.  Before charging, remove the cap from each cell of the battery.  Stop charging if the electrolyte temperature exceed 45oC.

CAUTION

6.3 Electrical appliance particularly motor-driven equipment will produce very high current while

starting, the below table provides the reference for connecting these apparatus to the generating set.

TYPE

WATTAGE

TYPICAL

APPLIANCE

EXAMPLE

STARTING

RATED

APPLIANCE

STARTING

RATED

●Incandescent

lamp

●Heating

appliance

X 1

Incandescent

lamp

Incandescent

lamp

100W

100VA(W)

100VA(W

)

●Fluorescent

lamp

X 2

X 1.5

Fluorescent

lamp

Fluorescent

lamp

80VA(W)

60VA(W)

●Motordriven

equipment

X 3~5

X 2

Refrigerator

Electric fan

Refrigerator

150W

450-750

VA(W)

300VA

7. STOP YOUR GENERATING SET

1. Disconnect the load from the generating set.

2. Turn off the air switch of the generating set.

3. Set the speed lever at “RUN” POSITION, run

the generating set without load for about 3

minutes. Do not stop the engine suddenly, otherwise the temperature will be damaged.

 Press down stop lever.  Concerning the electric starter, turn the

key to “OFF”

 Turn the fuel cock lever to “S” position.  Pull out the recoil starter handle until you

feel resistance (at the position, both intake/exhaust valve are closed.) and leave the handle in this position. This prevents the engine from rust.

 If the engine keep on running even after the speed lever is placed at the “STOP”

position, either turn the fuel cock to the “CLOSE” position or loosen the nut of high pressure fuel pipe on the pump side to stop the engine.

 Do not stop the engine with the decompression lever.  Do not stop the generating set with load. Stop it after the load removed.

With engine speed level at STOP position

stop lever

WARNING

8. PERIODIC CHECK AND SERVICE

Periodic check and service are very important for keeping the engine in good condition and durable. The chart below indicates what checks to make and when to make them.

 Shut off the engine before performing any service. If the engine must be run, make

sure the area is well ventilated. The exhaust contains poisonous carbon monoxide gas.

 After the generating set has been used, clean it immediately with a cloth to prevent

corrosion and to remove sediment.

Interals

Item

Every

day

First month

or 20 Hrs

Third month or

100Hrs

Sixth month

Or 500Hrs

Every year

or 1000Hrs

Check and refill fuel oil

Drain out fuel oil

Check and refill fuel oil

Check for oil leakage

Check and tighten fastening

parts

(Tighten the

cylinder head

bolts)

Replace engine oil

（First time）

（second time）

Clean engine oil filter

（Replace if necessary）

☆Replace air cleaner element

(Service more frequently when used in dusty

areas)

（Replace）

☆Clean fuel oil filter

(Replace)

☆Check fuel injection pump

☆Check nozzle

☆Check fuel pipe

(Replace if necessary)

☆Adjust clearance of intake/exhaust valves

(First

time)

☆Grind intake/exhaust valves

☆Replace pistion ring

Check battery electrolyte

Every month

☆Check carbon brush and slip ring

☆Check insulation resistance

The generating set has been stored more than 10 days

Note: “O” indicates that special tools are required, please contact with agent.

WARNING

8.1 Replace engine oil

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 the recommended oil.

8.2 Clean the engine oil filter

Cleaning time

Every 6 months or 500 hours

Replace if necessary

8.3 Replace the air cleaner clement

Do not clean the air cleaner element with detergent.

Replace time

Every 6 months or 500 hours

 Never run the engine without the element or with a defective element

8.4 Clean and replace fuel oil filter

The fuel oil filter also has to cleaned regularly to insure maximum engine output.

Clean time

Every 6 months or 500 hours

Replace time

Every year or 1000 hours

CAUTION

Oil filler cap/Dip stick

Drain plug

Oil filler cap/Dip stick

Oil Filter

Element

1. Drain out the fuel from the fuel tank.

2. Drain out the fuel from the fuel tank.

Screw off the small screw of the fuel cock and pull out the filter from the filer port.

3. Wash the filter thoroughly with diesel fuel.

Loosen the fastening nut, bottom cover and delivery discs for cleaning the deposit carbon.

8.5 Tighten cylinder head bolt

Tightening the cylinder head bolt requires a special tool. Do not try yourself. Contact with agent.

8.6 Check the injection nozzle and fuel injection pump

1. Adjust the clearance of the intake/exhaust valves.

2. Grind the intake/exhaust valves.

3. Replace the piston ring.

All these operation require special tools and skills, contact with your agent.

 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.

Fuel tank

Loosen the three small screws and remove the fuel filter

WARNING

8.7 Check and refill the battery electrolyte and charge the battery

The diesel uses a 12V battery. Battery electrolyte will be lost through continuous charging and discharging. Before starting, check for physical damage to the battery and also the electrolyte levels, and refill the distilled water till to the upper level if necessary. When actual damage is discovered, replace the battery. Check the battery electrolyte monthly.

 The battery electrolyte contains sulfuric acid. Protect your eyes skin and clothing. In

case of contact, flush thoroughly with water and get prompt medical attention, especially if your eyes are affected.

 The battery exhaust hydrogen gas, which can be highly explosive. Do not smoke or

allow flames or sparks near the battery, especially during charging.

8.8 Check the generating set carbon brush and slip ring

Often check the generating set carbon brush and slip ring. Readjust if there is spark.

WARNING

9. LONG-TERM STORAGE

If store the generating set for long periods, make the following preparation.

1. Operate the engine for about 3 minutes and then stop.

2. Stop the engine. Drain the engine oil while the engine is still warm and fill with fresh oil.

3. Remove the screw plug on the cylinder head cover and refill 2cc engine oil, then put the plug in place.

4. ■Recoil starting:

Push the decompression lever down (Non-compression position) and hold it while you pull the recoil starter 2~3 times. (Do not start the engine.)

■Electric starting:

Turn the engine 2~3 seconds with the decompression lever set at non-com-pression position, and the starting key at the “START” position. (Do not start the engine.)

5. Pull the decompression lever up. Pull the recoil starter slowly. Stop when you feel resistance. (at this position, both intake/exhaust valves are closed to prevent the engine from the rust.)

6. Wipe off the oil and dirt from the engine and store in a dry place.

10. TROUBLESHOOTING AND REMEDY

The diesel engine can not start

Fault Cause

Remedy

Fuel oil is not sufficient.

Refill the fuel oil.

Fuel cock is not at START position.

Turn it to START position.

Fuel injection pump and nozzle do not delivery the fuel or delivery insufficient fuel.

Remove the nozzle and repair it at test table.

The governor lever is not at START position.

Set the lever to START position.

Check the engine oil level.

The specified oil level should be between the upper level and lower level.

The nozzle has dirty.

Clean the nozzle

The speed and force to pull the recoil starter are not enough

Start the engine according to the start procedures included in this book.

The battery has no electricity.

Charge it or replace it with a new one.

The generating set

can not generate

Main switch not be turned on.

Turn the main switch to ON position.

The carbon brush already worn.

Replace the carbon brush.

The contact of the socket is not good.

Adjust the socket.

The rated speed can not attached.

Adjust it according to the requirements.

AVR is damaged.

Replace the AVR.

Meaning of crossed –out wheeled dustbin:

Do not dispose of electrical appliances as unsorted municipal waste, use separate collection facilities.

Contact your local government for information regarding the collection systems available. If electrical appliances are disposed of in landfills or dumps, hazardous substances can leak into the groundwater and get into the food chain, damaging

your health and well-being. When replacing old appliances with new ones, the retailer is legally obligated to take back your old appliance for disposals at least free of charge.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play with the appliance.