Opti Generators Diesel generator users manual_pdg
Contents
1. Large fuel tank with 12 hours continuous operating capability Automatic Voltage Regulator Automatic shutdown for low oil pressure Vibration isolation mounting between engine alternator feet amp base frame Reduced vibration and improving durability Non fused breaker protects for AC Overload protection and convenience AC Voltmeter 120V 240V switch DC 12V charging system car boat batteries Low fuel indicator oil alert Ground fault interrupter Dependable brush or brushless Alternator Advanced direct fuel injection system Provides low fuel consumption All American standard receptacles Vertical one man mobile unit featuring Rugged construction Includes battery truck generator excluded and hour meter 2 3 Basic operating parameters Under the given conditions the generator will output the specified power listed in the Table 3 below Table 3 Basic operating parameters Height above sea level ft Ambient temperature F Relative Humidity RH 68 20 C 60 lt 3280 8 lt 1000 m 41 104 5 40 C 2 4 Electric Diagrams for 4000 and 6800 Series L2 R2 Special Notes Blue Red The usually applied colors for G R2 R1 L2 amp L1 are Control Panel listed as follow G gt Yellow Green R2 gt Red R1 gt White L2 gt Blue G Yellow Green L1 gt Black L1 Black PAQA A G1 i MA G2 i FA Oil Pressure Sensor low Plug D3 We2. OptiGenerators International Inc Owner s Manual for OPTI4000DE OPT16800DE OPTIGSOOSDE Opti Generators optimize your Lifel Contents List PREFACE a E E E l Chapter 1 Overview of 4000 and 6800 Serles 2 LI Open rame mode oe pinnen E EER R N NENS EOR E SEN DCERE 2 ir la Ao AMA eli o ei eml ele mano al e 3 Chapter 2 Technical Specifications cnn ee 4 2 1 Tee Tee errada sorted 4 2 4 Standard AMA o Cc AA 6 2 3 Basic operating parameters 6 2 4 Electric Diagram A A lt lt lt 7 2 5 Ovena e N hoinc SG E WW 9 in ing e 9 2 9 2 han en giri EN ons ne 9 2 5 3 Connecting dimensions of output shafts and povver take off PTO flanges 10 Is tallatio el co st A A 11 2 6 1 BE on O A A L 11 2 6 2 Allowed clearance between belt wheel and engme ENNEN 12 shat d el tilt angles e 12 Ze ss o EE 13 2 8 Valve timing initial angle of fuel delivery and valve clearances roo 14 2 9 Torque specifications for various engine bolts and nuts cos 15 CHAPTER 3 OPERATING THE DIESEL GENERATOR rc 16 3 1 General main pointsofsafetyduringoperatlonofthegeneratorset 16 EE Fe Pie NO 16 3 1 2 Preventionfrominhalingexhaustemissions 16 3 1 3Preventionfromaccidentalbums 16 3 1 4 Electric Shock and Short GE EE 16 TEE 17 Ro Te ET 17 3 2 Prepa
3. a ez le E j Pull the rope hard and fast SH d Gs Geer O o lh Pull it all the way out ON Y Use two hands if necessary S Bar U d handle loosely K MES ai Full ne starting handle slowly I Hald the starting 1 Pal i A Util you feel GN 1 V d i resistance H ja Pi Then return it decompression lever l SNA PO slowly down and release Fi i A Ki Es vi tl SCH GH KL a gt SS SS ae For5 if you don t pull hard For5 if you don t pull the enough the engine won t rope all the way out the engine won t start ZI CHAPTER 4 MAINTENANCE 4 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 panel and frame For overhauling procedures please refer to the instruction manual of 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 1s off Please refer to the Table 4 1 below for the proper maintenance schedule Interval of maintenance Check amp fill enough fuel Dram fuel out of fuel tank Check amp replenish engine oil Check oil leakage Check amp tighten each engine part 1 Month or PO months or 20hrs 300hrs 1000hrs 100hrs o Tighten head bolts Every 6 months or Every year
4. please fully charge your battery or try using your vehicle battery to crank d If you can not hear cranking sound at all when you turn ignition key to start or use remote control unit to start electronic key switch or the solenoid of electric starter is burnt and needs replaced You can use a small copper wire to jump start your electric starter motor jump start your electric starter and see whether your engine turns over if it turns over the starter is good and key switch needs replaced otherwise starter needs replaced Make sure you leave key in OFF position or simply remove key from control panel when you use remote start Also please depress OFF button after you remote shut down generator otherwise the battery will be gradually drained 1t will also have a risk of burning solenoid Caution please disconnect battery from your generator prior to conducting any maintenance or repair Otherwise some electronic parts will be burned with power operation 35 If you perform all the above procedures and find fuel system is fine please further check your diesel engine Adjustment screw or tappet of your engine 1s probably snapped Remove fuel injector from your engine and take off cylinder cover pull recoil handle or manually rotate flywheel perceive whether you can see both intake and exhaust valves moves if one of them does not move please take a closer look at the cylinder head and make sure whether adjustment screw or tappe
5. Instructions for disassembling diesel engine le SE Gd ee a Loosen the end of high pressure metal fuel pipe to fuel injection pump and then remove the fuel injection pump from engine Remove fuel injection nozzle injector with high pressure fuel pipe from engine Remove cylinder gasket cover Remove rocker arm Remove two push rods Remove the half crankcase in alternator side drive shaft side from engine Remove cam shaft Replace the snapped tappet with a new one 5 2 1 3 Instructions for setting valves and reassembling diesel engine A How to reassemble a diesel engine 1 Suppose a diesel engine is disassembled at this step e g fuel pump fuel injector removed from rocker arm and push rods taken off engine DO NOT REPLACE THEM NOW 36 Un B OTHERWISE YOU CAN T PUT BACK THE HALF CASE OF ENGINE ON ALTERNATOR SIDE If tappets are snapped please replace them and put the new ones in holes In case you pull off balance shaft during disassembling engine and need replace please align balance gear and crank gear there are TWO DOTS and ONE DOT in balance and crank gears respectively you must align them at this step before aligning crank and cam gears Align crank gear drive shaft and cam gear cam shaft there are TWO DOTS and ONE DOT in crank and cam gears respectively you must align them at this step Put case gasket and match two halves of engine together tighten all bolts Put back push rods and ro
6. T Fig 4 1 Air filter element replacement 4 4 Fuel filter maintenance The fuel filter should be cleaned often to keep the engine running at maximum performance The recommended interval for cleaning or replacing fuel filter is 6 months or 500 hours of operation Two types of fuel filter are used in our portable diesel generators type A is solely used in open frame model type B is mainly used in silent model and may be used in some open frame units Fuel filter is either installed inside fuel tank open frame model or outside fuel tank in a fuel coke assembly silent model Please refer to Fig 4 2 for your convenience Type A installed inside fuel tank and invisible Type B installed outside fuel tank and visible Fuel Coke Assembly Fig 4 2 Fuel Filters used with different fuel coke assemblies 30 How to replace fuel filter a Type A fuel filter 1 Drain all the fuel out of fuel tank 2 Keep fuel tank right up loosen two hex nuts on a fuel coke assembly then take off fuel coke assembly 3 Loosen 3 small screws on a fuel gasket metal cover underneath fuel tank and remove metal plate cover 4 Take used fuel filter out of fuel tank remove circular rubber and O ring seals and paper based gasket s from the used filter and keep them for reuse if applicable and discard the used filter You may use diesel fuel to clean up the used filter for reuse However the use of new filter 1s recommended 5 Put circular
7. as follows l 2 Please refer to above generator operation instruction for start using key svvitch If you want to use remote start please make sure that your electronic key switch 1s either put on OFF position or taken avvay from the control panel There are two sets of ON and OFF buttons in RF key you can depress either one of ON buttons to start the generator and either one of OFF buttons to shut down the generator respectively If you use key switch to start the generator and then use RF key to shut it down make sure that you need turn electronic key switch to OFF position otherwise your generator battery will drain charge gradually In case your remote control unit fails and a remote jumper comes with your user s manual package please unplug your remote control unit first then plug the remote jumper this will enable you to use key switch to start your generator 1f there is no remote jumper with your package please follow the order shown in the picture of remote jumper to electrically shorten the two corresponding wires coming out of your control unit a small black box with either 7 or 8 wires on then you shall use key switch to start your generator If your remote start unit with 8 wires on has remote glow plug function the operating procedures are the same as the 7 wire remote control unit except the following There are two sets of ON and OFF buttons in RF key you must depress ON button of set 1 to start t
8. emmmer Di A D2 E2 pc12v gt Battery Po Electric Starter El 7 or 8 Wire Remote Unit 4 hogy ee DC12V Stabilizer l TE li a H Flywheel Alternator Solenoid e pal Alternator Va Capacitor with 2 wires AVR with 6 wires on mu Electric Wiring Diagram for Portable Diesel Generators Wiring Diagram for generator with Electric Start Remote Start amp Glow Plug PR M e et e aes ee A Nm amm MY rn te E name GE Pr ili Y Auxiliary Battery BLACK i Phase Rotor PONER Alternator a 1 L Ri RE pe 1 Capacitor or AVE L AC 124 Clow Yo tage r Plug Stabilizer Electric Starter Rectifier GREEN VELLON GREEN Device Electric Control Circuit Electric Output Wiring Diagram TENEN e e ee er TERENE BLACE BROWN WHITE BLUE Remote Signal Receiver Plug Male Ignition Key Switch Plug Remote Signal Receiver Plug Female 2 5 Overall Dimensions of Diesel engine 2 5 1 Diesel engine coding 186 NONE Recoil Start E Electric Start F Keyway Shaft FP Thread Shaft FG Taper Shaft FS Camshaft PTO Model Name Diesel engine coding begins with 3 digits the 1 digit stands for number of cylinder head and the last two digits for bore size in mm e g 186 means one cylinder head and bore size is 86 mm Three digits are followed by letter F and or by another letter that stands f
9. fitness for a particular purpose on OPTI products are limited in duration to twelve 12 months or one thousand hours from the date of purchase Some states countries do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you Some states countries do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights that vary from state to state and country to country The twelve month warranty is solely applicable to OPTI dealers and distributors All the terms to our dealers and distributors are also applicable to the end consumers of OPTI PRODUCTS except that the warranty period 1s six months for the end consumers of OPTI PRODUCTS 60
10. for disassembling diesel engne cece eee e eee ees 36 5 2 1 3 Instructions for setting valves and reassembling diesel engine 36 5 2 2 Causes and Troubleshooting for Deficient Power of Diesel Engine 38 5 22 linstruc onsforspeedadjustment 39 5 2 3 Causes and Troubleshooting for Engine Stopping Automatically 39 5 2 4 Causes and Troubleshooting for Exhaust with Black Smoke aaa aaaa aaa aa aucaa 39 5 2 5 Causes and Troubleshooting for Exhaust with Blue Smoke nana aaa aaa aaa cece 40 5 2 6 Causes and Troubleshooting for Exhaust with WhiteSmoke 40 53 2 CheckinggMethodsformalftunc onedEngine 40 5 3 OverhaulandTltoubleshootngforDieselGenerator 41 5 3 1 Causes and troubleshooting for the generator not being started ini 41 5 3 2 Causes and troubleshooting for the generator not generating electricity 41 5 4 Damage Cause and Remedy of Brushless Altemator ccc cece cece eee aa deve 42 5 5 Damage Cause and Rem da coca 43 5 6 Questions iC Rica A A A 43 CHAPTER 6 GENERATOR PARTS DIAGRAMSANDLISTINGS 44 Fig 6 1 Exploded view of frame assembiyfor4000DEand6800DE 44 Table 6 1 Partslistoftrameassembiy1or4000DE 6800DE 45 Fig 6 2 Exploded view of parts list for alternator and engi
11. generator please refer to Section 3 10 Procedures for recoil starting 19 3 4 Generator Break in A brand new engine must be properly broken in The break in period is about 20 hours An oil change for a brand new engine is about 20 hours or one month After break in period oil change shall be performed routinely every 100 hours or 3 months IMPORTANT Do not apply high load during the first 20 hours of break in period change engine oil and check oil filter after first 20 hours of break in running if you find any dirty or metal scraps on the oil filter please refer to Fig 3 4 please use diesel to wash them away otherwise it may cause serious damage to your engine A Oil Pressure Sensor B Factory Default Set Maximum Power Output Screw C Oil Filter D Oil Draining Bolt E Spring amp 4 Holes for Frequency Adjustment F Governor G Oil Dipstick H Emergency Stop Lever I Frequency Adjustment Screws 2 J Speed Handle Fuel Throttle Lever Fig 3 4 Partial Front View of Diesel Engine 3 5 Applying Load to your Generator After generator is started push circuit breaker to ON position and you should read 120V in volt meter when voltage selector is set for 120V output or 240V in volt meter when voltage selector is set for 120V 240V output When applying loads to generator make sure to apply loads in order Apply larger load onto the generator first If the generator labors great with applied load smaller lo
12. or Everyday Change lube oil nd 4 st 4 2 time amp C HM thereafter HI Clean oil filter O replace Replace air filter element Service more frequently when used in dusty O e replace Clean fuel filter U a Check fuel injection pump E E replace if necessary replace Check fuel injection nozzle Check fuel pipe Check dry battery fluid Monthly Note e mark indicates that 1t needs special wrench please contact with OPTI dealer Adjust the gaps of air intake amp exhaust valves 28 4 2 Changing the engine oil every 100 hours Engine oil is the most important factor in determining the life of your generator engine If you use poor engine oil or if you do not change the oil regularly the piston and cylinder will wear off easily or seize up The life of the other engine parts such as bearings and rotating parts will be shortened considerably as well About 1 month or 20 hours every 3 months or 100 hours Time to change engine oil All our portable diesel generators are installed low oil pressure automatic shut off function However manual check of engine oil level using dipstick oil filler cap 1s strongly recommended prior to cranking engine If the oil level is low fill it up to required level Oil 1s easily drained out of engine due to low viscosity and high fluidity when diesel engine is still hot If the engine is fully cooled the viscosity of oil turns higher and oil wil
13. rubber and O ring seals and paper based gasket s and then put gasket metal plate cover to the new filter 6 Install new filter to fuel coke assembly and then manually slight tighten two hex nuts to the bolts of filter 7 Place new filter inside fuel tank align positions for three small screws You can keep fuel tank upside down for your convenience 8 Tighten three small screws and two hex nuts completely b Type B fuel filter Type B filter is very easy to replace use one hand to hold the alumina head of fuel coke assembly and the other hand to hold thread flanged alumina ring turn loose the ring counterclockwise replace used filter with a new one and then tighten the ring completely 4 5 Fuel injection nozzle Check fuel injection nozzle every 6 months or 300 hours for possible blockage Please clean up carbon deposit in fuel injector Replace the used fuel injector if necessary 4 6 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 are required to do this 4 7 Battery check For dry battery make sure that the battery acid 1s full Electric starting system uses a DC12V 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 Fo
14. same time you must use the other wrench to hold metal pipe of fuel pump for avoiding its rotating Take out a spring and a plunger in the solenoid replace the solenoid means bypassing solenoid to fuel pump crank the engine and see whether you can start or not if works solenoid is burned and needs replaced 2 If you can not solve starting problem by bypassing solenoid fuel pump or fuel injector may have failed How to test fuel pump or fuel injector a Loosen the end of high pressure metal fuel pipe to fuel pump crank engine and see whether you can see diesel popped out of fuel pump if you can see diesel out of pump the pump is fine Otherwise fuel pump needs replaced b Take off fuel injector and test it open the cover right on the top of enclosure silent model or muffler cover open frame model loosen two 10MM nuts take out fuel injector with high pressure metal fuel pipe hooked up together reconnect the other end of metal fuel pipe to fuel pump so that make sure you can observe the tip of fuel injector when cranking engine if fuel injector is fine you shall observe 4 well sprayed diesel mists out of fuel injector tip if not try to use a piece of soft cloth to clean it and then try again if you still can not see four mists one or more tiny holes of fuel injector is are bitted and fuel injector needs replaced c Also please check your battery voltage level if it is below 12 5V you probably can not start your engine
15. working with battery If you contact with electrolytic liquid in your skin wash it immediately with clean water and soap if you contact with electrolytic liquid in your eyes wash them immediately with distilled water see a doctor as soon as you can 3 2 Preparation before operation 3 2 1 Fuel choices and fuel treatment Only use light diesel fuel The fuel must 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 It is dangerous to overfill fuel tank Never exceed 90 scale of fuel gauge Fresh diesel from gas station may contain water Please put it in a diesel container and let it sit at least overnight water and impurities will stay in the lower portion of container Decant or suck top portion of diesel in the container into fuel tank of generator Caution Do not overfill tank After filling tighten the fuel cap Never let fuel or fuel tank expose to sparks Be careful not to spill fuel when filling If any fuel is spilled make sure to clean up all the spilled fuel before starting engine 3 2 2 Charging battery We recommend the use of accumulators rated 20 hours shown in table 3 1 17 Either deep recycle maintenance free or dry battery white red color comes with your generator see Fig 3 2 You should use a trickle charge to fully charge your battery before you crank your generator for the first time If volt
16. 0 2or4 l 296 Fuel tank 4000 6800 open frame Fuel tank 6800 silent 299 2 1710622 M6 x 22 bolt GB5787 86 299 3 1710206 M6 washer GB90 85 304 1704302 Type A fuel filter 1704303 Type B fuel filter also refer to 6800s102 o 310 Control panel assembly silent model Control panel assembly open frame model Table 6 2 continued to next page Table 6 2 Continued from previous page Volt meter l Glow plug button E 120V outlet 2 Dual GFI 120V outlet Four prong twist lock 120V 240V dual 320 ed outlet Three prong twist lock 120V outlet 323 250V 10A fuse 3mm x 15mm 68005514 68005514 250V 10A fuse 5mm x 30mm 68005515 l 4 oe NINNIN L Eh Washer 68005225 ER ock a Fuel line fitting Rocker arm fastening bolt 78 1702100 78 1702102 49 l 17165 Valve clearance adjusting screw 1706075 M6 x 75 special nut 78 1702101 86 1702101 Rocker arm support Table 6 2 continued to next page 58 Table 6 2 Continued from previous page 78 1702106 86 1702106 78 1702702 86 1702703 78 1782802 86 1702803 78 1702902 355 358 359 360 36 362 Valve cap 2 Valve clip 2 Valve spring seat 2 86 1702903 78 17136 86 1713601 78 1702004 86 1702100 Valve spring washer 2 Valve guide oil seal between 353 amp 354 2 1711104 Pin 4 x 8 GB119 86 78 1710955 Double ended bolt AM6 x 55 GB899 88 86 1710956 Double ended bolt AM6 x 75 GB899 88 78 17122
17. 0 CO CO CO 00 00 Un BS LO NO Mo 00 UJ CO A 95 50 Table 6 2 Continued from previous page 78 1705102 9 ST 78 17157 86 1715701 e Fea 78 1701102 86 1701103 E 1710504 Key 4 x 12 GB1096 79 1 86 1710514 Key 5 x 14 GB1096 79 Valve tappet 2 Camshaft timing gear 86 1701000 ECS e 86 1703003 1703003 QE 1 86 1718003 1718003 17137 Double ended bolt AM6 x 22 GB899 88 1710103 Flange head hexagon M6 nut 78 17179 108 86 1718002 1718002 Inner shock proof sealing ring 78 1717602 Iw 281717602 _ 86 1717601 1 601 Air filter element N Bottom case assembly of air cleaner 78 17181 RO Y 1718101 Air filter shock absorber m ME mr 86 1718001 Outer shock proof sealing ring N 78 1718004 P S6 1718005 Air filter cover seal ring 78 1718006 ou me 6 1 861718007 007 Complete air filter cover 78 1718102 e 861718103 61718103 Cover shock absorber 78 17177 0 17177 e E 1710107 M6 wing nut 86 1710109 1710109 M8 wing nut e m 78 17174 86 1717401 1717401 1710612 M6 x 12 bolt GB5787 86 3 17022 Oil pump cover A i 1711334 O ring 34 5 x 1 8 GB3452 1 82 ge Air cleaner assembly I 78 17135 1 Lalin 86 1713501 1713501 Oil pump assembly 17135100 17135101 Table 6 2 continued to next page 51 Table 6 2 Continued from previous page l l 42 61703803 Friction plate gasket l 1703902 1704006 Sta
18. 01 AM 6 x 42 fuel injector bolt 86 17122 AM 6 x 50 fuel injector bolt 360 1710920 Double ended bolt AM8 x 20 GB899 88 l 354 1 78 17168 36 1716801 Rocker arm assembly E 363 68005516 68005517 68005518 68005519 255 5 68005520 l l l l l l 59 LIMITED WARRANTY Optigenerators International Inc OPTI warrants its PRODUCTS against manufacturer defects in materials workmanship and finish under normal use and service for twelve 12 months or one thousand hours whichever comes first from the original date of purchase This warranty does not cover any damage due to impairments from accidents damages caused by shipping company product misuse abuse product modifications or product negligence batteries and consuming parts such as automatic voltage regulator carbon brush filters fuses and gaskets This 12 month or one thousand hour warranty applies only to new products sold in the United States or Canada and 1s limited to the free parts replacement or defective unit replacement of OPTI products Warranty does not include costs of removal installation labor freight inconvenience or consequential damages To validate the warranty Product Registration Card must be completed and mailed to Optigenerators International Inc 1256 Oakbrook Dr Suite E Norcross GA 30093 or register on line at www optigenerators com CustomerService aspx within 30 days of original purchase Implied warranties of merchantability and
19. 41 Spring retainer 1705351 Stop plate 1705361 Pin 1705371 78 1705302 D 215 61705302 Fuel injector cap 1705381 Spring pin MF36AH 17144 Shock pad 78 1704102 233 17143 O Fancover bolt shock absorber 4 Collar D 78 1704502 361705504 Flywheel with gear 248 2 6800s102 Fuel filter also refer to 1704303 pj 248 3 68005108 O ringfuelgasket Plastic tube Table 6 2 continued to next page 54 Table 6 2 Continued from previous page 248 5 6800s105 Water float 257 2 6800s218 Flange head bolt 68005219 nee lows 258 2 6800s220 Flange head bolt O 6800300 6800s302 M8 x 32 flange hexagon head bolt gt 68005303 a M10 x 230 alternator bolt M10 x 210 alternator bolt ee Washer End cover Ex 269 68005310 Mo x 160 flange hexagon head bolt 4000310 Mo x 140 flange hexagon head bolt Table 6 2 continued to next page 55 Table 6 2 Continued from previous page 236 Capacitor l l l 4 l l l 4 l 282 3 e Commonality base 10 Table 6 2 continued to next page Table 6 2 Continued from previous page 291 68005415 Battery holder silent model 1 6800415 Battery holder open frame model 291 2 1710815 M8 x 15 bolt 68008416 DC12V solenoid used with cable DC12V solenoid installed in fuel pump 292 2 1710612 M6 x 12 bolt GB5787 86 1716002 M6 spring washer Washer 3 5 or 7 5 solid wheel 8 5 solid wheel Flat washer 10 Flat washer 2
20. 7141 17146 17147 EK 1 M6 x 55 flanged bolt GB5789 86 86 1710630 M6 x 70 flanged bolt GB5789 86 Table 6 2 continued to next page 49 Table 6 2 Continued from previous page Usa EA Piston ring set 86 1701403 6 17014100 First piston ring 17014101 Second piston ring 17014102 Oil ring complete 78 1701202 Piston 1 86 1701204 78 1701702 Dr 86 1701703 p 78 1701602 Retaining clip of piston pin Diameter 21mm 86 1701603 Retaining clip of piston pin Diameter 23mm 78 1701302 86 1701303 Connecting rod assembly 1 NO 74 75 76 TI 17013100 17013101 17013102 Crank pin box 17013408 Rod bolt 78 1701502 86 1701503 Connecting rod journal bearing 1 l 78 1706500 86 1706500 Balancing shaft assembly 78 1706502 86 1706503 Balancing shaft 1 1710507 Key 5 x 7 GB1096 79 2 78 1706602 l yi 36 1706603 Balancing shaft timing gear 78 1710001 Ball bearing 202 GB T276 94 86 1710000 Ball bearing 203 GB T276 94 78 1707000 86 1707000 Crankshaft assembly 78 1707702 86 1707703 Crankshaft timing gear 1710512 Key 5 x 12 GB1096 79 1710514 Key 5 x 14 GB1096 79 78 1700701 61700708 Crankshaft 1711601 6 x 8 plunger 78 1707802 gt 61707803 Balancing shaft driving gear 78 1710007 Ball bearing 307 GB 1276 94 86 1710008 Ball bearing 308 GB T276 94 1701304 l 1701305 Flywheel nut l Table 6 2 continued to next page H CO l l 7 l l l l NO NO 0
21. G 5 1 Inspections before Operation and Maintenance 5 1 1 Inspection before operation 5 1 1 1 Check the insulated resistance An insulated resistance usually results in the creepage of the alternator when it 1s below the regulated value and then brings on the security problems The user should check the insulated resistance between the master and subordinate reels and the insulated resistance between the reels and the crust with 500V mega ohmmeter regularly The value should not be under 2 M ohms at normal temperature otherwise these parts should be dried Use the electric cooker infrared ray or big bulb or something else to heat them up outside until the insulated resistance reaches the regulated value 5 1 1 2 Check the alternator assembly Make sure all the firming components are tight and the rotor is easy to turn by hand without impacting scrubbing and any abnormal noise Do not let the rain or other liquid drop into the alternator 5 1 2 Starting the generator The end of voltage output should be on before running the machine Generator should self excite generate voltage in gear and reach the rated power when engine speed is accelerated to the rated value Otherwise stop the machine and check it 5 1 3 Maintenance Keep generator away from the oil vapor acidic alkaline gas saline brume and do not let any other solid matter fall into the generator Keep drafty when the generator is running Do not put anything on the surface of generat
22. ad can then be added Never overload generator Otherwise generator will black smoke or circuit breaker will be stripped In this event decrease the number of small loads until generator labors normally Please see Table 2 1 for technical specifications of generator for your reference If the indication of the volt meter is too high or too low adjust the engine speed capacitor used for brushless alternator or electric resistance of AVR used for brush alternator accordingly Special skills are required to perform speed adjustment An authorized professional 1s recommended to perform this work If there are problems stop the generator immediately and fix the issue Note During operation the generator should be put in a place with good ventilation Never cover open frame generator using your own cage to solve a noisy problem as this will cause overheating problem and then damage your generator You must obtain our prior authorization for any change in our generator Otherwise the warranty for your generator will be voided 20 Do not apply more than two loads simultaneously Each load should be started one by one to avoid overloading generator The generator should be running at 3600 revolutions per minute in order to achieve the frequency of 60Hz The speed of the engine can be adjusted through speed governor CAUTION A alternator consists of two sets of windings namely R2 amp RI and L2 amp Ll see Fig 3 5a each set of winding give
23. age level of battery 1s low you may not start your generator Long time cranking may damage electric starter and engine Table 3 1 Specifications of recommended accumulators for electric start Model 178F 24 26 186F 36 45 a SE F 3 Fig 3 2 Maintenance free battery left and dry battery right battery actual color is subject to change without notice If it is dry battery the battery must be filled with battery acid to required level Acid can be purchased at a local automotive supply store To properly maintain your dry battery check the height of the battery acid once a month If the level of the liquid drops too low fill 1t with distilled water until it reaches up to maximum level mark If there is not enough battery acid diesel engine cannot be started It is important to keep the liquid level between the high and low limits If the level in the battery is too high the liquid may flow out and corrode surrounding parts 3 2 3 Filling engine oil Remove the dipstick from the engine make sure the generator is on level ground and fill the engine with SAE15W40 warm weather or SAE5W40 cold weather synthetic diesel engine oil Put the dipstick back into the hole to check the engine oil level see Fig 3 2 178FG 186FAG 18 Fig 3 3 Schematic for filling engine oil The following procedures help you start our generator with ease l 10 If dry battery WHITE RED COLOR comes with your gene
24. battery hooked up Otherwise a fuse new 2008 or later model or a control board for solenoid behind control panel will be burned 33 Table 5 1 Causes and Troubleshooting for the Engine Not Being Started CAUSES TROUBLESHOOTING Air exists in fuel system Release trapped air in the fuel hose Preheat cold air using glow plug first then crank engine Fill machine oil into crankcase after warming up Fill machine oil into inlet pipe Remove the connection belt from the machine Engine oil is viscous tapered shaft only start the engine and then stop it When it is warmed up assemble the belt and then restart the engine Failure of fuel system Check solenoid and see whether it is energized Check fuel injection pump Water mixed inthe fiel Clean fuel tank fuel filter and fuel pipe and change the fuel The fuel get thickening and can t flow easily Use prescribed brand fuel Check the position of governing handle or check Injection fuel is little or the spray is not excellent and clean the fuel nozzle change fuel injector if necessary Mainly by ill spray Incorrect delivery angle Leakage in gasket of cylinder head Deficiency in pressure of compression Run out of fuel and get air in the fuel hose should refill fuel into the fuel tank and drain fuel hose freely Fuel pipe leaks or fuel filter is obstructed Tighten the nuts of cylinder head in the diagonal Deficiency in pressure of compression sequence check the gasket of cyli
25. cker arm assembly tighten two bolts for holding rocker arm adjustment screws and nuts on rocker arm assembly and make sure adjustment screws touch push rods slightly so that you can lift up and down push rods DO NOT TIGHTEN ADJUSTMENT SCREWS FIRMLY AT THIS POINT OTHERWISE YOU CANT ADJUST VALVE GAP How to set valve gaps The 4 strokes for engine are intake gt spray fuel compress gt explode gt outtake exhaust When you spin flywheel you can see push rods and rocker arms moving back and forth to make intake and exhaust valves open and or close When both push rods move to their lowest positions both intake and exhaust valves are close then you can use your hand to move both rocker arms a little both valves are close at this position This position 1s very important you need adjust the valve gaps at this point the gap between rocker arm and valve clip a small round platform for both sides intake and exhaust valves 1s 0 15 0 20mm about 0 005906 0 007874 in You can use a filler ruler of 0 15 0 20mm thickness to adjust Ci Install fuel injector first then install fuel pump You must install fuel pump correctly otherwise you either can t start engine or overspeed engine Below are brief procedures for reinstallment l When you reinstall fuel pump pull its needle half way in OBSERVATION WINDOW bottom opening in fuel pump push speed handle fuel throttle lever halfway You can see a HOOD of speed ha
26. control board or replace solenoid Ignition Key or remote control unit fails Key or remote control unit Ignition Key or remote control unit fails Change if necessary Change if necessary necessary Electric starter fails Change starter 5 3 2 Causes and troubleshooting for the generator not generating electricity CAUSES TROUBLESHOOTING Power switch is on the position of OFF Turn the switch handle to the position of ON Bad contact of the socket Adjust the socket pins Burned AVR or capacitor Change the AVR or capacitor Nuts loosened in volt meter Tighten loosened nuts 41 5 4 Damage Cause and Remedy of Brushless Alternator 1 Switch is on the position of OFF 1 Turn the switch to the position ON 2 Worse connection of the plug or the control panel 2 Adjust the contactor of the plug or the wires inside the control panel 3 Check the stator at the point of the break if it is the just reason that causes problem change the stator or check the capacitor with the multimeter if the needle does not move change the capacitor 4 Check the rectifier by the Multimeter 3 Circuit break of the stator coil or the capacitor overloads Can not generate as the following steps connect the pens to each two of the four contactors of the 4 Short circuit of the rectifier rectifiers both in the clock wise way and in the counter clock wise way if you find that both ways are electrically conducti
27. ectric Outlets I x NEMA L14 30R for 120 240V 30A 1 x DC12V a 8 3A 73 9 x 50 x 58 9 open frame AE 91 9 x 53 1 x 70 6 silent 76 2 x 52 1 x 60 5 open frame vation JL PEAS L 94 5 x 54 6 x 73 7 silent Dimensions L W H in cm 4 Table 2 Technical specifications in British units 4000 Series 6800 Series Self excitation voltage 60Hz 4000 Watts 6500 watt 3500 Watts 5500 watt 29A 120V 14 5A 240 46A 120V 23A 240V Level dB a 231t Engine Model Bore x Stroke in x in Displacement n Rated Output HP Max Ouipu HP Jee OB Y iesel Lube Oil Capacity 0z 127 1 38 9 Fuel Tank Capacity Gal 3 3 open frame 3 9 silent Continuous Operation 15 Hours half load Hours 8 LC Recoil statt open frame only electric startand remote start SAE15W40 or 5W40 synthetic diesel engine oil 117 i 1 MR NM Engine Ge 89 pj YU Dimension LxWxH in 15 1 x 16 6 x 17 7 6 4 x 17 4 x 19 5 2 x NEMA 5 20R for 120V 20A E Cutis ERT T 1 x NEMA L5 30R for 120A 30A Seite LTE aun 1 x NEMA L14 30R for 120 240V 30A 1x DC12V 8 3A Net weight 1b 263 open frame 352 silent 29 1 x 19 7 x 23 2 open frame Product 27 2 18 5 x 21 9 i L W H in in 30 x 20 5 x 23 8 open frame Carton 28 2 x 19 1 x 23 4 37 2 x 21 5 x 29 silent 2 2 Standard Features Electric start Recoil start and Remote Control with Preheater Cold Start
28. em that occurred 3 State of residency 4 A detailed serving condition and time when the problem occurred 43 CHAPTER 6 GENERATOR PARTS DIAGRAMS AND LISTINGS Fig 6 1 Exploded view of frame assembly for 4000DE and 6800DE Table 6 1 Parts list of frame assembly for 4000DE 6800D E refer to Fig 6 1 Part Number 2 6 Enginecover 1l 6800 i O 8 Handle rubbercover 2 900 JL Mom TONG O TT ee SE i O A A QQ Mt 1 1710108 alsoreferto6800s224 AY Springwasher8 1 6800822 Oe vs AO MO E P SS m EN am EE PE SHEN s o o o NEN Gm E SR PB PI ii Mi Oi Oi O SH O 29 Vibration reducing Bracket 1 1 4000408 6800s408 ER TIO STS oo aa Ni OE Osm o ONE A Alme m Flat washer 10 Flat washer 20 oa 1710220 Cotter pin 32 x 32 gt 68005419 SES M10 x 15 bolt KE 1711015 M10 x 30 bolt 1711030 45 Fig 6 2 Exploded view of parts list for alternator and engine assemblies of 4000 and 6800 series x A S N H S gt Gosia TA 100 102 AA A Fig 6 3 Exploded view of muffler system and frame assembly for 6800SDE and of fuel tank and air cleaner assemblies for 4000 and 6800 series al TY 248 Type B fuel coke zeg DC 299 assembly 248 1 Type A fuel SE coke assembly 314 312 313 1315316 310 323 324 Table 6 2 Parts list of 4000DE 6800DE and 6800SDE refer to Figs 6 2 am
29. er Fuel Pump Solenoid Fuel Hose Top view of diesel engine Silent model has the same configurations as open frame model except that silent model has specially designed muffler system and sound proof enclosure 1 2 Soundproof silent model OPTI6800SDE ESEL GENERATOR Chapter 2 Technical Specifications 2 1 Technical specifications Table 1 Technical specifications in SI units 4000 Series 6800 Series De rushless 2 pole single phase xcitation elf excitation voltage Voltage regulator apacitor brushless alternator AV R brush alternator requency 0 000 Watts 500 watt 500 watt Generator 29A 120V 14 5A 240V 46A 120V 23A 240V 8 3A 8 3A 12V 12V ower factor cos p 1 0 Operanon NOISE 0 87 open frame 70 silent Level dB 7m j Insulation lalalalal as N ala vi e 17 T Salles S PIs o o lol gt a la o Olg E kr Q 3 VIS E a e e 4 Stroke air cooled single cylinder OHV mm x mm Tax Output KW Diesel Lube Oil Capacity 08 Engine Fuel Tank Capacity L 12 5 ontinuous Operation 12 Hours half load Hours gnition System tarting System i ube type 53 41 7 x 44 1 x 49 4 2 x NEMA 5 20R for 120V 0 20A 1 x NEMA L5 30R for 120A 30A O v zZ Ps U JOE TOA lr o O 22 2 3 E zZ e slots a 18 gt e lo ei E 5 pele ja Kei E A IB lo e T Ve S Ep Je fe pe o an 3 ad 10 oo Loo 4 pe m N pe ES A El
30. er off after 25 Sec you can also DEPRESS OFF button in SET 2 for power off earlier 24 3 8 Charging battery ll All 4000 and 6800 series diesel generators can automatically charge DC12V battery through voltage rectifier voltage stabilizer installed in the rear side of engine when they are running If generator is not used for a long time the battery should be disconnected to avoid energy loss from the battery 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 Do not reverse the polarities when attaching battery cables to battery Doing so will damage both battery and electric starter Battery will produce flammable gases during charging Do not expose the battery to any flames and sparks during charging as this may cause a fire To avoid sparking while connecting cables to battery connect the cables to the battery then to electric starter To disconnect battery cables first disconnect the cable at the end of electric starter 3 9 Stop generator l ZA Remove the electrical load off the generator Let the engine idle for 3 minutes after unloading Do not stop the diesel engine immediately Stopping the diesel engine suddenly may raise the temperature of engine abnormally and lock the nozzle and damage the diesel engine Turn key to the off position or depress off button in RF key If do not use generator for a lon
31. exibly balanced position 5 2 3 Causes and Troubleshooting for Engine Stopping Automaticall CAUSES TROUBLESHOOTING Malfunction of the fuel system Check solenoid fuel pipe fuel pump amp fuel injector Run out of fuel Fill fuel Remote control unit fails 5 2 4 Causes and Troubleshooting for Exhaust with Black Smoke CAUSES TROUBLESHOOTING Lighten the load change the unmatched loads if it does not comply with the requirements Bad spray Faulty fuel injection system change the nozzle 1f it is damaged Lack of air or leakage Damaged or clogged air filter Wrong grade of fuel Incorrect fuel injection pump timing Engine overheating Low compression ratio Incomplete fuel combustion 39 5 2 5 Causes and Troubleshooting for Exhaust with Blue Smoke CAUSES TROUBLESHOOTING Engine oil mixed in cylinder Check the oil level drain off the redundant engine oil Piston ring 1s clipped worn or lack of Check and replace the piston ring and cross hatch of elasticity hatch of each ring turned to the each ring same direction and make engine oil up Big gap between piston and cylinder Remedy or change 5 2 6 Causes and Troubleshooting for Exhaust with White Smoke CAUSES TROUBLESHOOTING Water mixed in diesel om the fuel tank and filter and change the diesel Faulty fuel injection system Incorrect fuel injection and valve timing Engine overheating Faulty fuel pump and or injection pump Improper air fuel mixt
32. g time please shut off fuel valve and then make sure that both intake and exhaust valves are closed for avoiding engine rusting Pull slowly on the recoil handle open frame models or use one of your hands to manually rotate fly wheel silent model until you feel resistance when the piston of engine is in the compression stroke where both intake and exhaust valves are closed Emergency Stop If you turn key to the off position or depress off button in RF key the engine is still running please depress emergency stop lever see Fig 3 4 to stop it manually If emergency stop lever fails please shut off fuel valve to stop it 25 3 10 Procedures for recoil starting lever in the RUN position If the engine doesn t start try again from A Pull the rope hard and fast Pull it all the way out Use two hands if necessary Hold the starting handle loosely O SK 9 4 Full the starting handle slowly Hold the starting handle firmly sue Until you feel resistance Push the Then return it decompression lever down and release 26 How to start your generator o Ope T ri the hule cock cl For3 don t pull the rope too fast or hard p a DI Put the engine speed lever in the RUN d position If the engine E AO doesn t start try again from OE ae M f Ki Kri Ji e Ea ps
33. he generator and OFF button of set 1 to shut down the generator respectively see Fig 3 6 also refer to Section How to Use Glow Plug 25 3 7 How to Use Glow Plug CS 9 MN WAR HEAT STAR STARTER SN A fan any Hab ACI20V 240 DC 12V 8 3A Gg a a i fe Fa e Vw _ Em Fig 3 7 Control Panel with Preheater Knob left and Preheater Button right Diesel generator will be very hard to start in cold winter However glow plug will help start diesel generator much easier There are two types of control panel used in our portable diesel generators Type A control panel has heat knob see Fig 3 7 A and Type B has preheater button see Fig 3 7 B For type A control panel please turn key counterclockwise to HEAT position and hold about 20 seconds to preheat cold for Type B control panel please depress a small red button right above grounding terminal and hold about 20 seconds to preheat cold If your diesel generator comes with 8 wire remote control unit it needs special order extra charge applies you can remote control glow plug The operating procedures are as follows Two sets of ON and OFF buttons used for remote starting engine and turning on glow plug respectively see Fig 3 6 Set 1 for starting engine and Set 2 for controlling glow plug Sets 18 2 are interlocked each other and only one set of ON amp OFF works at a time Set 2 is programmed for powering on glow plug 25 Sec and glow plug will automatically pow
34. he rotor has turnoff 6 Check the reel by the Multimer and D n EE 2 Short circuit of the rotor reels AVR 2 Change AVR firstly If the voltage is 4 Change the carbon brush or make the wrong connection right Can not generate burns not high enough change the rotor Low Voltage On NI SI N 3 Chang the stator 4 Adjust the resistance of AVR If the voltage remains change the stator of the alternator 1 AVR burns after load The voltage A AVR decreases even disappear 4 The sample voltage has short circuit 2 Disassemble the engine Maintain the PTO shaft and the inside pole of the rotor until the conic degree reaches to the reasonable level Then reassemble the engine 2 After loading the PTO shaft skids the voltage decreases and the alternator Others overheats 3 Short circuit of the rotor or the stator makes the alternator overheat The 3 Change the stator or the rotor voltage decreases If you are still having trouble please contact with your nearest dealer or with our company directly if necessary 5 6 Questions and doubts If you do not understand anything or have any questions please feel free to contact your local dealer or with our company directly Below is a list of some information you should have ready before contacting your local dealer or us 1 Model of diesel engine generator and engine model number 2 Purchase date and number of generator operating hours along with the probl
35. is operated on an incline the lubricating system within the engine will not perform well and may lead to engine failure 3 1 2 Prevention from inhaling exhaust emissions Diesel engine exhaust emissions have the potential to cause a range of health problems Diesel engine exhaust emissions commonly known as diesel fumes are a mixture of gases vapors liquid aerosols and substances made up of particles They contain the products of combustion including e carbon soot e nitrogen e water e carbon monoxide e aldehydes e nitrogen dioxide e sulphur dioxide e polycyclic aromatic hydrocarbons The carbon particle or soot content varies from 60 to 80 depending on the fuel used and the type of engine Most of the contaminants are adsorbed onto the soot Petrol engines produce more carbon monoxide but much less soot than diesel engines Never inhale exhausts emitted by the engine The exhaust emissions contain toxic carbon monoxide nitrogen dioxide sulphur dioxide and aldehydes 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 3 1 3 Prevention from accidental burns Never touch the muffler and its cover when the diesel engine is running Never touch the muffler and its cover immediately after the diesel engine is shut off as the muffler remains hot for some time 3 1 4 Elec
36. l be dense and sticky especially in winter it is more difficult to drain all the oil out or some impurities will remain in the engine Take the dipstick off Remove the oil drain bolt 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 Dipstick Oil drain bolt Warning Do not fill engine oil when engine is running 4 3 Air filter element replacement Paper based air filter element is used in diesel generators It is non reusable So do not try to wash the air filter for reuse purpose Replace air filter element every 6 months or 300 hours of regular operation Never start the diesel engine without the air filter Otherwise it can cause serious damage to the engine if foreign objects enter the intake system When the output of the diesel engine is reduced or the color of the exhaust emissions is abnormal replace the air filter element on time To replace an air filter element first loosen the butterfly wing nut take the cover of the air filter off and take the air filter element out then after replacing the air filter element replace the cover and tighten the butterfly nut firmly see Fig 4 1 29 Butterfly nut Air filter Cover Filter Core Ag d SS r SE een T VW E z gt f KI Ti gt Ch di i GY S ka e
37. nder as per the Loosened nut of cylinder head standard requirement When the engine with the Damage or leakage in the gasket of cylinder new gasket is heating tighten the nut of cylinder head again Big gap in the piston ring due to wear and tear Change the piston ring Leakage caused by each gap of piston ring lined in Vo e one direction Serious stickiness or breakage in piston ring Clean it by diesel fuel or change the piston ring Ka Skive the valves or send it to repair factory if the vestige is too deep er Disassemble the valve clean the stem and guide The valve stem 1s clipped in the guide pipe piper diesel ici 3 4 Incomplete combustion Interrupted of diesel fuel 3 Use remote jumper to test if it works the remote control unit fails and needs replaced 4 If remote jumper does not work please turn Key Switch to ON position use a multimeter voltage tester to measure the voltage on the solenoid put positive polarity to the conjunction of blue wire and solenoid and negative polarity to engine case you should read 12V in your meter If the reading is ZERO the solenoid control board named CJX22 control board in green color behind control panel fails and needs replaced If there is DC 12V power to solenoid please troubleshoot as follows 1 Take off solenoid from fuel pump using two wrenches You should use one wrench to hold the solenoid firmly and turn counterclockwise to take it off fuel pump at the
38. ndle when you move speed handle from left to right The HOOD is used to hold fuel pump needle so that you can simultaneously move needle while push speed handle from left to right Use one hand to replace fuel pump while use the other hand to hold speed handle half way let fuel pump needle right sit in the HOOD of speed handle tighten upper two nuts first then move fuel lever and see whether the needle moves with fuel throttle lever otherwise you need reinstall the fuel pump again 37 IMPORTANT NOTES When you need use a hammer during disassembling or reassembling process whenever necessary please NEVER USE METAL HAMMER to hit any parts otherwise you will deform or damage them 5 2 2 Causes and Troubleshooting for Deficient Power of Diesel Engine CAUSES TROUBLESHOOTING eine deyi eli be Check the fuel switch they should be opened fully PIP Clean the fuel filter and fuel pipe Inadequate fuel supplying Bad pressing of fuel pump Check or change the damaged parts of fuel pump Malfunction of the fuel nozzle eee se ar Adjust the injection pressure Incorrect injection pressure E EE TEE Check the speed of engine with the tachometer and E S then readjust the speed limit bolts moan D Fig 5 1 Speed Governing System 38 5 2 2 1 Instructions for speed adjustment There are three bolts used in the speed limit system see Fig 5 1 left C middle bottom and right A screws Screws A amp C are used for tigh
39. ne assemblies of 4000 and 6800 ES C E ee 46 Fig 6 3 Exploded view of muffler system and frame assembly for 6800SDE and of fuel tank and air cleaner assemblies for 4000 and 6800 series cc ec nce cececcecececeeeees 47 Table 6 2 Parts list of 4000DE 6800DE and 6800SDE 48 But Ee E EE 60 II PREFACE We appreciate your business The following manual is only a guide to assist you and 1s not a complete or comprehensive manual of all aspects of maintaining and repairing your generator The equipment you have purchased is a complex piece of machinery We recommend that you consult with a dealer if you have doubts or concerns as to your experience or ability to properly maintain or repair your equipment You will save time and the inconvenience of having to go back to the store if you choose to write or call us concerning missing parts service questions operating advice and or assembly questions Our air cooled diesel generators have some or all of the following features Lightweight construction Air cooled Four stroke diesel internal combustion engine Direct fuel injection system Electric remote and recoil start Open Frame Models only Glow plug also called preheater or cold starter Large fuel tank Automatic voltage regulator NFB circuit protector AC and DC outputs Low oil pressure automatic shutoff sensor Heavy duty big solid wheels Sound proof enclosure silent model only Specially de
40. ng or non conducting it needs replaced 5 Connection between the coil of the rotor and the rectifier 1s wrong which can not make the different magnetic poles N S 1 Low engine speed 1 Increase the engine speed Low Voltage 2 Short circuit of the rotor reels 2 Change the rotor 3 Short circuit of the capacitor or the stator 3 Chang the capacitor or stator 5 Check the reel and the rectifier by the Multimeter Kindly note the current way while connecting 1 The rectifier of the rotor gets short circuit and the output voltage 1 Check the rectifier as per the above decreases suddenly after loading instruction Replace a new one 2 After loading the Power take 2 Disassemble the engine Maintain the off PTO drive shaft skids This PTO shaft and the inside hole of the Others causes voltage to drop and alternator rotor until the conic degree reaches the to overheat reasonable level then reassemble the engine 3 Short circuit of the rotor or the stator makes the alternator overheat The voltage drops 3 Change the stator or the rotor 42 5 5 Damage Cause and Remedy of Brush Alternator 1 Switch is on the position of OFF 1 Turn the switch to the position ON or the control panel wires inside the control panel contact is bad or AVR burns AVR 4 The carbon brush wears out or its positive pole and its negative poles are connect crossly wie And change the stator if 1t needs 6 T
41. or for baffling ventilation and heat dispersion Do not operate under over loading condition continuously and inspect bolts and mechanical firming components routinely 5 2 Malfunction and Troubleshooting for Diesel Engine 5 2 1 Causes and Troubleshooting for the Engine Not Being Started There are many factors causing non starting issues General causes for non starting problem are summarized in Table 5 1 For brand new diesel generator if you can not start it it is usually caused by entrapped air in the fuel hose Please full off fuel hose from fuel injection pump and drain fuel freely to release all the entrapped air If you have used your generator for some time and find you can not start it or it shuts off automatically it is usually caused by failure fuel system such as running out of fuel non energized solenoid and burned solenoid or by failed remote control unit If there is no DC 12V power to solenoid please troubleshoot as follows 1 Check whether solenoid fuse blows out or not If it blows out replace it 2 If solenoid fuse is fine please directly use a copper wire to feed 12V to solenoid when disconnect blue wire to solenoid make sure electrically insulate it for avoiding short circuit and crank engine see whether you can start 1t or not If it works solenoid control board or remote control unit fails Caution there is a blue wire connected to the top of solenoid NEVER touch the blue wire to engine case while with
42. or the type of output shaft The letter F also means that an engine is air cooled If the coding ends up at a letter E it means that an engine comes with electric start The default stroke of 186 series diesel engine is 70mm However the stroke of a diesel engine may be expanded from 70 mm to 72 mm If it is true a letter A will be used directly after letter F for telling whether an engine is expanded 2 5 2 Overall engine dimensions unit in mm aril Leg La NA mE A A PER N b D 2 11 x 16 Central line of cylinder The values of letters in the above figures are tabulated in Table 2 3 Table 2 3 Overall dimensions of diesel engine B cC D EJF 203 145 96 199 5 41 5 43 5 104 144 1718 Note All data subject to change without notice 2 5 2 Connecting dimensions of output shafts and power take off PTO flanges Output Shaft PTO Flange 178 10 Output Shaft PTO Flange ec Y AN gt 10 E 2 6 Installation of diesel engine 2 6 1 Installation Conditions 1 There must be a tight stationary foundation for the diesel engine to avoid vibrations or movement when the engine is running For prolonged engine life consider using some type of motor mount 2 Make sure that the centering position of output shaft is properly aligned 3 For diesel engine with thread shaft or taper shaft make sure that matched machines must have the same
43. p 6 3 Part No Qty i 78 1700103 4 26 1700110 Engine cylinder block l 171134 Oring for oil dipstick 2 8 171216 nT 9 1723 Fuel pump fastening bolt short 1 10 17122 Fuelpump fastening bolt long 1 MH 1719605 Fuelpump gasket 0 5 1 17 1710636 Flange head hexagon bolt GB5789 86 1 78 1700302 36 1700303 Cylinder head bolt short 78 1704802 36 1704803 Special washer A 78 1705001 86 1705003 Cylinder head nut short 2 78 1719704 861706314 Cylinder head gasket 0 4 l p p peh 78 1704902 26 1704903 Cylinder head nut long 78 1700202 36 1700203 Cylinder head bolt long 28 78 17182 Oval ring gasket 5 1 x 2 5 1 86 1720106 Oval ring gasket 5 1 x 2 6 78 1704602 61704603 Crankcase cover gasket l 36 78 1710003 Ball bearing 206 GB T276 94 1 86 1710004 Ball bearing 207 GB T276 94 Table 6 2 continued to next page 48 Table 6 2 Continued from previous page 78 1701802 37 S6 1701803 Main bushing 1711111 Retaining pin 8 x 12 GB118 86 2 78 1701902 S6 1701903 Crankcase cover 40 78 1711703 Front oil seal 30 x 45 x10 86 1711705 Front oil seal 35 x 50 x10 78 1710083 26 1710083 Flange head hexagon M8 x 33 5 bolt 1710083 Flange head hexagon M8 x 33 5 bolt l l 78 1710084 86 1710084 Spring washer 78 1710085 45 1711602 Aluminum plug 8 x 8 Double ended bolt AM6 x 55 GB899 88 Double ended bolt AM6 x 75 GB899 88 1
44. r maintenance free battery please check the color of indicator green means the battery is good dark means recharging battery and Clear means replacing battery Caution Color indicator is only used for reference sometimes even though the indicator shows clear color the battery itself may still work well 4 8 Storage for a long period If your generator needs to be stored for a long period the following preparations should be made 1 Start and run the engine for about 3 minutes then stop 2 Change the engine oil with new oil of proper grade when the engine 1s still hot 31 Remove the screw plug out of the cylinder head cover and add 2CC of lubricating oil in plug hole then replace the plug Recoil starting a Depress the decompression lever non compression position and pull the recoil handle 2 or 3 times This pushes the intake out Do not start the engine Electric starting a Depress the decompression lever turn ignition key to ON position and crank the engine for 2 3 seconds Do not start the engine Pull the decompression lever up pull the recoil starter open frame or manually rotate flywheel silent until you feel resistance this 1s when the piston is on the compression stroke where both intake and exhaust valves are closed Having intake and exhaust valves closed will keep moisture away from combustion chamber and prevent engine from rust Clean the engine and store in a dry place 32 CHAPTER 5 TROUBLESHOOTIN
45. ration before OPEN seu ke e a rin its 17 3 2 1 Fuel choices and fuel treatment deh pe 17 22 PP e E Un In A 17 GAS 18 3 Generator Operatime Procedures ke ei da 19 3A Generator Break llora bre kane leb Be e b dl yalm pa e a dm nd ere 20 3S5Apply ngloadtoyourGenerator ee 20 3 6 OperatingProceduresforRemoteStart 22 27 How to Use Glow AA ll il e el me EE 24 ma DI NN E NN EN e nae aneue reece 25 3 9 Stop 1 i ll 23 3 10 Procedures for recoil SLAM EE e 26 CHAPTER A MAINLENAN ee A a 28 4 T nn ran E O 28 AA ens ne Olean 100 hours WE O e 29 Seem ir filter dement replace O A A a 29 AF ul Dt nanc A O E 30 A uc nj zle a A A 31 feo ylinder RA ten e O A 31 oa i eee e 31 oo llc re e 31 CHAPTER 5 TROUBLESHOO LEN LE 32 S IlnspectionsbeforeOperattonandMaintenance 32 5 11 Inspection Delore OMe e E 33 S l l lIChecktheinsulatedresistance 33 3 1 1 2 Check the alternator ASSEMIDIN genin venin ini ad nin 33 9 1 2 plartins NDE MELO gun gg 33 LS NITION ANCE asar e e e E 33 5 2 Malfunction and Troubleshooting for Diesel Engine aaa 33 5 2 1 Causes and Troubleshooting for the Engine Not Being Started 33 5 2 1 1 Instruc onsfordisassemblingalternatoriromengine 36 lI 5 2 1 2 Instructions
46. rator please add enough acid to required level FULLY CHARGE BATTERY prior to cranking diesel engine Add engine oil to the required level use oil plug to check Mobil Delvac SAE 15W40 warm weather or SAE 5W40 cold weather synthetic DIESEL ENGINE OIL is recommended Add enough diesel in fuel tank turn knob fuel Shutoff valve Down ON position On open Frame this 1s under Fuel Tank on enclosed Units this is on filter inside of the door Pull off the fuel hose connected to the fuel pump and LET FUEL DRAIN OUT FREELY then replace the fuel hose Connect fully charged battery to generator DO NOT apply any load at this point and put the CIRCUIT BREAKER to the OFF position Push RED lever next to oil level check stick to the RUN position Turn on to the START position and release the key to the ON position In cold winter area please turn key counterclockwise to HEAT and hold about 20 seconds to preheat cold air then turn clockwise to START engine release the key to on position after engine starts it helps start the engine in cold weather if your remote control unit has remote preheater function please see refer to operating procedures for remote start for your reference 11 Ifthe engine does not start wait 1 to 3 minutes and repeat the 8 or 9 12 Only try to use remote control after you successfully start the engine using a key switch Note Open frame models usually come with recoil starter If you want to pull start your
47. rting claw plate 1721901 Torsional spring 1721801 Helical spring 1704005 78 1703202 78 1703301 36 1703303 Flat torsional spring l 78 1703802 i 36 1703802 Recoil starter handle 78 1703502 36 1703503 Recoil starter rope 78 1703402 36 1703404 Recoil case assembly I 1719403 Fuel hose clamp 17189 78 1704702 61704700 Fuel injector pump I 1710608 M6 x 8 GB5787 86 78 1705602 36 1705603 High pressure fuel pipe 78 1705402 158 61705403 Muffler assembly 1710814 M8 x 14 bolt GB5789 86 1710208 Flat washer 8 1710308 Spring washer 8 Table 6 2 continued to next page 32 Table 6 2 Continued from previous page 1710108 M8 nut GB5789 86 164 1711400 Speed control lever assembly l 165 1716 o Speedcontrollever_______ 1 166 17168 Pantead screw 1 167 17164 o Control system brackt 1 168 1710618 o MG x 18 bolt GB5787 86 1 169 1710614 MG x 14 bolt GB5787 86 1 170 17166 Hexagonheadmut 1 m M s Throttlecable IR ime Speedlimitbot 1 78 17161 17169 Thin hexagon nut 78 1700502 61700503 Fork lever assembiy 3x22 pin 187 GE Fuel injector pump assembly Joint NO Y 1 bech kuch pudo bech keck CO Plunger 197 1704719 Shimst LL Spring pin 2 Control lever l Table 6 2 continued to next page 53 Table 6 2 Continued from previous page Fuel nozzle injector assembly 1705321 1705331 Nozzle spring 17053
48. s 120V output A voltage selector is used to obtain 120V and or 240V outputs see Fig 3 5d Two sets of windings are in parallel when a selector is set at left while two sets of windings are m serial when a Selector is set at right see Fig 3 5b amp c If you push voltage selector left for only 120V output you can apply full rated load at 120V outlets if push selector right for both 120V amp 240V outputs you can apply full rated load at 240V outlet from four prong socket however you can only apply HALF RATED LOAD at either 120V outlet total two 120V outlets from four prong socket Grounding Y ellow Green EN OT of mon TT E 0 Pass TIT 2 L1 Black Fig 3 5a Wiring diagram for alternator Fig 3 5b Parallel Connection Grounding 2 H 240V R2 LI 120V 120V RI NEMA L14 30R for 120 240V 30A Four Prong Socket Fig 3 5c Serial Connection 21 L R2 Blue Red dl ALERT BT ACIZOY Grounding Yellow Green w E i a a eem LI f Black Fig 3 5d Wiring Diagram of Electric Output for Control Panel 3 6 Operating Procedures for Remote Start Remote Jumper Remote Control Unit RF signal RF Key RF signal receiver transmittal key Fig 3 6 Remote Control Unit left and Remote Jumper right 22 There are two sets of ON and OFF buttons in RF transmittal key If your remote start unit with 7 wires on has no remote glow plug function the operating procedures are
49. signed exhaust system and power transfer box trucking generator only 4 Ze 4 Ze 4 Ze Ze Ze Ze Ze Ze SCS Ze SCS Ze Wi Ze Wi Ze Wi Ze SCS Ze The KSD air cooled diesel generators are widely used when electrical power is scarce Our generators provide a portable mobile solution in supplying power for field operations during project construction Some other known applications include pipeline construction and metal welding when electrical power 1s not available This manual will explain how to operate and service your generator set If you have any questions or suggestions about this manual please contact your local dealer or us directly 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 Optigenerators International Inc reserves the right to make changes at any time without notice and without incurring any obligation Chapter 1 Overview of 4000 and 6800 Series 1 1 Open frame model AA u di d a Pi e i Control Panel Governor System Fuel Filler Cap Fuel Tank Battery Starter Solenoid Starter Motor Voltage Stabilizer DC12V Recoil Starter Muffler Fuel Injector Air Cleaner Glow Plug Decompressure Lever Fuel Return Hose Cylinder Head Cov
50. t in mm a l 0 15 0 20 cold state 0 15 0 20 cold state Table 2 9 Ranges of temperature smoke and pressure Exhaust temperature C Engine oil temperature C Smoke Bosch lt 4 Pressure of injection MPa Kef cm 19 6 0 49 200 5 14 2 9 Torque specifications for various engine bolts and nuts Table 2 10 Allowed torque for various engine bolts and nuts Unit in N m Description ue ER Cylinder head nut 42 46 54 58 Flywheel nut 100 120 120 140 10 12 Retighten up after Tightening screw bolt break in period 20 23 of rocker support Standard M8 bolt 18 22 Standard M6 bolt 10 12 25 30 40 45 15 CHAPTER 3 OPERATING THE DIESEL GENERATOR 3 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 Otherwise it may lead to accidents or equipment damage 3 1 1 Fire prevention The proper fuel for the diesel generator set 1s light diesel fuel Do not use gasoline kerosene or other fuels other than light diesel fuel Keep all flammable fuels away from the generator as it may spark and ignite these gases In order to prevent fires from occurring and to provide enough ventilation for people and the machine keep the diesel generator at least 1 5 meters away from buildings or other equipment Always operate your diesel generator on a level site If the generator
51. t is snapped If adjustment screw 1s snapped try to take out the broken screw and replace it with a new one Make sure you correctly adjust the gap of valves in the range of 0 15 0 20 mm If tappet is snapped you must remove alternator from diesel engine and then disassemble engine for replacement 5 2 1 1 Instructions for disassembling alternator from engine 1 Drain out all the fluids from your generator including oil and fuel Remove generator frame open frame or soundproof enclosure silent from base pan 3 Loosen four long bolts for holding alternator first and then remove stator from alternator You should use two flat head screwdriver to warp up the stator out through two symmetrically distributed notches in the alternator cast case It usually takes less than 10 seconds to remove stator from alternator 4 Remove rotor from engine shaft Completely loosen the long bolt with a 14MM hex head nut that is used to hold rotor to engine shaft so that you can take 1t out However you should not take out the long bolt but to leave the loosened bolt in place then use a RUBBER HAMMER hit heavily hit the 14MM hex head nut of long bolt about 10 times at the directions of left right back and forth take out long bolt and then you shall pull out the rotor from engine shaft easily Warning Never use metal hammer rather than rubber hammer to hit the nut and avoid hitting in the bearing of rotor Otherwise the bearing will be broken 5 2 1 2
52. tening metal plate B A is also used for fine adjustment of speed and middle bottom screw for setting maximum fuel throttle Please note that there is an oval shaped hole in the metal plate B with A through Screw A is used for fine adjusting RPM Frequency lt 5 Hz moving B up decreases RPM while moving B down increases RPM There are two rows of three small holes right behind the metal plate B not shown in Fig 5 1 and four large holes in location E If the adjusted frequency gt 10 Hz the thick spring D is used for coarse tuning Try to hook two ends of D in one of six small and four large holes E respectively for obtaining desired frequency e g if we need change 60Hz to 50Hz this method will be involved Given position of hooked small hole the obtained frequency decreases in the order from left to right holes of E given position of hooked large hole the obtained frequency decreases in the order from left to right small hole in the same row and upper to lower small holes Frequency adjustment shall be conducted with a frequency meter Bolt F is preset for maximum power output position by manufacturer it NEVER touches fuel lever unless the maximum power output is reached So NEVER adjust the position of threaded bolt Caution If your generator runs unstable e g runs at upper or lower speed and you excludes fuel system problem you must try hooking the two end s of coarse spring D in different small and large holes to find out fl
53. the crankshaft shoulder and the outer center of belt pulley groove 2 6 3 Crankshaft driving and tilt angles Crankshaft driving angles must be larger than 120 see Fig 2 1a The tilt angles of engine must be kept within the allowed values shown in Fig 2 1b Output Shaft Tilt Allowed Tilt continuous running Engine Tilt Allowed Tilt continuous running Fig 2 1b Allowed tilt angles 12 2 7 Performance curves e r E 5 320 300 270 2 28 ve JE 2 240 al g kW h g hp h 1500 2000 2500 3000 3500 3600 4000 Speed of crankshaft RPM Fig 2 2 a Performance curve for 178 diesel engine fas pa CO el za SI L L PEA Pert im enamel fy 1500 2000 2500 3000 3500 3600 4000 Speed of crankshaft RPM Specific fuel consumption GJ 3 NO N Fig 2 2 b Performance curve for 186 diesel engine 13 Torque Output Performance is measured after 30 hours of running with air cleaner and exhaust silencer Measurement conditions for performance curves are listed in Table 2 5 Table 2 5 Measurement conditions for performance curves ISO 3046 1 2 760 mmHg 750 mmHg Relative humidity 2 8 Valve timing initial angle of fuel delivery and valve clearances Table 2 6 Valve timing Table 2 7 Initial angle of fuel delivery 178 186 Engine speed RPM 3000 3600 3000 3600 Ba angle EE SS Table 2 8 Valve clearance uni
54. thread size or coned angle as output shaft of engine 4 For diesel engine with keyway output shaft check whether the bearing hole installation hole on the belt pulley and keyway output shaft are properly aligned and whether their dimensions match Also make sure that the bolt of the engine shaft is tightened to the proper torque specifications 5 When the engine is matched with other belt driven machines the total desired belt distance traveled by the driven wheel must equal the total distance traveled by the driver pulley If this 1s not properly calculated and matched the desired speed on the driven pulley will be incorrect The diameter of driving belt pulley can be calculates as follows j Diameter of driven machine x speed of driven machine Diameter of engine belt pulley lt lt lt lt lt lt lt lt Diesel engine speed 6 Make sure that the belt is tightened properly 11 Note If the belt is installed too tight the engine will be overloaded and its bearings will wear at a high rate leading to engine failure if the belt is too loose the belt will slip at high speed and high load causing high pitch whistling noises 2 6 2 Allowed clearance between belt wheel and engine The belt pulley should be as close to the engine as possible The values of L are tabulated in table 2 3 Table 2 4 Allowed belt pulley to engine distances Min Diameter of pulley mm Note L means the distance between
55. tric shock and short circuits Never touch the generator if the generator 1s wet Also never touch the generator if your hand is wet Never operate your generator exposed to air in the field or outside buildings if the weather conditions call for any type of precipitation such as rain snow or fog To avoid electrical shocks the generator should be grounded Use a lead to connect the grounding terminal in the control panel of generator to the grounding surface of choice Please refer to Fig 3 1 before operating generator 16 Note When connecting devices to the generator make sure that the power for all the devices is rated lower than generator output Any of generator sockets should not be Kg T overloaded above its regulated EN IE wi h h d ba Safe d S E o Grounding terminal in the control panel Fig 3 1 Control Panel with Grounding Terminal l DA 3 1 5 Other safety items Before operating generator all operators must be aware of put the CIRCUIT BREAKER to the OFF position if any accidents occur Also all operators should be familiar with all the switches and their functions of generator before using it Wear safe shoes and suitable clothes during operation Always keep generator out of reach of children and animals 3 1 6 Battery The electrolytic liquid of battery known as battery acid contains sulfuric acid In order to protect your eyes skin and clothing wear protective glove and goggle when
56. ure 5 2 7 Checking Methods for malfunctioned Engine CAUSES TROUBLESHOOTING Check if the speed governing system 1s flexible and if air mixed in oil pipeline Abnormal noise suddenly sent out Stop the engine and inspect each movable parts carefully Speed sometimes fast sometimes slow Exhaust with black suddenly Check fuel system especially the nozzle Rhythmically metal knocking sound in the The fuel delivery angle is too big should adjust the cylinder angle 40 5 3 Overhaul and Troubleshooting for Diesel Generator 5 3 1 Causes and troubleshooting for the generator not being started CAUSES TROUBLESHOOTING Lack of diesel fuel Add diesel fuel Fuel switch 1s not on the position of ON start EC Turn fuel switch handle to the Ge of ON Air Air entrapped in fuel system 0 in fuel system Release ir air dor Eder ee dee Disassemble the nozzle and adjust it on the test table EEN m a Turn the governor handle to the position of RUN The standard of lubricating oil is between upper line Oil lever is too low or oil 1s too dirty H and bottom line L Change oil if necessary Recoil starter is not swift and powerful Start the engine according to Start Operation enough Procedure Dirty in the nozzle Clean the nozzle Ambient temperature is very low Preheat cold air No electricity of storage battery Charge up or change the storage battery Solenoid is not energized or stuck Check fuse CJX22
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