USER MANUAL - Northern Tool + Equipment
Contents
1. USER MANUAL PLEASE READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION ITEM DIES5500 DIESEL GENERATOR PREFACE Thank you for purchasing a diesel generating set This operation manual will tell you how to operate and service your generation set correctly Please read this manual before using the generating set to ensure the proper operation Follow the instructions to keep your generating set in the best working condition and extend the life of it If you have any commends or problem please contact with our sales company or the authorized agent This manual deals with the general items of the diesel generating set However the manual may vary with the development of the products in the future Please give special attentions to warnings and cautions Indicates that the severe personal injury even death will result if the instructions are not followed Indicates that the serious personal injury or equipment damage will result if the instructions are not followed diesel generating set will meet your requirement if you operate it according to the manual instruction Otherwise serious personal injury and equipment damage will result So reconfirms that you must to read and understand this manual before operating the generating set WARNING 1 TO PREVENT THE FIRE Never add fuel to the fuel tank while the engine 1s running Wipe off the overflowed fue2. air cool genset is cooling by air if altitude is more than 1000m air will be rarefaction so the effect will be not good In case overheating for gensets which are using in high altitude more than 1000m it should be running in low load Also it dosent mean that gensets can be overload if altitude 15 less than 1000m specification of genset in different temperature and altitude an M iis m os o3 2 1 Part name LDE series T type Engine starter switch Outlet fo cooling air Exhaust i 2 1 Fuel filler cap Lifting eye Low oil pressure J lamp Control Panel E type panel E model receptacle panel E type basic model panel E type panel model double voltage panel intelligent control panel 3 PREPARATION FOR STARTING 3 1 Selection and handling of the fule oil B Selection of fule oil Only use the light diesel which 1s most suitable for the engine B Keep dust and water out of the fule When filling the fule tank from druns make sure that no dust or water 1s mixed in the fule Otherwise the serious fule injection pump and nozzle problems will result B Do not overfill Overfilling is very dangerous Do not fill the tank beyond the top of the red plug inside the fule oil filter WARNING Refuel in a well ventilated area with engine stopped Do not smoke or allow flames or sparks in the area where the engine 15 refueled or where the fule oill
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4. usniq uoq1eo uonrsod NO 01 YOIIMS un MAU L YM 71 IJd 1 IFYO 1000 SIY 11915 AY o Surp1oooe AY 11915 2200 WLA JOMOT pue 249 Joddn u Aq q 24 p nous ay uonisod YVLS 01 1949 195 91981 1591 11 medas pue o zzou 0011504 THVIS un ong ION peseurep SI poyoene jou paads pari 0003 JOU SI 793208 Jo 1221002 au Apeolye 5 UO poun JOU YSIS POLJA ou seu Su L ysnous jou 19 10 5 10291 0 90910 pue paads seu 77 AY L 42940 uonisod 4 V LS 3 101 SI 99 Tony 1uoarorgnsur 10 on JOU o zzou pue uonisod 3V LS Jou SI 4209 JUSTOLJINS 100 SI Jon 95127 The generating set can not pes C3 un O ON O O un O O C generate CAUTION The installation and major repair work shall be carried out only by specifically trained personnel 11 Noise 74 1dB 87 6dB 85 4dB Electr
5. activated by low oil pressure or engine oil shortage simultaneously the en gine will stop The engine will stop immediately if restarted without refilling the engine oil Check the oil level and refil Do not loosen or readjust either the engine speed limiting bolt or fuel injection limiting bolt otherwise otherwise the performance will be affected 5 2 Checks during the running 1 Whether there 15 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 en gine and find out the fault cause or contact with agent Ee CAUTION B If the engine has been running the muffler will be very hot Be careful not to touch the muffler Never refill the fule tank while the engine is running 6 LOAD CAUTION Do not startn 2 or more machines simultaneously Start them one by one Do not use floodlights together with other machines CAUTION The generating set must not be connected to other power sources such as the power company supply mains In special cases where stand by connection to existing electrical systems is intended it shall only be performed by a qualified electrician who has to consider the differences between operating equipment using the public electrical supply network and operating the generating set B When using exten
6. aratus to generating set rator before it has been started If equipment is attached generator starting may cause sudden movements of the equipment and result in injuries and accidents Be sure to disconnect any apparatus from the generating set or prior to starting CAUTION Most appliance motors require more than their rated wattage for start up Do not exceed the the specified current limit of any socket Do not connect the generating set to a household circuit This could cause damage to the generating set and to electrical appliances in the house 5 WHEN CHARGING THE BATTERY 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 Batteries generate hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near a battery especially during charging Charge the battery in a fully ventilated place 6 PLEASE KEEP THE CHILDREN FROM THE GENERATOR A generating set may cause hazards that are not recognized by the layman and especially not recognized by children Protect children by keeping them at a safe distance from the generating set 7 IN USING Advice on the need of personal protection equipment e g hearing protection where the application is known CONTENTS 1 Main Technical Specifications and Date 1 2 C
7. ase abnormally the nozzle will blocked and the generating set will be damaged Press down the stop lever Concerning the electric starter turn the key to OFF Turn the fuel cock lever to 5 position Pull out the recoil starter handle until you feel resistance at this position both intake ex haust valve are closed and leave the handle in this position This prevents the engine from rust WARNING B If the engine keep on running even after the speed lever is placed at the STOP position either turn the fule cock to the CLOSE position or loosen the nut of high pressure fule 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 8 PERIODIC CHECK AND SERVICE Periodic check and service are very important for keeping the engine in good condi tion and durable The chart below indicates what checks to make and when to make them WARNING B Shut off the engine before performing any service If the engine must be run make sure the area 15 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 sixth month Every year or W day or 20 Hrs or 100 Hrs 500 Hrs 1000 Hrs Check and O Drain out fuel oi
8. connected with the battery Do not use DC 12V and AC at the same time CAUTION 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 45 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 generator set WATTAGE EXAMPLE We IO APPLIANCE STARTING RATED APPLIANCE STARTING RATED TYPICAL Incande A FR scent i NA Incandescent Incandescent lamp lamp Heating m N 100W applian 40W Fluorescent Fluorescent lamp Motor k driven 450 750VA 300VA 4 Refrigerator ment vei 150W 7 STOP YOUR GENERATING SET 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 incre
9. ffected 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 slip ring Often check the generating set carbon brush slip ring Readjust if there is spark 9 LONG TERM STORAGE 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 fresh oil 3 Remove the screw plug on the cylinder head cover and refill 2cc engine oil then put the plug in place 4 pg Recoil starting Push the decompression lever down Non compression position and hold it while you pull the recoil starter2 3times Do not start the engine Electric starting Turn the engine 2 3 seconds with the decompression lever set at the non compression 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 values 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 WARNING Indication that the installation and major repair work shall be carried out only by specifically trained personnel TROUBLESHOOTING AND REMEDY 10 HAV 20g da Sjuouraumbo o Surpiooop y 3snfpy Jayoos ay 1snfpy
10. ic Wiring Diagram for All Types of the Set lt 1 gt C type electric wiring diagram 230V Output Air switch eee 1 d sampling winding 2 X type electric wiring diagram single voltage output P22 E NELLE UTULA gt SUIPUIM SUIPULA aogeuoaxa 77 MAREA dino AZ r a A 123205 Indino gt ADET 1 11 eunssaud fio T auie amaaa dog lt 3 gt X type electric wiring diagram double voltage output LJ Ico gwu 1248244 WHI Indio sameway 1 1 PEN EB EN Jove Spur jroinus 21155224 i lt 4 gt E type electric wiring diagram single voltage output 8 8 54 gt 1 2 gt main wi pr fa stop indicator Flywheel generator 5 E type electric wiring diagram double voltage output fuse IT m E 22 4 Us aasa EE GM GE XE GE indjno snoaumnuits yom sss gt Gs Gss Gs mds Lasa ADE 7 indino lt 6 gt E type electric wiring diagram B
11. l A Check fool eskage O Check and tighten fasten mM ing parts Replace engine oil amp Tighten the cylinder head bolts Replace air cleaner Service more frequently when element used in dusty areas Clean fuel oil filter Check fuel pipe necessary Adjust clearance of intake exhaust valves Note indicates that special tools are required please contact with agent 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 pulg 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 every 6 months or 500 Time hours N m Replace if necssary Oil filter Drain 8 3 Replace the air cleaner element Do not clean the air cleaner element with detergent Replace time Every 6 months or 500 hours CAUTION Never run the engine without the element or with a defective element 8 4 Clean and replance fule oil filter The fuel oil filter also has to be cleaned regularly to insure maximum engine output 1 Drain out the fule from the fule tank 2 Drain out the fule from the fule tank Screw off the small screw of the fule cock and pull out the filter from the filler port 3 Wash the filter tho
12. l oil with a clean cloth Keep explosives and other flammable products and from the generating set prevent the fire and to provide adequate ventilation keep the generating set at least one meter away from buildings and other equipment during operation Operate the generating set on a level surface Do not put the generating set indoors while the engine 15 hot 1 To PREVENT FROM INHALING THE EXHAUST Exhaust gas contains poisonous carbon monoxide which 1s harnful to the health Never use the generating set at the confined places or poor ventilated locations If it s necessary to run the generating set indoors be sure to provide the adequate ventilation 3 Danger SCALDING can accure The muffler and the engine body are very hot while the engine is running or just after running do not touch these parts to prevent from being scalded 4 ELECTRIC SHOCKS SHORT CIRCUITS To avoid electric shocks or short circuits do not touch the generating set when your hands are wet This generating set 1s not waterproof so it should not be used in a place exposed to rain snow or water sprays Use of the generating set tor in a wet place can cause short circuits and electric shocks during operation B The generating set should be grounded to prevent electrical shocks from faulty appliances Connect a length of heavy wires between the generating sets ground terminal and an external ground source Do not hook up tools or other app
13. move the air cleaner cover and take out the element CAUTION Do not wash the element with detergent B Replace the element when its output decrease or a bad exhaust color 1s noticed Never run the generating set without the element otherwise the rapid engine wear will result 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 lamp GA ZEN WARNING Be sure to turn off the main switch before starting The generating set should be earthed to prevent electric shocks Z WARNING The generating set should be earthed to prevent electric shocks 2 Handling of dual voltage type generat ing sets Be sure to place the changeover switch in the correct position for the rated volt tage of the working instrument CAUTION B 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 instru ment lighting apparatus motor etc to their OFF position If the switches not OFF the sudden application of load when the engine 15 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 Loo
14. onfigurating 3 3 Preparation for Starting 6 4 Start the Generating Set 10 5 Operate the Generating Set 15 VIE 16 7 Stop the Generating Set 18 8 Periodic Checks and Service 19 9 Long term Storage 20 10 Troubleshooting and Remedy 25 11 26 1 MAIN TECHNICAL SPECIFICATIONS AND DATA d Data ions an ficat ical Spec Techn 1 Mai 1 098 096 6 1 osexossxseeu 068 099 9881 098 099 986 072 025 0 8 1 089 X 006 lt 2 3 089 x 006 x S2Z X3 089 x NOS x S2Z x3 068 006 x S2 X3 096 x x oozx3 SES X 397 X 389 WW HXMXT suosuawp 940 Wo s uonoeuuoo UOISSILUSUBI yeo 1 81 XI BININIS Inoy Z VE 8 AZL VE 8 AZL indino JUL SUOD UO9IIS uoneox3 eso i om amo Soma vv ve
15. roughly with diesel fule Loosen the fastening mut 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 Contanct with agent 8 6 Check the injection nozzle and fule injection pump 1 Adjust the clearance of the intake exhaust valves 2 Grind the intake exhaust valves 3 Replance the piston ring these operation require special tools and skills contact with your agent WARNING Do not perform the injection nozzle test near an open fire or any other kind of fire The fule spray may ignite Do not expose bare skin to the fule spray The fule may penetrate the skin and cause injury to the body Always keep your body away from the nozzle 8 7 Check and refill the battery electrolyte and charge the battery The diesel uses a 12V battery Battery elec trolyte will be lost through continuous charg ing 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 15 discovered replace the battery Check the battery electrolyte monthly WARNING The battery electrolyte contains sulfuric acid Protect your eyes skil and clothing In case of contact flush thoroughly with water and get prompt medi cal attention especially if your eyes are a
16. sen the bolt of the air cleaner check port cover to check the air cleaner 3 Screw off the wing nut to open the cover then 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 B Warm up the engine 5 minutes after the initial starting Run the engine at low speed and zero load before the engine becomes warm 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 B Replace the engine oil while the engine is warm after 20 hours running the old engine oil will be drained out completely Approx one month or 20hours Every 3 months or 100 hours 4 START THE GENERATING SET WARNING 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 fule cock 2 Set the engine speed lever at the RUN position 3 Pull out the recoil starter handle E Pull out the handle until you feel the resistance then return it back to the 1 tial position Press down the decompression lever It will return automaticallly when the recoil starter is pulled B Pull out the recoil starter handle briskly with both hands CAUTION Do not hook up tools or other apparatus to the generating set before
17. sion lines or mobile distribution networks the total length of lines for a cross section of 1 5 mm should not exceed 60m for a cross section of 2 5mm this should not exceed 100m 6 1 AC application 1 Be sure to run the generating set at rated speed otherwise AVR Automatic Volt age Regulator will produce the forced excitation If the running 15 for a long time under such condition AVR will be burned out 2 After switching on the 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 DS air switch should be set at OFF postion Otherwise the generating set and electric devices will be burned out and damaged 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 1s necessary to unload the generating set immediately and turn off the main switch and do checks Three phase generating set Balance three phases during the operation Stop the engine for check if the toler ance exceed 20 Be sure to keep the tolerance among three phases less than 20 The load for each phase m
18. starting 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 CAUTION B 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 Recoil starting 1 Open the cock 1 in the AUN position 1 3 PASSI n 4 wt 5 i z 1 5 i ai T a the engine doesn t a alan iry again 7 Full hard l and fast pull way use Iwo Tue eri em F wit NH hands if hecesgary the staring handig At Pull the staring ha ric NP net you resistance the string e i handle firmly Push the decompression ML lever down and release 4 Pd IX 5 an a Fi Recoil starting For 3 don t pull thi fast or too hard Far Jf you don pull the rope the way out the engines won t stant F Always pull ihe mpa a N the way out 4 2 Electric starting you don t p
19. 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 15 spilled make sure the area is dry before starting the engine 3 2 Check and refill the engine oil WARNING B Always check the engine level with the generating set on a level surface before starting and refill 1f necessary B The engine may be damaged if operated with insufficient engine oil it is also dangerous to refill too much engine oill as sudden increase in engine speed may be caused by its combustion CAUTION LBDE 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 1s used or if your engine oil 15 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 APL Choose the applicable viscosity oil according to the local ambient temperature 3 3 Service the air cleaner 1 Screw off the wing nut re
20. ull hard anough the angina 1 7 Aways pull the rope hard Y and fast Fi 1 Starting The preparations for electric starting are the same as for the recoil starting Open the fule 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 does not start after 10 seconds wait 15 seconds before start ing it again CAUTION B 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 2 Battery Check the battery electrolyte level every month Refill the distilled water until the upper limits if the electroly dropped to the lower limits CAUTION If the electrolyte level is too low the engine may fail to start because there 15 not sufficient power On the other side if the electrolyte level 15 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 For the generating set Low Oil Warning System the Oil Alarm Lamp will
21. ulpuw Bujdues t Buifueun Excitation winding 3 URN aseud ajbuis Low ail pressure indicating lamp T X3 E3 type electric principle diagram itaca _ Era M m lia 3 rh I HB i E ri Ise ic BLES i E 81 iiid C C a F nao dogs T qu 3 _ o 1 i Ar i jor AJ unana Is It 777777 7777777 177777777 NO IYA Description For set X3 type the components in the two point and line box are not mounted 8 T3 type electric principle diagram Buipuwa Mpu BuiBueu epueses s e HE 101219096 4 to 5pm 797 2738 PST CALL FOR SERVICE 866
22. ust 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 heavyduty motors then start the light duty motors NOTE If coverloading of the circuit trips the AC circuit protector reduce the electrical load on the circuit and wait a few minutes before resuming operation 6 2 DC applicetion 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 CAUTION 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 B When 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
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