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KIPOR Diesel Generator Service Manual

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1. on start le ed dr Fig Electric switch lock 57 4 1 5 Air cleaner A dirty air cleaner will obstruct air from entering carburetor thus reduces the engine working efficiency If the engine is running in dusty area clean the air cleaner more frequently Caution Never run the engine without the element or with a defective element the dirt may enter into engine to accelerate the engine damage Checking cleaning 1 Loosen screws on service cap remove the service cap 2 Push off the locking plate on the top of air cleaner remove the air cleaner 3 Take out the filter element 4 Wash the element in warm soap water rinse it and air dry completely Or clean with high fire point solution and air dry Soak the element in clean engine oil squeeze out redundant engine oil The redundant engine oil may prevent air to enter into foam element and would smok at engine starting 5 Reinstall the element in air cleaner If necessary clean the air cleaner rubber and housing Make sure that the seal ring of air cleaner cover is secured 6 Reinstall the air cleaner cover Reinstall parts in order Lock the locking plate on the top of air cleaner Make sure that the seal ring of air cleaner cover is the seal ring of air cleaner cover is damaged replace it 7 Reinstall the service Caution If the cover of air cleaner installed no
2. sure to turn off the main switch before starting The generating set should be earthed A ATTENDED Do not allow the handle grip to snap back against the engine Return it to prevent electric shocks gently When the engine is difficult to start in cold weather remove the screw plug from the cylinder head cover and add 2 cc engine oil 3 2 4 1 Recoil starting Start the engine according to the following procedures 3 2 4 2 Electric starting 1 Open the fuel cock 1 Starting The preparations for electric starting are the same as for the recoil starting M Open the fuel cock Note This procedure is not necessary for generating set of series KDE type T Set the engine speed lever at RUN position Note This procedure is not necessary for generating set of series KDE type T Turn the starting key to START position Remove your hand from the key as 2 Set the engine speed lever at the RUN position soon as the engine starts f the starting motor does not start after 10 seconds wait 15 seconds before starting it again A ATTENDED E Run the starting motor for long time will cost the battery power greatly even burn out the battery Always leave the starting key at ON position while the engine is running 48 49 3 2 5 Check battery Only KDE6500T 6700T TA generating set is equipped a 12V36AH maintenance free battery as factory standard configurat
3. KIP OR KIPOR POWER CO LTD Address Beside Jingyi Rd Third stage Development Section of Wangzhuang Industry Area Wuxi High amp New Technology Industry Development Zone TEL 0086 510 85200888 FAX 0086 510 85200999 E MAIL kipor 9 kipor com Version 3 Printing date 12 06 2006 KIPOR POWER MAINTENANCE MANUAL DIESEL GENERATOR SINGLE PHASE K DE2200X E KDE8500X E T TA KDE8700T TA KDA8700TA TAO THREE PHASE KDE6500X3 E3 T3 KDE6700T3 TAS KDA6700TA3 TAOS PREFACE Please read this instruction and ensure understand all regulations concerning handling check and maintenance thoroughly prior to application Failure to follow this instruction may cause serious accidents Incorrect operation is likely to lead accidents Operate and maintain the machine on the basis of thorough understanding of this instruction Place this instruction in the fitting box or near machine after reading because it is regularly needed If this introduction is lost or damaged please order one from local KIPOR dealer Please provide this introduction to another user whom machine will be transferred to Machine may be improved or modified Therefore actual conditions may be different from this introduction f you have any doubt please consult local KIPOR dealer Machine is the special diesel generator for ground application Safety information contained
4. 935 9 winding SE lt DE6500XWIEW KDE6500X E T 3 13 13 Welding I Welding Control KDE6500XW EW 0 15 0 152 18 18 winding NOTE 1 Sample winding voltage 16V Resistance 0 5 9 2 Measure the ohm mete the value is or co separately show 30 2 10 KDE6500EW XW 44 Hewgalbot 4 Guard shield of reactor Hexagonal flange face bolt M6x14 9 Fixed reactor Hexagonal fange face bolt __ 9 Hexagonal fange facenut M6 9 _ Output wire of reactor Median plate Hexagonal flange face bot 9 Hexagonal flange face nut Me 9 Oil scale Cross slotted panheadserew M amp x12 Oil switch subassembly Cross slotted pan head screw M5x12_ Oil switch Hexagonal flange face nut 9 Faxed oil tank and upper cover plate Hexagonal flange face bolt M6x25 9 Hexagonalbot o Back cover plate Hexagonal fange face bolt Mox 14 9 Hexagonal fange facenut_ me o ndrced air cover Hexagonal fange face bot M5x12 AVR control module Hexagonal flange face M6x40 9 Hexagonal fange me 9 Panne Gross slotted pan head M6X 16 9 Power supply regulator Hexagonal lange face bot m6x14 9 es Ed E L LE F E E 3 s NIN eo N cO Cleciromagnel Electromagnet fixed on the Cross slotted pan hea
5. Ga LS D I 97 CI 197 EMI 197 C UNI CT E L E y k 4 3 4 e 4 gt a FON IW r k A C s 4 Charing checkout position Common terminal for output Stating output Power supply input Engine oil alarming input grounding is valid Voltage selection 120 240 Input termianl 1 for current of phase C Input termianl 1 for current of phase B Input termianl 1 for current of phase Phase C voltage input the phase voltage is transformed Common torminal for voltage input Diagram of starting motor fuel oil control Both pin of common terminal starting motor to be connected Electric switch lock ae Ale yA Receptacle Air switch 2 Grounding bolt Panel Plastic veneer Fig Intelligent control panel 71 5 1 Setting 1 Press and hold down key FUN turn the electric switch lock from OFF to ON After 5 seconds enter the setting program 2 According to the number of voltage phases and the table below select corresponding toggle switch Toggle switch Display i i DIP4 DIP5 Meaning Left Right Left Right PH 1 PH1 ON ON OFF OFFER ON Single phase single voltage output PH 2 ON OFF OFF Double voltage selected output PH 2 RB OFF OFF BEM ON Double voltage selected output 23 OFF OFF WE OFF OFF ON eo 3 Press key FUN to enter frequency setting According to the frequency of
6. White ays Blue avis g 2 Hog Starting electromagnet Red avis 2 i LS rt S vv 25 I Seri 214 Purples Fe SAS 5 d IN o Yellow Green t Flywheel AC KDEG700TA Doulbe voltage selective output electric schematic diagram 18 g urrent sampling rey ET Grey Avil s Red Dean Red Set e 5 White Fuse icy LA Cl p 7 in Lis 9 Wien FUSE An g Whita v 13 9 A ki t i ie S Startin 9 Yellow Sun S g Him d Thote Ft electromaghet 5 B amp 4 Brow Purple sa Ad vale Assistant excitation Excitation windin Current mutual inducator Redas m eise winding electromagnetice s FUE E E gt Hi o cC o amp G Breaker Breaker Black tt att P k T c Single socket u LZ as Tiel Inding 1 socket e Yellow amp Greens i EI Red rit Black zou Voltage Sampling Simple ihtellagent screen x iain WI W Starting 53 X Avi d E electric motor gt LI Yellow Green Tit 5 Orange Flywheel ge 1 Regulator Blues s Fi KDE6700TA Double voltage simulataneous output electric schematic diagram KDE6500EW generator sets Gare
7. K Ze Je d Absorption board red black blue black white black 11 QE a s Welding output Plastic A tt Control modele lastic I Cr neat T Driving board e ck H KDE6500XW Manual amp electric start electric schematic diagram 20 KDE3500E3 T3 amp 6500E3 T3 generator sets Sampling input Breake Three phases 2 Main winding Yellow socket fu au Gren E wise S Fue Wi Wie Protec tid AYR Lr 15 White KDE3500E3 KDE6500E3 Electric schematic diagram the same D KDE3500T3 KDE6500T3 Electric schematic diagram the same 21 Electric switch lock H 1 Start T1 electromagnet e L ra k r 1 LJ SS Saman Breaker o f m D ee ee Flywheel generator a p 9 Yellow Ss Y 1 LJ d ECH H d i e Excitation winding ___ Green Green 5 H po us 3 x D eL J L 5 uy Vice winding Red TEM V T n pese ES rey E Winding gt Black Black 5 n protection E i Single Voil pressure Yellow amp Green yellow amp Green d receptacle Lindicator light 4 9 E 2 Important information 2 1 Release note This manual is to instruct you how to operate and maintain service Kipor generator sets in a proper way Please read the manua
8. d inducator Greet ees 1 ANA wei i Le I 7 Q sf Protection ums 4 foi k E E ein an dk Ve 3 Low oi zl VK qe pressure e Au Over loading Green T switch 84 protection R d 5 yelowi 2 83 a Bl cki d 5 E T Startrelay d Main winding Main winding EE b Je Whiter iin ce wi gt 52 Blue t Charging winding Sampling winding 155 Start o8 V electric d w ON TT motor T w 3 Jr wt Yellow amp Green KDE3500X KDE6500X KDE3500E KDE6500E Double voltage simultaneous output electric schematic diagram Double voltage selective output electric schematic diagram the same 14 15 Voltmeter indicates O x Output G SEA put Air switch x Wty Output 240y Output 121v Outp 241 Out Y Air switch H x1 Air switch a n f c lt AVR Green Protection Low oil gt N gt pressure switch D E gt 9 3 5 2 ren BI ck s 8 m S id eX z V Blue Se ES gi E m 5 Black 5 D 3 Blue Fu lt E w d 4 gt n Yellow amp Green Air switch KDE3500E KDE6500E Double voltage simult
9. external characteristic curves of KDE6700T TA generator sets 1 3 Overall dimension drawing Unit mm ws no LLLP generator sets mam ms 4 16 18 R ho 4 26 28 30 3 KDE6700T TA 120V KDE6700T TA 240V KDE6700T TA 6 AC external characteristic curves of KDE6700T3 TA3 generator sets KDE6700T3 TA3 416V 240V KDE6700T3 TA3 SSA 7 AC external characteristic curves of KDE6500EW XW generator sets E L oak gt FI I ET Eq 2 E Z 2 e KDE6500EW XW KDE6500EW XW KDE6500X E X3 E3 generator sets KDE6700T TA T3 TA3 generator sets 100000 000000000 07 mod i IL e gt NM HG far Pi 1 Wa E m L i SS G e ice Kai w WII I oz Y ox 1 4 Wiring diagrams of KDE2200X E generator sets Low oil pressure protection Le Air switch Single voltoge output Low oil pressure Cd indicator light Oo o on g Re A Gah FS PON fal Sg Fk Fs TOM gt 2 BE 95 155 5 o o Main winding le Charging winding Main winding ee Sampling winding KDE2200X single voltage output electric schematic diagram Voltmeter indicates Low oil presse
10. output voltage and table below select corresponding toggle switch Display Toggle switch DIPI Toggle switch DIP Meaning Frequency seing Left ll Right Frequency of output voltage is 60 Hz Left WW Right Frequency of output voltage is 50 Hz 4 Press key FUN to enter voltage setting According to the output voltage and table below select corresponding toggle switch Phase number setting Toggle Toggle Toggle switch Display switch switch DIP2 DIP3 Meaning DIP2 DIP3 Left Right Left Right U 120 OFF OFF Output voltage 120 ON OFF ON OFF D o D ie gt U 240 OFF ON RW OFF Output voltage 240 U 230 ON OFF Output voltage 230 5 Press key FUN to enter current setting Display IXXX X Regulate the potentiometer set to vary displayed value Clockwise to decrease and counterclockwise to increase The minimum variation is 0 3 Set the current value to rated current 6 After setting a Start generating set directly At this point the protection function for electrical parameter is revoked b Turn the electric switch lock from ON to OFF then restart generating set 2 7 Press and hold down key FUN Turn the electric switch lock from OFF to ON After 5 seconds enter setting program Start generating set The protection function for electrical parameters will be revoked 8 Charge and checkout the toggle switches as ta
11. Do not touch generator set with wet hands otherwise electric shock or circuit may happen Kipor diesel generator sets are not rainproof so please protect your generator set from rain snow and water Running at wet place may cause short circuit or electric shock 22 Please connect ground wire for your generator to avoid electric shock There 15 thick and long ground wire between panel ground terminal and the ground please ensure resistance of the ground wire is below 20 2 Do not connect any load to generator set before it starts otherwise the load may move suddenly when the generator set starts and cause injuries Do disconnect the load before start the generator set For most equipment starting power is bigger than the power at normal operation Do not excess current limit of the receptacle Do not connect your generator set to circuit of utility power for the difference of output frequency and voltage will damage your appliances and generator set 2 3 Significance of proper servicing Proper maintenance is critical to personal safety of the operator and reliability of the generator set Any mistake or oversight of the maintenance man may cause generator set failure engine damage and or physical injuries Improper servicing may cause dangers and lead to A WARNING Ma serious injuries or even deaths Please do follow the operation procedures and safety precuations stated in this manual Some of the most importan
12. Earth wire Back cover of motor Oil tank Fixed air cleaner Charging regulator 2 Bracket Hexagonal flange face bot 6 12_ 9 09 Battery bracket 6x12 IN IN O 36 KDE2200X E M8X25 M8X180 M6X120 Hexagonal flange face bolt Hexagonal flange face bolt Tighten bolt of fore back end cover Hexagonal flange face bolt Frame power Hexagonal nut Hexagonal nut Earth wire Hexagonal flange face bolt Cross slotted pan head screw Cross slotted pan head screw Antihunting bracket Hexagonal flange face bolt Oil tank Hexagonal flange face bolt Hexagonal nut Hexagonal flange face bolt Hexagonal nut Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal nut Cross slotted pan head screw Cross slotted pan head screw Nut Pannel Cross slotted pan head screw Hydraulic pressure regulator Hexagonal flange face bolt Hexagonal flange face bolt Hexagonal nut Hexagonal flange face bolt Nut Butterfly nut M6X12 M3X5 M4X8 M8X16 M6X25 N w Biol elo 5 5 N Flo o N gt N _ N N N M6X25 M5X20 M5X20 M5X12 M5X12 M5X12 M5X8 M6X16 M6X18 M8X16 M6X12 O 37 2 11 The set value for leaving the factory 2 11 1 The set value of the automatic adjuster of the voltage AVR Output voltage is set as rated voltage the setting of units load protecting current is
13. The fault phenomena is black smoke emitted from exhaust port during engine running generating set is overloaded Cause 1 Generating set is overloaded 2 Engine oil nozzle and oil pump have faults causing incomplete combustion in engine and carbon deposition on oil nozzles Remedy 1 Repeat the above mentioned steps for cleaning 2 Reduce the loading power of generating set 3 Refer to engine service for oil nozzle faults ring washer lain washer First stage muffler Exhaust pipe assembly assembly Fig Muffler 4 2 Control panel This section mainly deal with the remedy for faults caused by air switch voltmeter electric switch lock receptacle or PCB in control panel and actions which should be taken while the generating set faults such as no voltage output no voltage indication not starting automatic stopping etc present 4 2 1 A C receptacle Check Connect two poles of receptacle with a jumper The current should flow normally between conductor terminals There is current passed between receptacle ground terminal and receptacle installing set 59 Service 1 The fault phenomena is no voltage output in generating set Receptacle terminal is loosened receptacle terminal is melted Cause 1 Wring is loosened due to vibration 2 Receptacle patchplug is loosened to result in heating up Remedy 1 Add glue 2 Replace plug and receptacle 4 2 2 D C receptacle or post Check Connect two poles or posts of receptac
14. air 1 Check load for overloading 2 Check output circuit for short circuit 3 Check generator 4 Check current transformer 5 Check oil line for air 1 Check battery 2 Check charger 3 Check charging generator flywheel generator 4 Check fuel oil 5 Check oil line for air 15 Fault code display and actions to be taken default for 5 KW special requirement Note in North America 1 At protection of generating set the protected object and protection code are Code display Action to be taken displayed alternately in display window 2 When protection stopping happens you can press key FUN to inquire the Insufficient engine oil pressure 6 Check engine oil SC for 5 seconds then 7 Check fuel oil stop parameters before protection 3 Do not remove battery during generating set running otherwise the electrical 8 Check engine oil sensor device may be damaged Recor Orar 4 When stopping happens due to burn out of fuel oil the protection of P 01 P Fo 02 P 03 P 04 P 05 will happen because of air in oil line The air would be Frequency 65 Hz Sustain 5 Check oll We Zar air discharged completely after several times of restarting If necessary the oil line for 3 seconds then stop 6 Check fuel oil Frequency lt 57 Hz Sustain for 20 seconds then stop should be treated with air bleeding for normal running of generating set After y Ohedeendine gevemor starting the generating set may run unstably Run g
15. machine Fault caused by automatic voltage regulator AVR 9 The rising of voltage of generating set is high after capacitive load Check loading decrease load check the voltage of AVR secondary winding or replace AVR 10 Incorrect wiring for exciting Correct wiring 1 No display on screen Check 12V power supply of generating set and check wiring for loosening or replace display screen 2 Display wrong code Fault of intelligent control panel 3 Can not start 41 2 12 2 Flow Chart of Troubleshooting 1 Troubleshooting steps for difficult starting of diesel engine set Fig Flow chart for Diesel 1 Difficult starting of failure to start Circuit and battery section Oilway and fuel section Check that there is oil in tank Electric starting Recoil starting Check that the oil switch is on Check oil tank for clogging and Check the battery Can recoil Can not recoil leakage for sufficient voltage Check for 12V when starting switch at START Check flywheel hand disk Check the oil piping for clogging bending seizing and air presence Check the fuel filter clogging Check oil system Check the relay of electric starter for acting Check the harness of 12V battery of electri starter for 12V Check carburetor solenoid valve in carburetor system for intactness and seizing check oil and air piping for clogging Check the location and func
16. the 11096 of the rated load The following table is the reference value the electric parts for AVR will be changed according to the temperature 60HZ 120 240V Units erequene Rated Rated Rated Max Max Current Model Hz y power WR Wo power n REMO KVA A KVA value A KDE2200E KDE3500E sel c een c fa sel s ss see ss s Note The setting of no function and model units leave the factory as the same model setting in the above table 50HZ 230V Units Ere en Rated Rated Rated Max Max Current Model Hz y power E Es power Si E KVA A KVA value A KDE2200E TESES No protecting setting ofe e KDE3500E 12 2 KDE6700TA 18 3 s else Note The setting of no function and model units leave the factory as the same model setting in the above table KDE6500E3 38 2 11 2 The protecting setting values of the digital panel divide to A The standard setting value of leaving factory Low oil pressure protection Protection by stopping if the oil pressure low for 5s display P 01 Over frequency protection Output frequency 55 65 HZ protection by stopping for 5s display P 02 Over voltage protection The rated output voltage is 110 V protection by stopping for 3s display P 03 Over load protection The rated output current is 11096 protection by stopping for 1 hour display P 04 Charging malfunction warning No protection only display while charging malfunction displa
17. 6 3 3600 Si Summer 10 Winter 35 Chill cold Light diesel m Bore x stroke mm 86X72 86X72 19 Rated power Kw r min 5 7 3000 6 3 3600 Fuel model 0 ion Fuel consumption g kw h 360 360 Rated power kW r min 5 7 3000 6 3 3600 5 7 3000 6 3 3600 5 7 3000 6 3 3600 5 7 3000 6 3 3600 Displacement L Compression rate Fuel model Lubricating oil model Voltage deviation at steady state Frenquency rate Voltage wave type distortion rate zero load Insulation resistence at cold station Fuel consumption rate g kw h Capability of fuel tank L Continuous running time Hr Overall dimension mm LxW xH Noise level dBA 7m at rated load Structure type Lubricating oil model SAE10W30 above CC grade N L Ead G T Continuous running time h La Overall dimension L X W X 840x535x650 915x547x742 Net weight kg 1bs 115 120 188 model Function code X is recoil starter E is electric starter set T is electric starter Starling type te RANET wm 7 7 silent set A is digital control panel set O is automatic starter and automatic change os EVE OULA NO muras 2 P EW XW Open frame TW Silent Note Explaination for generating set model KDE is the generating set 2200 is the set m function with ATS A O code only used for above 6700 set model 1 2 The set power and voltage characteristic curves The foll
18. Four hole Grounding receptacle receptacle Ofamerican o american 001 style style Electric switch lock Voltmeter Electric switch lock pc receptacle Air switch Combined receptacle Eo rdhbfa of american receptacle style E style Me Grounding bolt Combined Three hole Three hole G Ounding receptacle receptacle receptacle receptacle bolt of american of american i i tyle tyle of american of american sly sty style style Electric switch lock DC receptacle Intelligent Air switch display Fuse base Grounding Three phase Honda bolt five hole receptacle of english style receptacle Fig Panel 61 Plug Screw M6x12 Fuse base lt Electric switch lock Intelligent display Gauge panel Three phase generating set Electric switch lock S Ave Nut Receptacle Air switch SN rounding bolt Panel Plastic veneer Gauge panel Three phase generating set 62 4 2 4 Voltmeter Check Connect electric supply which voltage range is the same as voltmeter to the terminal post of voltmeter The voltmeter should indicate normal voltage Service Fault phenomena is that there is AC current output during generating set running but no AC voltage indication The voltmeter is open circuit the wring of voltmeter is loosened Cause 1 Wring is loosened due to vibration 2 The element in voltmeter is damaged 3 The pointer of voltmeter is sei
19. This prevents accidents such as bearing seizures etc Select the most applicable engine oil It is very important to select the applicable engine oil for keep up the performance and life of the generating set If inferior engine oil is used or if your engine oil is not replaced periodically the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly So the generating set life will be shortened KIPOR recommends CC CD oil classified by API Choose the applicable viscosity oil according to the local ambient temperature Series KDE Type X E 3 2 3 Check air cleaner i 1 Screw off the wing nut remove the air cleaner cover and take out the element CAUTION E Do not wash the element with detergent Replace the element when its output decrease or a bad exhaust color is noticed Never run the generating set without the element otherwise the rapid engine wear will result 2 Reattach the air cleaner cover and screw on the wing nut 47 3 2 4 Check Starting Performance of Generating Set 3 Pull out the recoil starter handle WO out the handle until you feel the resistance then return it back to the initial position Press down the decompression lever It will return automatically when the recoil starter is pulled BI Pull out the recoil starter handle briskly with both hands Turn off the main switch and any other loads
20. al parameters in turn 1 Enter in turn display After starting of generating set press and hold down the key FUN for 2 seconds The electrical parameters will be in turn displayed in display window in following sequence Voltage Current power Frequency Running time Voltage of battery Voltage 2 Exit in turn display In in turn display condition press and hold down FUN for 2 seconds to exit in turn display Stopping Turn the electric switch lock from ON to OFF to stop the generating set 74 5 3 Maintenance Fault code display and actions to be taken factory default Code display Action to be taken Insufficient engine oil pressure Sustain for 5 seconds then stop Frequency exceeds 55 Hz or 65 Hz Sustain for 5 seconds then stop Output voltage exceeds 110 of rated voltage Sustain for 3 seconds then stop Overloading Load exceeds 110 of rating sustain for 60 seconds then stop load exceeds rating but less than 110 of rating sustain for 60 min then stop Charging fault 1 Check engine oil 2 Check fuel oil 3 Check engine oil sensor 4 Check oil line for air 5 Check connecting wire 1 Check oil line for air 2 Check fuel oil 3 Check engine governor 4 Check frequency of generator output voltage 1 Check generator output voltage 2 Check AVR 3 Check generator carbon brush 4 Check generator sampling winding 5 Check transformer unit 6 Check fuel oil 7 Check oil line for
21. aneous output electric schematic diagram the same Yellow amp Green 4 0 KDE3500T KDE6500T Double voltage selective output electric schematic diagram gt o KDE3500T amp KDE6500T generator sets 2 v KAS d Red ary S Um Z r E Da x V A d 2 M e gt T 55 EX E Ve 55 MT N G t Electric switch lock WU Ji E ic N P t D e US S RE z aS D gt tart t E Les es 3 electromagnet a 1 BY CS ii T eer E n Si H 5 5 8 E s Si E 8 se 5 I 49 EH 21 SZ reg 3 3s Re e ET ae 8 e Main windin Main winding 9 shoe a as Q Vol pressure Sampling winding D gt 4 e 7 j Kam 28 8 ai D Se 585 gt Q i 8 Zem KDE3500T KDE6500T Single voltage output electric schematic diagram Los e e gt Jui eunssaJd Won 16 ES KDE6500T KDE3500T Double voltage simultaneous output eletric schematic diagram KDE6700TA generator sets Excitation winding Assistant excitation uol e ioxg 5 Bluervis US estat 4 Current mutual inducator SH F urren
22. ar replace the stator assembly B Adjustment The spacing between the stator winding and rotor Insert a feeler between the stator winding and the projection of rotor Push the rotor winding to 90 180 270 360 The rotor rotate for one turn Secure the flange bolt connecting stator and front end cover The locking torque is 10 13 Nm 1 0 kgf m 7 5 Ibf ft Spacing 0 25 0 1 mm 0 020 0 004 in 65 Service The fault phenomena is no voltage no power output scrubbing of stator and rotor generator burn out generating set does not start Cause 1 Open circuit of winding 2 Short circuit of winding 3 Carbon brush wearing 4 Fixing parts loosened due to vibration 5 Front and rear end covers cracking 6 Seizing of stator and rotor 7 Engine crankshaft bearing wearing Remedy 1 Avoid overloading and ventilate to cool down 2 Replace carbon brush 3 Replace generator 4 Secure the connecting parts 5 Replace front and rear end covers 501 i Se Screw M5x14 Weldment of induced Carbon Rear end cover We de i ip Pu Si M6x175 Locking front end cover torque 10 13Nm Stator Bolt M10 Locking torque 50 55Nm k t 7 Rotor d Y i lt a amp Yellow Blue or green Bolt M5x18 sampling secondry winding p Ba Round n t AS lt Z Frontend Ka cover elt gt Bolt M8x30 Fig Components of electric machine 4 4 Cabinet 4 4 1 Right side plate Che
23. ate voltage of diesel engine set Fig Flow chart for diesel 3 Failure to regulate voltage Check the voltage on gauge panel No for 300 or above ves Check the socket connector of gen erator stator harness and sampling winding for loosened plug i Check the sampling harness Check the regulating potentiometer of generator or sesure the of AVR for damage socket connector Yes Replace AVR 4 Troubleshooting steps for low output voltage of diesel engine set insufficient power Fig Flow chart for diesel 4 Low voltage or insufficient power of generating set Check the load of generating set for overloading Checkout the power factor cos Vor overloading Overloading Not overloading Adjust or decrease the loading Check that the frequency of generating set is in the power of generating set rangs of rated frequency of generating set 52 5 49 5 H2 or 62 5 59 5H2 for zero load and full load in the range beyond the range Check the voltage of generating set for dropping Check the engine regulator system ges Check generator for Check AVR for Check the carburettor Check engine heating up UT work oil line system for sei regulating bolt zing or clogging or regulating lever for seizing Check the rotor in generator for iron core AVR w Check the rear end cover Check engine crankshaft for of generator for wearing or eccentricity or damaged bearing damaged rotor bearing 44 5 Troubleshooting steps fo
24. ay AbXXX in which the XXX is voltage value display voltage value of Three phase output line AB Press key FUN to display bCXXxX in which the XXX is voltage valuq display the voltage value of line BC Press key FUN to display CAXXX in which the XXX is voltage value display the voltage value of line CA 73 Press key FUN the current power indicating lamp will on The output current power is displayed in display window According to different phase number of output display current power as follows Phase number Display Single phase single voltage Display power VA Double voltage selected output Display power VA Double voltage simultaneous output Display power Display AXXX X in which the XXX X is current value display the current value of phase A Press key FUN to display DXXX X in which the XXX X is current value display the current value of phase B Press key FUN to display CXXX X in which the XXX X is current value display the current value of phase C Three phase output 3 Press key FUN the frequency indicating lamp will on the output frequency is displayed in display window 4 Press key FUN the running indicating lamp will on the accumulated running time hrs is displayed in display window 5 Press key FUN the battery indicating lamp will on the voltage of battery is displayed in display window 6 Press key FUN the voltage is displayed in display window Display electric
25. ble below Type of engine DIP1 three positions DIP2 three positions DIP3 three positions Remark three position toggle switch 5KW diesel According to the voltage of flywheel generator Warning Do not adjust this switch It is adjusted in factory The user and maintenance person should not vary the settings 5 2 Checks Starting check 1 Turn the electric switch lock from OFF to ON The rated current of generating set output is displayed in display window After 0 1 0 5 seconds the output voltage will displayed at this point the voltage is zero 2 Turn the electric switch lock from ON to ST STArt will displayed in display window The starting motor drive the engine to start Display of electrical parameters 1 After starting of generating set the voltage indicating lamp will on The output voltage is displayed in display window According to different phase number of output the voltage will be displayed as follows Single phase single voltage Display output voltage EE EES Display actual output voltage according to various selection Display AXXX X in which the XXX X is voltage value display the high voltage Double voltage simult value of output Press key FUN to display bXXX X in which the XXX X is voltage value display a lower voltage value of output Press key FUN to display gt in which the XXX X is voltage value display another lower voltage value of output aneous output Displ
26. ck Check the inlet and outlet of air duct on right side plate to ensure ventilation Each sound absorbing sponge should be clog free Service 1 The fault phenomena is insufficient AC current output during generating set running Air duct clogged 2 High temperature of engine Cause 1 Vibration 2 The sponge falls off by the effect of temperature Remedy 1 Replace sponge 4 4 2 Left side plate cooling plate Check Check the inlet and outlet of air duct on left side plate to ensure ventilation Each sound absorbing sponge should be not clogged or fall off Service 1 The fault phenomena is insufficient AC current output during generating set running Air duct clogged 2 High temperature of engine 3 High temperature of exhaust pipe 66 Cause 1 Vibration 2 The sponge falls off by the effect of temperature Remedy 1 Replace sponge 2 Replace heat insulating material 4 4 3 Cabinet Check Check the inlet and outlet of air duct on cabinet to ensure ventilation Each sound absorbing sponge should be not clogged Service 1 The fault phenomena is insufficient AC current output during generating set running Air duct clogged 2 High temperature of engine 3 High temperature of exhaust pipe Cause 1 Vibration 2 The sponge falls off by the effect of temperature Remedy 1 Replace sponge 2 Replace heat insulating material 4 4 4 Transformer in cabinet Check Checkout the resistance at two terminals of transfo
27. d screw M5x12 _ Fixed resistance Fixed capacitor clip Fixed capacitor Connecting plate of the fixed capacito Fixed absorbing plate and driving plate Cross slotted pan head screw Fixed IGBT and rectification bridgd Cross slotted pan head screw big 5 x16 Diverter 31 Besson fange face nut Hexagonal flange face M6 gt 12 Hexagonal flange face bolt M5x12 MAx 10 Pi Hexagonal bolt ve ue MBX 10 MBX 20 ue ue 20 M5x12 M4x10 M6x45 me M8x14 M3x10 M5x20 M3X6 M6x20 NENNEN l MERE NENNEN NENNEN NEN mas NENNEN ws MENNE _____ Bh Was NENNEN Was wass _____ O O 32 KDE6500T E 18 _______________ fmo 40 Frame parts Fan duct plate of motor tailstoc Hexagonal flange face _ 5 12 Resonance block Fore indrced air plate Backindrcedairplate Hexagonalflangefacebolt M6x18 9 Shockmitigation bracket Pressure plate of oil pipe Hexagonalflangefacebolt M6x25 9 Hydraulic pressure regulator Hexagonal flange face bolt M6x18 9 Hexagonalbot jw __ 9 m5x12 puni ch NIN NI N CH 6 Carbon brush Hexagonal flange face bolt 5 12 block Hexagonal flange face bolt M5x 12 8 Earth wire Jar wire Exhaust pipe Lower body of heat insulat
28. enerating set without load for 5 min then the generating set will resume to normal running 8 Check frequency of generator output voltage 5 When start with insufficient electricity of battery the display screen may be abnormal and the generating set will not start Charge the battery or replace with a new battery 6 The DIP switches on panel are set in factory Do not vary the settings by unprofessional person If varied the panel would not work abnormally 5 4 Parameter setting list Item Display Toggle switch Meaning Phassnumbat PH 1 DIP4 ON DIP5 ON Single phase single voltage output setting PH 2 DIP4 OFF DIP5 ON Double voltage selected output PH 2 DIP4 ON DIP5 OFF Double voltage simultaneous output PH 3 DIP4 OFF DIP5 OFF Three phase output F 60 DIP1 ON Output frequency 60 Hz F 50 DIP1 OFF Output frequency 50 Hz U 115 DIP2 ON DIP3 OFF Output voltage 115V U 120 DIP2 OFF DIP3 OFF Output voltage 120V U 230 DIP2 ON DIP3ON Output voltage 230V U 240 DIP2 OFF DIP3 ON Output voltage 240V Rated current Rated current Overloading Load exceeds 6 Check load for overloading rated 21 2A sustain for 60 seconds then stop Load exceeds rating in 19 2A 21 2A sustain for 60 min 9 Check current transformer then stop f Check output circuit for short circuit 8 Check generator 10 Check oil line for air Frequency Charging fault display wit
29. eys 02 ye eouejsiseJ uonejnsul Generating set 0192 je1 uo gen ady om AouenbuoJJ 9jejs peas uogernap Bungeouqn 9620 96270 3009930 3O0S 3O0 3O0ZZ30 1002 3 O IIIIIIYI X008930 Main technical specification of single phase and three phase generator sets KDE6500XW EW KDE6700TW 50 50 230 240 230 240 12 2 12 5 12 2 12 5 Welding voltage at zero load V 2 14 5 Electric starter Generating work condition AC N Tu Three phase lt 8 Electric starter 26 36000 36000 Self exciation and automatic voltage adjusting AVR GBT three phase rectify bridge PWM IGBT three phase rectify bridge PWM Welding work condition DC SAE10W30 above CC grade Welding and generating set 2 Single bearing lt 25 lt 5 lt 5 Rotor chute band damping winding 2 Electric starter Q lt E cO LLI e LLI gt lt O O LO cO LLI Q lt O O N cO LLI Q o summer 10 winter 35 chill cold diesel Single phase lt 5 KDE6500T Electric starter KM186FAG Inlined single 4 stroke air coole Displacement ml 418 418 Engine model KM186FAG Engine type Inlined single 4 stroke air cooled 910x530x740 915x547x742 910x530x740 915x547x742 Starting type c 19 5 7 3000
30. false the generating set will lag or stop suddenly It is necessary to unload the generating set immediately and turn off the main switch and do checks A ATTENDED if overloading of the circuit trips the AC circuit air switch reduce the electrical load on the circuit and wait a few minutes before resuming operation 3 2 6 2 DC checks 1 DC terminals are only for charging 12 V battery 2 Set the air switch at OFF position while charging On the 12 V output terminals a charge switch can be connected so the switch can be used for on and off purpose 51 A ATTENDED 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 generator and battery will burn out Do not contact the positive pole of the DC terminal with its negative pole otherwise the generating set damage will result Do not contact the positive pole of the battery with its negative pole otherwise the battery damage will result When a large capacity battery is charged excessive current flows charging current should not exceed 8 the fuse for the direct current will burn out Never run the generating set while it is still connected with the battery Never use DC 12 V and AC at the same time A ATTENDED Battery exhausts explosive gas Keep sparks flames and cigarettes away from the battery To prevent from creating a spark
31. h 5 Check battery out protection 7 Check charger Output voltage 8 Check charging generator flywheel generator 9 Check fuel oil 10 Check oil line for air Voltage 132V 264V 8 Check generator output voltage Sustain for 3 seconds then 9 Check AVR stop Voltage lt 105V 210V Sustain for 20 seconds then 10 Check generator carbon brush stop 11Check generator sampling winding 12 Check transformer unit 13 Check fuel oil 14 Check oil line for air 76 77 5 5 Diagram of Switch Position for Address Setting VA OA VI dl LAS zuan pue eBejoA i ye 19674 497 A09 A0S Buas 2 Dunes eDeyoA z Buas Buas 2 Dunes c Buas eDeyoA c Dunes eDeyoA c Dunes eDeyoA c 14674 191 14674 427 14674 191 14674 191 ASLL Dunes Jequinu aseud t Dumas Jequinu eseud p Dumas Jequinu eseud p Dumas Jequinu eseud p Dunes Jequinu aseud G Dues saquunu eseud G Gules saquunu eseud G Dunes aseud G 14674 427 14674 427 14674 427 14674 427 oseud jndino snoeuejnuuis jndijno p 5 s lqnodq eseud ejDuis Puas Bun s Bunjes Jequunu seud r Puas Jequunu eseud s 78
32. he electric starter turn the key to OFF Turn the fuel cock lever to S position BI Pull out the recoil starter handle until you feel resistance at this position both intake exhaust valve are closed and leave the handle in this position This prevents the engine from rust WARNING the engine keep on running even after the speed lever is placed at the STOP position either turn the fuel cock to the CLOSE position or loosen the nut of high pressure fuel pipe on the pump side to stop the engine E Do not stop the engine with the decompression lever E Do not stop the generating set with load Stop it after the load removed 54 4 MAINTENANCE 4 1 Oil line and intake exhaust parts This section mainly deal with the actions which should be taken while a fault of engine oil oil quantity variation air cleaner oil line or oil tank presents 1 In case of excessive engine oil filled exceeds 2 3 or white smoke emitted from engine during generating set running drain the oil 2 Refill engine oil to prescribed level The low oil alert lamp will on and the generating set will stop automatically 3 If the abnormal condition still presents carry out the troubleshooting checks for engine automatic stopping 4 1 1 Engine oil Check oil level Check the engine oil level with the engine stopped and the generating set on a level surface 1 Open the cabinet door 2 Remove the oil filler cap and check the oil level no
33. he service cap Oil nozzle z _ Air cleaner Engine oil filter Engine oil drain screw Fig Drawing of engine oil components 4 1 3 Oil tank fuel oil filter Cleaning 1 Remove the oil pipe from oil tank Remove the fuel oil filter 2 Remove the clogging material in filter Check the filter for damage Replace if necessary 3 Remove the oil tank Clean it with detergent After cleaning air dry completely then reinstall it 4 In quiet generating set the cabinet must be removed Remove the oil tank Clean it with detergent After cleaning air dry completely then reinstall it 5 Reinstall the filter into oil tank Connect oil pipe 6 Reinstall other parts in counter order for disassembling Refill the oil tank with diesel oil Check the oil pipe for leakage Oil leveller ew assembly Oil tank compont Buckel V RSS Rot 9 Aga componen baam Per Buckle ie Z i Oil pump component Fig Drawing of oil tank 56 4 1 4 Oil pipe oil pump 1 Check the oil pipe for deterioration cracking or leakage of diesel oil If the oil pipe has any abnormality replace it 2 Check the magnet of pump for deterioration cracking or leakage of oil If there is any abnormality replace the oil pump 3 Check for water accumulation or other foreign material in pump If any replace pump 4 After assembling check all parts for leakage again Service The fault phenomena is fluctuatio
34. in this introduction are extremely important Please read and understand it Content 1 Technical Specifications Deas 1 2Power vs Voltage Diagram of Generating Set Output Characteristic 1 3O0verall Dimension Drawers ngo ttti eta 1 4Electric Principle and Wiring Diagram Various Models of Generating Set 2 Important Information 2 1Versions Description 2 2Safety 2 3lmportance of Proper Maintenance 2 A4Important Safety Precautions 2 5Maintenance Regulations Deg c 4 2 9Maintenance Norm for Generating Set ETE LLL E gaa Facto Settings Ee 2 12 Troubleshooting Open shelf Diesel Engine and Quiet Generating Set 2 12 1General Symptom and Possible Cause 2 12 2How Chart of Troubleshooting etie ntpote ie Sibi 3 Maintenance Checker 3 1Service List O 2ODOcKS 3 2 1 Fuel Oil 3 2 2Check Engine Oil 3 2 3Check Air Cleaner 3 2 4 2Electric Starting 3 2 5Check Battery 3 2 6Checks during the Running 3 2 6 1 Check A C Output Characteristic 3 2 6 2 Check D C 3 2 7 Check Overload Operation 3 2 8 Check Stopping of Generating Set 4 Maintenance 4 1Oil line and intake exhaust parts 4 1 1Engine Oil 4 1 2Replace Engine Oil 4 1 3Oil Tank Fuel Oil Filter 4 1 4Oil Pipe Oil Pump 4 1 5Air Cleaner 4 1 6Muffler 4 2Control Panel 4 2 1A C Receptacle 4 2 2D C Receptacle or Terminal Post 4 2 3Sta
35. in winding kaa Sampling winding KDE3500X KDE6500X Single voltage output electric schematic diagram the same 13 Voltmeter indicates 241 Sampling winding Low oil pressure protection Rod Excitation 8 winding 5 S 2 5 Current Mn AVR SS D mutual inducator EY Wie Protection AVR k d zi HS ER E A Ca 3 Low oil HL id i A pressure r z E AWF Overloading switch 553 Protect es r3 p EA i sss ain winding Main winding ws m kia Charging winding Sampling winding L3 7 Black 5 25 EK Start electric motor 58 l KDE3500E KDE6500E Single roltage output electric schematic diagram the same KDE3500X KDE6500X We Double voltage selective output electric schematic diagram the same Yellow amp Green Voltmeter mdicates 11 Voltmeter indicates x vu 258 Output 240V amp 20V respectively x d si Si Output gt i X Be gt T Breaker oF gt 25 Air switch UU 233 Output et Xi Xin BEAT X1 28 Les e za 22 d ER TA t J 00 i lt 1 HERES SC CH KT h r t Voil pressure indicator light Stop electromagnet AWE Current mutual
36. ion x Lower level Check the battery capacity every month when in use Measure the voltage of battery it should not lower than 11 5V Otherwise the generating set will not start Check the charging circuit for fault It should be noted for customer of other generating set that if his self equipped battery is not a maintenance free battery he should check the battery electrolyte level every month Refill the distilled water until the upper limits if the electrolyte dropped to the lower limits ATTENDED WI the electrolyte level is too low the engine may fail to start because there is not sufficient electricity On the other side if the electrolyte level is too high the fluid will corrode the surrounding parts Do keep the electrolyte level between the upper and lower limits In installing battery the generating set should be stopped Set the battery to be installed beside the generating set Take out positive and negative connecting post of battery provided with generating set Fix them to the positive and negative poles of battery respectively Take out positive red and negative black connecting harness of battery Secure them to the positive and negative poles on battery terminal post Then put the battery onto the battery holder of generating set Secure it with battery clamping plate and bolt provided with generating set 2 For generating set equipped with low oil alerting system check that the low oil indicating lamp i
37. ion chamber Hexagonal head ____ 16 9 Cover plate of heat insulation chamber Hexagonalheadbolt M6x18 9 Cross slotted pan headscrew M5x20 Hexagonalnut Iw ndrced air cover of motor Hexagonal flange face bot M5x12 Crosssotedpanheadscrew M5X12 Pressure plate ofjar _ Hexagonal head ____ 9 Butelynt m __ 9 AVR fixed Hexagonal flange face bolt M6x25 9 Hexagonal head ____ 9 Plate of oil tank Hexagonal flange face bolt M6x25 9 Fan plate of air fiter __ Hexagonal head bet Jus 9 Electric door lock ____ Cross slotted pan head screw M5x12 Pannel Cross slotted pan head screw M6x16 9 Cabinet Hexagonal head ____ 5 9 Cover plate of cabinet back door Hexagonal head bot 15 9 Right side plate Hexagonal head bolt m6x15 9 Cover plate of airfiter Hexagonal head ____ 5 9 Left side plate Hexagonal head bot M x18 9 Radictor Hexagonalheadbot ____ 5 9 3 ____________ Hexagonal flange 30 3 ___________ M8 30 3 2 Paris of right side plate Hexagonalfangefacebot M5xi2 33 KDE6700T DS ee oe pias Rotor tough bo Tighten bolt of fore back end cover Hexagonal flange face bolt M6X140 10 1 Frame power Hexagonal ange face Mi0xas 40 a Hexagonalnut toa 4 Fra
38. l and main technical parameters to ensure your correct operation of the generator set and keep it run in best condition as well as quick troubleshooting Any questions and suggestions about this manual are welcome to contact us or our agents Please note that as our products are improving general items in this manual may be different from real products please service your generator set as stated in the Instructions packed with the generator set 2 2 Safety precautions Warning 2 2 1 To prevent fire Do not refill fuel when engine is running Wipe off spilt fuel with a clean cloth Keep flammable explosive materials away from generator set Run generator set at least 1 meter away from buildings and other equipment and keep good ventilation ll generator set at a horizontal level E Do not put generator set in a room when it is still hot 2 2 2 To avoid inhaling exhaust gas Exhaust gas contains poisonous monoxide which is harmful to health Don not run generator set at a poky or poorly ventilated place Sufficient ventilation facility must be available if generator is running in a room 2 2 3 To avoid injuries When generator set is running do not have your head hands foot etc close to rotating parts or exhaust port of hot parts otherwise you may be burnt or hurt Do not touch muffler or hot parts immediately after generator set stops Do not touch generator case during its operation 2 2 4 Electric shock short circuit
39. larming apparatus Service 2 The fault phenomena is automatic stopping during generating set running The relay on PCB is damaged Remedy 1 Checkout the resistance of two harnesses at the terminal post of alarming apparatus for on off relation Off is normal On is faulty 2 Replace PCB 3 Replace relay or 4 Replace engine oil alarming apparatus 63 4 3 Generator 4 3 1 Generator Check 1 Front end cover Check for cracking 2 Generator fan Take care not to damage the fan blade in disassembling and assembling 3 Rotor Remove engine oil and contaminant on surface part before installation Normal measured resistance should comply with table 2 9 The color should be red brown In case of burn out by short circuit it would become black and cracking would present Then the rotor should be replaced 4 Clip ring It should be smooth without any defect or distortion The semicircle of center boss should be clear In case of distortion the clip ring should be replaced 5 Through stud Locking torque is 50 55 Nm If locked not tightly the generator would be damaged by scrubbing of rotor and stator 6 Stator Check the external enamel covered wire for defect in disassembling and assembling Do not contact the copper wire part with ground or sharp metal part directly to prevent scuffing 7 Stator lead out Divided into main winding secondary winding sampling winding and 12V low voltage winding Checkout the resistance
40. le with a jumper Open the circuit breaker if any the current should flow normally between conductor terminals Service 1 The fault phenomena is no voltage output in generating set Receptacle terminal is loosened receptacle terminal is melted Cause 1 Wring is loosened due to vibration 2 Receptacle patchplug is loosened to result in heating up Remedy 1 Add glue 2 Replace plug and receptacle 4 2 3 Starting switch Check Circuit should be closed when switched on Circuit should be open when switched off In starting position the circuit should be closed Service 1 The fault phenomena is incapable to switch on start or stop Receptacle terminal of switch is loosened switch contact is melted Cause 1 Wring is loosened due to vibration 2 Switch patchplug is loosened result in heating up Remedy 1 Checkout the resistance for each switch position with a multimeters The on off relation should comply with the table above otherwise there would be fault 2 Replace patchplug and electric door lock start off I n Fig Position of electric switch lock 60 Low oil alert lamp Voltmeter Low oil alert lamp Voltmeter F gt SWITC w Aa gt n lock f Lego H Air switch DC receptacle Combined receptacle Grounding bolt style of american sty Three hole
41. ly Secondary winding Checkout the resistance between two blue green terminals of four position connector See table 2 9 for the resistance value If measured resistance exceeds above mentioned specified value check the harness of generator Replace the harness of generator if necessary If the harness of generator is regular replace the stator assembly AC winding Checkout the resistance of main winding on four position terminal board The resistance value between red white green terminals in 120V 240V simultaneous output In 120V 240V selected output the resistance for brown black red blue terminals which are L1 L2 R1 R2 respectively If measured resistance exceeds specified value in table 2 9 check the harness of generator Replace the harness of generator if necessary If the harness of generator is regular replace the stator assembly 12V low voltage winding Checkout the resistance between the green terminals on four position connector If measured resistance exceeds specified value in table 2 9 check the harness of generator Replace the harness of generator if necessary If the harness of generator is regular replace the stator assembly Sampling winding Checkout the resistance between the yellow terminals on four position connector If measured resistance exceeds specified value in table 2 9 check the harness of generator Replace the harness of generator if necessary If the harness of generator is regul
42. me parts Hexagonalnut m0 40 4 Air flue plate of motor tailstock Hexagonal flange face bolt M5X12 Resonant vibration block Hexagonal nut 40 4 9 09 Sack induced arf plate Hexegonel flange Shockmitigation bracket Pressure plate of oil pipe Hexagonal flange face bolt M6X25 9 09 Hydraulic pressure regulator Hexagonal flange face bolt M6X18 9 0 9 Carbon brush Hexagonal E TT 9 09 ws Rectification bolck Earth wire Air exhaust pipe 3 Lower body of heat insulation chamber Cover plate of heat insulation chamber M5X12 _ 6 CR EB EN Fan duct cover of motor M5X12 EN Gross pan head screw Pressure plate ofjar Hexagonalheadbolt 9 Battery Butterfly nut we 9 Parts of oil tank Hexagonal flange face bolt weg 9 Fan plate of air filter Hexagonalheadbott MeX15 9 Electric door lock Cross slotted pan head screw M5X12 Pannel Cross slotted pan head screw M6X16 9 Cabinet Hexagonal head wes 9 Cover plate of cabinet back door Hexagonal head bolt ____ 6 15 9 Right side plate Hexagonal head wes 9 Cover plate of air filter Hexagonalheadbolt weus 9 Left side plate Hexagonal head wes 9 Radiator Hexagonal head not wes 9 Muffler 3 Hexagonalnut M8 30 3 Parts of
43. n electricity winding Red A E 4 Excitation d I E T ad W AL winding Sampling v Gre d Assistant inding Black winding Yellow Green Absorptron board vs Red Black Orange Up mt IR BL o T T Welding di output Ir Control modele Plastic sheath 477 Drive board OFF ON relationship list of electic switch lock e eTo ele er o KDE6500EW Both manual start 19 On off relationship list of electric switch lock Generat winding TUER Assistant winding 0 Fe i D D Excitation winding 1 524 Uem n Sampling winding Geol 1 White ls Low oil dn pressure 4 switch Ju lt If ji Protection E na X motor Start EN electric e Fi Charging i regulator Yellow amp Green LA Absorption board T red black blue black white black Welding output e E rir Control modele 8 SE sheath I Driving board KDE6500EW Double vitage selective output with electric start Electric schematic diagram On off relationship list of electric switch lock Bed Breaker Generating winding 73 gt Palo Assistant windingi See Excitation winding hin 5 Black x Black Breaker Low pressure H switch Te Protection Bladki Blue Fut
44. n of engine running or automatic stopping fuel supply is insufficient or air presents Cause Air presents in oil tank oil pipe Generally in new engine or after oil break during running a lot of air would be entered in engine pump or high pressure oil pipe while fill oil Remedy 1 Stop the generating set Check oil tank and oil pipe for oil break 2 If oil break happens refill fuel oil 3 Loosen the circlip at the intake pipe of engine pump with a nipper pliers Place a container under the oil pump and oil pipe discharge the air from oil pipe which was entered in oil break Seeing oil flow out from oil pipe connect the oil pipe to the intake pipe of pump immediately and clip on Service The fault phenomena is not starting or automatic stopping The oil pump does not delivery oil Remedy 1 Loosen the discharging pipe at engine oil pump and high pressure oil pipe with a open end spanner 2 When starting open shelf generating set by recoil or electric starter pull out the discharging pipe of oil pump It is normal if there is oil in it If no oil replace the oil pump 3 For quiet generating set check the 12V power supply first Checkout the voltage Repeat the steps 1 and 2 Set the electric switch lock to ON position Checkout the 12V with a multimeter If the 12V presents replace oil pump If there is no 12V voltage check the electric wiring and electric switch lock service according to the gauge panel
45. 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 E Before charging remove the cap from each cell of the battery E Stop charging if the electrolyte temperature exceeds 45 52 3 2 7 Check Overload Operation Electrical appliance particularly motor driven equipment will produce very high current while starting the table below provides the reference for connecting these apparatus to the generating set in service by user WATTAGE TYPICAL ee APPLIANCE STARTING RATED Incande scent lam PM a A applian ce Fluoresc ent lamp lamp Motor driven Fluorescent Electric fan 53 EXAMPLE APPLIANCE STARTING RATED Ae Incandescent lamp 100VA 100VA 100W W W 80VA 60VA 40W W Fluorescent lamp 450 750 OVA W Refrigerator 150W 3 2 8Check Stopping of Generating Set 1 Disconnect the load from the generating set 2 Turn off the air switch of the generating set 3 Set the speed lever at RUN position run the generating set without load for about 3 minutes Do not stop the engine suddenly otherwise the temperature will increase abnormally the nozzle will blocked and the generating set will be damaged l Press down the stop lever E Concerning t
46. ngine oil o Check for oil leakage BECH NN Tighten the O cylinder head bolts p i JL _ Replace air cleaner element Cleanfueloifiter Om Check ug weer pump fof Check nozzle l lel _ Check fuel pipe JL bes Adjust clearance of intake exhaust valves Replace piston ring Check carbon brushandsipring L dodo 3 2 Checks 3 2 1Check fuel oil Select proper fuel oil Only use the light diesel which is most suitable for the engine Keep dust and water out of the fuel When filling the fuel tank from drums make sure that no dust or water is mixed in the fuel Otherwise the serious fuel injection pump and nozzle problems will result Do not overfill Overfilling is very dangerous Do not fill the tank beyond the top of the red plug inside the fuel tank Check and tighten fastening parts Replace engine oil Clean engine oil filter 46 3 2 2 Check engine oil A WARNING MAlways check the engine oil level with the generating set on a level surface before starting and refill if necessary The engine may be damaged if operated with insufficient engine oil it is also dangerous to refill too much engine oil as sudden increase in engine speed may be caused by its combustion CAUTION The generating set is equipped with low oil protection system This system will stops the engine automatically when the oil level falls below the lower level
47. of each winding it should be same as the parameter in table 2 9 Otherwise the stator should be replaced 8 Carbon brush There should be no open circuit between lug and pole of carbon brush and no short circuit between two poles 9 Rear end cover Check for cracking Disassembling assembling 1 Open the rear end cover for open shelf generating set Remove the cabinet cooling plate left and right side plate and muffler for quiet generating set 2 Remove the generator with wiring In quiet generating set must remove the induced draft hood then remove the harness 3 Remove 4XM6X175M bolt of rear end cover 4 Take out the stator 5 Fix the rotor with a belt spanner then remove 10MM flange bolt Caution Never knock the nut or rotor with hammer etc 6 Remove the rotor with a flywheel drawer 4 3 2 Installation of rotor Caution Remove the dust and oil pollution from the crankshaft and rotor part Check the magnetic part of rotor for attachment of metallic material or gasket 1 Insert the semicircle clip ring into key groove 2 Install the rotor on the crankshaft 64 3 Fix the rotor with a belt spanner secure the 10MM flange bolt to specified torque Tightening torque 50 Nm 5 0 kgf m 37 5 Ibf ft 4 3 3 Stator If measured resistance exceeds above mentioned specified value check the harness of generator Replace the harness of generator if necessary If the harness of generator is regular replace the stator assemb
48. onnect insert the connector as full as it goes If the connector is a locking type be sure that it is locked securely 2 6 4 Check the connector cover for breakage and check whether the connector female terminal is not open excessively Then connect the connector securely Check the connector terminal for rust Remove the rust using an emery paper or equivalent material before connecting the connector 2 6 5 Set the harness clips in the specified places of the frame securely and securely the wire harnesses 2 6 6 Clamp the cables securely 2 6 7 Clamp the wire harnesses securely so that they do not interfere with the rotating parts moving parts and the hot parts 2 6 8 Route and connect the wire harnesses properly Be sure that the harnesses are not slack twisted or pulled taut 2 6 9 Route the wire harnesses properly so that they do not contact with the shape edges and corners and the end of the bolts and screws on the body 2 6 10 If a wire harness contacts the end of the bolts screws or sharp edges and corners protect the contact part of the harness with a tube or by winding with an electrician s insulating tape If the wire harness has a grommet set the grommet securely 2 6 11 Take care not to pinch the wire harnesses during installation of a part If a wire harness has the damaged insulation repair by winding with the electrician s insulating tape 2 6 12 Read the tester manufacture s operation instructions carefully before opera
49. owing curves indicate generator performance at average conditions The performance may vary according to ambient temperature Before generator set leave the factory voltage is set beyond rated voltage When generator set start running output voltage should be equal to rated output as load time increase rated voltage decrease 1 AC external characteristic curves of KDE2200X E generator sets KDE3500X E usa 3 AC external characteristic curves of KDE6500X E generator sets 136 musasasa TT 12006 T rrr SS mauwa ETHETET 173 15 m m m m 220 0 2 4 6 KDE2200X E 240V WIR KRIS WWW te IL T LE 230 LLL 412 L I PT TT 220 024 6 8 1012 14 16 18 20 2 KDE6500X E 240V KDE6500X E KDE2200X E 4 AC external characteristic curves of KDE6500T generator sets __ 2 AC external characteristic curves of KDE3500X E generator sets 130 120 TT TP 1 44141 PTT tT ttt ty ma 250 024 6 8101214161820 22 24 26 28 3 KDE3500X E 120V KDE3500X E 240V 0 2 4 6 8101214 16 18 ptt REISER 0 2 6 10 8 5 240 KDE6500X E 5
50. protection A 4 SR Low oil pressure 240V amp 20V respectively ZU X 2 Output beker RI x b S v RI Xixi tv Output i T I 4041 gt THH L Een 7 indicator ligt e oe d DE CN N ee Chargng winding KDE2200X Double voltage selective output electric schematic diagram 12 Low oil pressure protection 4 Low oil pressure indicator light X Output Stop electomagnet Charging winding Excitation winding Main winding Main windin yee Voltmeter indicates 120V output h Output x i x i I Air switch L ed l i r Air switch 244 Iie Output ys kr Y 3 Dg nm 6 Air switch m CN a zt AVE sd L UNE 859 i 53 E Sampling winding KDE2200X Double voltage simultaneous output electric schematic diagram KDE3500X E amp KDE6500X E generator sets Voil pressure protection Voil pressure indicator light H Yellow Stop electromagnet t Black Charging winding Air switch Double voltage A simultaneousant put A T D Voltmeter T oH 4 i d i Vl em AVK Over loading protection AME Fs f 5 mutual i 1 A x ofa Sei E Ze st 1 E Si 3 85 3 Main winding Ma
51. r QD 9 D Fig Cabinet 1 2 3 69 or V Cover plate of air cleaner 5 SERVICE OF INTELLIGENT CONTROL PANEL English PVC v veneer Toggle switch for function setting ON DIP LLL 0 0 0 0 12355 AY B 1 Frequency setting 2 3 Voltage setting 2 ON 3 ON 230V 2 OFF 3 ON 240V 2 ON 3 OFF 115V 2 ON 3 ON 230V To regulate curret of protected point 2 OFF 3 OFF 120V 7 gy regulate current of phase ayo regulate current of phase B 4 ON 5 ON single phase 4 OFF 5 ON double voltage selected output 4 ON 5 OFF double voltage simultanceous output 4 OFF 5 OFF three phase ey regulate current of phase A v c regulate voltage of phase C or line CA oio regulate voltage of phase B or line BC regulate voltage of phase Aor line AB 70 Charging checkout negative Common terminal fur output Starting output Fuel oil control output Power supply input positive Protection input low is valid Starting signal high is valid Input terminal 2 for current of phase C Input terminal 2 for current of phase B Input terminal 2 for current of phase Phase B voltage input the phase voltage in transforned Phase A voltage input teh phase voltage in transforned lt Les DE 4 e OG 6 ZR di
52. r automatic stopping of diesel engine set Fig Flow chart for diesel 5 Automatic stop Check that the engine oil alert system is at low level the contact of alertor is y Add engine oil connected to casing Good Check the engine oil filter for clogging econ dee engine Good Check the engine oil sensor for groun 9 Replace engine ding oil sensor Good Yes Check the harness for short circuit 168 Replace connector Check that stopping is _Yes y Replace PCB energized Check gauge PCB whether the i gaug w Yes Replace engine ess is normal in energized state oil sensor Check oil system Replace engine Check the battery tank filter and carb oil filter for 12V uretor for clogging Yes No yes Check the 12V shutdown Check charging gt Replace charging Replace relay 4 circuit on gauge panel regulator for 12V regulator check the contact of relay Replace starting Yes for loosening check the switch lt starting switch Check flywheel for T E voltage output 45 3 MAINTENANCE CHECKS 3 1 Service List Periodic check and service are very important for keeping the engine in good condition The chart below indicates what checks to make and when to make them First month Third month Sixth month Every year Interval or100Hrs or500Hrs or 1000 Hrs Check and refill fuel oil Drain out fuel oil Check and refill e
53. right side plate_ Hexagonal flange face M amp X12 Connecting wire of battery 15 34 C2 ININ N gt gt N NININ Q gt KDE6500E le EL _________ 4 Earth wire Hexagonal fange face pot Iw 9 Gross slotted pan head sorew MGX5 P Gross slotted pan head ven 9 x Heapnimt ______ Jo Decorating plate Hexagonal fange face bot Jus 9 __________ _____ Ia Carbon brush Hexagonal fange face bolt Jun Rectification block Hexagonal fange face bolt Ju wire ________ lange face bot msx12 NN SS was SS SS SS Cross slotted pan head sorew M5x8 w Heegoan _____ Ia Hexonalfangefacebok mox lt i N 7 co gt a N 35 KDE6500E Front end cover 3 Rotor through bolt Hexagonal flange face bolt M10x225 50 5 Tighten bolt of fore back end cover Hexagonal flange face bolt M6 x 150 Frame power Earth wire Hexagonal flange face bot M6x8 9 0 9_ Muffler Hexagonalnut_ Ju 3 3 Fixed Hexagonal flange face bot _ 6 12 9 Pannel Cross slotted pan head screw M6 x 168 9 JN o Hexagonalflangefacebolt M5x16 Carbon brush Hexagonalflangefacebolt M5 20 E ___ ECH _ 9 C2 R Rectification
54. rmer with a multimeter Closed circuit is normal Open circuit is faulty The transformer is installed only in model KDE6700TA In other model there is no transformer Service The fault phenomena is no voltage indication during generating set running or a code of P 03 present Open circuit or short circuit of transformer Cause 1 Vibration 2 Fixing parts loosened or fall off Remedy 1 Replace transformer 4 4 5 Chassis Check Check the inlet and outlet of air duct to ensure ventilation Each sound absorbing sponge should be not clogged Service 1 The fault phenomena is that the wheel falls off during generating set running 2 Air duct clogged Cause 1 Vibration 2 Fixing parts loosened or fall off Remedy 1 Replace wheel Only in model KDE6700T TA TA3 have to remove the cabinet of generating set a e ss m hs hs e f y Sin NW Se e i GA 1 Ee Wi bw K ZU Wa L4 SC Ze D dd eer Ce s Cooling plate Left side plate Buoy sight window Shock pad of oil tank Fixing sheath for Bolt M6x16 sight window Bolt M x16 Rear door weldment Bolt M6x16 Kn ae doo L Bolt M5x15 olt M5x10 A E eh CN Transtormer Rm plate or door loc x Bolt M5x12 ofalrcleaner Spring washeff Cabimet weldment Shock pad of Spring washer 5 Bolt M6x20 air cleaner port 68 Right side plate e
55. rom fuel related parts 2 5 Service rules 2 5 1 Use Kipor recommended parts and lube or their equivalents otherwise engine may be damaged 2 5 2 Use special tools designed for the product 2 5 3 Easily damaged parts such as gaskets and O rings must be replaced when reassembling 2 5 4 When torquing bolts or nuts begin with larger diameter or inner bolts first and tighten to the specified torque diagonally unless a particular sequence is specified 2 5 5 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 2 5 6 After reassembly check all parts for proper installation and operation 2 5 7 Many screws used in this machine are self tapping Be aware that cross threading or over tightening these screws will strip the threads and ruin the hole 2 5 8 Use only metric tools when servicing this engine Metric bolts nuts and screws are not interchangeable with nonmetric fasteners The use of incorrect tools and fasteners will damage the engine 2 5 9 When using tools follow the instructions and symbols in page 2 3 24 2 6 Electric precautions 2 6 1 Hold the connector body to disconnect the connector Do not disconnect by pulling the wire harness To disconnect the locking connector be sure to unlock first and then disconnect 2 6 2 Check the connector terminals for bend excessive extrusion missing terminal or other abnormalities before connecting the connector 2 6 3 To c
56. rting Switch 4 2 4Voltmeter 4 2 5Air Breaker 4 2 6Engine Oil Alerting Apparatus 4 3Generator 4 3 1Generator 4 3 21Installation of Rotor 4 3 3Stator 4 4Cabinet 4 4 1Right Plate 4 4 2Left Plate 4 4 3Cabinet 4 4 4Cabinet Transformer 4 4 5Chassis 5 Service of Intelligent Control Panel for KDE6700TA TA3 5 1Setting 5 2Check 5 3Maintenance 5 4Parameter Setting List 5 5Diagram of Switch Position for Address Setting 1 SPECIFICATIONS 1 1 Main technical Specifications s lp youo p Vapul AD ejnuo 20302 uonejos Buue q euo eJnjonujs JojeJeuec uonejoxe JJjes edA uoneiox3 za wp ves Des sor za res ve Years Wis er wer wey oez bal oez aet 000 Waren 5 22 oe ee se s ee e Z Zt w EE O D O yoyo x ed A euiGu3 euiBu3 opeJ6 uonej nsu ojnuo J0j04 oneuBeuJ uonejoy dou uone nuoA euo eJnjonujs 5 ego __ IL eoon uonejoxe jjes adh uoneyox3 EOYLEVL E1002930 10 29 10089309 oo Generating Set ueis aen EES gel uon
57. s not on Fuel injection limiting bolt 50 A ATTENDED lI When the oil pressure is too low or the engine oil level is too low the low oil alerting system will act to stop the engine If no engine oil is refilled the engine will not restart Please check engine oil level first then refill engine oil E Never loosen or adjust engine speed limiting bolt and fuel oil limiting bolt 3 2 6 Checks during the running 1 Whether there is abnormal sound or vibration in generator 2 Whether the engine runs rough 3 Check the color of exhaust Is it black or too white If you notice any of the above mentioned phenomenon happened stop the engine and find out the fault cause according to troubleshooting 3 2 6 1 Check A C Output Characteristic 1 Be sure to run the generating set at rated speed otherwise the automatic voltage regulator AVR will produce the forced excitation If the running is for a long time under such condition AVR will be burned out 2 After switching on the air switch observe the voltmeter on the panel of the control cabinet the voltmeter should point to 230 V 50 Hz 120 240 V 60 Hz for single phase generating set 400 V 50 Hz 416 V 60 Hz for three phase generating set then the loading can be carried out 3 Connect the equipments 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
58. t MUtUAI INCUCATON Weires ER Red 3 15 Direct current socket eat PE 7M amp iri di Bs Black 15 _____ L T 5 Sampling Yellow amp Green 5 1 OFF ON relationship list of electic switch lock c windin ea wee EE comens Deier 4 EE Simple intellagent screen Current sampling Orey sl D E E z 2 L c 8 Fuse DU 8 ET g g Th Blue 5 5 5 e EAR g Starting 11 s 23 electromagnet 5 B Ges Fe 48 S n V M AVR 8 1 Starting 1 electric Protect motor Yellow Green 8 5 Orange Rv La KDE6700TA Single voltage output electric schematic diagram Current mutual inducator Brown Mee lt af g 2 Mi Black 4 k x Red ra Sampling Orangery tu Blues Fused A n z Red 27 direct current socket ER Blue Back E I gt OFF ON relationship list of electic switch lock winding pes 4 converter Red 1 Voltage sampling 1 i Simple intelldgent screen Current Simple L i sam ping Greyits 5 H2 Der 5 ct Onus Green via mdi E Whites 9 Fuse _ Mite Blues tt ev ech we Op 1e 3 2 7 Reds kd o Whites 68 2
59. t precaustions are given below However we can not warn you of all possible hazards You yourself are to decide whether a given maintenance task can be performed Failure to follow maintenance instructions and A WARNING Res precautions may cause serious injuries or even deaths Please do follow the operation procedures and safety precuations stated in this manual 2 4 Important safety precautions Make sure you have a basic and complete understanding of safe operations Please wear proper work clothes and equipped with proper safety facility Please keep the following in mind when performing maintenance and repair 23 You have read service instructions before performing maintenance and have necessary tools and skills so taht safe maintenance can be secured Switch off the engine before performing maintenance and repair to avoid the follosing hazards Nonocide poisoning by exhaust gas from the engine Ensure good ventilation condition whenever run the engine Burnt by hot parts Do not touch these parts until engine gets cool Injury by rotating parts Do not start the engine unless serving instructions require so Keep your hands fingers and clothes away from rotating parts of the engine To minimize possibility of explosion and fire when performing maintenance or repair if gasoline left in generator set only nonflammable solvent instead of gasoline can be used to clean the parts Cigarette spark and flame must be kept away f
60. t tightly it would fall during engine running due to vibration Never run the engine without air cleaner or with a defective air cleaner to prevent accelerated wear of engine Service The fault phenomena is fluctuation of engine running and incapable of power raising insufficient air intake Cause 1 Dirty air enters 2 Exhaust gas feedbacks during engine running which causes incomplete combustion in engine and carbon deposition on oil nozzles Remedy Repeat the above mentioned steps for cleaning Refer to engine service for oil nozzle faults Cover plate of cleaner Fig Cleaning of air cleaner 58 4 1 6 Muffler a Removing and reinstalling Caution Remove and reinstall the muffler after the engine is cooled down 1 Protective hood of muffler In quiet generating set the cooling plate must be removed then remove the muffler 2 Muffler Installation Before installing tap muffler with a plastic hammer to remove internal carbon deposition 3 Gasket of muffler Can not be reused Service 1 The fault phenomena is black smoke emitted from exhaust port during engine running insufficient air intake Cause 1 Dirty air enters 2 Exhaust gas feedbacks into air cleaner during engine running which causes incomplete combustion in engine and carbon deposition on oil nozzles Remedy Repeat the above mentioned steps for cleaning Refer to engine service for oil nozzle faults Service 2
61. te that the oil level should be a bit lower the oil filler 3 If the oil level is low refill oil to a position a bit lower the oil filler Check the stability of engine oil Check that no impurity is adulterated Recommended engine oil SAE10W 30 or SAE30 grade SE SF or SG of API service classification Engine oil is the main factor to affect the engine service life Use four stroke automatically purifying oil Recommended oil of SAE10W 30 is commonly used When the average temperature of user s area is within the applicable range for recommended engine oil the engine oil of other viscosity may be used Viscosity table 4 Tighten the oil filler cap 4 1 2 Replace engine oil Drain the oil while the engine is still warm since hot oil is drained fast and thoroughly 1 Remove service cap Remove the oil filler cap Drain the old oil into a suitable container For environment protection it is recommended to put the waste engine oil in a sealed container and delivery it to service station or recycle center of user s area Never pour the engine oil on the ground or debris Caution The used engine oil contains cancerogenous substance If contact with skin frequently or for long time skin cancer would be caused Clean your hands with soak thoroughly and rinse it immediately 55 2 Refill engine oil to specified position 3 check the oil level again after fueling if oil level 15 too low fuel to specified level 4 Reinstall t
62. tion of main damper and throttle of carburctor Check the gasket of cylinder head cover for damage and leakage Check the inlet valve and outlet valve in cylinder head cover for damage Check that the clearances between piston piston ring and cylinder sleeve are not excessive the liner is not seized Check electric starter spark plug test 42 2 Troubleshooting steps for voltage Fig Flow chart for diesel 2 No voltage No electricity generated Check gauging system in panel Check the connecting plug for loosening Check the air switch for damage Check the harness of air switch for dropout Check AVR Check connector of AVR Check rotor section Check stator section ondary winding for loosening Mid wass brush of rotor Check that the connection of Check AVR for output and collector Tor contact quadbit line bank and gauging panel is correct and is not lo m osened AVR secondary winding Check rotor for open circuit l for 3 4V voltage at swtiching on heck stat inding f Check collector for short circuit ele Stator winding for open Have voltage Have voltageCheck secondary winding Check stator winding for inte connector for loosening rturns short circuit CheckAVRfor Check electric damage machine Check magnetic steel of rotor for loss of magnetism check that the polarity of magnetic steel is not reversed 43 3 Troubleshooting steps for failure to regul
63. tion with tester Follow the instructions of the Service Manual Be sure that the battery built in a tester is fully charged and check the meter before inspection using the tester 25 2 7 Part name description KDE2200 6500E X external parts Fuel tank MW Air cleaner Starting handle Recoil starter Decompression lever Engine speed lever Oil drain plug Muffler Fuel filler cap 26 KDE6500T KDE6500T3 KDE6700TKDE6700T3 KDE6700TA KDE6700TA3 Fuel gavge Fuel tank cover Buon Gast Exhausts Fuel filter cap 5 Volometer Cooling plate Hook Switch lock RK Air switch Plug Handle Air filtrati Eareh bolt s d Dc terminal Rubber Door lock bad Split pin Battery positive line EE Battery cover Battery 1 a Battery earth line Battery pad Battery bracket gu Generator earth line 27 2 8 Serial number location Serial number location varies according to generator set series Open frame generator sets KDE2200X EKDE6500X E KDE6500EW XW at outer iron plate of generator stator to be specifically below fuel tank 28 Silent generator sets KDE6500T T3 KDE6700T T3 KDE6700TA KDE6700TAS Befor open the set look up at the air guide plate at the front of the set 29 2 9 The service standard for generating set mam volage at zero load V standard voltage at zero load V __
64. ulty Check and observe the engine rotation disassemble the engine to replace faulted part Oil delivery pipe of oil tank is bent or oil pipe is clogged il D 2 2 CO il D c c O O c K CO Remove it and check for open circuit The resistance reading in multimeter should be 0 3 The connection of receptacle is loosened or contact is melted Engine speed is unstable too high or too low Gauge panel of generating set 40 O gt o 2 c o W i o c D il c D c c c D O D c voltage is abnormal the voltage is fluctuated when loaded 8 Interturn short circuit of electric machine main winding H Open circuit of electric machine rotor winding coil 10 Short circuit of electric machine rotor winding coil Check resistance value at collector reconnect or replace carbon brush Check insulation resistance of stator and rotor by voltage withstanding gauge or replace stator and rotor of electric machine 8 The votage deviation of zero load and ful load is too large volle regulating ates low Check AVR and the temperature of electric machine for high temperature or replace electric machine or AVR Fault caused by electric
65. y P 05 B 5KW the special requirement of the North America Low oil pressure protection Protection by stopping if the oil pressure low for 5s display P 01 Lack frequency protection Output frequency 57HZ protection by stopping for 20s display P 02 Over frequency protection Output frequency 65HZ protection by stopping for 3s display P 02 Lack voltage protection The output voltage is 105V or 210V protection by stopping for 20s display P 03 Over voltage protection The output voltage is 132V or 264V protection by stopping for 3s display P 03 Over load protection The output current is between 19 2A and 21 24 protection by stopping for 1 hour display P 04 Over load protection The output current is 221 2A protection by stopping for 20s display 04 Charging malfunction warning No protection only display while charging malfunction display P 05 39 2 12 Troubleshooting Open shelf diesel engine and quiet generating set 2 12 1General symptom and possible cause The pump does not delivery oil Remove the high pressure oil pipe check for delivery of oil replace pump or clean Remove the high pressure oil pipe check for delivery of oil replace pump or clean The governor lever of engine throttle is faulty Oil nozzle is clogged Check exhaust gas or observe engine rotation clean or replace oil nozzle The starting motor has internal mechanical fault Oil level switch engine oil alerting apparatus is fa
66. zed Remedy 1 Checkout the resistance on voltmeter terminal posts with a multimeter for on off relation On is normal Off is faulty 2 Replace voltmeter Cause 1 The generator does not generate power Remedy According the troubleshooting for generator 4 2 5 Air switch Check Checkout the resistance at two ends of air switch with a multimeter The resistance should be infinity in OFF and zero in ON Service 1 The fault phenomena is that there is AC current output during generating set running but no AC voltage indication The voltmeter is open circuit the wring of voltmeter is loosened Cause 1 Wring is loosened due to vibration 2 The element in voltmeter is damaged 3 The pointer of voltmeter is seized Remedy 1 Checkout the resistance on voltmeter terminal posts with a multimeter for on off relation ON is normal OFF is faulty 2 Replace voltmeter 4 2 6 PCB parts for engine oil alarming and stopping Check Checkout the contact and circuit of relay on PCB with a multimeter for correct on off Service 1 The fault phenomena is low oil pressure indication alarming The indicating lamp on PCB always on Cause 1 The engine oil filter is dirty result in false alarm of engine oil 2 The relay on PCB is defective Remedy 1 Checkout the resistance of two harnesses at the terminal post of alarming apparatus for on off relation Off is normal On is faulty 2 Replace PCB 3 Replace relay or 4 Replace engine oil a

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