KDE11-100SS GENERATOR SET Maintenance Manal

Preface
This manual contains KDE11SS ， KDE13SS, KDE13SS3, KDE15SS3 generator types, which
written by KIPOR POWER CO.,LTD. It mainly guides KIPOR’S dealers and it’s eligible repairmen how
to properly operate and maintain KIPOR generator set . The manual doesn’t cover all the maintaining
knowledge of generator set. Therefore, the maintainers should have basic knowledge and skill in
generator maintenance technique. If not, but trying to maintain above-mentioned generator types will
cause damage and safe accident. To avoid this happening, please contact with KIPOR POWER CO.,
LTD. or agents in time. If you have any suggestions or requests，please contact us.
The manual is about universal item of KIPOR generator set, with the company’s improvement and
development, maybe the practical product content of generator set is inconsistent with maintenance
service manual, please follow the shop random manual. If the procedure has any modification or any
other important change, KIPOR will inform all the authorized agents and revise the content in the new
edition manual.
　　　　　　Content
1. Safety
1.1 Attentions
1.2 Install, move and transport genset
1.3 Fire prevention and explosion prevention
1.4 Protection
1.5 Chemical
1.6 Electric equipment
Warning labels and position
1.8 Rescue the injured hurt by electricity
Lifting, installation and deposit
2.1 Lifting
2.2 Installation
2.3 Deposit
3. Technical parameters
3.1 Main technical parameters of generator set
3.2 Maintenance parameters of generator set
3.3 Maintenance parameters of generator set
3.4 Electrical systematic elementary diagram
3.5 Fastening torque values
4. General explanation
4.1 Shape and structure of generator set
4.2 Electric cabinet
4.3 Diesel engine
4.4 AC brushless four poles synchronous generator
4.5 Genset fuel supply system
4.6 Genset structure air dust cooled system and water cooled system
5. Handling instruction of electric control parts
5.1 Operation panel
5.2 Operation of digital display controller function
5.3 ATS connects with generator set
5.4 Connection of load
6. Daily inspection and regular inspection
6.1 Regular inspection procedure
7. Operation indication
7.1 Fuel lubrication water cooled
7.2 Battery cell operation
7.3 Preparation before operation
7.4 Used method
8. Maintenance and repair of electrical system
8.1 Starting electrical motor
8.2 Charging generator
8.3 Generator
9. Maintenance and repair of engine
9.1 Installation drawing and some parts names
9.2 Engine disassembly and assembly
9.3 Engine check and maintenance
10. Failure and resolution
10.1 Doesn’t generate power or generate power abnormally
10.2 Digital panel electrical system
10.3 Warning system failure
10.4 Starting failure
10.5 Engine rotation speed unsteady
10.6 Exhaust color anomaly
10.7 Engine under-power
10.8 Fluctuation of service
10.9 Engine overheat
10.10 Hard shutdown
10.11 Abnormal sound while engine operating
1.Safety
1.1 Attentions
Thank you for purchasing KIPOR generator set.
Please carefully read and thoroughly understand this introduction and precautions and attentions
marked on the machine prior to operation, check and maintenance. Then official operation is allowed.
Please carefully read the following safety indications for avoiding unexpected accidents and damages.
This manual identifies conditions of risks and damages if operation is incorrect with following.
The sign shows that if not obey the indication will lead to serious injury and
death accident.
Danger
Indicates the potential risk should be noted, if not obey the indication will lead
to serious injury and death accident.
Warning
The sign shows that if not obey the indication might lead to mild injury
and damage.
Attended
●To get the best efficiency and ensure the longest life of generator set, must do preventative
maintenance in accordance with this manual. If generator set operates in bad status condition, it will
shorter duration of some parts.
●　Be sure all the servicemen have professionary training.
● However, it is impossible for our company to expect all risks concerning conditions of
operation, check and maintenance. Therefore warnings contained in the introduction and identified on
the machine are exclusive and complete. User shall take own responsibility for safety if user does
operation, check and maintenance not mentioned herein.
1.2 Install, move and transport genset
For safety, please observe following matters needing attention.
Warning
●　According to correlative standard, norm and other requests containing earth connection and
creepage fault to connect wire.
● Do not lift the machine at non-designated positions because of insufficient lifting strength.
Otherwise falling machine leads to mechanical damage or human injury.
●　Upon lifting the machine, please use the designated metal hook in the center of engine cover.
● Do not stand under lifted machine.
● Do not lift the machine when engine runs or don’t run engine when lift the machine.
● Incorrect overlapping-storage may cause falling and overturn of machine and mechanical
damage.
● Place the machine on the flat and solid ground. Keep machines level. Ensure that ground can
bear overlapping weight.
Max two layers of overlapping storage are allowed.
● Check if machine bolts are loose or missing.

● Separate machines with wooden lumps. Keep all wooden lumps bearing same weight.
● Do not run overlapped machines. Otherwise it may cause overturn and falling.
1.3 Fire prevention and explosion prevention
The fuel and exhaust-smoke of the generator are easily ignited and
explosive. Carefully deal with these matters and nip them in the bud. The BC
and ABC fire extinguishers in the machinery room should be in good condition.
Users must know how to use the fire extinguishers.
Danger
Ensure the ventilation is enough in the machinery room.

Ensure the machinery room, floor and generator surface are clean, if the fuel, battery solution or
refrigerating fluid leak out, please clear them up immediately.
Don’t put inflammables near by generator set.
Put the oily rag into the metal container with cover.
Smoking, sparking or other open flame action near by the battery and fuel are not allowed.
Because the volatile gas from fuel and the hydrogen from battery charging will cause explosion by
open flame.
Cut off the power supply of battery charger before connecting or shut-off battery.
The conducting objects like metal tool should be away from exposed live part(like output
electrode), prevent the arc-spark and fuel or gas explosion caused by arc-spark.
Don’t fill fuel when the generator set is working.
Don’t start the generator in the condition of the fuel leaked.
Start the generator repeatedly, check valve and heat machine stops will cause excess unburned
gas in the exhaust system. Please be very careful by now, there is potential explosion danger. You
should start generator set after exhausting gas.
1.4 Protection
The safety cover is installed on the rotating place of the generator set, be
careful all the risks of moving parts to people when the generator set starts.
Danger
When the safety cover is took apart, don’t start the generator set. When the generator set is
running, don’t reach under or nearby the safety cover to maintain.
When maintaining, the worker should wear work clothes, gloves and hat.
Palm, arm, long hair, loose-fitting clothes and jewelry should keep away from the moving or
rotating parts of generator set.
Don’t touch high temperature parts before generator cooling.
1.5 Chemical
The fuel, oil and battery solution belong to product of chemical industry, if
improperly used or managed them, it is harm to human body.
Warning
Don’t swallow or let skin touch harmful chemicals like fuel, oil, battery solution. If swallowing
them by careless, you should see a doctor in time, if the skin touches them, you should wash your
eyes with soap and clean water.
Don’t wear clothes stained by fuel, lubricant and battery solution.
When dealing with battery, please wear acid-proof apron, face shield or eye protector, once the
body is stained by acid liquor, wash it immediately with abundant water. If the acid liquor splashes into
eyes, please wash your eyes with clean water or 10% dilute boric acid solution, and see a doctor in
time.
1.6 Electric equipment
Correct installation, operation and maintenance can make sure the electric
equipment work efficiently and safely. If not, the injury even death is very likely
to occur.
Danger
Generator set must be connected load by qualified or experienced electrician, connected load
must conform to relevant electrical rules, standards and norms.
Ensure the earth specification of generator set conforms to local safety rules and standards of
electric.
Don’t stand in the water or humid ground to connect or dismantle load.
When the generator set generates electricity, human body or metallic object without insulation
protection doesn’t touch with live parts of generator set or power supply wire.
After connecting or disassembling load, please reset distribution cabinet cover immediately.
Don’t start generator set at open distribution cabinet cover.
The load or electric system supplied power by this generator set must consist with electrical
character of this generator set. And the power should be in the range of capacity of this generator set.
When maintaining the generator set, make sure you remember to cut off all the external power.
Keep all the electric equipments dry and clean. Please replace wire and insulator immediately if
they are any cracking, laceration or wearing. Keep wire and connection pole clean and close
connected.
Ensure all the electric parts and power connection of generator set have proper protection.
Only BC or ABC grade fire extinguisher can be used for electric equipment fire fighting.
When connecting into battery, keep positive pole and negative pole upright, otherwise it may
cause serious damage to electric equipment.
1.7 Warning labels and position

1.7.1 Lable position
4
7
3
2
6 1
5
10
11
12
8 9
1. Attention 2. Pay attention to exhaust 3. Pay attention to scalding 4. Pay attention to high
temperature 5. Lifting position 6. Prevent flame and fire 7. Forbid lifting the machine 8. Pay
attention to handling of storage battery 9. Avoid being involved in the running machine 10. Low oil
pressure warning 11. Pay attention to electric shock 12. Attended operations
1.7.2 Warning label
1. Pay attention to 2. Pay attention to exhaust 3. Pay attention to scalding
Check the engine while it is in Danger Don’t touch the water tank,
the cooling state. Check the The exhaust is harmful to the while it’s too hot to prevent
engine after it stopped. Be health. Do not run the unit in from the scalding.
care not to be scalded by doors or in poor ventilated
muffler and exhaust pipe. area.
4. Pay attention to high

5. Hooking position 6. No Smoking
temperature
Don’t open the water tank Hooking position Smoking or spark is

while high temperature. forbidden near to the filling
You may be scalded due to port. Otherwise the fire will
the hot water. be happened.
Be sure to refuel the unit
after the engine is stopped.
7. Hooking is 9. Avoid being involved in

8. Pay attention to not move battery
forbidden. the running machine
Hooking is forbidden. Don’t move the battery when the Don’t put the hand or
generator is running. fingers into the machine
while running. Otherwise
injury may be happened.
11. Pay attention to

10. Low oil warning
electric shock
Don’t run engine without checking oil level in case of

auto stop or lighting of oil pressure alert lamp. Check
engine oil before each start. Be sure to use SEA 10W30
grade CC.
12： Attended operations

◎ Please read the user manual carefully and operate the unit safely
Please read the user manual carefully before operation.
If the user manual and safety label are broken, please order from Kipor.
◎There is possibility of electric shook and fire. Don’t connect the unit to the utility lines or
home wirings.
◎Refuel the unit after the engine stopped to prevent the fire.
◎There is danger of electric shock and injury. Before starting, please firstly confirm that the
breaker is on the position of OFF.
◎Don’t move the unit while running to prevent from the injury.
◎Please operate by professional man with rich technology.
◎safety information:
There is high-voltage part, rotation part and high-temperature part. Do run the engine after
closing the lid.
◎Check and service the unit after the engine is completely stopped.
1.8 Rescue the casualties shocked by electricity

If electric shock occurs, cut off switch, shut down generator set emergently. If the power supply can not
be cut off, please separate the casualties shocked by electricity from the conductive matters as quickly
as you can. Avoid to directly touch with the conductive matters and the casualties shocked by
electricity, please remove the casualties shocked by electricity with dry batten or dry clothings or other
insulating material
If the injured was in a coma, give rescue breathing immediately according to the needs. Otherwise, the
injured will die. When the heart has stopped, do cardiac massage.
2. Lifting and transportation, installation and storage
2.1 Lifting and transportation
2.1.1 Lifting
●Lift generator with the lifting hook on the top of cover. Do not stand under the
lifted generator. If the generator falls down, it may cause hurt.
Warning
● 　 If lifting the generator with transportation hook or other parts, there is the risk of mechanical
damage or falling-down.
●　Do not lift or move the running generator. Some irrevocable errors like fan damage may occur.
●　Don’t run the lifted machine.
2.1.2 Transportation
● 　 If shipping with the truck, please fix the generator on the loading table in the truck for safety
concern.
●　Bind the generator with ropes at left and right hands indicated on below drawings after loading.
2.2 Installation
Please work the machine in the well-ventilated place. Bad

ventilation causes breath of waste gas thus to death.
Danger
●Do not work the generator in the building or place with cover, bad ventilation or static exhaust.
●Do not work the generator in the place with bad ventilation such as inside stockroom, tunnel, cabin or
enclosure channel.
●If it is necessary to run the machine on mentioned conditions, necessarily extend exhaust pipe
outside of room and provide proper ventilation device to ensure sufficient ventilation.
●Prevent exhaust vent direct to passerby or other's family.
2.2.1 Pay attention to vibration

Running machine produces vibration as inside engine is working.
Please observe the following requirements upon installation.
1)Place the generator on the solid ground and keep it level.
Abnormal vibration may occur if generator runs on the uneven ground.
2) If there is uptown around, residents may complain about noise. Therefore please install the
generator after solid foundation is completely finished. Consult local sales department of KAMA for
detailed information concerning vibration specification and foundation project.
2.2.2 Pay attention to noise

There is great noise if operator opens the side door as inside engine is working.
In addition, there is still certain noise even if side door is close.
1）Close the side door after machine is installed.
2 ） If there is uptown around, residents may complain about noise. Therefore please take additional
measures against noise. Consult local sales department for detailed information concerning noise
specification.
2.2.3 Pay attention to installation

This generator is portable and used as main or auxiliary power supply for outside work. Installation
shall consider below requirements.
1 ） Please install the machine on the flat and solid ground. Make sure bottom of the generator
contacts ground evenly. Error may occur due to generator vibration.
2 ） If it is necessary to run the machine on the inclined ground, make sure the side with radiator
upward and inclination angle within 10°. Engine may face over-heat due to bad working of water
temperature switch, air into cooling water pipe and etc.
3）Keep machine at least 200-300mm away from walls upon installation. Keep air vent of radiator and
suction inlet and exhaust vent of engine upward. Prevent them from any jam. Otherwise temperature
rise or reduction of cooling airflow may cause over-heat of engine or reduction of rotation. In addition,
temperature of exhaust or increase of load also may lead to shorter duration.
4）Run the machine in the place free of moisture, dust and rubbish and with fresh air.
Electricity leakage causes electric shock. If air vent of radiator is jammed, over-heat of engine may
occur.
5）Place the generator near to working equipments like motor, lamps and etc.
Long line reduces efficiency because of large resistance and electricity loss. And electricity fee turns
more.
6 ） When the generator loads down, please pay special attention to impact load and release loads
gradually and evenly.
2.3 Storage
Please store generators as following if two-layers storage is required.
●Check if generator hood is damaged or screw is loose or released.
●Check if the ground is flat and solid and can bear static weight of overlapped generators.
●Place the wooden lumps between generators.
●Prevent generators in the upper layer from inclination.
●Prevent generators in the upper layer heavier than those in the lower layer.
●Do not run the generator at the status of storage.
2.3.1 Long-term storage

Please implement following maintenance for the generator idle for long-term.
● Drain off cooling water in cold season or at the status of long-term storage.
(Mentioned action is no need if anti-freezing liquid is used.)
1）Take off upper hood and open radiator cover.
2）Take off drainage plug of cooling water in the frame of generator to drain inside water.
3）Loosen the drainage plug at the side of cylinder and drain out the water.
4）Close radiator cover, hood and drainage plug after drainage finishes.
It is necessary to drain off cooling water. Otherwise rest cooling water in the
engine may freeze and expand thus to damage the machine
Attention
●Please clean mud, dust and oil remained on the machine surface.
●Must finish periodic check prior to maintenance.
●In order to prevent dew concentration in the fuel tank. Drain off fuel or fill fuel completely.
●Disconnect cable of storage battery with (-) pole.
●Apply lubricant to operating devices and relevant connections.
●Please cover the plastic hood and similar parts in order to prevent water or dust into control box,
radiator and muffle of exhaust pipe.
●Store the machine in the place without moisture or dust and with good ventilation.
●Please charge the storage battery once per month to resolve intrinsic shelf depreciation during
machine storage.
●Please do no-load running for short time and at low speed if machine is idle for long term and prior to
load running.
3.Technical parameters
3.1Main technical parameters of generator set
3.1.1Overall dimension
Model KDE11SS、KDE13SS、KDE13SS3、KDE15SS3
Overall length 1570mm
Width 780mm
Height 1050mm
3.1.2Main technical parameters(single-phase generator set)
Model KDE11SS KDE13SS

Rated frequency Hz 50 60 50 60
Rated output capacity KVA 8.5 10.5 10 12
Max. output KVA 9.5 11.5 11 13
Rated voltage V 115/230 120/240 115/230 120/240
Rated current A 74/37 87.6/43.8 87/43 100/50
Generator
Rated rotation speed rpm 1500 1800 1500 1800

Circuit mode Single-phase and three circuits
Power factor 1.0
Insulation grade F
Steady-state voltage
≤2.5
deviation (%)
Frequency step down (%) ≤0.5
Air circuit breaker(selected
40A 50A 50A 50A
value)
Pole number 4
Brushless self-excitation and constant voltage
Excitation mode
（with AVR）
Panel type Digital panel
Voltage V 115/230 120/240 115/230 120/240
Output
Receptacle Two single phase receptacles

Connection pole With
DC12V output Without
Fuel tank capacity L 65
Set
Continuous running time h 17 15 17 15

Overall dimension: LXWXH mm 1570×780×105
Net weight Kg 675 685
Working assorting weight Kg 750 760
Noise level (7m) dB(A) 50HZ:51 60HZ:53
Structure type Ultra silent
3.1.3 Main technical parameters of three-phase generator set
Model KDE13SS3 KDE15SS3

Rated frequency Hz 50 60 50 60
Rated output capacity KVA 10.6 13.1 12.5 15
Max. output KVA 11.6 14.5 14 16.5
Rated voltage V 230/400 240/416 230/400 240/416
Rated current A 15.3 18.2 18 20.8
Generator
Rated rotation speed rpm 1500 1800 1500 1800

Circuit mode 　 Three phase, four lines, Y connection
Factor power 　 0.8 0.8(lag)
Insulation grade 　 F
Steady-state voltage
　 ≤2.5
deviation (%)
Frequency step down (%) 　 ≤0.5
Air circuit
　 16A 20A 20A 25A
breaker(selected value)
Pole number 　 4
Brushless self-excitation and constant voltage
Excitation mode 　
（with AVR）
Panel type 　 Digital panel
Voltage V 230/400 240/416 230/400 240/416
Output
Receptacle 　 Two single phase receptacles

Connection pole 　 With
DC12V output 　 Without
Fuel tank capacity L 65
Continuous running time h 17 15 17 15
Set
Overall dimension:
mm 1570×780×1050
LXWXH
Net weight Kg 675 685
Working assorting weight Kg 750 760
Noise level (7m) dB(A) 50HZ:51 60HZ:53
Structure type 　 Ultra silent Ultra silent
3.2 Maintenance parameter of engine
3.2.1 Specifications and characteristics
Model KD388 KD388Z

Three-cylinder, vertical, Three-cylinder, vertical,
water cooled, four stroke,
Type Water cooled,
direct injection,
four stroke, direct injection supercharging
Bore x Stroke 　mm 88×90
Displacement L 1.642
Compression ratio 18.2 17.5
Firing order 1－3－2（from flywheel terminal）
12.3/1500 14.8/1500
14.8/1800 17.8/1800
Rated power/Rated rotation speed
18.1/2200 21.7/2200
kW/r/min
19.6/2400 23.5/2400
24.6/3000 29.5/3000
Max. torque (N·m) 96/1800 116/1800
Lubricate type Pressure splashed mixing type
Starting type Electric starter

Rotation direction of output end (face
Anticlockwise
to flywheel)
Fuel brand 0#(summer), -10# or -20#(winter), -35#(chillness)
Fuel consumption （ Rated rotation
230/1500
speed g/(kW·h)/r/min
Lube oil brand SAE 10W－30、20W－40 or L－ECD grade
Lube capacity L 6.9
Fuel consumption g/(kW·h) 2.72
Starting motor V,kW 12V 1.4kW
Charging generator capacity V,A 12V 15A
Battery capacity V,AH 12V 80AH
Overall dimension: LXWXH mm 610×480×642
Net weight 　kg 170 175

3.2.2 Fit clearance and magnitude of interference
NO. Name Standard dimension Fit Remark

dimension
1 Cylinder diameter / Piston head Φ88+0.025
0 /Φ88-0.49
-0.51
0.49~0.535
land diameter
2 Cylinder diameter / Piston skirt Φ88+0.025
0 /Φ88-0.14
-0.16
0.14~0.185
upper diameter
3 Cylinder diameter / Piston skirt Φ88+0.025
0 /Φ88-0.05
-0.07
0.05~0.075
diameter
4 Piston pin pore diameter / Piston Φ26+0.008
+0.002/Φ26-0.006
0
0.002~0.014
pin diameter
5 Height of ring groove / Height of 2+0.06
+0.04/2-0.02
-0.01
0.05~0.08
the 1st ring
+0.02/2-0.02
-0.01
0.03~0.06
the 2nd ring
+0.02/4-0.025
-0.010
0.03~0.065
the 3rd ring
8 Piston ring gap clearance Ⅰ 0.25~0.40
9 Piston ring gap clearance Ⅱ 0.25~0.35
10 Piston ring gap clearance Ⅲ 0.15~0.30
11 Aperture diameter of connecting Φ26 +0.025
+0.015 /Φ26 0
-0.006
0.015~0.021
rod bushing / Piston pin diameter
12 Aperture diameter of connecting Φ48+0.039
0 /Φ48f5-0.025
-0.036
rod bearing / Connecting rod 0.025~0.075

journal
13 Aperture diameter of main Φ54+0.043
0 /Φ50f5(-0.025
-0.036)
0.025~0.079
bush /Main journal
14 Crankshaft axial clearance 28+0.15
+0.10/28-0.038
0
0.10~0.188
15 Side clearance between journal 28+0.20
+0.10/27.7-0.03
0
and connecting rod bid end 0.40~0.53

/Journal gap clearance
16 Connecting bolt hole/ Φ9.5+0.015
0 /Φ9.5-0.009
0
0~0.024
Bolt locating journal
17 Camshaft bore / Camshaft Φ45H7(+0.025
0 )/Φ45e7-0.050
-0.075
0.05~0.10
journal
18 Camshaft axial clearance 4.5+0.15
+0.10/4.5±0.05 0.05~0.20
19 Aperture of machine stem/ Φ12H7( +0.018
0 )/Φ12 -0.016
-0.027
0.016~0.045
Outside diameter of valve stem
20 Idle gear seat hole / Idle gear Φ20H7(+0.021
0 )/Φ20g6-0.007
-0.020
0.007~0.041
seat
21 Aperture of idle gear bushing / Φ46H7(+0.025
0 )/Φ46f6-0.025
-0.041
0.025~0.066
Idle gear seat
22 Gear box oil pump / Diameter of Φ90H9(+0.035
0 )/Φ90-0.08
-0.12
0.08~0.155
outside rotor
23 Axial clearance of inside / 11+0.08
+0.05/11-0.02
0
0.05~0.10
Outside rotor of oil pump
(Center of crankshaft to the top
of cylinder + cylinder gasket) / 230  0.03  0.7 标准值1.1
24
Piston + connecting rod + 47.6  0.05  137  0.03  45  0.03.96 ~ 1.24
0
crankshaft radius
25 Aperture of valve guide / Inlet Φ8H7(+0.015
0 )/Φ8-0.035
-0.050
0.035~0.065
valve rod diameter
26 Aperture of valve guide / Exhaust Φ8H7(+0.015
0 )/Φ8-0.040
-0.055
0.04~0.07
valve rod diameter
27 Aperture of valve rocker arm / Φ16H7+0.018
0 /Φ16f6-0.016
-0.027
0.016~0.045
Axial diameter of rocker arm
28 Flywheel location aperture / Axial Φ85H8(+0.054
0 )/Φ85h8-0.054
0
diameter of crankshaft flywheel 0~0.108

terminal
29 Aperture of cylinder cover guide / Φ13H7+0.018
0 /Φ13+0.065
+0.050 -0.032~- Interference
Outside diameter of valve guide 0.065
30 Hole of cylinder cover inlet valve Φ38H7+0.025
0 /Φ38+0.12
+0.10 Interference
seat / Outside diameter of inlet -0.075~-0.12
valve seat
31 Hole of cylinder cover exhaust Φ31.5H7(+0.025
0 )/Φ31.5+0.12
+0.09 Interference
valve seat / Outside diameter of -0.065~-0.12
exhaust valve seat
32 Camshaft hole of cylinder block / Φ48H7+0.025
0 /Φ48+0.10
+0.08 Interference
Outside diameter of camshaft -0.055~-0.10
bushing
33 Outside diameter of idle gear / Φ50H7(+0.025
0 )/Φ50v7+0.106
+0.081 Interference
-0.056~-
Outside diameter of idle gear
0.106
bushing
34 Aperture of connecting rod small Φ29H6+0.013
0 /Φ29+0.042
+0.026 Interference
-0.013~-
end / Outside diameter of
0.042
connecting rod bushing
35 Aperture of crankshaft gear Φ38H7(+0.021
0 )/Φ38r6+0.050
/Journal of crankshaft gear 0.050
36 Aperture of timing gear / Camshaft Φ30H7+0.021
0 /Φ30r6+0.041
gear journal 0.041
37 Flywheel ring gear / Flywheel Φ296H7+0.052
0 /Φ296u7+0.402
rabbet circle 0.402
3.2.3 Main Adjusting Data Table

Item Normal value
Non-compression space 0.8～1.0
height inside the cylinder mm
Advance angle of fuel supply 16°±1°B.T.D.C
Injection pressure Mpa 20±0.5，Supercharge 22±0.5
Valve close Inlet valve Open at B.T.D.C 10°， close at A.B.D.C45°
and open Exhaust valve Open at B.B.D.C 56°， close at A.T.D.C12°
phase
Max. rise distance of 8.9
inlet/exhaust valve mm
Valve clearance mm （ cold 0.10～0.15
state）
Air valve sub-quality product 0.5±0.1
mm
Lube pressure Mpa 0.25～0.5
3.3 Maintenance parameter of generator

3.3.1 Main parts maintenance detecting parameter of single-phase generator and generator set
Generator set model KDE11SS KDE13SS

Generator model KF11-4P KF13-4P
Frequency 50 60 50 60
When main winding is
0.445 0.353 0.353 0.254
23V：L1L2+R1R2
Each winding
Main winding of rotor 5.55 6.01
resistance measuring
U-V
condition of generator:
V-W
The ambient Rotor
W-U
temperature of is 20℃ winding of 1.54 1.54
Three
±2℃ exciter
groups are
The measured value
same
deviation on the right
Stator
form isΩ±10% F（+）
winding of 19.5 19.5
F（-）
exciter
The measuring
Sampling voltage V 115 115
conditions of resistance
voltage and current:
Exciter full field voltage V 32.1 30.1
Rated output voltage is
230V, frequency is
50Hz,rated power,
ambient temperature Exciter full field current A 1.31 1.01
20℃±2%, the deviation
is V±0.1%
3.3. Main parts maintenance detecting parameter of three-phase generator and generator set
Generator set model KDE13SS3 KDE15SS3
Generator model KF13-4P KF15-4P
Frequency 50 60 50 60
U-N（O） 0.964 0.674 0.685 0.537
Main
V-N（O） 0.964 0.674 0.685 0.537
winding
Each winding W-N（O） 0.964 0.674 0.685 0.537
resistance measuring Main winding of rotor 5.55 6.01
condition of generator: U-V
The ambient V-W
Rotor
temperature of is 20℃ W-U
±2℃ Three
exciter
The measured value groups are
deviation on the right the same
form isΩ±10% Stator
F（+）
F（-）
exciter
The measuring
Sampling voltage V 200 200
conditions of resistance
voltage and current:
Exciter full field voltageV 41.1 38.8
Rated output voltage is
230V, frequency is
50Hz, rated power,
ambient temperature Exciter full field current A 1.69 1.32
20℃±2%, the deviation
is V±0.1%
3.4 Principle diagram of electrical system
electrical schematic diagram

3.4.1 Single-phase univoltage output
3.4.2 Single-phase dual voltage simultaneous output
3.4.3 Three-phase voltage output
3.5 Tightening torque values
value Tightening
Thread specification Remark
Item torque（N·m ）
Cylinder cover bolt M10×1.25×98 80±5
Main bearing bolt M12×1.5×73 120±5
Connecting rod bolt M9×43 60±5
Flywheel bolt M10×1.25×32 70±5
Crankshaft pulley bolt M14×1.5×30 180±10
M6 8~12
M8 18~26
M10 45~60
M12 80~100
Other bolts: mechanical property
M14 130~150
is 8.8 grade
M16 180~210
JJ type
M18 240~270
bolt 7T
M20 350~400
M8 13~16
M10 20~28
Joint bolt M12 25~32
M14 38~45
M16 48~55
4. General explanation
4.1 Outlook and structure of generator set
1. Fuel inlet 10. Transportation hook
2. Fuel meter 11. Air vent
3. Check side door(one side of generator) 12. Exhaust vent
4. Check side door(one side of machine) 13. Cover of water tank
5. Drain cock of cooling water 14. Output panel
6. Drain cock of lubricant 15. Door of operation panel
7. Drain cock of fuel 16. Operation panel
8. Cover of fuel tank 17. Single-phase socket
9. Lifting hook
1. Controller 13. Lubricant filter
2. Fuel tank 14. Drain cock of lubricant
3. Fuel feed pump(only for fuel tank with machine) 15. Drain cock of fuel
4. Fuel filter 16. Engine
5. Air filter 17. Filter(Fuel/water separator)
6. Exhaust vent 18. Fuel feed pump(only for outside fuel tank)
7. Cover of water tank 19. Storage battery
8. Water tank 20. Operation panel(Instrument panel)
9. Fan belt 21. Single-phase socket
10.Exhaust muffle 22. Earth terminal
11.Auxiliary 23. Generator
12.Drain cock of cooling water 24. Output panel

4.2 Electric cabinet
NO Name Qty NO Name Qty

1 Door lock 1 18 Automatic voltage regulator 1
2 Instruments panel welding 1 19 Flange face bolt M5X20 7
3 Organic glass of instruments panel 1 20 Breaker 1
4 M6Nut M6 6 21 Electrical mounting plate welding 1
5 Filling pump select switch 1 22 Charging regulator 1
6 Intelligent display screen 1 23 Midget relay 3
7 Monitor location assembly 4 24 Flange face bolt M5×14 7
8 Power light 1 25 Preheating relay 1
Organic glass of instruments
9 Ignition switch 1 26 1
panel
10 Fuse box 1 27 Hinge(1)welding 4
11 Regulation resistance 1 28 Front wall assembly welding 1
1
12 Emergency stop button 1 29 Flange face bolt M6×12
4
5
13 Flange face bolt M6×12 30 Plug receptacle output panel 1
3
14 Hinge2.5 2 31 Flange face bolt M6×20 8
15 Panel welding 1 32 Output panel assembly 1
16 Digital control module 1 33 Junction box cover board 1
17 Flange face bolt M6X20 8 34 Front wall cover board 1
4.3 Diesel engine
Diesel multi-cylinder engine adopts KD388 engine of KIPOR and consists of three-cylinder, vertical
and four-stroke piston-rod, the burning type is direct injection, the lubricate system is pressure and
splash mixing; the diesel multi-cylinder engine uses forced circulation cooling system made up of
radiator and fan and pump, it has auxiliary functions of electric starter, air heater and charging
genertrix. The function of diesel engine is to convert heat produced by diesel oil consumption into
mechanical energy.
4.4 Brushless four–pole synchronous alternator

KIPOR company uses KF series synchronous brushless alternator with rotor exciting dynamo self-
excitation and stator sampling and sub winding, the alternator supplies exciting current to rotor main
winding by AVR self-excitation and control and adjust the generator output voltage. It makes the
generator voltage output smoothly. The function of the generator is to convert mechanical energy
output by generator into electric energy.
4.5 Fuel supply system of generator set
Generator set uses two-way electric pump fuel supply, one way is that generator own fuel tank passes
the electric pump fuel supply to fuel pump of engine, the other way is that outside oil tank automatically
supplies fuel to own fuel tank of generator set by electric pump fuel supply, which ensures unimpeded
flow of fuel supply. The generator set needn’t manual fueling.
4.6 Air dust cooled system and water cooled system of generator set structure
Generator set uses enclosed silent housing construction that makes radiant heat and running noise
produced by running engine reduce, it becomes the real silent generator set.
5. Handling instruction of electric control parts

5.1 Operation panel
It contains intelligent display controller, breaker, switch of fuel pump, starter, output voltage regulator,
emergency stop button and power supply indicator lamp.
The
intelligent
display is
made up of
display panel, module control panel, ATS control panel, only the display panel is on the operation
panel, module is installed in the machine cabinet. The ATS control panel is installed in the outside
control box of ATS, you can select to use or not. All the functions can be operated on the display
panel.
5.1.1 Fuel filler button
Use fuel pump to fill fuel into fuel tank with machine from outside fuel tank.
●If turn the fuel filler button showed in the drawing to AUTO, fuel pump starts filling fuel when fuel in
the fuel tank with machine is below lower level. Fuel pump stops filling fuel when fuel in the fuel tank
with machine is up to upper level. Please note that fuel pump does not work if fuel in the fuel tank with
machine is not below lower level, even though turn the fuel filler button in right drawing to AUTO. In
such case, turn the fuel filler button to MANUAL and release it if fuel fill-in is required. Machine stops
filling fuel automatically and return to the AUTO filling status as fuel tank is full.
Do not forget STOP operation of power supply switch of outside fuel tank
Warning
●If there is no outside fuel tank,

Turn the switch to STOP. If power supply switch of feed pump is at AUTO, feed pump starts working
when fuel in the fuel tank with machine is below lower level, leading to idle running and damage of
feed pump.
●If there is outside fuel tank,
Regularly check fuel level in the outside fuel tank.
If there is no fuel in the outside fuel tank and pump power-supply switch is at AUTO, fuel level in the
fuel tank with machine cannot be up to upper limit, which causes long-term idle running and damage of
feed pump.
5.1.2 Starter
Work start, running and stop.
Take out the start key and keep in the proper place if generator is not used.
Attention
●OFF
Indicate that start key is taken out and engine stops.
Intelligent indication lamps are all off.
●ON
Keep the position when machine works.
●START
Indicate start position of engine. In the case that starter is turned to this
position, machine is preheated and starts. If operator releases the start key, starter returns to ON
automatically.
●Pre-heating (HEAT)
Automatically start pre-heating upon start of intelligent panel controller. Operator can define
preheating time.
When intelligent display shows PRE-H, machine is preheated. After preheating, machine
automatically enters into start procedure. When intelligent display shows START, machine is running.
5.1.3 Breaker
To supply power produced by generator to main switch of 3-phase joint of output terminal block
Automatically cut off the switch when loading equipment is at short-circuit or over-load. Protect the
generator.
Do not operate loading equipment ON/OFF with the breaker. If user requires
ON/OFF function, add Load ON/ OFF switch between 3-phase joint and
loading equipment. Otherwise there are some errors of breaker.
Attention
●It is at OFF when engine starts. It is at ON when power is used.
●If there is over current, regulating handle of breaker maintains between ON

and OFF when breaker is cutoff. This condition is named tripping. By then turn
regulating handle downward to OFF. If regulating handle does not return to
original position, it is not allowed to turn regulating handle to ON.
5.1.4 Voltage regulator

It is used to regulate output voltage. If turn it right, voltage rises. If turn it left, voltage falls down.
●Voltage regulation range
5.1.5 Intelligent display controller

The intelligent display controller uses one-chip microprocessor to check and monitor the operating
conditions of engine, such as oil pressure, cooled temperature, and charging voltage parameter. The
engine running trouble will be displayed by code. And it can check and display the output frequency,
output voltage, output current(three-phase) or power (single-phase), running time, battery voltage. The
intelligent display controller controls the start and stop of generator set through one-single
microprocessor. When setting up ATS, it will monitor and judge the utility power, and realize the
conversion between utility power and generation power. The intelligent display controller can be used
absolutely to combine into common generator set, also be used for ATS generator set which
transforms between utility power and electric power generation.
5.1.5.1 Running electric parameter display function
(1) Indicate output voltage;

(2) Indicate output current;
(3) Indicate output frequency;
(4) Indicate running time;
(5) Indicate battery voltage;
(6) Indicate voltage of utility electric network (available just with ATS)
5.1.5.2 Warning indication & protection function

(1) Low and over voltage protection
(2) Low and over frequency protection
(3) Over current protection
(4) Engine oil pressure warning
(5) Overheat warning (special units)
(6) Charging motor fault warning
(7) Emergency stops warning indication
(8) AVR protection indication
5.1.5.3 Starting function

(1) Preheat start (special unit)
(2) Direct startup (common units)
5.1.5.4 The stop of the unit and troubleshooting function

5.1.5.5 Supply transfer function and ATS function
5.2 The operation of the display panel functions
5.2.1 Knob Function-setting Function
●While the control panel with ATS function, the system will supply two setting parameter to the user:
1. Push down the "Supply switch" and "Automatic/manual " for 2 second after starting the generator 10
s and under stand-by, it enters to user parameter functions;
2. Push down the "item" key to choose function-set item. These are 2 functions to choose for the
consumer:
(1)” Real time clock” setting;
(2)” Auto startup time” setting;
3. Push down the "phase sequence switch" key to affirm the parameter set.
4. Push down "start" key, "stop/clear" key and "supply transfer" key to set up and down parameter.
The details of the setting are as followed:
(1) Clock (hour, minute) setting:

(2) When the screen displays “SETT” (setup timer), push down “supply transfer” key to choose “hour”
and “minute”.
a. When choose to set “hour”, two last digital diodes start glittering at left. Push down “start” or
“stop/clear” to set “hour”. The clock will increase or decrease1h by pushing down “start” or “stop/clear”
key each time.
b. When choose to set “minute”, two last digital diodes start glittering at right. Push down “start” or
“stop/clear” to set “minute”. The Clock will increase or decrease1m by pushing down “start” or
“stop/clear” key each time. Then you should push down “phase sequence switch” to affirm what your
choose.
●Time parameter setting for auto startup of inspection machine (just for ATS):
After entering setting function, push down the “item” key.
When the screen displays “SEAST” (Setup automatic start time), push down “supply transfer” key to
choose “intervals of automatic inspection in day”, “startup time (hour, minute)” and “automatic running
time”.
a. When choose to set “intervals of automatic inspection in day”, the screen displays “DAYXX” (X
indicates value, DAY indicates interval of automatic inspection, XX=0 indicates automatic start time of
inspection is invalid). Push down “start” or “stop/clear” to set “intervals of automatic inspection in day.”
The one-day will be increased or decreased by pushing down “start” or “stop/clear” key each time.
b. When choose to set “startup time (hour, minute)”, the screen displays “XX=XX”. Push down “supply
transfer” key to choose “hour” and “minute”.
When choose to set “hour”, two last digital diodes start glittering at left. Push down “start” or
“stop/clear” to set “hour”. “The Start time” will increase or decrease1h by pushing down “start” or
“stop/clear” key each time.
When choose to set “minute”, two last digital diodes start glittering at right. Push down “start” or
“stop/clear” to set “minute”. “The Start time” will increase or decrease1m by pushing down “start” or
“stop/clear” key each time.
c. When choose to set “Automatic start running time”, the screen displays “rt XX” (X indicates value, rt
indicates automatic start running time). Push down “start” or “stop/clear” to set “automatic start running
time”. “The Automatic start running time” will increase or decrease1m by pushing down “start” or
“stop/clear” key each time. Then you should push down “phase sequence switch” to affirm what your
choose.
●Exit the setting function:

Pushing down the “Supply transfer” and “Auto/manual” key simultaneously for 2s, it will exist setting
function and return electrical parameter indication state.
5.2.2Running Indication Function

Push down the “item” key to choose the display parameter.
1. Display output voltage
When output voltage indicating lamp lights, digital diode displays: (unit: V)
“XXXX.X” Single-phase output indication
Dual-phases (any phase) output indication
“AXXX．X” Display output voltage of phase A
“BXXX．X” Display output voltage of phase B Dual phase output simultaneously
“CXXX．X” Display output voltage of phase C
“AXXX．X” Display output voltage of phase A

“BXXX．X” Display output voltage of phase B
“CXXX．X” Display output voltage of phase C Three-phase output voltage display
“ABXXX” Display voltage of wire AB
“BCXXX” Display voltage of wire BC
“CAXXX” Display voltage of wire CA
It can switch to display the different phase voltage and line voltage by pushing down the “phase
sequence switch” key.
2. Display output current or output apparent power
The digital diode indication information is as followed, when indicating lamp is got on. (Unit: A or VA)
“XXXXX” Single-phase output current display. VA
“XXXXX” 　 Dual-phase output current display. VA
“XXXXX” Display dual-phase output current display at the same time
“AXXX．X”
“BXXX．X” Three-phase output phase current display.
“CXXX．X”
It can switch to display the different phase current by pushing down the “phase sequence switch” key,
when it is in the state of displaying output current.
3.The output frequency display
The digital diode displays “XX.XX” (Hz), when output frequency indicating lamp lights.
4. The running time display
The digital diode displays “XXXX.X” (hours), when running indicating lamp lights.
For example: 0.1 hour means 6 minutes. It will log the running time every 6 minutes.
5. The battery voltage display
The digital diode displays “XXX.X” (V), when battery voltage indicating lamp lights.
6. Voltage of power network display
a. If insert ATS control panel as machine is energized, then ATS function is available. If voltage of
power network is normal, indication light of normal voltage will be on and digital diode displays
“XXX.X” (V). If voltage of power network is abnormal, indication light will be glittering and digital diode
displays “XXX.X” (V).
b. If ATS control panel is not been inserted, ATS function is valid and voltage of power network does
not display.
5.2.3Starting Function
1. Push down the “start” key or turn on “electric door lock” directly to start the unit when there is no
fault of the unit. The preheat time is varied from the ambient temperature. It will connect the starter
motor automatically after preheating successfully.
2. When the unit is in warning state, you should push down the “stop/clear” key to eliminate the fault
before starting the unit.
Note: If voltage of power network is normal and push down “start” key, machine cannot start provided
that ATS is effective and under Auto. Then choose “manual” or “semi-auto” to set ATS working
condition to start machine.
3. If digital diode displays “Pre-H”, it means that machine is under preheating as to start preheating. If
digital diode displays “Start”, it means that starter motor has been connected as to connect starter
motor.
5.2.4Stop Function
1. When unit is starting or preheated, you can push down the “stop/clear” key to stop the unit.
2. When the unit is running or starting, you can push down the “stop/clear” key to stop the unit.
3. Delay stopping unit in relation with “delay stop for protection functions” when unit enters into
“warning protection”. Push down “stop/clear” key to stop unit if unit enters into protected stop delay.
4. To unit with ATS, unit delays stop according to normal delay setting when ATS' power supply
transfers from generator to power network.
5. To unit with ATS, running unit automatically stops with respect to inspection running time setting
when ATS is at working condition of automatic inspection unit.
5.2.5Troubleshooting and Clear Function

When there is some fault of the unit, the corresponding warning indicating lamp will light.
Push down the “Item” key to observe the information of the electrical parameter when the unit stops for
the fault.
Push down the “stop/clear” key to clear the fault state, making unit stay at the pre-start state and fault
warning light off.
5.2.6Fault Warning and Protection Function

1. Engine oil pressure is not enough:
When the unit detects that the engine oil pressure isn't enough lasting for 5s, the unit will stop and
start stop protection after 1s delay. The low oil pressure-indicating lamp will glitter. Digital diode
displays fault code “P-01”, warning lower engine oil pressure.
2.Over-heat warning:
When the unit detects overheat signal, fault indicating lamp will glitter. Digital diode displays “P-08”,
meaning too hot water in unit. The unit will stop and start stop protection after 10s delay after
mentioned indications last for 10s.
3. Charging motor fault warning:
When the unit detects fault signal of the charging motor, fault indicating lamp will glitter. Digital diode
displays “P-07”, meaning unit-charging fault. There is no protection for charging fault.
4. Over/low voltage protection warning
(1). If the output frequency is set as 50Hz but it is over 55Hz, over/low protection indicating lamp will
glitter and digital diode displays “P-02” warning over/ low frequency for 3 seconds later with the unit
stops.
(2). If the output frequency is set as 60Hz but it is over 65Hz, over/low protection indicating lamp will
glitter and digital diode displays “P-02” warning over/ low frequency for 3 seconds later with the unit
stops.
(3). If output voltage is 110% set voltage, fault indicating lamp will glitter and digital diode displays “P-
03” warning overpressure for 3s later with the unit stops and over/low protection light will be on.
5. Overload protection
(1).When the single-phase current, delivered by the dual-phase circuit simultaneously, is 100%～110%
of the set current the fault indicating lamp will glitter and digital diode displays “P-04” warning overload.
Then large unit will cut off the air switch but not enter into stop protection, while small unit will enter
into stop protection an hour later.
When single-phase current is over 110% of the set current, the fault indicating lamp will glitter and
digital diode displays “P-04” warning overload. Then large unit will cut off the air switch but not enter
into stop protection 60 second later, while small unit will enter into stop protection.
(2) Three-phase unit:
When the current of any phase reaches the 100 ～ 110% of the set current, fault indicating lamp will
glitter and digital diode displays “P-04” warning overload. Large unit will cut off air switch but not enter
into stop protection 1hour later. When the current of any phase is over the 110% of the set current,
fault indicating lamp glittering and digital diode displays “P-04” warning overload for 60s, large unit will
cut off air switch but not enter into stop protection, while small unit will enter into stop protection.
(3). Dual-phase selectively output unit:
When to choose “230V” or “240V” for output voltage, fault-indicating lamp will glitter and digital diode
displays “P-04” warning overload provided that unit current reaches the 100%-110% of set current.
Large unit will cut off air switch but not enter into stop protection 1hour later, while small unit will enter
into stop protection. When the current is over the 110% of the set current, fault indicating lamp
glittering and digital diode displays “P-04” warning overload for 60s, large unit will cut off air switch but
not enter into stop protection, while small unit will enter into stop protection.
When to choose 115V or 120V for output voltage, fault-indicating lamp will glitter and digital diode
displays “P-04” warning overload provided that unit current reaches the 200%-220% of set current.
Large unit will cut off air switch but not enter into stop protection 1hour later, while small unit will enter
into stop protection. When the current is over the 220% of the set current, fault indicating lamp
glittering and digital diode displays “P-04” warning overload for 60s, large unit will cut off air switch but
not enter into stop protection, while small unit will enter into stop protection.
(4) Dual output-voltage simultaneity unit:

Error indicating light glitters when unit current reaches to 100%-110% setting current under voltage of
230V or 240V. And digital diode shows P-04, indicating overload alarming. One hour later, large unit
shuts down without stop protection while small unit with stop protection, while small unit will enter into
stop protection. Error indicating light glitters when unit current is over 110% setting current. And digital
diode shows P-04, indicating overload alarming. 60 seconds later, large unit shuts down without stop
protection while small unit with stop protection, while small unit will enter into stop protection.
Error indicating light glitters when unit current reaches to 100%-110% setting current under output
voltage of 115V or 120V. And digital diode shows P-04, indicating overload alarming. One hour later,
large unit shuts down without stop protection while small unit with stop protection. Error indicating light
glitters when unit current is over 110% setting current. And digital diode shows P-04, indicating
overload alarming. 60 seconds later, large unit shuts down without stop protection while small unit with
stop protection.
6. Start fault warning：
If the unit doesn't start successfully in 8 second after the unit is connected to starter motor, it will cut off
the starter motor relay automatically and digital diode displays P-05 warning start fault.
7. Emergency stop indication:
If the unit detects the signal of the emergency stop continuously, emergency stop indicating lamp will
glitter and digital diode displays P-06 meaning unit emergency stop 0.3 seconds later. If unit is on
condition of running, unit will stop and will not be able to start only if emergency stop keeps effective.
5.2.7 Supply Transfer Function, ATS function and Automatic Start Inspection Function
1. Identification of ATS control panel connection
Effective identification of ATS function is available when to connect ATS control panel with plug on
digital panel.
a. Light indicating lamp to set working conditions by system when unit starts and identifies connection
with ATS control panel. And indicating lamp of network power will be on, meaning effective ATS
function.
b. Black out indicating lamps for automatic, manual, network power and unit power when unit does not
identify connection with ATS control panel, meaning invalid ATS function.
2. Supply transfer function
a. Supply transfer function will be invalid in accompany with invalid ATS function.
b. Push down “supply transfer” key to change supply between network and unit when effective ATS
works at “manual” or “semi-automatic” condition. Indicating lamp for network power will light on when
power is supplied by power network. Indicating lamp for unit power will light on when power is supplied
by unit itself.
c. When ATS is operative in Auto state; “Power Switch” key is not available.
3. ATS working state option
a. In case that ATS loses its function, ATS working state option and its switch are all invalid.
b. When ATS is operative, push down “Manual/Auto” key to change its working state. When ATS
operates in Auto state, the auto indicating light is on. Likewise, the manual indicating light is on when
ATS operates in Manual state. While ATS operates in Semi-auto state, both indicating lights are on.
c. In any cases, push down “Stop/clear” key to convert ATS into “Manual” state.
4. Automatic transfer switch
a. When ATS is operative as well as in “Network Power” state, the system checks voltage every one
second. Once continuously for 3 seconds check the voltage exceeding ±10% of pre-set voltage, it
indicates abnormal voltage and lights the indicating light as well. Unit is then started and the system
makes time delayed according to pre-set power switch and checks voltage and frequency of unit.
Once voltage of unit reaches up to ±5% of pre-set voltage and frequency recovers, the unit is allowed
to be connected to power supply with indicating light of Unit Power Supply on, while the indicating light
of Network Power is off.
b. When ATS is operative as well as in “Unit Power Supply” state, the system checks voltage every
one second. Once continuously for 6 seconds check the voltage exceeding ±10% of pre-set voltage, it
indicates normal voltage and stop the indicating light as well. The system makes time delayed
according to pre-set power switch and converts to electric network supply. Indicating light of Electric
Network Supply is on and time-delayed stopping procedure is started.
5. Self-start check
When ATS is operative, comparing reading of current time with self-start check time, which matches
and the unit is self-started.
a. Provided that the unit starts successfully, it operates for some time with pre-set self-start check on.
Once all checked states are normal, the unit stops.
b. Provided that the unit cannot start, it delays for a while and restarts. In case that the unit cannot
start for 3 times, it gives off fault alarming and the self-start check is failed as well.
5.2.8 Cycling Display Setup For Various Electric Parameters

1. Push down “Start” key to enter into display of various electric parameters as unit is running.
2. Push down “Start” key to exist display of various electric parameters as unit is displaying
parameters.
Kinds of code list ：P-01 oil pressure alarm
P-02 over/low frequency alarm
P-03 over/low voltage alarm
P-04 unit overload alarm
P-05 starting trouble alarm
P-06 emergency stop alarm
P-07 charging faulty alarm
P-08 unit overheat alarm
PRE-H unit preheating indication
5.3 The connection of ATS and generator set

5.4 Connection of load
5.4.1 Capacity of motor
If select the motor with improper capacity, it is impossible to start the motor.
Decide the capacity of motor as per followings:
●According to type, application, start method, quantity and operating power of motor, features of
generator, type of auto voltage regulator, starting capacity of generator is different.
Upon starting motor, its current is 5-8times of rated current. Its rapid rise of starting current causes
instant overload of generator. Then voltage of generator falls down rapidly. Therefore sometimes it is
difficult to start the motor.
It is recommended to discuss with manufacturer of motor upon decision of capacity. User can
calculate the capacity simply with below formulas.
1)Input power of squirrel-cage asynchronous motor (kVA)
Rated power of motor (kW)
Input power (kVA)= 　　　　　　　　　　　　　　　　　　　　　　　
Motor efficiency x Power factor
Power factor of motor: 0.8 Motor efficiency: 0.8

Input power (kVA)=1.56x rated power of motor (kW)
2)Direct-starting squirrel-cage asynchronous motor (with knife switch)
Generator capacity = 2x input power of motor
3)Direct-starting squirrel-cage motor (with contactor)
Generator capacity = 3x input power of motor
4)Star/ triangular-starting squirrel-cage motor
Generator capacity = 1.2~1.5x input power of motor
●It is required to balance the load if more than one AC electric welder is used.
Therefore user shall distribute phases equally as per following:
The input power of one electric welder should be adjusted below 1/3 of generator’s output. If it is
overload, the generator is possibly to be burnt out.
5.4.2 Selection of 3-phase cable
Please select the cable with proper diameter after taking into account tolerable current of cable and
distance from generator to loading equipments.
If load current exceeds tolerable current, lead is burnt to damage due to over-heat. In addition,
following conditions also can cause lead damage such as too long cable, super-small diameter,
excessively large voltage-drop of lead, reduction of input voltage of loading equipments, or reduction
of efficiency of loading equipments.
5.4.3 Connection of loading equipment
Please notice the following safe matters for security, otherwise it will cause
death.
Danger
●Touching output terminal of running machine may cause electric shock even death risk, particularly
when hands are wet.
●Start connection work after cut off breaker and stop running machine.
●Application of damaged cable may cause electric shock. Forbid using such cable.
●Laws forbid connecting power supply of generator with inside distributing line (common distributing
line accepting power from the power company).
●If connection with inside distributing line, there is over-current of inside distributing line and generator
thus to cause fire or electric shock accident.
●Please do not connect the machine with inside distributing line.
5.4.4 3-phase power supply
●Connect cable with 3-phase joint of output terminal block.
● If 3-phase motor rotates in the reverse direction, please exchange any two lines of three terminals.
U
V M
W
N
5.4.5 Single-phase power supply (120V/240V)

There are two connection methods for single-phase power supply, i.e. single-phase socket and 3-
phase joint as indicated in the below drawing.
Please select proper connection method.
Socket and breaker are two 15A circuits (W-phase use). 3-phase joint combines N-phase with U, V
and W-phase. Regulate the voltage with voltage regulator.
Tolerable current of generator takes single-phase and 3-phase into account. If select single-phase
output, output of single-phase is only 1/3 of 3-phase output (unit: KW).If use single-phase and 3-phase
at the same time, please limit output of each phase below 1/3 rated power (unit: kw).
●Check AC current instrument on the operation panel is up to or over rated current.
●As use N terminal with U, V and W terminals, in order to keep phase balance, please equally use
output of generator, i.e. 1/3 rated power. If unbalance load is necessary, difference between 3-phase
shall be within 20%.
●For single-phase socket or VN, WN. Prevent overload of generator.
●For single-phase socket
Turn the single-phase breaker to ON to energize socket.
●There are two single-phase sockets (below 15A) on the panel.
●Prevent overload of generator if single-phase power is used via single-phase socket or VN, WN.
5.4.6 Connect loading equipment

●Add Load ON/ OFF switch between wiring terminal of generator and loading equipments.
If breaker of generator is also used as load switch of loading equipments, error is possible for breaker
due to frequent start and stop.
●Turn the breaker at side of generator to OFF upon connecting cable. And connect the cable when
engine stops for safety concern.
●Do not connect cable with joints at other phases.
●Close cover of output terminal block and screw down holding screws upon finish of cable connection.
●Using load with other generators may cause error of generators.
5.4.7 Low-load operation
Prevent low-load operation for long term.
●Long-term operation is allowed when load exceeds 1/4.
●Operation period shall be no longer than 5hours if load is within the scope of 1/8-1/4.
If run the machine at low-load, carbon collects on the engine and exhaust pipe. Engine works badly.
5.4.8Earth
Provide reliable earth to generator and loading equipments.
If no reliable earth, electrical leakage may flow through human body and cause
serious injury.
Danger
　　
Decide diameter of earth line as per technical specifications of electrical facilities. Select the size with
proper load capacity. Please use earth pole in compliance with following earth resistance.
●Earth resistance of loading equipment shall be below 500Ω.
● Information of common earth
Implement earth of outside box and loading equipments independently. However common earth is
acceptable if independent earth is difficult on site.
1） Select the maximum value for diameter of common earth cable in accordance with respective
requirements.
2） Select the minimum value for earth resistance of common earth cable in accordance with
respective requirements.
3） Reliably screw down terminals.
● Handling attentions for earth project
1）Earth pole shall be placed in the shady and wet place. Upper part shall be in the soil.
2）If earth pole is placed in the place where there is a lot of passerby, please carefully fix it to avoid
blocking passerby.
3）Connect lead extension as following
Weld lead extension or use proper sleeve. Meanwhile cover connection part with insulation tape. In
addition, connection part shall on the ground.
4）Do not place the earth pole of the machine within 2m away from earth for lightening rod.
5）Not allow using the same earth line with telephone.
6）Not allow using the same earth line with others.
6. Daily and periodic check

Due to the bad condition and extension work time, the capability of the engine will become worsen.
Such as: increase the consumption of the fuel and oil, and increase the harmful matter of the exhaust,
increase the vibration and noise, and then shorten the life of the engine. Reinforce the maintenance,
daily and periodic check, you can keep the unit’s efficiency and prevent the fault.
Check
Daily check and periodic check
Daily check: You should do the daily check before starting the engine every day, and perform it as a
regulation.
Periodic check: Advise you make a running diary, note every day’s running and checking result, add
up the unit’s work time, make periodic check and maintenance according to the following table.
System Check Start 50h 250h 500h 1000h 2000h
check
Check and fill fuel level in the fuel
○
tank
Fuel leakage check ○
Fuel Drain off water from fuel tank or oil
○
water separator
Replace filter element of fuel ◎
Washing of filter ○
Check and fill lubricant level ○
Lubricant leakage check ○
Lubricant Replace lubricant ◎After
◎First
first
Replace filter element of lubricant time
time
Check and fill cooling water ○
Clean the element of radiator ○
Replace cooling water ◎
Cooling Clean and repair cooling-water
●
water system
Water leakage check ○
○First
Cooling fan belt check ○
time
Rubber Replace fuel pipe and cooling water
○ ◎
pipe pipe
Operation Speed regulator operation ○
system Idle speed adjustment ●
Air intake
Clean and replace air filter element ○Clean ◎
system
Check alarm system ○
Electrical Check electrolyte fluid level and
○
equipmen battery charge
t Check working conditions of
○ ●
instruments and fuse
○Afte
Adjustment of inlet/exhaust valve ○First
Cylinder r first
clearance time
cover time
Wearing of inlet/exhaust seal ring ●
Check and adjustment of injection
Fuel ○
pressure
injector
Check and adjustment of injection
and ○
timing
injection
Repair fuel injector and injection
pump ●
pump
Confirm movements of breaker and
○ ●
digital panel executive components
Generator Check protective earth ○ ●
Check if panel and terminals are
○ ●
loose
Measure insulation resistance or
○ ●
withstand voltage
Check if circuit connections and
cable surface insulation are friction ○ ○
or scuffing
Check if any screw or nut is loose ○
2
years
Check if all rubber hoses and materials of vent-
○ ○ ● or
pipe are distortion
every
400h
Check the air dust ports of each machine cabinet
○ ○ ●
and anti-vibration and sound-proof material
Periodic check is divided into several intervals like 50hours, 250hours, 500hours, 1000hours and
2000hours.
The time interval of the periodic check can ahead or delay according to engine’s use, loading
conditions, quality of fuel and lubricant and other conditions. See table
○：Check　　　◎：Replace 　　　●： Consulting agent or dealer
6.1 Periodic checking routine

6.1.1 The first 50 running hours:
Because the engine just start running, the inside running parts abrasion each other, the lubricant will
be polluted soon. You should replace the lubricant and oil filter element. It is easier and quicker to
drain the lubricant, when the engine is still hot.
When drain the hot oil, be care of scalded. Do not make the hot oil splash to
you. Make sure the screw is tightened, if not, it will result in severe accident.
Warning
Drain the lubricant: Prepare a pot to keep the oil; Loose the screw with a spanner, start to drain the
oil; After drain out the oil, be sure to tighten the screw
2）Replace the oil filter element: Screw off the filter element wider shins with a
spanner; Clean the filter seat; Install a new element, wipe a thin flat of lubricant
in the sealed gasket, tighten it by clockwise, then use the spanner to screw
down 3/4 circle. (tighten torque 20～23N·m)
Replace the oil filter element
3）Add new oil about 6.9L
Running the engine about 5 minutes to preheat the unit, and check the leakage. After stopping the
running 10minutes, and then check the oil level of the oil bottom cover, and supply to the upper limit.
After the first maintenance, you should replace the engine oil and filter element every 250 hours.
6.1.2 Check for every 50hours

1）Drain out the fuel tank empty: Prepare a basin to keep the oil; Screw down the plug, drain out the
water and dirt empty; Fit on the plug and tighten it, check oil leakage.
2）Check the battery:
When check the electrical system, please break off the cathode grounding lead, short circuit will
produce fire, it may cause fire disaster;
Be sure to provide adequate ventilation, it will produce hydrogen gas during charging, the hydrogen
gas will be burned by any fire source;
Check the level of the electrolyte, if the level close to the lower limit, supply oil to the upper limit. if the
electrolyte is over low, it will shorten the service life of the battery, even explode if the temperature is
too high, the oil level decline quickly in summer, and you should check and supply the distilled water
frequently;
When start the engine, if the crankshaft speed is lower than normal, and the starting is failed, recharge
the battery. If it still fails, you should replace the battery.
3）Check the air cleaner: Air cleaner element is easy to be polluted by the dust, oil mist, steam. It will
increase the enter resistance, and the air will decrease, the engine will produce smoke. You should
clean and check frequently, even replace it. When the engine work in the dusty place(stone pit, coal
field, building field), even clean the element more frequently,
clean out the impurity. Take out the element from the air cleaner
shell, blow the inside with the compress air, and blow out the
dust. If the paper element is damaged, please change it. Clean
the grease in the air cleaner shell, cover the intake with cloth,
prevent the rubbish drop into the intake pipe.
Clear the air filter
4) Install the air cleaner, keep the element and rubber tube sealed, avoid air enter into the cylinder not
through the cleaner element.
5）Drainage and cleaning of water oil separator, drain depositional water and rubbish in the filter.
① Open check side door, put oil holder below the drain port of filter of water
oil separator.
②Loose drain plug, let out depositional water and rubbish in the filter.
③If you can not drain of the intermixing water, please loose exhaust plug.
④Please exhaust air after water drainage.
⑤Please close check side door.

1）Change the lubricant and oil filter element, replace it every 250hours from the second time.
2) Check and clean the radiator chip:
The dust and dirt adhered to the radiator chip will
reduce the cooling capability, make the engine over
hot, according to the situation, you can clean it
ahead, even clean it every day;
Blow out the dirt and dust with 196kPa （ 2kgf/cm 2
） or less pressure compressed air, if it is still dirty,
you should use cleanser and water to wash
thoroughly;
Before using the compressed air, please wear the
protection glass to protect your eyes. Prevent the
dust or float pieces hurt your eyes;
Do not use the high-pressure tap and high-pressure air to wash Clear the radiator
by force, do not use the brush to scrub, or the radiator chip will be element
damaged.
3 ） Replace the air cleaner element: The damaged air cleaner element will make the air into the
cylinder not through the air cleaner element, it will damage the valve, cylinder, piston, piston ring
quickly.
If the element is plastered with dust, it will be hard to start the engine, the power will drop, and there
will be black smoke. Replace the element terminally, and clean the shell, it’s benefit to the engine.
1）Replace the fuel filter: Replace the diesel filter element terminally, before it choked by the grease.
①　Turn off the switch of the fuel tank, disassemble the oil pipe, take off the element, then clean the oil
filter seat
② Replace a new diesel element, install the fuel filter, pay attention to the sealed terminal cover of the
filter element, prevent the un-filtration fuel enter into the fuel injection pump.
③ Install in and out fuel pipe, turn on the switch of the fuel tank, advert drain out the air empty.
Otherwise the diesel engine will be hard to start or stop running after starting.
2）Replace the cooling water: After the cooling water is not hot, drain it, avoid the splash hot water
scalding people.
① If the cooling water or cooling liquid contain the rust and scale, the cooling effection will be
depressed.
② The cooling water should be replaced once a year at least. Drain the cooling water, and then add
cleanly soft water.
3）Check and adjust the valve clearance:
Make sure the valve is closed before adjusting the gap, there will be clearance.
Note: The 1-cylinder, 2-cylinder, 3-cylinder of engine is marked from flywheel end to gear room,
which is different from the general method. There are top dead center reticules of each cylinder, you
can look at it from dead center view port （φ30）of flywheel cover, the top dead center reticule of 1-
cylinder is marked on the belt wheel.
1 Single cylinder method of adjusting valve clearance
a) Make sure the first cylinder piston locate in compression top dead center, then you can adjust the
clearance between the intake and exhaust valve (0.1～0.15)mm of 1-cylinder
b) Turn the flywheel about 240°by counterclockwise, and then adjust clearance between the intake
and exhaust valve of 3-cylinder
c) Turn the flywheel about 240°by counterclockwise, last adjust clearance between the intake and
exhaust valve of 2-cylinder
Note: After all above, make sure put the adjusting bolt cap together tight, or it will become loose, result
in the unit can not work normally.
2 Valve clearance adjustment at twice method:
a) Put the 1-cylinder piston on compression top dead center, you can adjust the following clearance,
see table 6
Table 6 Valve clearance adjustment at first time
Cylinder order 1-cylinder 2-cylinder 3-cylinder
Adjustable valve Intake Exhaust Intake ○ ○ ○
b) Rotate the flywheel about 240°by counterclockwise(rotary direction of the engine), make the piston
of 3-cylinder locate in compression top dead center, then adjust the other valve gap which is not
adjusted, see table 7.
Table 7 Valve clearance adjustment at second time
Cylinder order 1-cylinder 2-cylinder 3-cylinder
Adjustable valve ○ ○ ○ Exhaust Intake Exhaust
4）Check and adjust the injector: Check and adjust the injection pressure and quality of the spray on
the test-bed.
If the injection pressure is incorrectly, you can screw down the injector shell, replace the different
thickness adjusting gasket, make the pressure reach the right value. （20±0.5）MPa。
Check injector
Replace and adjust gasket
The injection pressure is right, but the quality of the spray is bad. You can clean the injector orifice or
replace the injector element.
③ 　 Put the injector into the cylinder cover, the gasket should be original, to make sure the unit’s
extended distance (2.2 ～ 2.3)mm. If the warp of the extended distance is too large, the power, fuel
consume, exhaust smoke of the diesel engine, will be affected greatly.

1）Check and adjust of injection advance angle(The adjust need special tool, special knowledge and
skill, you should ask a respected professional person do it. )
①Concrete steps (PL plunger pump)
a ） Loose the two-end nut of 1-cylinder high pressure oil pipe, take off the high pressure oil pipe,
mount the tube union of the side oil supply advance angle , swing the flywheel repeatedly around the
compression top dead center 90°range, until the diesel oil spreads out from tube union .
b）Withdraw flywheel to the top dead center about60°, then turn the flywheel anticlockwise (or turn
the crankshaft belt wheel clockwise with sleeve and torque spanner), stare oil face wave of tube
union, once oil face wave, stop it immediately.
c）Check the flywheel upper scale mark, the scale in front of the top dead center 16°±1°is on the
sight hole centerline of top dead center of flywheel cover. Please adjust the advance angle of oil
supply, if there is extraordinary disparity, the methods as following:
d ） Loose the ６ -M8×16 bolt of the tight small circle cover board on gear room cover, take off the
small circle cover board.
e ） Relax the ４ -M8×20 bolt of tighten oil supply gear (Don’t take it off, if only there is relative
movement between the oil supply gear and contact flange of oil pump).
f) Turn the camshaft of injection pump with sleeve and connecting rod as crankshaft rotation direction
(clockwise), the director angle of oil supply will increase, otherwise, reduce.
g)Screw up the oil supply gear after adjusting; Put back the small circle cover board and screw it.
②　Concrete steps (VE injection pump)
a）Remove all high-pressure oil pipes and boil cap, install a micrometer
in the hole of bolt cap. Press the meter into 2mm. See right fig.
b ） Turn the crankshaft to put the 1-cylinder piston in front of the top
dead center about 30° ～ 40°, adjust the micrometer to zero. Wave the
belt wheel, and check the reading of the micrometer. See right fig.
c ） Turn the crankshaft as crankshaft rotation direction: as clockwise
rotation the belt wheel, and align the oil supply scale mark （ 16° ） on
belt wheel with ▼(top dead center)on gear room cover. See
right fig. The reading of the micrometer is 0.5mm. If not, the oil
supply timing is wrong, need adjust it.
The adjust method is:
Loose the three fixing nut of injection pump and the fixing bolt
of injection pump bracket, adjust the injection timing by
changing the angle of injection pump installation. See right fig.
d）If the reading is greater than 0.5mm, pull the oil pump shell
upside(away from engine). Reduce the reading to the standard
value; if the reading is smaller than 0.5mm, push the oil pump
shell upside(near engine). Increase the reading to standard
value.
e） Screw up the fixing nut of injection pump and fixing bolt of
injection pump bracket after adjusting.
f） Remove the micrometer, install bolt cover.
g） Install high pressure oil pipe of 3 or 4 cylinder in turn.
2）Clean the scale and iron rust of cooling system

There will be much iron rust and scale in the radiator after
running 1000hours; it will make the cooling water deterioration, reduce the radiating effection, rise the
cooling water temperature. You should clean it at this time. The work need special knowledge and skill,
you should ask a respected professional person do it.
6.1.6 Check after running 2000hours
1）Check and replace fuel, lubricating oil, cooling water, rubber hose.
Check rubber hose at time, if it is broken
2）Check and lap the seal band of inlet and exhaust valve .
The work need special knowledge and skill, you should ask a respected professional person do it.
Check the sealability of valve, the subquality product of the valve, the width of seal band and the
clearance between the valve stem and valve guide.
3）Check the performance of the injection pump.
The job needs oil pump test bed adjusted by professional staff. Check oil supply quality of rated spot,
the starting-up oil mass, the uniformity of each cylinder, the flexibility of each part of speed regulator,
the highest and lowest rotation speed limit and so on.
7. The indication of running and operation

7.1 Fuel· Lubricating oil· Cooling water
7.1.1 Fuel
● Please use the right light diesel to the engine performance. If not, the engine performance can’t be
exerting, or the parts may produce fault.
The ambient temperature is the standard; choose the fuel base on the following
condition.
Standard Choosing method
GB 252-1994 Light diesel, summer 0#, winter -10#, -20#
JISK2204 2#（Above -5℃），3#（Above-25℃）
● The usage of fuel

Please keep the fuel away from the rain and rubbish.
(1) If there is water or rubbish in the fuel, the engine can’t run well. Please use the clean container to
keep the fuel.
(2 ）If there is water or rubbish in the fuel, don’t move the container, put it for several hours silently,
deposit the water and rubbish to the bottom, suck the clean fuel through the pump.
7.1.2 Lubricating oil

●The choice of the lubricating oil
Use the best oil (CD grade) 10W-30, 15W-40
● The use of the lubricating oil

1）While keeping and using the lubricating oil, don’t let the rubbish and dust into the oil. While adding
the oil, please clean the small dust round the oil filling oil.
2）Don’t use the different kinds mixing lubricating oil, avoid reducing the lubricating performance.
7.1.3 Cooling water
●The daily manage of the engine cooling water is very important.
You must use clean soft water (tap water) for cooling water.
● While using the cooling water, you must add the antifreeze with antirust function. The cooling water
will freeze in the cold winter, will frost crack the parts of the cooling water system. Besides, the clean
water can rust easily; it may result in bad cooling. As though, using in the warm area, it can avoid
rusting.
● If there is little antifreeze, while the temperature falls down, will destroy the cooling or rusting.
If there is too much antifreeze, the cooling status will not be good.
Antifreeze
1 ） The antifreeze have the anti-rust function, you needn’t add antirusting agent. Besides, the
antifreeze can use for one year. The mixing ratio is between 30% and 50%.
The lowest
Below -15 -20 -25
temperature ℃
The mixing ratio % 30 35 40
2 ） You should choose the antifreeze with anti-rust function. Please follow the mixing ratio of the
manufacture. Please change it by one year.
7.2
The operation of the battery
Because the battery may produce the explosion hazard gas, It may bring
explosion or injury.
Warning
●Charging in the ventilated place. Or there will be the danger of the combustion and explosion.
● No smoking, spark or other fire while charging.
● While connecting the battery cable, don’t contact the “+” end with “-” end.
● Don’t connect wrong, produce the spark, it may have flammable air, result in explosion.
There is weak sulphuric acid in the electrolyte. If operation is wrong, you may
have bad injury.
Danger
● While the cloth or skin is wet by electrolyte, please clean it with plenty of water. If the electrolyte
goes into the eyes, clean the eyes with water at once or take care of the doctor.
7.2.1The attention of battery charging

●While charging the battery.
1) Take down the wire of the battery, and charging.
2）Take down all bolts while charging.
3）First take down the grounding wire and then remove the wire of the battery end.
（ If there is other tools between (+) end and the generator, it may result electric spark, so it is
danger.）While install the wire of the battery end, connect the grounding wire at last.
4）Scavenging fully while charging.
It will produce flammable air while charging, it may result in explosion, so don’t approach the spark.
5）While the battery is too hot ( over 45℃）, stop for a while, and then charging.
6）After charging fully, you should stop charging at once.
There will be some defect, if charging again after charging fully.
①The battery is too hot.
②The quantity of the electrolyte reduces.
③The battery is abnormal.
7 ） While connecting the battery wire, please connect the “+” wire, and then connect the “-”wire.
Connecting the wire in reverse will damage the generator, please take attention.
7.3 Preparations before starting

7.3.1 Fill fuel
Fill the proper fuel. Improper fuel may lead to risk of fire. Please confirm the
type of fuel in advance. Clean any overflowed fuel.
Danger
● Fuel tank is provided with lock. Open the lock and take off the cover of fuel tank. Fill clean and
clear fuel without water and foreign matters into fuel tank.
● In order to prevent any overflow when machine is running, fill-in amount shall be approximately
90% of tank volume.
Volume of fuel tank: 65L
7.3.2 Keynotes for filling fuel with outside fuel tank
Ensure tight connection of fuel pipe with fuel inlet of outside fuel tank. Any
loose connection leads to fuel spill. Idle running of fuel feed pump causes
damage. Please pay more attention to fuel level in the outside fuel tank. Try
best to avoid idle running.
Danger
●Location of outside fuel tank
Place the outside fuel tank within 5m away from generator.
In addition, foundation height for outside fuel tank must be within 0-5m.
●Recommended fuel
Light diesel oil
●Keynotes for piping

●Filling fuel operation
1 ） Open the maintenance door of generator, turn the oil filler button to AUTO (the switch is
downward) .
2）Check the fuel content in the outer fuel tank.
3）If the fuel of own fuel tank of generator is below the lower limit, the fuel pump starts working and
supplying fuel.
4 ） If the fuel of own fuel tank of generator reaches to upper limit, stop running fuel pump and
supplying fuel.
5）When using the outer fuel tank or stopping filling fuel, please turn fuel filler button to STOP.
7.3.3 Fill lubricant
Keep lubricant level between upper and lower scale marks. Lubricant level
shall not exceed the upper mark. Ejection of lubricant from the breather hole
may cause engine errors.
Attention
1）Keep engine level upon lubricant fill-in.
2）Take off the yellow cover of lubricant inlet on the top of gear chamber. Add recommended diesel oil
up to the upper mark of oil gauge.
3 ） Measure the lubricant with oil gauge. In order to get correct level, please clean the oil gauge
before inserting it into lubricant. Lubricant trace remained on the oil gauge indicates measurement.
Re-confirm it after 3-5min running.
Volume of lubricant:
7.3.4 Fill cooling water
Screw the cover of radiator water inlet tightly.

Otherwise, ejected steam or hot water may cause scalding.
Warning
● Add cooling water as per following procedures. Please add anti-freezing liquid into cooling water.
● Fill water into radiator
1）Turn the cover of radiator towards left side and take it off.
2）Add the cooling water till it overflows from water inlet of radiator. Slowly fill cooling water to avoid
any foam.
3）Close the cover of radiator tightly to prevent any water leakage. Direct the inside clip towards notch
of water inlet. Then press down the cover and turn the cover towards right side for 1/3 cycle to close
the cover.
● Fill water into overflow bucket of auxiliary tank
1）Please take off the cover of water inlet of auxiliary tank. Add cooling water up to the upper scale
mark. Then re-mount the cover.
2 ） Check if joints of rubber hoses connecting auxiliary tank and radiator are loose, released or
damaged. If any, auxiliary tank cannot work.
3) Check the rubber pipe of the auxiliary tank for disconnection, loosen or damage. If the rubber pipe is
not at good condition, don’t use the auxiliary tank.
Volume of cooling water is :
Radiator
7.3.5 Trial running
● Run the generator that is new or idle for long-term at low speed and without load for short term
before load running. Deliver the lubricant to all abrasion parts. If start the load running without
mentioned operation, it may cause abnormal abrasion or damage to piston, cylinder sleeve, crank
shaft, bearing and other parts.
1） Turn the breaker of generator to OFF.

2） Insert the start key and turn it to ON. Then engine starts. Run the engine for about 5min to
check if any abnormal sound and leakage of water, oil and gas.
3） Turn the key to OFF and stop engine.
7.3.6 Quantity re-confirmation of lubricant and cooling water
Please re-confirm the quantity of lubricant and cooling water after 5-minute trial running, if lubricant or
cooling water is filled into for the first time or is replaced.
Trial running distributes lubricant and cooling water around the machine. During re-check level of
lubricant and cooling water shall be lower. By then, please make up insufficiency.
7.4 Operation
Following parts in the running generator are extremely dangerous, such as

radiator fan, belt and other rotation parts, engine, cylinder hood, exhaust pipe,
muffle and other parts at high temperature and high voltage.
Danger
●Close the side door of running machine.
●Stop running machine before check and maintenance.
●Carry on following checks prior to each start.
1. Remove foreign matters in the generator

●Check if there is any tool or rag in the generator.
●Check if there is any rubbish or inflammable matter around muffler or engine. If any, remove it away
immediately.
●Check if suction inlet and exhaust vent of generator is jammed by rubbish or rag. If any, remove it
away immediately.
2.Check in the generator

①Any oil leakage in the engine
②Any fuel leakage in the fuel system
③Any water leakage in cooling water system
④Broken distribution line, short circuit or loose joint
⑤Check if any screw is loose or released.
Do not run the machine before eliminating any founded abnormality.

3. Check and fill fuel
Regularly check rest fuel level in the fuel tank and add recommended fuel on the basis of need.
4.Check and fill lubricant
①Check lubricant level with oil dipstick.
②Add recommended engine oil from oil-inlet of gear case when oil level is insufficient.
Check the lubricant with oil dipstick. Add lubricant up to upper scale mark with check
5. Check and fill cooling water
Generator is still hot when machine is running or after machine stops. In such
case, do not open the cover of water inlet of radiator because ejected steam
and hot water are extremely dangerous. As temperature falls down, envelop
the cover of water inlet of radiator with cloth. Then open the cover. Close
radiator cover tightly after checking.
Warning
1）Check and add cooling water before machine is running and when engine is cold.
2）Confirm and check the quantity of cooling water by level in the auxiliary tank.
If water level is between the upper and lower scale marks, it means normal.
Check if there is any change on water level before or after using machine once a week.
●Normal change on water level
Prior to running (cold status): low level

After stop (high-temperature status): upper level
(Note) Open the radiator cover. Check and add cooling water if there is no change on water level after
running compared to that prior to running. In addition, check rubber hoses connecting radiator cover
and auxiliary tank; confirm if any connection is released, loose or broken.
7.4.1 Keynote for no-load start
If the breaker at side of generator and loading equipments

is at ON, please do not start the machine. Power is
supplied to loading equipments and runs machine
suddenly when engine starts, which leads to damage.
And it may cause electric shock or errors of loading
Danger equipments.
1) Start
Start the machine in the following order.
①Confirm breaker at side of generator and loading equipments is at OFF

②Insert the start key and turn it to ON. Indication lamp of intelligent display is on. Please confirm it.
③Turn the key to START then release it. Key returns to ON automatically. Engine is pre-heated and
starts.
●Check that intelligent display shows no error code when engine starts.
●Repeat start operations. Carry on start operations after engine stops running completely. Operation
on the running machine causes errors of starter and damages start motor.
2）Adjustment of frequency and voltage

Make adjustment after machine is heated and runs.
Heat the machine for about 5 minutes (no-load).
①Adjust the regulating screw rod of oil-pump rotation speed till frequency is up to rated value.
②Adjust the voltage with voltage adjuster as per specifications.
7.4.2 Keynote for load running
1）Pre-running check
① Confirm that voltage, current and frequency shown in the intelligent panel are normal.
②　Check if fuel switch of outside fuel tank is at the correct position.
③　Check the environment of engine.
④　If color of exhaust is normal or not
Colorless or light gray: Normal
Black: Abnormal (insufficient combustion)
Blue: Abnormal (Combustion of lubricant)
White: Abnormal (No combustion of fuel or too much water contained in the fuel)
⑤ If any sound is abnormal, or running is stable, or there is any abnormal vibration or not
⑥　If there is any leakage of fuel, lubricant and cooling water
⑦　Check if breaker at the side of loading equipments is at OFF.
⑧　Turn the single-phase and three-phase breaker of generator to OFF.
2）Load conditions
Forbid increasing or reducing speed rapidly, over-load or other unreasonable

operations during the first 50hours for new engine.
Attention
①Turn the breaker (single-phase/ 3-phase) of generator to ON

②Turn the breaker at the side of loading equipments to ON
3）Adjustment during running

Adjust the rotation, frequency and voltage according to load.
4）Checks during running
If generator produces any abnormal sound, please stop running it immediately

for check and repair. If continue running machine at abnormal status,
unexpected serious accidents may occur.
Warning
Check if there is any abnormality of generator, or below conditions occur for running generator.
① Check all instruments and central indication lamps

Check voltage, current and frequency in accordance with specifications. Check if indication lamps are
on.
② If color of exhaust is normal or not

Colorless or light gray: Normal
Black: Abnormal (insufficient combustion)
Blue: Abnormal (Combustion of lubricant)
③ If there is any abnormal sound and vibration
④ If there is any leakage of fuel, lubricant or cooling water

⑤ If rest fuel is sufficient
If fuel supply is interrupted during machine runs, please eliminate air remained in the fuel pipe after
fuel fill-in.
5）Stop the machine
Stop the machine in the following order.
1）Turn the breaker at the side of loading equipments to OFF.

2）Turn the breaker (single-phase/ 3-phase) of generator to OFF
3）Please run the machine at cold status for about 5minutes (no-load)
Do not stop the machine suddenly if load running starts. Otherwise
temperature of engine parts rises rapidly, leading to blow engine or cylinder
scoring.
Warning
4）Turn the start key to OFF to stop running machine.

5）Take off the key and keep it properly
7.4.3 Running on the automobile

●If run the machine temporarily on the automobile, please do not block or cover the air inlet or exhaust
vent of generator.
●If place materials around the breather hole of machine and run the machine, machine may face to
over-heat.
●Keep the gap between driver seat and machine within 200-300mm to the least extent. Meanwhile
there is no any blockage around the breather hole of machine. Then start the machine.
8. Maintenance service of electrical system

8.1 Start motor
8.1.1 Disassembly
Motor disassembly
（1）Disassembly the leading-out wire terminal of winding from magnet switch wiring terminal.
（2）Loose the transfixion bolt and the setscrew of carbon brush holder
（3）Take off the back-end shield, stator, carbon brush holder, armature in turn.
(4）Assemble sequence and disassemble sequence are opposite, smear lubricant grease on the end
B of armature spline while assembling.
1. electromagnetic switch 2.armature 3.leading-out wire terminal of winding 4.stator

5. carbon brush holder 6.back-end shield 7.transfixion screw 8. setscrew of carbon brush
Electromagnetic switch disassembly

（1）Loose the three bolts of end cover
（2）Take off end cover and magnet iron core.
Reducer /clutch disassembly

（1）Loose three bolts of tightened driving shell ,(two are outside of motor, one is inside of motor),
（2）Take off driving shell, clutch subassembly, steel ball, return spring and drive gear in turn.
(3）When assembling, please smear new lubricant grease.
1. driving shell 2.decelerating clutch 3.steel ball 4. return spring

5. electromagnetic switch 6.driving gear 7.idler gear 8. driving gea
8.1.2 Inspection and maintenance of starter motor

Motor inspection
1) Disassemble the motor excitation and armature winding output
wire from C connector.
2) Connect the motor positive terminal with the battery positive
connector
3) Connect the motor out shell with the battery negative connector.
The motor should rotate, if no rotation please check the two windings of motor.
Electromagnetic switch inspection

1) Disassemble the starting motor from the motor seat and
prepare a 6V battery.
2) Connect the electromagnetic switch out shell and C connector
with the battery negative connector by two wires.
3) Connect the battery positive pole with S receptacle by a wire,
and the gear shaft should jump out suddenly. If the C connector
is disconnected, the gear shaft should remain at the extend position, which indicates tha the
electromagnetic switch is normal.
4) Pay special attention that the connection time is only 3 to 5 seconds, otherwise the winding will be
burnt and damaged.
Commutator inspection and maintenance
（1）Check the commutator for wear, if slightly worn, burnish and polish with fine rubber
（2 ）Measure diameter of commutator with outside micrometer, if diameter dimension is small than
limiting size, please change armature.
(3）If there is much difference between excircle wire harness of commutator and axes parallelism,
but the diameter of axle minimum limit of size is in the allowable value. And please correct to the
specified value on the lathe. Fig (a) is good, Fig (b) is bad.
Check the electric brush for wear

（1）If there is soil and dust on the wearing surface, please burnish with abrasive cloth.
(2）Measure the carbon brush height A with vernier caliper. If it wears heavily, which indicats small
size of A, please replace the carbon brush.
Check the electric brush bracket

Check the insulating performance between the insulating electric brush bracket and supporting plate, if
it is current conducting, please replace electric brush bracket.
Check the armature
Measure the electric conductivity of commutator copper sheet , armature core and armature winding
with ohmmeter:
(1 ） If the commutator copper sheet and armature core is current conducting, please replace
armature.
（ 2 ） If commutator copper sheet and armature winding are not current conducting, please replace
armature.
(3）If the commutator copper sheet is current conducting, please replace armature.
Check the stator winding

(1) Test electric conductivity of stator winding output wire with an ohmmeter, if no conductivity, please
replace stator. Refer to Fig. a
(2) Test insulativity between stator winding coil and stator shell with an ohmmeter, if conductivity,
please replace stator. Refer to Fig. b.
图a 图b
Check the armature rolling bearing

If swing the rolling bearing, there should be small radial and axial clearance, smooth running. If swing
heavily, clagging or damage will happen, and please replace the rolling bearing.
Check the decelerating cluth

(1) Check all gears of decelarating clutch for damage or wea, if severely
worn or damaged, please replace decelerating clutch or related gear.
(2) Check flexibility of decelarating clutch. Smooth radial operation and rotation must be secured. No
skid when given a force, normal performance maintained, otherwise please replace.
Check the electromagnetic swith

Test the electric conductivity of contact disc in electromagnetic switch. Hold
magnetic core with your thumb. Test electric conductivity between connector C
and B. If no conductivity, please check contacting and fastening between the
two connectors and inner copper sheet.
8.2 Generator
8.2.1 Generator disassembly
Generator rotor assembly
Rotor fan
The fuction is to rotate the fan by rotor, take off the motor energy and cool the motor rotor and
stator winding.
Exciter rotor
It consists of rotor rectifier and rotor winding, its function is to invert the exciter stator magnetic
field into rotor excitation current, so that to provide the rotation magnetic field and generate electricity
for stator.
8.2.2 Inspection
Rotor winding inspection
The function of rotor winding and also the electricity generating principle is that the rotor winding
inverts the excitation DC current into current magnetic field, the stator winding generates induced
electric potential by means of engine rotation and rotation magnetic field. If the generator doesn’t
generate electricity, it is possibly caused by no output of generator. Generally speaking, such faults
usually occur in case of long time operation, long time max power output, high working temperature or
big no power consumption. And these faults will result in inner temperature of rotor winding rises,
insulation performance of lacquered wire reduces, short circuit among wires and finally the motor rotor
is burnt and damaged. Main faults are: output voltage reduces after the generator set runs at the
related power, AVR voltage potentiometer regulation doesn’t work or the AVR fuse splits. To avoid
such faults, please check the rotor commucator, the resistance of motor rotor winding, the motor
appearance and winding color, if the winding splits, you should replace the rotor assembly.
Possible fault of rotor

1) Rotor metal core and stator inner ring wear: the location of motor two ends changes
① The engine rotation shaft and side cover location hole wear.
② The motor bearing wears
2) The rotor winding frame splits: the rotor winding is heated to high temperature and inflates, so that
the fame splits. Please avoid high temperature or long time conntinuly working under no power load
condition.
3) The exciter rotor winding changes color or is burnt:: the pressure-proof value of rectifier diode is not
sufficient and the diode is breakthrough, so that the winding changes color. But this kind of fault is not
normal, as there equipped with current protection and quick fuse protection in AVR. This fault occurs
only when the fuse changed or protection current increases.
4) The bearing out ring location groove splits or wears: this kind of fault occurs mainly in case of long
time running. The reason is that the material structure distorts after long time wear and heat. However,
the occurance probability is very little, it usually occurs in the end of generator operation period.
5) The diode assembly fixed screw looses or the diode damages: this kind of fault occurs in case of
short time running, the possible reason lies in the installation. The fixed bolt looses under running
vibration, as well as the diode. Or it is because of the diode fault.
Check the exciter rotor assembly

Rotor electricity generating winding: its function is to generate induced electric potential on rotor
winding and AC 3-phase voltage by means of AVR output excitation. The AC cuurent is transferred into
DC current by rotor commutator, and supplied to rotor excitation winding, providing magnetic field of
the main generator rotation.
Check the rotor electricity generating winding:
Check the rotor excitation generator winding by measuring the resistance of red, yellow, green
output wire of winding and the resistance of out shell with resistance meter. The qualified resistance
between output wires is 1.54Ω, otherwise it is faulty. The resistance between output wire and out shell
should be infinite, and the indication should be open circuit, otherwise it is faulty.
Check the exciter stator winding
The function of exciter stator winding is to invert the AVR excitation DC current into current
magnetic field. The electricity generating principle is also that the rotor winding generates induced
electric potential by means of engine rotation and rotation magnetic field. However, it is not the
magnetic field rotates but the generating winding inverts, which is the difference. If the generator
doesn’t generate electricity, it is possibly caused by no output of generator resulted by open circui or
short circuit of exciter stator winding. Generally speaking, such faults usually occur in case of long time
operation, long time max power output, high working temperature or big no power consumption. And
these faults will result in inner temperature of rotor winding rises, insulation performance of lacquered
wire reduces, short circuit among wires and finally the motor rotor is burnt and damaged. Main faults
are: output voltage reduces after the generator set runs at the related power, AVR voltage
potentiometer regulation doesn’t work or even the AVR fuse splits. To avoid such faults, please check
the rotor commutator, resistance of motor rotor winding, the motor appearance and winding color, if the
winding splits, you should replace the rotor assembly.
Check the generator stator winding
The function of generator stator winding is to invert the excitation DC current into magnetic force
line so that to generate electricity. The electricity generating principle is that the stator winding
generates induced electric potential by means of engine rotation and rotation magnetic field. If the
generator doesn’t generate electricity, it is possibly caused by no output of generator resulted by open
circui or short circuit of exciter stator winding, or caused by generator stator fault. Generally speaking,
such faults usually occur in case of long time operation, long time max power output, high working
temperature or big no power consumption. And these faults will result in inner temperature of stator
winding rises, insulation performance of lacquered wire reduces, short circuit among wires and finally
the motor stator is burnt and damaged. Main faults are: output voltage reduces after the generator set
runs at the related power, AVR voltage potentiometer regulation doesn’t work or the surface
temperature of motor is high. To avoid such faults, please check the resistance of motor stator
winding, the motor appearance and winding color, if the winding splits, you should replace the rotor
assembly.
Refer to 3.3 Generator maintenance data for detail maintenance data.
Measure the rotor insulation pressure-proof
To avoid personal damage caused by high voltage of dielectric strength tester,

please put on the insulation gloves, insulation protection shoes and lay an
insulation mat on the workplace before testing. Refer to the operating
instruction of dielectric strength tester for detail operation.
Danger
Testing conditions: testing voltage 750V, drain current ＜10mA
Testing method: connect the grounding terminal of dielectric strength tester with the metal core of
motor rotor, and connect the high pressure output terminal with any terminal of rotor winding output
wire. Turn on the dielectric strength tester for measurement. If the drain current exceeds the
prescribed value, please check the rotor for insulation or replace the rotor.
Measure the rotor insulation pressure-proof
To avoid personal damage caused by high voltage of dielectric strength tester,

please put on the insulation gloves, insulation protection shoes and lay an
insulation mat on the workplace before testing. Refer to the operating
instruction of dielectric strength tester for detail operation.
Danger
Testing conditions: testing voltage 1500V, drain current ＜10mA

Testing method: connect the grounding terminal of dielectric strength tester with the out shell of motor
stator, and connect the high pressure output terminal with any terminal of stator winding output wire.
Turn on the dielectric strength tester for measurement. If the drain current exceeds the prescribed
value, please check the stator for insulation or replace the stator.
9. Engine maintenance
9.1 Installation chart and parts name
9.2 Disassembly and assembly of engine
9.2.1 Engine disassembly
Prepare necessary placing space and container before disassembly, put each kind of bolt, nut and
relevant parts together, so that you will not mix them when reassembly.
Find out where the problems lay before disassembly, don’t disassemble the unnecessary parts.
Disassemble the diesel filter assembly
1) Loose the two M8X30 bolts which tighten the diesel filter,
2) Disassemble the diesel filter assembly from the inlet pipe
Disassemble the oil filter seat

1) Loose the three M8X20 bolts which tighten the oil filter
2) Disassemble the oil filter seat and oil filter seat gasket
Disassemble the charging generator and adjusting plate of charging generator
1) Loose bolt M8X30 and nut M8 which tighten the charging generator and its adjusting plate
2) Loose the other flange bolt M8X70 of charging generator which tightens the gear chamber cover,
and disassemble the charging generator
3) Loose the bolt M8X30 which tightens the adjusting plate of charging generator, disassemble the
adjusting plate of charging generator
Disassemble the V type strip AV13X970
Disassemble the fan gasket, fan and belt pulley of water pump
1) Loose the four bolts M6X40 which tighten fan, fan gasket and belt pulley of water pump
2) Disassemble the fan, fan gasket and belt pulley of water pump in order
Disassemble the belt pulley of crankshaft

1) Loose the bolt M14X1.5X30 which tightens the belt pulley of crankshaft
2) Disassemble the pressure plate and belt pulley of crankshaft
Disassemble the water pump

part and water outlet seat
1) Loose the three bolts M8X60
which tighten the water pump
part, and disassemble the water
pump part and water pump
gasket.
2) Loose the three bolts M8X16 which tighten the water outlet seat, and disassemble the water outlet
seat and water outlet seat gasket
Disassemble the high pressure oil pipe

1) Loose the four screws M4X14, and disassemble the oil pipe clip
2) Loose the pipe connector of high pressure oil pipe of each cylinder, and disassemble the high
pressure oil pipe
Disassemble the fuel injector

Loose the three bolts M8X35 which tighten the fuel injector, and disassemble the pressure plate
washer, pressure plate of fuel injector, fuel injector and heat insulation sleeve.
Disassemble the cylinder cover and respirator pipe
1) Loose the respirator pipe clip on the inlet pipe, and pull out the respirator pipe.
2) Loose the three nut heads which tighten the cylinder cover, and disassemble the cylinder cover
and sealing gasket.
Disassemble the exhaust pipe

Loose the four bolts M8X80 (eight bolts for KD488) which tighten the exhaust pipe, and two M8 nuts.
Disassemble the exhaust pipe and exhaust pipe gasket.
Disassemble the inlet pipe and inlet pipe gasket

Loose the four bolts M8X20 and bolt M8X80 which tighten the inlet piep. Disassemble the inlet pipe
and inlet pipe gasket.
Disassemble the gear chamber cover

1) Loose the eleven bolts M8X55, three bolts M8X90 and three bolts M8X16 which tighten the gear
chamber cover.
2) Disassemble the gear chamber cover and gear chamber cover gasket
Disassemble the cylinder cover assembly, valve rocker arm part and valve pushing rod
1) Loose the two bolts M8X25 (three bolts for KD488) and six bolts M8X50 (seven for KD488) which
tighten the valve rocker arm. Disassemble the valve rocker arm part.
2) Loose the fourteen cylinder cover bolts (eighteen bolts for KD488) which tighten the cylinder cover,
and disassemble the cylinder cover and cylinder cover gasket.
3) Take out the valve pushing rod from the pushing rod hole
Disassemble the starting motor

Loose the two bolts M12X25 which tighten the starting motor, and disassemble the starting motor form
flywheel shell.
Disassemblet he flywheel and flywheel cover

1) Loose the six bolts M10X1.25X32 which tighen the flywheel, and disassemble the flywheel.
2) Loose the ten bolts M10X25 which tighten the flywheel cover, and disassemble the flywheel.
Disassemble crankcase oil tray
1) Revolve the cylinder block 180°, and loose the fourteen bolts M8X45 and four bolts M8X20 which
tighten the crankcase oil tray.
2) Disassemble the crankcase oil tray and crankcase oil tray gasket
Disassemble the flywheel oil seal seat and rear oil seal seat gasket
Loose the nine bolts M8X30 which tighten the flywheel oil seal seat and rear oil seal seat gasket, and
disassemble the flywheel oil seal seat.
Disassemble the rough filter

Loose the two bolts M8X35, and disassemble the rough filter and rough filter gasket
Disassemble the stay plate of crankcase oil tray

1) Loose the two bolts M8X25 which tighten the stay plate of crankcase oil tray
2) Disassemble the stay plate of crankcase oil tray and stay plate gasket of crankcase oil tray.
Disassemble the driving gear of fuel pump and fuel injection pump part
1) Loose the four bolts M8X20 which tighten the driving gear of fuel pump and disassemble the
driving gear of fuel pump.
2) Loose the three nuts M8 which tighten the fuel injection pump part, and disassemble the fuel
injection part from the stay plate of gear chamber
Disassemble the idle gear part

Loose the three bolts M8X40 which tighten the idle gear partand disassemble the idle gear part.
Disassemble the camshaft thrust plate and camshaft

1) Loose the two bolts M8X16 which tighten the camshaft thrust plate.
2) Draw out camshaft from engine.
Disassemble the valve tappet
Rotate the cylinder block 90° and lay it on the level, draw out the valve tappet from the tappet hole.
Disassemble the gear chamber plate

Loose the three bolts M8X16 which tighten the gear chamber plate, and disassemble the gear
chamber plate and gear chamber plate gasket.
Disassemble the piston connection rod assembly

1) Loose the connection rod bolt of each cylinder, take off connection rod cover and pull out the
piston connection rod assembly from cylinder.
2) Reassemble the connection rod bushing, connection rod cover and connection rod bolt.
3) Store or lable the parts in order, to avoid mixing. (don’t mix the piston connection rod parts)
Disassemble the crankshaft amd main bearing cover

1) Loose the bolts which tighten the main bearing, and take off the main bearing cover in order (the
No. 4 main bearing cover with thrust)
2) Reassemble the main bushing, main bearing cover and main bearing cover bolt, don’t assemble
mistakenly.
9.2.2 Engine reassembly
Matters need attention before reassembly:
1) Clean and check all the parts completely
2) Lubricate the moving parts and rotating parts with new oil
3) Use the new gasket, O-seal ring, oil seal and rubber pipe
4) Use liquid seal gum to avoid oil leaking
5) Make sure the clearance between each part (oil film, thrust and so on) is correct.
Reassemble the crankshaft and main bearing cover

1)Smear oil on the surface of main bearing bush and crankshaft main journal, put crankshaft parts
inside main bearing hole steadily, let crankshaft approach to one terminal and leave space to install a
piece of crankshaft thrust plate in the output terminal flute, pay attention that the thrust plate’ oil groove
side should be towards crankshaft. Then let crankshaft approach the other terminal, and put in another
thrust plate.
(2)Install main bearing cover orderly according to the number on the top of main bearing cover, arrow
direction on the main bearing cover should be towards to the output terminal of engine.
(3)Tighten main bearing cover bolts to stipulate torque for three times in the order of first middle, then
double end（120±5)N·m.
(4)Revolve crankshaft with hands easily, and without drag.
(5)Check crankshaft axial clearance.
Reassembly the piston connection rod assembly

(1)Smear new oil on piston ring、piston pin、cylinder cover and connecting rod big-end hole.
(2)The opening of piston ring should be staggered: the 1 st ring and the 2nd ring staggered 180°, the 2 nd
ring and the 3rd ring staggered 100°. Avoid piston main pushing side, lean piston skirt flute on the side
of main oil duct.
(3)Install disassembled piston connecting rod parts into cylinder cover according to original cylinder
number, clamp piston ring with special tools, push piston into cylinder, then close the connecting rod
cover. Notice that connecting rod body and bush locating skirt of connecting rod cover should be on
the same side, never turnaround.
(4)Smear thread fasten glue on thread of connecting rod bolt, tighten uniformly to stipulate tighten
torque for three times(60±5)N·m.
(5)Rock connecting rod cover with hands, it should move smoothly and can’t be seized.
Install the gear chamber plate

Install the gear chamber plate on the front end of cylinder block, and tighten it wih three bolts M8X16.
Make sure that the bottom of gear chamber plate is on the same level with the bottom of cylinder
block, otherwise, oil leakage will occur.
Install the valve tappet

Smear little oil on the surface of valve tappet and install it in the tappet hole.
Install the camshaft and camshaft thrust

1) Smear little oil on the surface of camshaft, and install it in the camshaft bearing hole. Make sure
that it can work without resistance.
2) Tighten the camshaft thrust with two bolts M8X16 and check the axial clearance.
Install the idle gear part

Turn crankshaft gear and camshaft timing gear to the proper location, align the sign A on idle gear
with sign A on crankshaft gear, sign C on idle gear with sign C on camshaft timing gear. Revolve
crankshaft slightly, install idle gear into machine body idle gear seat hole, tighten with three M8X40
bolts, check rotation agility and gear clearance.
Install the fuel injection pump parts and driving gear of fuel injection pump
1) Install the fuel injection pump parts on the gear chamber plate with three studs AM8X25, and tighten
it with three nuts M8.
2) Install the driving gear of fuel injection pump on the connection panel and tighten it with four bolts
M8X20.
Make sure check the number of gear, and oil supplying mark of connection panel and gear.
Install the stay plate of crankcase oil tray

Smear glue on both sides of stay plate gasket of crankcase oil tray, and install it together with the
stay plate on the cylinder block. Tighten them with two bolts M8X35.
Install the rough filter parts

Install the rough filter gasket and rough filter parts on the cylinder block, tighten them two bolts
M8X35.
Install the oil seal seat of flywheel end

Smear glue evenly on the oil seal seat of flywheel end, and install it. Tighten it with nine bolts
M8X30.
Install the crankcase oil tray

1) Smear glue evenly on the stay plate and crankcase oil tray. Install the crankcase oil tray gasket
first, then upend the crankcase oil tray and install it. Tighten the crankcase oil tray with four bolts
M8X20 and fourteen bolts M8X50.
2) Tighten the crankcase oil tray symmetrically and evenly, in order of first center then the two sides.
Install the flywheel cover and flywheel

(1)Revolve the machine in 180°direction, and make crankcase oil case upwards. Align the two locating
pin hole of flywheel cover with the relevant column pin and install them on the machine body, tighten
them with ten M10×25 bolts, tighten torque is （ 45 ～ 60 ） N·m, (torque of the four bolts which
incorporate with aluminum back block is 35～45N·m ).
(2) Align flywheel column pin hole with crankshaft column pin, and install it on the crankshaft, tighten it
with six N10×1.25×30 flywheel bolts.
(3) Use equilateral triangle method to tighten up flywheel bolt, tighten to
the stated torque （65～75） N·m uniformly for three times.
Install the starting motor

Install the starting motor on the flywheel cover (pay attention that the connection should be
outward). Tighten it with two bolts M12X25, the tighten torque is (80～100)N·m.
Install cylinder cover assembly, valve rocker arm parts and valve pushing rod
(1) Install valve pushing rod into engine pushing rod hole. Pay attention that it should be installed in
the concave ball hole of tappet;
(2) Smear little oil on both sides of cylinder cover gasket, install it on the engine, notice that the gap of
cylinder cover should align with gap of engine.
(3) Smear little oil around wall of cylinder cover with oil gun, revolve crankshaft, left piston at the
appropriate location, close cylinder cover assembly, tighten the fourteen cylinder cover bolts in proper
order, then tighten them uniformly with torsion spanner for three times, torque is (75～85)N·m.
(4)Put on valve rocker arm parts, tighten them with two M8×25 bolts and six M8×50 bolts.
(5)Revolve crankshaft belt pulley, adjust valve clearance according to 2.4.3 of this manual, fill a 0.10
width ruler in the middle of rocker arm, tighten valve clearance screw and valve clearance nut. Valve
clearance is permitted between 0.10～0.15. Adjust valve clearance of each cylinder in the same way.
Adjust the oil supplying advanced angle and install the gear chamber cover
(1)Make angle graduation line of flywheel at compression upper dead point 16°of the 1 st cylinder;
(2)Connect fuel injection pump with diesel, drain our air inside pump;
(3)Turn oil pump gear shaft with sleeve spanner, drain oil from oil drain valve of the 1 st cylinder, there
should be no air bladder in oil.
(4)Turn about 60° in anticlockwise direction, then turn oil pump crankshaft slightly in clockwise
direction, your eyes should watch the oil wave of oil drain valve, once there is wave, please stop
rotating, tighten a bolt to fasten oil supply gear.
(5)Check again whether oil supply advanced corner is 16°±1°, if not, please adjust properly to correct
it.
(6)Finally fasten the four M8X20 bolts, tighten oil supply gear.
Install the inlet pipe and inlet pipe gasket

Tighten the inlet pipe gasket and inlet pipe on the cylinder cover with bolt M8X80 and four bolts
M8X20.
Install the exhaust pipe and exhaust pipe gasket

Tighten the exhaust pipe gasket and exhaust pipe on the cylinder cover with six bolts M8X80.
Install the cylinder cover

1) Seal the cylinder cover with three O-seal rings and tighten it with three nut heads.
2) Connect one end of the respirator pipe with the inlet pipe and tighten it with pipe clip.
Install the fuel injector

Install the heat insulation sleeve on the fuel injector, and install the fuel injector inside the fuel
injector hole on the cylinder cover. Install the pressure plate of fuel injector and pressure plate gasket,
tighten them with three bolts M8X35.
Install the high pressure oil pipe parts

Install the high pressure oil pipe of each cylinder, tighten the oil pump end and nozzle end nut.
Install the water outlet seat and water pump parts

1) Smear glue on both sides of water outlet seat gasket and install it on the front end of cylinder
cover. Install the water outlet seat and tighten it with three bolts M8X16.
2) Smear sealing glue on both sides of water pump gasket and install it together with water pump
parts on the cylinder block. Tighten them with bolt M8X50 and three bolts M8X60.
Install the crankshaft belt pulley

1) Set the crankshaft belt pulley aligned with the location pin, and install it on the crankshaft.
2) Install the pressure plate, and tighten it with bolt M14X1.5X30, the tighten torque is (120±10)N·m.
Install the belt pulley of water pump, fan gasket and fan
Install the belt bulley of water pump, fan gasket and fan on the flange panel of water pump, tighten
them with four bolts M6X40.
Install the V-type strip AV3X970 and tighten it
Install the charging generator and the adjusting plate of charging generator
1) Tighten the adjusting plate of charging generator on the water outlet seat with bolt M8X30
2) Install the flange end of charging generator on the gear chamber cover, and tighten it with bolt
M8X70.
3) Connect the other end of flange end with the adjusting plate of charging generator with bolt M8X30
and nut M8, to adjust the belt pulley of water pump.
Install the oil filter parts

Smear glue on both sides of oil filter seat gasket and install it on the cylinder block and tighten the
oil filter parts with three bolts M8X20.
Install the diesel filter assembly

1) Tighten the diesel filter parts on the inlet pipe with two bolts M8X30.
2) Connect with the fuel pipe (oil inlet pipe and oil outlet pipe) and tighten it.
9.3 Engine inspection and maintenance

9.3.1 Cylinder cover
Combustion chamber surface of cylinder cover
Disassemble the fuel injector, inlet valve and exhaust valve, clean the surface of combustion
chamber to check for crack and damage. Check the tiny crack with dye penetration.
Inlet/ exhaust valve seat
Clean cylinder cover、valve and valve sealing cone, insert valve into valve pipe, measure valve sunk
mete with deep vernier caliper. If the valve sunken mete or valve ring width exceeds much, please
modify it in the same way of changing the valve or valve seat gasket.
Model KD388
Item Standard
Valve sinking 0.5～0.7
quantity
Inlet /exhaust valve and valve pipe

(1) Clean the gathered carton inside valve pipe; check the outside diameter of valve stem with outside
micrometer.
(2)Check valve pipe aperture with inside lever meter, account its fitting clearance, if it exceeds the
limitation valve, please change valve. If it still can’t attach to the limitation valve after changing valve,
please change valve pipe.
Fitting clearance between valve pipe aperture and inlet /exhaust valve
rod diameter
Model KD388、KD488
Item Standard Maintaining
limitation
Valve piep Inlet：0.035～0.065 0.10
aperture and
inlet valve rod
diameter
Valve pipe Exhaust：0.040～ 0.12
aperture and 0.070
exhaust valve
rod diameter
Notice: There installs valve pipe oil seal on inlet/exhaust valve pipe, so do change new parts when
maintaining valve pipe oil seal.
Valve spring
(1)Measure the free length of valve spring with vernier caliper, and change the valve spring if the free
length exceeds limitation valve.
(2)Measure the vertical valve of valve spring; revolve valve spring to see whether the whole side of
valve spring is connected with square. Change valve spring if the measured vertical valve exceeds the
limitation valve.
(3)Check whether there is any crack or corrosion on front of valve spring, if there is any please
change it.
Lube oil clearance between rockshaft and valve rocker arm hole
Measure the outside diameter of rockshaft with outside micrometer; measure the aperture of valve
rockshaft hole with inside lever meter. Then account lubrication clearance, if the measured lube oil
clearance exceeds limitation valve, please exchange rockshaft and valve rocker arm.
Fitting clearance between valve rocker arm hole and rockshaft diameter
Model KD388
Item
Maintaining
Standard
limitation
Valve rocker
arm hole and
0.016～0.045 0.10
rockshaft
diameter
Adjust the valve clearance

Adjust the valve clearance when the engine is cold.
Model KD388、KD488
Item Standard
Inlet valve 0.10～0.15
clearance
Exhaust valve 0.10～0.15
clearance
Measure the cylinder compression clearance height

(1)Disassemble cylinder cover, put fuse ф1.5×10mm of the same height on the four points of piston
top, reassemble cylinder cover, tighten cylinder cover bolts according to the stipulated order and
torque.
(2)Revolve crankshaft in anticlockwise direction, flat fuse, disassemble cylinder cover and take out flat
fuse, and measure its thickness. Take the average valve of four fuses as cylinder compression
clearance.
9.3.2 Camshaft part and idle gear part
Axial clearance of camshaft
Assemble micrometer, lead the top to camshaft head, remove camshaft for-and aft, and measure the
axial clearance of camshaft. If the measured clearance exceeds the promised limitation valve, please
change the camshaft thrust plate.
Model KD388
limitation
Axial clearance of 0.05～0.20 0.40
camshaft
Lube oil clearance of camshaft axial diameter

Measure the outside diameter of camshaft journal with outside micrometer, measure camshaft inside
aperture with inside lever meter, account the lube oil clearance. If the measured valve exceeds the
limitation valve, please change camshaft or bushing.
Model KD388
Item
Standard Maintaining
limitation
Camshaft
aperture and
0.05～0.10 0.15
camshaft neck
journal
Cam height
Measure the height of cam at its top point with outside micrometer, if the measured height exceeds the
limitation valve, please change for a new camshaft. (Height for inlet/exhaust cam is 38.7±0.03).
Lube oil clearance between idle gear bushing and idle gear seat
Measure outside diameter of idle gear seat with outside micrometer, measure inside aperture of idle
gear bushing with inside diameter lever meter; account the lube oil clearance. If the measured
clearance exceeds the limitation valve, please change for a new idle gear bushing.
Model KD388
limitation
Idle gear bushing
aperture and idle
0.025～0.066 0.12
gear shaft
diameter
9.3.3 Piston and piston pin

Piston
(1) Check piston top and combustion chamber surface, clear up
the gathered carton on them, please be careful and don’t hurt the
surface. Check whether there is any injury on the surface of
combustion chamber.
(2) Check piston outside diameter, if damage of piston surface or
ring groove exceeds the limitation valve, please change for a new
piston.
(3) Check inside aperture of piston pin, if the valve of it exceeds the limitation valve, please change for
a new piston.
Piston pin
Measure the outside diameter of piston pin, if the measured valve
exceeds the maintenance limitation, or has been grinded severely
into echelon form, then you should replace the piston pin.
Model KD388
Item
Maintaining
Standard
limitation
Piston pin
aperture and
0.002～0.014 0.03
piston pin
diameter
Connection rod
(1)Clamp measurement in the big head hole and small head hole of connecting rod to check the its
depth of parallelism and distortional deformation. If the depth of
parallelism exceeds promised limitation, please replace connecting rod.
Model KD388
Item Standard
Parallel degree between 0.025/100
connection rod big head hole
and small head hole
Distortion degree between 0.04/100
connection rod big head hole
and small head hole
(2)Check the surface of connecting rod bushing to see whether there is any gaffing、melting or seizure,
if there is gaffing or damage , please change the bushing.
Lube oil clearance between piston pin and connection rod small head bushing
Measure the outside diameter of piston pin which connected with connecting rod bushing with outside
micrometer, measure inside aperture of connecting rod small head bushing with inside diameter lever
meter; count the lube oil clearance. If the measured valve exceeds the limitation valve, please replace
the piston pin and bushing.
Model KD388
limitation
Connection rod bushing aperture 0.015～ 0.021 0.06
and piston pin diameter
Piston pin
(1) Use special tools to assemble or disassemble piston ring, don’t separate piston ring too hard.
(2) Clear up the gathered carton in the ring groove; use thickness gauge or depth gauge to measure
the clearance between piston ring and ring groove. If the measured valve exceeds the limitation valve,
please replace piston ring or piston. If the clearance is too big, air leakage will be caused, and then
result in leakage of lube oil.
Model KD388
Item Maintaining
Standard
limitation
Ring groove height and
0.05～0.08 0.20
the 1st ring thickness
0.03～0.06 0.15
the 2nd ring thickness
0.03～0.065 0.15
the 3rd ring thickness
(3) Assemble piston ring to damage parts of cylinder cover, measure piston ring gap clearance with
thickness gauge. If the measured valve exceeds the limitation valve, replace piston ring or cylinder
cover.
Model KD388
Item Standard
Open clearance of
0.25～0.40
the 1st ring
Open clearance of
0.25～0.35
the 2nd ring
Open clearance of
0.15～0.30
the 3rd ring
9.3.4 Crankshaft
Axial clearance of crankshaft
1 ） Install micrometer gauge, lean the top of micrometer gauge to crankshaft terminal, remove
crankshaft fore and aft, measure axial clearance of crankshaft. If the
measured valve exceeds the promised limitation valve, please
replace the thrust plate.
Model KD388
limitation
Axial clearance 0.10～0.188 0.40
of crankshaft
Lube oil clearance of crankshaft, connection rod bushing hole and main bearing hole
(1) Painting check of journal neck
Clean crankshaft, check whether there is crack by painting infiltrating or magnetic inspection. If there is
crack or severe damage, please replace the crankshaft.
(2) Measure diameter of connecting rod journal with outside micrometer; measure connecting rod
bushing diameter with inside lever meter, then count the lube oil clearance. If the measured valve
exceeds the limitation valve, please replace crankshaft or connecting rod bushing.
Model KD388
Item Maintaining
Standard
limitation
Connection rod
bushing aperture
and crankshaft 0.025～0.075 0.15
connection rod
shaft diameter
(3) Check crankshaft main journal diameter with outside micrometer, measure the main bearing hole
diameter with inside lever meter, then count the lube oil clearance. If the
measured valve exceeds limitation valve, please replace crankshaft or main
bushing.
Model KD388
Item Maintaining
Standard
limitation
Main bearing hole
and main neck 0.025～0.079 0.15
journal
9.3.5 Lubricating system
Inside /outside rotor clearance of oil pump
Measure the clearance between outside rotor and inside rotor with
thickness gauge, if the measured valve exceeds limitation valve, please
replace the oil pump parts.
Model KD388
limitation
Axial clearance of inner /outer 0.05～0.10 0.15
rotor of oil pump
Clearance between oil pump hole of gear chamber and outer rotor
Measure the clearance between outer rotor and oil pump hole with thickness gauge. If the measured
value exceeds the limitation value, please the oil pump rotor parts.
Model KD388
limitation
Clearance between oil pump 0.08～0.155 0.20
hole and outer rotor
9.3.6 Cooling system

Fan belt tension
Press the fan belt with 10kg force between the two belt pulley, check whether the fan belt flexivity is 8
～12mm. If the belt flexivity is not within the limitation range, adjust the location of charging generator
to adjust it.
Open temperature of thermostat

Add a piece of line between valves of thermostat, put thermostat
and a temperature gauge into a barrel. Heat the water in barrel
gradually, hold on the line and hang thermostat in air. Thermostat
will open as the water temperature increases, please read the
temperature. Go on heating, when the thermostat opens for about
6mm, then read again the temperature. If the temperature is not in
the leaving factory range, you should replace thermostat.
Model KD388
Item Standard
Open temperature of 69.5℃～72.5℃
thermostat
Complete open 85℃
temperature of
thermostat
Check water leakage of radiator
Fill some water into radiator, install radiator tester, and increase water pressure to 137kPa. Check the
water leakage of radiator, if the quantity of water leakage is too much, please replace radiator. If the
water leak hole is small, please adjust with radiator filling agent.
9.3.7 Fuel system

Check the fuel pressure
Install fuel injector on fuel injector tester, remove test handle of fuel
injector slowly, and check the instant pressure when fuel is ejected out. If
the measured valve is not within the limitation range, please replace fuel
injection gasket.
Check the spray of fuel injector
Install fuel injector on fuel injector tester, and check the spray of fuel
injector. If the state of spray is not good, please replace fuel injector parts.
Check the sealing of fuel injector

Install fuel injector on fuel injector tester, raise the fuel pressure,
and keep at 12.7MPa for 10s. If there is oil leakage, please replace
fuel injector parts.
10. Troubleshooting
10.1 Fail to generate or abnormal generating
Fault Reason Troubleshooting
Disassemble to check whether it is open circuit, the
1. The air breaker fails
resistence should be '0'
Control 2. The connection wire of control panel
Check the wiring harness
panel looses
3. The receptacle connector looses or
Check or replace the receptacle
melts
1. The outlet terminal of motor stator
Check the wiring harness
looses
2. The connection terminal of motor stator
Check or replace the connection terminal
crazes or melts
Check the resistence of connection terminal,
3. Break circuit of motor main winding coil
reconnect or replace the stator
Check the resistence of connection terminal,
4. Short circuit of motor main winding coil
reconnect or replace the stator
5. Open circuit of motor exciter winding Check the resistence of secondary winding insert,
coil reconnect or replace the stator
6. Open circuit of motor sampling winding Check the resistence of sampling winding insert,
coil reconnect or replace the stator
Check the motor temperature and resistence, or
7. Short circuit of motor main winding coil
replace the stator
8. Open (break) circuit of motor rotor Check the resistance of rotor exciter, reconnect or
winding coil replace the rotor
Check the resistance of rotor exciter, reconnect or
9. Short circuit of motor rotor winding coil
replace the rotor
Motor 10. The motor rotor exciter loses Check the voltage of stator coil of rotor exciter or
fault excitation AVR output terminal
11. Short circuit of motor rotor collection check the resistance of collection ring, reconnect or
ring replace the rotor
12. The motor rotor connection shaft Check the motor noise when starting and the
looses resistance, replace the front end cover
Check the motor temperature and resistance, or
13. Short circuit of motor stator /rotor
replace the stator or rotor
14. Motor fault caused by engine output Check the engine noise when starting or motor
shaft wearing temperature, replace the engine
Check the motor noise when starting or motor
15. The motor fan crazes
temperature, replace the rotor
Check the motor noise when starting and the
16. The motor bearing is worn
resistance, replace the front end cover
17. The motor stator or rotor is Check the motor temperature and resistance, or
overheated replace the stator or rotor
18. Short circuit of interturn or the stator
Check the wire color of stator or rotor winding
/rotor coil changes color
19. The generator insulation resistance Check the insulation resistance of stator /rotor with
decreases piezometer, or replace the motor staor /rotor
1. The adjusting potentiometer fails, can't
Check the output voltage, adjust or replace AVR
regulate the voltage
Check the output voltage or adjust AVR, check the
2. The voltage deviates
connection wiring harness
3. The generator set stops automatically,
Check the output power, adjust or replace AVR
wrong current setting
4. The electrical apparatus element fails Replace AVR
5. No excitation output after inputting the Check AVR excitation output voltage, adjust or
sampling signal replace AVR
AVR
6. Insufficient excitation voltage of exciter
fault Chekc the magnetic steel of motor exciter
magnetic steel
7. Outout increases and AVR
Check the load
consumption increases
8. Deviation between full load and zero Check AVR and motor temperature, replace motor
load is too big or AVR
Check or decrease the load, check the voltage of
9. The voltage increases too much
AVR secondary winding, or replace AVR
10. The excitation connection wire is
Modify the connection wire
mistaken
Control 1. No displaying
Check the 12V electric power, and the connection
panel 2. Error displaying
wire, or replace the display
fault 3. Fail to start
10.2 Digital panel electrical system

1. The fuse on the panel breaks Replace the fuse
2. The electric starting switch fails or
No display Check or replace the electric starting switch
poor connection
3. Poor connection of inserter Check moduel No.9, PIN inserter and data wire
1. Insufficient oil quantity Refill in oil
2. The lubrication system is faulty Check the lubrication system
Replace the low oil pressure switch of the same
P-01 3. The low oil pressure switch fails
model
4. Short circuit of low oil pressure
Check the circuit
switch
Check the sampling wiring harness, there should
1. Sampling wire disconnects
be no voltage or frequency display on the panel
Check the output frequency with multimeter, the
2. Abnormal frequency (Too high or displaying value should be the same with the real
P-02
too low) value. Adjust the engine rotating speed, set the
output frequency the same with the factory setting
3. Abnormal fuel system, the engine
Check the fuel system
rotating speed is unstable
Check the voltage sampling wiring harness, there
1. The sampling wire disconnects
should be no voltage or frequency display
Check the output voltage with multimeter, the
2. Abnormal voltage (too high or too displaying value should be the same with the real
P-03
low) value. Adjust AVR, set the output voltage the same
with the related value
3. Open circuit of excitation circuit Check the excitation wire and carbon brush
4. AVR or motor fails Replace AVR or motor of the same type
Decrease load less than the related load, turn on
P-04 1. Overload
the brealer
1. Fuse of starting circuit disconnects Replace the fuse of the same type
2. Starting circuit disconnects or poor
Check the circuit and inserter
P-05 connection of inserter
3. The starting motor fails Replace the starting motor
4. The charging motor fails No input of starting signal
P-06 1. The emergent stopping button fails Replace the emergent stopping button
Check the charging generator AC signal wire and
P-07 1. Open circuit of charging circuit
inserter
　 2. Charging motor fault Replace the charging geberator of the same model
Disconnect the breaker, stop the generatot set
1. The temperature of cooling water is
after running with zero load for a while. Restart the
too high
generator when the water temperature decreases
2. Insufficient water in the water tank Refill in cooling water
P-08
3. Short circuit of water temperature
Check the circuit
switch
Replace the water temperature switch of the same
4. The water temperature switch fails
type
10.3 Alarm system fault

1. Insufficient oil Refill in oil
Lubricant alarms
2. The oil filter is blocked Replace the filter element
1. Insufficient cooling water in Refill in cooling water
radiator
2. The radiator element is dirty Clean the radiator element
Cooling water
3. Cooling water leaks, the Check the leaking parts, clean or replace
temperature
cooling water pipe is polluted the cooling water pipe
indicator light
4. The fan and driving V strip of Tighten or replace
water pump loose
5. Cooling water pump fault Maintain or replace the water pump
1. Battery fault Check the electrolyte and recharge, or
Charging indictor replace the battery
light 2. Circuit fault Check, repair or replace
3. AC generator fault Repair or replace the generator
Insufficient inlet Air filter element is dirty Clean the filter element with
pressure indicator compression air or replace it
light
10.4 Fail to start

1. No fuel in the fuel tank Refill in fuel
2. Air mixed in the fuel system Drain out air
3. The electromagnetic valve is off Check the electromagnetic valve, repair or replace
4. The fuel is not qualified Use the correct type of fule
5. The air filter element is dirty Replace the filter element
6. The circumstance temperature is Use the air heater
low
Suppl 7. The fuel filter element is blocked Replace the diesel filter element
ying 8. The oil supplying timing is Check and adjust the oil supplying advanced angle
syste incorrect
m 9. The fuel injector is blocked Check or replace the nozzle parts
fault 10. Incorrect inlet /exhaust valve Check and adjust the valve clearance
clearance
11. Cylinder compression is poor Check the cylinder compression pressure, standard
value is 3.1 Mpa, and the minium value is 2.2 Mpa
(1) The valve leaks gas Check and grind the valve
(2) The cylinder, piston and piston Maintain by professional
ring are severely worn
12. The starting oil quantity of oil Check and adjust on the test desk
injection pump is too little
1. Insufficient battery electric Check the connector or the electrolyte level and
quantity or the connector looses proportation and recharge
2. The engine rotates with no load Check or replace the engine
Circuit
3. Hard to mesh Adjust the relative position between engine and
fault
flywheel gear ring end
4. Low rotating speed Voltage drops greatly in winter or battery guide wire is
slender
10.5 Instable engine rotating speed
Insufficient oil supplying Adjust or clean

Instabl
Oil supplying angle of oil pump is
e Check the oil pump or replace the nozzle
incorrect or nozzle is faulty
engine
Generator is over load or short circuit Check the load or check the output current
rotating
Insufficient cooling water, or high Check the water level of water tank after
speed,
temperature caused by fan belt skiding stopping the engine and check the fan belt
too
Insufficient oil pump pressure caused by
high or
oil leakage or inlet /exhaust valve Check the inlet /exhaust valve clearance
too low
clearance leaks gas
10.6 Abnormal color of exhaust smoke

1. The engine is overload Reduce load
2. The air filter element is blocked Clean or replace the air fileter element
3. The fuel is not qualified Use the correct type of fuel
4. The valve clearance is too big Check and adjust the valve clearance
5. The fuel injector is blocked or leaks Checl the fuel pressure and spray
oil quality
Black smoke
6. The oil supplying timing is incorrect Check and adjust the oil supplying
advanced angle
7. The valve is not sealing Check, repair and grind the sealing ring
strip
8. The cylinder, piston and piston ring Repair or replace
are over worn
Check the oil level in the crankcase oil
1. The oil level is too high tray with oil rule and drain oil
2. Too much spray of respirator Check the sealing of respirator valve
3. The valve oil seal fails to work or and fluent of oil return hole
Blue smoke
valve rod clearance is too big Replace the valve oil seal or repair the
4. The inlined ring is installed valve and guide pipe
mistakenly (the 2nd ring) Check and repair (the oil stripper is at
the bottom side)
1. Temperature in winter is low, so it is Drain out oil and water
normal for white smoke after starting,
the white smoke will disappear when
temperature rises
2. Much water mixed in the fuel, the Check the fuel injection pressure and
water vapor drains out spray quality
White smoke
3. The fuel fails to pulverizate, the oil Check and adjust the oil supplying
vapor drains out advance angle
4. The fuel injection advanced angle Check why the cooling water inleaks in
is too late, oil vapor drains out the cylinder and mend it
5. The cylinder, cylinder cover and
cylinder gasket leak
10.7 Insufficient engine power

Isufficient 1. The air filter element is dirty, air Clean or replace the filter element
engine power inlet is not fluent
2. The fuel filter element is dirty, oil Clean or replace the filter element
inlet is not fluent
3. Fuel duct is blocked, oil supplying Check and clean or replace the oil pipe
is not fluent
4. Air sucked into the oil suction pipe Check for leakage and air exhausting
connector
5. The speed adjusting spring softs, Check and adjust the engine rotating
rotating speed reduces speed
6. The oil quantity limitation level is Enlarge the oil quantity limation level
too little, insufficient oil supplying
7. The oil supplying quantity of oil Check the oil supplying of oil supplying
supplying pump is too little pump
8. The oil supplying advanced angle is Check and adjust
wrong
9. The oil injection pressue and spray Check and adjust
are poor
10. The valve clearance is incorrect Check and adjust
11. The oil quality is poor Use the correct type of fuel
12. The ventilation hole of fuel tank Check and dredge
cover is blocked
13. The cylinder compression Check the cylinder compression
pressure is insufficient pressure is 3.1 Mpa
(1) The valve leaks gas Check and grind the valve or replace
the valve and valve washer
(2) The cylinder gasket leaks gas Tightent the cylinder cover bolt or
replace the cylinder gasket
(3) The cylinder, piston and piston Replace the relevant parts
ring wears
(4) The installation hole of fuel Tighten or replace the fuel injector
injector leaks gas washer
10.8 Instable running

1. Air mixed in the fuel system Drain out air, check the leakage of oil
suction pipe connector
2. The accelerator pulling rod is not Operate on the oil pump test desk
flexible or clearance is too big
Instable running 3. Speed adjusting is not flexible Operate on the oil pump test desk
4. Oil supplying of each cylinder of Operate on the oil pump test desk
fuel injection pump is not uniform
5. The spray quality of fuel injector is Operate on the oil pump test desk
poor
10.9 The engine is overheated

Outlet water 1. Insufficient cooling water in the Refill in cooling water
temperature is water tank
too high 2. Air resistance in the cooling water Refill in water or drain out air
tank
3. The engine is overload Reduce load
4. The fan belt looses and rotating Tighten or replace the belt
speed reduces
5. The cooling water pipe is blocked Check or replace
6. The fuel injection is too late Adjust the oil supplying advanced
angle
7. Abnormal combustion Check the spray quality
8. The surface of water tank is too Wash the heat dissipation chip of
dirty water tank
9. The cooling system is incrusted Wash the incrustation and iron rust
severely professionally
10. The thermostat is damaged Replace the thermostat
11. The water pump is faulty, Check, repair ot replace the water
abnormal water pumping pump
12. The water temperature gauge is Replace
faulty, wrong reaction
1. Too much or too little oil Check the oil level with oil gauge
2. The oil quality is too bad Use the correct type of oil
3. The gas blowby of piston ring is too Check the damage of cylinder and
much piston ring, scuffing and clipping of
Oil temperature cylinder
is too high 4. The cooling water temperature is Eliminates according to above
too high mentioned
5. The engine is overload Reduce the load
6. The oil temperature gauge is Replace
damaged
10.10 Suddenly stop

Suddenly 1. No fuel in the fuel tank Refill in fuel
stop 2. Fuel piep leaks, air sucked into the oil Check for leakage; drain out air
duct
3. Fuel filter element is blocked Replace the fuel filter element
4. The electromagnetic valve of oil pump Check the electric circuit and
is powered off, cutting off the fuel electromagnetic valve
supplying
5. Fuel supplying pump fails to pump Replace the oil supplying pump
6. Fuel injection pump damages, fails to Replace the oil injection pump
pump
7. The crankshaft fails to rotate Disassemble the engine and find out the
reason
(1) Scuffing and clipping of cylinder Maintain by professional
(2) The oil pressure is too low or lack of Maintain by professional
oil
(3) The oil pump is damaged and fails to Maintain by professional
pump
(4) The valve hits the piston, cylinder Maintain by professional
sheath and cylinder cover
10.11 Abnormal noise during running

1. Valve clearance is too big, sound of Check and adjust the valve clearance
shocking
2. Cleanrance between piston and Check and rereplace the worn parts,
cylinder is too big, sound of shocking keep the correct clearance
3. Axial clearance between main bushing Check the crankshaft neck journal,
and connection rod bushing is too big, replace the bushing
sound of shocking
4. Clearance between piston pin and Check and replace the connection rod
connection rod small head bushing is too bushing and piston pin
Abnormal
big
noise
5. Clearance between piston ring and ring Replace the piston and piston ring
during
groove is too big
running
6. Crankshaft axial clearance is too big Replace the thrust
7. The valve hits the piston Check the valve clearance, valve
distribution phase and cylinder
compression clearance
8. Gear clearance is too big, sound of Replace the gear
shocking
9. Fuel injection is too early, sound of Check and adjust the oil supplying timing
cylinder hitting
10. The fuel injector parts are seized Clean or replace the nozzle parts

KDE11-100SS GENERATOR SET Maintenance Manal

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KDE11-100SS GENERATOR SET Maintenance Manal

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Preface

1.2 Install, move and transport genset

For safety, please observe following matters needing attention.

● Check if machine bolts are loose or missing.

Ensure the ventilation is enough in the machinery room.

1.7 Warning labels and position

1.7.2 Warning label

1. Pay attention to 2. Pay attention to exhaust 3. Pay attention to scalding

4. Pay attention to high

Don’t open the water tank Hooking position Smoking or spark is

7. Hooking is 9. Avoid being involved in

11. Pay attention to

Don’t run engine without checking oil level in case of

12： Attended operations

1.8 Rescue the casualties shocked by electricity

Please work the machine in the well-ventilated place. Bad

2.2.1 Pay attention to vibration

2.2.2 Pay attention to noise

2.2.3 Pay attention to installation

2.3.1 Long-term storage

Overall length 1570mm

Model KDE11SS KDE13SS

Rated rotation speed rpm 1500 1800 1500 1800

Receptacle Two single phase receptacles

Continuous running time h 17 15 17 15

Model KDE13SS3 KDE15SS3

Rated rotation speed rpm 1500 1800 1500 1800

Receptacle Two single phase receptacles

Model KD388 KD388Z

Compression ratio 18.2 17.5

Firing order 1－3－2（from flywheel terminal）

Max. torque (N·m) 96/1800 116/1800

Lubricate type Pressure splashed mixing type

Starting type Electric starter

Lube capacity L 6.9

Fuel consumption g/(kW·h) 2.72

Starting motor V,kW 12V 1.4kW

Charging generator capacity V,A 12V 15A

Battery capacity V,AH 12V 80AH

Overall dimension: LXWXH mm 610×480×642

Net weight kg 170 175

NO. Name Standard dimension Fit Remark

rod bearing / Connecting rod 0.025~0.075

and connecting rod bid end 0.40~0.53

diameter of crankshaft flywheel 0~0.108

3.2.3 Main Adjusting Data Table

3.3 Maintenance parameter of generator

Generator set model KDE11SS KDE13SS

3.4 Principle diagram of electrical system

electrical schematic diagram

1. Fuel inlet 10. Transportation hook

2. Fuel meter 11. Air vent

3. Check side door(one side of generator) 12. Exhaust vent

4. Check side door(one side of machine) 13. Cover of water tank

5. Drain cock of cooling water 14. Output panel

6. Drain cock of lubricant 15. Door of operation panel

7. Drain cock of fuel 16. Operation panel

8. Cover of fuel tank 17. Single-phase socket

2. Fuel tank 14. Drain cock of lubricant

Receptacle 　 Two single phase receptacles

Net weight 　kg 170 175