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WUXI KIPOR POWER CO., LTD.

Beside Jingyi Rd

Third-stage Development Section of

Wangzhuang Industry Area, Wuxi High &

New Technology Industry Development Zone

Wuxi, Jiangsu Province, PRC

TEL: 0086-510-85205041

FAX: 0086-510-85203796

E-MAIL: [email protected]

Version 1, Printing date June.13, 2008.

MADE IN CHINA

Summary of Contents for KDE100SS3

Page 1: ...WUXI KIPOR POWER CO LTD Operation Manual KDE11SS KDE13SS3 KDE16SS KDE20SS3 KDE25SS KDE30SS3 KDE30SS KDE35SS3 KDE35SS KDE45SS3 KDE60SS3 KDE75SS3 KDE40ST3 KDE100SS3...

Page 2: ...ough understanding of this instruction Place this instruction in the fitting box or near machine after reading because it is regularly needed If this introduction is lost or damaged please order one f...

Page 3: ...uction 8 3 Installation and transportation 11 4 Connection of load 13 5 Fuel lubricant cooling water battery 18 6 Running the generator 22 7 Periodical maintenance and service 28 8 Troubleshooting 34...

Page 4: ...s very likely to occur Attended operation Indicates that mechanical damage or shorter duration is likely to occur in case of neglect Don t lend this generator to others or use it together with others...

Page 5: ...ne immediately Report to the superior and take proper measures Forbid working the machine before abnormality is eliminated The warning labels should be stick to the main body of the generator Stick th...

Page 6: ...erating Cut off the breaker circuit to stop the generator before opening the control box to transfer the voltage Ground protection If ground mode is not right the ground protection won t function And...

Page 7: ...you open the radiator cover while the temperature of the cooling water is very high the splashed water or steam may scald you seriously The temperature of cooling water is very high immediately after...

Page 8: ...tify the warning label DANGER NOT RUN at obvious positions such as starting switch in order to avoid unnecessary persons carry out unintended operation Never check or maintain the generator when the e...

Page 9: ...fted generator Don t lift or move the generator when the engine isn t stop Otherwise it may break the cooling fan and cause a fatal fault Fix the generator with ropes after putting a generator into th...

Page 10: ...concern It is forbidden to connect the generator with distribution line of power company and distribution line in the building willfully Only professional technicians with required skills are allowed...

Page 11: ...ting level 2 Cooling water inlet 9 Water outlet 3 Control panel door 10 Fuel outlet 4 Emergent stop button 11 Oil outlet 5 Output connection box 12 Slotted hole 6 Muffler exhaust 13 Fuel filling port...

Page 12: ...3 Inner structure Rainproof cap Radiator Muffler Oil water separator Overflow pot Air filter Battery Alternator Engine Oil filter Fuel filling port of inner fuel tank Fuel filling pump of outer fuel...

Page 13: ...aust vent upwards preventing them from any jam Otherwise temperature may rise or cooling airflow may be reduced thus causes overheat of engine or reduction of rotation speed In addition temperature of...

Page 14: ...embling the generator The noise of the open frame generator may impact on the people nearby Take measures to prevent the noises ex to build room against noises Placement The generator should be put on...

Page 15: ...nd be broken Lift the generator by using the lifting lever at the center of the engine cover Anyone shouldn t stand under the lifted generator Don t lift or move the generator when the engine isn t st...

Page 16: ...power of squirrel cage asynchronous motor kVA Input power kVA Rated power of motor kW Motor efficiency x Power factor Power factor of motor 0 8 Motor efficiency 0 8 Input power kVA 1 56x rated power...

Page 17: ...apacity specified in the technical standard for the electric appliance Please use the grounding rod of whose resistance meets the electrical standard If it classes to D grounding No 3 grounding ground...

Page 18: ...e the proper sleeve Cover the connection part with insulation tape The connection part shall be above the ground Please check it periodically Keep the grounding rod at least 2m away from the lighting...

Page 19: ...f generator takes single phase and three phase current into account When AC voltage meter reading is 400 416 the single phase output voltage is 230 240V If select the single phase output output of sin...

Page 20: ...tighten the forcing screw securely 4 4 Selection of 3 phase cable Attended operations Please select the cable with proper diameter after taking into account tolerable current of cable and distance fro...

Page 21: ...22 30 38 100A 22 30 38 50 50 60 200A 60 60 60 80 100 125 300A 100 100 100 125 150 200 The application of the multi core insulating cable mm2 Length Current Below 50m 75m 100m 125m 150m 200m 50A 14 14...

Page 22: ...GB T252 1994 JISK2204 5 or above 10 2 15 or above 20 25 or above 30 3 2 Use of fuel a Fuel with water or foreign matters may cause bad working b Store the fuel in the clean container c Container shall...

Page 23: ...icant 3 Use of lubricant Avoid foreign matters or dust falling into lubricant upon storage and handling Please pay particular attentions to minor foreign matters around lubricant inlet upon lubricant...

Page 24: ...e falls down Thick anti freezing liquid also affects cooling effect for engine Mix according to proper combination ratio 2 Anti freezing liquid It is no need to add more anti rustiness agent because a...

Page 25: ...much battery energy even burn the starting motor Never check the battery until the engine is stopped Don t disconnect the battery when the generator is still running otherwise the motor or control ci...

Page 26: ...ding to extreme risk When connecting the distribution line of storage battery connect the positive wire first and negative wire finally Ensure sufficient ventilation during charging Keep away from ign...

Page 27: ...any overflow when machine is running fill in amount shall be approximately 90 of tank volume 6 1 2 Keynotes fro filling fuel with outside fuel tank Ensure tight connection of fuel pipe with the outsid...

Page 28: ...e remained on the oil gauge indicates measurement d Re confirm it after 3 5min running 6 1 4 Fill cooling water Close the radiator water inlet cover tightly Otherwise ejected steam or hot water may ca...

Page 29: ...running without mentioned operation it may cause abnormal abrasion or damage to piston cylinder sleeve crank shaft bearing and other parts a Check if any abnormal sound or leakage of water oil or gas...

Page 30: ...or rag in the generator Check if there is any rubbish or inflammable matter around muffle or engine If any remove it away immediately Check if suction inlet and exhaust vent of generator is jammed by...

Page 31: ...is cool Attended operations Check quantity of cooling water 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...

Page 32: ...ne is heated and runs Heat the machine for about 5 minutes no load a Adjust the regulating screw rod of oil pump till frequency is up to rated value b Adjust the voltage with voltmeter as per specific...

Page 33: ...tended operations If generator produces any abnormal sound please stop running it immediately for check and repair If continue to run machine at abnormal status unexpected serious accidents may occur...

Page 34: ...nutes at zero load d Turn off the starting switch key to stop the engine e Pull out the key and keep it safely Attended operations Never stop the engine emergently Otherwise the temperature of engine...

Page 35: ...s a good practice to do routine check before machine starts every day Refer to 6 1 for keynotes about check before work Please use the original parts Replace the damaged parts with our original parts...

Page 36: ...eplace engine oil Replace engine oil filter element Clean air cleaner Measure insulation resistance of the generator Once for a month Check specific gravity of the battery electrolyte Check for every...

Page 37: ...e the oil filter with special wrench Clear the filter installation end Smear thin lubricant on the seal gasket Screw on the filter with hands and then tighten it with the special wrench securely 3 Che...

Page 38: ...pread oil film on the spring gasket surface Install it by oil cleaner wrench connect surface with oil cleaner gasket and tighten c Run engine for a while after replace the element Check oil position B...

Page 39: ...roportion 7 1 3 Check for every 500 Hrs Check for every 500 Hrs should cooperate with check for every 250 Hrs 1 Check spring gasket of fuel filter a Screw off the fuel filter by filter wrench and take...

Page 40: ...lace of important parts Make sure to periodically replace the parts which may cause fire hazard due to aging or damage Replace the parts of fuel system fuel pipe and fuel tank cover every two years or...

Page 41: ...Clean the radiator Replace seal ring of fuel filter Clean the inner of the fuel tank Replace the air cleaner element Check valve clearance First Adjust fuel nozzle Check fuel injection time Check damp...

Page 42: ...while Don t service the electric fan until it stops entirely Electric shock Don t touch the inner parts with high voltage during the running Stop the engine and disconnect the breaker to service and m...

Page 43: ...n oil pipe Bad Air around pipe Empty air Fuel oil cleaner walled up Replace fuel oil cleaner element clean or replace filter Compression leakage Mend the engine The engine stops automatically And the...

Page 44: ...tifier is burnt Rotor circuitry break The voltage value is not right or there is no voltage Engine circuitry is burnt Bad voltmeter Replace Bad AVR Consult with dealer Bad VR Rotary rectifier is burnt...

Page 45: ...system 5 Wipe off the dirty and grease stain on the machine 6 Remove the battery cable Charge the battery once a month 7 Check the generator periodically 8 Prevent vapor or dust falling into the cont...

Page 46: ...the modified coefficient is C 0 04 Counting example When the rated power of generator is PN 5KW altitude is 1000m ambient temperature is 35 relative humidity is 80 the rated power of generator is P PN...

Page 47: ...KD388G KD488G Type Three cylinder 4 stroke direct injection Four cylinder 4 stroke direct injection Cylinder No Bore Stroke mm 3 88 90 4 88 90 Displacement L 1 642 2 19 Compression ratio 18 2 1 Rated...

Page 48: ...cylinder 4 stroke direct injection supercharged Four cylinder 4 stroke direct injection Cylinder No Bore Stroke mm 4 93 102 4 93 102 4 105 125 Displacement L 2 771 2 771 4 33 Compression ratio 18 2 1...

Page 49: ...ree cylinder 4 stroke direct injection Four cylinder 4 stroke direct injection Cylinder No Bore Stroke mm 3 88 90 4 88 90 Displacement L 1 642 2 19 Compression ratio 18 2 1 Rated power KW r min 12 3 1...

Page 50: ...ylinder 4 stroke direct injection Four cylinder 4 stroke direct injection CylinderNo Bore Stroke mm 4 93 102 4 93 102 Displacement L 2 771 2 771 Compression ratio 18 2 1 Rated power KW r min 23 2 1500...

Page 51: ...r 4 stroke direct injection Four cylinder 4 stroke direct injection Cylinder No Bore Stroke mm 4 105 125 4 105 125 Displacement L 4 33 4 33 Compression ratio 17 5 1 Rated power KW r min 40 2 1500 46 7...

Page 52: ...er 4 stroke direct injection Four cylinder 4 stroke direct injection Cylinder No Bore Stroke mm 6 105 125 6 105 125 Displacement L 6 494 6 494 Compression ratio 17 5 1 Rated power KW r min 59 1500 70...

Page 53: ...15W40 Fuel consumption g kw h 320 Fuel tank capacity L 95 Engine Continuous running time h 6 Overall dimension LXWXH mm 1900 950 1200 Net weight kg 985 Starting mode 12V electric starting Noise at zer...

Page 54: ...stage Development Section of Wangzhuang Industry Area Wuxi High New Technology Industry Development Zone Wuxi Jiangsu Province PRC TEL 0086 510 85205041 FAX 0086 510 85203796 E MAIL kipor kipor com V...

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