2. OPERATING THE DIESEL GENERATOR
2-1 General main points of safety during operation of the generator set.
In order to operate the generator set safely ,please follow all the instructions provided in this manual
carefully . Doing so otherwise may lead to accidents and or equipment damage.
2-1.1 Fire prevention
The proper fuel for the diesel generator set is light diesel fuel . Do not use gasoline, kerosene and or
other fuels other than light diesel fuel. Keep a11 flammable fuels away from the generator as the
generator may spark and ignite these gases. In order to prevent fires from occurring and to provide
enough ventilation for people and the machine ,keep the diesel generator at least l .5meters away
from buildings and or other equipment.Always operate your diesel generator on a level site .If the
generator is operated on an incline , the lubricating system within the engine will not perform well
and may lead to failure of the engine.
2-1.2 Prevention from inhaling exhaust gases
Never inhale exhaust gases emitted by the engine. The exhaust gases contain toxic carbon monoxi-
de.Never operate your generator in places with poor ventilation.ln order to operate this machinery
indoors , a suitable ventilation system for the building is required to draw the poisonous exhaust
gases out.
2-1.3 Prevention from accidental bums
Never touch the muffler and its cover when the diesel engine is running .Never touch the muffler and
cover after the diesel engine has been used ,as the muffler remains hot for a good period of time.
2-1.4 Electric shock and short circuits
Never touch the generator if the generator is wet.Also never touch the generator if your hand is
wet.Never operate your generator if the weather conditions call for any type of precipitation such as
rain ,snow or fog .To prevent electrical shocks,the generator should be grounded. U se a lead to
connect the grounding end of the generator to the grounding surface of choice. Please refer to
Fig.2-1 and Fig .2-2 before beginning to use the electric generator.
NOTE:
When connecting devices to the generator, make sure all other devices are rated lower than
the generators output. Any generator socket should not be overloaded over its regulated limit.
2-1.5 Other safety points
Before operating this generator, ali operators should have a good knowledge of how to break the
circuit if any accidents occur. Also, all operators should be familiar with ali the switches and func-
tions of the generator before using this machine. While operating the generator, wear safe shoes
and suitable clothes during operation. Always keep children and animals away from the generator.
2-1.6 Battery
The electrolytic liquid of the battery also known as battery acid contains sulfuric acid. In order to
protect your eyes,skin and clothing, wear protective gear when working with the battery. If you
come in contact with the electrolytic liquid, wash it immediately with clean water. Also, if the elec-
trolytic liquid comes in contact with your eyes, see a doctor immediately.
2-2 Preparation before operation
2-2.1 Fuel choices and fuel treatment
Fuel tank
Use only light diesel fuel. The fuel should be filtered clean. Never let dust and water mix with fuel in
the fuel tank. Otherwise it will clog the fuel lines and oil nozzles. It may also damage your pressure
pump. Note: It is dangerous to overfill the fuel tank. Never exceed the red piston in the filter.
a. After purchasing fuel, put it into a drum and let it sit for 3-4 days.
b. 3-4 days later, insert half of the fuel sucker into the drum (water and impurities stay in the lower
portion of the drum).
Air filter element
Do not wash the air filter. The element is made of dry material, which does not permit washing.
When the output of the diesel engine is bad or the color of the exhaust gas is abnormal, replace the
air filter element. Never start the diesel engine without the air filter.
NOTE:
Never smoke near the opening of the fuel tank. Do not let sparks get near the fuel or fuel tank
and do not overfill tank. After filling, tighten the fuel cap.
2-2.2 Filling engine oil
Pouring inlet of lubricating oil
Put the generator set at level state, Fill the lubricating oil to it till the inlet. At the same time. Check
the oil level with dipstick. It is neecessary only to insert the dipstick lightly. Caution: Don 't ratate the
A.P.I
Classification of maintenance for diesel engine. The lubricating oíl should be CC or CD grade.
Engine oil is the most important factor in deterrnining the life of your generator engine. If you use
poor engine oil or if you don't change the oil regularly,the piston and cylinder will wear easily or
seize up. Also,the life of the other parts in your engine such as bearings, and other rotating part will
shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea to check
the amount of oil inside the engine .If the oil leve! is low ,fill it before tarting the engine. A good time
to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is
more difficult to drain all the oil out or sorne impurities will remain in the engine.
WARNING:
Don't fill engine oil when diesel is operating.
2-2.3 Check the air filter
(1)Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.
Do not use detergent to wash the air filter element. When the performance of the engine decreases
or when the color of the exhaust gases is bad, exchange the filter element.Never start the engine
without the air filter as foreign objects may enter the intake and damage the engine.
(2)After replacing the air filler element, replace the cover and tighten the butterfly nut firmly.
2-2.4 Checking the generator
(Note:Only certain welder generator sets have an electric Jan incorporated on them.)
Before starting the generator,make ure the air switch is in the "off" position .Starting the generator
with the switch in the "on" switch is very dangerous.
The generator should be grounded in order to prevent electric shock.
Use dry compressed air(with pressure about 1. (96 x 105 Pa )to blow the dust out in the electric
control cabinet and at the surface of the generator. Check to see how clean the surface
of the sliding ring is. Check the pressure of the carbon brush.Also,check whether the position
11
of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.
According to the electric wiring diagram, check to see whether the connecting wire is correct and
the connected place is firm.
Use a 500 M
Ω
meter to measure the insulation resistance of the electrical part. The resistance
should be no less than 5 M
Ω
. When measuring devices ,make sure the capacitor is turned off.
Otherwise, it will bum the capacitor. (For the low noise set,the inspection may not be performed).
2-2.5 The fuel and oíl in a new engine is drained before sold.
Before you start the engine, please fill the fuel tank and engine oíl first.Then,check to see if there are
air bubbles in the engine. lf there are, follow these procedures.Loosen the connecting nut between
the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles.
Then replace the connecting nut and tighten it.
2-3 Checking the operation of the diesel engine
2-3.1 Low-pressure alarm system.
The diese) engines have a low-pressure sensor system where if the oil pressure drops to low, the
sensor will shut the engine off. The purpose of having this system is to ensure that the engine does
not seize up. If there is not enough oil in the engine,the temperature of the oil will be raised too high.
On the contrary, if there is too much oil in the engine, the engine oil can slow the engine down
considerably.
2-3.2 Engine break in
When you purchase a brand new engine, the engine must be properly broken in. The break in period
is about 20 hours. (1 )Avoid overloading the engine when brand new.
(2) Change the engine oil according to specifications.An oíl change for a brand new engine is about
20 hours or every month,an older engine,the oil change is about 100 hours or three months.
2-4 Starting the generator set
2-4. 1 Manual starting.
Start the engine in accordance with procedures below: (1) Put the fuel switch in the "ON" position.
(2) Turn the handle of the engine to the "RUN" position.
(3) Pull the recoil starter handle out until you feel resistance. lt will reset to its original position
automatically. The handle should be reset into its recoil device slowly to prolong the life of the life
of the engine starter.
(4) In cold clima te, it is difficult to start the engine. To remedy this, pull the rubber plug out from the
rocker of the diese) engine and fill 2 ml of engine oíl. Before starting, put the rubber plug back in
place. If you don 't put the rubber plug back in place, rain, dust and other dirt can enter into the
diesel engine. It will cause the parts inside the diesel engine to wear quickly and lead to engine
failure.
2-4.2 Electric starting
The procedures for preparing to start eh engine are the same as the manual starting engine.
2-4.3 Battery
1. Insert key into ignition and put it in the "off' position.
2. Put the speed handle in the “RUN” position.
3. Tum the start switch clockwise to the "START" position; To set the silent type, first turn it clockwi-
se to the "RUN" (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now tum it
clockwise to the "START" position.
4. After the diesel engine is started, remove your hand from the switch handle; the switch will auto-
matically reset itself to the "ON" position.
5. lf the engine is not starting after 10 seconds of cranking, wait about 15 seconds before trying it
again. If you crank to long, the voltage of the battery will drop. This can lead to improper ignition.
When the diesel engine is operating, let the ignition retain on the 'ON"position.
NOTE:
If you crank the starter to long, the battery may be drained too much to provide enough
energy for proper engine ignition. Also, when the diesel engine is operating, Let the key retain in the
"ON" position.
IMPORTANT NOTICE:
Ali of our units come with a dry battery for shipping safety purposes.
In order to get your generator started for the first time; the battery must be filed with battery acid
which can be purchased at a local automotive supply store and slowly charged (trickle charged) for
a day. After charging, the battery may be used. To proerly maintain you battery; check the height of
the battery acid once a month. If the level of the liquid drops too low, fill it with distilled water until it
reaches the high mark. If there is not enough battery acid, then the diesel engine cannot be started.
lt is important to keep the liquid level between the high and low limits.
lf the leve] in the battery is too high, the liquid may flow out and end up on surrounding parts resul-
ting in corrosion of these parts. Note: Avoid too much or to little of battery acid. Check and fill it
once a month if necessary.
2-5 Procedures for starting the generator set
This procedure applies to the DDAEXE series recoil starting style models.
