DE25SS K DE30SS KDE35SS KDE30SS3 K DE35SS3 KDE45SS3 K DE60SS3 K D E 7 5 S S 3 K D E 10 0 S S 3 K DA 4 0 S T 3 KDE40ST3 K DA 4 0 S T O 3 SUPER SILENT TYPE CONTENTS 1. Safety label 1 2. Parts name 2.1 Appearance and parts name 2.2 Inner structure and parts name 2.3 Control panel 2.4 Electric schematic diagram 2.5 Electric wiring diagram 2.6 Generator function and operation manual 6 6 7 8 10 14 22 3. Transportation and storage 3.1 The transportation of the generator set 3.2 Storage 24 24 25 4. The connection of the load 4.1 The choice of the cable 4.2 The ground of leakage protector 27 27 28 5. Running mode 5.1 The check of the initial starting 5.2 Starting mode 5.3 Run 5.4 Stop 5.5 Protective 31 31 35 37 39 40 12. APPENDIX 6. The oil, cooling water and fuel 6.1 Engine oil 6.2 Cooling water 6.3 Fuel 41 41 41 42 Modified coefficient table of ambient condition power The conditions of generator rated output: Altitude: 0 m Ambient temperature: 25 Relative humidity: 30% Ambient modified coefficient: C (Relative humidity 30%) 7. Battery 7.1 Cautions for charging the battery 43 43 Altitude (m) 45 46 47 50 51 52 1000 2000 9. Troubleshooting 53 3000 10. Long-time storage 57 4000 11. The main specification data 58 0.54 0.52 0.5 0.48 0.46 0.64 0.62 0.6 0.58 0.56 0.87 0.75 0.85 0.73 0.82 0.71 0.80 0.69 0.78 0.66 0 500 1 0.93 0.98 0.91 0.96 0.89 0.93 0.87 0.90 0.84 25 Ambient temperature ( 30 35 ) 40 45 8. Periodical maintenance and service 8.1 The check of initial 50 hours 8.2 The check of every 250 hours 8.3 The check of every 500 hours 8.4 The check of every 1000 hours 8.5 Periodical maintenance and service chart Note: When the relative humidity is 60%, the modified coefficient is C-0.01 When the relative humidity is 80%, the modified coefficient is C-0.02 When the relative humidity is 90%, the modified coefficient is C-0.03 When the relative humidity is 100%, 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 P=PN (C-0.02) = 5 , relative humidity is 80%, the rated power of generator is: (0.82-0.02) = 4KW - 12. APPENDIX 65 Ultra Silent enerator (Three phase) 1. SAFETY LABEL The followings are illumination of the safe label. Indicates a strong possibility of severe personal injury even death if instructions are not followed. Indicates a possibility of personal injury or equipment damage if instructions are not followed. In order to make the generator to extend its service life, follow these instructions.Lend this generator to others, or use it with others who must read this manual beforehand and understand the whole operation manual. It will impact on safe performance and reduce the life if you modify the generator.We wouldn't warrant the generator that is modified or not used with genuine parts. The warning labels should be stick to the main body of the generator. Don't damage the label or let the labels fall off. Strictty follow the lables Exhaust gas Three phase "Y" connection/Brushless self-excitation and constant voltage (AVR) DANGER direct injection WARNING 0# (summer), -10# (winter), -35# (chillness) diesel SAE10W30 (above CD grade) KDE40ST3/KDA40ST3/KDA40STO3 water cooled CAUTION 1300 12V Electric starter Ultra silent 272 950 960 95 78 70 - KM493G-1 400/230 102 4-stroke 93 40/3000 0.8(lag) 18.2:1 2.771 3000 30.4 54.8 50 38 H 2 4-cylinder in line 2250 WARNING DANGER The exhaust is toxic. Exhaust gas contains poisonous carbon monoxide. Overall dimension: LxWxH(mm) Noise at related load dB (A)/7m Rated rotation speed (r/min) Loop mode/Excitation mode Never run the generator in an enclosed area. Structure type Continuous running time Rated power[kW/(r/min)] Rated frequency (Hz) Power factor (cos ) EXHAUST Rated output (kVA) Rated output (kW) Compression ratio Fuel tank capacity Model Fuel consumption Rated voltage (V) Rated current (A) Noise dB (A)/1m Insulation grade Starting system Be sure to provide adequate ventilation. The exhaust vent shouldn't open to the passenger and the others. Engine model Displacement Bore x Stroke Pole number Lube oil type Engine type Weight(kg) Fuel type -64- Set Engine Generator - - DANGER DANGER DANGER Electric shock Ground protection Danger Rotary parts Generator Don't touch the inner rotary parts. It's very dangerous. Close and lock the side door when running the super quiet generator. If you have to open the side door, don't stick head and hands to generator inner. The cooling fan of the radiator will go on rotating after stopping the engine for a while. Maintain and service the generator inner parts only after stopping it. If ground mode is not right, the ground protection won't function. And it will cause electric shock even to death. The outer box grounding terminal and load machine outer box must be grounded. It will cause electric shock even death if touch the naked cable during the running. Cut off the circuit to stop the generator before connecting the terminal. Never touch the machine with wet hands or electric shock will occur. Output terminal cover should be closed. Tighten all screws before running this generator. There is enough voltage even at an idle speed, therefore, make sure the generator is stopped thoroughly. Don't touch the inner circuit when generator is running. Control box should be closed all along and all of its screws should be tightened before running the generator. Close and lock the side door of the super quiet generator before operating. Cut off the breaker circuit to stop the generator, before opening the control box to transfer the voltage. Engine Set - Model RUNNING KDA30SSO3 KDA35SSO3 KDA45SSO3 KDA60SSO3 KDA75SSO3 KDA100SSO3 Rated frequency (Hz) Rated output (kVA) Rated output (kW) Rated voltage (V) Rated current (A) Rated rotation speed (r/min) Loop mode/Excitation mode Power factor (cos ) Insulation grade Pole number Engine model Engine type 50 24 19.2 400/230 34.6 1500 60 28 22.4 416/240 38.9 1800 50 28 22.4 400/230 40.4 1500 60 35 28 416/240 48.6 1800 0.8 (lag) H 4 KM493G H 4 KM493ZG 50 37 29.6 400/230 53.4 1500 60 45 36 416/240 62.5 1800 50 50 40 400/230 72.2 1500 60 60 48 416/240 83.3 1800 50 62 49.6 400/230 89.5 1500 60 75 60 416/240 104 1800 0.8 (lag) H 4 KD4105G 4-cylinder in line 4-sroke water cooled 4-cylinder 4-cylinder in line 4-sroke water cooled direct injection in line 4-sroke supercharge water cooled direct injection 50 80 64 400/230 115 1500 60 100 80 416/240 138.8 1800 Three phase "Y" connection/Brushless self-excitation and constant voltage (AVR) Three phase "Y" connection/Brushless self-excitation and constant voltage (AVR) H 4 KD4105ZG 4-cylinder in line 4-sroke water cooled direct injection supercharge H 4 KD6105G H 4 KD6105ZG 6-cylinder in line 4-sroke water 6-cylinder in line 4-sroke water cooled direct injection cooled direct injection supercharge - Bore x Stroke Displacement Compression ratio Rated power[kW/(r/min)] Fuel type Lube oil type Fuel consumption Fuel tank capacity Continuous running time 93 102 2.771 18.2 : 1 93 102 2.771 18.2 : 1 105 125 4.329 17.5:1 0# (summer), -10# (winter), -35 (chillness) diesel 105 125 4.329 17.5:1 105 125 6.494 17.5:1 23.2/1500 30/1800 28.5/1500 36.9/1800 41.6/1500 49.3/1800 51/1500 60.6/1800 62/1500 SAE 10W30 (above CD grade) 320 95 12 Overall dimension: LxWxH(mm) 1900 Weight(kg) Starting system Noise dB (A)/1m Noise at related load dB (A)/7m Structure type 105 125 6.494 17.5:1 74/1800 76/1500 SAE 10W30 (above CD grade) 300 95 10 950 960 12V Electric starter 91/1800 0# (summer), -10# (winter), -35 (chillness) diesel 300 95 11.5 1200 1900 950 985 68 51 70 53 68 51 70 53 Ultra silent 68 51 9 1200 8 2250 950 1270 12V Electric starter 24V Electric starter 290 95 7 1300 6.5 2250 950 1310 24V Electric starter 290 110 6.5 1300 6 2700 1140 1650 24V Electric starter 280 110 5 5 1500 2700 1140 1680 24V Electric starter 4 1500 70 53 68 51 70 53 68 51 70 53 Ultra silent 68 51 70 53 Model KDA30SS3 KDA35SS3 KDA45SS3 KDA60SS3 KDA75SS3 KDA100SS3 Rated frequency (Hz) 50 24 19.2 400/230 34.6 1500 0.8 (lag) H 4 KM493G 4-cylinder in line 4-sroke water cooled 4-cylinder 4-cylinder in line 4-sroke water cooled direct injection in line 4-sroke supercharge water cooled direct injection 60 28 22.4 416/240 38.9 1800 0.8 (lag) H 4 KD4105G KD4105ZG 4-cylinder in line 4-sroke water cooled direct injection supercharge 50 28 22.4 400/230 40.4 1500 1800 1500 1800 1500 1800 1500 1800 48.6 53.4 62.5 72.2 83.3 89.5 104 416/240 400/230 416/240 400/230 416/240 400/230 416/240 28 29.6 36 40 48 49.6 60 64 400/230 115 1500 35 37 45 50 60 62 75 80 60 50 60 50 60 50 60 50 60 100 80 416/240 138.8 1800 Rated output (kVA) Rated output (kW) Rated voltage (V) Rated current (A) Rated rotation speed (r/min) Loop mode/Excitation mode Power factor (cos ) Insulation grade Generator Three phase "Y" connection/Brushless self-excitation and constant voltage (AVR) Three phase "Y" connection/Brushless self-excitation and constant voltage (AVR) H 4 KM493ZG 4 H H 4 KD6105G H 4 KD6105ZG 6-cylinder in line 4-sroke 6-cylinder in line 4-sroke water water cooled direct injection cooled direct injection supercharge Pole number Engine model Engine type Engine Set Displacement Bore x Stroke 93 2.771 18.2 : 1 0# (summer), -10# (winter), -35 (chillness) diesel 102 2.771 18.2 : 1 17.5:1 4.329 93 102 105 125 105 125 4.329 17.5:1 105 125 6.494 17.5:1 74/1800 105 125 6.494 17.5:1 76/1500 SAE 10W30 (above CD grade) 91/1800 0# (summer), -10# (winter), -35 (chillness) diesel Compression ratio Rated power[kW/(r/min)] Fuel type Lube oil type Fuel consumption 23.2/1500 30/1800 28.5/1500 36.9/1800 41.6/1500 49.3/1800 51/1500 60.6/1800 62/1500 SAE 10W30 (above CD grade) 320 95 12 950 960 12V Electric starter 300 95 10 1200 985 70 53 68 51 70 53 Ultra silent 68 51 1900 950 1200 11.5 9 8 2250 300 95 7 950 1270 70 53 68 51 1300 6.5 2250 290 95 6.5 950 1310 24V Electric starter 290 110 6 1300 2700 1140 1650 24V Electric starter 280 110 5 5 1500 2700 1140 1680 24V Electric starter Fuel tank capacity Continuous running time Overall dimension: LxWxH(mm) 1900 Weight(kg) Starting system Noise dB (A)/1m 4 1500 12V Electric starter 24V Electric starter 68 51 70 53 68 51 70 53 Ultra silent 68 51 70 53 Noise at related load dB (A)/7m Structure type CAUTION CAUTION Hot parts CAUTION Storage Fire hazard The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. Let the engine cool before storing the generator indoors. The engine exhaust system is heated during operation and remains hot immediately after stopping the engine. - High temperature Fuel and lubrication is extremely flammable under certain conditions. Refuel in a good ventilated area with the engine stopped. Don't place the flammable and explosive materials near the generator. Keep away from cigarette, smoke and sparks when refueling the generator. Be sure to refuel in a well-ventilated location. Wipe up spilled fuel at once. WOOD It will fall off or collapse to cause an accident if placed in a wrong position. Make sure that engine cover is not broken, and its screws are not loosened or missed. The generator set should be put on a level ground hard enough to afford its weight. If put a generator set on another generator, the weight and size of above one should be less than that of the other. Don't run the generators set when stacks together. Otherwise, the above generator will fall off to cause an accident. water. accident. generator. unconscious. explosive accident. CAUTION CAUTION CAUTION will cause an accident. may burn you seriously. Radiator cover put hand and head into the engine to avoid scalding. high, the splashed water or steam may scald you seriously. will gather enough to cause fire hazard or explosive accident. Check the battery after stopping the engine. Don't refill the cooling water until the engine is cooled. Operator's duties The usage of the battery The battery may produce flammable gas. Be careful to avoid any explosive connects with an extension cable. Otherwise, it will cause the fire hazard even Don't operate the generator when the operator is very tired or drunk, or If you open the radiator cover while the temperature of the cooling water is very Generator Wear protective clothing and mask to avoid an unexpected hurt. Disconnect the ground table when servicing and maintaining the generator. Don't open the radiator when running or immediately after stopping the engine. Charge the battery in a good ventilated place. Otherwise, the flammable gas The positive terminal shouldn't be connected to the negative terminal when Rated frequency (Hz) Rated output (kVA) Rated output (kW) Rated voltage (V) Rated current (A) Rated rotation speed (r/min) Loop mode/Excitation mode Power factor (cos ) Insulation grade Pole number Engine model Engine type Close and lock the side door when running the super quiet generator. And don't Be care to operate the generator set according to the instructions, otherwise it Avoid touching the electrolyte because it contains sulfuric acid. Otherwise, it If electrolyte contacts with skin or clothes, clean it with a large quantities of To prevent scalding, pay attention to the warning marks attached to the Engine Set -4Model KDE30SS3 KDE35SS3 KDE45SS3 KDE60SS3 KDE75SS3 KDE100SS3 50 24 19.2 400/230 34.6 1500 60 28 22.4 416/240 38.9 1800 50 28 22.4 400/230 40.4 1500 60 35 28 416/240 48.6 1800 0.8 (lag) H 4 KM493G H 4 KM493ZG 50 37 29.6 400/230 53.4 1500 60 45 36 416/240 62.5 1800 50 50 40 400/230 72.2 1500 60 60 48 416/240 83.3 1800 50 62 49.6 400/230 89.5 1500 60 75 60 416/240 104 1800 0.8 (lag) H 4 KD4105G 4-cylinder in line 4-sroke water cooled 4-cylinder 4-cylinder in line 4-sroke water cooled direct injection in line 4-sroke supercharge water cooled direct injection 50 80 64 400/230 115 1500 60 100 80 416/240 138.8 1800 Three phase "Y" connection/Brushless self-excitation and constant voltage (AVR) Three phase "Y" connection/Brushless self-excitation and constant voltage (AVR) H 4 KD4105ZG 4-cylinder in line 4-sroke water cooled direct injection supercharge H 4 KD6105G H 4 KD6105ZG 6-cylinder in line 4-sroke 6-cylinder in line 4-sroke water water cooled direct injection cooled direct injection supercharge Ultra Silent Generator (Three phase) - Bore x Stroke Displacement Compression ratio Rated power[kW/(r/min)] Fuel type Lube oil type Fuel consumption Fuel tank capacity Continuous running time 93 102 2.771 18.2 : 1 93 102 2.771 18.2 : 1 105 125 4.329 17.5:1 0# (summer), -10# (winter), -35 (chillness) diesel 105 125 4.329 17.5:1 105 125 6.494 17.5:1 23.2/1500 30/1800 28.5/1500 36.9/1800 41.6/1500 49.3/1800 51/1500 60.6/1800 62/1500 SAE 10W30 (above CD grade) 320 95 12 Overall dimension: LxWxH(mm) 1900 Weight(kg) Starting system Noise dB (A)/1m Noise at related load dB (A)/7m Structure type 105 125 6.494 17.5:1 74/1800 76/1500 SAE 10W30 (above CD grade) 300 95 10 950 960 12V Electric starter 91/1800 0# (summer), -10# (winter), -35 (chillness) diesel 300 95 11.5 1200 1900 950 985 68 51 70 53 68 51 70 53 Ultra silent 68 51 9 1200 8 2250 950 1270 12V Electric starter 24V Electric starter 290 95 7 1300 6.5 2250 950 1310 24V Electric starter 290 110 6.5 1300 6 2700 1140 1650 24V Electric starter 280 110 5 5 1500 2700 1140 1680 24V Electric starter 4 1500 70 53 68 51 70 53 68 51 70 53 Ultra silent 68 51 70 53 Ultra-silent Generator (Single phase) 4-cylinder in line 4-stroke water cooled direct injection 4-cylinder in line 4-stroke water cooled direct injection supercharge 4-cylinder in line 4-stroke water cooled direct injection KDE35SS/KDA35SS/KDA35SSO CAUTION 44/1800 70 53 7 24V Electric starter Noise 2/146 120/240 1800 Close the door of the super quiet generator when it is running. Otherwise its 1300 60 35 35 146 noise will reach a very high level. Open-frame generator would cause a hearing damage for its high noise level if stay at this condition for a long time. Put on the earplug if necessary or take other protective measures. KD4105G 125 4.329 17 : 1 300 105 2/130 Single phase, three loops/Brushless self-excitation and constant voltage(AVR) 115/230 37/1500 1500 2250 1270 950 95 H 4 68 51 50 30 30 8 130 CAUTION Caution Cable Connection 0# (summer), -10# (winter), -35# (chillness) Connections for standby power to a building's electrical system must be made by a qualified electrician, which accords with all applicable laws and electrical codes. Improper connections can allow electrical current from the generator to back feed into the utility lines. Such back feed may electrocute utility company workers or others who are contacting the lines during a power outage. And when utility power is restored, the generator may explode, burn, or cause fires in the building's electrical system. KDE30SS/KDA30SS/KDA30SSO 2/117 36.9/1800 120/240 SAE 10W30(above CD grade) 1800 70 12V Electric starter KM493ZG 1200 117 53 51 Ultra silent 60 28 28 102 18.2 : 1 2.771 300 9 950 1900 2/100 93 28.5/1500 115/230 1500 985 1.0 95 H 4 100 68 10 50 23 23 KDE25SS/KDA25SS/KDA25SSO 2/100 120/240 30/1800 CAUTION 70 12V Electric starter Transportation 1800 1200 53 60 24 24 9 Don't use rope or ladder to lift the generator. Otherwise, the generator will fall down if they are broken. Anyone shouldn't stand under the lifted generator. Lift the generator by using the lifting lever at the center of the engine cover. 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 the car. 100 KM493G 102 18.2 : 1 2.771 320 950 11 1900 93 23.2/1500 115/230 2/87 1500 960 95 H 4 68 Noise dB (A)/1m 87 Noise at related load dB (A)/7m Loop mode/Excitation mode Rated rotation speed (r/min) Continuous running time Rated power[kW/(r/min)] Rated frequency (Hz) Power factor (cos ) Rated output (kVA) Rated output (kW) Compression ratio Fuel tank capacity Fuel consumption Rated voltage (V) Rated current (A) Insulation grade Overall dimension: LxWxH (mm) Starting system Model 51 Structure type 50 20 20 Engine model Displacement Bore x Stroke Pole number Lube oil type Engine type Weight(kg) Fuel type - - Set Engine Generator - - 2. PARTS NAME Instruments Panel Mounting Lever 2.1 The appearance and the outer part name Lifting Lever Output Panel Generator Engine Set -6Water Drainage Engine Oil Drainage Fuel Outlet Model Rated frequency (Hz) Rated output (kVA) Rated output (kW) Rated voltage (V) Rated current (A) Water Inlet Exhaust Vent Fuel Inlet KDE30E3 KDE35E3 KDE45E3 KDE60E3 KDE75E3 KDE100E3 50 24 19.2 400/230 34.6 60 28 22.4 416/240 38.9 50 28 22.4 400/230 40.4 60 35 28 416/240 48.6 50 37 29.6 400/230 53.4 60 45 36 416/240 62.5 50 50 40 400/230 72.2 60 60 48 416/240 83.8 50 62 49.6 400/230 89.5 60 75 60 416/240 104 50 80 64 400/230 115 60 100 80 416/240 138.8 Rated rotation speed (r/min) 1500 1800 1500 1800 0.8(lag) Power factor (cos ) Insulation grade Pole number Engine model Engine type 1500 1800 1500 1800 1500 1800 1500 1800 Loop mode/Excitation mode Three phase "Y" connection/Brushless self-excitation and constant voltage(AVR) Three phase "Y" connection/Brushless self-excitation and constant voltage(AVR) Open frame (three phase) H 4 KM493G H 4 KM493ZG 4-cylinder in line 4-sroke water cooled direct injection 4-cylinder in line 4-sroke H 4 KD4105G 4-cylinder in line 4-sroke water cooled direct injection H 4 KD4105ZG 4-cylinder in line 4-sroke water cooled direct injection supercharge 0.8(lag) H 4 KD6105G 6-cylinder in line 4-sroke water cooled direct injection H 4 KD6105ZG 6-cylinder in line 4-sroke water cooled direct injection supercharge - Bore x Stroke Displacement Compression ratio Rated power[kW/(r/min)] Fuel type Lube oil type Fuel consumption Fuel tank capacity Continuous running time 93 102 2.771 18.2 : 1 93 102 2.771 18.2 : 1 105 125 4.329 17:1 0# (summer), -10# (winter), -35 (chillness) diesel L-ECD grade 15W30 or 15W40 105 125 4.329 17:1 105 125 6.494 17:1 23.2/1500 30/1800 28.5/1500 36.9/1800 41.6/1500 49.3/1800 51/1500 60.6/1800 62/1500 74/1800 105 125 6.494 17:1 76/1500 L-ECD grade 15W30 or 15W40 91/1800 0# (summer), -10# (winter), -35# (chillness) diesel 320 95 12 Overall dimension: LxWxH(mm) Weight(kg) Starting system Noise dB (A)/1m 300 95 10 1450 800 1050 720 12V Electric starter 300 95 11.5 9 1450 760 1050 750 12V Electric starter 290 95 8 7 1660 830 1200 1120 24V Electric starter 290 110 6.5 6.5 1660 830 1200 1120 24V Electric starter 280 110 6 5 1960 850 1300 1220 24V Electric starter 5 4 1960 830 1300 1220 24V Electric starter 91 Noise at related load dB (A)/7m Structure type 93 81 83 91 81 93 83 Open frame 91 81 93 83 91 81 93 83 91 81 93 83 91 81 93 83 Model Rated frequency (Hz) Rated output (kVA) Rated output (kW) Rated voltage (V) Rated current (A) KDE25E KDE30E KDE35E 50 20 20 115/230 87 2/87 1500 Single phase, three loops/Brushless self-excitation and constant voltage(AVR) 1.0 F 4 KM493G KM493ZG 4 H H 4 KD4105G 1800 1500 1800 1500 100 2/100 100 2/100 117 2/117 130 2/130 120/240 115/230 120/240 115/230 120/240 146 2/146 1800 24 23 28 30 35 24 23 28 30 35 60 50 60 50 60 Generator Rated rotation speed (r/min) Loop mode/Excitation mode Power factor (cos ) Insulation grade Pole number Engine model Engine type Open frame (Single phase) 4-cylinder in line 4-stroke water cooled direct injection 4-cylinder in line 4-stroke water cooled direct injection supercharge 4-cylinder in line 4-stroke water cooled direct injection Engine 11. MAIN TECHNICAL SPECIFICATIONS AND DATA Set Displacement Bore x Stroke 93 102 2.771 18.2 : 1 23.2/1500 28.5/1500 30/1800 18.2 : 1 36.9/1800 2.771 93 102 105 125 4.329 17 : 1 41.6/1500 49.3/1800 Compression ratio Rated power[kW/(r/min)] Fuel type Lube oil type Fuel consumption Fuel tank capacity 0# (summer), -10# (winter), -35# (chillness) L-ECD grade 15W30 or 15W40 320 95 11 1450 800 1050 720 12V Electric starter 300 95 9 10 1450 800 1050 720 12V electric starter 300 95 9 8 1450 760 1050 720 24V Electric starter Continuous running time 7 Overall dimension: LxWxH(mm) Weight(kg) Starting system Noise dB (A)/1m 91 81 93 83 91 81 Open frame 93 83 91 81 93 83 Noise at related load dB (A)/7m Structure type Muffler Fan Radiator Engine 2.2 Inner structure and parts name Motor Oil Filter Oil-water Separator -7- Air Cleaner Oil Filler Oil Dipstick Fuel Filter Battery 2.3 Control panel Floodlight switch Control panel floodlight 10. Long-time storage Power supply indicator light Smart control panel Starter switch Fuse base Breaker Oil gauge Voltage adjustor knob To store the generator for a long time, please put it in a dry, dustless, and wellventilated place, and store it according to the followings. (1) Clean away the dirt and dust that cling to the outer surface of the generator. (2) Remove the battery, and charge it fully before storing it. It 's better to charge it every month to eliminate the effect of the battery discharge. (3) Service and repair the broken or damaged parts to make sure the generator can start normally. (4) Referring to the operation manual to handle the engine fault. reduction voltage voltage increase The panel applicalbe for KDE30SS3 KDE35SS3 KDE40ST3 KDE45SS3 KDE60SS3 KDE25SS KDE30SS KDE35SS Floodlight switch Control panel floodlight Power supply indicator light CAUTION Storage Emergency stop button Smart control panel Breaker Oil gauge It will fall off or collapse to cause an accident if you don't place the generator in a right position. Do remember the correlative proceeding if you pile other things on the machine. Make sure there is no damaged engine cover, loosen screw or missed accessory. The generators set should be put on the level ground hard enough to afford their weights. If put a generator set on another generator, the weight and size of the above one should be less than that of the other one. And the stacking layer shouldn't be over two. Insert stow-woods to the clearance between the upper layer and lower layer as shown in the figure. And put the generators on the stow-woods evenly. Put the wood mat as shown in the figure. Don't put them out of the place that specified in the figure. Don't run the generators while stacking each other. Otherwise, the above one may collapse or fall off. Off On Voltage adjustor knob WOOD Start Fuse base Starter switch reduction voltage voltage increase The panel applicalbe for KDE75SS3 KDE100SS3 -8- - - Fault Reason Bad voltmeter Bad AVR Solution Replace Smart control panel Power supply indicator light Oil gauge Consult with dealer The voltage value is not right or there is no voltage. ZNR is burnt Rotary rectifier is burnt Rotor circuitry break Engine circuitry is burnt Bad voltmeter Bad AVR Replace Consult with dealer reduction voltage voltage increase Start Voltage adjustor knob Starter switch Off On The generator can't reach rated voltage. Bad VR Rotary rectifier is burnt ZNR is burnt Generator cable is burnt Smart control panel Operation indicator light Emergency stop button The panel applicalbe for KDE30E3 KDE35E3 KDE25E KDE30E KDE35E Rotation speed is too low Bad voltmeter Over voltage Bad AVR Bad VR Rotary rectifier is burnt Voltage decreases too much when connected with load. Bad AVR Main winding or excitation winding is burnt Load is not equal Bad breaker Breaker can't work. Bad breaker Load circuitry is shorted Increase the speed Replace Consult with dealer Consult with dealer Off On Start Make them equal. Consult with dealer Fuse base Voltage adjustor knob Electric starter key The panel applicalbe for KDE45E3 KDE60E3 KDE75E3 KDE100E3 Check - - -9- Yellow/Green20# Red20# Black/white20# Yellow/white20# ATSopertional Black/white20# Yellow/white20# Black20# Yellow20# Generator DC sampling input ON-OFF list electric starter key Muni cipal charging power input Utility AC samling input Generator supply output Utility supply output Utility input~ Yellow8# Green8# Red8# Black8# Yellow8# Green8# Red8# Black8# Yellow20# Texting shunt trip Black20# Yellow20# Yellow8# Yellow8# Green8# Green8# Red8# Red8# Black8# Black8# Yellow,Green8# 2.4 Electric principle diagram Yellow8# Green8# Red8# Black8# KDE30SS3 Red,Black20# Green,Black20# Yellow,Black20# Red/Green20# Red/Blue20# Green18# Blue18# Green18# Orange18# Red18# Red10# Red18# Green20# Yellow10# White20# White10# Blue10# Start electromagnet Start electric motor Yellow,Green18# Purple/Orange18# Red18# Blue20# Blue18# Blue20# Purple18# Abnormal signal input Current sampling Voltgage sampling Electric fan KDE35SS3 KDE40ST3 Charging alternator Running signal input Orange18# Working power supply Starter signal input Gray/White20# Preheat signal output Gray20#Starter signal output Purple20# Overload signal output White20# Gray20# Charging input signal Yellow20# Green20# Red20# Black20# 28 M1 Electric fan 1 27 P1 Fuel gauge 1 26 SL Fuel amount sensor 1 PLY-MB3-D 25 A2 Smart display screen 1 PLY-MB3-ATS-S 24 A1 ATS control module PLY-MB3-C 23 A0 Smart panel control module 1 22 HL1 Power supply indicator light 1 AC230V(green) 1 DC12V 10W 21 HL Panel floodlight 1 RF1004 20 S3 Panel floodlight switch 19 S2 Water temperature swtich 1 1 18 S1 Low oil switch 1 17 M Start motor 1 16 GB Battery 1 15 EH Warm-up plug Acdelerography electromagnetism 1 14 YV Voltage regulator potentiometer 1 WX111-2K 5% 13 Rp 1 QDC-100A DC12V 12 KA1 DC contactor 3 HFV4 DC12V 20A 11 KA2 KA3 KA4 Minitype relay 1 KBPC2510 10 V1 Rectifier bridge 3 50A/5mA 9 L1 L2 L3 Current mutualinductor 1 BX210C 8 FU1 Fuse base 2 BX2041 7 FU2 FU3 FU4 Four-circuit fuse box 1 LAY37-1125 6 Estop button SB 1 JK427 Electric starter key 5 SA Charging board assembly 1 -220V/27V 50VA TC 4 2 KDE12STA-13300 3 U V W N Output board assembly A50-40-00 2 KM1 KM2 Reversible AC Contactor 1 Breaker(with shunted exciter release&secondary contact 1 BO-100EB 125A QF 1 Qty. Material Remark Name No. Code Fault Over hot Engine shell Vibration is too big. Slow zero load speed Engine can't reach the highest rotary speed Engine stops because of low oil pressure Zero load speed is too high Abnormal noise Engine Generator Bad axletree Reason Not fix tightly Electrical fan Abnormal voice Check around Abnormal voice Abnormal voice fasten bolt loose Air in the oil pipe Air in the oil pipe Fan strap looses Badness oil switch Thermostat abnormal If cooling-water lacked Regulator lever regulates badly Radiator cooling orifice walled up Clean radiator cooled part Regulate pole to regulates badly Adjust regulator lever to get shorter Electrical fan abnormal Electrical fan abnormal Badness regulator lever engine oil is not enough Engine air cleaner walled up - Tight Mend Mend Mend Solution Replace Fix tightly Move thing Eliminate air Eliminate air Replace filter Fill engine oil Adjust to short Replace switch Maintain fan strap Maintain thermostat Check and replace fuse Check and mend receptacle guarder Adjust regulator lever to get longer Check if cooling water lacked Engine can not start Ambient temperature is very low. Engine can't start while starter is running. Start motor doesn't run or it its speed is so slow. The engine stops automatically. And the rotating speed can't reach the rated speed. No fuel oil Fuel is frozen. Starter badness The wire breaks Air in the oil pipe Fuse disconnection Start switch badness Bad Air around pipe Battery leakage Fuel winding does not work Compression leakage Air cleaner is clogged. The earth terminal is imperfect Repair Speed handle lever trouble Repair Battery unclamped or rutsted Install after cleaning Fuel oil cleaner walled up Clean , and replace fuel oil cleaner Some water accumulated Heat, empty fuel oil tank ,fuel oil cleaner in the fuel system is frozen and water in oil pipe Fuel oil cleaner walled up Replace fuel oil cleaner element, clean or replace filter Electric fan Red18# Black18# Green18# Blue18# Green18# Orange18# Red10# Blue18# Blue20# Blue20# Red18# Green20# oil pump White10# Blue10# Start electromagnet Start electric motor Charging alternator Yellow,Green18# Purple/Orange18# Yellow10# Red18# White20# Running signal input Orange18# Red18# Purple18# Current sampling Voltgage sampling Empty air Mend the engine Yellow/Green20# Red20# DC charging output(15v,2-3A) Black/white20# Yellow/white20# Black/white20# Yellow/white20# Muni cipal charging power input Red20# Black20# Red4# Black4# Black4# White4# Red4# Red4# Black4# Black4# white4# Red4# Green/YellowRV6.0 Red20# Texting shunt trip Red20# Generator DC sampling input Utility AC samling input Fill oil Repair Replace Replace Replace Empty air liquid measure Replace air cleaner element Use JIS-3 oil, or choose the applicable viscosity oil according to the freeze area Check the fuse, if disconnection, replace it ,check and replace winding if necessary Utility supply output Generator supply output ATSopertional ON-OFF list electric starter key KDE25SS KDE30SS KDE35SS KDE25E KDE30E KDE35E( ) - Black20# Black20# Red20# Red,Black20# Red,Black20# Red,Black20# Red,Black20# Red/Green20# Red/Blue20# Abnormal signal input Working power supply Starter signal input Preheat signal Gray/White20# output Starter signal Gray20# output Overload signal Purple20# output White10# Brown20# Charging input signal 28 M1 Electric fan 1 27 P1 Fuel gauge 1 26 SL Fuel amount sensor 1 PLY-MB3-D 25 A2 Smart display screen 1 PLY-MB3-ATS-S 24 A1 ATS control module PLY-MB3-C 23 A0 Smart panel control module 1 22 HL1 Power supply indicator light 1 AC230V(green) 1 DC12V 10W 21 HL Panel floodlight 1 RF1004 20 S3 Panel floodlight switch 19 S2 Water temperature swtich 1 1 18 S1 Low oil switch 1 17 M Start motor 1 16 GB Battery 1 15 EH Warm-up plug Acdelerography electromagnetism 1 14 YV 1 WX111-2K 5% Voltage regulator potentiometer 13 Rp 1 QDC-100A DC12V 12 KA1 DC contactor 3 HFV4 DC12V 20A 11 KA2 KA3 KA4 Minitype relay 1 KBPC2510 10 V1 Rectifier bridge 3 50A/5mA 9 L1 L2 L3 Current mutualinductor 1 BX210C 8 FU1 Fuse base 2 BX2041 7 FU2 FU3 FU4 Four-circuit fuse box 1 LAY37-1125 6 Estop button SB 1 JK427 Electric starter key 5 SA Charging board assembly 1 -220V/27V 50VA TC 4 2 KDE12STA-13300 3 U V W N Output board assembly A50-40-00 2 KM1 KM2 Reversible AC Contactor 1 Breaker(with shunted exciter release&secondary contact 1 BO-100EB 125A QF 1 Qty. Material Remark Name No. Code Yellow/Green20# Red20# Black/white20# Yellow/white20# Black/white20# Yellow/white20# Red20# Black20# Red4# Utility input~ Black4# Black4# Red20# Red20# Black4# Red4# Black20# Black4# Red4# Green/Yellow Red18# Black18# Utility AC DC charging output(15v,2-3A) samling input Utility supply output Generator supply output opertional Muni cipal charging power input Generator DC sampling input ON-OFF list electric starter key Red4# Black4# Red4# Black20# Red20# Red,Black20# Red,Black20# Red/Blue20# Green18# Blue18# Green18# Orange18# Red18# Red10# Blue20# Blue20# Red18# Blue18# Green20# White White10# Blue10# Yellow10# oil pump Abnormal signal input Running signal input Orange18# Current sampling Red/Green20# Voltgage sampling Electric fan KDE25SS KDE30SS KDE35SS KDE25E KDE30E KDE35E Charging alternator Yellow,Green18# Purple/Orange18# Working power supply Starter signal input Purple18# Red18# Gray/White20# Preheat signal output Gray20# Starter signal output Purple20# Overload signal output Start electromagnet White10# Brown20# Start electric motor Charging input signal 28 M1 Electric fan 1 27 P1 Fuel gauge 1 26 SL Fuel amount sensor 1 PLY-MB3-D 25 A2 Smart display screen 1 PLY-MB3-ATS-S 24 A1 ATS control module PLY-MB3-C 23 A0 Smart panel control module 1 22 HL1 Power supply indicator light 1 AC230V(green) 1 DC12V 10W 21 HL Panel floodlight 1 RF1004 20 S3 Panel floodlight switch 19 S2 Water temperature swtich 1 1 18 S1 Low oil switch 1 17 M Start motor 1 16 GB Battery 1 15 EH Warm-up plug Acdelerography electromagnetism 1 14 YV Voltage regulator potentiometer 1 WX111-2K 5% 13 Rp 1 QDC-100A DC12V 12 KA1 DC contactor 3 HFV4 DC12V 20A 11 KA2 KA3 KA4 Minitype relay 1 KBPC2510 10 V1 Rectifier bridge 3 50A/5mA 9 L1 L2 L3 Current mutualinductor 1 BX210C 8 FU1 Fuse base 2 BX2041 7 FU2 FU3 FU4 Four-circuit fuse box 1 LAY37-1125 6 SB Estop button 1 JK427 5 SA Electric starter key 4 TC Charging board assembly 1 -220V/27V 50VA 2 KDE12STA-13300 3 LN Output board assembly A200-1 2 KM1 KM2 Reversible AC Contactor 1 Breaker(with shunted exciter release&secondary contact 1 BO-100EB 125A 1 QF Qty. Material Remark Name No. Code generator. 9. TROUBLESHOOTING CAUTION CAUTION Hot Part DANGER Electric shock DANGER Rotating Part hand and head into the engine to avoid scalding. while. Don't service the electric fan until it stops entirely. Let the engine cool before storing the generator indoors. Stop the engine to service and maintain the inner structure. The Usage of The Battery It's very dangerous to touch the rotating parts in the generator. Don't touch the inner parts with high voltage during the running. Stop the engine to service and maintain the inner parts of the unit. Remove the negative terminal when servicing the generator. It will explode to cause a severe accident if the battery used in a wrong way. The cooling fan of the radiator will go on rotating after stopping the engine for a Close and lock the door, when running the super quiet generator. And don't put To prevent scalding, pay attention to the warning marks attached to the - Generator Check fan belt Check engine oil Clean the radiator Replace engine oil *Adjust fuel nozzle Engine Check & service item *Check damper rubber *Check valve clearance Check the cooling water Check the exhaust color Replace oil filter element Check battery electrolyte *Check fuel injection time Clean air cleaner element Check if the relay can work Check the loosen assembly Replace seal ring of fuel filter Check for water or oil leakage Check and clean Measure insulated resistance Replace Clean the inner of the fuel tank Replace the air cleaner element Check meters and warming light Check sound- absorbed material Check battery electrolyte density Check the nylon tube & rubber tube Check circuit terminal and connection Check protection for electrical leakage Relative manual reading is required. Green/Yellow Check fuel, drain out sediment and impurity 8.5 PRIODIC CHECK AND SERVICE SCHEDULE Note: The item with "*" Mark, you can consult with agent/dealer. The item with " " mark indicates time for the initial check. RedAWG18# GreenAWG18# YellowAWG18# Electric fan Red,BlackAWG20# Green,BlackAWG20# Yellow,BlackAWG20# Red/BlueAWG20# Blue GreenAWG18# BrownAWG18# OrangeAWG18# GreenAWG18# OrangeAWG18# Abnormal signal input Running signal input OrangeAWG18# Current sampling Black/WhiteAWG20# Black/WhiteAWG20# Voltgage sampling YellowAWG20# GreenAWG20# RedAWG20# BlackAWG20# Overload signal output Refer to different type of the engine, check time is abit different. BlueAWG18# WhiteAWG18# BlueAWG18# BlueAWG18# GreenAWG18# RedAWG18# PurpleAWG18# BlueAWG10# BlueAWG10# Orange/GrayAWG20# WhiteAWG20# OrangeAWG18# YellowAWG10# WhiteAWG10# The electric principle diagram applies to KDE45SS3 KDE60SS3 KDE75SS3 KDE100SS3 - Yellow,GreenAWG18# Purple/OrangeAWG18# PurpleAWG18# First First First Yellow,GreenAWG20# Utility AC RedAWG20# DC charging output(15v,2-3A) samling input BlueAWG20# BlueAWG20# BlueAWG20# BlueAWG20# Muni cipal charging power input YellowAWG20# YellowAWG20# Generator DC sampling input Utility input~ Texting shunt trip YellowAWG6# GreenAWG6# RedAWG6# BlackAWG6# Daily check 50 hrs 250 hrs 500 hrs 1000 hrs Utility supply output ON-OFF list electric starter key Generator supply output RedAWG10# RedAWG18# Working power supply Starter signal input turbine scroll bar scrollbar extinguisher RedAWG10# Fuel pump RedAWG18# Gray/White AWG20# Preheat signal output GrayAWG20# Starter signal output Start electromagnet Start electric motor Charging alternator WhiteAWG20# Brown20# Charging input signal Automatic voltage adjustor AVR PLY-DAVR-95S 30 control template of fire extinguisher A3 29 Extinguisher 37B34-56010 M2 28 1 YZ-250-4 250W 0.85A M1 Electric fan 27 1 8111 DC24V P1 Fuel gauge 26 1 SL Fuel amount sensor 25 1 PLY-MB3-ATS-D A2 Smart display screen 24 1 PLY-MB3-ATS-S A1 ATS control module 23 A0 Smart panel control module 1 PLY-MB3-ATS-C 22 HL1 Power supply indicator light 1 AC230V(green) 21 1 DC12V 10W HL Panel floodlight 20 RF1004 1 S3 Panel floodlight switch 19 S2 Water temperature swtich 1 18 1 S1 Low oil switch 17 1 M Start motor 16 1 Charging alternator 15 1 45-60ST3 12V 75-100ST3 12V 150Ah GB Battery 14 1 EH Warm-up plug 13 Voltage regulator potentiometer 1 WX111-2K 5% Rp 12 3 QDC-100A DC24V DC contactor 11 KA1 KA2 KA3 1 KBPC2510 V1 Rectifier bridge 10 3 20A/5mA 9 L1 L2 L3 Current mutualinductor 1 BX201C FU1 Fuse base 8 2 BX2041 Four-circuit fuse box 7 FU2 FU3 FU4 1 HVW411ER SB SB1 Estop button 6 1 JK427 SA Electric starter key 5 1 -220V/27V 50VA TC Charging transformer 4 3 U V W N Output board assembly 2 KDE12STA-13300 A75-40-00 45:63A 60:75A 2 KM1 KM2 Reversible AC Contactor 1 Breaker 1 BO-100EB 75:100A 100:150A QF 1 Qty. Material Remark Name No. Code 2.5 Electric connection diagram Yellow green (3) Check circuit terminal and connetion terminal Check if there is rust and burnout in main and vice circuitry Voltage adjusting potentiometer Oil gauge Orange White Blue Gray Emergency stop button Tin nelded connector on opening thread Tin nelded connector on opening thread Power indicating lamp Opening thread Floodlight Yellow Emergency stop button Yellow green Green Panel wiring harness: applicable KDE30SS3 KDE35SS3 Black Blue KDE40ST3 Electric starting key Orange Purple Red Red Red 8.4 Check every 1000Hrs (1) Clean the fuel tank Eliminate the sediment and water in the fuel tank. (2) Replace the air cleaner element Refer to the relative item. (3) Check anti-vibration material If the shockproof material damaged or distorted, you can consult with agent. (4) Check the nylon tube & rubber tube If the nylon tube &rubber tube is vulcanized or bad quality, you can consult with agent to change it. (5) Check sound absorber. If sound absorber looks aged obviously or it has been peeled, you can consult with agent. Yellow green Floodlight switch Black white Red blue Brown Blue Yellow Red blue Red Brown White Blue Blue Purple Gray Green Blue Black white Red blue Blue Orange Red - - -51- 8.3 Check for every 500 Hrs Separating bag Check for every 500 Hrs should cooperate with check for every 250 Hrs. (1) Check spring gasket of fuel filter. Put filter box together with filter a. Remove spring gasket of fuel filter by filter wrench. b. Clean filter and daub slim engine oil on filter surface , then install it . Don't screw so tight. Yellow Green White White 20# Yellow White Yellow green Blue Blue Red Green Yellow green Green Red c. Eliminate the air of fuel pipe, after replace spring gasket. Charging motor Gray Orange Green Corrugated pipe Black Blue Orange Corrugated pipe Green Brown Breaker Green Red Corrugated pipe Black Starting relay Charging relay Blue Yellow black Green black Red black Green Corrugated pipe White Yellow green Yellow Blue Black white Red blue Starting motor Yellow green Yellow green Yellow green Preheating relay Red blue 20# Blue Red (2) Clean radiator Please clean the radiator orifice by using steam or high-pressure air. Yellow green Red Corrugated pipe Gray Red Yellow green 20 Orange Blue Gray White Green Orange beyond1.5M ,In order to not damage the fan and pipe. connected with steam or high pressure water directly. Purple Back white Connecting wiring harness: applicable for KDE30SS3 KDE35SS3 KDE40ST3 -50- Red blue Yellow Black Red Besides, take off the electric fan, avoid it being Red Yellow green CAUTION Red Yellow Charging relay Cleaning operation with high pressure air should be done Yellow green Red 20 Black Gray Green White Orange Brown Yellow Green Starting motor Starting relay Preheating relay Charging relay Yellow green Breaker Orange Green Starting relay Yellow green Yellow 16# Green White Charging motor White Yellow green Yellow green Blue Preheating relay Orange Green Yellow Green Orange Purple Green Gray White 20# Yellow green Purple Blue Red Back white Blue Red Yellow Red Corrugated pipe Gray Red Distribution White 20 Green Gray Yellow Red Corrugated pipe Black Blue Yellow black Green black Red black Corrugated pipe White Yellow green Yellow Corrugated pipe Black Red Orange Separating bag Green Red Black Corrugated pipe Yellow green Brown Blue Red blue Black white Starting motor Blue Green Yellow green Blue Red Red Gray Green White Red blue 20# 20 Black Charging relay Yellow green Starting motor Yellow green 20 Starting relay Preheating relay Red blue Gray Orange Brown Yellow Green Connecting wiring harness: applicable for KDE30SS KDE25SS KDE35SS Measurement: Charge ratio(%) (4) Check battery proportion battery and proportion as follow. 0.01 error 100 75 80 90 Temperature( ) insulation resistance between bolt and engine frame. Charge the battery if the charge ratio is less than 75%. It is possible to leakage and take place fire when lower than 1M output terminal, breaker, and cable. Consult with dealer for any question. Refer to right fig, loose output negative wire, and turn breaker to ON . Measure The engine can't start maybe for the storage battery leakage. If like that, you should measure the proportion of battery electrolyte. The relation chart between - 20 1.23 1.24 1.25 1.24 1.25 1.26 1.26 1.27 1.28 1.28 1.29 1.30 0 -10 . Clean and dry clean compressed air. DANGER (3) Clean air cleaner element. check if it is above 1M Install air cleaner, and clean it. . Refer to diesel engine operation manual. When dry dust clag on air cleaner element Electric Shock Check the element. If it has been scathed, replace it. Check insulation resistance after stopping engine. Measure one time every month by using 500V insulating-resistance meter When dry dust clag on element, please remove the element and blow it with dry, Blue Preheating relay Charging relay Starting motor Starting relay Connect to the engine case Yellow green Yellow green Green Starting relay Green 20# Red Breaker Orange Green Charging motor White Purple Green Yellow green Gray Yellow green Orange Purple Yellow green Orange Green Blue Yellow Green 20 Green Distribution Blue White Corrugated pipe Black Blue Gray Red Yellow Back white Red Red Red Red Yellow black Green black Red black White Yellow green Red blue Yellow Orange Red Black Red Gray Yellow Corrugated pipe Corrugated pipe Corrugated pipe Red Green Black Corrugated pipe Yellow green Brown Blue Red blue Black white Starting motor Green Blue Separating bag Blue Yellow green 20 20 Yellow green Black Red Gray Red blue 20# Green Orange Brown White Yellow Green White Connecting wiring harness: applicable for KDE30SS KDE25SS KDE35SS double voltoge red blue Power indicating lamp Floodlight Floodlight switch orange green opening thread red orange Corrugated pipe Emergency stop button Corrugated pipe yellow black red yellow green white black yellow green black Emergency stop button green green Brown green green Purple yellow green black white Corrugated pipe red Purple orange red red Electric starting key blue gray blue black white green red blue insurrance Corrugated pipe brown blue red blue black white Brown black white red blue gray white blue yellow green orange blue opening thread Voltage adjusting potentiometer Oil gauge black white red blue Brown blue Tin plating of opening thread Emergency stop button Panel wiring harness: applicable for KDE45SS3 KDE60SS3 out the oil. (1) Replace engine oil engine operation manual. Replace for every 250 Hrs Replace for every 250 Hrs (2) Replace oil cleaner element 8.2 Check for every 250 hours. sure oil position is in between H and L a. Remove element by oil cleaner wrench. cleaner wrench, connect surface with oil cleaner gasket, and tighten. b. Clean element, spread oil film on the spring gasket surface. Install it by oil c. Running engine for a while after replace the element. Check oil position. Be Before replace spring gasket, it is upturned. Remove the oil drain bolt and drain d. Concerning oil cleaner spring gasket, you can consult manufacturer and diesel - 8.1 Check for the initial 50 hours Replace engine oil in 50 Hrs for the first time, after the second time replace it in white yellow 250 Hrs. blue Green Red green yellow green green white orange gary Corrugated pipe green 3 4 breaker yellow Green Corrugated pipe Corrugated pipe 1 2 black Preheating relay Drain out engine oil Tighten the screws Distribution Purple b. After that recover the oil drain bolt and tighten. Purple yellow green red engine warms. c. If it is new oil, please fill with filling pipe. Fill under the upper lever. d. Run engine for a few minutes after fill engine oil , and check oil position orange Corrugated pipe Distribution orange red red (2) Replace engine oil filter element. wrapping pipe Starting relay Charging relay orange white green Preheating relay green yellow blue yellow white green gray red yellow green Connecting wiring harness: applicable for KDE45SS3 KDE60SS3 - yellow green brown blue blue red yellow green Charging relay (between the position of H and L). gray red gray green yellow blue Starting motor Starting relay red a. Remove oil drain bolt ,drain oil empty .It is easy to drain oil out empty, if the blue yellow green blue white green red OK Corrugated pipe yellow Add engine oil Check after running a few minutes blue green Starting motor red yellow green (1) Replace engine oil seperated corrugated pipe black/white red/blue yellow black/white yellow/green white green green blue red/blue 8. PERIODICAL MAINTENANCE AND SERVICE Check period black orange red Brown blue Gray blue Check for initial 50 hours: Replace engine oil Replace engine oil filter element Corrugated pipe KDE100SS3 Check for every 250 hours: Replace engine oil Replace engine oil filter element Clean air cleaner Measure insulation resistance of the generator.(once for a month) Check density of the battery electrolyte. Panel wiring harness: applicable for KDE75SS3 Floodlight switch yellow/green Power indicating lamp yellow green Purple red yellow/ green Check for every 500 hours: Replace the fuel filter element Clean the radiator Check the electrical circuit terminal & wiring connector Cooperating with the check every 250 hours. Black white red/blue black/white red/blue Brown blue Emergency stop button Black green yellow/green Brown Check for the 1000 hours Clean inner of the fuel tank Replace air cleaner element Adjust fuel injection time Check anti-vibration rubber Oil gauge orange white Brown Electric starting key orange blue potentiometer Check the nylon tube & rubber tube black/white red/blue blue Check sound absorber Cooperate with the check every 250 hours and check every 500 hours. Refer to engine operation manual for the details Corrugated pipe gray Purple red red - - yellow/green blue DANGER Corrugated pipe purple DANGER Gray green Electric Shock yellow blue green yellow Maintain and service the inner parts after stopping the generator completely. Maintain and service the inner parts only after stopping the generator completely. Double power switch red/black red/black Corrugated pipe Corrugated pipe CAUTION red The Usage of The Battery orange Incorrect usage will result in explosive accident. Loose the negative terminal cable when maintaining and checking the generator. upwards coiling, same direction with 8# Distribution Purple red red/blue Corrugated pipe Green yellow black red red gray green yellow orange Gray Wear the protective clothing and use safe tools when servicing the unit. Corrugated pipe Don't wear the tie or loosen clothing. Otherwise it will catch the unit and cause an unexpected accident. orange Charging relay blue Purple Starting relay CAUTION The Handling of The Waste Fuel yellow/ green CAUTION Notice Board Put a notice board on the start switch to show the machine is in maintenance. Connecting wiring harness: applicable for KDE75SS3 KDE100SS3 - - yellow/ green yellow/ green Brown When handling the waste fuel, please use container. Waste fuel pollute environment, so don't pour them into stream, ocean and lake. Handle of poisonous engine oil, fuel, cooling water and battery, please refer to the related provision. white green Preheating relay Corrugated pipe yellow blue blue yellow /green Charging relay red CAUTION white Protective Clothing Distribution red black Starting motor Starting relay red black blue Preheating relay The engine exhaust system will be heated during operation and remain hot immediately after stopping the engine. yellow Corrugated pipe yellow/green green CAUTION Hot Parts green blue white green red Starting motor red Be careful for the rotary parts! Maintain and service the generator after stop rotating. The cooling fan of the radiator will still rotate after stopping the engine for a while. Maintain and service the generator inner parts after stopping it completely. yellow/green Corrugated pipe red green white red yellow/green white Danger Rotary parts green orange yellow Periodical maintenance and service 2.6 Generator function and operation manual 1) Setting of the instrument, indicating light and generator sets: refer to the operation manual of intelligent panel for details. 2) Using method of the switch and adjustor. 1. Starting switch Switch for starting, running and stopping. Pull out the key and preserve it safely if you don't use the generator. 7. THE USAGE OF THE BATTERY CAUTION Battery applications The battery may produce flammable gas. If handle it by mistaken, it will cause explode and serious hurt or death. Charge the battery in a good ventilated place. Otherwise, the flammable gas will gather enough to cause fire hazard or explosive accident. The positive terminal must not be connected with the negative terminal when connecting an extension cable. Otherwise, the spark will ignite the flammable gas around the battery and cause the fire hazard even explosive accident. Disconnect the grounding table when servicing and maintaining the generator. Avoid touching the electrolyte because it contains sulfuric acid. Otherwise, it may burn you seriously. The most dangerous accident is blindness. Check or use the battery after stopping the engine. Never disconnect the battery during operation, otherwise, the engine or START CAUTION OFF it indicates for the position of key and that the generator is stopped. ON It indicates that the machine is running. START It indicates for the position of starting the motor. Turn on the switch to this position to start and preheat the generator set. It will automatically revert to position ON after starting. HEAT The intelligent panel will preheat automatically while starting at the same time, the preheating time can be set easily. Generator is preheating when the intelligent panel shows PRE-H, and starting when START is showed. 2. Main breaker Functions: terminal. Automatically cut off the switch in the case of short circuit or overload, to prevent the generator. Position OFF for starting engine, while ON for using electricity. Breaker The breaker governor handle will stop between position ON and OFF, if it is cut off by over current STARTER SW OFF ON controlling circuit will be burnt. 7.1 Cautions for charging the battery Remove negative terminal cable from the battery, then remove the positive terminal cable. Connect the positive cable at first, and then connect negative cable. Eliminate the flammable gas gathered by opening the bolts when charging the battery. Pause charging the battery, if the temperature of the battery electrolyte is over 45 . Stop charging the battery if full charged. If go on charging the battery, it will cause that: a. The battery is over hot. b. The battery electrolyte is decreased. c. The battery is in a bad condition. It will damage the AC alternator if connect the battery pole conversely. - Supply the electricity to the main switch of three phase connector of output 6.3 FUEL (1) The usage of fuel Please light fuel CAUTION 3. Voltage adjustor Caution: Don't use the breaker when start or stop the load machine, otherwise, there would be accident happened. CAUTION If use other fuel, or water, dirty mixed fuel, the engine performance might decline, maybe come forth the serious troubleshooting. (1) The usage of fuel light fuel It will be penalized for using heavy oil, kerosene, light mixed fuel, or other fuel. Make sure use light oil. (2) The usage of fuel in cold condition Use corresponding scale of diesel fuel according to different season. Make sure fuel be adapt to surroundings temperature. The function is to adjust the output voltage. The voltage will increase if turn to right, while decrease if turn to the converse direction. Possible voltage adjusting range 50Hz (V) Maximum Value Minimum Value 250 2 60Hz (V) 260 2 CAUTION Below 200 Below 210 4. Fuse (1) Preheating circuit: Fuse (Capacity is 50A) (2) Charging circuit: Fuse (Capacity is 20A) (3) Controlling power circuit: Fuse (Capacity is 10A) 5. Panel indicating light and switch: The panel indicating light is used in the night to read values on the display. It will light at once the switch is turned on. Caution: The indicating light will be turned on even if the generator is not running. So please turn off the light in case of not running or long-time storage. 6. Indicating light for operation: it indicates that the generator is at running statement. 7. Emergency stop button: Press this button to stop the generator quickly in case of emergent accident. The button will lock itself if it is pressed down. Resolve the button clockwise to restart the machine, and anticlockwise for waiting. 8. Oil gauge It indicates for oil lever in the fuel tank and suggests refueling in time. - - - - 3. TRANSPORTATION AND STORAGE 3.1 Transportation method Don't lift the generator with rope or ladder, which cannot afford the weight of unit. Be sure to hang the handles at the central top of the unit with the ring. 6. ENGINE OIL, COOLING WATER, FUEL 6.1 Engine oil (1) Select the oil Use engine oil for API Service classification CD or higher.