a

G E N E R A T O R SET-

OPERATIONAL M A N U A L

12(Open frame)

12S(Silent type)

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ORIGINAL INSTRUCTION
 CONTENT

1. S a f e t y I n s t r u c t i o n s

2. S p e c i f i c a t i o n s ....

3. C o m p o n e n t s o f Generator Set

12 C o m p o n e n t s ?iscunaraaessorssesenuenarnuneuneenwensnaarrernnoneseneonnsenenusmanmn rennen 3

12S C o m p o n e n t s .......resesensasnnssaneeansmenensunsorenenn anennasannar.

12S(A) C h e c k Before O p e r a t i o n ......susuossonsonnerersaruesonn

4. Preparation B e f o r e Start
12 C h e c k B e f o r e Operation .......rueesesnneossnsnnunsssraneonssnnsnnsntnnnnsonssnnnnnsenen 6

12S(A) C h e c k Before O p e r a t i o n . . . . . . . . . - . . anenennen nursussnenssnsrsnesorensenanennenare 7

5. Operation n.oennnnansusenensntseenenenennnnenenansennn
nennsonne ensneassnsnnannasnnennsunanernnannnne 8

6. S t o p p i n g G e n e r a t o r ......unusesussusessesensenennennennanenn so nsonsenensenenunennnnonensumnen B

7. M a i n t a i n a n c e a n d R e m e d y o f G e n e r a t o r S e t

1 2 C h e c k a n d M a i n t e n a n c e ..

12S(A) Check and Maintenance .

8. A p p e n d i x and Suggestions .......euseunneenesnsnnnsensonnzuennonsaenennssnsennassnenensenner 12

9. M e t h o d s of Unexpected P r o b l e m ...z.ursseascorensonsnsennennnnononnononennsnennonanunen 13

10. E l e c t r i c a ! W i r i n g D i a g r a m ( S i n g l e p h a s e G e n e r a t o r ) . . . . . . u s s n e n e e 1 4

1 1 . E l e c t r i c a l W i r i n g D i a g r a m ( T h r e e p h a s e G e n e r a t o r ) . . . . . . . . . . . . . . - u n n n . 14
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4. S a f e t y I n s t r u c t i o n s 2. S p e c i f i c a t i o n s

Notes: Please read this manual carefully and makes sure well understanding to Een
»
avold serious d a m a g e o n users or products.

D o careful Inspection before starting e a c h time.

n s [mem [ ww|
«
In o r d e r t o p r e v e n t fire d i s a s t e r a n d k e e p t h e g e n e r a t o r set u n d e r w e l l ventilation
?condition, p l e a s e k e e p t h e g e n e r a t o r s e t at l e a s t 4 m e t r e f r o m o t h e r objects. A n d

make generator set far a w a y from combustibles.

» K e e p kids a n d pets f a r a w a y f r o m r u n n i n g g e n e r a t o r s e t t o p r e v e n t empyrosis

a n d o t h e r p o s s i b l e injuries.
«
M a k a e v e r y o p e r a t i o n s t e p w e l l k n o w n a n d f o r b l d a n y p e r s o n w h o are not

trained o p e r a t i n g g e n e r a t o r set.
« M a k e s u r e a d d i n g fuel u n d e r w e l l v e n t i l a t i o n c o n d i t i o n w h i l e t h e generator s e t ?s

s h u t t i n g d o w n . F u e l ?s c o m b u s t i b l e s a n d c a n e a s i l y c a u s e e x p l o s i o n
« D o n o t o v e r f i l l t h e fuel tank, t n e r e s h o u l d b e no fuel o n t h e fuel cap.
»
M a k e s u r e t h e fuel c a p is s c r e w e d tighlly,
« If a n y fuel spill, m u s t c l e a n a n d m a k e c o m p l e t e v o l a t i l i z a t i o n b e f o r e starting the Frequency

generator.

«
M a k e s u r e t h e r e a r e n o c i g a r r e t e s , fires a n d s p a r k s o n w h e r e t h e g e n e r a t o r ?s Voltage
refueled o r fuel storage.
* D i e s e l e n g i n e s p r o d u c e t o x i c c a r b o n m o n o x i d e e x h a u s t f u m e s , d o n o t breath

e x h a u s t f u m e s . N e v e r o p e r a t e u n i t In e n c l o s e d a r e a s o r i n s d e q u a t e ventilated

areas.
Max output KVA
[u 41711
[mem]
113.758113.75| 11711 [13.75513.75]

« O p e r a t e t h e u n i t o n s t a b l e g r o u n d , o t h e r w i s e t h e fuel w o u l d spill out. Power factor 1.0 08 10 08

» T h e e x h a u s t o f m u f f l e r is v e r y h o t w h e n o p e r a t i o n , e v e n a f t e r use. avo?d
Fuel tank capacity 25
t o u c h i n g t h e e n g i n e o r m u f f l e r w h i l e i h e y are still hot. To a v o l d firg h a z a r d or

b u m , m o v e a n d s t o r e t h e unit w h e n c o m p l e t e l y c o o l d o w n . Duration of full

Fuel c o m s u p t i o n g / k w . h

Size (LxWxH) 910x578x668

Net weight 170 174

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3. G e n e r a t o r S e t A s s e m b l y C o m p o n e n t s
128 Components
12 Components

[Item| Description Description Quantity

[ 1 ] Control gate 1
M u f f t e r a s s y Il 1

2 1 C o n r e i p| e n1e | r Shock absorber

Battery b o a r d s

Front cover
| 1 |
Inner covr
1|
[ 5 ] Uppersiie | 1 | De] [ 1|
I[ 8 7_|R u b b e r e
| o v
4 e |
r | 10| B o n o m| s 1e a|
] ?Alternator clapboard
| 1 | [2011
Fueitank | 1 |
Alternator Wheel 2
Mufller heatco 1
nsulation Lock wheel 2
Muffter assy I
| 1 7
| B o o overr i |o c2 |k
Right door
D I
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12SA Components 4. I n s p e c t i o n B e f o r e O p e r a t i o n
LDG12 Check Before Operation
1. O l l l e v e l
Notice: Checking oll level before operation
each time.
@ O p e n i n g lock b u t t o n , a n d t h e n r a l s e u p p e r
cover.
@ L o o s e n oil g a u g e . c l e a n it w i t h d i s h c l o t h ,

7 a n d t h e n i n s e r t Into filter n e c k (do n o t

screw). A d d i n g e n g i n e oil If i t b e l o w t h e
t o w e r !imit (Indludes l o w e r l i m i t ) w h e n t a k e
out, t h e w a y s of a d d i n g oil a s b e i o w . ( 7 . 1 . © ) , F i n a l l y ,
R

Install a n d plug olf g a u g e .

Notice: It will c a u s e e n g i n e d a m a g e d s e r k o u s i y w h e n t h e
g e n e r a t o r is r u n n i n g i n t h e s h o r t a g e o f l u b r k c a t i n g
oil.
@®
C h e c k a n y d a m a g e o f t h e battery, if d a m a g e d , p l e a s e

G
r e p l a c e battery.

2. Fuel level
C a u t i o n . P l e a s e refuel in a w e l l v e n t i l a t e d p l a c e , m a k e s u r e t h e r e i s no s m o k i n g o r
flames and sparks w h e n refuel.

©®
O p e n t h e g e n e r a t o r cover, @®
C h e c k fuel l e v e l , i f it is v e r y
Description [Quantity Description Tauantity] u n s c r e w t h e fuel tank cap. low, a d d t h e f u e l .

Control Door Assembiy The Altemator Assembly]

Rear Cover Plate
Control Panel Assembiy
Engine Maintenance Board [Altemator Maintenance boarel|

Undergan |
Flip Lock
Left Cover Beam

© F i l i n g t h e fuel to t h e fuel @ S c r e w t h e fuel t a n k c a p w e l l

filter shoulder. fit t h e g e n e r a t o r c o v e r . "

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12SA Check Before Operation 5. O p e r a t i o n
1. O i l i e v e l Single Phase Control Panel Three Phase Control Panel
Notice: Checking oll l e v e l b e f o r e operation sach Starter switch AC circuit breaker Starter suntch AC circust breaker
time.

© Open right door, You will see the oil gauge.

@ L o o s e n oil g a u g e , c l e a n It w i t h d i s h e l o t h , a n d t h e n
Insert i n t o f i l t e r n e c k (do n o t s c r e w }. A d d i n g
e n g i n e oil i f i t b e l o w t h e l o w e r l i m i t ( i n c l u d e s l o w e r
tim?t) w h e n t a k e out, i h e w a y s o f a d d i n g oil a s
b e l o w . ( 7 . 1 . © ) , Finally, i n s t a l l a n d plug oil g a u g e .
N o t i c e : It w i l l c a u s e e n g i n e d a m a g e d s e r i o u s i y
w h e n the g e n e r a t o r is r u n n i n g in t h e
s h o r t a g e o f l u b r i c a t i n g oil.
2. F u e l l e v e i {1) C h e c k i n g b e f o r e o p e r a t i o n
Caution: P i e a s e r e f u e l in a w e l l v e n t i l a t e d p l a c e , T u m t h e A C circuit b r e a k e r s w i t c h to " O F F " p o s i t i o n , T o p r o t e c t y o u r p e r s o n a l
m a k e s u r e t h e r e is n o smok?ng o r f l a m e s security, m a k e s u r e t h e g e n e r a t o r shoukd b e g r o u n d .
a n d s p a r k s w h e n refuel.
@® O p e n left d o o r , c h e c k t h e fuel v o l u m e indicator.
If fuel l e v e l is low, u n s c r e w the t a n k cap, fill t h e fuel t h o u g h fuel filter. A f t e r filing
fuel, s c r e w b a c k t h e t a n k cap.

si
(2) S t a r t i n g g e n e r a t o r
Electric s t a r t i n g
&®
T u r n the s t a r t i n g k e y at "start" p o s i t i o n ( n o m o r e t h a n 8
seconds), remove y o u r hand f r o m the k e y as s o o n as t h e e n g i n e
s t a r t s a n d let t h e k e y r e t u m a u t o m a t i c a l l y to initial p o s i t i o n . If t h e
starting motor doesn't start, please w a i t for a b o u t 3 0 s e c o n d s
b e f o r e a t t e m p t i n g t o start a g a i n .
(3) A C a p p l i c a t i o n
@ If g e n e r a t o r w o n ' t o p e r a t e f o r a p e r i o d t i m e , drain r e m a l n i n g fuel t h r o u g h t h e
d i s c h a r g e h o l e in t h e b o t t o m of fuel t a n k ( l o c a t e d In t h e b o t t o m o f g e n e r a t o r
@®
In a c c o r d a n c e w i t h t h e a c t u a l s i t u a t i o n to c o n n e c t t h e load

below panel). , t h r o u g h t h e load t e r m i n a l s o r w i r i n g s o c k e t .

® C h e c k a n y d a m a g e o f the battery, i f d a m a g e d , p l e a s e r e p l a c e battery.

@®
C o n n e c t A C circuit breaker, t h e g e n s e t b e g i n t o o f f e r p o w e r .
6. S t o p p i n g G e n e r a t o r
OFF
C a u t i o n : D o n o t stop g e n e r a t o r w h e n it's w i t h load. it w i l l d e s t r o y t h e
generator. Z A R m

© Turn off A C breaker n E n

Turn t h e b r e a k e r s w i t c h t o " O F F " p o s i t i o n . t sr] > )
@& Turm o f f s t a r t e r s w i t c h
T u m t h e k e y to " O F F " p o s i t i o n .

START)

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7. M a i n t e n a n c e a n d R e m e d y o f G e n e r a t o r Set 12 Maintenance
N o t i c e : P r o p e r m a l n t e n a n c e Is n o t o n l y t h e b a s i s of s a f e , e c o n o m i c a l a n d e n s y 1. C h a n g e t h e o l l
w a y o f g e n e r a t o r o p e r a t i o n , b u t a l s o h e l p f u l to r e d u c e t h e a i r pollution. © P l e a s e p r e p a r e t h e oil c o n t a i n e r u n d e r t h e d r a l n p l u g , u s e t h e f o r k t o r e l e a s e
W a r n i n g : If t h e m a i n t e n a n c e I n s t r u c t i o n s are n o t f o l l o w e d properly, i t m a y c a u s e the drain plug, t h e n b e g i n to pull o u t t h e oll, w h e n t h e oll pull o v e r , Ifn a r a s s a ? y
s e r l o u s p e r s o n a l Injury. use i e d i e s e l t o c l e a n t h e i n s i d e of t h e c y l i n d e r b l o c k . In t h e e n d l o c k t h e drain
Maintenance Schedule us
m äck.

Maintain period
Every t h r e e | Everyt h r e e
months or | montns or
Item m o n t h 100 hours 1 0 0 hours N
working hours

@® O p e n t h e lock, o v e r t h e f r o n t c o v e r (4 1 . @ ) , s c r e w t h e c y l i n d e r h e a d oil c a p ( 2 )
Air cleaner a s t h e photo, pull t h e oll unt?l r e a c h t h e ofl g a u g e m a x l i m i t e d ( 4 . 1 . @ ) , in t h e
siement end screw back the cylinder head stud.

The valve gap

T h e I?quid o f »
the battery

2. A l r c l e a n e r

© R e m o v e t h e s i d e plate o f t h e e n g i n e , r e l e a s e t h e clip,
u n l o a d t h e l o w e r half part
o f t h e a i r cleaner, a n d take o u t t h e f i l t e r e l e m e n t i n the middle; wash the filter
<

R e c o m m e n d oll SAE VEPHLITIIIEIRSERSWITFTTTN element with diesel fuel and put it back in Ihe a?r cleaner after ?t is dry.
4 stroke diesel engine oil, API CE, CF w Pzzzzizzzz - _

the same as the C G (SAE10W-30) oil. 20 ZZEITEEIEN

77777,

diesel engine maintenance classification

A Pshould b
Ol be CE or over CE standard EZZZZA Recommend number
[ D T ] C a n use r a n g e

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 C E .
C E : 0
12S(A) Maintenance 8. A p p e n d i x a n d S u g g e s t i o n s
1. C h a n g e the oll
© O p e n l e f t d o o r , u s e t h e f o r k t o r e l e a s e t h e d r a i n plug (don't t a k e o u t s c r e w ) , p u t 1. a s ry to store the generator in correct way to keep generator in good
t h e oil g u i d e g r o o v e u n d e r t h e d r a i n p l u g , l e t its o u t l e t c o n n e c t w i t h oil
c o n t a i n e r , t h e n c o m p l e t e l y r e m o v e t h e d r a n p l u g . T h e n b e g i n to pull o u t t h e oll,
condition. Following steps are to protect the generator from rust and corrosion
w h e n t h e oil p u l i o v e r , i f n e c e s s a r y , u s e t h e d i e s e l t o c l e a n t h e i n s i d e o f t h e which would damage its performance and appearance. Besides, the generator will
C y l i n d e r b l o c k . In t h e e n d l o c k t h e d r a i n plug b a c k .
start easier with these steps.
© Cleaning
If the generator.has Just run over, clean it after cooling at l e a s t 2 hours. T h e n
deant h e s u r f a c eo f generators, p a i n t t h e damage p a r t , a n d c o a t w i t h at h i n
layer of film.
Fuel
@&

D i e s e l f u e l deteriorates d u r i n g s t o r a g e , w h i c h w i t m a k e t h e s t a r t i n g o f
generator more difficult and produce give materials that would clog the fuel
@® M o v e t h e p l a s t i c r o u n d e d I?d on t h e t o p o f g e n s e t , u n s c r e w t h e cyl?nder h e a d oil systern. It is necessary to clean or replace the fuel system if diesel fuel
c a p , fill t h e oil until r e a c h t h e oil g a u g e m a x limited (4.1. © ) , In t h e e n d s c r e w deteriorates during storage.
b a c k the c y l i n d e r head stud.
2. Storage instructions
©®
D o n o t t o u c h t h e muffler. A r o u n d t h e e x h a u s t p o r t o f t h e m u f f i e r is v e r y h o t

while g e n e r a t o r is r u n n i n g a n d the h e a t will remain for s o m e time after

g e n e r a t o r stops. To p r e v e n t b u m o r fire, d o n o t m o v e t h e g e n e r a t o r i n t o t h e
s t o r a g e r o o m until i t is c o o l e d .

@®
S t o r a g e r o o m s h o u l d b e of g o o d v e n t i l a t i o n a n d f a r f r o m f i r e p l a c e l i k e s t o v e ,

w a t e r heater, dryer, etc, in o r d e r to a v o i d p o s s i b l e s e r i o u s i n j u r y a n d d a m a g e to

e q u i p m e n t . S t o r a g e r o o m s h o u l d n o t b e i n t h e w e t a r e a s w h i c h w o u l d c a u s et h e
g e n e r a t o r rust a n d c o r r o s i o n .
So Move e u fth tt c u will s e e t h e air
M o v e t h e upper plate a n d b a c k cover o f t h e generator, you

© c i e a n e rT
. e l e a s e t h e clip, u n l o a d t h e l o w e r half p a r t o f t h e a i rc l e a n e r , a n d a k e © P u t t h e g e n e r a t o r o n al e v e l s u r f a c e a s tilting m a y c a u s e f u e l o r oil l e a k s .
o u t t h e f i l t e r e l e m e n t in I h e m i d d l e ; w a s h t h e filter e l e m e n t with d i e s e l fuel ar? 3. T r a n s p o r t
p u t it b a c k in t h e a i r c l e a n e r a f t e r it is dry. ©® I f t h e g e n e r a t o r h a s j u s t r u n over, P l e a s e d o t h e s h i p m e n t a f t e r c o o l i n g o n e h o u r

b e c a u s e t h e e x h a u s t i n g s y s t e m is still h o t w h i c h m a y b u m y o u a n d f i r e o t h e r
things.

@ P u t t h e g e n e r a t o r on a l e v e l s u r f a c e w h i l e s h i p p i n g to p r e v e n t l e a k i n g t h e oil.

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ce
M n T u t N nerator)
9. M e t h o d s o f U n e x p e c t e d P r o b l e m 10. E l e c t r i c a l W i r i n g D i a g r a m ( S i n g l e P h a s e Ge! )

Bad connections of =
Check the power Current fine Check each connector N o =
Hate -
control system =
1. Charge the battery
Battery power Is low 2. Change the battery

Check fuel and

De
Fuel deteriorat?on or Dra?n the fuel tank and
contain deteriorated fuel | add fresh fuel

P?ston ring worn or rings | Change and adjust

in wrong place piston ring

Check cylinder Valve clearance is not Adjust the clearance as

compression correct per operational manual .
Bolts of cylinder head ? u
are not tighten Re-tight t h e bolt

C h e c k fuel s u p p l y Fuel oil o r switch of fuel R e p l a c e o r repair

systern oil p l u g s d e f e c t i v e parts

N o v o l t a g eo u t p u t

A C circuit b r e a k e r Is Turm t h e A C circuit

not open breaker to "ON? position
Check A C circuit
breaker A C circuit b r e a k e r R e p l a c e the A C
is broken eircuit b r e a k e r

Check AVR A V R is b r o k e n R e p l a c e AVYR

S e n d g e n e r a t o r to M o t o r f a i l u r e , circuit Replac l a c e or repair

repair center failure d e f e c t i v e parts