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Transcript
DIESEL GENERATING SET
Single-phase:
Three-phase:
KDE9000SS KDE11SS
KDE13SS KDE16SS
KDA9000SS K DA9000SSO
KDA11SS K DA11SSO
KDA13SS K DA13SSO
KDA16SS K DA16SSO
KDE9000SS3 KDE13SS3
KDE15SS3 KDE20SS3
KDA9000SS3 KDA9000SSO3
KDA11SS3 KDA11SSO3
KDA13SS3 KDA13SSO3
KDA16SS3 KDA16SSO3
WUXI KIPOR POWER CO., LTD.
Preface
Warning
Please read this instruction and ensure understand all regulations concerning
handling, check and maintenance thoroughly prior to application.
Failure to follow this instruction may cause serious accidents.
Incorrect operation is likely to lead accidents.
Operate and maintain the machine on the basis of thorough 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 from local KIPOR
dealer.
Please provide this introduction to another user whom machine will be
transferred to.
Machine may be improved or modified. Therefore actual conditions may be
different from this introduction.
If you have any doubt, please consult local KIPOR dealer.
Machine is the special diesel generator for ground application.
Safety information contained in this introduction are extremely important.
Labeling of machine
At panel
Forbid removing labels without proper reasons.
Labeling of engine
On the top of engine cylinder hood
Forbid removing labels without
proper reasons.
Mark the engine No. at one side of engine.
Purchase of parts and contact for occurrence of errors
If user intends to purchase certain parts or finds any errors, please provide type
of machine and actual running period to local KIPOR after-sales department.
For example:
Type: KDE15SS3
Actual running period: 1000hours
Error description:
Information about labeling, purchase of parts
and contact for occurrence of errors
The choice of the electric cable depends on the allowable current of the cable
and the distance between the load and the generator. And the cable section
should be big enough.
If the current in the cable is bigger than the allowable current, it will become over
hot and the cable will be burnt. If the cable is long and thin, the input voltage of
the electric appliance will be not enough, causing that the generator doesn't start.
In the following formula, you can calculate the value of the potential "e".
The relations among of the allowable current, and length, section of the Insulating
cable (single core, multi-core) are as follow:
(Presume that the use voltage is 220V and the potential is below 10V.
2The application of the single-core insulating cable section mm
2The application of the multi-core insulating cable section mm
The choice of the electric cable
Potential (v) = Current (A) 3Length
Section area
1
58
50A
100A
200A
300A
Current
Lengthbeneath 75m 125 20015050m 100m
8
22
60
100
14
30
60
100
38
60
125
200
22
38
60
100
22
50
80
125
30
50
100
150
50A
100A
200A
300A
Current75m 125 20015050m 100m
14
38
38 2
60 2
14
38
38 2
60 2
22
38
38 2
60 2
22
50
50 2
60 2
30
50
50 2
80 2
38
60
50 2
100 2
Lengthbeneath
71
Content
1. Safety
1.1 Safety marks
1.2 Attentions
1.3 Warning labels
2. Machine introduction
2.1 Use and laws
2.2 Main technical parameters
2.3 Outlook and parts' names
2.4 Structure
2.5 Operation panel
2.5.1 Configuration and name
2.5.2 Functions and operation introduction
2.5.3 Functions and identification of protectors
3. Connection of load
3.1 Capacity of motor
3.2 Selection of 3-phase cable
3.3 Connection of loading equipment
3.3.1 3-phase power supply (400V/415V)
3.3.2 Single-phase power supply (120V/240V)
3.3.3 Connect loading equipment
3.3.4 Low-load operation
3.4 Earth
4. Transportation and overlapping-storage
4.1 Lifting attentions
4.2 Transportation attentions
4.3 Overlapping-storage attentions
5. Installation
6. Operation
6.1 Fuel, lubricant and cooling water
6.1.1 Fuel
6.1.2 Lubricant
6.1.3 Cooling water
1
1
2
7
11
11
12
17
18
19
19
20
22
23
23
24
25
25
25
27
27
27
29
29
29
30
31
33
33
33
34
34
The conditions of generator rated output:
Altitude: 0 m Ambient temperature: 25 Relative humidity: 30%
Ambient modified coefficient: C (Relative humidity 30%)
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 P =5KW, altitude is 1000m, ambient N
temperature is 35 , relative humidity is 80%, the rated power of generator is:
P=P (C-0.02) = 5 (0.82-0.02) = 4KWN
Modified coefficient table of ambient condition power
Ambient temperature ( )Altitude
(m)
0
500
1000
2000
3000
4000
25
1
0.93
0.87
0.75
0.64
0.54
30
0.98
0.91
0.85
0.73
0.62
0.52
35
0.96
0.89
0.82
0.71
0.6
0.5
40
0.93
0.87
0.80
0.69
0.58
0.48
45
0.90
0.84
0.78
0.66
0.56
0.46
70
11. APPENDIX
6.2 Operation of storage battery
6.2.1 Check of storage battery
6.2.2 Charging attentions
6.3 Pre-start preparations
6.3.1 Fill fuel
6.3.2 Keynotes for filling fuel with outside fuel tank
6.3.3 Fill lubricant
6.3.4 Fill cooling water
6.3.5 Trial running
6.3.6 Quantity re-confirmation of lubricant and cooling water
6.4 Operation
6.4.1 Pre-start checks
6.4.2 Adjustment upon start and no-load
6.4.3 Keynote for load running
6.4.4 Stop the machine
6.4.5 Running on the automobile
6.4.6 Start procedure
6.5 Long-term storage
7. Maintenance and check
7.1 Check
7.1.1 Torque list
7.2 Periodical checks and intervals
7.3 Periodical check
7.3.1 Per 50hours
7.3.2 Per 250 hours
7.3.3 Per 500hours
7.3.4 Per 1000hours
7.3.5 Per 2000hours
8. Error-shooting
9. Electrical wiring drawing
9.1 Wiring drawing of generator
9.2 Wiring drawing of engine
9.3 Fuel system drawing
9.4 Lubricant system drawing
10. Warranty statement
11.Appendix
69
10. Warranty statement
Below things can't be guarantee repaired.Aging after a period of time, such as nature fading on cover of decorated dope and plated metal.General feeling phenomenons which don't affect quality and performance, such as sound, shock, etc. Problems brought by typhoon or flood.Problems brought by medicine or salt damage.
Cost of below things is not paid.Expendable, such as spark plug, air cleaner, fuel filter, lamp, tie plate, seal washer, fuse, and brush and grease and so on.Repair machine not in KIPOR generator service store or store where you bought the machine.
Check, clean, adjust and maintain timely.Inconvenient and loss brought by can't work, such as shutout or business loss.Compensate cost beyond instruction in this warranty statement.
Guarantee rangeThis guarantee is just for generator bought inland, and will be end if bring abroad.
Ways to receive guarantee repair.Please bring generator, warranty statement and invoice to the store you bought the machine or KIPOR generator service store to get guarantee repair. We will not provide guarantee repair if you don't bring with warranty statement.
Guarantee repair go into effect.The guarantee repair goes into effect as soon as you and the supplier write down some important terms on the warranty statement and sign or seal.
Thank you for buying
Guarantee termThe term of guarantee repair starts from the day you bought the machine and lasts one year. But if machine is long-term or frequently used, the guarantee term will be six months.Other guarantee things Battery will be guaranteed according to standards made by the accessory producers. Please consult with the store you bought the machine or KIPOR generator service store. (Only for generators with battery).
Things which can't be guaranteedErrors caused by below reasons can't be guarantee repaired.
Fail to check and maintain machine timely according to the instruction. Fail to operate according to the instruction.Badly or wrongly maintain.Over-time work.Change without promise of KIPOR.Error caused by inattentionUse anti-purity accessory or discommend grease.
KIPOR products, if disqualification happens to your generator sets, our company will ensure below followings according to this warranty statement.
Guarantee contentOur company will provide free repair if material or product disqualification happen to the genuine part of your generator. (Free repair is called guarantee repair in below passage, which means change and repair the parts). In addition, the disqualification parts will belong to KIPOR.
WUXI KIPOR POWER CO.LTD
Beside jingyi Rd, Third-stage Development section of Wangzhuang Industry Area.
Wuxi High & New Technology Industry Development Zone.
Indicate that mechanical damage or shorter duration and etc. is likely to occur in case of neglect.
However, it is impossible for our company to expect all risks concerning conditions of operation, check and maintenance. Therefore warnings contained in the introduction and identified on the machine are exclusive and complete. User shall take own responsibility for safety if user does operation, check and maintenance not mentioned herein.
1. Safety
Please read and observe all safety and precaution
information. Failure to observe them and incorrect
operation can lead to serious injury even death.
1.1Safety marks
Please carefully read and thoroughly understand this introduction and
precautions and attentions marked on the machine prior to operation, check and
maintenance. Then official operation is allowed.
Identify conditions of risks and damages if operation is incorrect with following
Indicates the extreme risk. Incorrect operation can lead to
serious injury even death.
Indicates the potential risk. If no measures are taken to
avoid risk, serious injury even death is very likely to occur.
Attention reminds operator not to ignore potential risks. If no
measures are taken to avoid risk, mild or moderate injury or
mechanical damage is very likely to occur.
68
9.4 Lubricant system drawing
To c
ylin
de
r h
oo
d
Co
olin
g w
ate
r
pu
mp
Ra
dia
tor
Au
xilia
ry
bo
x
Bypass tube
Fu
el i
nje
ctio
n p
um
p
67
9.3 Fuel system drawing
To c
ylin
de
r h
oo
d
fill o
il in
to r
ock
er
Ca
m b
ea
rin
g
To
ge
arb
ox
(fill
oil
in th
e
ge
ar
of w
ork
ing
oil
pu
mp
Cra
nk
be
arin
g
Bypa
ss p
ipe
valve
Fu
el i
nje
ctio
n p
um
p
Lubr
ican
t pum
p(bu
ilt
in re
lief v
alve
)
Lu
brica
nt fil
ter
Oil
tra
y
2
Only professional technicians with required skills are allowed
to operate this machine. Otherwise, accidental injury or electric
shock is possible.
Do not operate the machine when user is extremely tired,
drinks alcohol or takes certain medicine. Unwell operator
makes incorrect responses or acts slowly upon emergency
situations, leading to accidental injury and so on.
Please wear proper clothes and safety devices.
If any abnormality is found,Please pay attention to any abnormality concerning sound,
vibration, color of exhaust, oil leakage and abnormal alarm
during running, check or maintenance. If any abnormality is
found, stop running machine immediately. Report to the
superior and take proper measures. Forbid working the
machine before abnormality is eliminated.
Forbid taking fill-in cover of water tank off at high
temperature.After work and engine stops, temperatures of cooling water
and lubricant are still high. In addition they are under certain
pressure. If operator drains lubricant or cooling water or
replaces filters in such case, scalding occurs probably.
Operator must carry out such operations in the specified order
after temperature falls down.
As engine stops running and water temperature falls down,
slowly turns fill-in cover to release inside temperature. Then
take off fill-in cover of water tank.
Required fire-fighting apparatus and first-aid devices Place fire-fighting apparatus around to avoid fire risk.
Place first-aid devices.
Place statement about treating fire and accidents on site.
Publicize contact information of emergency center and its
telephone number on site.
Waste gas from engine is toxic. Prevent poisoning of waste
gas.
Do not run the machine in the place with bad ventilation or
full of waste gas.
1.2 Attentions
3
Do not run the machine in the place with bad ventilation such
as room, stockroom, cabin, tunnel and enclosed box.
If it is necessary to run the machine on mentioned conditions,
necessarily extend exhaust pipe outside of room and provide
proper ventilation device to ensure sufficient ventilation.
Mount the plug screw to water outlet of exhaust muffle and
ensure no leakage of waste gas. Otherwise there is risk of
leakage of waste gas.
Electric shockTouching output terminals of running machine leads to electric
shock even death, particularly when hands are wet.
Cut off the breaker and stop running machine before wiring.
(If machine is run with shunt feeding, please cut off power
feeder outside of machine.)
Close the cover of output terminal and screw down holding
screws when machine is running.
Touching the circuit in the control panel of running machine
leads to electric shock even death. Please screw down holding
screws.
Close the breaker (OFF) and stop the machine before opening
the control panel in consideration of changeover of running
machine and other reasons.
Stop engine and take out ignition key before checking the
control panel.
Keep far away from rotating part of running machine.If operator touches part of running machine rotating at high
speed, he/ she will be injured.
Close side door of running machine carefully.
If it is necessary to open side door of running machine, keep
hand and face away from rotating part of running machine.
Stop running machine prior to check and maintenance.
Precaution of fire risk Fuel, lubricant and anti-freezing liquid are easily inflammable
materials. If they are exposed to flame or ignition source, there
is fire risk.
66
9.2 Wiring drawing of engine
Fu
el n
ozz
le
Fu
el f
ilte
r
Wa
ter
sep
era
tor
(2)
Fu
el p
um
p o
nly
fo
r o
uts
ide
fu
el t
an
k (e
lect
rica
l)
Fu
el i
nje
ctio
n p
um
p
Elec
trom
agne
tic fe
edin
g pu
mp
Fu
el t
an
k
Wa
ter
sep
era
tor
(1)
Inle
t co
nn
ect
ion
of o
uts
ide
fu
el t
an
k
4
Please stop running engine upon fuel fill-in. Additionally,
prevent cigarette or match or other ignition source close to the
machine during fuel fill-in.
Do not place inflammable materials (paper scrap or sawdust)
or hazardous materials (grease, thin liquid, powder and etc.)
near the machine.
Wipe off overflowed fuel and lubricant immediately.
Keep inflammable materials away from vent because hot
waste gas can ignite inflammable materials.
Pay attention to parts under high-temperatureHeated parts of running machine are exposed to high
temperature even when machine stops working. There is
scalding risk.
Close side door of running machine carefully.
If it is necessary to open side door of running machine, do
not touch exhaust muffle, exhaust pipe, cylinder hood, machine
body, generator casing and similar parts.
Check and maintain the machine after engine is cold
completely.
Even if machine stops working, some inside parts are still hot.
Pay special attention to operation of storage batteryStorage battery can produce inflammable gas. So incorrect
operations can lead to explosion or serious injury.
Do charging in the well-ventilated place. Otherwise it is
exposed to ignition and explosion risks due to inflammable gas.
Do not connect (+) and (-) poles of storage battery upon lead
connection. Additionally do not connect wrong leads. Splashed
spark may ignite inflammable gases from storage battery thus
to cause explosion.
Electrolyte of storage battery contains thin sulfuric acid.
Incorrect operation can lead to serious injury.
If clothes or skin touches electrolyte of storage battery,
immediately wash with plenty of water. If eyes touch electrolyte
of storage battery, immediately wash with plenty of water and
consult physician.
If electrolyte of storage battery is below LOWER LEVEL, do
not use storage battery. Inside aging of storage battery leads to
shorter life even explosion.
65
Re
d 2
0#
yello
w &
gre
en
20
#
Red
& W
hite
20#
Yel
low
& W
hite
20#
DC
cha
rgin
g ou
tput
Civic
-electri
city
input
Yello
w 12
#
Gre
en 1
2#
Red
12#
Blac
k 12
#
Red
18#
Green1
8#Blu
e 18#
Blue 1
8#
Yellow
20#
Yellow
12#
Green
12#
Red 1
2#
Black
12#
Blu
e &
Whi
te 2
0#
AC
cha
rgin
g in
put
Red
20#
Bla
ck 2
0#
Yello
w 12
#
Gre
en 1
2#
Red
12#
Blac
k 12
#
Yello
w 12
#
Gre
en 1
2#
Red
12#
Blac
k 12
#
Yellow
& Gre
en 12#
Civ
ic-e
lect
ricity
A
C i
nput C
ontr
ol
mod
ule
Gen
erat
or A
Csi
gnal
inpu
t
Brow
n &
Blue
20#
Ye
llow
&
B
lue
20
#KM
1
Oran
ge &
Bl
ue 2
0#
Pin
k &
B
lue
20
#
Pu
rple
&
Gra
y 2
0#
Purp
le &
Bla
ck 2
0#
Civic
-elec
tricit
y su
pply
outp
ut
Gen
erat
or
supp
ly o
utpu
t
Cont
rol
signa
l
Yello
w 12
#
Gre
en 1
2#
Red
12#
Blac
k 12
#
Yello
w 0.
5G
reen
Re
d Bl
ack
0.5
0.5 0.
5
Red
& B
lack
20#
Gre
en &
Bla
ck 2
0#
Yel
low
& B
lack
20#
Pur
ple
20#
Gre
en 1
8#
Red
18#
White
18#
Red
18#
Red 1
4#K
1Gr
een 1
4# Gree
n 20#
Whit
e18#
Blue
18#
Ora
nge
18#
Red &
Blue
20#
Green&
Blue2
0#
Gary
& B
lue20
#
Blac
k & B
lue20
#Blu
e 18#
Blue 1
8#
Adjus
ter
Yellow
16#
Blue 1
0#
Yellow
10#
Brown
18#
Batter
y
Yellow
& Gre
en18# Pu
rple &
Orange
18#
Starting
electro
motor
Starting
magne
t
Red
10#
Pink
20#
Gray
18#
Gray &
White 2
0#
Ora
nge
18#
Abno
rmal
sig
nal in
put
Runn
ing
signa
l out
put
Intelli
gent
pane
l con
troller
Intellig
ent pa
nel
displa
y
Startin
g sign
al inpu
tBr
own 2
0#
Reheat
ing sign
al outp
ut
Startin
g signa
l outpu
t
over lo
ading si
gnal ou
tput
Whit
e20#
ATS
optio
ns
On/
off r
elat
ion
shee
t of s
witc
h lo
ck:
Volta
ge s
ampl
ing
Cur
rent
sam
plin
g
Water
temp
eratur
e sw
itch
Low
oilpre
ssure
sw
itch
Flyw
heel
AC
Volta
ge sa
mpli
ng
Blac
k 20
#sh
unt t
rip
Gree
n & Bl
ue 2
0#
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11 10 9 8 7 6 5 4 3 2 1 No
SA
1
M1
M2
SA
TC
GB
L1
L2
L3
W3
W2
W1
U,V
,W,N
,E
SB
B2
011
C
B2
011
C
Fu
1
YV
KM
1,K
M2
K3
K1
,K2
,K4
QF
Co
de
SQ1
SQ2
SQ3
AVR
(Inte
lligen
ce)
FU2
FU3
FU4
Fu
el f
ee
d p
um
p
Le
ve
l co
ntr
olle
r
Ign
itio
n s
witch
Tra
nsfo
rme
r
Ch
arg
ing
re
gu
lato
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Sto
rag
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atte
ry
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R
Exc
itatio
n w
ind
ing
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ee
t fu
se
lin
k
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ee
t fu
se
lin
k
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ay c
ut-
ou
t b
ox
Fu
se
(6
x3
0)
10
A
AC
co
nta
cto
r
DC
co
nta
cto
r
Re
lay
AT
S m
od
ule
Inte
llig
en
t sc
ree
n
Inte
llig
en
t m
od
ule
Bre
ake
r
Na
me
Selec
tion s
witch
of fu
el fee
d pum
p
Curre
nt m
utua
l-ind
icato
r
3-ph
ase
outp
ut b
oard
Emer
genc
y st
op b
utto
n
Wind
ing of
char
ging g
ener
ator
Windin
g of po
wer ge
neratio
n and
samplin
g
Thro
ttle
elec
trom
agne
t
1 1 1 1 1 1 1 1 3 2 1 1 2 1 2 1 2 1 1 1 1 Qty
.
3S
S3
-10
B
DC
12
V
Jk4
27
35
Ah
50
/5m
A
HV
W4
11E
R
10
A
20
A
B2
04
1C
B2
01
C
A2
6-4
0-0
0
PLY
-MB
-D
Ma
teria
l
220V
/15V
40A
6-QW-
36 12
V 36A
h 310
A
PLY-
DAV
R-9
5S
QDC-
100A
DC1
2V
HFV4
12V
20A
PLY-
MB-
ATS-
S1
PLY-
MB-
ATS-
C
B0-1
00EB
3P/
16A
Rem
ark
ABB
BeiYu el
ectric
5
Prohibit lifting the machine with non-designated
hook.Do not lift the machine at non-designated positions
because of insufficient lifting strength. Otherwise falling
machine leads to mechanical damage or human injury.
Upon lifting the machine, please use the designated
metal hook in the center of top cover.
Do not stand under lifted machine.
Do not lift the machine when engine starts or runs.
Pay attention to overlapping-storageIncorrect overlapping-storage may cause overturn of
machines and mechanical damage.
Place the machine on the flat and solid ground. Keep
machines level. Ensure that ground can bear overlapping
weight.
Two layers of overlapping storage are allowed. Machines
on the upper layer must be smaller and lighter than this
machine.
Check if machine bolts are loose or missing.
Separate machines with wooden lumps. Keep all
wooden lumps bearing same weight.
Do not move overlapped machines. Otherwise it may
cause overturn and falling.
Maintenance attentionsMeaning of warning labels for check and maintenance
During check and maintenance, serious accident even
death may occur if unnecessary persons start the engine
or operate speed-regulating lever.
Identify the warning label [Danger Not run!] at obvious
positions such starter in order to avoid unnecessary
persons carry out unintended operation upon check and
maintenance.
Check and maintenance after engine stops.Start check and maintenance after engine stops.
If maintenance requires running engine, such
maintenance must be done by two persons. One person is
responsible for maintenance while the other person is
ready for stopping running engine at any time.
Maintenance operator shall take precautions against
body and clothes into rotation parts of machine.
Danger
Not run
64
Red
18#
Green1
8#Blu
e 18#
Blue 1
8#
Yellow
20#
Yellow
20#
Red
20
#ye
llow
& g
ree
n 2
0#
Oran
ge &
Whit
e 20
#
Red
& W
hite
20#
DC
cha
rgin
g ou
tput
Blu
e &
Whi
te 2
0#
Red
20#
Bla
ck 2
0#
Civ
ic-e
lect
ricity
A
C i
nput
A
TS
Con
trol
m
odul
e
Gen
erat
or A
Csi
gnal
inpu
t
Brow
n &
Blue
20#
Ye
llow
&
B
lue
20
#
Oran
ge &
Bl
ue 2
0#
Pin
k &
B
lue
20
#
Pu
rple
&
Gra
y 2
0#
Purp
le &
Bla
ck 2
0#
Civic
-elec
tricit
y su
pply
outp
ut
Gen
erat
or
supp
ly o
utpu
t
Cont
rol
signa
l
Intelli
gent
pane
l con
troller
Intellig
ent pa
nel
displa
y
Startin
g sign
al inpu
t
Red
& W
hite
20#
Yello
w &
Whi
te 2
0#A
C c
harg
ing
inpu
t
Civi
c-elec
tricity
inp
ut ~
Pur
ple
20#
Gre
en 1
8#
Red
18#
White
18#
Red
18#
Red 1
4#Gr
een 1
4# Gree
n 20#
Whit
e18#
Blue
18#
Ora
nge
18#
Red &
Blue
20#
Green&
Blue2
0#
Gary
& B
lue20
#
Blac
k & B
lue20
#
Blue 1
8#
Blue 1
8#
Adjus
ter
Yellow
16#
Blue 1
0#
Yellow
10#
Brown
18#
Batter
y
Yellow
& Gre
en18# Pu
rple &
Orange
18#
Starting
electro
motor
Starting
magne
t
Red
10#
Pink
20#
Gray
18#
Gray &
White 2
0#
Ora
nge
18#
Abno
rmal
sig
nal in
put
Runn
ing
signa
l out
put
Brow
n 20#
Reheat
ing sign
al outp
ut
Startin
g signa
l outpu
t
over lo
ading si
gnal ou
tput
Whit
e20#
Red
20#
Bla
ck 2
0#
Gar
y 20
#
Gra
y 2
0#
Bla
ck 1
2#
Red
12#
Blac
k 12
#Bl
ack
8#Red
12#
Red
8#
Bla
ck 2
0#
Red
& B
lue2
0#
Red
8#
Bla
ck 8
#
Red
8#
Bla
ck 8
#Bla
ck 8#
Red
8#
Red
8#
Blac
k 8#
Bla
ck &
Whi
te 2
0#AT
S op
tions
On/
off r
elat
ion
shee
t of s
witc
h lo
ck:
Volta
ge s
ampl
ing
Cur
rent
sam
plin
g
Water
temp
eratur
e sw
itch
Low
oilpre
ssure
sw
itch
Flyw
heel
AC
Volta
ge sa
mpli
ng
shun
t trip
Yello
w &
Gre
en 1
2#
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11 10 9 8 7 6 5 4 3 2 1 No
SA
1
M1
M2
SA
TC
GB
L1
W3
W2
W1
U,N
,E
SB
B2
011
C
B2
011
C
Fu
1
YV
KM
1,K
M2
K3
K1
,K2
,K4
QF
Co
de
SQ1
SQ2
SQ3
AVR
(Inte
lligen
ce)
FU2
FU3
FU4
Fu
el f
ee
d p
um
p
Le
ve
l co
ntr
olle
r
Ign
itio
n s
witch
Tra
nsfo
rme
r
Ch
arg
ing
re
gu
lato
r
Sto
rag
e b
atte
ry
AV
R
Exc
itatio
n w
ind
ing
Sh
ee
t fu
se
lin
k
Sh
ee
t fu
se
lin
k
4-w
ay c
ut-
ou
t b
ox
Fu
se(
6x3
0)
10
A
AC
co
nta
cto
r
DC
co
nta
cto
r
Re
lay
AT
S m
od
ule
Inte
llig
en
t sc
ree
n
Inte
llig
en
t m
od
ule
Bre
ake
r
Na
me
Selec
tion s
witch
of fu
el fee
d pum
p
Cur
rent
mut
ual-i
ndic
ator
3-ph
ase
outp
ut b
oard
Emer
genc
y st
op b
utto
n
Wind
ing of
char
ging g
ener
ator
Windin
g of po
wer ge
neratio
n and
samplin
g
Thro
ttle
elec
trom
agne
t
1 1 1 1 1 1 1 1 1 2 1 1 3 1 2 1 2 1 2 1 1 1 1 Qty
.
3S
S3
-10
B
DC
12
V
Jk4
27
QC
D-3
5A
h
50
/5m
A
HV
W4
11E
R
10
A
20
A
B2
04
1C
B2
01
C
A2
6-4
0-0
0
PLY
-MB
-D1
Ma
teria
l
220V
/15V
40A
6-QW-
36 12
V 36A
h 310
A
PLY-
DAV
R-9
5S
QDC-
100A
DC1
2V
HFV4
12V
20A
PLY-
MB-
ATS-
S1
PLY-
MB-
ATS-
C1
B0-1
00EB
2P/
50A
Rem
ark
ABB
BeiYu el
ectric
6
Pay attention to electric shockSome parts of running machine are under high voltage. It is
dangerous.
Start check and maintenance after engine stops.
Pay attention to parts at high-temperatureAs certain parts in the machine are hot
It is necessary to start check and maintenance after engine
stops.
Please pay particular attentions. Even if machine stops
working, some inside parts are still hot. Therefore check and
maintain the machine after engine is cold completely.
Attentions for handling storage batteryIncorrect operation may lead to explosion even serious injury.
Take out the earth line of storage battery (-) pole then cut off
power supply upon mechanical check and maintenance.
Connect (+) pole prior to (-) pole upon connection of storage
battery.
Lighting apparatus must have explosion-proof.
Please use lighting apparatus with explosion-proof upon
check of fuel, lubricant, cooling water and electrolyte of storage
battery. Otherwise, explosion may occur.
Periodical change of important parts
Periodically change following parts because aging or
Several warning identifications are marked on the machine for safety concern.
Keep identifications clean regularly. Prevent them from contamination or damage.
In case of contamination or damage, replace it with new one.
1) Labeling
NO.
1
2
3
4
5
NO.
6
7
8
9
10
Meaning
Pay attention to high temperature
Forbid lifting the machine
Lifting position
Prevent flame and fire
Pay attention to exhaust and scalding
Pay attention to electric shock and connect earth line
Meaning
Attended operations
Pay attention to handling of storage battery
Avoid being involved in the running machine
Attentions for inside check of engine
62
P-08
P-01
P-02
P-03
P-04
P-05
P-06
P-07
Check excitation line and carbon brush
Replace AVR or motor in same type
Replace fuse in same type
Check circuit and inserts
Replace start motor
No signal input of successful start
Check fuel supply system and fuel pump
Replace emergency stop button
Replace charging motor in the same type
Error Analysis Solutions
No start display
3.Open-circuit of excitation circuit
4.Burnt AVR or motor
1.
1.Broken fuse of start circuit
2.
3.Damage of start motor
4.Damage of charging motor
5.Error of fuel system
1.
1.Open-circuit of charging circuit
2.Error of charging motor
1.High-temperature of cooling
water.
2.Insufficient cooling water
3.
4.
1.Broken panel fuses
2.
3.Bad contact of inserts
1.Insufficient lubricant
2.Error of lubrication system
3.
4.
1.Broken sampling harness
Bad contact or damage of switch lock
Damage of low-oil-pressure switch (normal open)
Earth short-circuit of low-oil-pressure switch
2.Abnormal frequency (excessive or below)
3. Abnormal fuel system; instable rotation speed of engine
1.Broken sampling harness
2.Abnormal voltage (excessive or below)
Earth short-circuit of water temperature switch
Damage of water temperature switch (normal open)
Damage of emergency stop button or short-circuit of normal open point
OverloadReduce load till load is below rated value.
Broken wire of start circuit or bad contact of inserts
Replace fuses
Fill lubricant to rated value
Check lubrication system
Replace with same type
Check circuit
Check output frequency with AVO meter; calibrate actual value as per displayed value; adjust rotation speed of engine; keep output frequency compliant with ex-works setting
Check voltage sampling harness if not indicate voltage or frequency after machine starts
Check or replace switch lock it according to on-off relation of switch lock
Check module nine PIN inserts and data line
Check fuel system
Check voltage sampling harness if not indicate voltage or frequency after machine starts
Check output frequency with AVO meter; calibrate actual value as per displayed value; adjust AVR to ensure output voltagecompliant with rated value
Add cooling water to rated level
Check circuit
Cut off breaker; idle machine for certaintime; stop machine and re-start it after water temperature falls down.
Reduce load till load is below rated value. Then close breaker.
Check signal of AC charging generator and inserts
Replace water temperature switch in the same type
8
c. Forbid lifting the machine.
Falling danagerForbid lifting
d. Attended operations.
Danger
(2) Warning label (identification)
a. Pay attention to exhaust and scalding. b. Lifting positions
Use the proper device in the room and other places with bad ventilation because of hazardous waste gas.
Pay attention to exhaust
Attention Attention
Pay attention to scalding
Touching hot parts may cause scalding risk.
Carefully read and thoroughly understand this introduction prior to use.
If this introduction or safety identification is damaged, please order one from
KIPOR sales department.
Forbid connecting the machine with distribution line of power company and
distribution line in the building willfully.
Stop the engine before fuel fill-in.
Check if breaker is cut off before machine starts.
Forbid moving running machine.
Use the machine after its wheels are fixed.
Only professional technicians with required skills are allowed to operate this
machine for safety concern.
There is risk of electric shock and injury.
Some parts in the machine are under high voltage, rotation and high temperature.
Close side door before machine starts.
Parts in the cover of output terminal and control panel are under high voltage.
Close side door before machine starts.
Stop running machine prior to check and maintenance.
Lifting position
Attention
Attention
61
Abnormality Possible reasons Solution
Check and replace
Check, adjust and repair
Check and replace
Check and replace
Check and replace
Reduce load
Error of AVR
Error of AVR
Imbalance load
Bad function of field circuit
Bad adjustment of speed-regulating knob
Bad function of voltage regulator
High-temperature of generator due to overload
Adjust load to balance load at 3 phases
Cannot turn single-phase breaker to ON
Excessive voltage
Voltage falls down considerably withincrease of load
Cannot adjust voltage
Pointer of current meter does not work with load.
Pointer of freque-ncy meter does not work.
Cannot turn 3-phasebreaker to ON
Replace
Replace
Check and repair
Re-operate
Error of frequency meter
Bad breaker
Short-circuit of load circuit
Replace;
connect with U-phase
terminal
Replace
Check and replace
Error of current meter or
CT; use terminals not at
U phase
Bad breaker
Short-circuit of load circuit
Improperly release of cutoff
and electricity leakage alarm
9
AttentionDanger
Danger
U V W N
AC400/415V
AC400/415V AC400/415V
AC230/240VAC230/240V
AC230/240V
h. Pay attention to electric shock and connect earth line
e. Prevent flame and fire.
Fire is possible if flame is
close to fuel inlet.
Stop the engine upon fuel
fill-in.
f. Avoid being involved in
the running machine.
g. Pay attention to high temperature.
Prohibit put hands or fingers into running machine.
There is injury risk.
Do not open water fill-in cover at high temperature.
Splash of hot water may cause scalding.
Avoid being involved in the running machine Pay attention to high temperaturePrevent flame and fire
Earth joint of engine hood(earth line for
machine body)
Risk of electric shockPlease connectearth line
Consider balance of phases if single-phase output is used.
Risk of electric shock
Please connect earth
line
Do not terminals of running machine.
Touching may cause risk of electric shock.
Pay attention to electric shock
60
Jammed air filter
Bad charging of storage battery
Abnormality Possible reasons Solution
Ce
ntra
l ind
icatio
n la
mp
s are
on
.
Damage of rotationspeed meter
Check and fill
Replace
Repair and replace
Check and replace
Check and replace
Repair
Replace
Repair and replace
Damage of volometer
Error of AVR
Broken wire
Bad function of breaker
Jammed filter core aperture
Loose or damaged V belt
Loose terminals, corrosion or broken wire of terminals
Insufficient electrolyte
Bad function of storage battery
Error of AC generator
Check, adjust and replace
Check, repair and replace
Replace
Clean and replace the filter core
Bad volometer
Error of AVR
Bad operation and adjustment of speed-regulating knob
Broken wire or bad contact of voltage regulator
Replace
Check and replace
Check and adjust
Repair and replace
Error of guide-blade rotator
No voltage from generator
Pointer of rotation-speed
meter does not work.
(Time recorder does not work.)
Below rated voltage
10
Attention
i. Pay attention to handling of
storage battery
Operation of cable is exposed to risk of electric shock.
Read the introduction and operate correctly.
Explosion causes injury.
Do not drill, blow out, impact or disassemble the machine or be close to flame and fire.
Electric shock: Upon operation of cable
Explosion
Read the introduction Disassembly, repair andprohibition of flame and fire
Disassembly, repair andprohibition of flame and fire
j. Attentions for inside check of engine
Check the machine after the engine is cold.
If machine check requires running engine, particularly do not touch exhaust
muffle, exhaust pipe, and similar parts in order to avoid scalding risk.
59
Engine stops
Rotation speed below
rated value
Instable rotation speed,
abnormal, fluctuation, rise
or reduction
Lubricant pressure
falls down
(engine stops)
Temperature rise of
cooling water
(engine stops)
Abnormality Possible reasons Solution
Ce
ntra
l ind
icatio
n la
mp
s are
on
.
Air into fuel pipe
Dirty filter core or jammed filter core apertures
Dirty air filter core
Incorrect wiring of speed-regulating knob
Bad function of fuel-injectionvalve, speed regulator andfuel-injection pump
Eliminate air
Clean or replace filter core
Clean and replace filter core
Insufficient lubricant level
Spill of lubricant
Jammed core apertures of lubricant filter
Bad function of oil pressure switch
Repair
Adjust and repair
Fill lubricant
Check and repair
Replace filter core
Replace
Check and fill
Check, adjust and replace
Clean
Check and replace
Clean cylinder, cylinder hood, radiator and coo-ling water pipe
Check exhaust positionof radiator and ensure good ventilation around generator
Insufficient cooling water
Improper operating
environment
Contamination of coolingwater pipe
Damage of temperature controller
Seriously jammed radiator by oil dirt
Loose or damaged V belt
11
2. Machine introduction
2.1 Use and laws
This machine is portable and used as main or auxiliary power supply for
outside work.
Some countries regulate the connection of machine with inside distribution line
accepting power from the power company. Please pay particular attentions to
and observe relevant laws and regulations in local countries and areas.
This product is applicable for moving electrical equipments. Please observe
relevant laws and regulations and make legal declaration.
Only professional technicians with required skills are allowed to operate this
machine for safety concern.
58
[Attended operations]
Immediately stop running generator for check and repair if any abnormality is
found.
Continue running abnormal generator may cause unexpected serious accidents.
8. Error-shooting
Abnormality Possible reasons Solution
Cannot rotate
motor
Rotation speed
below rated value
No
t wo
rk en
gin
e
Bad function of starter
Excessive viscosity of lubricant
Bad function of start switch
Bad earth, loose joint, broken line
Release, loose or corrosion of storage battery terminals
Shelf depreciation of storage battery
Insufficient fuel
Air into fuel pipe of fuel system
Jammed core of fuel filter
Bad function of fuel-off solenoid valve
Incorrect wiring position of speed-regulating knob
Frozen fuel
Frozen water in the fuel system
Clean and screw down
Repair
Replace
Replace
Check and replace
Check electrolyte level and specific gravity
Fill fuel
Eliminate air
Replace
Check and replace fuse for off-circuit.(If it is a b n o r m a l , f i n d o u t reasons then replace it)
Check and replace fuel-off solenoid valve
Use improper fuel in the cold areas.Recommended 3# light oi l .Forbid using heavy fuel.
Repair
Eliminate the water in fuel tank, fuel filter and fuel supply pipe at hot status.
12
Rated output
(capacity)
Rated voltage
Rated current
Rated rotation speed
Circuit mode
Factor power
Insulation grade
Pole number
Excitation number
Model
Type
Total displacement
Rated power
Compression ratio
Rated rotation speed
Burning type
Cooling type
Lubricate type
Starting type
Fuel
Lubricating oil
Battery motor capacity
Charge DC generator capacity
Battery mode
Fuel consumption/ rated time
Overall length
Width
Height
Net weight
Weight at running
Structure type
KVA
kW
V
A
rpm
--
cos
--
--
--
V
kVA
kVA
--
--
mm
L
kW
R/min
--
--
--
--
--
--
L
L
L
L
V-kW
V-A
--
mm
mm
mm
kg
kg
g/KW.h
KDE9000SS/KDA9000SS/KDA9000SSO
50Hz
6.0
6.0
115/230
26 2/26
1500
60Hz
7.2
7.2
120/240
30 2/30
1800
1.0
H
4
Brushless self-excitation and constant voltage (with AVR)
115/230 120/240
Two single phase receptacles
Output terminal post
KD373
Vertical, water cooled, four stroke, diesel engine