V.

200610

Operation and Maintenance Manual

of Diesel Engine Generator Sets

SHANGHAI YANGKE ENGINE CO., LTD.

 Content

Chapter 1 Brief 1

Chapter 2 Main equipments and technique parameters 2

Chapter 3 Control principle of the diesel engine generator set 3

Chapter 4 Mounting and use 4

Chapter 5 Maintenance and trouble shooting 5

SHANGHAI YANGKE ENGINE CO., LTD. Page 1, Total 17

 CHAPTER-1 BRIEF
GF、SMS、GFT and other series diesel generator sets are made in YangKe
company(called as the units in the brief), which synthesize advanced technique
about brushless synchronous generator, excitation device and general structure etc.,
which are equipped with national standards diesel engine such as 95 series, 135
series, 190, S1100 (S 1105, S1110) and domestic well-known diesel engine work
such as WEICHAI, YANGDONG, Shanghai tractor and internal combustion engine
company, Shanghai New Holland. The quality of their productions is superior and
their techniques are advanced generators. Our company is able to supply high
quality, durable and economic generators for global customers.
The ordering of Set model is explained for as follows:
1 2 3 4

GF ——

SMS ——
1. Rated power of the diesel generator set.
2. GF means three-phase open type diesel generator set.
SMS means silent diesel generator set.
3. Z means the automation.
T means the mobile trailer diesel generator set.
B means semi automation.
4. The function fills in.
For example：
10GF means three-phase open type diesel generator set of 10KW.
20SMSZ means a 20 KW silent automatic diesel generator set.
90GFT means a 90 KW mobile trailer diesel generator.

Section-1 Structure of units

The diesel engine generator sets in YangKe company are the alternator sets,
which are high quality, durable, convenient maintenance, and able to supply mobile
or fixed power source for mine, factory, enterprise, hotel, hospital, village, town,
fishing or herding, forest, highway or bridge, communication or broadcast and so on,
and used as backup power supply of mansion, work mineral, hospital, square, bus
station and cabaret.
SHANGHAI YANGKE ENGINE CO., LTD. Page 2, Total 17
 The control methods of the machine set can be classified as manual control,
half-automatic control and full-automatic control etc. Cooling systems can be divided
into a open type circulatory system and a close type circulatory system. Starting
methods can be divided into handing recoil or electric starter. The generator can be
divided into brushless or brush by excitation, CONTROL or Non CONTROL, thrice
harmonious wave etc.
Constitutions of the units:
a. Diesel engine.
b. Alternator.
c. Radiator, joint and public chassis.
d. Control panel.
e. Fuel tank, battery, spare parts, accessories and tool boxes.

Section-2 Technical performances of the units

The power of the diesel generator sets which ranges from 8 KW to 500 KW, and
the frequency ranges from 50 Hz to 60 Hz. According to the requirement of
customers, there are enough species to meet with different customers' requests.
Diesel generator set in the land is manufactured according to “GB2820”.
Self-startup and emergent diesel generator set is manufactured according to
“GB12786”. Export diesel generator set is manufactured according to “JB4122”.
Mobile electric station is manufactured according to “GB/T2819” other than the
above-mentioned relevant standards.
When the machine set is zero load, its voltage ranges from 95% to 105% rated
voltage. when power factor is 0.8, steady adjust ratio, instantaneous adjust ratio、
steady time、fluctuant ratio of the voltage and the frequency should not exceed
specifications in the following table:
Voltage Frequency
Rated
Steady Instantaneous Steady Steady Instantaneous
power Type Fluctuant Steady Fluctuant
adjust adjust ratio time adjust adjust ratio
(KW) ratio (%) time (s) ratio (%)
ratio (%) (%) (s) ratio (%) (%)
Ⅰ ±1 +20/-15 0.5 0.5 1 ±5 3 0.5
Ⅱ ±3 +20/-15 1.0 1.0 3 ±5 5 1.0
≤250
Ⅲ ±5 —— 3.0 1.5 5 ±5 7 1.5
Ⅳ ±7 —— —— 1.5 6 ±5 —— 1.5
＞250 ±2.5 +20/-15 1.5 1.0 （0~5） ±5 7 1.0
The table data are at the environment temperature 298k. The data must be adjusted when
the environment temperature.

SHANGHAI YANGKE ENGINE CO., LTD. Page 3, Total 17

 Note:
1. When the machine set is 0~25% rated load, its voltage and frequency fluctuant rate is
permitted to exceed 0.5.
2. Don't include the voltage change between cold status or hot status while computing the
steady voltage adjust ratio.

Section-3 Working environment of the machine set

The machine set can supply the provision power and work credibly under the
following conditions:
1. The surrounding environment temperature is 273K~313K;
2. The altitude height is no more than 1000 meters;
3. The air humidity is less than 95% (at temperature 298K);
The working environment temperature of the normal set should be more than 273k,
otherwise it should be pre-heated. The working environment temperature of the
automatic set should be more than 288k; otherwise you should start the set at a
warmer temperature.
Usually, the altitude height of the set should be less than 1000 meters. The height
of 4000 meters is permitted only but with lower output power.
High temperature and wet environment will accelerate the generator aging, and
decrease the diesel engine output power, and have serious effects on the service life
and the credibility of the machine set.
Rated power of the machine set means 12 hours continuous power under the
standard condition: the atmosphere pressure Pa=100kpas (750mmHg), the relative
humidity φ =30%, the environment temperature T=298K. When the machine set has
been used continuously for more than 12 hours, its electricity power will be at 10%
discount of the engine rated power which cannot exceed the rated power of the set.
Under nonstandard working conditions, the customer should modify the diesel
engine power in order to prevent the diesel engine from overloading.
Modify formula：P=(Pe·K1-Pf)·K2
In the formula：
P: Output power of the machine set (kW).
Pe: The diesel rated power under standard condition (kW).
Pf: The fan power (kW).
K1: Temperature, humidity and atmosphere pressure modify correction efficiency
in nonstandard (correction efficiency table).

SHANGHAI YANGKE ENGINE CO., LTD. Page 4, Total 17

 K2: the generator efficiency (kW).
When the computed power of the machine set is lower than the rated power of the
set, it is used according to the computed one. When the computed power of the
machine set is bigger than the rated power of the set, it is used according to the rated
one.
Power correction table:
Power correction efficiency when relative humidity=30%
Altitude Atmospheric Atmospheric temperature (℃)
pressure
(m) (KPa) 0 5 10 15 20 25 30 35 40 45
0 100 1.10 1.08 1.06 1.04 1.02 1.00 0.98 0.96 0.93 0.90
200 97.63 1.07 1.05 1.03 1.01 0.99 0.97 0.95 0.93 0.90 0.87
400 95.39 1.04 1.02 1.00 0.98 0.96 0.94 0.92 0.90 0.88 0.85
600 93.16 1.01 0.99 0.97 0.96 0.94 0.92 0.90 0.88 0.85 0.83
800 90.92 0.98 0.96 0.95 0.93 0.91 0.89 0.87 0.85 0.83 0.80
1000 88.68 0.96 0.94 0.92 0.91 0.89 0.87 0.85 0.82 0.80 0.78
1500 83.42 0.89 0.87 0.85 0.84 0.82 0.81 0.79 0.76 0.73 0.71
2000 78.42 0.83 0.81 0.79 0.77 0.76 0.74 0.73 0.70 0.68 0.65
2500 73.68 0.77 0.74 0.73 0.72 0.70 0.68 0.66 0.64 0.62 0.60
3000 69.21 0.70 0.69 0.67 0.66 0.64 0.63 0.61 0.59 0.57 0.55
3500 64.87 0.65 0.63 0.62 0.61 0.59 0.58 0.56 0.54 0.52 0.50
4000 60.79 0.60 0.58 0.57 0.56 0.54 0.53 0.51 0.49 0.47 0.45

CHAPTER-2 MAIN EQUIPMENT AND TECHNIQUE PARAMETERS

1. GF series diesel generator set:
The GF series diesel generator set (the power scopes 10-500 KW) is the main
product of YangKe company. It is top-quality. It is advanced technology. GF series
diesel generator set is the alternator set, which is steady, durable and convenient
maintenance. The set can supply steady, credible and economic power for global
customers. The automatic voltage adjusting rate of the machine set can meet with
the common usage under three-phase symmetrical load within 0~100% rated power
and 0.8 power factor, which can be adjusted with the scope of 95~105% rated power
at zero load. The machine set can startup directly the rat-cage type three-phase
asynchronous motor whose rated power within 30~70% rated power of the set. When
the machine set is operated during three-phase asymmetrical load, and if phase
current is less than rated current and three-phase current is less than 20%, the
continuous operation of the set for a long time is admitted.
Technique parameters are as follows:

SHANGHAI YANGKE ENGINE CO., LTD. Page 5, Total 17

 Model Rated Rated Rated Rated Fuel Engine Alternator Dimension
output voltage current frequency consumption model model （mm）
(KW) (V) (A) (Hz) (g/kW*h)
8GF 8 400/230 14.4 50 295AD TFW-8 1800*800*820
≤250.2
10GF 10 400/230 18 50 295AD TFW-10 1800*800*820
12GF 12 400/230 21.6 50 2100AD TFW-12 1800*800*820
≤247
15GF 15 400/230 27 50 YD485 TFW-15 1900*850*850
20GF 20 400/230 36 50 ≤238 YSD490 TFW-20 2000*850*850
24GF 24 400/230 43.3 50 ≤258.4 K4100D TFW-24 2000*850*850
32GF 32 400/230 57.6 50 ≤242 R4100 TFW-32 2300*950*900
40GF 40 400/230 72.1 50 R4105ZD1 TFW-40 2400*1050*1200
≤231
50GF 50 400/230 90.2 50 R4105ZD1 TFW-50 2400*1050*1200
64GF 64 400/230 115.4 50 ≤224 R6105ZD1 TFW-64 2800*1100*1200
75GF 75 400/230 135.3 50 R6105ZLD TFW-75 2900*1100*1200
100GF 100 400/230 180.4 50 ≤218 R6105AZLD TFW-100 2900*1100*1200
120GF 120 400/230 216.5 50 R6113ZLD TFW-120 3100*1100*1200
150GF 150 400/230 270 50 12V135AZD TFW-150 3100*1100*1200
200GF 250 400/230 361 50 12V135AD TFW-200 3100*1300*1650
250GF 300 400/230 451 50 12V135JZD TFW-250 3500*1300*1700
≤250
300GF 400 400/230 504 50 12V135AZD TFW-300 3500*1300*1700
400GF 500 400/230 722 50 Z12V150ZD TFW-400 5500*1350*1950
500GF 250 400/230 902 50 Z8V190D2 TFW-500 5270*2040*2778

2. SMS series diesel generator set.

SMS(low noise) series diesel generator set can install common control, four
protections, YK-2000, DACTS 704C full-automatic controller with ATS, self startup,
self protection, self jump in, self shift and self shut down and so on equipments
according to the customer's requirements.
Rated Rated Rated Rated Fuel
Engine Alternator
Model output voltage current frequency consumption Dimension (mm)
model model
(KW) (V) (A) (Hz) (g/KW*h)
8SMS 8 400/230 14.4 50 ≤269.3 YD380 TFW-8 1700*800*720
10SMS 10 400/230 18 50 ≤250.2 YD480 TFW-10 1800*800*820
12SMS 12 400/230 21.6 50 YD485 TFW-12 1800*800*820
≤247
15SMS 15 400/230 27 50 YD490 TFW-15 1900*850*850
20SMS 20 400/230 36 50 ≤238 YD4100 TFW-20 2000*850*850
24SMS 24 400/230 43.3 50 ≤258.4 K4100D TFW-24 2000*850*850
32SMS 32 400/230 57.6 50 ≤242 R4100 TFW-32 2300*950*900
40SMS 40 400/230 72.1 50 R4105ZD1 TFW-40 2400*1050*1200
≤231
50SMS 50 400/230 90.2 50 R4105ZD1 TFW-50 2400*1050*1200
64SMS 64 400/230 115.4 50 ≤224 R6105ZD1 TFW-64 2800*1100*1200
75SMS 75 400/230 135.3 50 R6105ZLD TFW-75 2900*1100*1200
100SMS 100 400/230 180.4 50 ≤218 R6105AZLD TFW-100 2900*1100*1200
120SMS 120 400/230 216.5 50 R6113ZLD TFW-120 3100*1100*1200

SHANGHAI YANGKE ENGINE CO., LTD. Page 6, Total 17

3. GFT series mobile power station.
Rated Rated Rated Rated Fuel
Engine Alternator
Model output voltage current frequency consumption Dimension (mm)
model model
(KW) (V) (A) (Hz) (g/KW*h)
10GFT 10 400/230 18 50 295AD TFW-10 2800*1600*1800
12GFT 12 400/230 21.6 50 ≤257 295AD TFW-12 2800*1600*1800
15GFT 15 400/230 27 50 395AD TFW-15 2800*1600*1800
20GFT 20 400/230 36 50 495AD TFW-20 2800*1600*1800
24GFT 24 400/230 43.3 50 ≤252 495AD TFW-24 2800*1600*1800
30GFT 30 400/230 54.1 50 495AZD TFW-30 2800*1600*1800
40GFT 40 400/230 72.1 50 4135D TFW-40 3100*1600*1800
50GFT 50 400/230 90.2 50 4135AD TFW-50 3100*1600*1800
≤233
75GFT 75 400/230 135.3 50 R6105ZLD TFW-75 3100*1700*2200
90GFT 90 400/230 162.3 50 6135AD TFW-90 3100*1700*2200
100GFT 100 400/230 180.4 50 ≤230 R6105AZLD TFW-100 3100*1700*2200
120GFT 120 400/230 216.5 50 R6113ZLD TFW-120 3300*1700*2200
≤226
150GFT 150 400/230 270 50 12V135AZD TFW-150 3300*1700*2200
200GFT 250 400/230 361 50 ≤230 12V135AD TFW-200 3600*2000*2300
250GFT 300 400/230 451 50 12V135JZD TFW-250 4000*2200*2400
≤233
300GFT 400 400/230 504 50 12V135AZD TFW-300 4000*2200*2400

4.1 Water-cooling single-cylinder diesel generator sets.

Model 8GF-SF 10GF-SF 12GF-SF
Alternator model STC-8 / TWG-8 STC-10 / TWG-10 STC-12/TWG-12
Three times harmonic with brush
Alternator type
or brushless self-excitation with AVR alternator
Rated frequency (Hz) 50 / 60
Rated voltage (V) 50Hz: 400/230, 230 or 60Hz: 240/120, 120
Rated output power (kW) 8 10 12
Power factor cosΦ Single phase: 1.0 / Three phase: 0.8
Phase number Single phase / Three phase
Rated rotation speed (rpm) 1500 / 1800
Dimension (L×W×H) (mm) 1470×800×1220 1600×800×1220 1600×800×1220
Net weight (kg) 350 360 380
Engine model S1100 (M) S1105 (M) S1110 (M)
Engine type Water-cooled, single-cylinder, 4-stroke, diesel engine
Bore × Stroke (mm) 100×115 105×115 110×115
Displacement (L) 0.903 0.996 1.093
Compression ratio 17 17 17
Rated power [kW(HP)/rpm] 11 (15)/2200 12.13 (16.5)/2200 13.24 (18)/2200
Fuel consumption (g/kW×h) ≤238
Cooling mode Hopper or Radiator
Fuel tank capacity (L) 11.5 14.5 15.5
Starting system Hand cranking (electric starting)

SHANGHAI YANGKE ENGINE CO., LTD. Page 7, Total 17

4.2 Water-cooling single-cylinder low-noise diesel generator sets.
Model 8SMS-1 10SMS-1
Alternator model TWG-8-4 TWG-10-4
Alternator type Brushless self-excitation with AVR alternator
Rated frequency (Hz) 50 / 60
Rated voltage (V) 50Hz: 400/230, 230 or 60Hz: 240/120, 120
Rated output power (kW) 8 10
Power factor cosΦ Single phase: 1.0 / Three phase: 0.8
Phase number Single phase / Three phase
Rated rotation speed (rpm) 1500 / 1800
Dimension (L×W×H) (mm) 1600×950×1170 1600×950×1170
Net weight (kg) 550 560
Engine model S1110M S1115M
Engine type Water-cooled, single-cylinder, 4-stroke, diesel engine
Bore × Stroke (mm) 110×115 115×115
Displacement (L) 1.093 1.195
Compression ratio 17 17
Rated power (kW) 13.24 (18HP)/2200 14.7 (20) / 2200
Fuel consumption (g/kW×h) ≤238
Cooling mode Radiator
Fuel tank capacity (L) 11.5 14.5
Starting system Electric starting

CHAPTER-3 CONTROL PANEL OF THE UNITS

Section-1 Function and structure

The control systems of the machine set are divided into the cabinet type, the
electrical engineering integral type and so on.
Generally, the control systems are divided into an open type, nature cooling type.
The cabinet type is fit for fixed or bigger capacity set. Because of small scale
components, the cabinet type is compact, small and light.
The indicating light and various diagraph appearances (such as voltage gauge,
current gauge, the frequency table etc.) are showed in Figure 1, Figure 2. These
gauges show the operation state of the machine set .The user can know about the
inner conditions with these gauges.
The user can regulate and control the set by various switches, buttons, regulating
hand handles and so on in the panel. There is a sensor of an instrument, an
automatic voltage modulator and a control device in the control system. The
automatic machine set control principle is explained in ‘The Automation Machine Set
Usage Manual’.

SHANGHAI YANGKE ENGINE CO., LTD. Page 8, Total 17

 Sketch map of the control panel:

Figure-1

Figure-2

SHANGHAI YANGKE ENGINE CO., LTD. Page 9, Total 17

 Section-2 Circuit diagram
The electric circuit diagram is the path of the electric current expressed with the
diagram example and sign. The circuit diagram of the machine set is drawn
according to the electricity equipments circumstance and the usage request of the
machine set, according to the national standard. It is the basis and the instruction
data of installation、adjust and maintenance. The operator should master specialized
knowledge.
The electric system of the machine set can be divided into three parts as main
electric circuit, excitation adjusting voltage and assistant electric circuit. The
automation machine set is also equipped with automatic control circuit. Such as
Figure 3, Figure 4 show.
1. Main electric circuit
The main electric circuit includes synchronous generator、the excitation machine
and the electricity switch(include a main switch and the division switch) etc.. For the
parallel operation machine set, it is equipped with parallel operation and automatic
adjust electric circuit.
The general principle of the machine set is as follows:
With the force of diesel engine, both the generator and the excitation machine
revolve in the rated and steady speed rate. When the excitation circuit work normally,
the excitation machine (three times harmonic excitation generator and phase
compound generator) setups self excitation voltage immediately. After excitation
voltage is rectified, the voltage of the generator is steady at rated one.
During the normal work of the generator, because of a certain reason (for example:
load variety, various speed rate, temperature variety of the round group etc.), the
generator voltage is up or down .At the time, the automatic voltage modulator A.V.R.
(phase compound equipment), reduces or increases the excitation current to
maintain voltage by the tiny voltage deviation.
The output side of the generator is connected with the input side of the main switch
by the line box, and then the output side of the main switch is led towards division
switch and load, which is connected with measure gauge and no power loss current
mutual sensor in series. While needing outward power supply, the set will output
current, after connecting a main switch and then control panel of the division and
then button on according to the requirements.
2. The excitation adjust voltage circuit while adjusting automatically and then work
of automatic voltage modulator A. V. R , the magnetic field current of the generator

SHANGHAI YANGKE ENGINE CO., LTD. Page 10, Total 17

depends on the pass angle of the control silicon SCR measured by A.V.R. in order to
adjust the output voltage of the generator.
The electric principle diagram of the control panel of the machine set:

Figure-3 Diesel engine circuit diagram

Figure 4 Diesel generator circuit diagram

CHAPTER-4 MOUNTING AND USE OF THE UNITS

Section-1 Mounting and use of the units

Storage, Mounting and location of the diesel engine generator sets should match
following conditions:
1. Engine room should be bright, well ventilated, low humidity, where the
environment temperature is less than 313k;
2. In the night, work space should have a good lighting equipment. In the outdoor
SHANGHAI YANGKE ENGINE CO., LTD. Page 11, Total 17
usage, you should add the protection cover in order to avoid rain pour and sun;
3. The environment should be clean and be prohibited to place caustic things such
as acidity, alkalescency and so on nearby;
4. Exhaust pipe should be unimpeded. You should avoid long pipe or make a
sudden turn as far as possible. When the pipe is connected to the outdoor, you'd
better tilt outside slightly in order to make coagulant out;
5. If the machine set isn't fixed on the foundation, you can place rubber plate below
the set to decease vibration;
6. When the set is above 30KW, you should pay attention to your installations:
a. The foundation is concrete, but the foundation can not be together with the
building foundation. The distance between the two foundations should be more than
1.5 meters;
b. While assembling, you must use horizontal ruler in order to the horizon degree
of the machine set fixed;
c. For the sake of the safety, the generator and switch screen must be connected
to ground, and the ground line cross area isn't smaller than the one of the generator
output line. The line can be connected to the underground water pipe or deeply under
the underground steel plate in order to reliably ground. The resistance is less than 50
ohm.
d. The open cooling machine set must install another water pipe line in order to
supply full cooling water;
e. In order to reduce the environment noise, you can use muffler;
f. After assembling, the eccentricity between the generator shaft and the
crankshaft must be smaller than 0.15 millimeter; the flutter of the generator shaft to
the flywheel side face should be less than 0.5/400;
g. Storage battery should be well connected with the circuit of startup and charge.

Section-2 Usage of the machine set

Before using the machine set, you should read ‘Usage Manual of the Maintenance
of the Machine Set’ and the manuals of the diesel engine, generator and control
panel etc. usage maintenance manual.
1. Preparation of startup
※ Note: The fuel、engine oil and coolant that the machine set uses should be
referred to ‘Usage manual of the diesel engine’.
a. To get rid off dust、the water vestige and rust etc. from the machine set and oil

SHANGHAI YANGKE ENGINE CO., LTD. Page 12, Total 17

dirt 、ash dirt from the air filter.
b. To wholly check the machine set: tightly connecting, manipulating the
organization flexibly, revolving crankshaft easily.
c. To check whether the coolant is full or not, whether the water pump is full or not,
whether the antifreeze is added or not in the winter, whether the pipe is leak or not,
whether the pipe is chocked or not.
d. To check the fuel in the tank, to open the fuel switch, to loose high pressure oil
pump, to expel air in the fuel pipe, to screw bolt tightly;
e. To check engine oil indicator between two scales, to check enough engine oil in
fuel pump and activator;
f. To check the credibility and sensitivity of activator lever and fuel pump gear, to
check enough engine oil here;
g. To check all electric wire(include charge、startup circuit) whether connection is
true and connection is good;
h. To keep water and oil pipe joints of diesel engine、lubricating system、cooling
system etc from leaking;
i. To check integrality, cleanness, break, looseness of control panel;
j. To cut off rectifier and capacitor etc. and disconnect ground line, and then
measure resistance between wire and rotor round wire with 500megohm gauge
which must be more than 3megohm, otherwise to dry the circuit.
k. To check generator switch line without any error, and load should be connected
with control panel by two sides switch , which should be insulated from wire net(Air is
cut off; U, V, W of the generator are corresponding to control panel main side);
l. To check switch position of the control panel, to check division position of main
switch.
m. To check fingers (should show zero);
2. Startup of the machine set.
a. Pressure adjust switch should be at hand position;
b. You should open the fuel switch, and fix the hand lever of fuel control at 700 rpm
fuel control position in the meantime.
c. You should pump fuel by hand in succession until a pump pressure and ringing
squeak.
d. You can startup diesel engine by hand and electric button. After the rotate speed
reaches a certain one, the engine can startup;
e. After the diesel engine startup, the rotate should be at 600 rpm~700 rpm. You
should pay attention to the pressure of engine oil which is above 0.3MPa and the
SHANGHAI YANGKE ENGINE CO., LTD. Page 13, Total 17
charge pressure which is above 0.35MPa. If the manometer shows zero, you should
shut down immediately.
f. If the machine set is low speed operation, you can rise up to 1000 rpm~1200rpm
as a preheat operation. When the water temperature is at 323k~333k and the engine
oil temperature is at 318k or so, you can rise up to 1530rpm~1560rpm. At the time
the frequency meter should show 50HZ and the voltage gauge should show
380V~410V. If the voltage is higher or lower, you can adjust with A.V.R.
g. If the work of the machine set is normal, you can open the generator and the air
switch output power, and then you can add a load gradually. You mustn't add a load
suddenly.
Note:
a. Each kind of diesel engine startup should be referred to the manual;
b. If the machine set is stored for a overlong period, the generator loses magnetic
and the voltage can’t be established. At this time, you can use the storage battery to
charge magnetism. When the charge, the magnetic field round L1 (+) to be
connected with positive node of the storage battery and L2 (-) with the negative node
of the storage battery. Wrong connection is forbidden. Brushless motor must
disconnect F+ or F- in A.V.R. After charge magnetism, you can connect the nodes.
c. If you press button above 10 seconds, you can't startup still. You should wait a
minute or so and startup for the second time. If you fail for three times continuously,
you should find out the failure reason;
3. The operation of the machine set.
The operation of the machine set.
After the new machine set is installed carefully, you should wear away at the initial
stage for 60 hours.
a. After stable operation of the set, the staff should pay attention to pressure、
temperature、drain water temperature of the engine oil and show of the gauges.
b. You should check checks fuel、engine oil and coolant periodically whether the
quantity is ample or not;
c. New machine set must replace engine oil after 60 hours operation below
60%~80% rated power. Then you can operate the set at above 1500rpm with load,
otherwise A.V.R and magnetic round will damage.
d. machine set usage environment if outrun XU3 YONG4's condition that the mark
settle, output the power should press .
e. You should pay the following attentions: When the generator revolves, you
should notice the cooling condition and the voltage and electric current shouldn’t
SHANGHAI YANGKE ENGINE CO., LTD. Page 14, Total 17
exceed rated values; if sound is abnormal, you should shut down immediately and
check. You should notice water temperature、oil temperature、oil pressure at any time.
If there is a abnormal thing, you should shut down and check. Abnormal things are as
follows: Oil leaking、water leaking、air leaking and so on; The color of exhaust gas
(Normal condition is caesious; Abnormal condition are blue-black or dark-black);
Other things such as oil, water, metal are in the generator; Asymmetry current
exceeds 25% or each phase load current exceeds rated one.
f. You should record in detail during operation, including environment parameter、
machine operation parameter、open machine time、shut down time、break down
reason、debug methods and the name and quantity of the replace components etc.;
4. Shut down of the machine set.
Take the big machine set as an example to describe as follows:
4.1 Shut down normally;
a. You should unload gradually and then close the load switch.
b. After the set descends to 600-800 rpm at zero load and operates for several
minutes, then you can push again the oil pump hand handle to stop oil supply. After
you stop the set, you should put the hand handle at the lowest position.
c. When the environment temperature is less than 278k, the cooling water of the
diesel engine and the water pump should be empty in order that the body of the
machine set is frozen to crack. If you add antifreeze liquid, you don't need to empty
cooling water. When it's necessary, the machine set room should be equipped with
constant temperature devices, where the temperature is above 278k and you can
startup the set easily.
d. During a short term operation, you should keep air from entering fuel pump.
During a long term operation, you should close the fuel switch after shutting down.
e. Over a long period shutting down, you should empty engine oil.
4.2 Shut down in a hurry.
When there are the following troubles with the machine set, you must shut down
the set in a hurry. At the time, you should unload at first, and then switch the fuel
pump handle to cut off the fuel in order that the engine stops immediately.
a. The data of the manometer descends below 1KPa (while working with load
normally)
b. The set makes a voice of quick knocks, some components damage or the set
sends out abnormal voice;
c. Cylinder, piston, actiyator and so on choke;
d. The voltage of the generator exceeds the maximum value;
SHANGHAI YANGKE ENGINE CO., LTD. Page 15, Total 17
 e. It take places a fire disaster or other natural ones;
f. When water temperature exceeds 363k, you should turn off the air switch at first,
and then you slow down the rate of the set to 700rpm.After water temperature falls a
little, you can stop the machine and check it.

CHAPTER-5 MAINTENANCE AND TROUBLE SHOOTING

Section-1 Maintenance and maintain of the machine set
The machine set is composed of the diesel engine, the generator control panel and
so on. Each main component has different maintain way. Because each machine set
needs a careful maintain, it should be based on different manual.
The machine set often works or stops for a short period and then should be
maintained once every week as follows:
1. Each part of the set should be clean. You should wipe each part off dust、grease
stain;
2. You should check the connections of the electric components and leads in order
to get rid of ill connect or short circuit.
3. You should check the connections of all parts of the machine set and lubrication
status.
The general maintenance of the generator is as follows:
1. The generator should be kept from damp and be put in dry room;
2. No matter while storing or operating the set, you should keep miscellaneous
things such as drops of water, metals etc from entering the set;
3. While running, you shouldn't see more than 1.5 millimeters of sparks on the
collectors, and temperature of the collectors is not more than 353k;
4. Don't let the generator in the steam. Don't use it in the dusty situation;
5. After the bearing has been working for 3000 hours, you should add lubricant
grease that is the 3rd calcium fat. The amount of grease should be half of the oil
room capacity. The grease should be clean and the bearing temperature shouldn't be
more than 368k;
6. Check whether each component of the excitation part disconnects or loosens or
not.

※ The debug of the machine set: The operation of the diesel engine refers to
‘Operation and maintenance manual of diesel engine’ (‘Usage manual of diesel
SHANGHAI YANGKE ENGINE CO., LTD. Page 16, Total 17
engine’ in a detail).
The operation of the generator refers to ‘Operation and maintenance manual of the
generator’ (‘Maintenance maintenance manual’ in a detail).

Declare: Because the structure and performance will improve continuously in the
following manufacture, the content of the manual may have a little discrepancy with
the real product. YangKe company will make a continuous improvement in order to
satisfy with customers' requests.

SHANGHAI YANGKE ENGINE CO., LTD.

ADD.: No.20 Ronghui Road, Rongbei, Songjiang Zone, Shanghai, China
TEL: +86-21-57784118, 57784265 FAX: +86-21-57784183
Http://www.yang-ke.com E-mail: yangke@yang-ke.com

SHANGHAI YANGKE ENGINE CO., LTD. Page 17, Total 17