OPERATOR MANUAL

DIESEL GENERATOR
AGT 10001 DSEA
AGT 12003 DSEA

www.agt.ro
We are thank you on this way for purcasing our product!

WARNING! Before using the generator set, read this manual carefully to use
your equipment correctly and to familiarize yourself with the safety and operating
rules.
The manual defines the purpose for which the equipment was built and contains
all the necessary information that guarantees your safe and correct use.
The manual is an indegral part of the generator set and must be carefully stored
and attached to the quipment when it is passed on to another user.
This user manual must be used in conjuction with the engine user manual and
controller user manual.

NOTE: Due to our constant concern for the improvement of our products as well
as the ongoing research and development program, certain operating
procedures, features and spare parts are subject to change without notice.

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 Contents

1. SAFETY INSTRUCTIONS...................................................................................................................................... 4
2. WARNING LABELS.............................................................................................................................................. 5
3. TABLE WITH DANGEROUS AREAS...................................................................................................................... 6
4. TECHNICAL SPECIFICATIONS ............................................................................................................................. 8
5. COMPONENTS................................................................................................................................................... 9
6. TRANSPORT...................................................................................................................................................... 12
7. PRELIMINARY CHECKING.................................................................................................................................. 13
8. INSTALLATION.................................................................................................................................................. 16
9. USE .................................................................................................................................................................. 20
10. RUNNING THE GENRATOR............................................................................................................................... 23
11. PERIODICAL MAINTENANCE AND SERVICE ...................................................................................................... 29
12. TROUBLESHOOTING ............. .......................................................................................................................... 36

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 1. SAFETY INSTRUCTIONS

Before operating the generator set or stating any maintenance operation, the
operator must read and understand all warnings regarding the hazards in this
manual and in the technical documentation of the engine and controller.

However, the manufacturer cannot anticipate all the possible situations that may
involve possible risks in the real conditions of use and operation of the generator
set.
Various operations and/or maintenance procedures not explicitly recommended
in the user manual must be approved by the manufacturer.
If it is necessary to use a procedure that is not specifically recommended, the
user must ensure that this is a safe operation, which cannot cause material
damage or personal injury. The manufacturer assumes no responsibility for
material damage or personal injury resulting from non-compliance with safety
regulations.

Read the following safety rules carefully:

1. Do not allow the use of generator set by persons without the necessary
qualification.
2. Keep children and animals away from the generator set.
3. Do not check the equipment while it is in operation. Always stop the engine
before ant check, being careful not to touch the hot patrs.
4. Never connect the generator set directly to the public distribution network.
5. Do not use the generator in rain or snow. Do not intervene with wet or
damp hands. Failure to follow these recommendations may result in electric
shock to the user. Do not clean the generator set with water.
6. The generator set shall operate only on a flat and stable
surface, not on gravel, sand, crushed stone or other unstable or
sloping surfaces.
7. Make sure that the electrical connection from the generator to the load is
not crushed by heavy parts or in contact with vibrating parts; it may break and
cause a flame or short circuit.
8. Make sure that the engine is stopped before each refueling and/or refiling
with oil/water.
9. Do not operate the generator set with the fuel tank, oil or radiator cap open.
After each refueling, make sure that the fuel and/or oil tank plugs are closed
properly to avoid leaks.

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 10. Place the generator set at least 1 meter from buildings or other structures,
do not use the generator in garage rooms or any other insufficiently ventilated
englosed spaces. Always keep the exhaust pipe free of foreign bodies or other
obstacles to avoid gas poisoning.
11. Do not approach the rotating parts of the equipment with loose clothing or
long unprotected hair, so as not to injure yourself.
12. The generator set must operate remotely from flammable and explosive
material or products (petrol, oil, polystyrene, paper, sawdust, etc.).
13. In the event of excessive noise, oder or prolonged vibration, switch off the
generator immediately and contact the nearest service center.
14. Do not obstruct the cooling and exhaust grilles.

2. WARNING LABELS

Read the manual before use!

Warning! Danger of electric shock.

Warning! Hot surfaces.

Warning! Danger of fire. Do not smoke

or use open flames near the generator.

Switch off the generator while refueling

and check for leaks.

Do not use the generator indoors!

Do not use the generator in the rain

and in high humidity conditions!

Do not use the generator exposed to

sunlight!

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 Read the fuel and oil safety
instructions!

Hot surfaces! Keep your distance!

Diesel fuel is flammable and explosive.

The engine emits carbon monoxide

which is a toxic gas. Do not use the
generator indoors.

Ground indicator.

Guaranteed sound power level

according to 2000/14/EC Directive.

Wear ear protection!

3. TABEL WITH DANGEROUS AREAS

Danger info Area Protective measures

- Allow the engine to cool down
before performing any
- Engine body. maintenance on it.
- Exhaust, the gallery - Allow the generator to cool
and its terminals. before opening the side panels.
- External housing - Do not park near the generator
Danger of burns
near the exhaust during operation.
pipe. - Maintenance operations will only
be carried out by qualified and
authorized personnel.

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 - Use means of transport
appropriate to the type and weight
specified.
- Do not park/pass near or under
Danger of - Moving the
the equipment while moving it.
crushing equipment
- Keep the equipment suspended
only for the time strictly necessary
to move it.

- Keep your distance from the

exhaust area during operation of
Danger of - Exhaust pipe
the equipment or wear a protective
intoxication
mask.

- When replacing the battery, wear

gloves, goggles and all appropriate
protective equipment.
- When recharging the battery, in
addition to using gloves, goggles
Danger of and appropriate protective
corrosion and/ - Battery holder equipment, remove the battery
or explosion from the equipment case and place
it in a well-ventilated area.
- Strictly follow the battery
manufacturer's recommendations.

- Make sure that the generator is

switched off properly and the
connection connector to a
possible automatic panel is
disconnected before opening any
panel of the equipment.
- Make sure that the terminal at
Cutting or - Engine fan the positive pole of the battery is
injuring - Alternator fan disconnected before carrying out
any inspection and/or
maintenance on the equipment.
- Make sure all panels are
installed before turning on the
equipment.

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 - Make sure that the generator is
switched off properly and the
connection connector to a
possible automatic panel is
disconnected before opening any
panel of the equipment.
- Make sure that all loads are
disconnected and that the main
- The electrical switch in in the OFF position
Danger of
panel before carrying out any inspection
electric
- Alternator and/or maintenance on the
shock
contact box electrical equipment.
- Make sure all panels are
installed before starting the
equipment.
- Maintenance operations will
performed only by qualified and
authorized personnel.

4. Technical specification

AGT 10001 DSEA AGT 12003 DSEA

Voltage 230 V / 50 Hz 400V / 50 Hz
Power factor 1 0.8
Max. power 9,6 kVA 12 kVA
Continuous power 8,5 kVA 10,6
Speed 3.000 rpm
Engine diesel, 2 cylinders, liquid cooling
Governor electronic
Engine power 16 HP at 3.000 rpm
Displacement 794 cm 3
Fuel diesel fuel
Alternator synchronous, AVR type with brushes
Fuel tank capacity 25 liters
Working autonomy 8,5 h at a charge 8,5 h at a charge of
of 8,5 kVA 10 kVA
Starting electric
Protection IP 23
Controller type HGM420
Speed regulator electronic
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 Voltage stabilizer electronic (AVR)
Oil bath capacity 2.3 liters
Oil type API CD or CF
Cooling liquid antifreeze solution ( 2.6 liters)
Glow spark plugs Yes
Overload protection Yes
Short circuit protection Yes
Lack of oil pressure protection Yes
Temperature protection Yes
High/low speed protection Yes
Protecţie tensiune mare/mică Da
Overall dimensions 1230mm × 675mm × 770mm
Weight 280 kg

5. Components

Bușon rezervor

Electrical Fuel level indicator

panel with
protection
door

Emergency
stop button
Ground
connector

Power
sockets Access door
for
maintenance

Suction
grids

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Exhaust
muffler
Access door for
maintenance

Cooling
air
exhaust
grille
Hooks for
lifting with a
crane

Antifreeze Exhaust Fuel tank

food cap gallery

FUel valve

Fuel filterl

Air
filter

Vibration Oil
Expansion filter
tank damper

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 Exhaust
Alternator gallery Engine

Radiator

Battery Oil drain Oil cap

valve and
dipstick
AGT 10001 DSEA electric panel
Single-phase Missing phase
Controller socket 16A magneto-thermal
Schuko switches

Magneto-thermal Single-phase
Controller switches for power socket 63A
switch sockets type CEE

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 AGT 12003 DSEA electric panel
Single-phase Single-phase Missing phase
Controller socket 16A socket 16A magneto-thermal
Schuko type CEE switches

--

Magneto-thermal Three-
Controller switches for phase
switch power sockets socket 16A
type CEE

6. TRANSPORT
The following precautions must be taken during the transport of the generator
to ensure the safety of you and those nearby and to avoid damage to the
equipment or its components:
- all transport operators must be performed only by qualified and trained
personnel;
- all transport operations must be carried out with the engine switched off, all
loads disconnected and all automatic or remote starting devices disconnected;
- during transport operations it is mandatory to use the personal protective
equipment specified by the legislation in force.
- before driving, make sure that the fuel tank of the generator is not full, to
avoid leakage.
- protect the generator from weather during transport. In case of rain or snow,
cover the generator with a nylon foil. Singe some engine components retain for a
while after shutting down, wait at least half an hour after shutting down the engine
before covering the generator;
- make sure that the movement area is free of any obstacles or impediments;
- do not install on the equipment any device or accessory not specified by the
manufacturer and which may increase the mass or volume of the equipment;

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 - do not subject the generator to sudden movements during transport;
- make sure that the travel procedure does not exceed the time strictly
necessary to reposition the equipment and do not leave the generator suspended
for a long time;
- the use of points other than those indicated in this manual may cause
damage to the equipment and injury to operators.

Generators sets can be transported with a forklift, with straps and chains, or in
some specific cases with a low speed construction trailer.
In the first case, make sure that the means of transport can lift the entire weight of
the generator, as indicated in the technical data.
Insert the fork of the truck under the generator only on the long side and make
sure that it protrudes from the opposite side.
Do not insert the fork of the truck on one of the short sides.
In the second case, before starting the lifting, make sure that the points used for
lifting are fixed correctly on the generator and that the lifting machine is suitable
for lifting the complex mass of the generator, as indicated in the technical data.
Make sure that the straps or chains used are suitable for lifting the complex mass
of the generator as indicated in the technical data and check that they are not
broken or damaged.
In the above cases it is mandatory to move the generator in a horizontal position
and with the lifting hook placed on top.
If you want to move the generator on the road, install it on an approved trailer.
Follow the specific instructions of the trailer manufacturer.

THE GENERATOR WILL BE INSTALLED ONLY BY QUALIFIED PERSONNEL

AND IN ACCORDANCE WITH THE SAFETY RULES IN FORCE IN THE
COUNTRY IN WHICH THE GENERATOR WILL OPERATE. INSTALLATION
STAFF MUST KNOW AND APPLY THE SAFETY AND FIRE PREVENTION
RULES IN FORCE BEFORE STARTING INSTALLING THE GENERATOR.

7. PRELIMINARY CHECKS

The generator set is intended for the production of electricity as a source of

failure in the event of failure of the national electricity network or for commercial
activities in locations where there is no temporary distribution network.
This generator set is not intended to replace the national electricity grid with
continuous operation (24 hours a day) or together with solar panels, wind
turbines or other alternative electricity generation systems.

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 Task analysis
Before starting up the equipment, carry out a careful analysis of the types and
powers of the loads to be connected to the generator. The correct sizing of the
generator in relation to the expected consumption is a mandatory condition to
avoid the danger of damage to the connected devices or to the generator itself.
This analysis should normally be performed before purchasing the generator.
If you are not in possession of such an analysis performed by qualified personnel
(e.g. by design engineers for electrical installations) before putting the equipment
into operation - obligatory to our technical service, providing all the data related
to the tasks, as well as the series of the generator and the data of the distributor
or supplier of the equipment.
In principle, the continuous power of the generator must be greater than the
sum of the connected loads, applying the following correction factors for each
type of load: 1 for resistive loads, 3 for electric motors or equipment that includes
them, 1.5 for UPS, neon lamps, inverter welding machines or other nonlinear
loads.

Analysis of environmental conditions

Once you have established that the type of loads to be connected is compatible
with the purchased generator, you must make sure that the conditions of use are
also suitable for the installation of the generator. In particular, the equipment
must not be used indoors or in danger of explosion and must be placed at an
appropriate distance (minimum 20 meters) from heat sources or liquid, or
gaseous fuel tanks.
The generators are designed to operate away from bad weather (rain, snow,
high humidity...) and dusty atmospheres.
It is also recommended that the generator not be exposed to direct sunlight,
especially during the warmer months. This can ensure better cooling of the
equipment and as a result maintain its rated power.
The nominal values of the operating conditions for which the equipment is
designed and which represent the reference point for the characteristics entered
in the technical data are the following:

Ambient temperature: between -5°C and +25°C

Relative humidity: between 0% and 35%
Atmospheric pressure: 1 bar
Altitude: from 0 to 100 meters above sea level
Power factor for single-phase equipment: cosφ = 1
Power factor for three-phase equipment: cosφ = 0,8
Load type: balanced, without distortion
Fuel type: according to standard EN 590:1993
Tolerances: +/- 5%

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 Changing these conditions causes changes in the operation of the
generator. In particular, the increase in ambient temperature causes a power
drop corresponding to a decrease of approximately 2% for every 5°C which
exceeding 25°C.
Dropping the temperature below the 5°C set-point has no effect on power
but affects engine start. In these cases, a series of adjustments must be made
according to the actual operating temperature. Contact your distributor or our
technical service for more information.
The increase in altitude means a thinning of the intake air and as a result, a
loss of power corresponding to a decrease of 1% for every 100 meters.
Increasing humidity can cause insulation problems with alternator windings.
Variation of the power factor to values well below the nominal ones can
cause a voltage drop and as a result can damage the connected loads.
The fuel used must be high quality diesel for motor vehicles, correctly
stored and without water particles or other liquids. The use of bio-fuels is
prohibited.
The use of fuels, other than those recommended or contaminated will void
the warranty.
Note that the power values specified in the technical data are only reached
after the complete running-in of the equipment after 50 hours of operations.
During running-in, do not exceed the use of 75% of the declared power under the
actual operating conditions.
In the case of installation in closed spaces, European regulations provide a
series of safety conditions more restrictive than the installation in open places,
but at a purely technical level it is necessary to ensure correct ventilation and
adequate exhaust fumes. In case of installation in an enclosed room, contact our
technical service and present the main data of the respective space (room
dimensions, dimensions and position of the windows...) or a plan of the room.
Our specialists will provide you with all the information necessary for a
correct installation.
Warning!!! Installing the generator in an enclosed space without prior
authorization will void the warranty.

Safety systems analysis

On the right side of the electrical panel is a red mushroom emergency button. In
the event of any type of danger, pressing this button guarantees the immediate
shutdown of the equipment.
It is recommended to place a fire extinguisher in the immediate vicinity in case of
fire danger.

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 8. INSTALLATION

Removing the packaging

The generator set is delivered fully packaged to avoid damage during transport.
Before installation, remove the nylon protection or cardboard box, without
throwing them in the environment but handing them over to a collection center
according to local regulations.

It is very important to remove all packaging completely as it may impede

proper ventilation and exhaust fumes, as a result of which there is a high risk of
damage to the generator.

Identification of documentation and accessories

Make sure you have the operating instructions for the motor, controller, and
mounting accessories.
Normally, the documentation is on the case but for transport reasons it can also
be placed inside.

Check the authorized service centers in your area immediately. If you do not
find information or if there are no support centers in your area, contact your
dealer for detailed information.
After identifying the most convenient service center for your requirements, write
down your contact details on the "NOTES" page at the end of this manual.

Positioning
Place the generator on a sufficiently rigid flat surface (remove the wooden pallet
on which it is delivered), insulated from other structures and able to support the
entire mass of the equipment. When laying on a cement surface, it is
recommended to install dampers under the generator feet to reduce the vibration
of the sheet metal components and to reduce noise.

Roof
If you install a roof over the generator to protect it from environmental factors,
follow theses recommendations:
- ensure proper ventilation of the equipment, without clogging the suction and
exhaust grilles;
- ensure the evacuation of exhaust gases through flexible extension tubes,
resistant to high temperatures, outside the built protection;
- make sure that the materials from which the roof is made are not flammable,
in order to avoid fires;
- before starting the engine, remove nay plastic tarpaulins used to protect the
equipment from the weather.

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 Fuel supply
Check the fuel level in the tank with the inspection tool next to the cap or
directly through the cap and refill if necessary, using a clean container with no
traces of other liquids.
Take all necessary measures to avoid spilling fuel on the ground and polluting
the environment.
Do not exceed the maximum level of the tank and do not allow fuel to drain
from it. After completing the operation, close the tank cap tightly and wipe off any
small fuel leaks with a clean cloth.

Warning !!!
Use only fresh fuel. Fuel kept in canisters for a long time produces sediment that
can damage the engine. Do not use special additives or fluids to start the engine
as they may damage the gaskets and other rubber parts.

Danger !!!
- Refuel only with the engine switched off.
- Do not smoke or approach with open flame during refueling.
- Refuel only in well-ventilated areas.

Checking the oil and fluid level in the radiator

Open the appropriate panels on the housing for access to the dipstick and
radiator cap.
Follow the engine manufacturer's instructions in the engine manual to check
the oil level and top up if necessary.

Warning!!!
Poor or used quality oil can cause engine problems and shorten its life. Change
the oil if it is contaminated or after the number of hours in the maintenance table.

Checking the battery

Disconnect the ground wire (-) before checking the electrical installation.
An accidental short circuit can cause a fire.
Provide adequate ventilation around the battery.
Ventilate the area around the battery and keep any source of fire at bay.
During operation and charging, the battery generates hydrogen, which can ignite.
Battery electrolyte
Avoid contact of the eyes and skin with the battery electrolyte, which is a very
strong acid and can injure you. Wash immediately with plenty of clean water.

17
Check battery electrolyte level (maintenance only).
If the electrolyte level is close to the lower limit, fill to the upper limit. Insufficient
electrolyte shortens battery life and leads to explosion due overheating.
The electrolyte level tends to drop faster in summer. Check the level more often
during this period and top up with distilled water.
If the engine engagement is slower than normal and the starter fails, recharge
the battery. If the engine does not start even after the battery is recharging the
battery, replace the battery.

Visual inspection for leaks

Check that is no leakage of liquid on the surface on which the equipment is
placed. In the event of a leak, contact your dealer, manufacturer or service
center.

Visual inspection of ventilation grilles

Check that the ventilation grilles (suction and exhaust) are not blocked. Remove
any leaves or other foreign matter that may clog the vents before starting the
engine.

Exhaust check
Check that the exhaust pipe is not pointing at an obstacle or that it is at least 2
meters from the pipe.

Checking the integrity of the housing

Check that all doors and panels are installed correctly and tightly closed. Starting
the equipment with the doors open can adversely affect cooling/ventilation,
increase the noise level and injure the operator.

Checking the switches

Check that the power switches and auxiliary switches are in the OFF position.
Otherwise open the protective cover and move the lever from the ON position to
the OFF position.

Grounding
Before starting up the generator, the connection must be made with a cable with
a corresponding section between the earthing terminal on the electrical panel (or
on the housing) marked with the letters GND and stake stuck in the ground near
the generator, according to current regulations. The cable cross section must be
dimensioned according to the power of the generator and the distance at which
the stake is located. Neither the ground terminal nor the cable are supplied as
standard.

18
 For the safety of operators and electronic components it is mandatory to
install a differential protection or an insulation monitoring device. These
protections are not supplied as standard because they are normally already
mounted in the general electrical panel of the electrical installation to which the
generator is to be connected.
When connecting the generator to an electrical installation with a residual
current circuit breaker or an insulation monitoring device, the alternator null must
be grounded for the differential protection to be active.
If the use of the generator does not require its connection to an electrical
installation equipped with a residual current circuit breaker, provide this
protection on board the generator.
However, it is recommended to contact our technical service to specify the
connections to be made.

Warning!!!
The manufacturer is not liable for any damage caused by failure to ground the
installation or incorrect connection of the differential protection.

Warning!!!
Under no circumstances use the ground terminal as a negative terminal to start
the generator with an external battery. This operation damages the internal
wiring (in some cases it can cause fires) and leads to the loss of the equipment
warranty.

Connecting the load

Considering that the load analysis has been performed according to the
instructions above and that the type of load to be applied is compatible with the
characteristics of the generator, connect the load to the socket on the generator
electrical panel (in the case of electrical panels with sockets) or connection for
load.

Warning!!!
Never connect the generator directly to the mains or in parallel with another
generator. This operation can cause serious damage to the generator set and/or
connected loads.

Warning!!!
Alternatively, the generator can be connected to the mains via a switchboard
(available separately).
The switch panel must be installed by a professional electrician based on
the diagrams and instructions on the panel.

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9. USE

9.1 Layout of the control panel

9.2 Instruction of buttons

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9.3 Automatic start/stop operation
Auto model is selected by pressing the button; a LED besides the
button will illuminate to confirm the operation.

9.3.1 Automatic start

21
9.3.2 Automatic stop

9.4 Manual start/stop

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10. RUNNING THE GENERATOR

10.1 Pre-start preparation

Implement pre-start preparations in the following order upon preliminary use.
10.1.1 Fill fuel
Recommended fuel type:
GB/T252-1994 light diesel 0# in summer, -10#, -20#, -30# in winter
● Fill the proper fuel. Improper fuel may lead to risk of fire. Please confirm the
type of fuel in advance.
● Clean any overflowed fuel. Don’t start the engine before cleaning.
● In order to prevent any overflow when machine is running, fill-in amount shall
be approximately 90% of tank volume.

10.1.2 Fill lubricant

Keep lubricant level between upper and lower scale marks. Lubricant level shall
not exceed the upper mark (H). Ejection of lubricant from the breather hole may
cause engine errors.
a. Keep engine level when filling in lubricant.
b. Take off the black cover of lubricant inlet on the top of gear chamber. Add
recommended lubricant up to the upper mark (H) of oil gauge.
c. Measure the lubricant with oil gauge. In order to get correct level, please clean
the oil gauge before inserting it into lubricant. Lubricant trace remaining on the oil
gauge indicates measurement.
d. Re-confirm it after 3-5min running.

10.1.3 Fill cooling water

Close the radiator water inlet cover tightly.
Otherwise, ejected steam or hot water may cause scalding.
Add cooling water as per following procedures. Please add anti-freezing liquid
into cooling water.
● Fill water into radiator
a. Turn the radiator anticlockwise and take it off.
b. Add the cooling water till it overflows from radiator water inlet. Slowly fill
cooling water to avoid any foam.
c. Close the radiator cover tightly to prevent any water leakage. Direct the inside
clip towards notch of water inlet. Then press down the cover and turn the cover

23
towards right side for 1/3 cycle to close the cover.
● Fill water into overflow bucket of auxiliary tank
d. Please take off the water inlet cover of auxiliary tank. Add cooling water up to
the upper scale mark. Then re-mount the cover.
e. Check if joints of rubber hoses connecting auxiliary tank and radiator are loose,
released or damaged. If any, please repair or change them to avoid cooling water
leakage.

10.2 Trial running

Run the generator that is new or idle for long term at low speed and without load
for short term before load running. Deliver the lubricant to all abrasion parts. If
one starts the load running without the operation mentioned, it may cause
abnormal abrasion or damage to piston, cylinder sleeve, crank shaft, bearing and
other parts.
a. Check if any abnormal sound or leakage of water, oil or gas.
b. Reconfirm the quantity of lubricant and cooling water.
Please re-confirm the quantity of lubricant and cooling water after 5-minute trial
running, if lubricant or cooling water is filled for the first time or is replaced.
Trial running distributes lubricant and cooling water around the machine. During
re-check, the level of lubricant and cooling water shall be lower. By then, please
make up for insufficiency.
● Fill in lubricant （refer to 10.1.2）
● Fill in cooling water（refer to 10.1.3）

10.3 Running
Following parts in the running generator are extremely dangerous, such as
radiator fan, belt,engine, cylinder hood, exhaust pipe, muffle and other parts at
high temperature and high voltage.
● Close the side door of running machine.
● Stop running machine before check and maintenance.
Run the machine with all instruments on the operation panel.
10.3.1 Pre-start checks
Carry on following checks prior to each start.
1) Remove foreign matters in the generator
● Check if there is any tool or rag in the generator.

24
● Check if there is any rubbish or inflammable matter around muffle or engine. If
any, remove it away immediately.
● Check if suction inlet and exhaust vent of generator is jammed by rubbish or
rag. If any, remove it away immediately.
2) Check in the generator
● Any oil leakage in the engine
● Any fuel leakage in the fuel system
● Any water leakage in cooling water system
● Broken distribution line, short circuit or loose joint
● Check if any screw is loose or released
Do not run the machine before eliminating any founded abnormality.
3) Check and fill fuel
Regularly check rest fuel level in the fuel tank and add recommended fuel on
time (refer to 10.1.1).
4) Check and fill lubricant
● Check lubricant level with oil gauge.
● Add recommended diesel lubricant from oil-inlet of gear chamber when oil level
is insufficient.
Check the lubricant with oil gauge. Add lubricant up to upper scale mark with
check (refer to 10.1.2).
5) Check and fill cooling water

Generator is still hot when machine is running or after machine stops. In such
case, do not open the water inlet cover of radiator because ejected steam and
hot water are extremely dangerous. As temperature falls down, envelop the
cover of water inlet of radiator with cloth. Then open the cover. Remove the water
inlet cover after releasing the inner pressure.
Check and fill the cooling water before running the machine when the engine is
cool.

25
【Attended operation】
Check quantity of cooling water
Confirm and check the quantity of cooling water by level in the auxiliary tank.
If water level is between the upper and lower scale marks, it means normal.
Check if there is any change of water level prior to use of machine every day.
● Normal change of water level
Prior to running (cold status): low level
After stop (high-temperature status): upper level
Open the radiator cover. Check and add cooling water if there is no change of
water level after running compared with that prior to running. In addition, check
rubber hoses connecting radiator cover and auxiliary tank. Confirm if any
connection is released, loose or broken.
6) Check special earth of generator
Confirm if special earth for generator body, leakage alarm and earth of loading
equipments work properly.
Please do not connect N-phase of 3-phase joint directly to earth line.

10.3.2 Adjustment upon start and no-load

● If the breaker at side of generator and loading equipments are at ON, please
do not start the machine. Power is supplied to loading equipments and running
machine suddenly will lead to damage. And it may cause electric shock or errors
of loading equipments.
1) Start the machine at normal temperature
Start the machine in the following order
a. Confirm breaker at side of generator and loading equipments at OFF.
b. Insert the start key and turn it to ON. Indication lamp of intelligent display is on.
Please confirm it.
2) Adjustment of frequency and voltage
Make adjustment after machine is heated and runs.
Heat the machine for about 5 minutes (no-load).
a. Adjust the regulating screw rod of oil-pump till frequency is up to rated value.
b. Adjust the voltage with voltmeter as per specification.
3) Run at low load

26
Prevent running the generator for long time at low load.
● It is allowed to run the generator for long time, only when the load is up to or
above 1/4 of full load.
● It is prohibited to run the generator for more than 5 hours, when the load is only
1/8 to 1/4 of full load.
Running the generator for long time at low load will cause carbon deposit on the
engine and exhaust pipe, thus reducing the engine performance.
10.3.3 Keynote for load running
1) Pre-running check
a. Confirm that voltage, current and frequency shown in the intelligent panel are
normal.
b. Check the environment of engine.
● Check the color of exhaust
Colorless or light gray: Normal
Black: Abnormal (insufficient combustion)
Blue: Abnormal (Combustion of lubricant)
White: Abnormal (No combustion of fuel or too much water contained in the fuel)
● Check the sound, running state and vibration
● Check leakage of fuel, lubricant and cooling water
● Check if breaker at the side of loading equipments is at OFF
● Turn the 3-phase breaker of generator to ON.
2) Load conditions
【Attended operation】
Forbid increasing or decreasing speed rapidly, over-load or other unreasonable
operation during the first 50 hours for new engine.
a. Turn the breaker to ON
b. Turn the breaker at the side of loading equipments to ON
3) Adjustment during running
a. Adjust the rotating speed, frequency and voltage according to load.
4) Checks during running
【Attended operation】
If the generator produces any abnormal sound, please stop running it

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immediately for check and repair. If one continues to run machine at abnormal
status, unexpected serious accidents may occur.
Check if there is any abnormality of the generator (check the conditions below).
a. Check all instruments and central indication lamps
Check voltage, current and frequency in accordance with specifications. Check if
indication lamps are on.
b. Check the color of exhaust
Colorless or light gray: Normal
Black: Abnormal (insufficient combustion)
Blue: Abnormal (Combustion of lubricant)
c. Check abnormal sound and vibration
d. Check leakage of fuel, lubricant or cooling water
e. Check the rest fuel level
If fuel supply is interrupted during machine running, please eliminate air
remaining in the fuel pipe after fuel fill-in.

10.4 Stop operation

Stop running the generator in following orders:
a. Turn off the breaker of loading equipment
b. Turn off the breaker of generator.
c. Run the generator for 5 minutes at zero load.
d. Turn off the starting switch key to stop the engine.
e. Pull out the key and keep it safely.
【Attended operation】
Never stop the engine emergently. Otherwise, the temperature of engine parts
will rise rapidly, resulting in damage or scuffing of cylinder.

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11. PERIODICAL MAINTENANCE AND SERVICE

Carry out periodic check

Aging and poorer performance appear if engine runs for long time.
Accident and error may occur if there is no check, maintenance or service,
causing great consumption of fuel, bad exhaust and large noise. What’s more,
the service life of engine becomes shorter.
Routine and periodic check and maintenance can effectively avoid error and
accidents. In addition, periodic check on electrical system can avoid electric
shock.

Electric shock

Never check or maintain the generator until it is completely stopped with the
breaker cut off.

Please observe pre-start checks

Implement routine and periodic check before working it every day. It is a good
practice to do routine check before machine starts every day.
(Refer to 6.1 for keynotes about check before work).

Please use the original parts

Replace the damaged parts with our original parts.

Otherwise, the mechanical performance falls or duration of engine turns shorter.

Warning label for maintenance

During checking or maintaining the generator, identify the warning

label ’DANGER NOT RUN’ at obvious positions, such as starting switch, in order
to avoid unnecessary persons carry out unintended operation.

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 Protective clothing

■ Wear the protective clothing and use safe tools when servicing the generator.
■ Don’t wear the tie or loose clothing. Otherwise, it will catch the unit and cause
an unexpected accident

The handling of wasted water

■ When handling the wasted fuel, please use the container.

■ Wasted fuel pollute environment, so don’t pour them into stream, ocean or
lake.
■ To handle poisonous engine oil, fuel, cooling water and battery, please refer to

the related regulations.

Periodic check as per running record

Establish the running record for daily operation, maintenance and check.
Periodic check is divided into several intervals like 50 hours, 250 hours, 500
hours, 750 hours and 1000 hours.
11.1 Check period
Check for initial 50 hours:
■ Replace engine oil
■ Replace engine oil filter element
■ Check the fan belt tension
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 specific gravity of the battery electrolyte.
Check for every 500 hours:
■ Replace the fuel filter element
■ Clean the radiator

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■ Check the electrical circuit terminal & wiring connector
■ Cooperating with the check every 250 hours.
Check for the 1000 hours
■ Clean inner part of the fuel tank
■ Replace air cleaner element
■ Adjust fuel injection time
■ Check anti-vibration rubber
■ Check the nylon tube & rubber tube
■ Check sound absorber
■ Cooperate with the check every 250 hours and check every 500 hours.
Refer to engine operation manual for the details

11.1.1 Check for the initial 50 hours

(1) Replace engine oil
Replace engine oil in 50 Hrs for the first time, after the second time, replace it in
250 Hrs.
a. Remove oil drain bolt, drain oil empty, and run
the engine for 3-5 minutes. It is easy to drain oil out,
if the engine warms.
b. After that, recover the oil drain bolt and tighten.
c. If it is new oil, please fill it with filling pipe. Fill
under the upper lever.
d. Run engine for a few minutes after filling engine
oil, and check oil position (between the position H and L).

(2) Replace engine oil filter element.

Remove the oil filter with special wrench.
Clear the filter installation end.
Smear thin lubricant on the seal gasket.
Screw on the filter with hands and then tighten it with the special wrench
securely.

11.1.2 Check for every 250 hours.

(1) Replace engine oil

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Replace for every 250 Hrs
(2) Replace oil filter element
Replace for every 250 Hrs
The maintenance time should be shortened in the case of dusty areas.
Before replacing spring gasket, it is upturned. Remove the oil drain bolt and drain
out the oil.
a. Remove element by oil cleaner wrench.
b. Clean element, spread oil film on the spring gasket surface.
Install it with oil cleaner wrench, connect surface with oil cleaner gasket, and
tighten it.
c. Run engine for a while after replacing the element. Check oil position. Be sure
oil position is between the position H and L
d. Concerning oil filter spring gasket, you can consult manufacturer and diesel
engine operation manual.

(3) Clean air filter element

Refer to diesel engine operation manual.
When dry dust clag on element, please remove
the element and blow it with dry, clean
compressed air.
■ Check the element. If it has been scathed,
replace it.
■ Install air filter, and clean it.
(4) Check the insulation resistance

Electric Shock

■Check insulation resistance after stopping the engine.

■ Don’t measure the insulation resistance until disconnecting the connection wire
of AVR or controller. Otherwise, they will be severely damaged.
Measure the insulation resistance once a month by using 500V
insulating-resistance meter. Check if it is above 1MΩ.
Measurement:
Disassemble the three-phase cable, and turn breaker to ON.

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Measure the insulation resistance between output terminal and engine frame.
It is possible for electricity leakage or fire hazard when the insulation resistance
is lower than 1MΩ. Clean and dry output terminal, breaker, and cable.
Consult with dealer for any question.

11.1.3 Check for every 500 Hrs

Check for every 500 Hrs should cooperate with check for every 250 Hrs.
(1) Check spring gasket of fuel filter.
a. Screw off the fuel filter by filter wrench, and take off the spring gasket.
b. Clean filter and daub slim engine oil on filter surface, then install it.
Don't screw too tightly.
c. Eliminate the air of fuel pipe, after replacing spring gasket.
(Refer to the engine operation manual for the manufacturer and model of spring
gasket)
(2) Clean radiator
Please clean the radiator orifice by using steam or high-pressure air.
(3) Check circuit terminal and connection terminal. Check if there is rust and
burnout in main and vice circuitry

11.1.4 Check every 1000Hrs

Check for every 1000 Hrs should cooperate with check for every 250,500 Hrs.
(1) Clean the fuel tank
Eliminate the sediment and water in the fuel tank.
(2) Replace the air filter element
Refer to the relative item.
(Consult the agent for the manufacturer and model of air filter)
(3) Check anti-vibration material
If the shockproof material is damaged or distorted, you can consult the agent.
(4) Check the nylon tube & rubber tube
If the nylon tube &rubber tube is vulcanized or of bad quality, you can consult the
agent to change it.
(5) Check sound absorber.
If sound absorber looks aged obviously or it has been peeled, you can consult
the agent.

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Periodic replacement of important parts

● Be sure to periodically replace the parts which may cause fire hazard due to
aging or damage.
● Replace the parts of fuel system, fuel pipe and fuel tank cover every two years
or 4000 hours, whenever there is any abnormality.
●Replace the air filter element, fuel filter element and oil filter element
periodically. Otherwise, the engine may be damaged, reducing its useful life.

11.2 Periodic check and service schedule

Routine and periodic checks are extremely important for maintaining good
conditions of generator.
【Attended operation】
Establish the periodic check plan in order not to miss any required check.
Neglect or ignore will lead to errors or shorter duration, even electric shock.
Professional technology and skills are needed for check and maintenance whose
check interval is over 1000 hours. Please consult the sales department or the
dealers.

◇Check and clean ● Replace

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Note: The item with "*" Mark, you can consult the agent/dealer.
The item with "☆" mark indicates time for the initial check.
Refer to different type of the engine; check time is a little different.
Relative manual reading is required.

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12. TROUBLESHOOTING

【Attended operation】
Immediately stop the running generator for check and repair if any abnormality is
found.
To continue running the abnormal generator may cause unexpected serious
accidents.

Rotating Part

It's very dangerous to touch the rotating parts in the generator.

■Stop the engine to service and maintain the inner parts of the unit.
■The cooling fan of the radiator will go on rotating after stopping the engine for a
while. Don't service the electric fan until it stops entirely.

Electric shock

■Don't touch the inner parts with high voltage during the running.
■Stop the engine and disconnect the breaker to service and maintain the inner
structure.

Hot Part

It's very dangerous to touch the hot parts in the generator.

■Stop the engine to service and maintain the inner parts of the unit.
■The machine keeps hot after stopping the engine for a while. Don't service the
machine until it totally cools down.

The Usage of the Battery

■It will explode and cause a severe accident if the battery is used in a wrong way.

■Remove the negative terminal when servicing the generator.

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37
 Fault Reason Solution
Bad voltmeter Replace
BadAVR Consult with dealer
The voltage value is not right or ZNR is burnt
there is no voltage. Rotary rectifier is burnt
Rotor circuitry break
Engine circuitry is burnt
Bad voltmeter Replace
BadAVR Consult with dealer
Bad VR
The generator can't reach rated
Rotary rectifier is burnt
voltage.
ZNR is burnt
Generator cable is burnt
Rotation speed is too low Increase Ille speed
Bad voltmeter Replace
Over voltage BadAVR Consult with dealer
Bad VR
Rotary rectifier is burnt Consult with dealer
Voltage decreases too much BadAVR
when connected with load.
Load is not equal Make them equal.
Bad breaker Consult with dealer
Breaker can1 work. Bad breaker
Load circuitry is shorted Check

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 AGENT TRADE
Soseaua de Centura nr. 32, Comuna Tunari,
cod 077180, Judetul Ilfov, Romania
Tel: +4021-2665131; +4021-2665132
e-mail: [email protected]
www.agt.ro