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DIESEL GENERA TOR SET

TIER 4 FINAL SERIES
A713VS

www.powerlinkworld.com
Version Record

Version Date Description

Original release. Including PLC-7420 control system
F 2022–02–20
and engine exhaust aftertreatment system.
 FOREWORD
Thank you for purchasing our diesel generator set.
This manual contains information for the correct operation and maintenance of your
genset. It also contains important safety and installation information or troubleshoo­
ting guidelines. Please always keep this manual with the equipment for handy use.
Please operate this equipment after throughly reviewing and understanding the con­
tents of this manual.
This manual does not cover diesel engine and alternator maintenance procedures.
Please consult the engine and the alternator operation and maintenance manuals if
necessary.
POWERLINK reserves the right to modify the characteristics of its products at any
time in order to incorporate the latest technological developments. The information
contained in this document may therefore be changed without notice.
Without express written permission from us, any part of this manual cannot be repr­
oduced in any form or by any means.
Copyright 2020 POWERLINK

必 SAFETY SYMBOL
This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and
on labels on the machine itself to warn of the possiblity of personal injury. Read these
instructions carefully. It is essential that you read the instructions and safety regulatio­
ns before you attempt to assemble or use this unit.

心 DANGER It indicates a hazardous situation which, if not avoided,

WILL result in serious injury or even death.

心 WARNING It indicates a hazardous situation which, if not avoided,

COULD result in serious injury or even death.

心 CAUTION It indicates a hazardous situation which, if not avoided,

COULD result in minor or moderate injury.

心\ It indicates potential hazards which can cause injury.

NOTE It indicates additional information which is important to

a procedure.
TABLE OF CONTENTS

TABLE OF CONTENTS
1 Safety Information........................................ 1 6 Maintenance ................................................ 37
1.1 Safe Operation...................................... 1 6.1 General ................................................. 37
1.2 Safety Label Meaning ........................... 4 6.2 Maintenance Schedule ......................... 38
1.3 First Aid................................................. 9 6.3 Generator Set Maintenance.................. 39
6.4 Air Cleaner............................................ 40
6.5 Engine Coolant ..................................... 40
2 Product Overview......................................... 12 6.6 Engine Oil and Oil Filter........................ 41
2.1 Applications and Features .................... 12 6.7 Fuel Filter.............................................. 42
2.2 Product Type......................................... 13 6.8 Fuel pre-filter,Change ........................... 43
2.3 Function of Major Components............. 14 6.9 Battery Maintenance ............................ 44
2.4 Exhaust Gas Aftertreatment System..... 15 6.10 Lifting and Transporting ....................... 46
2.5 Component Identification ...................... 17 6.11 Overnight Storage................................. 46
6.12 Long-term Storage................................46
3 Installation.................................................... 18
3.1 General Inspection Prior to
7 Troubleshooting .......................................... 47
Installation............................................. 18
7.1 General ................................................. 47
3.2 Outdoor Installation Require-
ments .................................................... 18 7.2 Generator Set Troubleshooting ............ 48
3.3 Outdoor Installation Instructions ........... 19 7.3 Control System Troubleshooting .......... 49
7.4 Engine Troubleshooting........................ 50
3.4 Generator Set Electricity 7.5 Alternator Troubleshooting ................... 52
Connections.......................................... 20 7.6 Battery Charge Troubleshooting .......... 53

4 Pre-check Before Starting............................ 21

4.1 General Pre-check................................ 21
4.2 Checking Engine Oil Level.................... 22
4.3 Checking Fuel Level.............................. 23
4.4 Checking Coolant Level........................ 24
4.5 Checking Battery Coulomb ................... 25

5 Operation For PLC-7420 Control

System ......................................................... 26
5.1 Main Electrical Components.................. 26
5.2 Control Module ..................................... 27
5.3 Working State Chart ............................. 28
5.4 Operation Instruction............................. 31
5.5 Protection Function................................ 34
5.6 Convenience Receptacles..................... 35
5.7 Terminals Diagram ................................ 35
5.8 Parameter Configuring.......................... 36

i
 CHAPTER 1 — SAFETY INFORMATION

1 Safety Information
1.1 Safe Operation

Before the machine leaves the factory, the parameters have been adjusted according to the practical
instance. The user needn't adjust personally. Modifying or resetting the parameter of controller must be
permitted and operated by the equipment administrator or manufacturer authorized person.
Before operating the machine, read the following safety regulations carefully and find out the local require-
ments in safety. It can reduce the possibility of personal injury, damage to the equipment, or improper
service.
The operation, maintenance and repair must be carried out only by authorized and competent personnel.
The owner is responsible for maintaining the genset in good safety conditions.
Read carefully the safety symbols attached on the genset and obey all messages that follow the symbols
to avoid possible injury.

1
CHAPTER 1 — SAFETY INFORMATION

2
CHAPTER 1 — SAFETY INFORMATION

3
CHAPTER 1 — SAFETY INFORMATION

1.2 Safety Label Meaning

4
CHAPTER 1 — SAFETY INFORMATION

5
CHAPTER 1 — SAFETY INFORMATION

6
CHAPTER 1 — SAFETY INFORMATION

7
CHAPTER 1 — SAFETY INFORMATION

8
 CHAPTER 1 — SAFETY INFORMATION

1.3 First Aid

9
CHAPTER 1 — SAFETY INFORMATION

10
CHAPTER 1 — SAFETY INFORMATION

11
CHAPTER 2 — PRODUCT OVERVIEW

2 Product Overview
2.1 Applications and Features 2.1.2 Features

2.1.1 Applications
• High powerful & reliable performance: the pow-
erful Engine and reliable alternator ensure
Generator set is one type of AC power supply excellent performance of genset.
equipment, which is driven by diesel engine that • Equipped with exhaust aftertreatment system
drives the synchronous alternator to generate (EGR, SCR, DOC), the emissions reach Tier 4
electricity. The genset is used as a power source Final class.
for three main types of services as follows:
• Excellent protection class design; the vents with
(1) Continuous service filters preventing the intrusion of rain and dust,
Used as a main power to not only provide daily applicable in the harsh environment.
power for families, enterprises, governments etc. in • High-grade noise reduction technology and excel-
the area which has not yet built up a power grid, lent exhaust system can absorb large amount of
but also can build small system of power station noise and heat generated in operation, but not af-
through paralleled diesel gensets which can sup- fect the habitant environment.
ply power continuously. In this circumstance, the
gensets' running hour is not limited. • The genset adopts powder spray processing.
With the canopy made of galvanized electrolyte
(2) Standby service board for car use, it is rustproof for over 5 years.
Used as standby power supply to provide con- The genset has good corrosion-resistance, and
tinue electric power for the area where continuous can not be invaded by rain and rust, even if they
power supply must be ensured, such as hospitals, are violent and strong enough.
industrial facilities, airports etc. Keep the genset in • Designed with the drag eyes, lifting rings and fork-
standby state at any time and start to run when the lift channels, be convenient for transfer and trans-
mains supply is abnormal. In this circumstance, port.
the gensets' running hour is 8h at least.
• Designed with wide opened access doors to allow
(3) Emergency service easy access for maintenance and repairing.
Used as auxiliary power supply to solve energy
interruptions that may cause serious problems to 2.1.3 Ambient Condition
people, physical and/or ����damage. The
genset can start in short time to provide steady • Temperature: -25℃ to 50℃ (use the coolant
electric power for the loads when the mains supply heater below 5℃)
happens abnormity, and switch to stop after the • Humidity: Less than 80%
mains supply becomes normal. Generally the
genset continues working for a few hours (≤12h). • Altitude: Less than one thousand (1000) meters

12
 CHAPTER 2 — PRODUCT OVERVIEW

2.2 Product Type3

13
CHAPTER 2 — PRODUCT OVERVIEW

2.3 Function of Major Components (6) Alternator

The alternator produces and outputs electrical
Modern generator set is a mini power station which
power. We choose alternator for its superior perfor-
is driven by the diesel engine. Generally speak-
mance and reliability. All the standard alternators
ing, it contains the diesel engine, alternator and
are the machines without carbon brush,
control system. The engine drives the alternator
wound as "2/3 pitch", with class H insulation.
to produce output electrical power while the con-
trol system controls the operation and output of (7) Control System
the genset and protects the machine from possible
malfunctions. Besides, the genset also includes ac- PLC-8610 is a microprocessor based control unit
cessories such as the control panel, switch cabinet, contain-ing all necessary functions for protection of
radiator, fuel tank, battery for startup and control, the genset and the breaker control. Furthermore, it
protective device, muffler and base frame. contains all necessary three-phase measuring
circuits and presents all values and alarms on the
(1) Diesel Engine LCD display. The module has the function of load
The diesel engine is equipped with sharing which enables the module to share the ac-
exhaust aftertreatment system (SCR, DOC). tive load (kW) equally when operating in parallel
The emissions reach Tier 4 Final class. We with other gensets. The load sharing is performed
so each genset takes a portion of the load that is
choose engine for its superior performance and
calculated in percent ac-cording to the nominal
reliability and the fact that it has been specifically power.
designed for powering the generator set.
(2) Cooling System
The engine cooling system is either air cooled or
water cooled. The air cooled system consists of
high capacity fan to pull cool air across engine to
cool it. The water cooling system is comprised of
radiator, pusher fan and a thermostat. The alterna-
tor cooling system is air cooled which consists of a
fan to pull cool air across alternator to cool it.
(3) Engine Electrical System
The engine electrical system is 12 (or 24) volt DC
electricity whose negative pole is earthed. It con-
sists of the start motor, battery and battery charger.
The positive pole of battery connects to start motor
and the negative one connects to battery switch.
(4) Fuel Tank & Base Frame
The engine and alternator are coupled together and
mounted on a heavy duty steel base frame. This
base frame includes a fuel tank with a capacity of
approximately 8 hours (or 24 hours) operation at
full load.
(5) Vibration Isolator
The generator set is fitted with vibration isolators
7420
which are designed to reduce engine vibration be-
ing transmitted to the foundation on which the gen-
erator set is mounted. These vibration isolators are
fitted between the engine/alternator feet and the
base frame.

14
 CHAPTER 2 — PRODUCT OVERVIEW

2.4 Exhaust Gas Aftertreatment System IMPORTANT!

Failure to follow these instructions when installing an
Exhaust aftertreatment technology is used to emissions-certified engine is a violation of Federal
comply with mandatory Tier 4 Final and Stage IV and Californian legislation (40 CFR 1068.105 (b)).
standards. All installation requirements must be The penalty is a fine or other punishment pursuant to
followed for the system to comply with emission the Clean Air Act.
regulations.
The technology is based on treating exhaust gases IMPORTANT!
with an additive before they pass through the If the engine is installed for use in the USA such that
catalytic converter. The additive – AdBlue®/DEF the engine decal with information on emission control
solution –reacts with the oxides of nitrogen (NOx) is difficult to read during routine engine maintenance,
and converts them into nitrogen and water, which a similar decal must be affixed to the machine pur-
occur naturally in our environment. suant to U.S 40 CRF 1068.105.
The additive is a solution of 32.5% urea in water.
The solution must comply with the ISO-22241 NOTICE! For use in environments with extremely high
standard. The additive used by the technology has concentrations of airborne sodium (NA) and potas-
different names in different markets, such as DEF sium (K), contact Volvo Penta Sales Engineering
or AdBlue®(1). Industrial for advice.

1 Engine 7 Temperature sensor

2 Pump, high flow system 8 Dosage valve, high flow system
3 Solenoid valve, tank heating 9 Silencer with catalytic converter
4 Sensor connector, ULS unit 10 ACM (control module)
5 AdBlue®/DEF tank 11 NOx sensor (downstream catalytic converter)
6 NOx sensor (upstream of catalytic converter)

15
CHAPTER 2 — PRODUCT OVERVIEW

When the engine is started, the ACM checks that the Shutdown procedure after operation
AdBlue®/DEF tank level sensor indicates a sufficient
amount of solution in the tank. In order to prevent hoses from bursting if the AdBlue®/
DEF solution freezes, the system is emptied after oper-
Solution temperature; if the temperature in the tank ation via a shutdown procedure each time the engine
falls below 10°C (50°F), a solenoid valve opens allow- is switched off.
ing hot engine coolant to pass through a heating coil in Because the procedure runs for around 1.5 - 2 minutes
the tank. The AdBlue®/DEF hoses are heated electri- (depending on hose length), it is extremely important
cally at 5°C (41°F). When the solution in the tank not to switch off the battery main switch before the
reaches 15°C (59°F), the solenoid valve closes and shutdown procedure has run its course.
heating stops.

The pump builds up a pressure in the hoses between

the pump and the AdBlue®/DEF dosage valve. The
solution is injected into the exhaust gases before they
reach the silencer. The NOx sensors measure the level
of nitric oxide (NOx) in the exhaust gases upstream
and downstream of the catalytic converter. If emissions
exceed the approved level, a warning lamp lights up
on the instrument panel and a fault code is stored.

16
 CHAPTER 2 — PRODUCT OVERVIEW

2.5 Component Identification

1 Exhaust outlet
2 Coolant inlet
3 Emergency stop button
4 Air inlet
5 Control cabinet Cable
6 trench
7 Fixing hole
8 Air outlet
9 Fire extinguisher
10 Engine
11 Alternator
12 Fuel tank
13 DEF tank
14 SCR
15 Air filter
16 Base
17 Radiator
18 Fuel inlet

17
 CHAPTER 3 — INSTALLATION

3 Installation
3.1 General Inspection Prior to Installation 3.2 Outdoor Installation Requirements

The delivery scope depends on your order. Prior to

commissioning, please check whether all required
parts have been provided. Please check the order
confirmation for any possible accessory equipment. The soundproof type and container type generator
The standard product provides technical docu- set whose canopy is designed to minimize noise,
ments as follows: keep out undesirable weather elements and provid-
ing cooling and inside ventilation, can be installed
• �����of conforming. outdoors. In addition, make sure the location you
• Test report. selected satisfies the following requirements:
• Operation manual.
• Wiring diagram.
• The documentation of engine & alternator.
POWERLINK also provides parts list, spec-
ifications, engineer handbook etc. Contact
POWERLINK for complete information or technical
support through the website, phone, fax, or email if
you encounter a problem when using your product • The generator set should be installed in an area
or product documentation. that is protected from direct harmful gases or liq-
uid, dust, metallic particles, shock and vibration.
• The generator set should be mounted on a ��I
smooth, noncombustible level surface. A con-
crete pad is ideal and provides a secure instal-
Each generator set has been thoroughly inspected lation.
prior to shipment from the factory. However, be • Access must be provided to allow the soundproof
sure to check for damaged parts or components canopy or control cabinet to be opened or re-
during transportation, or loose nuts and bolts, which moved for service and maintenance.
could have occurred in transit.
• Installation should prevent water level from reach-
• Ensure all safety labels are legible and in place. ing the genset. Drainage must be adequate to
Clean or replace as required if necessary. drain standing water from the installation founda-
• Check all surfaces for leakage (oil, fuel or tion.
battery ���Report any leakage to the proper • Installation should prevent obstructions by a
maintenance personnel. buildup of leaves, grass, sand, snow etc. If these
• Inspect the machine structure to ensure there is items pose a problem, consider building a small
no crack or other discrepancies in the ���of fence or other break to protect the unit from ac-
the machine, welding leg or the body. cumulation of debris.
• At least 1.2 meters (47.5 inches) clearance must
be provided on all sides for air ��. And be care-
ful, the exhaust gas pipe and hot air exhaust pipe
can't faces the doors or windows of the buildings.
• The safe bearing capability of the geological mate-
rial should be carefully evaluated when selecting
a location for installation.

18
 CHAPTER 3 — INSTALLATION

3.3 Outdoor Installation Instructions

11

19
 CHAPTER 3 — INSTALLATION

3.4 Generator Set Electricity Connections Load Cables Selection

Select the cable with proper diameter, based on
its allowable amperage and the distance between
the genset and the load. There is maximum 5%
marginal drop only for the rated voltage between
the terminals of loads and genset via the cables. It
should be considered while selecting the cable.
Cable Selection
WARNING: Risk of injury!
Current (A) Minimum Current (A) Minimum
Always adhere to the prescribed operating method cross-sectional cross-sectional
described below for all setting work. Never break a area (mm2) area (mm2)
single safety rule! Otherwise you will risk injury from
9 0.5 78 16
restarting, electric shock or parts which may �off.
12 0.75 105 25
Setting work operation rules
14 1 130 35

18 1.5 155 50

25 2.5 200 70

33 4 250 95

42 6 290 120
• Ensure that setting work is only carried out by 58 10 335 150
specialists or appropriately trained persons.
* NOTE: If the current exceeds the allowable amperage of
• Ensure that no setting work on the generator set is single cable, parallel multi cables to satisfy the demand
undertaken until these operating instructions are through the connection points on the power cable terminal.
understood.
• Wear protective equipment such as safety
glasses, leather gloves, heavy shirt and trousers
and high shoes when working on generator set.
• Connecting of parts and components under cur-
rent is prohibited. • If load exceeds allowable amperage, the cable
• Ensure all insulating and grounding connections may be damaged for overheating.
are in accord with requirements. • If the cable is either too long or it’s cross-sectional
• Prior to setting work: area is too small, there will be greater voltage
drop between cables which bring voltage drop to
– Switch off the main switch (both generator set’s loads. It will cause serious damage to the con-
and mains’s) and secure it against unintentional nected loads.
switch-on.
– Switch off the battery switch of the generator set
and secure it against unintentional switch-on.

3.8.1 Loads Connections

STOP THE GENSET FIRST!

Loads can be connected to the generator by the
Power Ouput Terminals or the convenience recep-
tacles. Make sure to read the operation manual and
switch ALL circuit breakers to the OFF position be-
fore attempting to connect a load to the generator.

20
 CHAPTER 4 — PRE-CHECK BEFORE STARTING

4 Pre-check Before Starting

4.1 General Pre-check

21
CHAPTER 4 — PRE-CHECK BEFORE STARTING

4.2 Checking Engine Oil Level

• Normally the oil level is to be checked when

the engine is stopped. Wait a few minutes
before reading off the level, so that the oil
• Oil must be used which conforms to Class
has time to run down into the oil sump. VDS-3 15W-40 oil as per API CI-4 ACEA E7
• Dipstick marked STOP/OPERATING can be classification. Select the oil viscos-ity based on
read both when the engine is stopped and ambient temperature, see the chart below for
when it is running. Use the STOP side of the details.
dipstick when the engine is stopped and the
OPERATING side when in operation. • If the machine is not level when checking the
engine oil, you cannot obtain accurate oil level.
• The oil level must be inside the marked area
on the dipstick. Never fill above the • Do not ���� the engine oil. The level can-
maximum limit on the oil dipstick. not exceed the upper limit because the excessive
amount of engine oil may damage the engine.
• Only fill oil when the engine is stopped.
• Do not smoke or make naked �� near the ma-
• The oil level sensor only measures the oil chine when ���
the engine oil.
level when the ignition is switched to on, not • Do not leave oil anywhere for environmental pro-
continuously during operation. tection. Wipe off oil residue on the engine or
around after adding.

22
 CHAPTER 4 — PRE-CHECK BEFORE STARTING

4.3 Checking Fuel Level

Diesel fuel should conform to: Ultra Low Sulfur Fuel

Only.

23
 CHAPTER 4 — PRE-CHECK BEFORE STARTING

4.4 Checking Coolant Level

Filling a completely empty system

NOTICE! Mix the correct amount of coolant in
advance, to ensure the cooling system is completely
Do not open the coolant filler cap when the filled. Refer to Technical Data, page 89 for the correct
engine is hot, except in emergencies, as coolant volume.
this could cause serious personal injury. NOTICE! Do not start the engine until the system is
Steam or hot fluid could spray out. vented and completely filled.

IMPORTANT: 1 Open the caps to both the expansion tank (1 and 2)

Only use coolant recommended by Volvo and radiator (3).
Penta. Top up with the same type of 2 Fill coolant into the expansion tank until it is
coolant as already used in the system. completely full, to the MAX mark on the sight glass.
Different types of coolant must not be 3 Fill the radiator. If nipples are fitted to the
mixed. connections at the bottom of the radiator (4) these
can also be used to fill the radiator.
NOTICE! Only fill coolant with the engine
stopped. Fill slowly, to allow air to flow out. 4 Top up until the system is completely full.
Check coolant level daily before starting. 5 Vent the system through openings on the
expansion tank and radiator.
Coolant Level, Checking and Topping
Up
1 Check that the coolant level is above the
MIN mark on the sight glass (2).
2 If necessary, fill the expansion tank (1)
to the MAX mark on the sight glass.

1
MAX

MIN

24
 CHAPTER 4 — PRE-CHECK BEFORE STARTING

4.5 Checking Battery Coulomb

25
CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5 Operation For PLC-7420 Control System

5.1 Main Electrical Components

26
 CHAPTER 6 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5.2 Control Module

27
CHAPTER 6 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5.3 Working State Chart

(1 Manual Operation State

28
 CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

(2) Remote Operation Chart

29
CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

(3) AMF Operation Chart

30
 CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5.4 Operation Instruction (2) Stop

1) Shut off all switches and circuit breakers of loads
(from low to heavy in sequence).
2) Shut off the Genset Main Circuit Breaker and
other circuit breakers.
3) Press the Stop Button.
4) The engine will idle for about 1 minute to cool
• Before switching on the Main Circuit Breaker, down. Then it stops.
make sure all circuit breakers and switches of 5) Turn the Key Switch to "OFF".
loads are shut off. Otherwise, it may cause an
electric shock to the operator. 6) Turn the Battery Isolator to "OFF".

• During operation the control system would alarm

if the genset fails to start, or output voltage and
frequency are not accord with the preset values.
Do not close any load before restarting or remov-
ing faults.
• Turn off all switches of loads before stopping. Oth-
erwise, it might cause damages to the genset and
themselves.

5.4.1 Manual Operation

(1) Start
1) Shut off every switch and circuit breaker of loads.
2) Shut off the Genset Main Circuit Breaker (GB)
and other circuit breakers.
3) Turn the Battery Isolator to "ON".
4) Turn the Key Switch to "ON".
5) Press the Manual Mode Button. Its LED illumi-
nates.
6) Press the Manual Start Button, then the fuel
solenoid is energised, and after delay time the
starter motor begins to run and make the engine
crank.
7) After the engine starts successfully, keep it idling
for about 5 minutes to let it warm up. The con-
trol system checks automatically output voltage
and frequency. If they are right, the Genset
Available LED would illuminate. Then switch
on the Genset Main Circuit Breaker, the Close
Genset LED illuminates.
8) Switch on every switch or circuit breaker of loads
(from heavy to low in sequence), export power
to load.

31
CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5.4.2 Remote Operation • Operation Instruction

The genset can be set remote control function. (1) Start
Connecting to the remote control switch by 9 or 4 1) Press the Remote Start Button.
pin communication connector realizes remote start
and stop. 2) When the control module receives remote start
signal, it will perform the auto start sequence.
NOTE: Remote start and AMF functions can only
be applied separately. 3) After the genset starts successfully, switch on ev-
ery switch of loads (from heavy to low in se-
• Setting remote control switch quence). The genset will export power to load.
1) Connect the remote communication line (if ap- (2) Stop
plied) to the communication connector on the
genset. 1) Shut off all switches and circuit breakers of loads
(from low to heavy in sequence).
2) Make a remote start switch through connecting
the corresponding terminals in the other end of 2) Press the Remote Stop Button.
communication line with suitable wirings. The 3) The engine keeps idling until cooling time is over.
user can distribute the wiring according to the Then it stops.
genset wiring diagram.
In addition, connecting 9 pin connector to ATS
• Adjusting the genset to remote control mode control cabinet can realize to transfer automatically
1) Turn the Battery Isolator to "ON". the power supply of loads between the mains and
genset. Refer to “ATS Control Cabinet Operation
2) Turn the Key Switch to "ON".
Manual” for details.
3) Press Auto Mode Button. Its LED illuminates.
4) Switch on the Genset Main Circuit Breaker.

32
 CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5.4.3 AMF Operation 5) The control module will monitor the mains. The
genset does not start and is in standby mode if
PLC-7420/7320 control system has AMF function. the mains is normal.
It is able to realize to start and stop the genset
automatically by connecting 9 pin communication • Operation Instruction
connector to the mains, and transfer automatically (1) Start
the power supply of loads between the mains and
genset by the control of genset's motor main circuit 1) If the mains becomes abnormal (e.g. over-volt-
breaker (if applied). If in doubt, refer to local Elec- age, under-voltage, over-frequency, under-fre-
trical Supply Company for advice. quency etc.), the Mains Breaker (MB) would be
shut off automatically, and the control module
• Setting communication between the genset would perform the auto start sequence.
and mains
2) If the genset starts successfully and runs at
1) Connect the mains communication line (if ap- correct voltage and frequency, GB would be
plied) to the communication connector on the switched on automatically, and the unit exports
genset. power to load.
2) Connect the corresponding terminals in the (2) Stop
other end of communication line to the mains
(L1,L2,L3,N) with suitable wirings. The user 1) If the mains recovers, the control module would
can distribute the wiring according to the perform stop sequence automatically.
genset wiring diagram. 2) After delay time, GB is shut off automatically and
• Adjusting the genset to AMF control mode MB switched on.

1) Shut off Genset Main Circuit Breaker (GB). 3) The engine keeps idling until cooling time is over.
Then it stops.
2) Turn the Battery Isolator to "ON".
NOTE: If the user wants to stop manually the
3) Turn the Key Switch to "ON".
genset, first press the Manual Mode Button to
4) Press Auto Mode Button. Its LED illuminates. make the genset be in manual mode, then press
the Stop Button.

33
CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5.5 Protection Function

• Refer to troubleshooting guidelines in this manual
to repair the machine and remove the fault. Con-
tact POWERLINK or our authorized distributor for
help if you could not deal with it.
• Press the emergency stop button if an emergency
or serious fault occurs and the genset will be
stopped immediately.

34
 CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5.6 Convenience Receptacles (if applied) Every convenience receptacle is equipped with a
separate circuit breaker protecting it. While the
The genset can be equipped with the single-phase genset is running, if the current in one convenience
(2 or 3 pin) and three-phase convenience recepta- receptacle is above its rated value, the correspond-
cle (4 or 5 pin) according to the customer's require- ing circuit breaker would turn to the “OFF” position
ment. The user can supply power for the loads con- automatically and interrupt its circuit.
veniently. For the parameters of rated voltage and
current refer to the technical document please.
1) Turn every circuit breaker protecting conve-
nience receptacle to the “OFF” position.
2) Loosen the fixing bolts on the plug and disassem-
bles the plug.
3) Connect load cables to the plug in the proper
position and fix them with bolts.
4) Reassemble the plug and tighten the fixing bolts.
5) Put the plug into the convenience receptacle.
6) Turn the corresponding circuit breaker to the
“ON” position when the genset is running, then
turn on the switch of load. So power supply is
sent to the load side.

5.7 Terminals Diagram

(1) PLC-7420 Control System Terminals

35
CHAPTER 5 — OPERATION FOR PLC-7420 CONTROL SYSTEM

5.8 Parameter Configuring digit you have just entered will now show "#" for
security. Repeat this process for other digits of
the PIN number. Press the Accept Button after
editing the final PIN digit, the PIN is checked for
validity. If the number is not correct, you must
re-enter the PIN.
• Stop the machine before setting any parameter.
4) If the PIN is correct (or the module PIN has not
• Some parameters can be reset by the user been enabled), the editor is displayed as below
through the control panel, and the others can only illustration. Then enter the editor interface.
be changed using the PC utility software. Con-
tact POWERLINK or our authorized distributor
for technical support if you encounter a problem
when configuring parameters.

Although full configuration of the module is possible

using configuration software, selected parameters
that may require adjustment in the field are able to
be adjusted via the module's fascia.
5) Press the Left/Right Button to cycle to the sec-
1) Ensure the engine is at rest and the module is in tion you wish to view/change.
STOP mode by pressing the Stop Button.
6) Press the Up/Down Button to select the param-
2) Press the Stop button and Accept button si- eter you want to view/change within the currently
multaneously. If a module security PIN has been selected section.
set, the PIN number request is then shown:
7) Press the Accept Button to enter edit mode.
The parameter begins to flash to indicate that you
are editing the value.
8) Press the Up/Down Button to change the pa-
rameter to the required value.
9) Press the Accept Button to save the value. The
parameter ceases flashing to indicate that it has
3) Press the Accept Button, the first "#" changes to
been saved.
"0". Press the Up/Down Button to adjust it to the
correct value. Press the Right Button for next 10) Press and hold the Accept Button to exit the
digit when the first digit is correctly entered. The editor at any time.

36
 CHAPTER 6 — MAINTENANCE

6 Maintenance
6.1 General • Onlyuse original spare parts, oils, coolant and
operating materials released by POWERLINK for
the maintenance work.

• Maintenance should be performed by a licensed

engineer.
• For detailed maintenance procedures on the
engine or alternator, refer to their own operation
manual.
• Prior to starting any maintenance work, always
• Always adhere to the prescribed operating
method described below for all maintenance
stop the machine as described in these operating
work. Never omit a single safety step! Otherwise
instructions prior to removing any safety cladding
you will risk injury from restarting, electric shock
or safety devices. �� the safety cladding or
or parts which may �off.
safety devices immediately upon completion of
the maintenance work. • Before performing any check or maintenance,
stop the engine and remove the start key.
• Following the maintenance schedule and using
the machine properly will bring longer life, better • Accidental starting of the machine during
performance, and safer operation. Perform each maintenance can cause severe personal injury or
maintenance procedure at the time period indi- even death, so before performing maintenance,
cated or after the number of operating hours in- please switch off battery switch and disconnect
dicated, whichever comes ��� negative (-) cable ��to reduce the risk of arcing.

37
 CHAPTER 6 — MAINTENANCE

6.2 Maintenance Schedule

Your Volvo Penta engine and its equipment are designed for high reliability and long life. The engines
are built to have the smallest possible environmental impact. If given preventive maintenance,
according to the maintenance schedule, these qualities will be retained and unnecessary malfunctions
will be avoided. In order for the warranty to be valid, the owner must make sure that the services in the
service intervals are performed.

NOTICE! For emission related warranty rights see Emission Control System Warranty Statement.

Service Intervals
Service intervals are shown below. The service content can be found in the Service Protocol available
for download at www.volvopenta.com.

NOTICE! More information on how to perform service and maintenance can be found in the Service
and Maintenance handbook. Information on how to purchase the Service and Maintenance handbook
can be found at www.volvopenta.com.

Extended service intervals

The interval between engine oil changes may be extended in certain circumstances. To determine
whether the service interval may be extended, Volvo Penta's conditions for extended service intervals
must be met and an oil analysis performed. Contact your Volvo Penta dealer for further information.

Special Interval Service S1 Every 1000 hours of operation, or every 12 months.(1)(2)

Special Interval Service S2 Oil analysis.

Special Interval Service S3 After the first 1000 hours of operation.

Type A Service Every 1000 hours of operation.

Type B Service Every 2000 hours of operation.
Type C Service Every 8000 hours of operation.

1) Oil change intervals vary, depending on oil grade and sulfur content of the fuel. Refer to Oil
recommendations.
2) Change oil filters every time the oil is changed.

38
 CHAPTER 6 — MAINTENANCE

6.3 Generator Set Maintenance

Inspect the genset daily or after every eight hours
of operation, whichever comes first. Check the me-
chanical, exhaust, fuel, and DC electrical systems
as described below.
(1) New Machines

• Run the genset at least 60–100% of continuous • Inhalation of exhaust gas can result in severe per-
load for the first 100 hours. sonal injury or even death. Check exhaust sys-
• Change engine oil and replace oil filter after the tem audibly and visually for leaks daily. Repair all
first 50 hours. leaks immediately if necessary.
(4) Fuel System
Start the genset, inspect the fuel supply lines, re-
(2) Mechanical System turn lines, filters, and fittings for leaks during the
Inspect any signs of mechanical damage. Start the machine running.
genset and listen for any unusual noise, which may Inspect all flexible sections for cuts, cracks and
indicate mechanical problems. Repair them imme- abrasions. Make sure that the fuel lines do not rub
diately if necessary. against anything that could break them. Replace
Inspect the mounting fasteners to make sure the worn fuel line components if necessary before leaks
genset is secure in its compartment. If use an un- occur.
der-floor housing, make sure that the genset is se-
cured to the housing.
Check the genset air inlet and outlet area, make
sure that they are not blocked with debris.
Clean the machine immediately whenever dust and
dirt begin to accumulate. Usually remove dust and
dirt with a damp cloth.
• Fuel leakage will cause a fire hazard which can
result in severe personal injury or even death if
ignited. When checking for leaks, do not smoke
or allow any spark, flame or other ignition source
in the area. If any leaks are found out, repair them
immediately.
• Do not clean the genset when the engine is run- (5) DC Electrical System
ning.
Inspect the battery terminals for clean and connec-
• Protect the alternator,air cleaner, control panel, tions for tight with the genset off. Loose or corroded
and electrical connections from cleaning solvents connections may cause resistance which can im-
because cleaning solvents can damage electrical pede starting. Clean and reconnect loose battery
connectors. cables if necessary.
(3) Exhaust System In order to reduce the possibility of arcing , always
Start the genset, inspect the entire exhaust system disconnect the negative (-) battery cable first and
including the exhaust pipe, exhaust elbow and muf- connect it after maintaining.
fler during the machine running.
Visually and audibly check for leaks at all connec-
tions, welds, gaskets, and joints.
If any leaks are found out, shut down the machine
and do not operate until corrected. Replace cor-
roded exhaust components if necessary before
leaks occur. • Ignition of explosive battery gas can create severe
personal injury.
• Wear goggles, protective rubber gloves and apron
and do not smoke while servicing batteries.

39
 CHAPTER 6 — MAINTENANCE

6.4 Air Cleaner 6.5 Engine Coolant

6.4.1 Clean air ilter element Change coolant

1) Loosen clips on the air cleaner housing and re-

move the dust cap.
2) Remove the air filter element.
3) Blast the compressed air to the air filter element
from inside. Do not open the coolant filler cap when the engine
is hot, except in emergencies, as this could cause
4) Use a clean cloth to wipe the filter sealing surface serious personal injury. Steam or hot fluid could
and the inside of the outlet tube. spray out.
5) Reinstall the air cleaner in the reverse order.
IMPORTANT:
The coolant contains corrosion-inhibiting
6.4.2 Change air filter element
additives. Never drain the engine cooling system
1) Loosen clips on the air cleaner and remove the on engines, which are to be put in storage.
dust cap.
1 Stop the engine before draining the coolant.
2) Remove the air filter element.
2 Remove the caps to both the expansion tanks
3) Change a new air filter element. (1and 2) and radiator (3).
4) Reinstall the air cleaner in the reverse order. 3 Place a suitable vessel for the coolant to drain
off into.
4 Open all drain points (4). Drain the coolant from
theradiator and engine block using a drain hose.
5 Check that all coolant drains out. Clear away
any deposits found inside the drain tap/plug.
• Do not remove the air cleaner while operating or There is otherwise a risk that coolant will remain
immediately after stopping the machine. and cause freeze bursting. Check whether the
installation has any further taps or plugs at the
lowest points of the coolant lines.
6 Shut any taps and check that the spring-
loaded covers on the nipples close completely.
Install the rubber plugs.

40
 CHAPTER 6 — MAINTENANCE

6.6 Engine Oil and Oil Filter

Hot oil and hot surfaces can cause burns. Hot oil and hot surfaces can cause burns.

Oil changes must be done when the engine is hot. 1 Clean the oil filter bracket (2).
1 Connect the drain hose to the oil drain pump and 2 Remove all oil filters with a suitable oil filter
check that no leakage can occur. extractor (1).
3 Clean the mating surface of the oil filter
2 Pump the oil out (or remove the bottom drain plug bracket.Make sure that no pieces of old oil
and drain the oil). seal are left behind. Carefully clean round the
Collect all the old oil and old filters, and hand them inside of the protective rim (2) on the oil filter
to a re-cycling station for destruction. br acket.
3 Remove the drain hose (or install the bottom drain 4 Put a thin layer of engine oil on the seal
plug). rings of the new fuel filters.
5 Install the new oil filters. Tighten the filters
¾–1 turn after they touch.
6 Top up with engine oil, start the engine and
let it run for 20-30 seconds.
7 Turn off the engine, check the oil level and
top up as required.
8 Check sealing round the oil filters.

41
 CHAPTER 6 — MAINTENANCE

6.7 Fuel Filter

Fire hazard. When carrying out work on the fuel Fire hazard. When carrying out work on the fuel system
system make sure the engine is cold. A fuel spill make sure the engine is cold. A fuel spill onto a hot
onto a hot surface or an electrical component surface or an electrical component can cause a fire.
can cause a fire. Store fuel soaked rags so that Store fuel soaked rags so that they cannot cause fire.
they cannot cause fire.
IMPORTANT:
IMPORTANT Do not fill the new fuel filter with fuel before assembly.
Always
: observe the greatest cleanliness during There is a risk that contamination could get into the
refueling and work on the fuel system. system and cause malfunctions or damage.
Only use the grades of fuel recommended in
the fuel specification. 1 Clean round the fuel filter.
2 Remove the filter with a suitable filter remover.
Draining condensate, fuel system Collect any spilled fuel in a collection vessel.
NOTICE! Put a collection vessel under the fuel 3 Clean the filter mating surface on the filter bracket.
filter tocollect the condensate and fuel.
4 Lubricate the seal with diesel fuel and install the
1 Open the drain nipple in the base of the fuel new fuel filter. Tighten the fuel filter in accordance
pre-filter. with the instructions on the fuel filter.
2 Tighten the drain tap when fuel without water
starts to run out.

42
 CHAPTER 6 — MAINTENANCE

6.8 Fuel Pre-filter, Change

1 Undo the cable from the water trap sensor. Fuel system, bleeding
2 Remove the water trap filter from the filter
housing. 1 Check that there is sufficient fuel in the tank,
and that any fuel taps are open.
Collect any spilled fuel in a container.
3 Remove the lower part of the water trap from 2 Release the hand pump on the fuel bracket
the filter. by pushing down and twisting the plastic handle.
4 Clean the lower part of the water trap with a soft 3 Vent the fuel system by pumping with the
rag.Check that the drain hole in the lower part is hand pump.Air is vented to the tank via the fuel
not blocked. return pipe. No breathing nipples need be
5 Install a new seal on the lower part and opened.
lubricate the seal with diesel fuel. Re-install the 4 Lock the hand pump, push down and twist the
lower part of the filter. handle.
6 Lubricate the seal with diesel fuel. Screw the 5 Start the engine and allow it to idle fast for
filter onto the filter bracket by hand until the rubber about 10 minutes.
seal just touches the mating surface. Then tighten
a further half turn, no more. 6 Perform a leakage and function check.
7 Connect the cable to the water trap sensor.

43
 CHAPTER 6 — MAINTENANCE

6.9 Battery Maintenance 6.9.1 Battery cable disconnecting

The user should check and charge the battery pe- ALWAYS be sure the battery cables are properly
riodically. The power of battery will decrease while connected to the battery terminals as shown below.
it is unused for a long period of time or start failure The Red Cable is connected to the positive terminal
repeatedly. Charge it in time while these occurred. of the battery, and the Black Cable is connected to
the negative terminal of the battery.

• Batteries present the hazard of explosion that can

result in severe personal injury.
• NEVER smoke or allow any ��I
���spark, pi-
lot light, arc-producing equipment or other ignition
sources around the battery area.
• Do not disconnect battery cables while the ma-
chine is cranking or running because explosive
battery gases could be ignited.
• Battery electrolyte can cause severe eye dam-
age and burns to the skin. Wear goggles, rubber
gloves and other protective device when working 6.9.2 Battery power checking
with batteries.
POWERLINK adopts maintenance free battery. So
it is not necessary to add distilled water or elec-
trolyte, only check the coulomb periodically.

44
 CHAPTER 6 — MAINTENANCE

6.9.3 Battery charging

45
 CHAPTER 6 — MAINTENANCE

6.10 Lifting and Transporting

The top of the genset has one or several lifting
lugs attached to the lifting frame inside the hous-
ing. Refer to the Technical Data for the weight • Do not use lifting points located over the engine,
of the genset. Make sure the lifting devices have alternator or other components.
enough capacity to lift the unit safely. When lifting
the genset, attach a sling securely to the lifting lug. • Inspect lifting lugs for dents, damage, weld or par-
ent metal cracks or other discrepancies. Replace
When transporting the genset, it should be secured or repair it before lifting if anything is improper.
properly with ropes tied to the roping lugs at the top
of the genset for fixing. • Do not stand nearby while lifting.

6.11 Overnight Storage 6.12 Long-term Storage

Proper operation is essential for preserving top If the genset would not be used for more than two
genset performance and reliability when storing months, perform the following procedures to store
the genset overnight. it.
1) Check and make sure the engine battery switch 1) Make sure the engine battery switch and all
and all genset circuit breakers are placed “OFF” genset circuit breakers are placed “OFF” posi-
position. tion.
2) Make sure that the control cabinet and access 2) Close and padlock the control cabinet and ac-
doors are closed and padlocked. cess doors. Remove the start key.
3) Turn off the fuel supply valve (if equipped). 3) Turn off the fuel supply valve (if equipped).
4) Disconnect the battery cables (negative [−] cable
first) from the starting battery and store the bat-
tery.
5) Store the genset where dust and humidity are
less as possible.
• Do not store it overnight in a low lying area that 6) The genset should be running in 30% rated load
might fill with water during a heavy storm. until it reach a stable operating temperature once
every six months. Meanwhile it should be run-
ning in full load in order to prevent oil pollution
jam in exhaust system once every year.

46
 CHAPTER 7 — TROUBLESHOOTING

7 Troubleshooting
7.1 General
When performing any troubleshooting, follow the
guideline below.
Be careful!
For detailed troubleshooting procedures about en-
gine/alternator, refer to engine/alternator operation Besides these, the coupler maybe unlike in differ-
manual. ent countries; check and make sure the trailer and
its coupler are correct and follow the guideline of
Keeping generator set level, making battery con-
governmental agencies for trailing. Failure to follow
nections clean and tight, checking fuel level and not
these procedures may seriously harm to the equip-
overloading etc., will help to reduce the possibility
ment and cause seriously hurt even death during
of engine shutdown.
trailing.
Contact POWERLINK or our authorized distributor
to ask for help for complicated maintaining and re-
placing operation.

47
 CHAPTER 7 — TROUBLESHOOTING

7.2 Generator Set Troubleshooting

Trouble Causes Remedies

1. Oil pressure sensor is defective. 1. Repair or change the sensor.
2. Lubricant oil is insufficient. 2. Add lubricant oil.
Low engine oil pressure 3. Oil hose has leak. 3. Tighten or change oil hose.
4. Oil filter is clogged. 4. Change oil filter.
5. Improper kind of oil is used. 5. Change to proper kind of oil.
1. Coolant is insufficient . 1. Add coolant.
2. Coolant pipe has leak. 2. Tighten or change coolant pipe.
3. Fan belt is loose. 3. Tighten the belt.
High coolant temperature 4. Radiator core is clogged. 4. Clean radiator core.
5. Coolant temperature sensor is
5. Repair or change the sensor.
defective.
6. Engine thermostat is defective. 6. Repair or change the thermostat.
1. Fuel is insufficient. 1. Add fuel.
Low fuel level 2. Fuel tank has leak. 2. Repair or change fuel tank.
3. Fuel level sensor is defective. 3. Repair or change the sensor.
1. Air filter element is clogged, and air is
1. Clean or change air filter element.
insufficient.
Power drops after running a period
2. Fuel filter is clogged, and fuel is 2. Drain water/sediment or Change fuel
of time
insufficient. filter.
3. Engine ignition time is incorrect. 3. Adjust the ignition time as required.
1. Ground connection is defective. 1. Check ground wiring.
Ground metal part is electriferous
2. Insulating resistance is too low. 2. Measure insulating resistance.

48
 CHAPTER 7 — TROUBLESHOOTING

7.3 Control System Troubleshooting

Trouble Causes Remedies

1. The main breaker position rests
1. First turn the breaker to off , and then
on the position between ON and OFF
turn it to on.
Main breaker cannot be turned to on improperly.
2. Check and repair the load circuit or
2. Short circuit on the load.
change it .
1. Control module cable is disconnected 1. Connect the module cable to the
to the battery. battery.
2. Charge the battery with the utility
Control module cannot run 2. Battery power is insufficient.
power.
3. The fuse is damaged. 3. Change the fuse.
4. Control module is defective. 4. Repair or change the control module.
1. Decrease the loads to meet the rated
1. Loads total exceeds the rated current.
output.
Voltage drops quickly when 2. Check AVR. and change it if
2. AVR. of alternator is defective.
connecting to the load necessary.
3. Adjust the frequency to the load
3. Use wrong frequency.
frequency.
Frequency is stable, but voltage is 1. Check AVR. and change it if
1. AVR. of alternator is defective.
unstable necessary.
After connecting to the load, voltage
and frequency is stable, but current 1. Customer load is unstable. 1. Check and adjust the customer load.
is unstable
1. Check AVR. and change it if
Voltage cannot go up to the rated 1. AVR. of alternator is defective.
necessary.
value
2. Frequency is low. 2. Adjust frequency as required
1. Check AVR. and change it if
Voltage exceeds the rated value 1. AVR. of alternator is defective.
necessary.
1. Check the meter, and change if
1. The meter is defective.
necessary.
Electric meter has no reading
2. Circuit is disconnected, or terminal is 2. Find the cut position and connect
loose. again.

49
 CHAPTER 7 — TROUBLESHOOTING

7.4 Engine Troubleshooting

Trouble Causes Remedies

1. Battery switch is off. 1. Turn the switch to on.
Starter motor 2. Battery output is weak. 2. Charge the battery.
cannot drive or
speed is low 3. Battery is deteriorated. 3. Change the battery.
4. Battery terminal is loose. 4. Tighten the terminal.
1. Check fuel system, and add fuel if
Engine cannot 1. Fuel is insufficient.
necessary.
start
Starter motor 2. Fuel hose has leak. 2. Tighten or change fuel hose.
drives, but
3. Drain water/sediment or Change fuel
engine cannot 3. Fuel filter is clogged.
filter.
start
4. Gauze filter is clogged. 4. Clean or change gauze filter.
5. Air is mixed in fuel line. 5. Extract the air.
1. Fuel hose has leak. 1. Tighten or change fuel hose.
2. Fuel filter in the water/fuel separator is 2. Drain water/sediment or Change fuel
clogged. filter.

Engine starts but stalls at once 3. Gauze filter is clogged. 3. Clean or change gauze filter.
4. Lubricant oil is insufficient. 4. Check oil level, add oil as required.
5. Air is mixed in fuel line. 5. Extract the air.
6. Air filter element is clogged. 6. Clean or change air filter element.
1. Check fuel system, and add fuel if
1. Fuel is insufficient .
necessary.
2. Check to see if lubricating oil filter is
2. Overheating of moving parts.
working properly.
Output is insufficient
3. Air filter element is clogged. 3. Clean or change air filter element.
4. Check the fuel injection pump element
4. Injection pump is defective. and delivery valve assembly, replace if
necessary.
1. Improper kind of fuel is used. 1. Select proper fuel.
2. Air filter element is clogged. 2. Clean or change air filter element.

Muffler releases black smoke 3. Adjust the loads to meet the rated
3. Loads total exceeds the rated current.
output.
4. Accumulation of gas carbon is high on
4. Clean out gas carbon.
the exhaust pipes and muffler.
1. Air filter element is clogged. 1. Clean or change air filter element.
2. Lubricant oil is redundant and exceeds
2. Drain the redundant oil.
the limited.
Muffler releases white smoke
3. The piston ring(s) is(are) worn out. 3. Change piston ring(s).
4. Large clearance between cylinder and
4. Change the piston and cylinder.
piston.
1. Check and change the fuel, check and
1. Fuel contains water or air
clean the fuel system.
Muffler releases blue smoke 2. Injector nozzle atomizes badly. 2. Repair or change Injector nozzle.
3. The cylinder or/and gasket is
3. Repair or change cylinder and gasket.
damaged.

50
 CHAPTER 7 — TROUBLESHOOTING

Trouble Causes Remedies

1. Lubricant oil is insufficient. 1. Check oil level, add oil as required.
2. Fan belt broken or elongated. 2. Change belt or adjust belt tension.
3. Coolant insufficient. 3. Add coolant.
4. Radiator net or radiator fin clogged with
4. Clean net or fin carefully.
dust.
5. Improper kind of fuel is used. 5. Select proper fuel.
6. Coolant temperature gauge or sensor 8. Check coolant temperature gauge or
Engine overheats is defective. sensor and replace if necessary.
7. Overload running. 7. Reduce load.
8. Radiator corn or coolant route is 8. Clean or replace radiator or defective
clogged. parts.
9. Fan, radiator cap or radiator is
9. Replace radiator or defective parts.
defective.
10. Check thermostat and replace if
10. Thermostat is defective.
necessary.
1. Verify the solenoid is not being
energized by a short in the wiring. Check
1. Electrical or manual fuel shutoff not the linkage to the shutoff lever for binding.
closing. Check for the ability of the spring in the
Engine shut off failure solenoid to move the lever to the shutoff
position.
2. Fumes generated while the engine is
2. Locate and isolate the source of fumes.
running is drawn into air intake.
1. Extract the air in fuel system and check
1. Air is mixed in fuel line.
for suction leaks.
Engine surges at idle 2. Idle speed is set too low. 2. Check and adjust low idle screw.
3. Drain water/sediment or change fuel
3. Fuel filter is clogged.
filter as necessary.

51
 CHAPTER 7 — TROUBLESHOOTING

7.5 Alternator Troubleshooting

Trouble Causes Remedies

1. Intertwist the cut winding and weld
1. Winding is cut.
firmly .
2. Wiring terminal is loose. 2. Tighten the wiring terminal .
No voltage or voltage is insufficient
while running 3. Clean or replace the defective
3. Wiring terminal is defective.
terminal .
4. Adjust the speed and keep the rated
4. Speed is too low.
speed.
1. Speed is unstable. 1. Keep the rated speed.
Voltage is unstable
2. AVR is defective. 2. Check AVR, and change if necessary.
1. Overload running. 1. Reduce load.
Alternator overheats 2. Vent-pipe inside the alternator is
2. Blow and clean the inner .
clogged.
1. Speed is too high. 1. Keep the rated speed.
Voltage is too high
2. AVR is defective. 2. Check AVR, and change if necessary.
1. Speed is too low. 1. Keep the rated speed.
Voltage is too low while running
without load 2. Check AVR, and change if necessary
2. AVR is defective.
.
1. Speed setting is incorrect. 1. Check and adjust the speed.
Voltage is correct without load, but
2. Short circuit on the rotor. 2. Check resistance of the circuit.
too low under load
3. Armature of excitation is defective. 3. Check resistance of the circuit.
1. Check the cut winding, intertwist and
1. Winding of magnetic field is cut.
weld firmly .
Voltage disappears while running 2. Check rotor, repair it and change if
2. Rotor of excitation is defective.
necessary.
3. AVR is defective. 3. Check AVR, and change if necessary.

52
 CHAPTER 7 — TROUBLESHOOTING

7.6 Battery Charge Troubleshooting

Trouble Causes Remedies

1. Battery post is defective. 1. Check and clean the post.
2. Battery post is connected incorrectly. 2. Check the connection post.
No charge current 3. Check the wiring to the charger from
3. No mains supply.
mains supply.
4. Power fuse is burned-out . 4. Change the fuse.
Display nothing on the charge current 1. Measure the current with the standard
1. Charge current meter is defective.
meter amperemeter .
1. Mains supply power is low. 1. Check mains supply.
2. Plug of the charger transformer does
Charge rate is too low 2. Check the plug of charger transformer.
not match with the mains supply voltage.
3. Battery post is loose. 3. Tighten the battery post.

Fuse of mains supply is burned-out 1. Power of the fuse does not match. 1. Change the proper fuse.
repeatedly 2. There is short circuit. 2. Check and connect all wiring.
1. Battery post is defective. 1. Check and clean the post.
Charge clip heats
2. Bolt of the clip is loose. 2. Clean and tighten the bolt.
1. Battery is deteriorated. 1. Change the battery.
Battery voltage does not rise 2. Check the battery, and change it if
2. Battery has been damaged.
necessary.

53
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02.2023

2023