Generator set technical manual 1

VPOWER Engineering (Shen Zhen) Ltd.

VPOWER GENERATOR SET

Operation / Service /Maintenance Manual

2014 Edition
VPOWER GENERATION

Table of Contents
Content
Chapter 1

Weekly maintenance and safety regulation.....

1.

Weekly maintenance work system. 2

2.

Weekly maintenance work. 2

3.

The normal working condition of the engine. 4

4.

The generator test running.

5.

Safety precautions and notices... 5

6.

Wrong activation. .

7.

Battery...

Chapter 2

Commonly operation.. ... 8

1.

Common Operation..

2.

The generator control panel .

3.

control panel introduction.....

4.

The Generator Controller DSE8610 Introduction. 10

5.

The generator start and stop...... 17

Chapter 3

Daily maintenance.....

Chapter 4

Maintenance plan... 19

Chapter 5

Troubleshooting.. ... 20

Chapter 6

Connection documents of after-service. 22

18

Chapter 1
1.

Weekly Maintenance And Safety regulation

Weekly maintenance work system:

The following weekly maintenance work system is applicable for the running status of
generator in common condition, but if the engine works in bad condition( such as
dust flying upward, poor-ventilated environment), the maintenance period should
z

2.

been shortened.
If around the engine engine, the generator should not been started.

Weekly Maintain work

Preventative maintenance begines with day-to-day awareness of the condition of the
engine and its systems.Before starting the engine,check the oil and coolant
levels.Look for:
z Leaks
z Loose or damaged parts
z Worn or damaged belts
z Any change in engine appearance
COOLING SYSTEM
-- The coolant level must be checked daily and more often.
-- The water level should be 2 below affusion mouth.
-- If exchange the cooling water, inspect the proportion of antifreeze supplied.
-- Inspect all the cooling piping and collet whether water leakage (like abrasion)
-- If use heat-scattering water tank, make sure no substance block the heat-scattering
sheet.
-- If use the heat-exchanging device, make sure all vavles are in right position.
Fill the cooling system with coolant to the bottom of the fill neck in the radiator
fill or expansion tank.
CAUTION:
-- Any time a significant amount of coolant is added, the Diesel coolant Additive
concentration must be checked. If the concentration is low, engine damage will
result.
NOTE:
-- Some radiators have two fill necks, both of which must be filled when the cooling
system is drained.
Lubrication System
-- Inspect the oil level of the lubricating oil to make sure it is within regulated scale
standard.
-- Inspect the oil quality of the lubricating oil to make sure whether water or fuel
2

mixing into.
-- Inspect the lubricating system to make sure whether leakage exist.
Fuel Oil System
-- Inspect whether the valve of the fuel pipe is open.
-- Inspect whether the fuel pipe leaks.
-- Inspect the oil level of the fuel box to make sure that fuel should been supplied
before it is exhausted.
-- The vehicle must be level when checking the oil level to make sure the
measurement is correct.
CAUTION:
Never oprate the engine with the oil level below the low mark or above the high
mark.Wait at least 5 minutes after shutting off the engine to check the oil. This
allows time for the oil to drain to the oil pan.
-- Check the valve of the fuel oil pipeline to have to leak.
Air cleaner System
-- Inspect whether the air-cleaner device is clean and observe the indicator (if
with)when generator running.
-- Inspect the oil level of the oil tray of the wet air-cleaning device(if used).
-- Under extremely dirty conditions an air pre-cleaner can be used. Clean the
pre-cleaner jar and dry-type air cleaner dust pans daily or more often, as necessary,
depending on operating conditions.
The switch function of circuit.
-- Inspect whether all the terminal indicator lights of the switch system of
internal-combustion engine are ok.
-- Check the engine monitor system daily (push button to test) per the manufacturers
recommentation to verify proper operation.
Battery
-- Inspect whether the electricity bottle liquid is enough, and its proportion should be
higher than 1.265.
CAUTION:
When using jumper cables to start the engine, make sure to connect the cables in
parallel:positive(+) to positive(+) and negative (-) to negative(-). When using an
external electrical source to start the engine, turn the disconnect switch to the OFF
position. Remove the key before attaching the jumper cables.
Belt
-- Inspect the intensity of the strap of cooling fan and the charger(if one strap is
found wore, the whole group should been changed)
3

-- Measure the belt tension in the center span of the pulleys. Refer to the
manufacturers recommendations for the use of the belt tension gauge.
-- Visually check the belts every 250 hours or 6 months.Replace the belts that are
cracked or frayed. Adjust belts that have a glazed or shiny surface which indicates
belt slippage. Correctly installed andtensioned belts will show even pulley and belt
wear.
-- The belt must be correct tension, correct size or length, pulley alignment, correct
installation.
Control connecting pole
-- Inspect whether liquid force or the lubricating of the electronic timing pull pole is
sufficient.
-- If with wind-blocking gate controller, confirm whether the system is good and
lubricating is enough.
-- Well-ventilated.
-- Confirm whether the ventilating system of the crankcase of the
internal-combustion engine is good.

3.

The normal working condition of the engine

Lubricant ressure
The lowest safety oil pressure
oil temperature
Cooling water temperature
Over-temperature (shut down)
The ighest fuel oil temperature
Engine oil grade

3 ~ 8 bar
2 bar
194 ~ 226 oF ( 90 ~ 108 oC )
160 ~ 202 oF ( 60 ~ 95 oC )
2150F(1020C)
90 oF ( 32 oC )
Above CF

The exchange period of the lubrication oil and fuel oil

-- Exchange the generation oil colander every 250 working hours or every year.
-- Exchange the fuel oil colander every 250 working hours or every year. And if
thegeneration has oil-water separate, the period may be prolonged. If the fuel oil
colander is air-logged, it should be exchanged momentarily.
-- Blow off the air-colander with compressed air every 100hrs, and exchange the
air-colander every 500hrs.
4.

The generator test running

1 ) Unloaded test (Remark:
allowed.)

the test time unloaded more than 10 minutes is not

A . Check that the air switch of the controlling-panel should be on the OFF
position.
B . Turn the select switch on the MANUAL position, and then press down
START key.
C . Check every voltage by the switchover phase-order switch.
D . Check whether the frequency is normal or not.
F . Stop the engine and turn the switch on the AUTO position.
2 ) Loaded Test.
A . Check that the select switch is on the OFF position.
B . Check that the air switch of the controlling-panel is on the ON position.
C . Turn off the Mains electricity, the set will activate automatically after some
time.
D . Check every voltage by switchovering the phase-order switch.
E . Check whether the frequency is normal or not by the cymometer.
F . Check the load current by the amperemeter.
G . Check the oil-pressure (4~8 bar).
H . Check the temperature of the water.
Running the set 30 minutes under the situation of more than 50% of the rated load,
if the status is very well, you can turn to city electricity for power supply. And
before stopping, the set should be running unloaded for a period of time for
cooling.
I. Allow the engine to idle three to five minutes before shutting it off after a load
operation. This allows adequate cool down of pistons, cylinder liners, bearings
and turbocharger componens.
J. Turn the ignition key switch to the off position, the engine stop running. If
the engine fairs to stop running. Rotate the manual fuel shutoff thumb screw
counterclockwise to make sure the valve is not being held open by the manual
override screw.
Remark: International standard (CAN/CAS-C282-M89, 1989.5) regulates that all
generator should run loaded for 60 minutes every month.
5.

Safety precautions and notices

Like other electricity facility, generators if not maintained and operated
properly,also ill cause life danger and limb wound.
The best way to prevent accident from happening is to understand the potential
danger and keep facility in good condition. For the safety, now indicate the
common precausions related to generator operation as following :
5

 DANGER

The danger emblem indicates that if no close attention is paied to, it will cause
people injury and death, generation damage.
WANRNING

The warning emblem indicates that if no close attention is paied to, it will cause
serious people injury and death, generation damage.
CAUTION

The caution emblem indicates that if no close attention is paied to,it may cause
people injury or generation damage.
Remark :These emblems should been paied attention to during install,operation or
maintenance,but it does not mean danger.
These safety emblems should been pasted on the relative obvious position of the
generator group to remind the operators or maintenance technician of paying
attention to these potential danger. As to the explanation of these emblems,you can
refer to all the safety precautions in this manual to make sure whether you have
understood the meaning of these emblems like emblems loss or damage which
should been exchanged quickly.

6.

Wrong activation
Warning

Wrong activation may cause injury or death.

When working around the generator, firstly should break the battery away from
cable( remove cathode then connect)
Make the generator switch at the position of OFF.when working around the
facilityjoined with fuel generation, should remove activation electricity bottle and
cable(remove before connecting) to make generator group impossible to work.
If the above measurement is not taken, the generator group may been automatically
switched or remote switch control activation.

7.

Battery
Warning

The electrolyte can cause serious injury or death.

-- It is necessary to wear protective glove and clothes because the electrolyte can
cause permanent hurt to eyes,can burn skin and ablate clothes.
Warning
-- Exploding can cause serious injury or death,the relay of the battery charger can
6

cause sparking.
-- The battery should been installed at well-ventilated place, and far away from
flammable gas.
The electrolyte of the battery can cause serious injury or death. the electrolyte can
cause permanent hurt to eyes,can burn skin and ablate clothes. So when working
around battery, should wear safety antiseptic glove. If electrolyte spatters to skin,
should rinse for 15 minutes with sufficient clean water. If electrolyte spatters to
eye, you should seek the first-aid kit for medicining. The battery cant be appened
vitriol or it may cause the electrolyte metamorphosing.
Exploding will cause serious hurt or death, the gas liberated by the battery may
cause exploding, so around the battery smoking is prohibited and blaze or sparkle
generation is prohibited. Especially when the battery is charging, you should avoid
touching the terminal with tools, avoil exploding caused by sparkle. Before you
move the battery, you should turn off the watch, finger ring and other bullion
ornements. Do not connecte the anode and the cathode of the activation generation
shortly. Do not tset the capacity of the electric-bottle in the way of short, the
sparkle may emblaze the gas liberated by the battery or steam of fuel oil. The case
contained
battery should be put in the breezy place to avoid explosive
gathering. Do not pull out the electric tie-in when charging to avoid sparkle
generation.Before pulling out the electric tie-in, you should turn off the power of
the charger first.The cathode of the power should be dismantled first and
connected last.
-- Removal: Disconnect the (-) negative battery cable first, then disconnect the (+)
positive cable.
-- Connect: Connect the (+) positive battery cable first, then connect the (-) negative
cable.

Chapter 2 Common Operation

1. Common Operation
Before starting the generator set, check for the following procedures. (Special
maintenance procedures refer to CUMMINS Operation and maintenance
Manual)
Fuel oil system
-- Check the oil level,The vehicle must be level when checking the oil level to make
sure the measurement is correct.
-- Operate the engine with the oil level between the low mark and the high mark.
Cooling sytem
-- The coolant level must be correct.
Fill the cooling system with coolant to the bottom of the fill neck in the raiator fill
or expansion tank.
Some radiators have two fill necks, both of which must be filled when the cooling
-system is drained.
Any time a significant amount of coolant is added, the diesel coolant additive
-- concentration must be checked. If the concentration is low, engine damage will
result.
--

--

Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow
the engine to cool to below 50 before adding coolant.

Air cleaner:
Clean the air cleaner jar and pans daily or more often, as necessary, depending on
-operating conditions.
Other
Check the oil pressure indicators, temperature indicators, warning lights and other
-gauges to make sure they are operational.
Check the engine monitor system (push button to test) per the manufacturers
-recommendation to verify proper.

-- VPOWER-- Operation Manual --

2.

3.

The generator control panel

Note: panel electric elements arrangement may not agree with actual, please use the actual
arrangement shall prevail.

V500G CONTROL PANEL INTRODUCTION

ymbol
W1

term
Genset Controller
DSE 8610

Function and Operation

The DSE8610 is an Automatic Engine ControlModule,
designed to provide advanced load share functionality for
diesel and gas generating sets that include nonelectronic
and electronic engines. The module also provides
excellent engine monitoring and protection features.
The modules load share functions include, automatic
synchronizing with built in synchroscope and closing
onto dead bus. Direct and flexible outputs from the
module are provided to allow connection to the most
commonly used speed governors and automatic voltage
regulators (AVRs).
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-- VPOWER-- Operation Manual --

W2

PB1
L
B1

A
SW1

SW2
SW3
SW4
SW5
SW6

4.

The module has been designed to combine a maximum

of 16 generators and 16mains (utility) supplies up to a
maximum of 20 in one system, e.g. 16 generators and
4mains (utility) supplies (DSE8610 required to
synchronise with the mains).
The module has the ability to monitor under/over
generator volts, over current, under/over generator
frequency, under speed, over speed, charge fail,
emergency
stop, low oil pressure, high engine temperature, fail to
start, low/highDC battery volts, fail to stop, generator
short circuit protection, reverse power, generator phase
rotation error, earth fault protection, loss of speed signal,
fail to open, fail to close, out of sync,MPU open circuit
failure, negative phase
sequence and loss of excitation.
EM133
The EM133 is a smart DIN Rail Tou Energy Meter. The
EM133 can serve any application from residential energy
metering,through industrial emergy and harmonic
analysis through utility comprehensive substation
automation.
Emergency
Stop When the Generator is abnormal, press the Emergency
Button
stop button would stop the Generator immediately.
Fault Light
When the generator set occurred the fault, Light is on.
Buzzer
When the generator set occurred the fault, Buzzer is on,
Warning the worker to check the Generator, and remove
the fault.
Charging Meter
For battery charging meter
Power
Select Turn to ON position, Open the Controller of DSE8610,
Switch(OFF/ON)
Turn to OFF position, Close the Controller of
DSE8610
Charging Switch
Charging selector switch For battery charging (off / on)
Freq. Select Switch This selection switch can change the Generator of
frequency&voltage(50Hz-400V/60Hz-380V/60Hz-480V)
Volt Trimmer
This knob can change the magnitude of
(50Hz/400V)
voltage(50Hz/400V)
Volt Trimmer
This knob can change the magnitude of
(60Hz/380V)
voltage(60Hz/380V)
Volt Trimmer
This knob can change the magnitude of
(60Hz/480V)
voltage(60Hz/480V)

The Generator Controller DSE Model 8610 Introduction

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-- VPOWER-- Operation Manual --

4.1

ICON DESCRIPTIONS

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-- VPOWER-- Operation Manual --

4.2
4.2.1

OPERATION
CONTROL

Control of the DSE 8610 module is via push buttons mounted on the front of the module
with STOP/RESET, MANUAL, AUTO, ALARM MUTE/LAMP TEST and START functions.
For normal operation these are the only controls which need to be operated. The smaller push
buttons are used to access further information such as engine instruments and load switching.
Detail of their operation is covered later in this document. The following descriptions detail the
sequences followed by a module containing the standard factory configuration. Always refer
to your configuration source for the exact sequences and timers observed by any particular
module in the field.
CAUTION: - The module may instruct an engine start event due to external influences.
Therefore, it is possible for the engine to start at any time without warning. Prior to performing
any maintenance on the system, it is recommended that steps are taken to remove the battery
and isolate supplies.

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-- VPOWER-- Operation Manual --

4.2.2

AUTOMATIC MODE OF OPERATION

Automatic mode is used to start the set in response to an external start requirement from another
device. A number of options exist for the remote start input (selectable using 5xxx configuration
software).

Remote Start on Load input indicates to the controller that it should start the set, and run off load.

Remote Start on Load input indicates to the controller that it should start the set, synchronise (if
required) and share load with any other sets in the system.

Remote Start on Load Demand input indicates to the controller that it should start the sets,
synchronise (if required) and share load with any other sets in the system, automatically starting and
stopping sets on changing load demand.

NOTE: - If a digital input configured to panel lock is active, changing module modes will

and i

not be possible. Viewing the instruments

is NOT affected by panel lock. If

panel lock is active the Panel lock indicator (if configured) illuminates.

This mode is activated by pressing the

pushbutton. An LED indicator beside the button will

illuminate to confirm this operation.

Should the remote start input (if configured) become active then the following sequence is observed.
To allow for short term or false remote start signals, the Start Delay timer is initiated. After this delay,
if the pre-heat output option is selected then the pre-heat timer is initiated and the corresponding
auxiliary output (if configured) will energise.

NOTE:- If the Remote Start signal is removed during the Start Delay timer, the unit will
t

db

t t

After the above delays the Fuel Solenoid (or enable ECU output if configured) is energised, then
one second later, the Starter Motor is engaged.

NOTE:- If the unit has been configured for CAN Bus, compatible ECUs will
receive the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part
No. 057- 004 for more information on utilising DSE modules with electronically
controlled engines.

The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the
13

-- VPOWER-- Operation Manual -set number of attempts, the start sequence will be terminated and Fail to Start fault will be displayed.
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency
measured from the alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing
can be used for speed detection (This is selected by PC using the 5xxx series configuration software).
Rising oil pressure can also be used to disconnect the starter motor, however it cannot be used for
underspeed or overspeed detection.

NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. This
prevents excessive wear on the engine.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure, High
Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilise
without triggering the fault.
If the system has been started by a remote start off load input, the set will run off load.
Otherwise, the Warm Up timer, if selected, is initiated, allowing the engine to stabilise. After the
Warm-up timer has expired then the module will close the load switching device.
In the case of a single generator system, the Generator Contactor/Breaker will be instructed to
close. The generator will then supply the requirements of the load.
On a multi-set system, if the common generator bus is live, the 8610 module will first synchronise
the generator to the bus before closing the Generator Contactor/Breaker.
A token is held by the module that first closed onto the dead bus and as only one token exists for
each multi-set system, this prevents other sets in the system from attempting to close their own
breakers.
For added security, the modules also monitor the bus. If this is found to be live, then the
synchronisation process begins.
Once the load switching device is closed, the 8610 will then ramp to share the load with the other
generators in the system.

NOTE:-A load transfer will not be initiated until the Oil Pressure has risen. This
prevents excessive wear on the engine.

When the Remote start signal is removed, the Stop delay timer is initiated. Once this has expired,
the module will ramp the load from the generator to remaining set (Multi-set systems only). The
Generator Contact/Breaker will open and the Cooling timer is then initiated, allowing the engine a
cooling down period off load before shutting down. Once the Cooling timer expires, the Fuel Solenoid
is de-energised, bringing the generator to a stop.
14

-- VPOWER-- Operation Manual -For full details of multi-set operation please refer to the manual The Guide to sync and load share
Pt1
Should the Remote Start signal be re-activated during the cooling down period, the set will return on
load.

NOTE:- When synchronising is enabled, the bus is checked before closing any
load switching device. If the bus is live, synchronising will take place before any closure
takes place.
- Synchronising can be disabled if the application does not require this function.
Contact your genset supplier in the first instance for further details.
- The internal Scheduler can be configured to operate the system in the same manner
as described for the Remote start input. Please refer to the 5xxx Configuration Software
manuals for full details on the feature.

4.2.3

MANUAL C MODE OF OPERATION

Manual mode is used to allow the

operator to control the operation of the generator, and to

provide fault finding and diagnostic testing of the various operations normally performed during
Automatic mode operation.
MANUAL, mode is selected by pressing the pushbutton. An LED besides the button will illuminate to
confirm this operation. When the START (

I) button is operated, the module will initiate the start

sequence.
NOTE: - There is no Start Delay in this mode of operation.
If the pre-heat output option has been selected, this timer will be initiated and the auxiliary output
selected energised.
After the above delay, the Fuel Solenoid (or ECU output if configured) is energised, and then one
second later, the Starter Motor is engaged.

NOTE:- If the unit has been configured for CAN Bus, compatible ECUs will receive
the start command via CAN Bus. Refer to the Manual CAN and DSE Wiring. Part No. 057004 for more information on utilising DSE modules with electronically controlled
engines.
The engine is cranked for a pre-set time. If the engine fails to fire during this cranking attempt then
the starter motor is disengaged for the pre-set rest period. Should this sequence continue beyond the
set number of attempts, the start sequence will be terminated and Fail to Start will be displayed.
When the engine fires, the starter motor is disengaged and locked out at a pre-set frequency
measured from the Alternator output. Alternatively, a Magnetic Pickup mounted on the flywheel housing
can be used for speed detection (This is selected by PC using the 5xxx series configuration software).
Rising oil pressure can also be used to disconnect the starter motor; however, it cannot be used for
underspeed or overspeed detection.
After the starter motor has disengaged, the Safety On timer is activated, allowing Oil Pressure,
15

-- VPOWER-- Operation Manual -High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to
stabilise without triggering the fault.
Once the engine is running, the Warm Up timer (if selected) is initiated, allowing the engine to
stabilise before it can be loaded. Once the warm up timer has expired the generator is then
available to go on load and the Generator Available LED will illuminate on the front panel.
The generator will run off load unless:
1. A Remote Start on load signal is applied
2. An on-load run is configured in the scheduler.
3. The Close Generator button is pressed.
On a multi-set system, if the common generator bus is live, the 8610 module will first synchronise
the generator to the bus before closing the Generator Contactor/Breaker to close.
A token is held by the module that first closed onto the dead bus and as only one token exists,
this prevents other sets in the system from attempting to close their own breakers.
For added security, the modules also monitor the bus. If this is found to be live, then the
synchronisation process begins.
During the parallel run the module can be configured to either run at a fixed level output, such as
when used in parallel with an infinite bus. Alternatively, it can be configured to load share with
other generators on the bus. For full details of these mode please refer to the manual The Guide
to sync and load share Pt1

If the Open Generator button is pressed while in parallel, the module will ramp the load on the

remaining generators and then open the generator contactor/breaker.

If the Open Generator button is pressed and the generator is connected to the common generator

bus then the load is ramped off the generator and the contactor/breaker is opened.
If Auto mode is selected and the remote start on load signal not active, and the scheduler is not
calling for a run, then the Return Delay Timer will start.
Once this has expired then the module will exit parallel operation and will ramp the load back to the
remaining generators. It will then open the Generator Contactor/Breaker. The generator will then run
off load allowing the engine a cooling period.
Selecting STOP (O) de-energises the FUEL SOLENOID, bringing the generator to a stop.
WARNING: - Operation of the STOP button in any mode will stop the generator operation
and return the load switching system to a safe state. This operation may lead to loss of
supply to the load. It is recommended that the STOP button is only operated once the
generator is OFF LOAD and the mains supply provides power to the load.
- Synchronising can be disabled if the application does not require this function.
Contact your genset supplier in the first instance for further details.
- When synchronising is enabled, the bus is checked before closing any load witching
device. If the bus is live, synchronising will take place before any closure takes place.
:- Upon closing the load switching device, the module checks that the bus becomes live.
If it does not, an alarm is generated to indicate the problem.

Detail data pls refer to DSE8610AUTOSTART CONTROL MODULEOPERATING MANUAL

5.

The generator start/stop

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-- VPOWER-- Operation Manual --

5.1 Manual Start

Turn the select switch SW1 on the ON position and set the controller to MANUAL
mode(

). Then press the Start button( ),The generator will running,observed the

volt and RPM, They are normal , then press the load switch(

), The generator will

with load output.

5.2 Auto Start

Turn the select switch on the ON position anf the set the controller to AUTO
mode, Genset will start automatically when there is a main failure.

5.3 The generator stop

5.3.1 Manual stop
Press down the controller stop button. The generator will stop.

5.3.2 Auto stop

While the controller is in AUTO mode. Genset will main comes back to normal.

5.4. . The generator paralleling

5.4.1 Manual paralleling:
Turn the select switch SW1 on the ON position and set the controller to MANUAL
mode(

). Then press the Start button( ),The generator will running,observed

the volt and RPM, They are normal , then press the button (

), The controller of the

generator will automatically monitor the volt, RPM, phase angle on the MAINS, and
auto close the Gen ACB.

5.4.2 Auto paralleling:

Turn the select switch SW1 on the ON position and set the controller to Auto
mode(

).The genset will running when it received the remote starting signal.

The controller of the generator will automatically monitor the volt, RPM, phase angle
on the MAINS, and auto close the Gen ACB.

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-- VPOWER-- Operation Manual --

Chapter 3 Daily Maintenance

Preventative maintenance begines with day-to-day awareness of the condition of the
engine and its systems.Before starting the engine,check the oil and coolant
levels.Look for:
z Leaks
z Loose or damaged parts
z Worn or damaged belts
z Any change in engine appearance
1.Check the oil level daily
Never oprate the engine with the oil level below the low mark or above the high
mark.Wait at least 5 minutes after shutting off the engine to check the oil. This allows
time for the oil to drain to the oil pan.
2.Check the coolant level daily
Do not and cold coolant to a hot engine. Engine castings can be damaged. Allow the
engine to cool to below 50(120) before adding coolant
3.Air cleaner(filter) checking daily
Clean and check the air cleaner daily or more often.
4.Check the engine monitor system
Check the engine monitor system daily or more often..
5. Recommended lubricant grade and glue the degree
Environment Temp
Above 0
Above -23

Recommended lubricant oil grade and glue the degree

FRESH AIR
COMPRESS AIR
20W/50 or 10W/40
20W/50 or 10W/40
10W/50 or 10W/40
10W/50 or 10W/40
CC/SE, CC/SF
CD/SE, CD/SF
CD/SE, CD/SF
CE/SF, CE/SG
CE/SF, CE/SG
SHPD

6. Detailed the maintenance procedures too much, please refer to ENGINE &
ALTERNATOR Operation and maintenance Manual.

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-- VPOWER-- Operation Manual --

Chapter 4 Maintenance plan

1FUEL FILTER

PRIME GENSET: Every 250~1000 hours replaced the fuel filter

STAND BY GENSET: Half a year replaced the fuel filter ---TYPE: FS1006
QUANTITY`: 2entries
2OIL FILTER

PRIME GENSET: Every 250~1000 hours replaced the oil filter

STAND BY GENSET: Half a year replaced the oil filter---TYPE : LF3325QUQNTITY :

5entries
3WATER FILTER

PRIME GENSET: Every 250 hours replaced the water filterSTAND

BY GENSET: Half a year replaced the oil filter---TYPE : WF2076QUANTITY :

2entries
4BY PASS OIL FILTER

PRIME GENSET: Every 250 hours replaced the by pass oil

filterSTAND BY GENSET: Half a year replaced the by pass oil filter---TYPE : LF777
QUANTITY : 2entries
5AIR FILTER

PRIME GENSET: Every 400 hours replaced the air filterSTAND BY

GENSET: one year replaced the air filter, Also according to the filter indicator to replaced.
---TYPE : AH1135QUANTITY : 2entries
6MIXING TANK WATER

Check water level day to dayHalf a year replaced the

coolant water
7REMOTE TANK WATER

Check water level day to dayHalf a year replaced the

coolant water
8DAILY OIL TANK Check the oil level daily, added fuel oil in time.
9LUBRICATION OIL Replacement of half a year.
10THE GENERATOR SET IN A SMALL MAINTENANCEPlease refer to Engine
Opration and Maintenance Manual.
11THE GENERATOR SET IN A HEAVY MAINTENANCEPlease refer to Engine
Opration and Maintenance Manual.

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-- VPOWER-- Operation Manual --

Chapter 5

Troubleshooting

Fllow the suggestions below for troubleshooting:

z Study the problem thoroughly.
z Refer to the engine system diagrams.
z Do the easiest and most logical things first.
z Find and correct the cause of the problem.
Troubleshooting table
FAILURE
Engine cant
start

CAUSE
Battery voltage too low or bad;

CORRECTIONS
Charge or replace;

Battery connection broken, loose or corroded

Controler fuse bad;
Emergency button have no reset
Failure to shut off;
Engine switch in OFF position
Engine will not Fuel pump manual override open;
shut off
Fuel pump shut-off valve disc stuck;

Check battery connections;

Replace the fuse;
Check and reset;
Check,removed the failure and reset;
Select switch to START position.
Check to make sure manual override
screw is out to maximum travel;
Check opening and closing of
electrics;
Fuel tankvents plugged;
Remove,clean,or replace vents;
Fuel drain lin restricted;
Check fuel drain line for loops,
crimps, or clamped points;
Engine running on fumes drawn into air Locate and isolate the source of
intake.
fumes.
No AC export Over current switch placed in OFF Select to ON position;
position;
Engine failure
Contact the service.
Engine
will Oil pressure too low to shut down;
shut down
Engine temp too high to shut down;
Coolant level too low to shut down;

Check the lubrication level;

Check the air cleaner and fan belts
Check the coolant level.

Engine hard to Engine cranking speed low;

Check engine cranking RPM;
start or will not Engine driven units engaged;
Disengage engine driven units;
start
Cold start aid needed or not working Install cold start aid. Check, repair, or
correctly;
replace if necessary.
Fuel filter plugged;
Replace fuel filter;
Air in the fuel system
Check for air in fuel, tighten fuel
connections and and filter, check fuel
tank stand pipe;
Fuel suction line restricted;
Check fuel line for restrictions;

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-- VPOWER-- Operation Manual --

Intake air system restricted;

Check intake air system for

restrictions;
Verify by operating engine from a
temporary supply tank;

Fuel contaminated

Detailed the maintenance procedures too much, please refer to Engine & Alternator
Operation and maintenance Manual.

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-- VPOWER-- Operation Manual --

Chapter 6

Connection Documents of after-service

VPOWER Engineering (Guang Zhou) Ltd.

Room 2107, 21/F, Newpoly Tower, No.2 ZhongShan 6 road,Yuexiu District, GuangZhou,
China.
Post510180
Tel208326 6748
Fax208326 6948

VPOWER Engineering (ShenZhen) Ltd.

Building B7,North Yan Chuan Industrial Park,Songgang Town,Bao
An,Shenzhen,Guangdong Province,PR China.
Post518105
Tel7552706 4703-4
Fax7552706 5135

VPOWER Holdings Ltd.

Unit 3801B, Level 38, Tower 2, Metroplaza, No. 223 Hing Fong Road, Kwai Chung,Hong Kong.

Tel08522687 6517
Fax08522687 6854
E-mail : sales@vpowerhk.com

Design
Manufacture
Service
Generator Set Manufacturer
Parallel Panel Manufacturer
Power Quality & Saving System
Power Monitoring System
Environmental Management
Filtering Equipment & System
Genuine Engine Parts
Engine Overhaul Services

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