OWNER’S MANUAL DY8500 GENERATOR AIR-COOLED DIESEL ENGINE GENERATOR 1- 8 8 8 - 5 57- 5 2 4 4 s a l e s @ b o s s fo r k l i f t s . c o m w w w . b o s s f o1 r k l i f t s .
TABLE OF CONTENTS: Chapter 1: Overview Technical Specifications & Data.......................... 3 Chapter 2: Operating The Diesel Generator 2-1 General Main Points of Safety During Operation........................................................................... 4 2-1.1 Fire Prevention................................................ 4 2-1.2 Exhaust Gases................................................ 4 2-1.3 Accidental Burns........................................... 4 2-1.
CHAPTER 1: OVERVIEW TECHNICAL SPECIFICATIONS & DATA (in SI Units) Diesel Engine Generator ITEM/MODEL DG8500LN Excitation Self-excitation voltage Voltage System Condenser Compensation System Frequency (Hz) 60 Rated power (kW) 6.3 AC Rated Voltage (V) 110, 220, 230, 240, 110/220, 120/240, 220/380, 230/400 DC Rated Output (V-A) 12-8.3 Speed (rpm) 3000/3600 Engine Model 190F Type Single-cylinder, vertical, 4-stroke, air-cooled, direct-injection Output Continuous (kW) 7.6/8.
CHAPTER 2: OPERATING THE DIESEL GENERATOR 2-1 General main points of safety during operation of the generator set. In order to operate the generator set safely, please follow all the instructions provided in this manual carefully. Failing to do so may lead to accidents and or equipment damage. 2-1.1 Fire Preventions The proper fuel for the diesel generator set is light diesel fuel. Do no use gasoline, kerosene and or other fuels other than light diesel fuel.
NOTE: When connecting devices to the generator, make sure all other devices are rated lower than the generators output. Any generator socket should not be overloaded over its regulated limit. 2-1.5 Other Safety Points Before operating this generator, all operators should have a good knowledge of how to break the circuit if any accidents occur. Also, all operators should be familiar with all the switches and functions of the generator before using this machine.
2-2 Preparation Before Operation 2-2.1 Fuel Choices and Fuel Treatment Air Filter Element Fuel Tank Do not wash the air filter. The element Use only light diesel fuel. The fuel should be is made of dry material, which does not clean. Never let dust and water mix with fuel permit washing. When the output of the in the fuel tank. Otherwise it will clog the fuel diesel engine is bad or the color of the lines and oil nozzles.
2-2.2 Fill Engine Oil Fabrication Oil Filling Inlet Put the generator set in a level state. Fill the oil into the oil-filling inlet. At the time of checking the oil level, it is necessary only to lightly insert the oil ruler. Please pay attention that you should not rotate the oil ruler. Top Limit (H) Low Limit (H) Volume Type Volume (L) English Gallon 186FG 1.65 (0.36) A.P.I. Diesel engine maintenance classification. The lubricating oil should be CC or CD Grade.
2-2.3 Check Air Filter 2-2.4 Checking the Generator (1) Loosen the butterfly nut, take the cover of Before starting the generator, make sure the the air filter off and take the air filter out. air switch is in the “off” position. Starting the generator with the switch in the “on” position is very dangerous. The generator should be grounded in order to prevent electric shock. Use dry compressed air (with pressure about BUTTERFLY NUT 1.
2-3 2-3.1 Checking the Operation (3) Check the outer cover of the oil of the Diesel Engine nozzle. Loosen the butterfly nut and Low-pressure alarm system. open the outer cover. The diesel engines have a lowpressure sensor system where if the oil pressure drops too low, the sensor RUBBER will shut the engine off. The purpose COCK of having this system is to ensure that the engine does not seize up. If there is not enough oil in the engine, the temperature of the oil will be raised too high.
2-4 Starting the Generator 2-4.1 Manual Starting The procedure for preparing to start Start the engine in accordance with the engine are the same as the procedure below: manual starting engine. 2-4.2 Electric Starting (1) Put the fuel switch in the “ON” position. 2-4.3 Battery 1. Insert key into ignition and place in FUEL SWITCH the “off” position. 2. Put the speed handle in the “Run” position. 3.
NOTE: If you crank the starter too long, the battery may be drained too much to provide enough energy for proper engine ignition. Also, when the diesel engine is operating, let the key remain in the “ON” position. Check the level of the water in the battery once a month. If the level of the liquid drops too low, fill it with distilled water until it reaches the high mark. If there is not enough distilled water, then the diesel engine cannot be started.
2-5 2-5.1 Proper Operation 2-6 Loading of the Generator Set 2-6.1 Load Conditions Operating the Diesel Engine Exert loads in accordance with the Pre-heat the diesel engine for 3 specified parameters. minutes under no load conditions. First check the height of the 2-6.2 Output of Electricity lubricating oil level, if it is low, refill it. 1.
various devices are too high. In this 5. When charging the battery, the event, decrease the number of small battery produces flammable gases. devices until everything is functional. Do not smoke, flames, and sparks The total drawn power should not get near the battery while it is exceed the maximum output power charging as this may cause a fire. To of the generator.
4. Press down on the brake handle. 7. Finally, pull slowly on the recoil 5. If equipped with an electric starter, handle until you feel resistance turn the key to the “OFF” position. (this is when the piston is on the 6. Put the fuel handle to the “S” compression stroke, where the intake position. and exhaust valves are closed). What this does is prevent the engine from rusting when not in use.
CHAPTER 3: MAINTENANCE 3-1 Maintenance Schedules Keeping your generator well maintained will prolong the life of your generator. Everything needs to be checked including the diesel engine, welder, generator, control cabinet and frame. For overhauling procedures, please refer to the instruction manual of the relative subassembly. If you need these manuals, please call our company and we will send you one. Before starting the maintenance, make sure the diesel engine is off.
3-1.1 Changing the Engine Oil 3-1.4 Fuel Filter Maintenance (every 100 hours) 1. The fuel filter should be cleaned Take the oil cover out. Take off the oil often to keep the engine running at drain plug when the diesel engine is maximum performance. still hot. Be careful of hot oil and hot 2. The recommended time period for engine as you may bet burned. The cleaning the fuel filter is 6 months or bolt is located at the bottom of the 500 hours of operation. cylinder.
3-2 Storing for Long Periods of Time If your generator needs to be stored for long periods of time, the following preparations should be made: 1. Start the diesel engine for 3 minutes then stop it. 2. When the engine is still hot, change the engine oil with the new engine oil of the proper grade. 3. Pull the rubber plug out of the cylinder head cover and put 2CC of lubricating oil in it, then cover the plughole up again. 4.
CHAPTER 4: OVERHAULING AND TROUBLESHOOTING 4-1 Overhauling & Troubleshooting Procedures Generator won’t generate electricity and has no welding voltage Diesel engine won’t start Causes of Malfunction Remedy Not enough fuel. Add fuel. The switch of fuel is not at “OPEN” position. Turn the switch of fuel to “OPEN” position. High pressure pump and nozzle do not inject fuel or the injected amount is less. Disassemble the nozzle and adjust it at test table.
CHAPTER 5: PART LISTINGS Overall view of engine generator assembly Number Part Description Quantity Part Number 1 Series Diesel Engine 1 4LN1/6LN1 2 Starter Motor 1 4LN2/6LN2 3 Flywheel Generator 1 4LN3/6LN3 4 Bolt 2 4LN4/6LN4 5 Voltage Regulator 1 4LN5/6LN5 6 Battery Cable (red, black) 2 4LN6/6LN6 7 Battery 1 4LN8/6LN7 8 Oil Level Sensor 1 4Ln9/6LN8 9 Generator 1 4LN9/6LN9 10 Output Panel Assembly 1 4LN10/6LN10 11 Throttle Cable 2 4LN11/6LN11 12 Connector
Exploded view of frame assembly Number Part Description Quantity Part Number 1 Muffler Cover Plate 1 4LN17/6LN17 2 Muffler Elbow 1 4LN18/6LN18 3 Left Outer Cover 1 4LN19/6LN19 4 Fuel Gauge 1 4LN21/6LN21 5 Fuel Tank Sleeve 1 4LN22/6LN22 6 Main Cover 1 4LN23/6LN23 7 Door Knob 1 4LN24/6LN24 8 Right Outer Cover 1 4LN27/6LN27 9 Output Panel Assembly 1 4LN28/6LN28 10 Air Cleaner Cover 1 4LN29/6LN29 11 Lower Chassis 1 4LN30/6LN30 12 Engine Tray Mounts 4 4LN31/6LN
Electric panel parts drawing Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Part Description Positive DC Port Negative DC Port Grounded Bolt Bolt Large Nut Bolt Bolt Large Nut Current Adjusting Switch 3 Prong Socket Bolt Electric Panel Bolt Electric Panel Starter Switch Large Nut Oil Alert Lamp Hour Meter Hour Meter Bolts DC Fuse Voltmeter Nut 4 Prong Socket Breaker Bracket Nut Breaker Wiring Harness Electrical Box 21 Quantity 1 1 1 2 1 2 2 1 1 6 6 1 1 6 1 1 2 1 1 1 2 1 1
Generator Head Assembly Number Part Description Quantity Part Number 1 Front End Cover 1 4LN64/6LN64 2 Diode 2 4LN65/6LN65 3 M4 x 8 Bolt 2 4LN66/6LN66 4 Fan Blade 1 4LN67/6LN67 5 Bearing 1 4LN68/6LN68 6 Rotor Unit 1 4LN69/6LN69 7 Center Bolt 1 4LN70/6LN70 8 Motor Cover 1 4LN71/6LN71 9 Stator 1 4LN72/6LN72 10 Long Bolt 4 4LN73/6LN73 11 Capacitor 1 4LN74/6LN74 12 Wiring Seat 1 4LN75/6LN75 13 M5 x 15 Bolt 6 4LN76/6LN76 14 Stator Unit 1 4LN77/6LN77 15
Fuel System Components Number Part Description Quantity Part Number 1 Fuel Cap 1 4LN79/6LN79 2 Seal 1 4LN80/6LN80 3 Filtering Cup 1 4LN81/6LN81 4 M5 x 10 Screw 2 4LN82/6LN82 5 Fuel Lever Indicator 1 4LN83/6LN83 6 M6 x 25 Bolt 4 4LN84/6LN84 7 Large Flat Washer 6 4 4LN85/6LN85 8 Fuel Tank Lining 4 4LN86/6LN86 9 Shock Absorbing Gasket 4 4LN87/6LN87 10 Fuel Tank 1 4LN88/6LN88 11 M6 Nut 4 4LN89/6LN89 12 O Ring Seal 1 4LN90/6LN90 13 Fuel Tank Filter 1 4LN91/
