Daewoo DDAE10500DSE-3G Diesel Generator User's Manual

Index

• 1. Main Technical Specifications and Data
• 2. Use for the Generator Set
• 3. Maintenance of the Generator Set
• 4. Maintenance and Remedy of the Generator Set
• 5. Appendixes
• Warranty

1. Main Technical Specifications and Data

2. Use for the Generator Set

2.1 Use Essentials and Cautions

To ensure safe operation of the generator set, read and understand this operation manual. Pay close attention to the main points listed below to avoid personal accidents and equipment damage.

2.1.1 Fire prevention

The combustion oil used is light diesel oil. Do not use gasoline, kerosene, or other oils. Use a clean cloth to wipe off any overflowed oil. Keep flammable and explosive materials (gasoline, kerosene, matches) away from the set, as the area around the exhaust noise suppressor becomes very hot when the diesel engine is running.

For fire prevention and sufficient ventilation, maintain at least 1.5m distance between the set and buildings or other equipment during operation. Operate the welder and generator set on a smooth floor; if the set is tilted, oil may overflow.

2.1.2 Prevent the suction of exhausted gas

Do not use the welder and generator set in poorly ventilated areas. If operating indoors is necessary, ensure adequate ventilation to protect personnel and livestock from carbon monoxide poisoning.

2.1.3 Prevent the burn

When the diesel engine is running and hot, do not touch the noise suppressor or its housing.

2.1.4 Electric shock and short-circuit

To avoid electric shock or short-circuits, do not contact the welder and generator set if it is wet or if your hands are wet. The set is not waterproof and should not be used in rain, snow, or mist. To prevent electric shock, the generator set must be grounded. Connect the grounding terminal to an external grounding device using a conductor. Do not connect other equipment to the welder and generator set.

2.1.5 Other safety main points

Operators should be familiar with all switches for quick braking. Only individuals who have received correct guidance should operate the set. Operators should wear safety shoes and suitable clothing. Keep children and livestock away from the welder and generator set.

2.1.6 Charge the battery

The battery electrolyte contains sulfuric acid. Protect your eyes, skin, and clothes. If contact occurs, wash immediately with water. If eyes are affected, seek medical attention. Hydrogen produced during charging is explosive; do not smoke near the battery and prevent sparks. Charge the battery in a well-ventilated area.

2.2 Preparation before the Start

2.2.1 Select and treat with the combustion oil

Use only light diesel oil. Filter the combustion oil cleanly. Ensure no dust or water mixes into the combustion oil or oil tank, as this can block the high-pressure pump and oil nozzle.

ATTENTION: Overflowing oil is very dangerous. Filling the oil into the oil tank should not exceed the top of the red cock inside the filler. Do not smoke when filling or storing diesel oil. Prevent sparks in this area. Do not overflow the oil during filling. Secure the cover nut on the oil inlet after filling.

2.2.2 Filling the Machinery Oil

Place the generator set on a level surface. Fill the oil into the oil-filling inlet. When checking the oil level, lightly insert the oil ruler without rotating it.

A.P.I. Diesel engine maintenance classification: Lubrication oil should be CC or CD grade.

The quality of lubrication oil significantly affects engine performance and reliability. Using poor quality oil or not changing it as stipulated can lead to piston blockage and accelerated wear of cylinder, bearings, and moving components, reducing engine life.

The set has a low oil pressure alarm/stop device. Check oil quantity before starting; add oil if insufficient. Discharge machinery oil while the engine is hot, as it is difficult to drain cleanly when cool.

WARNING: Do not fill machinery oil into the diesel engine while it is running.

2.2.3 Check the air filter

Unfasten the butterfly nut, remove the filter cover, and take out the filter core. Do not wash the filter core with detergents. Replace the filter core if output is reduced or exhaust gas color is poor. Never start the generator set without the air filter core, as this will cause rapid engine wear. Reattach the filter core and fasten the butterfly nut.

2.2.4 Inspection for the generator set

Before starting, ensure the air switch is in the "OFF" position. Starting the diesel engine with the switch not in "OFF" state while under load is dangerous.

Ground the generator to prevent electric shock. Use dry compressed air (pressure < 1.96×10⁵Pa) or manual methods to blow dust from the control box. Check slide rings, carbon brush pressure, and their position for correct fitting. Ensure fixings are reliable and contacts are good. Verify wiring lines and connection joints are firm according to the electric wiring diagram.

2.2.5 Before delivering the diesel engine from the factory, the fuel oil and the machinery oil had been discharged.

Before filling fuel oil and starting the engine, check for air in the oil circuit. If present, discharge it by unfastening the connecting nut between the oil injection pump and the oil transmission pipe until no air bubbles appear, then retighten the nut.

2.3 Inspection and Operation of the Diesel Engine

2.3.1 Low oil pressure alarm system/ breaking device

The diesel engine is equipped with a low oil pressure alarm/breaking device. If oil pressure drops, the device automatically stops the engine to prevent damage from insufficient lubrication. If the engine runs with insufficient oil, the oil temperature can rise excessively. Conversely, too much oil can cause the machinery oil to burn, leading to sudden speed increases and "abnormal fast running." Ensure the machinery oil level is at the stipulated height.

2.3.2 Trial run operation

For a new engine set, avoid heavy loads during the first 20 hours of operation to preserve engine life. Operate at no more than 75% of the rated load. Change the engine oil as stipulated: initially every 20 hours or monthly, then every 3 months or 100 hours.

2.4 Starting the Generator Set

2.4.1 Recoil start (manual start)

Follow these steps to start the engine:

1. Switch on the fuel oil switch to "ON".
2. Set the engine speed handle to "run" position.
3. Draw out the buffer start handle until resistance is felt. Release it to its initial position. Press down the pressure reduction handle (it will restore automatically when the buffer starter is drawn).
4. Quickly pull the buffer start handle with both hands. Do not let the handle fly out of your hand after starting, as it could strike the diesel engine. Slowly and lightly return the handle to its position to avoid starter damage.

CAUTION: Never pull the start handle while the diesel engine is running, as this will damage the engine.

In cold weather, if the engine is difficult to start, unplug the rubber cock on the rocker arm and add 2ml of machinery oil. Plug the rubber cock before starting. Ensure the rubber cock is plugged except when adding oil, to prevent dirt entry that can cause rapid wear.

2.4.2 Electric start

1. Preparation is the same as for hand start.
2. Insert the electric door key and set it to "OFF".
3. Set the diesel engine speed handle to "RUN".
4. Turn the start switch clockwise to "START".
5. Once the engine starts, release the switch handle; it will automatically return to "ON".

If the engine does not start after 10 seconds, wait 15 seconds and try again.

CAUTION: Prolonged rotation of the start motor can drain the battery, causing start motor hysteresis. When the diesel engine is operating, always leave the start key in the "ON" position.

2. Battery

Check the electrolyte level monthly. Add distilled water if the level drops to the lower mark. If the electrolyte is too low, the engine may not start due to insufficient electric power. Keep the liquid level between the higher and lower limits. If the electrolyte is too high, it may overflow and corrode surrounding components. Charge the battery monthly.

2.5. Operation Procedure for Starting the Generator Set

This procedure is for the recoil hand-drawing start mode:

1. Open the fuel cock.
2. Set the engine speed lever to "RUN" position.
3. Hold the starting handle until resistance is felt.
4. Pull the starting handle slowly, then return it slowly.
5. If the engine does not start, repeat from step 3.
6. Push the decompression lever down and release.
7. Pull the rope hard and fast. Pull it all the way out. Use two hands if necessary.
8. Hold the starting handle firmly.

Diagram Description: An illustration shows a sequence of steps for starting the generator using a recoil starter. It depicts opening the fuel cock, setting the speed lever, feeling resistance on the pull cord, pulling the cord, and the engine starting.

3. Maintenance of the Generator Set

3.1 Regular Maintenance

Regular inspection and maintenance are crucial for keeping the welder and generator set in good condition. The set comprises the diesel engine, welder generator, control cabinet, frame, and other components. Refer to the operation and maintenance manual for each assembly section for detailed information.

Before performing maintenance, turn off the diesel engine. If the engine must run, ensure good ventilation to discharge potentially poisonous carbon monoxide gas. After use, wipe off dirt with a clean cloth to prevent corrosion and remove sink materials.

The chart indicates checks to perform and when. A mark (●) signifies that special tools and skills are required; consult your dealer.

3.1.1 Changing engine oil (every 100Hrs)

Remove the oil filler cap. Drain the old oil while the engine is warm. The drain plug is at the bottom of the cylinder block. Tighten the drain plug and refill with recommended oil.

3.1.2 Cleaning the oil filter

3.1.3 Changing the air cleaner element

This is a wet-type element; do not wash it with detergents. Change the element every 6 months or 500 hours (or sooner if dirty).

CAUTION: Never start the engine without the element or with a defective element. Change the element promptly.

3.1.4 Cleaning and replacing the fuel filter

The fuel filter must be cleaned regularly for maximum engine output.

Drain fuel from the fuel tank. Loosen the fuel cock screws, pull out the filter, and wash it thoroughly with diesel fuel. Remove the lock nut, end cap, and diffuser discs to clean carbon deposits. Cleaning time: Every 3 months or 100 hours.

3.1.5 Tightening cylinder head bolts

This requires a special tool; do not attempt it yourself. Refer to the diesel engine manual.

3.1.6 Checking the injection nozzle, injection pump, etc.

Includes adjusting valve clearance for intake and exhaust valves, lapping intake and exhaust valves, and replacing piston rings. These tasks require special tools and skills. Do not perform injection nozzle tests near open flames, as fuel spray can ignite. Avoid exposing bare skin to fuel spray, as it can penetrate skin and cause injury.

3.1.7 Checking and replenishing battery fluid and charging the battery

This diesel engine uses a 12V battery. Battery fluid is lost during charging/discharging. Check for physical damage and electrolyte level before starting. Replenish with distilled water up to the upper mark if necessary. Replace the battery if actual damage is discovered.

Battery fluid check: monthly.

3.2 Maintenance for a long time storage

For long-term storage, follow these preparations:

• Operate the diesel engine for about 3 minutes, then stop it.
• While the engine is still hot, drain the old lubricating oil and refill with new oil.
• Pull out the rubber plug on the engine cover, add 2ml of lubricant into the cylinder, and replace the plug.
• Maintenance of starting position:
  • Manual starting: Press the pressure-reduce handle (non-compression position) and pull the recoil handle 2-3 times (do not start the engine).
  • Electric starting: With the starting handle in the non-compression position, operate the engine for 2-3 seconds. Do not start the engine when the switch is in the start position.
• Pull the pressure-reduce handle out, then slowly pull the recoil starter. When it is fully engaged, stop. This positions the intake and drain valves closed, preventing rust.
• Clean the unit and store it in a dry place.

4. Maintenance and Remedy of Generator Set

If electricity is still not generated, take the generator to a dealer.

5. Appendixes

This section contains wiring diagrams for various generator models, including HDY3000L, HDY4200L, HDY6500L, and HDY6500LXT. These diagrams illustrate the internal electrical connections of the generator and its control box.

Diagram Description (HDY3000L/HDY4200L/HDY6500L): The diagram shows the Generator and Control Box components. Key elements include Field Winding, Stator Winding, Capacity Winding, Charge Winding, AC Switch, Volt Meter, AC Socket, Rectifier, Capacitor, Fuse, Low Oil Pressure Switch, and Ground Terminal. Connections between these components are indicated by lines and labels (e.g., U1 red, U2 black, Z1 yellow, Z2 yellow, brown, blue, black, red).

Diagram Description (HDY6500LXT): This diagram also details the Generator and Control Box. It includes components like rotor excitation winding, main winding, DC winding, rectifier, AC switch, voltmeter, AC socket, battery, start motor, stop electric magnet, and low oil pressure protector. Various colored wires (green, red, black, yellow, blue, brown, white) connect these parts.

EC Declaration of Conformity

DIESEL GENERATOR

Model: DDAE10500DSE-3G

Brand: DAEWOO

We GBR Corp. LTD, Room 1002, 10/F., David House, 8-20 Nanking Street, Jordan, Kowloon, Hong Kong, China, declare under our sole responsibility that this product is in conformity and accordance with the following standards and regulations.

The undersigned is responsible for the compilation of technical documentation.

Satisfies the requirement of the Council Directives:

• Machinery Directive 2006/42/EC
• Low Voltage Directive 2014/35/EU
• Essential health and safety requirements of the Directive 2006/42/EC
• Compliance with EN 60204-1:2018 gives compliance with the Low Voltage Directive 2014/35/EU

And conforms to the norms:

• GB/T 19001-2016/ISO9001:2015

Signature and Stamp on undersigned responsible.

Date: January 2022

Warranty Card

Please fill in the following details:

The product is in good conditions and fully complete. Read and agree the terms of the warranty.

GUARANTEE

The warranty period starts from the date of sale and covers 2 years for all power products. During the warranty period, free repairs are provided for failures caused by poor-quality materials or manufacturing defects. The guarantee is valid only when the warranty card and cutting coupons are properly filled. The product must be submitted for repair in its original form and complete.

WARRANTY DOES NOT COVER

• Mechanical damage (cracks, chips, etc.), damage from aggressive media, foreign objects, or improper storage (corrosion).
• Failures caused by overloading, product misuse, or use for unintended purposes. Signs of overload include melting/discoloration of parts, simultaneous failure of multiple components, or piston ring destruction. Failure of the automatic voltage regulator due to incorrect operation is also excluded.
• Failures caused by clogging of fuel and cooling systems.
• Wear parts such as carbon brushes, belts, rubber seals, oil seals, shock absorbers, springs, clutches, spark plugs, mufflers, nozzles, pulleys, guide rollers, cables, recoil starter, chucks, collets, removable batteries, filters, safety elements, grease, removable devices, equipment, knives, drills, etc.
• Electrical cables with mechanical or thermal damage.
• Product opened or repaired by an unauthorized service center.
• Preventive maintenance, care products (cleaning, washing, lubrication), installation, and configuration.
• Natural wear and tear (production share).
• Failures caused by using the product for business activities.
• Missing or incomplete warranty card, or missing seller's seal/stamp.
• Absence of the holder's signature on the warranty card.