Könner & Söhnen Diesel Generator

Introduction

Thank you for purchasing a Könner & Söhnen HEAVY DUTY series diesel generator. This professional machinery is designed for heavy-duty operation with an extended service life, potentially exceeding 3,000 operating hours with proper adherence to operation and maintenance schedules. This manual provides essential safety recommendations, operation, and maintenance instructions. The manufacturer reserves the right to make alterations without prior notice. For the latest information and service center locations, visit www.ks-power.de/en.

Safety Information

⚠️ Failure to follow recommendations marked with this sign may lead to serious injury or death.

Working Area Safety

• Do not operate near flammable gases, liquids, or dust, as the hot exhaust system can cause fire or explosion.
• Maintain a clean and well-lit work area to prevent injuries.
• Keep unauthorized persons, children, and animals away from the operating area. Consider fencing the area if necessary.

Electrical Safety

• The generator produces electricity, posing an electric shock risk if safety regulations are neglected.
• Do not operate in high humidity conditions; keep the generator in a dry place.
• Avoid direct contact with grounded surfaces like pipes or radiators.
• Immediately replace damaged power cables, as they increase the risk of electric shock.
• All connections to the network must be made by a certified electrician according to electrical rules and regulations.
• Connect the generator to protective ground before operation.
• Do not connect or disconnect the generator to consumers located in water or on wet/damp soil.
• Do not touch parts of the generator under voltage.
• Connect only to consumers that match the generator's electrical characteristics and rated power.
• Store all electrical equipment dry and clean. Replace wires with damaged insulation and worn/damaged contacts.

Personal Safety

• Do not operate if tired, under the influence of drugs or alcohol, as inattention can cause serious injury.
• Prevent inadvertent starts by ensuring the switch is OFF when not in use.
• Ensure no foreign objects are on the generator when it is turned on.
• Maintain a stable position and balance when starting.
• Do not overload the generator; use it only for its intended purpose.
• Ensure adequate ventilation to avoid inhaling exhaust gas (CO₂), which contains poisonous carbon monoxide.

Precautions When Working with Diesel Generators

• Before operation checks, ensure the generator is on a flat surface with the engine switch OFF.
• Check all moving parts for damage; remove damaged parts before use.
• Use only recommended oils and fuels for repair and maintenance. Using other lubricants or parts voids the warranty.
• Servicing should only be performed by qualified personnel. Find service centers at www.ks-power.de/en.
• Keep the generator dry and well-ventilated when not in use.

⚠️ The generator runs on automotive diesel fuel conforming to Euro V emission standards. Do not use gasoline, kerosene, or fuel oil. Ensure the diesel fuel type corresponds to the operating season.

Using low-grade fuel can degrade specifications or cause engine failure. Do not add chemical additives to diesel fuel or mix it with used engine oil or fuel oil. Keep the fuel tank and refueling accessories clean. Sulfur content in fuel should not exceed 0.5% (0.05% recommended). Sediment and water content should not exceed 0.05%. A cetane number of at least 45 is required. Biodiesel (e.g., B5) is permitted if it contains no more than 5% FAME. More details are available at ks-power.de/betriebsantleitungen.

⚠️ To prevent electric shock and damage, do not simultaneously switch on three-phase and single-phase circuit breakers.

Safety Symbols

General Operation Symbols:

• Symbol 1: ⚠️ General safety warning – observe manual instructions.
• Symbol 2: ? Exhaust gas hazard (CO₂) – operate only in well-ventilated areas.
• Symbol 3: ? Avoid high humidity environments.
• Symbol 4: ? Do not smoke while operating.
• Symbol 5: ⚡ Electric shock hazard – observe safety precautions.
• Symbol 6: ? Read the owner's manual carefully.
• Symbol 7: ✋ Do not touch with wet or dirty hands.
• Symbol 8: ? Observe fire safety regulations; do not operate near open flames.

Battery Handling Symbols:

• Symbol 1: ? Wear protective rubber gloves when handling the battery due to dangerous acid electrolyte. Rinse immediately with water and seek medical advice if contact occurs.
• Symbol 2: ? Avoid open flames near the generator.
• Symbol 3: ?‍?‍?‍? Keep children away from the generator work area.
• Symbol 4: ? Battery releases explosive hydrogen while charging.
• Symbol 5: ? Read the owner's manual carefully before operating.
• Symbol 6: ? Wear safety goggles when operating the battery.

Main Overview

The generator features the following main components:

• 1. Reinforced steel frame: Provides structural integrity.
• 2. Fuel tank cap: For filling the fuel tank.
• 3. Air filter: Filters air entering the engine.
• 4. Antivibration supports: Reduce vibration during operation.
• 5. Fuel pump: Supplies fuel to the engine.
• 6. Oil dipstick: For checking and filling engine oil.
• 7. Oil drain hole: For draining engine oil.
• 8. Emergency switch engine: For immediate shutdown in emergencies.
• 9. Maintenance panel: Houses controls and indicators.
• 10. Soundproof housing: Reduces noise levels (on specific models).
• 11. Wheels: For portability.

Scope of Supply typically includes: Generator, Packaging, Owner's manual, and Accessories.

Accessories may include:

• Portable plug 230V, 16A (2P+PE)
• Portable plug 230V, 32A (2P+E)
• Portable plug 400V, 16A (3P+E+N)
• Start key
• Open end wrenches (8x10 mm, 12x14 mm, 17x19 mm)
• Screwdriver (6.0 mm, PH2)

The manufacturer reserves the right to make design changes without notice.

Models Description

Specifications for various Könner & Söhnen diesel generator models:

KS 6100HDE / KS 6102HDE

KS 8100HDE-1/3 ATSR / KS 8102HDE-1/3 ATSR

KS 8200HDES-1/3 ATSR / KS 9200HDES ATSR / KS 9202HDES ATSR

KS 9300DE ATSR Super S / KS 9302DE ATSR Super S

*Fuel consumption depends on load, fuel quality, season, altitude, and technical condition.

LwA: Sound power level. LpA: Sound pressure level at 7m.

Optimum operating conditions: 17°C–25°C ambient temperature, 0.1 MPa barometric pressure, 50–60% relative humidity. Continuous loads should not exceed 80% of rated power.

Terms of Use

It is recommended to ground the generator before operation. Ensure the total power of connected consumers does not exceed the generator's rated capacity.

Types of Consumers and Inrush Current: Consumers are divided into active (heat-generating) and reactive (motor-driven). Reactive consumers, especially those with electric motors (compressors, pumps, washing machines), can have brief starting currents 2-3 times higher than their running power. Consider these inrush currents when selecting a generator.

⚠️ To prevent electric shock and damage, do not simultaneously switch on three-phase and single-phase circuit breakers.

Before Starting

Generators are supplied without fuel and motor oil. Residues may be present from factory testing.

Check the Fuel Level

1. Remove the fuel tank cap and check the fuel level.
2. Fill fuel to the level of the fuel filter, ensuring no air is in the fuel system.
3. Tighten the fuel tank cap securely.

Check the Oil Level

1. Unscrew and clean the oil level gauge.
2. Reinsert the gauge without screwing it in.
3. Remove the gauge again and check the oil level against the mark.
4. Add oil if the level is below the mark.
5. Screw the oil gauge back in.

For electric start models, charge the battery before commissioning. Use an external charger or run the generator for at least one hour at 50% load for the first start.

Diesel fuel type must correspond to the operating season.

Control Panel

The maintenance panel includes:

• 1. LED-display: Shows Voltage (V), Frequency (Hz), current time since last start (T1), and total time since commissioning (T2).
• 2. Engine start: Button or key for starting the engine.
• 3. VTS system switch: For selecting single-phase (230V) or three-phase (400V) operation.
• 4. Circuit breaker: Protects against overcurrent.
• 5. Oil level indicator: Shows engine oil level.
• 6. Grounding terminal: For connecting to earth ground.
• 7. Fuel heater: Aids starting in cold conditions.
• 8. Output for ATS: Connection for Automatic Transfer Switch (on specific models).
• 9. 12V DC fuse: Protects the 12V DC circuit.
• 10. 12V DC outlet: For 12V DC appliances.
• 11. Sockets: For AC power output (e.g., 230V, 400V).

Starting to Work

Ensure the total power of connected consumers does not exceed the generator's nominal power. Do not connect devices before starting the engine.

⚠️ Modifications to fuel or speed controllers can cause engine damage and void the warranty.

⚠️ Do not run the generator at nominal to maximum load for more than 30 minutes continuously.

Professional installation by a certified electrician is recommended for connecting equipment to the power supply. The manufacturer is not liable for damage resulting from incorrect installation or operation.

First 20 Operating Hours Requirements

• Limit connected loads to 50% of nominal power.
• Change the oil after the first 20 hours, preferably while the engine is hot.
• Check and clean the air filter and fuel filter.

Manual Start Procedure

1. Connect the positive battery terminal.
2. Turn the motor safety switch to ON.
3. Pull the starter handle until resistance is felt.
4. Remove the rubber plug under the decompressor lever (Fig. 2) and push the decompressor to reduce cylinder pressure.
5. Vigorously pull the starter handle to start the engine.
6. Return the starter motor to its original position carefully after starting.
7. After three minutes of operation, switch the machine protection (Emergency switch) to the ON position.

Electric Start Procedure

1. Connect the positive battery terminal.
2. Turn the motor safety switch to ON.
3. Set the ignition key to ON.
4. Turn the key clockwise to START.
5. Release the key after the engine starts; it will return to ON automatically.
6. If the engine fails to start after 10 seconds, wait 15 seconds before trying again.
7. After three minutes of operation, switch the machine protection (Emergency switch) to the ON position.

⚠️ If the engine fails to start after multiple attempts, there might be air in the fuel system. Purge the system.

⚠️ Connect devices one by one, respecting their maximum power. Do not connect consumers within the first 1-2 minutes after starting. Do not stop the generator with connected devices, as this can cause breakdown.

Verify connected devices are working before turning the generator on. If a device stops unexpectedly, turn off the generator via the emergency switch, disconnect the device, and check it.

Starting in Cold Season

If the air temperature is below +5°C, use the "Warming-up" function: turn the ignition key to ON, push and hold the heating button, then turn the key to START. Do not hold the ignition key in "Warming-up" for more than 10 seconds to avoid damaging the incandescent candles.

During Generator Operation

• Ensure voltage is within specified limits (230V ±10% or 400V ±10%). Stop operation if voltage is excessive.
• Connecting to a continuous voltage socket is for accumulator recharge only. Verify polarity (+ to +, - to -).
• Connect charging device wires to the accumulator first, then to the generator. Network connections must be done by a certified electrician.
• Do not use 12V voltage simultaneously with 230V/400V AC output.

Stopping the Engine

1. Disconnect all devices. Set the circuit breaker to OFF.
2. Let the generator run at no load for 3 minutes for cooling.
3. Turn the key to OFF.
4. Use the emergency stop switch only in emergencies.

Connecting Devices

Do not run the generator at nominal to maximum load for more than 30 minutes. After starting, verify voltage readings are nominal.

Starting with ATS Unit

When using an ATS unit, the start key on the control panel must be in the "OFF" position.

For Three-Phase Diesel Generators

Distribute load evenly across all three phases. The load on any single phase should not exceed 1/3 of the total generator capacity. Maximum permissible imbalance is 20%. Connecting only 1 or 2 phases can damage the generator. Total load and current must not exceed nominal values.

⚠️ Failure to follow these instructions may damage rotor/stator windings and the AVR unit.

Models with VTS System

Models designated "1/3" feature a VTS phase switching system, allowing operation in single-phase (230V) and three-phase (400V) modes with minimal power loss.

Switching modes is only permitted when the load is completely switched off.

⚠️ Overload may activate generator protection. Reduce load and reconnect no earlier than 5 minutes after switching off.

Technical Maintenance Works

Regular technical maintenance is crucial for generator performance and longevity. If independent maintenance is not possible, contact an official service center.

The manufacturer is not responsible for damages resulting from non-performance of regular maintenance.

Damages may also occur from using non-original spare parts, improper storage, or maintenance performed by unauthorized personnel.

Maintenance Schedule:

Manual Compliance: Adhere to this manual's recommendations for maintenance, operation, and storage. Non-compliance absolves the manufacturer of responsibility for damages.

This applies to: use of specified lubricants, avoiding unauthorized modifications, operating the device as intended, and preventing indirect damages from faulty equipment.

Service center addresses are available at www.ks-power.de/en.

Recommended Oils

Use SAE 10W-30 or SAE 10W-40 oils designed for four-stroke cycle vehicle engines, as they contain approved cleaning additives. Motor oils with different viscosity levels may be used if the average air temperature in your region falls within the specified temperature range for that viscosity.

Viscosity Chart:

10W-30, 10W-40

Engine Oil Replacement or Adding

Check oil levels regularly per the maintenance schedule. If the level is low, add the required quantity. When changing oil, remove and clean the oil filter before reinstalling.

To Drain the Oil:

1. Place a drain pan under the engine.
2. Turn the drain cap (under the oil dipstick cap) with a 10mm hexagon spanner.
3. Allow all oil to drain.
4. Replace and tighten the drain cap.

Oil Filling:

1. Ensure the generator is on a flat surface.
2. Unscrew the oil gauge cap.
3. Using a funnel (not included), pour the specified engine oil into the crankcase. The oil level should be near the top of the oil filler opening.

Air Filter Maintenance

Regularly check and clean the air filter to ensure sufficient airflow to the carburetor. Clean more frequently in dusty conditions.

⚠️ Never run the engine without the air filter, as dirt and dust can cause rapid engine part breakage, which is not repairable.

Air filter replacement is required every 100 operating hours, or every 10 hours in unusually dusty conditions.

Fuel Filter Technical Maintenance

Könner & Söhnen diesel generators use two types of fuel filters to prevent contaminants from entering the engine.

Coarse Cleaning Fuel Filter

Remove and clean this filter every 500 operating hours, or after encountering hard particles. Use diesel fuel for cleaning; never use water.

1. Remove the fuel cap.
2. Remove the fuel filter.
3. Clean the filter with diesel fuel.
4. Reinstall the filter into the fuel tank.

Fuel Filter in the Fuel Supply Pipeline

This filter must be replaced every 100 operating hours. It is located under the fuel tank on the fuel hose entering the engine.

1. Loosen hose clamps near the fuel valve and drain fuel into a suitable container.
2. Loosen metal staples on both sides of the fuel filter.
3. Remove the filter.
4. Install the new filter, ensuring the arrow indicates the correct fuel flow direction.
5. Tighten the bracket on the fuel hose.

⚠️ Ensure the fuel filter is installed in the most upright position possible.

Accumulator Maintenance

For models with electric start, periodically check the battery voltage. If below 12V, charge the battery using an external charger.

To prevent battery discharge, run the generator for at least 30 minutes monthly. If the generator is stored long-term, disconnect the battery. The supplied battery requires no additional maintenance. Long-term storage may lead to battery failure; charging every three months with an external device is recommended to prolong battery life.

Battery warranty is three months from the date of purchase.

Generator Storage

Store the generator in a dry, dust-free, and locked location, away from children.

⚠️ The generator must remain ready for operation. Malfunctions must be repaired before storage.

Long-Term Storage Recommendations

• Drain the fuel tank.
• Drain the engine oil.
• Pull the manual starter until light resistance is felt to close intake and exhaust valves.
• For electric start models, disconnect the negative battery terminal.
• Clean the generator of dirt and dust.

Reverse these steps when starting the generator after long storage.

⚠️ If electric start attempts fail, the accumulator may be de-energized. Perform a full accumulator charge before the next operation.

Battery and Generator Disposal

Dispose of generators and batteries separately from ordinary waste to prevent environmental damage. Recycle them responsibly at designated disposal sites.

Possible Failures and Solutions

⚠️ To prevent electric shock and damage, do not simultaneously switch on three-phase and single-phase circuit breakers.

Average Power Usage

Typical power consumption (in Watts) for common household appliances:

Warranty Service Terms

The international manufacturer warranty is 1 year from the date of purchase. Local legislation may grant longer warranty periods; contact your local dealer for details. The seller is responsible for warranty service.

The warranty covers manufacturing defects and will result in exchange or repair. Keep the warranty card safe; a duplicate will not be provided. Proof of purchase is required for warranty claims. The warranty card must be correctly completed by the retailer and customer.

Warranty Exclusions:

• Failure to comply with manual instructions.
• Damaged or missing identification stickers, labels, or serial numbers.
• Malfunctions due to improper transportation, storage, or maintenance.
• Mechanical damages (cracks, chips, impacts, deformation), including those from freezing water with foreign objects inside.
• Improper installation, connection to mains, or misuse.
• Malfunctions that cannot be diagnosed or demonstrated.
• Issues resolvable by cleaning, adjustment, or routine maintenance.
• Use for business-related purposes.
• Faults caused by product overload (signs include molten/discolored parts, damaged cylinder/piston surfaces).
• Automatic voltage regulator failure due to careless handling.
• Faults caused by power grid instability.
• Contamination of fuel, oil, or cooling systems.
• Mechanical or thermal damage to electrical cables or plugs.
• Foreign liquids, objects, or metal chips inside the product.
• Malfunctions caused by non-original spare parts, materials, or oils.
• Damage caused by natural factors (dirt, humidity, temperature extremes, disasters).
• Simultaneous failure of rotor and stator.
• Wear parts and accessories (spark plugs, filters, belts, hoses, tires, etc.).
• Preventive maintenance tasks (cleaning, greasing, washing, installation, adjustment).
• Tampering, independent repair, or modification.
• Malfunctions from normal wear and tear or end-of-life.
• Continued operation after detecting a malfunction.
• Batteries are warranted for three months.
• Use of low-grade or inappropriate fuel.

EC Declaration of Conformity

This product complies with European Community Directives: Machinery Directive 2006/42/EC, Electromagnetic Compatibility Directive (EMC) 2014/30/EC, and Noise Directive 2000/14/EC. It also complies with (EU) 2016/1628 for Non-Road mobile machinery emissions. Applied standards include EN ISO 8528-13:2016, IEC 60034-1:2010, and EN55012:2007+A1:2009. The diesel engines (KS 440HD, KS480HD, KS 520HD) conform to European Emission Standard Euro V, confirmed by EU TYPE-APPROVAL CERTIFICATE. Test reports were dated 12/08/2019. The CE mark is used under the manufacturer's responsibility.

Contacts

Deutschland:

DIMAX International GmbH
Flinger Broich 203 -FortunaPark-
40235 Düsseldorf, Deutschland
www.ks-power.de
Orders: orders@dimaxgroup.de
Customer Service: support@dimaxgroup.de
Warranty, Repair, Service: service@dimaxgroup.de
General Inquiries: info@dimaxgroup.de

Polska:

DIMAX International Poland Sp.z o.o.
Polen, Warczawska, 306B
05-082 Stare Babice,
www.ks-power.pl
info.pl@dimaxgroup.de

Україна (Ukraine):

ТОВ «Техно Трейд КС»
вул. Електротехнічна 47, 02222, м. Київ, Україна
www.ks-power.com.ua
sales@ks-power.com.ua

Россия (Russia):

ТД «Рус Энержи К&C»
129090, г.Москва, проспект Мира, д.19, стр.1, эт.1, пом.1, комн.66, офис 99B
www.ks-power.ru
info@ks-power.ru