1

Safety and WarningRead and understand this manual and other related instruction before operating and performingmaintenance on the generator. Correct installation and the use of qualified maintenance spare parts willmake the generator in good working condition and reach a longer service life.

The generator must be operated by trained personnel. The maintenance must be carried out by authorizedpersonnel. The personnel who is in charge of the operation and maintenance must understand the safetyprecautions and maintenance procedures.

To avoid accident, never try to start the generator under unsafe situation or do not attempt to operate thegenerator under irregular situation.

Refer to cleaning, maintenance and repairing work, users must shut off the generator and turn off therelative switch or remove the cables from battery.The warning signs also should be put at thecorrespondent place to avoid accident.

The emission exhausted by the engine is detrimental to the health of personnel. The emission of allindoor generators must be piped outdoors.

The exhaust pipe and muffler will generate heat during work. So fire insulation materials should be usedand the generator should be away from flammable materials.

Ensure of adequate ventilation and clean environment in the engine room. Do not place flammable objectsand liquid nearby the engine.

Smoking and any other behavior that may cause fire is never allowed in the workshop. Because once thevolatile gas from the fuel and the hydrogen produced by battery charging meet the fire could cause anexplosion.

BC and ABC fire extinguisher should be equipped in the engine room. The operator and maintenancepersonnel are required to know how to use them. In the case of the fan guarder or other safety protectivecover removed, do not attempt to start the generator; when turned on, do not attempt to repair under ornearby these protective devices by hand.

Hands, arms, long hair, jewelry and loose clothing should be away from pulleys, belts and other rotatingparts.

When working in the engine room, should wear overalls, gloves and hats.

When the generator is running and the coolant is not completely cooled, do not try to unscrew the radiatorcap, so that to avoid the steam or hot water spray out and hurt personnel.

Do not swallow, and do not let skin touch the fuel, coolant, lubricant and other liquid electrolyte; once theliquid splashed, wash immediately with plenty of water.

Long time suffering from noisy environment is harmful to hearing. Personnel who often working aroundthe generator is recommended to wear ear protection equipment. Output cable connection must becomplied with the relevant conditions, norms, standards and a qualified electrical cable should be used inpower output distribution.

When welding, it is prohibited to connect the generator directly to the ground or iron. To avoid the harm tothe appliances, bearings and so on inside the generator.

Ensure the generator to be earthed safely and reliably.

2

1. Overview

1.1 Brief introductionJACA series diesel generator, as core product of Hangzhou JACA Electromechanical Equipment Co.,LTD,

with excellent performance has been widely used in construction, communications, finance, mine development,leasing, and other special occasions. As you would expect on JACA, its generators uphold safer, cleaner, morereliable, as well as to meet the individual requirements of your design to provide users with high reliability andprofessional products; and by the virtue of low noise, energy saving, stable performance, it provides a reliableguarantee for the development of many enterprises.

1.2 Diesel engineAccording to different grades of power and combined with various brands of diesel engines that performance

advantages in specific power range, JACA diesel generators choose the engine with excellent performance, highreliability, and also pay special attention to the advanced technology of emission reduce , fuel consumptionreduce and noise control.

1.3 AC Generator

JACA diesel generators mainly choose the AC alternators of domestic or international famous brands withhigh-performance single bearing, brushless and self-motivation. Take STAMFORD alternator as example, it hasthe following characteristics:

●four pole brushless self-motivation, single bearing, H-class insulation, IP23 protection grade.●2/3 pitch coiled stator can effectively eliminate the harmonic voltage for three times, inhibit the output

voltage’s wave form distortion; when in parallel connection to the grid or other generators it can effectivelyinhibit excessive neutral currents and reduce magnetic heating.

● Rotor is assembled after balancing test, complete damper winding can help reducing the voltage deviation andthe heat under unstable load.

● The output power of the exciter rotor is transferred to the generator rotor by three-phase full-wave rectifier.The rectifier is protected by a suppressor to against the damage caused by short circuit or the impact created bygenerator combination.● Automatic Voltage Regulator (AVR) has the character of protecting automatically off-load to the engine.

Allowing a one-time full load to the generator, stable voltage regulation can achieve ± 1% (to meet the specialrequirements of ± 0.5%). If you select a permanent magnet generator excitation (PMG) system, the generatorhas a high motor starting capability, and immunity to the change of output voltage wave form non-linear loads(such as SCR DC motors, UPS, etc.) .

● Telephone influence factor TIF <50, telephone harmonic coefficients THF <2%. The brushless devicesand high-quality AVR ensure the transmission interference is very small.

1.4 The Control Panel of GeneratorAny style of JACA generators is using the top grade control panel. We choose domestic or imported high

quality control panel for intelligent generator as the core controller, with more functions of monitoring, display,interactive operation, remote communication and protection.

JACA generator control panel adopts steel structure which is solid and reliable; the overall outlook isbeautiful and special locks used in firming is easy for maintenance.

1.5 Optional Configuration of Silent Generator1.5.1 Outlet Manner Adding Mouth for Coolant

JACA silent type generator specially designed outlet manner adding mouth for users. When adding coolantusers only need to open the pressure cap of the water tank and the adding mouth on the generator, then directly addthe coolant to the engine from the outside. It is also easy to observe the coolant level.

1.5.2. External Exhaust Mouth for LubricantsJACA generator specially designed external exhaust mouth for users to release lubricant emissions . It is

another humanized design feature of JACA generator, which provides users with a more convenient operationmode. When discharge or replace lubricant users only need to open the ball valve to release the lubricant.

3

1.5.3. The perfect way of loading and unloadingJACA silent type generator specially designed a variety of different ways to load or remove for its users . It is

equipped with chassis hatch, small ones are also designed with overhead lifting and forklift selection to bettermeet the requirements of movable usage as a non-fixed power.

1.6 Others

Besides above mentioned components, diesel generator also have some key accessories; for example: battery,battery cables, muffler, flexible corrugated exhaust pipe, exhaust pipe, efficient absorber, as well as optionalparts: base type fuel tank for big power generator, independent fuel tank for daily use, soundproof canopy,engine lubricant, coolant and other specialized functions for customer using. For detailed spare parts of eachmodel, please refer to the packing list and purchasing contract.

2. Installation2.1Outline

Proper installation should be made before normal use, working room must be designed to meet the anticipateduse and maintenance operations, and the design must comply with building codes, fire codes and other applicableregulations of local.

In order to cooperate uses with installation, this chapter simply describes the using condition andinstallation requirements, for further detailed technical information please refer to the generatormanual or contact our technical department.

2.2 TransportationJACA diesel generator while in the transportation, need necessary security. In addition, the generator should

be firmly fixed in the truck, in order to avoid the vibration may cause parts loosing or damaging. Prohibits anyperson stand on it or material be put on it, so that to avoid damage caused by pressure.

When unloading the generator from the vehicle, you should use a forklift or lifting equipment to avoid itfalling on the ground and getting damaged.

JACA diesel generator is designed with lifting holes on the common base, some optional silent typegenerators are also specially designed with an overhead lifting holes, special forklift holes and etc; According tothe marks and guidance on the generator users can do the loading and unloading, never use the rings on theengine or alternator to hang up diesel generators.

2.3 Foundation design

The base for laying and fixing diesel generator is very important, it must meet the following requirements:• Have sufficient rigidity and stability to prevent deformation that may affect the coaxial of diesel enginesand alternators and other accessories;• Support the weight of the entire generator, absorb the vibration caused by unbalanced force duringgenerator running;• The base should not be connected with the foundation of other buildings;• The width and depth of the foundation should meet the requirements;• Guarantee a certain basic levelness and smoothness;• Users can reserve discharge channel to exhaust the waste water and lubricant; and also reserve outputpower distribution cable channel. Normally, concrete foundation is a reliable and easy installation way, wesuggest users adopt it priority. When pouring the concrete base you should ensure the surface is smooth andwithout any damage.Combination with horizontal or similar devices to install generator and its exhaustsystem is recommended. Base design can be calculated as follows :(attached: diesel generator base diagram)

4

1. Generator length x width: L1×W12. Base length x width:L2×W2L2=L1+400（mm)

W2=W1+400(mm)3.B=2×M÷(L2×W2×D）

B： base thickness M：generator weight

L2：base length W2： base width

D：the density of concrete ( reference: 2322kg/m3 )

Base diagram of diesel generator

2.3 The Design of Generator RoomInstallation of generator must be designed to apply to all the expected operation and maintenance needs;

complete installation must comply with building codes, fire codes and other applicable regulations of local;and also need pay attention to the following aspects, which is very important .

● Ensure that diesel generators are protected from the rain, sun, wind and other damage;● Ensure the room with good air intake and exhaust condition, has a sufficient large ventilation area,

meantime to exhaust the hot air from the radiator out of the engine room and to prevent the return;

● Ensure to discharge the exhaust emissions produced by the engine, and reduce the impact on thesurrounding environment as much as possible; muffler and exhaust pipe must be supported by theroof of the house, the support frame can accept the expansion of the exhaust pipe; Absolutelyprohibit the exhaust system to be installed directly on the generator;

5

● Around the diesel generator should be enough space to facilitate cooling, operation, maintenanceand so on. Generally speaking, at least 1 to 1.5 meters around the generator, 1.5 to 2 m on the top of

the generator are not allowed to have any other object;● Generator room must be configured with fire-fighting equipment of required levels ;● Generator room must be configured with the appropriate emergency lighting measures that speciallyfor operation and maintenance work;● Eliminate the storage of flammable and explosive materials in the generator room.

Attachment: layout diagram for open type generator room and silent type generator room.

Open type generator room layout schematic

6

Note: if customers need, our company can customize the room layout and specific installation dimensionsaccording to the user's specific requirements.

silent type generator room layout schematic

Note: Our silent type generator can be installed for outdoor use, if indoor use needed, you can refer to abovediagram for installation. If needed, our company can customize the room layout and specific installationdimensions according to the user's detailed requirements.

7

2.4 Generator installation2.4.1 Generator to be placed

The absorbers of JACA diesel generators have been pre-installed on the generator (except for some specialones), please refer to installation diagram and correctly set it on a flat solid basis, according to the mountingholes on the base , use bolts fastening the generator on a concrete foundation ; Normally speaking, any otherextra measures to avoid absorbing is not suggested.

All components should be connected with an external connector on the machine by a flexible manner. Forexample, the exhaust pipe connect to the generator through damping tube ; flues, fuel inlet pipe, return pipe,electrical cables, etc. should also be connected via a flexible connection, so as to minimize the vibration to thesurrounding objects.

2.4.2 VentilationWhen a generator with radiator is installed

inside the room, the basic principle is to exhaust hotair out of the room, and intake the cool air into theroom, and as much as possible to reduce the inflowof hot air.

The figure on the right shows the idealposition of generator inside in the room . The aim isto get the cold air from the lowest position, forcingthem through the radiator then be exhausted out ofthe room.

Users can make a cover by metal plate or canvas to exhaust hot air, the connection of the cover to theradiator must be flexible in order to cut off the vibration, and ensure hot air be completely discharged.

Effective flow area of the cover should be 1.25times larger than the front area of the radiator core and thecover should be smooth and with less acute angle bend so as to reduce wind resistance. The relative effectiveinlet flow area should also be 1.25 times larger than the front area of the radiator core.

Users install protection net and blind with too much or too big cambers in the inlet and outlet places willlead the effective flow area reduced, the resistance will increase, therefore, it is necessary to further increase theflow area. In general, the air from the water tank of the engine is sufficient to meet the requirements of the engineroom ventilation.

The temperature of intake air in the engine should be below 30ﾟC. If the temperature is always higher thanthis value, the output power will be reduced. Therefore the fresh air is always needed on time to refresh the airin the engine. If the engine is equipped with a remote radiator, we must adapt forced ventilation, it is better touse two fans, one fan intakes air into the engine room, the other fan is used as exhaust fan, to draw the hot airout of the room . Refer to the engine with thrust fan, it is better to use a separate pipe to discharge emissionsproduced in crankcase. Otherwise may reduce the cooling capacity of the radiator.

2.4.3 Smoke Exhausting

JACA standard diesel generator is provided with industrial muffler, flexible bellows, elbow and so on. Userscan use these accessories, self design and install the exhaust system in the engine room. But should alwaysrefer to the following aspects:● Ensure that the entire exhaust back pressure is not higher than the maximum allowable value of theengine;the maximum exhaust back pressure generally does not exceeds 5Kpa● Fix the exhaust system so that the exhaust manifold and the turbo boost won’t be affected by the pressurefrom different direction.;● Be flexible for thermal expansion and contraction;● Be flexible for vibration ;● Reduce exhaust noise.

8

If the exhaust back pressure of engine is much tooover will lead directly to:●Output power loss;●Fuel deteriorate;●Exhaust gas temperature risen.

If you install more than one generator, try todischarge the exhaust gas from the different flues. Ifthe conditions are inconvenient to install a separateexhaust pipe, based on the situation no exceed thetotal exhaust back pressure, install a movable plateto prevent back flow on the branch exhaust pipe.

More typical exhaust unit installation diagram.

In the exhaust system, flexible bellows should be used to connect exhaust pipe with diesel turbo boost softly, ithas three functions:● Isolate the vibration and the weight of the exhaust pipe from the diesel generator;● Compensate the thermal expansion of the exhaust pipe;● If the diesel generator is installed in the shockproof bottom shelf, when the generator start up and shutdown compensate the movement of side-sway. Note: 1. rainwater or condensate enter the engine exhaust systemcan cause serious damage. Therefore, need to install a drain in the long exhaust pipe, its position should be asclose to the generator. 2. If the tip of exhaust pipe is higher than the building, users should do lightning processingfor example grounding connection.

2.4.4 Noise Reduction

During the operation, the diesel generators typically produce 90 ~ 110dB noise, with the increasing of theload, the noise also increased slightly.

In order to satisfy the standard of noise level made by Environment Bureau and not to produce noisepollution to the surrounding environment or affect the normal life of the residents that to take measures to reducethe noise is extremely important. Noise reduction project is a comprehensive professional engineering item, whenthe users design and take action of the noise reduction program they should consider the issues of the minimumrequired

amount of the wind and the exhaust no exceed the reference value during the operation. Otherwise, it willseriously affect the power output, the generator temperature will be too high, also cause the frequentlymalfunction, and even shorten the life of the diesel generator.

JACA can provide integral silent type and super-silent type diesel generators for users’ choice.

2.5 Cooling System

Standard JACA diesel generator is already equipped closed cyclical cooling system with water tank and fan; closedwater-cooling engine drive cooling pump to produce cyclical power, make the coolant in the cylinder block andcylinder head constantly circulating cooling. The cooling pump of engine, the radiator or heat exchangerconstitutes a closed and pressured cooling system.

The most common cooling system is radiator and the cooling fan directly driven by the engine, thealternative is the heat exchanger, remotely located radiator or remotely located cooling tower. If the remotecooling fan is mounted too high, the transition should be added to the tank to prevent the internal pressure due toexcessive heat.

All kinds of chips stuck on the radiator will greatly reduce the cooling performance, therefore in dustyenvironments it is necessary to clean the radiator often.

9

2.5.1 CoolantThe cooling system should use the coolant that can protect the engine against corrosion and freezing. The

coolant is consist of pure water with anti-freeze fluid or pure water with anti-rust fluid, the water PH value shouldbe between 6 to 8. Generally recommended to use distilled water, the mixing ratio required is according to thelocal climate and environment. Please refer to the instruction of the anti-freeze fluid , well mix the fluid in aseparate container and add it to the water tank, so as to ensure the fluid does not freeze under low temperature.Use water with anti-rust fluid as coolant at the area never freeze. Refer to the instruction of the anti-rust fluid ,again well mix the fluid in a separate container and add it to the water tank. Once the anti-rust fluid is filled, thegenerator should be started to get the best protection against corrosion.

Engine coolant has the following three functions:

● To provide adequate heat transfer capability;● To prevent any corrosion of metal materials and sealing materials inside the cooling system;● To provide the adequate anti-freeze ability.

Select the anti-freeze fluid with qualified brand recommended and approved by the engine manufacturer isthe key to ensure the normal use of the engine. Even in the areas won’t froze, it is also recommended to useanti-freeze fluid throughout the year so as to prevent the engine from freezing, and also increase the boiling pointof the coolant under high temperature that is to make the water tank not easy to boil. Never mix using any kind ofanti-freeze fluid and anti-rust fluid, because this will create a lot of foam and reduce its cooling performance. Ifgenerator failures like leakage, corrosion and etc. are caused by using the anti-freeze fluid of poor quality or notapproved by the engine manufacturer will not get warranty service.

2.5.2 Coolant replacement

Effectiveness of anti-freeze and anti-rust fluid would be reduced day by day, so the coolant must bereplaced periodically. Anti-freeze mixture fluid should be changed every two years, the mixture of anti-rust fluidshould be changed at least once a year, if the coolant filter be equipped and it should be changed every sixmonths. For detailed replacement cycle of engine please refer to the manual).

Coolant exhausting should ensure that the generator is shut down and the body is completely cool andlater open the tank cover. Then open the drain plug on the water tank and the releasing plug on the engine to leakthe water. If the generator has equipped with a coolant filter, remove the filter and replace it.

2.5.3 Cleaning work of the cooling system

When replacing the coolant, engine cooling system needs to be cleaned, users can refer to the following steps:

• Empty the cooling system;•Washing the cooling system by water;•Filling the cooling system with 15% -20% concentrated coolant, then releasing afterrunning once or twice;•After emptying the cooling system, wash it with a mixture of neutral;• If contaminants are still there, repeat the cleaning until the system is clean enough;•After the system is completely cleaned, fill in well mixed new coolant. Note: If the coolingsystem is regularly cleaned, then use only a small amount of additives or just use clean water toflush is enough.

2.5.4 Adding coolant

● Before adding the coolant to the coolant system please ensure the drain plug of the water tank and the engineshould be closed;

● Adding coolant to the system should be not too fast, so as to avoid the formation of air embolism;

10

● he air should be discharged through the injector and the exhaust valve on the engine body. If the coolingsystem is connected to the heater, the control valve should be opened, and maintained with ventilation. Note:the exhaust valve on the engine is generally located on the commanding heights of water system or at the sideof water thermostat and temperature sensors. It can also through slightly loosen the water temperature sensor,and tightened the sensor to exhaust the gas when the coolant flow out.

● When inject the coolant, the coolant level should be 5 cm below the tank welding surface or coolant levelindicator line. Ensure that the generator is shut down and completely cooled before adding coolant. Neverstart the generator until the system is ventilation and full of coolant. After adding coolant, users should payattention to start and warm-up the generator. At the same time check the coolant level and add the coolant ofthe same specifications if necessary.

● Some of the generators that are equipped with coolant filters, the filter valve should be opened before beingofficially put into use.

2.6 Lubrication system

The lubrication system is mainly consisted of oil base, oil pump, oil pan, oil pipes, oil cooler, oil filter, inneroil passages of engine and various internal relative motion of lubricating parts. Its main function is to reducefriction and wear through providing long lasting protection film between the parts of the engine; take away someof the heat absorbed by the parts; flush the surface of the parts, improve the sealing effect. Prevent the surface ofthe components away from corrosion.

Users can choose the lubricants models according to the environment and self conditions. The lubricantsshould be changed after using 100 hours(For details please refer to engine maintenance instructions).

Not only using lubricants with good quality, appropriate viscosity and meet the requirements of the engine, butalso regular replacement of the lubricant and filter are the key to the normal use of the diesel generators; Failurescaused by using wrong type or low quality lubricant or never change lubricant or filter on time will not getwarranty service.

2.7 Fuel SystemJACA diesel generators require clean diesel fuel that without air or water, it should also have the suitable

pressure, and the indicators of the fuel sulfur content, etc. must meet the national standards. The temperatureneeds to meet the temperature requirements of the local environment . Generally speaking, the fuel system ofdiesel generator consists of two parts: the fuel system of engine and the external fuel system. We only need toinstall an external fuel system that includes oil tank, oil pipe and etc.

2.7.1 Oil TankWe can supply based fuel tank for users, it provides ready-made tank, pipe and oil level meter; the fuel system

does not require users to install any other thing, just need to inject fuel into the tank.

When users create their own fuel tank, it should be noted that alternate tank should be made of stainlesssteel or steel, do not paint or galvanize to the interior of fuel tank, in order to prevent the chemical react with thediesel fuel that may cause damage and reduce the quality, purity and burning efficiency of the diesel fuel. On theother hand, the oil tank should be equipped with:

• Breather pipe on the top of the tank;• Inspection hole on the top of the tank• Observation glass for oil level• Leakage valve at the bottom of the tank;• Grounding cable between the injecting port and the fuel tank;• Oil input area and oil return area should have a perforated baffle to reduce heat transfer.• The end of oil pipe should be 50mm above the bottom of the oil tank to prevent the sediment andwater be drawn to the pipe;• For some of the generator, the oil level in the oil tank should be above the position of oil injector toprevent oil return which may lead problem in generator starting work.

11

2.7.2 Oil Tank Installation• The installation position should make the maximum suction lift no more than two meters. Pump suctionlift should be calculated from the bottom of the oil tank;• The installation position should make the oil return lift no more than 1.5 meters. The oil return lift shouldbe calculated from the top of the oil tank;•The direction of oil pipe should prevent the fuel from too much influence of the heat produced by thegenerator.• The maximum allowable temperature of fuel injection pump is 60℃• Ensure the inject pipe and the return pipe no leakage is very important;• Using flexible pipe to connect the generator and the pipeline, if the generator adapt the flexible installationof using absorber, then it must be equipped with a flexible pipe.•When the engine inject pipe is longer than 6 meters and shorter than 10 meters, the diameter of the injectpipe should be at least 20% bigger than the fixed flexible pipe of the engine. The return pipe should beconnected back to the top of the tank, should not be directly connected to the inject pipe.

2.7.3 The use of fuelFuel composition has a very significant impact on the work and life, and also the emissions of diesel engine.

In order to obtain the required power, economic fuel consumption and achieve the required emission standards,only the fuel that meet international or national standards should be used.

Low temperature, sulfur content, specific gravity and content of water and impurity etc. should be the firstconsidered while users select the fuel. Fuel with different quality will directly affect the start, lubrication, poweroutput, emissions, the cycle of fuel filler replacement and other performances.

For specific fuel requirements of diesel generator please refer to the random engine manual.

Refueling tank must be did when the generator is turned off. Restart the generator some time after the fuelis added so as to prevent the impurities being absorbed into the fuel pipe and causing the fuel filter blockage,and also prevent the lack of engine oil and the serious reduction of output power. Failures caused by the usingof poor quality fuel will not warranty service.

2.8 Control SystemsJACA diesel generators are equipped with the control panels that select top domestic or imported smart

meter as the core control system.● Intelligent control panel: can be both manual control and remote control by an external control signal lines,

users must correctly link the signal control lines to the screen. Refer to the control panel random data.● Optional "ATS" screen: power / main automatic transfer switch control panel. Refer to the control panel

random data.

2.9 BatteryJACA diesel generator is with a standard configuration and maintenance free starting battery. To use the

maintenance free storage battery is only need to connect the cable.Users can use the standard battery cable that matched with the generator to connect the red line to the

positive end and the black line(or blue line) to the negative end, and then properly connect with the end of themotor.Most engines of JACA series diesel generators are already connected.

The energy storage capacity of the starting battery will decide whether the diesel engine can besuccessfully started within the prescribed time. When the diesel generator is in operation, its self-charginggenerator takes responsible to continue charging the starting battery.

Ensure of proper connection of the positive and negative, once mistake made will lead to failure! (the charginggenerator will be certainly damaged)When the generator is in operation, never try to cut off the battery cables!

12

2.10 Distribution systemJACA series diesel generators adapt three-phase five-wire distribution system, that is the three-phase line offire, a centerlines, a safe ground wire, which means the center line and the earth wire is not connected, the usercan according to their distribution requirements, choose the three-phase four-wire power output, that meansconnect the centerline to the earth line (base), in order to solve the illusion of centerline sometimes charged.

JACA series diesel generator requires users to do safety ground connection, for the connection place pleaserefer to the ground markers on the base of the generator.

3.Running operation3.1 Check before running

JACA diesel generator can generate power once after installed. Before running, following items should bechecked:• Whether the generator surface or around is with debris obstruction;• Whether intake and exhaust passages in the engine room is smooth;• Whether cooling water tank level is normal;• Whether air filter indicator indicates normal;• Whether the oil level is within the normal range;• Whether the fuel valve is opened, the fuel supply to the engine is already normal;• Whether the battery cables are connected properly;• Whether the load power equipment is ready. when the generator directly load, the air

switch should be cut off before starting the generator.Once a good operation (maintenance) program be established by users, and it willcreate a basic long-term protection to trouble-free operation.

3.2 Generator operation3.2.1Preheat

The generator is equipped with a preheater, before starting, the operator can determine whether preheatthe generator according to the ambient temperature. The control panel can be controlled with the enginewarm-up button to start the heater, in order to achieve the purpose of preheating.

3.2.2 Power-onTurn the power switch on the control panel from "OFF" to "ON". If the background lights on the

instrument panel is brighten, it shows the control panel is powered, meanwhile fuel pipe of the generator is alsoturned on and the controller is also in operation.

3.2.3 Start upSome of the control panels have the idle / full switch, users can choose the start manner according to

actual needs. Usually idle running time should be no more than five minutes; and the generator should never berun at idle for a long time.

Press the start button, the maximum duration should be no more than 30 seconds. Once startedsuccessfully, you can release the start button, and the generator enter the running state.

Recommendation: In order to prolong the life of the battery and the starter motor, it is better to start-upwithin 5 to 10 seconds. If the start is not successful, you can wait a minute and then repeat it again.

The control panel with self-starting (or communication) instrument, its preheating, start-up period and startfrequency are all controlled by the program which users can set or change by selves. For detail please refer tothe random instructions.

When the generator control panel is break down, the inspection and repairing must be done before restarting.

Any force to start the engine without control panel and lead the failure will not get the warranty service.

13

3.2.4 Operation

When the generator enter full speed running and the voltage, frequency are normal and stable, then thegenerator can be put into normal generating work. When the generator is running, the operator should alwaysobserve whether the operation is normal, whether the control panel indicates at the normal position, whetherthe control panel indicates the presence of pre-alarm, and make record of the fuel lever and other operatingparameters regularly (Refer to below example).

3.2.5 Emergency Stop

Once the operator finds a serious failure of the generator, press the emergency stop button on the controlpanel to immediately shut down the generator. If nothing special happens, we do not recommend users pressthe emergency stop button to shut down the generator.

3.2.6 Normal shutdown

Before the generator normal shutdown, first separate the load, and then run the generator without loadafter a certain time about 3 to 5 minutes to allow it cool down sufficiently and normally shut down. Do notperform cooling operation at idle speed.

For the generators have breakdown valve installed, it is invalid to turn off the key on the control panel toshutdown it. The right way to stop the generator is you must stop the generator by turn off the stop button onthe control panel. Press the stop button until the generator is completely stopped.

3.3 After running

After the generator is shut down, it is necessary to do following work:● Check if the generator have the "three-drain" phenomenons of lubricant, fuel and coolant;● Close the fuel valve;● Close the air intake and exhaust facilities if necessary;● Turn off the generator output breaker;● Close the power key switch on the control panel, take the key and keep it safe if necessary;●When long time won’t use the generator or doing maintenance work, you must remove the negative cable of

the battery, and also leak the fuel and coolant if necessary.

For self-starting generator, part of the terms above are not suitable. You should keep it at standbysituation, make it ready for emergency start.

3.4 Running Record

Every time users must make record for the generator when it is running. The basic content shouldinclude: current running time, total running time, oil pressure, oil temperature, power voltage, frequency,maximum power and current and also other records like the operation situation, with or without fault alarmand shutdown etc.

With correct and complete operation and maintenance record, users can obtain the correct and perfectafter-sale warranty service.

14

Example: record table:

3.5 Precautions

When the engine temperature is low, the idling time should be extended; but when the generator iswarm-up, to run at idle for a long time is not allowed. To run continuously without load or with light load isnot allowed, they will cause the turbo boost and the exhaust system leakage; long time overload is also notallowed,

otherwise it will lead failure and reduce the service life. Spare parts disassemble and replacement areprohibited when the generator is running. Add the same coolant to the cooling system.When open the coolantpressure cap, pay attention to the high temperature, to prevent steam or hot coolant spray wounding; becareful with hot lubricant discharging. Users must use the fuel that meet national standards, otherwise it maycause the fuel pump or injector failure;

Engine with a turbo boost is not recommended to bear more than 50% sudden load, otherwise, it willcause speed problem; users are recommended to adapt reducing pressure or change frequency to control thestart of large-scale electrical equipment, to slow the greater impact on the generator;

Standby generator or the one is not used for a long time is recommended to run at least once a month toreach operating temperature, and at least once a year to make it with a full load running for about four hours,by this way can burn the coke in the engine and exhaust system;

Control the parallel operation by manual must ensure the synchronization of same frequency , samephase sequence, same phase and voltage then can turn on the power; Before stop the generator, users shouldfirst turn off the power then shut down the generator. The generator must be used with person on duty toprevent the failures.

Timing Engine Parameter Alternator Parameter FailureRecord

Operator Remarks

Start/stopTime

AccumulatedOperation time

oilpressureBar

WaterTemperatureﾟc

VoltageV

CurrentA

FrequencyHZ

PowerKW

15

4. Maintenance4.1 Outline

For different types of generators, users should use them according to reference engine maintenanceinstructions ;In order to obtain the maximum safety and service life, to do regular maintenance is essential, ifwe can strictly abide by the relevant regulations of the maintenance, we can guarantee the performance of thegenerator and reduce the damage to the environment;

Correctly identify and strictly abide by the identification of graphics, words, warnings, etc. that on the bodyof JACA diesel generators will be helpful to the correct maintenance and safe operation; when doing themaintenance work, you must shut down the generator, and remove the negative battery cable to avoid startingthe generator by mistake.

4.2 Engine

Before starting● Check the oil level;● Check the coolant level;● Check the air filter restriction indicator;● Check the radiator and external ventilation;● Check engine drive belt group;● Check fuel supply situation;Common use generator should be checked every 6 to 8 hours, standby generator should be checked oncemore after being shut down.

New generator is depending on the operating conditions, to be checked in 100 to 300 hours if necessary● Check the valve backlash;● Check the injector;

Run every 50 hours● Discharge the water from oil-water separator● Check the electrolyte level of the battery ,exclude the maintenance-free battery;

Run every 50 to 600 hours or at least 12 months

● Replace the lubricant and lubricant filter; quality difference , sulfur content difference and fuelconsumption difference will lead the lubricant change cycle to be different. When change thelubricant you must also replace the filter . Otherwise, the replacement of the lubricant will becomemeaningless. If the lubricant quality is still good and no need replaced, then by replacing the oil filterto filter impurities in the oil.

● Replace the fuel filter, clean or replace the fuel filter element and the water separator core of somemodels, check and clean the fuel pipe; The replacement cycle is based on the fuel quality (if containmuch impurities), whether the filling manner of the fuel tank is reasonable, whether regularlycleaning the fuel tank (sewage), once the engine exhaust smoke is in different color, the outputpower is reduced, you should first check the fuel system.

Every 400 hours operation● Check and adjust the transfer belt and replace if necessary;● Check and clean the core of radiator;● Discharge the emissions from the fuel tank;

16

Every 800 hours operation● Check whether the turbo boost is leakage;● Check if the air intake pipe is leakage;

Every 1200 hours operation● Adjust the valve backlash;

Every 2,000 hours operation, or at least 24 months● Replace the air filter (whether need to replace it in advance is depending on the ambient air quality );● Replace the coolant and coolant filter (some generators that have coolant filters);● Wash the radiator core and the channel of the water tank;

Running every 2400 hours● Check the injector;● Completely check and wash the turbo boost;● Comprehensive inspection of the engine equipment;

4.3 Alternator

The internal and external of the alternator should be cleaned regularly and the frequency is depend on thelocal environment. When cleaning needed, you can follow below steps: cut off the power, clean all the dust,dirt, grease, water or any liquid on the appearance, and also clean the ventilation network, because theseobjects adhered to the coil will overheat or damage the coil insulation. It is better to use a vacuum cleaner toclean the dust and dirt instead of using blower or water to clean.

The generator must be dried if the resurgence cause the decrease of the insulation resistance, for thedrying methods and detailed maintenance please refer to random "generator use and maintenance manual."

4.4 Control panel

Ensure the surface of control panel be clean, and the instrument display be clear and the operation buttonor key flexible and reliable. When the generator is in operation, vibrations will cause the meter to zerodeviation, fasteners loosen, so regularly calibrate the control panel, tighten the connections, cables arenecessary. To do the maintenance work of the control panel must first to learn more about the principle pleaserefer to random manual of control panel.

4.5 Start Battery

The battery in storage must be proper charged before using to ensure the normal capacity.Avoid the battery to be started at low temperatures. The battery could not work normally at low temperatures,and long term battery discharge may cause the failure of cracking or explosion.

Standby battery should regularly perform maintenance and power charging, we recommend users to buythe battery float charger.

4.6 Maintenance records

Every time after maintenance work be done, users must record the detail work. Complete maintenancerecords are the basic issue for maintenance , with it the generator can obtain the necessary conditions for legalsale and warranty service.

17

Sample maintenance record sheet:

Generator Type: Engine Type: Alternator Type:

Generator Code: Engine Code: Alternator Code:

Accumulated Operation Hour： Maintenance Cycle：

Maintenance Reason: Regular maintenance or failure maintenance)

Check and repair

Check and adjust

Replace spare parts

Clean andmaintenance

Others

Maintenance Result：

Maintenance personnel signature：

18

5.Troubleshooting5.1 Outline

There are many issues that may cause failure to the diesel generator , and the failure phenomenons have therelevance. This chapter focuses on the possible failures of JACA diesel generator. Users can refer to it fortroubleshooting. (Especially for new users)

It must be emphasized: Most failures are due to the wrong installation, operation and maintenance; If usersdoubt about the failures are caused by generator itself then you should make sure of the proper installation,operation and regular maintenance etc. Otherwise, the normal operation and reference service will not beguaranteed.

5.2 Troubleshooting table:

Symptom Cause Factor Solving Method

The generatorFails to start

Insufficient battery capacity Maintain the battery by charging or rehydration,replace the battery if necessary

The control panel is without power Check if the fuse in the control panel is break

Some generators(EFI) start too fast and EFIcontroller still hasn't passed the self-test

Reset the control panel then restart (stop for 3 ~ 4S)

Start relay failure Replace this relay

Motor starter failure Analyze the reason and replace it if necessary

Stop running and could not be started byoperator

Completely examine and look for reasons

Difficult instarting orstart-up time istoo long

Insufficient battery capacity Maintain the battery by charging or rehydration,replace the battery if necessary

Inadequate warm-up before start check the preheat components

Start potentiometer is too small for thegenerators with electronic controller

Check the instruction of the electronic controllerand turn up the potentiometer

The generator is in low temperature Try to increase the body temperature, suggested touse heater

the generator is in plateau with thin aircondition

Run at idle speed after a certain time then to rise infull speed

Use the wrong type or brand fuel Must be replaced

The fuel contains water Replace the fuel, it is recommended to install waterseparator

The fuel system is with air or without fuel Discharge the air,use manual fuel pump to leak thefuel from the fuel return pipe

Serious block of fuel filter Regularly replace the fuel filter

Serious block of intake system Regularly replace the air filter

19

Symptom Cause Factor Solving Method

Difficult instarting orstart-up timeis too long

Fuel pump and injector failure(with jam)

Let authorized personnel inspect pumps, analyze thereason. Mainly due to prolonged use of substandardfuel

Pump failure Do inspection, repairing and replace it if necessary

Stop solenoid valve failure Do inspection, repairing and replace it if necessary

Serious block of intake system Check and Troubleshooting

Electronic speed control board failure Check whether powered,replace if necessary

Generatorcould not keeprunning afterstart

The fuel contains water Replace the fuel, it is recommended to install waterseparator

The fuel system is with air or without fuel Discharge the air,use manual fuel pump to leak thefuel from the fuel return pipe

The block of fuel filter or air filter Regularly replace the three filters

Idling speed operation time is not enough atthe place with thin air

Appropriate to extend the idling time, ensure thegenerator is warm-up

Use the wrong type or brand fuel Replace the fuel

When thegeneratorstarts easilyget overspeed

The starter and potentiometer of electronicspeed controller is not properly adjusted

Refer to random electronic speed controllermanual, and slightly adjusted the potentiometer

Overspeed protection value is set too small Overspeed protection value should be slightlyadjusted and to be no more than 17%

Mechanical governor structure Check if the throttle lever flexible and ensure thecorrect adjustment

Injection pump system failure Let authorized personnel inspect and repair

Generator

starts with

black smoke

exhausting

Block of air intake system Regularly replace the three filters

Using the wrong type or brand fuel Replace the fuel

Engine temperature is too low Observe until the engine reaches normal

temperaturePlateau area with thin air Engine should be power reduced if used in plateau

Intake air temperature is too high Intake air temperature should not exceed 40ﾟc

Block of Fuel pipe and fuel filter Clean the fuel pipe, replace the fuel filter and fuel

coarse filterTurbo boost badly worn out Repair and replace if necessary

Wrong backlash Check and adjust the backlash

Wrong oil supplying time Check the data of fuel pump and let authorized

personnel do the checking and adjusting

20

Symptom Cause Factor Solving Method

Exhaust blue or

white smoke

too much lubricating oil in the engine Check the lubricant level

Using the wrong type or brand lubricating Change the lubricant and filter, ensure to use the

Using the wrong type or brand fuel Replace and ensure to use the correct type of fuel

Leakage of cylinder head Check the cylinder head and cylinder gasket and

The engine reaches overhaul deadline Completely repare the Engine

The generator

could not reach

the rated

running speed

The generator is in overload status Reduce the load, do not exceed the rated load

The potentiometer of electronic speedcontrol board is in error

Refer to electronic governor manual and do theright set or replace

Electronic speed control system failure Repair or replace itMechanical speed controller improperlyadjusted Or loosen

Check and adjust

Fuel pipe block or too small Maintenance or replacement

The fuel contains water Replace fuel, to install water separator if necessary

Three filters are not replaced on time Regularly replace the three filters

Frequency meter or speed meter failure Replace it

Running speed

is not stable

Throttle lever of mechanical governor is Correctly check and adjust it

Electronic speed governor systemimproperly adjusted

Refer to the electronic governor instructions andcorrectly set

Speed system out of control Let relevant authorized personnel overhaul

Have air or water in the fuel system Check and discharge it and replace the fuel

The load is in big difference and with toomuch frequency

Try to control the load

The generator

is running

unstable and

vibrating

Have air or water in the fuel system Check and discharge it and replace the fuel

Block of air filter Regularly replace three filters

Too much lubricant, or lubricant brand iswrong

Check the oil level or change the lubricant andfilter, ensure to use the correct type of the lubricant

The engine intake air temperature is too high Intake air temperature should not exceed 40ﾟCExhaust pipe block or back pressure too high Reduce the back pressure and make the engine

exhaust gas fluently

Injection pump system failure Let authorized personnel overhaul

Incorrect valve backlash Check and adjust valve backlash

Cooling fan damaged Check and repair, and replace if necessary

The generator base is not smooth, and themounting position of absorber is not correct

Check and adjust the position

The using conditions are too bad, the engine

need overhaul in advance

Engine Overhaul

21

Symptom Cause Factor Solving Method

The lubricant

pressure is too

low

Lubricant level is not correct Check the lubricant level then add or discharge thelubricant

The lubricant brand incorrect Use the correct brand of lubricants

Lubricant is long time withoutrereplacement

Regularly change the lubricant

Lubricant filter blockage Regularly replace the three filters

The temperature of lubricant is extremelyhigh

Check and repair or replace the lubricant cooler

Crankshaft or bearings worn out or damaged Check and repair or replace them and also lookingfor the reasons

Valve damage Replace the valve

Suction filter of oil tank blocked Check and repair or replace the oil pipe and clean

the suction tube and suction filterFailures of lubricant alarm switch (sensor)or instrument

Check the control panel, instrument, body sensors,repair or replacement to troubleshooting

Coolant

temperature is

too high

Coolant shortage dding coolant

Radiator blocked Find the solutions to block reasons, clean theradiator

Poor ventilation of radiator According to installation requirements, increasingthe effective area of ventilation to ensure thesmooth flow ventilation

The cooling fan is in improper operation Check the tension of fan belt, replace the belt ifnecessary

Fan damage Repair or replace

Pump damage Repair or replace

Thermostat failure Replace

Fuel pump failure Let authorized personnel overhaul or replace

Oil supply is not timed correctly Check fuel pump data and let authorized personnel

Intake temperature of environment is toohigh

Keep the engine room ventilation and reasonablyreduce the temperature

Generator serious overload Load control, prohibit long time overloadingoperation

Coolant alarm switch (sensor) or instrumentfailure

Check the control panel, instrument, body sensors,repair or replace to troubleshooting

22

Symptom Cause Factor Solving Method

The fuel

consumption is

overproof

External or internal fuel leakage Check and exclude the leakage

Air filter block Regularly replacePlateau area with thin air To operate in lower power

Engine temperature is too low Looking for reasons

Generator is serious overload Control the load prohibit long time overloadingoperation

The exhaust pipe is blocked and backpressure is too high

Check the exhaust pipe, control the back pressure

Oil supply is not timed correctly Check the fuel pump data and let authorized

Incorrect valve backlash Check and adjust valve backlashThe generator enters the overhaul deadline Overhaul the generator

Lubricant

consumption is

overproof

Lubricating oil leakage Check and exclude the leakage

Wrong type or brand of lubricant Change the lubricant and filter, ensure to use thecorrect lubricant

Turbo boost seal and bearing worn out Repair or replace

Piston, cylinder, crankcase badly worn out Check the reason, confirm if enter overhaul period

Insufficient

output power

Relative to the rated power the generator hasbeen overloaded

To operate with reduced load

Power shortage in plateau area Output power should be adjusted in the area withsea level above 1000 meters

Fuel pipe too small or block of fuel filter Check and increase the fuel pipe diameter, reducethe fuel tube resistance, replace the fuel filter

Using the wrong type or brand fuel Replace the fuel and the filter, ensure to use thecorrect type fuel

Return pipe blocked or fuel tank breatherblocked

Check and Troubleshooting

Exhaust pipe blocked and back pressure toohigh

Check the exhaust pipe, control the back pressure

Inadequate of intake air and air filterblocked

Regularly replace the three filters

Intake temperature is too high Keep the engine room ventilation and reasonablyreduce the intake air temperature of the generator

Fuel temperature is too high Try to control the input fuel temperature <70ﾟCInjector pump or speed control system failure Let authorized personnel overhaul or replace

Turbo boost impeller damage or failure Repair or replace

Incorrect valve backlash Check and adjust valve backlash

Oil supply time is not correct Check the fuel pump data and let authorizedpersonnel overhaul adjust

The generator has entered the overhaulperiod

Overhaul the generator

23

Symptom Cause Factor Solving Method

The generator

could not stop

when running

Self start generator with ATS start signal iscut off, but is still running

The situation is regular, the generator will stop afterenter the cooling program

Stop valve is out of control Check whether the line wiring is correct, replacethe valve if necessary

Electronic mechanical governor failure Let authorized personnel overhaul

First turn off the control panel power switch,then press the stop button

You must press the stop button first and then turnoff the power switch

Oil control instrument failure Repair or replace

No fuel or fuel with water or air Check and exclude recommended to install waterseparator

Fuel, air filter blocked Inspect, regularly replace the three filters

Electronic governor failure Let authorized personnel overhaulStop valve protect the shutdown action Check the alarm code, excluding shutdown failureGenerator control panel or control systemfailure

Refer to the control panel manual and repair thecontrol panel

Electric

switch failureThe electric switch automatically tripped

Tripped because of overloadThe switch of palallel operation cut offFailure caused by generator itself , need maintenance

The electric switch could not powered on

Overload or short circuit caused trip, need to restart

Palallel control could not be synchronized

Generator switch failure, require maintenance orreplacement

Control panel

failure

Alarm and shutdownControl panel detects failure and shut down thegenerator, troubleshooting cut off the power andrestart the generator

Electricity failure cause generator could notstart

ATS control system failed to provide "on" signal,checking and troubleshooting

Self start instrument must be powered and workingin the "auto" situation

The control contact wire connection error, check,correct the connection

Self start instrument failure,repair or replace

Electricity is normal but the generator cannot be shut down

The generator is cooled in 3 to 5 minutes

ATS provides "on" signal without turn off, checkthe ATS failure

The instrument makes wrong set of the oil solenoidvalve

24

Symptom Cause Factor Solving Method

Control panel

failure

Unable to achieve remote monitoring

Confirm whether the generator is equipped with

"three remote" control system

Check if the communication line connection is

correct

Confirm if the communication software is correctly

installed in the control computer

Whether use the right password to set the

communication mode

Three remote" instrument failure, repair or replace

Dear user:

Please correctly fill in the "Warranty Registration Form" and send it to our company by email,fax or courier.Copy or scan is also valid. This may help you achieve legal warranty service andperfect after-sales service like technical support and spare parts support during you use "JACA"brand generators.

Thank you again for choosing JACA diesel generator!

Our contact way:Address: No.151 Qiaomo West Road, Qiaosi Street Yuhang district, Hangzhou 311101 ChinaTEL：+86-571-86637576FAX：+86-571-8663513524hours service Mobile：+86-13735460009Email：cw@jacapower.comWebsite：www.jacapower.com

www.jacagenset.com