KUMATSUGEN GP12000MAT Oil Generator 11KVA User Manual

GP12000MAT 053309

v2.2

WWW.NIKOLAOUTOOLS.GR

Technical data

Model|

GP12000MAT

Rated voltage & frequency

| AC 230/400V DC 12V-8.3A / 50Hz
Displacement|

633cc

Rated output

| 10kVA
Max. output|

11kVa

Fuel tank

| 15Lt
Noise db(A) / db(A)|

72db

Generator type

| Closed type, three-phase
Engine type|

Air cooled, single cylinder, 4-stroke

Dimensions

| 1120x640x860mm
Weight|

213kg

Other characteristics

|

Electric starter, transfer wheels

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.

• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

• Always use the product with the supplied equipment. Operation of the product with non-provided equipment may cause malfunctions or even serious injury or death. The manufacturer and the importer shall not be liable for injuries and damages resulting from the use of non-conforming equipment.

SAFETY INSTRUCTIONS

Warning: Read the manual before operating the generator. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. After reading the manual, store it in a safe place for future reference.

Important note: In this manual, the terms ”generator”, ”generating set”, ”generator-set” and ”gen-set” are used interchangeably.

• Only authorized and trained personnel should operate the generator.
• If the generator is known to be unsafe or shows signs of damage, stick a ”Danger” sign on it and cut off the negative wire (-) of the battery, so that the generator cannot be started. Do not connect the wire until the generator has been repaired and is safe to use.
• If the internal parts of the equipment need cleaning or maintenance, remove the negative wire of the battery.
• Allow the generator to run for several minutes before connecting any electrical devices.
• Malfunctioning parts must be turned off immediately and removed.
• Prolonged exposure to high noise levels can be hazardous to hearing. Wear hearing protection.
• Turn off all connected electrical devices before stopping the generator.
• Do not overload the generator.
• The exhaust gas emitted by the generator contains poisonous carbon monoxide which can build up to dangerous levels in confined areas.
• Use the generator only outdoors in well-ventilated areas.
• Always check for spilled diesel fuel and immediately wipe it up before starting the generator.

Installation, movement and transportation

• The generator must be placed on a firm, level surface.
• The wires, grounding and electricity leakage protection equipment used must conform to the relevant standards and other requirements.
• Ensure that the exhaust pipe or muffler is far away from combustible substances.
• Make sure that the pendant and its supports are fixed firmly, correctly connected and can bear the weight of the generator.
• Stand at a safe distance from the generator while it is being lifted.
• Do not sit on the towed generator set or walk and stand on it while it is being transported.
• Before transporting, turn the fuel valve to the ”OFF” position.

Fire and explosion hazard

• The fuel used by the generator and the gas it emits are combustible.
• Don’t store any combustible liquid near the engine.
• Since the cloth used to wipe the equipment can become stained with oil, it must not be stored near the engine.
• Do not smoke, use any tool that produces sparks or perform any other action which can cause the exhaust gas to explode.
• Cut off the power source of the battery charger before connecting or disconnecting the battery.
• Keep all objects which conduct electricity such as metal tools etc. away from the output electrode so as to avoid an electric hazard.
• Don’t inject fuel into the fuel tank while the generator set is operating.
• In case of fuel leakage, don’t try to start the generator.
• Be particularly cautious if a large quantity of unburned gas accumulates in the ventilation system as there is potential danger of explosion. Gas accumulates if the generator is started unsuccessfully repeatedly. Only start the generator once the gas has been vented.

Machinery

• Don’t try to start the generator set if the fan shroud or other safety protection cover has been removed. Don’t try to put hands under or near these protective devices for maintenance while the generator set is operating.
• Keep your palms, arms, long hair, loose clothes and jewellery away from the belt pulley and other rotating parts. Note: Some rotating parts can not be seen clearly while the generator set is operating.
• Watch out for the boiling hot oil, exhaust gas, and hot surface of generator set, as well as sharp surfaces or angles.
• The surface of the generator during operation is hot, for this reason do not touch it with your bare hands.
• Operators of the generator and all nearby workers must wear protective clothes, gloves and hats/helmets.
• Using ether to support ignition is not applicable to pre-heater with gas.
• Generally speaking, all these substances assisting starting are not recommended to be used in all engines, because they can reduce their efficiency and shorten their service life.

Chemicals

• Don’t drink fuel, oil, lubricant or battery electrolyte, or allow them to come into contact with skin. In case said substances are drunk, see a doctor immediately. In case said substances come into contact with your skin, you must wash your skin with soap and clean water immediately.
• Don’t wear clothes stained with fuel or lubricant.
• Wear an acid-proof apron, a face mask and protective goggles when handling the battery. In case the battery electrolyte is touched, wash hands immediately with plenty of water.

Refuelling

• Always shut down the generator before refuelling.
• Allow the generator to cool for at least 2 minutes before removing the fuel tank cap. Loosen the cap slowly to relieve pressure in the fuel tank. Avoid spilling fuel.
• Do not fill the fuel the tank above the upper limit line.

Electrical safety

• The generator can only be operated efficiently and safely if it is correctly installed, operated and maintained.
• Always ground the generator before using it.
• The connection of load must only be performed by an experienced, qualified electrician.
• Make sure that the generator set (including the towed generator set) will be connected to an electric device whose specifications meet local standards for use.
• Stop the generator set and cut off the negative wire (-) of the battery before connecting or removing the load.
• Don’t connect or remove the load while standing in water or damp ground.
• While the generator is generating electric power, charged parts or supply lead must not be touched by human body or by metal parts without insulation.
• After the load is connected or removed, the cover of the junction box must be closed, and don’t operate the generator set when the cover is open.
• The load or power system powered by the generator set must be compatible with the characteristics of the generator set, and must be within the capacity of the generator set.
• Cut off all power sources before performing maintenance.
• Keep all electrical equipment dry and clean. If any cut or wear, discoloration or corrosion of the insulation pipe of lead is found, the insulation pipe must be replaced.
• The terminal posts must be kept clean and compact.
• Make sure that all places where the power sources are connected and the removed power lines have proper insulation.

Safety labels

• Maintain all safety labels on the unit clean and readable. If a safety label is no longer readable, have it replaced.

Charging the battery

• The generator has an automatic charging function. The battery emits hydrogen gas while charging, which is a highly explosive gas. Do not smoke while charging the battery.

PREPARING THE GENERATOR FOR USE

Usage of the oil/water separator

• The diesel generator is equipped with an oil/water separator (Fig. 1) which drains off water from the diesel.
• In order to drain off water from diesel, turn the tap of the oil separator counterclockwise.
• Once the water has been drained off, turn the tap of the oil separator clockwise to prevent diesel from leaking.

Fig. 1

1. Oil/water separator

Note: Before starting, the fuel switch should be opened to prevent air from going into the fuel pump.
Note: Before starting, the speed regulating handler should be set to the ”RUN” position. If the generator has not been used for a long period of time, the handler should be set to the ”STOP” position.

Fig. 2

1. Fuel switch
2. Lube oil dipstick
3. High speed position
4. Low speed position
5. Speed limiter
6. Lube oil coarse filter

Checking the oil level

To check the oil level, take the following steps:

1. Verify that the generator is shut down and on a level surface.
2. Unscrew the oil filler/dipstick cap from the engine.
3. With a dry cloth, wipe the oil off of the dipstick that is located on the inside of the cap.
4. Insert the dipstick and then remove it again. There should be oil on the dipstick. If there is no oil on the dipstick, or oil is visible only at the very end of the dipstick, add oil until the engine crankcase is filled.
5. Put the oil filler/dipstick cap back in place.

Changing/adding oil

To drain the oil from the generator, take the following steps:

1. Place a tray underneath the generator to catch oil as it drains.
2. Unscrew the oil drain plug.
3. Allow all the oil to drain from the generator.
4. Put the oil drain plug back in place and tighten it.

To add oil to the engine, take the following steps:

1. Confirm that the generator is on a level surface.
2. Unscrew the oil filler/dipstick cap from the engine.
3. Using a funnel, add high detergent motor oil to fill the engine to the correct quantity.
   When the engine is full, the oil level should reach the lower lip of the oil filling opening.

Fig. 3

1. Oil drain plug
2. Draining groove
3. Lube oil fine filter

Check the air filter

1. Unscrew the bolt and take out the side plate.

2. Loosen the clipper to take out the air filter cover and reveal the air filter element.
   • Do not clean the element with detergent.
   • The element should be replaced if the output power drops or if the exhaust gas is black.
   • Do not start the generator without the air cleaner in place. Doing so will cause damage to the generator.

3. After putting the air filter element back in place, fit the cover on top of the air filter and retighten the clipper firmly.

Check the generator

• Before starting the generator, turn off the main switch.
• Ground the generator correctly.

Warning: Failure to properly ground the generator can result in electrocution.

Check the fuel piping

• When filling the generator with fuel, ensure that there is no air in the piping.
• In case there is air in the piping, remove it by unscrewing the fuel pump until no air bubbles come out from the diesel and then retighten the screws again.

CHECKING & OPERATING THE ENGINE

Check the lube oil level

• Check the lube oil level prior to each starting.
• It is very important to ensure that the oil level is between the upper and lower limit of the oil dipstick.

Engine break-in

• Before operating the generator normally, the engine should be broken-in for a period of 20 hours.
• Avoid over-loading the engine during the break-in period.
• Change the lube oil after the break-in period has passed.

Fig. 4

1. Upper limit
2. Lower limit

STARTING THE GENERATOR

Preparation before starting

1. Turn the fuel switch to the ”ON” position.
2. Set the speed handler of the engine to the ”RUN” position.

Starting

1. Insert the key and turn it to the ”OFF” position.
2. Set the speed handler to the ”RUN” position.
3. Turn the key clockwise to the ”START” position.
   • If the generator fails to start within 10 seconds, wait 15 seconds before attempting to start the generator again.

Note: If it is difficult to start the engine during winter season, add 2 ml lube oil in the inlet gas passage.
Note: It is very important to retighten the dipstick firmly before starting.

BATTERY

• If the battery is of liquid-added type, the electrolyte levels should be checked on a monthly basis.
• The engine can not be started if the electrolyte level is low. In this case, distilled water should be added.
• If the electrolyte level is too high, the liquid will overflow and corrode the parts nearby.
• During operation, the generator can automatically charge the battery.
• If the generator is used as a stand-by generator, the battery should be charged.

OPERATING THE GENERATOR

Operation of the engine

1. Check the lube oil level. If the level is low, add enough oil so that the level is between the upper and lower limit.
2. Run the engine for three minutes without load to heat it up.

Inspection during operation

1. Check whether there is any abnormal sound coming from the generator or whether the generator is vibrating intensely.
2. Check whether the engine is running properly.
3. Ensure that the color of the exhaust gas is not black or too white.
   • If the generator fails to pass the inspection, the operator should stop the generator immediately and contact the supplier.

ADDING THE LOAD

Adding loads to the AC socket

• When starting the generator, look at the indicator light to check whether there any faults.
• The generator should be run at the rated speed (set the speed handler to the ”RUN” position.)
• When the voltage indication on the control panel reaches ±10% of the rated limit, the load can be added.
• In case the generator does not work properly, remove the loads and find the cause of the problem.
• In case of overloading, reduce the load, then start the generator again in a few minutes.
• If the voltage indication is too high or too low, stop the generator and find the cause of the problem.

Adding loads to the DC socket

• Before charging automatic-type batteries, the wire from the cathode of the battery must be disconnected.
• Connect the charging wire between the battery terminal and the generator anode. Pay attention to the anode and cathode.
• Charge the battery in a well-ventilated area.

Note: Before charging the battery, open the battery cover. If the electrolyte liquid temperature is over 45°C, do not charge the battery.
Note: Do not attempt to start a car with the generator.

MAINTENANCE

Caution: Never perform maintenance procedures while the generator is running. Allow the generator to cool before commencing any maintenance procedures.

Warning: Improper maintenance and/or failure to correct any problems prior to operating the generator can cause a malfunction which could cause death or serious injury.

Note: The mark ”•” indicates that a special spanner must be used.

Change the fuel filter

1. Close the fuel switch.
2. Reveal the fuel filter element by loosening the covers of the oil/water separator. Afterwards, replace the fuel filter.

STORAGE

When the generator has not been operated for more than three months, it should be stored. If the generator has been in storage for 6 months, take the following steps before operating it:

1. Drain off the fuel and lube oil.
2. Remove dust and oil from the outer parts of the generator and from the control panel.
3. Clean the crankcase and gear chamber with diesel and kerosene. Afterwards, drain off the diesel and kerosene.
4. Inject the right amount of rust-proofed oil or lube oil without water (heat the lube oil to about 120°C until no foam exists) into the crankcase. Then, run the engine for 3 minutes to circulate the oil to all the moving parts.
5. Inject rust-proofed oil or lube oil without water into the intake manifold and then run the engine rapidly. Once that is done, close the intake/exhaust valve.
6. Wrap the air filter with water-proof paper and insert water-proof paper into the muffler to prevent dust and moisture from entering.
7. Take out the key.
8. Store the generator in a clean, dry and well-ventilated area free of corrosive materials.

TROUBLESHOOTING

the fuel switch handler to the ”OPEN” position
The engine is out of diesel fuel| Add diesel fuel
Oil is low| Add or replace oil
The injector can’t spray fuel or the sprayed amount is too little| Repair and adjust the injector
The speed control handle is not in the ”RUN” position| Set the handler to the ”RUN” position
There is no electricity in the fuel-cut solenoid| Turn the key to the ”ON” position and check whether there is voltage output (12V-13V)
Dirt in the nozzle| Clean the nozzle
No electricity in the battery| Replace or charge the battery
The generator isn’t outputting electricity| The socket contacts are worn| Adjust the socket
The voltage is too low| The engine isn’t reaching its rated speed| Set the speed control handler to the operation position
Check the AVR (automatic voltage regulator)| Adjust the resistance clockwise

The generators have been manufactured according to strict standards, set by our company, which are aligned with the respective european quality standards. The generators are provided with a warranty period of 24 months for non- professional use and 12 months for professional use. The warranty is valid from the date of purchase of the product. Proof of the warranty right is the purchase document of the generator (retail receipt or invoice). Under no circumstances shall the company cover the relevant cost of spare parts and respective required working hours unless a copy of the purchase document is presented. In case the repair has to be done by our service department the cost of transportation (to and from) is entirely borne by the sender (client). The generators must be sent for repair to the company or to an authorized workshop in the appropriate way and means of transport.

WARRANTY EXEMPTIONS AND RESTRICTIONS:
1)Spare parts that wear out naturally as a consequence of being used (wheels, handles, spark plugs etc.).
2)Generators damaged as a result of non-compliance with the instructions of the manufacturer.
3)Generators poorly maintained.
4)Damages as a result of exceeding the maximum load or maximum duration of continuous operation according to the specifications of each generator type, as presented in the instructions manual.
5)Generators given to third entities free of charge.
6)Storing the generator for a long time with fuel.
7)Damage as a result of mistaken assembly or bad maintenance.
8) Damage as a result of mistaken mixing of fuel with oil.
9) Damage as a result of poor quality of fuel or lubricant.
10) Damage as a result of not cleaning the generator as required.
11)Generators that have been modified or disassembled by unauthorized personnel.
12)Generators used for rent.

The warranty covers only the free of charge replacement of the component that presents a manufacturing defect or material failure. In case of lack of a specific spare part the company reserves the right to replace the generator with another of the same kind. After all warranty procedures have been concluded, the warranty period of a generator shall not be extended or renewed. The spare parts or tools that are replaced remain in the possession of our company. Requirements, other than those mentioned in this warranty form, regarding repairing a generator or damage thereof, do not apply. Greek law and relative regulations apply to this warranty.

WARRANTY

This appliance is a quality product. It was designed in compliance with current technical standards and made carefully using normal, good quality materials. The warranty period is 24 months for non-professional use and 12 months for professional use and commences on the date of purchase, which can be verified by the receipt, invoice or delivery note. During this warranty period all functional errors, which, despite the careful treatment described in our opera ng manual, are verifiably due to material flaws, will be rectified by our after-sales service staff. The warranty takes the form that defective parts will be repaired or replaced with perfect parts free of charge at our discretion. Replaced parts will become our property. Repair work or the replacement of individual parts will not extend the warranty period not will it result in a new warranty period being commenced for the appliance. No separate warranty period will commence for spare parts that may be ted. We cannot offer a warranty for damage and defects on appliances or their parts caused by the use of excessive force, improper treatment and servicing. This also applies for failures to comply with the opera ng manual and the installation or spare and accessory parts that are not included in our range of products. In the event of interference with of modifications to the appliance by unauthorized persons, the warranty will be rendered void. Damages that are a ributable to improper handling, over loading, or natural wear and tear are excluded from the guarantee. Damages caused by the manufacturer or by a material defect will be corrected at no charge by repair or by providing spare parts. The prerequisite is that the equipment is handed over assembled, and complete with the proof of sale and guarantee. For a guarantee claim, only use the original packaging. That way, we can guarantee quick and smooth guarantee processing. Please send us the appliances post-paid or request a Freeway sticker. Unfortunately we will be unable to accept appliances that are not postpaid. The warranty does not cover parts that are subject to natural wear and tear. If you wish to make a warranty claim, report faults or order spare parts or accessories, please contact the after-sales center: Subject to change without prior notice.

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