Shangchai Diesel Generator Operation and Maintenance Manual

Application and Operating Conditions of Shangchai Generator Sets

1.Operating Capacity: The unit can operate continuously at rated power for 12 hours (including 1 hour at 10% overload). If the rated power is designated as standby power, the unit can only run at full load for 1 hour without overload capability.

2.Installation Environment: Suitable for indoor use or protected outdoor areas shielded from sun, rain, and snow.

Startup Procedures

(1) Pre-Startup Checks

1.Verify correct battery connections.

2.Inspect load cable wiring for accuracy.

3.Check oil and cooling water levels.

4.Confirm fuel supply is connected.

5.Ensure the air switch is in the OFF position.

(2) Pre-Startup Preparation

1.Check and top up coolant in the diesel engine radiator if low.

2.Pull out the oil dipstick; add lubricating oil to the specified level if insufficient.

3.Ensure an adequate fuel supply.

4.Test battery voltage (recharge if below 24V) and check battery fluid levels.

(3) Manual Startup Mode

1.Open the ATS cabinet: Verify the dual-power transfer switch key is in AUTO mode (keyhole vertical = AUTO; horizontal = MANUAL). Note: In MANUAL mode, a wrench may be used for manual switching.

2.Turn the control panel key switch to "ON" – confirm instrument backlighting illuminates and parameters are normal. Press the manual mode button (hand icon) to activate the manual indicator light. Press the start button (green icon); after a 3-second delay, the backlight will turn off, and the unit will start at idle speed before accelerating to rated speed. Verify all panel parameters, then press the closing button to supply power.

(4) Automatic Startup Mode

1.Open the ATS cabinet: Ensure the dual-power transfer switch key is in AUTO mode (keyhole vertical).

2.Turn the control panel key switch to "ON" – confirm instrument backlighting illuminates and parameters are normal. Press the AUTO mode button to activate the automatic indicator light; the unit enters standby.

3.Operation Logic:

With mains voltage detected: Unit remains on standby.

Mains voltage loss: Unit starts automatically, and the transfer switch switches to generator power.

Mains recovery: Transfer switch switches back to mains power; unit shuts down after a ~100-second delay and returns to standby.

Daily Maintenance

1.Inspect the diesel generator daily.

2.Check oil and coolant levels.

3.Inspect for damage to the generator and check belts for looseness or wear.

Weekly Maintenance

1.Repeat all daily inspection items.

2.Inspect the air filter; clean or replace the element.

3.Drain water/sediment from the fuel tank and fuel filter.

4.Inspect the water filter.

5.Check the starter battery.

6.Start the unit and verify normal operation.

7.Clean radiator fins (front and rear) using compressed air and water.

Generator Room Management Rules

1.Unauthorized personnel are prohibited from entering. Entry requires approval and accompaniment by staff.

2.Flammable/explosive hazards are strictly forbidden. Fire extinguishing equipment must be accessible; smoking is prohibited in the room and near fuel tanks.

3.Maintain cleanliness: No dust, rust, oil stains, or debris on floors, walls, or equipment. Ensure paintwork is intact and clean.

4.Ensure adequate ventilation, lighting, and functional door operation.

5.The generator room must remain locked; keys are held by designated electricians.

Diesel generator supplier Dingbo Electric kindly reminds that the no-load operation time of the unit should not exceed 10 minutes, and continuous operation of the unit under no-load or low load conditions is not allowed. It is not allowed for the unit to be overloaded for a long time, otherwise the pantograph generator unit will malfunction and the service life of the unit will be reduced. It is strictly prohibited to start or stop the unit with load. It is strictly prohibited to disassemble or replace components on the unit during operation.

Dingbo Power was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. If you want get more information, please feel free to send email to [email protected] we will pay highly attention on your question.