Content

Preface……………………………………………………………………………………….02

Safety regulation…………………………………………………………………………….03

Chapter 1 Purpose and operation condition……………………………………………….04

Chapter 2 Genset model brief introduction…………………………………… ………….05

Chapter 3 Main technical performance ………………………………………………….. 06

Chapter 4 Configuration……………………………………………………………….. …07

Chapter 5 Lifting……………………………………………………………………… … 08

Chapter 6 Installation……………………………………………………………………...09

Chapter 7 Preparation before start…………………………………………………………20

Chapter 8 Start up………………………………………………………………………… 21

Chapter 9 Procedure for normal stop…………………………………………………… ..22

Chapter 10 Maintenances and services………………………………………………………23

Chapter 11 Usual faults and solution………………………………………………………..28

Chapter 12 Instruction and maintenance of bettery…………………………………………50

Unit conversion table………………………………………………………………………..54

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 Preface

This manual contains all the information of installation, operation, maintenance, fault tracing and
solution of THS series standard genset. Manual introduce the work principle and some parameters of
genset. Please kindly read this manual carefully as well as the attached files, such as diesel engine
manual, generator manual, before installation, operation and maintain service for the genset to make
sure the operation is correct.

We strongly recommend that installation, maintenance service of genset should be done by trained
engineer with qualified certification to make sure the genset running normally for long time.

The genset was assembled with precise instrument, if you

want to weld any component during installation and
maintenance please consult us first.

Please don’t start the genset before reading this manual to

prevent any accident.

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 Safety Regulation

Please read this instruction before use the gen-set. It contains the information when you install, operate and
maintain the gen-set, and assure the safety and effect when you operate it.

◆ Fuel is easy to burn; improper operation will cause fire and explosion
When the set is working, fill the fuel tank is forbidden, as it is very dangerous that fuel touch with
diesel engine and exhaust.
Smoking and firing is forbidden, for the fuel is inflammable.
Please check the fuel pipe is fixed and no leaking.
Please assure all the pipes having valves.
Smoking is forbidden when battery is overhauled. Lead-acid battery can bring hydrogen which is
explosive.

◆ Fatal exhaust gas

Please assure a proper exhaust system, and check the system frequently to avoid leakage.
According to the maintenance schedule, to check and assure the pipes are stable. Exhaust gas
Can’t be used to warm house.
Please assure the ventilation is unblocked.

◆ Operating machine can cause accidents.

Please keep away from the running machine, such as your hands, clothes and metal accessories.
Please disconnect the battery loop before you maintain and service for the gen-set. To avoid
unexpected start up, please disconnect negative wire firstly, and then disconnect the positive wire.
Please check the stable degree of all components. Please check brackets and pipe clamps are fixed,
and the shields of gadgets are going to driving belt and fan.
Don’t wear loose clothes and metal accessories. For loose clothes can be sucked into whirling
machine, while metal accessories can cause the short of electric terminal.
Please apart from hot and rotational components, when the working set needs adjustment.

◆ Electroshock can cause heavy wound and death

Please disconnect the electricity before you open the cover of electric equipments. Put dry wood
board on the metal floor near the equipments and use insulating mat. Wet clothes (especially wet
shoes) and skin are forbidden.
Please pay more attention on high voltage when operating.
Please comply with the rules, all the operation and maintenances are operated by a trained and
certificated technicians. To avoid the unexpected close, please put a label on an open switch.
Any commercial electricity can爷t connect with genset directly. Or it can produce a dangerous
voltage. Thus we need to connect an approved isolation switch or an approved parallel system.

◆ Common safety precaution

The boiling point of cooling water in genset is too high. Please don’t open the cooling tank or the pressure head
of heat exchanger when genset is not working, if you want to relief pressure, please cooling the genset first.
Some cancerogenic substances are discovered in fuel, such as benzene and some leaded
substance, please don’t suck or contact with the fuel.
Some cancerogenous substances are discovered in used lube. Please don’t suck or contact with the fuel when
you checking or exchanging lube oil.
Put fire extinguishers in a convenience place. Foam extinguisher can爷t use to put out electric
burning.
Keep rag from genset.
Keep the surrounding of genset clean and dry, and remove all the blocks.
Operating when you tired or drunk is forbidden.

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 Chapter 1 Purpose And Operate Condition
THS series diesel genset is assembled by diesel engine, generator, control panel, radiator (heat exchanger) and
coupling. It’s designed to apply to different occasions and purposes, such as factory and mine, department,
schools, buildings, hotels, military, hospitals, construction sites, oil field, telecommunications, as primary or
backup power.

If the altitude under 1000 meters, ambient temp between +5℃～+40℃, and relative humidity is 60%, Genset
can run continuously for 12hrs in rated mode (which contains overload 10% running 1 hr). When the working
hour exceeds 12hrs, the output power will be adjusted to 90% of rated power, and the power can’t higher than
the rated power of genset.

If the parameters are above the mentioned parameters, then the output power of diesel engine should be
adjusted according to the diesel engine manual, while the generator’s according to GB755-2000 “rotating
generator rated parameter and performance”.

Please don’t operating genset when conductive dust and corrosive gas filling in air. Even though genset is
waterproof and mould proof.

Equipped with Auto refueling system, the genset could be work full automatically for prime power or emergency
power supply, which can perform as prime or standby power supply with remote control, actualize to transfer
automatic between genset and mains, genset and genset.

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 Chapter 2 Genset model brief introduction
TH S W 15 P T - A C1 05 40 - 1

1 2 3 4 5 6 7 8 9 10 11

Design series code

Genset voltage code

Genset frequency code

Control model code

Genset function code

Alternator brand code

Genset operation condition

Genset power or capacity

Engine brand code

Genset character code

Company code

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 Chapter 3 Main Technical Performance

‹ When the voltage of genset between 95%~100% of the rated voltage, power factor between
0.8(lagged)~1,when 3-phase symmetry load is changing slowly or suddenly in the range of rated load
which is between 0~100%, or 100%~0, genset can achieve the parameters as follows:

z Steady voltage regulation factor： ±2.5%

z Steady frequency regulation factor： ≤0.5%

z Transient voltage regulation factor：-15% （suddenly load），+20%（suddenly unload）

z Voltage stable time： ≤4s

z ， +10%（suddenly unload）
Transient frequency regulation factor：-7%（suddenly load）

z Frequency stable time： ≤3s

z Voltage fluctuate factor： ±0.3%

z Frequency fluctuate factor：≤3%

‹ The voltage adjustment range under no load is 95%～105% of the rated voltage.

‹ In rated mode, the voltage change from cool to hot is less than 2% of the rated voltage.
‹ In no load state, while voltage and frequency rated, the line voltage waveform deviation factor is less
than 5%.
‹ Under rated power factor, loading by 3-phase symmetry load, as 25% resistive load of rated phase
power added on any phase, the total load current of the added phase can not exceed the rated value,
and the genset can work normally. In that case, the difference between the max (or mix) voltage and
the average value of 3-phase line voltage can not exceed 5% of the average of 3-phase line voltage.
‹ 2 gensets can be running stably in paralleling operation in rated power factor and the load range
between 20~100% of the total rated power, and actualize exchanges between active power and
reactive power. The allotted difference of active and reactive are less than ±10%.

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 Chapter 4 Configuration

Genset is making of diesel engine, generator, control panel, radiator, coupling and base frame. Diesel
engine and generator are connected by a resilient shaft coupling. The flywheel of diesel engine drives
generator by the help of the coupling. For single bearing construct in comply with the standard of SEA interface,
the flywheel housing of engine and the end shield of generator connected by flange and screw. This method
assures the axiality between engine’s crankshaft and generator’s rotor. It also absorbs the shock brought from

start, stop and load change. Absorbers are fitted between engine, generator and base frame.（referring to

。
Graph-1）

Graph-1 Outline of land using genset

Diesel engine coupled with charging generator and charging regulator. You can charge the start battery set
when gen-set is working. And the gen-set keeps and regulates the output voltage in the rated range
automatically. The cooling system of engine is closed circulating water cooling.

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 Chapter 5 Lifting Of Genset

Please use tight wire or rope with proper length and lifting capacity to lift the genset. To avoid accident, please operate
carefully, for genset will tilt a little when lifting.

Wrong lifting method and wrong wire or rope will

cause serious accident and equipments damage. The rings on engine
and generator can used for lifting whole set

Figure 2 Lifting Of Genset diagram

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 Chapter 6 Installation

1. Base and installation

1.1 installing factors

The main factors of installing a genset:floor's burden,the position of the aisle and maintenance and
service,shock,ventilate,exhaust pipe's connection and heat insulation,noise reduction,dimensions
and position of fuel tank,and also the environmental regulation of your state.

1.2 antishock devices

For THS series diesel gensets,we installed efficient damper.This device aborb 85-90% shock of
genset.Meanwhile,we sent along exhaust system bellows which insulate the shock from exhaust
system.When you installing the genset,please apply some essential shockproof measure
synchronistically such as soft connecting of output cable,evase ventilate pipe,suspending
installation of exhaust system.

1.3base requirements

There is a set of high efficient damper in THS series diesel gensets,so the genset needn't special
base.you can install the genset on floor or mattess which is enough intensity.The floor must be
horizontal and smooth,and the flatness is ± 5°,and the floor should burden 1.5-2times of genset
weight in steady.
If the floor can't meet the burden,please use concrete base.This is a sample,reliable and cheap
method.Please refer to the following formula to design and calculate the thickness of the base:
FD=W/ (D窑B窑L)
FD=thickness o f base, M
W=gross weight of genset, Kg
D= Concrete intensity, 2403Kg/M3
B=width of base, M
L=length of base, M

Concrete base should be higher than floor 100~200mm, and form a base.
When you pouring concrete please focus on:
1. Assure the concrete base is horizontal
2. Assure the base can burden the weight of the genset.

2. Genset installation
2.1 installing sketch of machine room

Machine room must be big enough to let the air recycle freely. Big room also can assure the good
performance of genset, reduce the power loss, and prolong the life of genset. Combustibles and
explosive materials are forbidden in the machine room. And other materials which are easily being
inhaled into genset shouldn`t put in

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For the installation of common genset,please assure the back pressure is less than rated
value,the mouth of inlet air and exhaust air must meet the technical specification,and prevent
the reflux of warm air,and enough room for maintaining.
Some gensets need to install standby fuel tank inside of machine room and meet the
requirement of environment and fire departments.
There is enough inlet or exhaust air hole.If the value of the air is not qualified,please install
additional exhaust pipe or separate water tank. We recommend you to reserve enough room
for operating,maintaining and ventilating around and over the genset.

Please reserve enough room for operating and

maintaining,when auto load transform system(ATS)or
synchronization system are installed in the same room.

2.2 cable connecting

Consider the convenience and satety,when you conncting the cable of genset to
ATS,switchboard and parallel cabinet,we recommend you to pave cable into cable channel in
advance,and apply for some methods to prevent penetrant and electric loss.Electric
connecting must be reliable conncting,prevent loosen and break caused by shock and the
ageing or cracks of isolation.
The selection of cross-sectional area:The output cable of genset should not be too
small,which should be chosen as per the rated currency and refer to the cable selection
manual.

3.Fuel supply system

3.1Fuel
The elements of fuel have played an important role to ensure the normal performance and
the useful life of diesel engine and the componet nof discharge.To gian the rated power,fuel
economy and meet the discharge standards of local environment department,please use the
clean light fuel which should meet the standards of Chinese and international.In
china,common 0# clean diesel is ok.While the genset should assemble the oil water
separator,and apply for some measures to anti freeze and congeal.The oil water separator
should discharge water and other impurity periodically changing the filter core if necessary.
Most of the fuel will transform and deposit after long time storage.For standby genset,it’s
recommended to store some fuel for several hours continuous working. Thus,the best
maintenance perild to clear the fuel tank completely is 18 months.

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3.2Fuel tank
The capacity of fuel tank should be designed according to the fuel consumption of full load.
The following aspects should be noted when you make the tank:
To ensure the thorough discharge of water and heavy impurity,,fuel discharge mouth should
be in the bottom of the tank.Please keep the clearance of fuel,and the distance of oil
outlet(inlet set) and tank bottom is no less than 50mm to ensure the pure of fuel,any water
and other impurities are forbidden in combustion chamber.
To avoid the reduction of burning efficiency and prolong the working time and useful life of
diesel engine,the hot oil of vitta and air can’t enter into the ol outlet and engine directly. Thus
the min distance between oil outlet and oil return mouth should be 300mm.generally,oil
suction is lower than oil transfer pump,while the vitta is higher than oil transfer
pump.Howeve,to avoid the pressure difference too large,the former distance can’t less than
1000mm,and the latter distance is 2500(different engine,the value will be different).For the
difference has played an important role to ensure the normal performance of oil transfer
pump and the normal supply of fuel.
Additionally,please add a drip pan with a little inclination in the tank bottom to collect the
overflowing or leaking oil.
Vent pipe is necessary in the tank top,to exhaust the foul gas and balance the air pressure
timely.
Steel board is the best material of fuel tank.To avoid the chemical reaction between fuel and
tank material,and form impurity and worsen fuel subsequently,painting and galvanizing is
forbidden.Copperplate and galvanized sheet can’t be the materail of tank.
The capacity of tank according to the set working time and the requirement of local fire
department.If the fuel tank is lay in the machine room,an insulating wall is necessary,and a
fire door is added.
The formula to calculate the tank capacity as follows:
Capacity(L)=rated power of engine (KW) x fuel consumption of engine(L/KW.H) x refuel
period(H) x 1.2

3.3 Oil pipe installation

The material of oil pipe should be black iron seamless steel tube,Can't be galvanized
tube.The channel of pipe should keep away from the heat bring by the engine.The max temp
of fuel before the injection pumps between 60°-70°.Different type,the temp will be different.
It's recommended to apply flexible joint between engine and vitta,and make sure the vitta is
no leaking.

4.Lubrication system
The main function of lube is to lubricate and cool the movable components of the gensets.

Exhaust system
The exhaust gas and smoke created by the working genset can't affct the surroundings.So
the exhaust system should be good designed and installed.
The system must contain no less than one muffler.The THS series diesel gensets assembled

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industrial heavy-duty muffler.
To avoid the high temp in machine room,ensure a good running environment and no scald of
operators subsequently and also decrease the noise of exhaust system and
turbocharger,contracting thermal insulation muffling materials on the exhaust air ducts is
necessary.On the out end of the duct should be waterproofed,such as cut a proper angel on
the duct end or add waterproof cap on it.
The number of elbows and total length of exhaust should as small as possible. Or else,the
exhaust back pressure will be higher and lead output power loss,affect the normal operation
and short useful life of genset.The pipe diameter in the genset specification usually is based
on the exhaust pipe length (6m) and one elbow and one muffler at most.In actual
installation,the length of pipe and the number of elbows are more than the prescript in
specification,please increase the diameter accordingly.The range depends on the length of
pipe and the number of elbows.
The first duct from the exhaust main pipe of turbocharger must contain a section of flexible
bellows which was sent along with the genset.The second part of the exhaust pipe should be
flexible supporting,to prevent the incongruous installation, the side press and compressive
stress created by the relative displacement of exhaust system in thermal effect of working
genset.All the supports and suspending equipments should flexible.
When the machine room has several sets,please design and install the exhaust
systemseparately for each set.Common exhaust pipe for several gensets is forbidden.For
different set has different exhaust pressure,the common pipe will cause abnormality and add
the exhaust back pressure.Foul air and smoke will return through common pipe,and affect
the normal power output,even damage the gensets.

6.1 exhaust muffler

THS series diesel gensets assembled industrial muffler.Please choose following mufflers if
necessary.
A industrial heavy-duty muffler
To silence high frequency noise,be fit for common area.
B residential muffler
To silence middle or low frequency noise,be fit for the area with high demanding of
environment.

6.2 exhaust pipe

The thickness of exhaust pipe can't thinner than 2mm.It's recommended to choose steel pipe
with low thermal expansion parameter.If condition permit,all pipes should be contracted
thermal insulation muffling materials.Especially,in those places easily burn the operators.
Usually,the pipe increase per 6m,the sectional area of pipe should be increase 4-6%.
Elbows should be calculated in the total length of the pipes.The method is:the length of
elbows with 90° equal to 2.5-2.8 times of the pipe's outer diameter.
The corresponding length please according to formula(1):
L=2.5×D
L=corresponding length of the pipe
D=pipe diameter

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Formula(2) used to calculate the exhaust back pressure:
P=1.98CLRQ²/D
P=the pressure of mercury
C=0.00059(exhaust flow of engine is 100-400cfm)
0.00056(exhaust flow of engine is 400-700cfm)
0.00049(exhaust flow of engine is 700-2000cfm)
0.00044(exhaust flow of engine is 2000-5400cfm)
L=length of the exhaust pipe(m)
R=exhaust density per cube(kg/m³)
R=39.2/temp of exhaust air+273.3°C
Q=exhaust flow per minute(L/min)
D=diameter of pipe(mm)

6.3 installation of exhaust pipe

If the exhaust pipe need to through the wall,a flexible expansion joint is
necessary.Otherwise,exhaust pipe will be longer for the affection of thermal and cold
shrink,and create side pressure and compressive stress which affect the stability of the
exhaust system,speed up the abnormal consumption of the exhaust and supercharge
system,and break the wall.

When installing the pipe, no side pressure, no compressive

pressure and no lifting force is best, so please keep the
bellows trip free release.

6.4 reduction of exhaust resistance

The total exhaust back pressure will be reduced, if exhaust air and smoke flowing freely.If the
exhaust back pressure of diesel genset is over large, it will lead the output power loss,the
performance and life time will be shorter.
The main factors to lead the high exhaust back pressure of genset
①The diameter of pipe is too small
②the length of pipe is too long
③the number of elbow is too large
④the smooth degree inside of the pipe is too low
⑤the muffler resistance of exhaust system is too big
⑥the high back pressure caused by some critical length
⑥ the high back pressure caused by some critical length
THS series diesel gensets assembled industrial muffler solved the question about exhaust
resistance when we are design it. The data of max exhaust back pressure mentioned in some
relative specification eliminated the harmful affection of muffler. When designing and

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installing the exhaust system, you need not consider the exhaust resistance created by the
device. The length of exhaust pipe, elbows and the smooth degree inside of the pipe, affect
the value of the back pressure directly. Therefore, increase the diameter of pipe accordingly
is a good method to avoid the back pressure created by overflowed resistance. The max
back pressure value of different type will be different. Please refer to the attached file

《Genset Technical Parameter》. The pipe's length and the elbow's number also affected by

the condition of machine room. Please ask the manufacturer for details.

7. Cooling and ventilation system

Ventilation system has played an important role to affect the

output power, consumption of fuel, exhaust of heat airflow
and useful life.

When THS series diesel gensets working, clean air is sucked into combustion chamber and
mix with fuel and create power by burning. Thus genset has been driven. Meanwhile,
abundant of heat air is created when genset working must exhaust out of machine room, it
will consume lots of cool air. Therefore, standard genset must possessing recycle water
cooling or oil cooling system in itself, the cooling and ventilation system of machine room is
necessary. Please make sure there is enough air flowing in the machine room to renew the
cool air burning in the engine and exchanging with the heat air in machine room so that the
temp in the machine room near the environmental temp and keep the genset temp in normal
working range. If the dimensions of inlet and outlet air in your machine room can’t meet the
requirement of the manual, please apply imperative vent mode to meet the need of normal
burning and cooling of genset.
In building, the vents always assembled with jalousies and metal safety mesh curtains.
When calculating the size of air inlet, please take the useless section of jalousie and metal
curtain. In winter, genset is in standby mode, it running occasionally. However, the temp in
machine room must keep proper temp, to prevent the freeze of cooling water, and affect the
normal startup or damage the genset. Thus, the vents must be regulable so that the vents
can be closed be auto or manual when genset stopped. Additionally, install the attached
water tank heater is better, and keeps the heater working.

7.1.1 Air inlet

The proper position of air inlet should meet: the density of dust is as low as possible;
no impunity nearby. If condition permits, the inclined top near the control penal is the best

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choice. Install jalousie and metal safety mesh curtains on it to insulate impunity and ensure
the cross-ventilation. To prevent the return of thermal air, air inlet should far away from air exit,
and let the air flow directly. Air inlet should be preventing to keep rain and other impunities
away. For general recycle water cooling diesel gensets with closed type, the min net
dimensions of air inlet is not less than 2 times of the effective area of radiator core of gensets.
If the dimension is too small, the air inlet will be reduced and the temp of genset will rise
consequently. And affect the genset work, the power output, the maintained period and the
useful life.

7.1.2 Air exit

If the air exit installed jalousies and metal safety mesh curtains, please make sure the
min net dimensions is not less than 1.4 times of the effective area of radiator core. The centre
of the air exit and the centre of radiator core should be concentric. And the ratio between
width and length of air exit is in consonance with the ratio of radiator core. To prevent the
return of thermal air and the outspread of mechanical shock, it's recommended to install
flexible damping trumpet-shaped ventilate channel between radiator and air exit.

7.1.3 Air recycles

Good ventilation system must ensure enough air to inflow and outflow, and recycling freely in
the machine room. Thus, the machine room should be big enough, and keep the temp steady
and air flowing smooTHSy in the room. If condition permits, ventilation system should be
inflow and outflow directly, and prevent the thermal air return to the machine room absolutely.

7.2 Cooling system

The cooling system of THS series diesel gensets can be divided into 3 types to meet
customer's need:
① water cooling with closed recycling fan

② separate heat exhaust system

③ heat exchanger cooling

7.2.1 Water cooling with closed recycling fan
Usually, the standard configuration of THS series diesel gensets contain closed recycling fan
water cooling with water tank inside. Totally, cooling system contains cooling water system
and cooling air system.
When radiator is installed in the end of engine, to place the genset, radiator core should near
the air exit just as the preliminary requirement (it's recommended the max distance between
radiator core and exit is 150mm). Otherwise, thermal air will be return.
If the genset can't be placed as mention method, a canvas ventilating channel with steel

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flange must be installed in the system so that the radiator and ventilating jalousie can be
connected.
The elbows of ventilating channel must have perfect curvature radius. If long flowing pipe is
necessary, the sectional area must increase, to decrease the back pressure of radiator.

7.2.2 Separate heat exhaust system

When genset be installed in the basement, the actual space may limit the use of ventilating
channel. In this case, we usually apply for other cooling method.
The cooling system with divided cooling water tank is a choice we recommend. In this system,
radiator is separate from genset, electric fan used to cooling. This system can be used as a
totally enclosed unit in the wild, and as a room device in open mode. To ensure the
synchronous working of electric fan and genset, we recommend customer apply genset
output power as the power source of electric fan.
When radiator is installed over 3m or the horizontal distance is over 10m, a separated water
tank and an electric water pump is necessary. The measure of separated tank depends on
the capacity of cooling system that is needed pipes plus cooling water consumption.
Cooling water is driven by an electric recycling pump and recycling from divided tank to
radiator and genset. Usually, the power source of radiator fan and water pump motor is
genset. Their consumed power should be calculated into output power of genset. When
genset is not working, the cooling water wills inflow to water tank from radiator. When genset
is working, keep enough cooling water in tank, to assure the good performance of cooling
system.
Notes:

① prevent any impunity into coolant

② the overfall of divided water tank may cause the oxygenation of coolant

③ air can't stay in this system, so the venting pipe is necessary.

④ proper water treatment is necessary to meet the working requirement of genset.

⑤ prevent the coagulation of coolant
⑥ make sure coolant flowing freely (no press) in genset
⑦ if radiator and genset are in the same level, then divided tank is useless. An expanding
water tank over the radiator can be used instead. The expanding tank allow the water
expanding be heated and replace the cooling water.

7.2.3 Heat exchanger system

Another method is heat exchange cooling method which can be divided to 2 modes, one
isstandard heat exchanger cooling, and the other is divided water tank with heat exchanger
cooling. The essential room of this system less than divided water tank cooling. The closed
water channels of this system using the ball valve of supplement water tank to auto replace

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the losing cooling water in vaporization, to ensure enough cooling water in this system.
THS series diesel gensets can assemble heat exchanger to meet customer's requirement.
Heat exchanger can be used in many occasions, such as: the area where water may be
polluted, the occasion where cooling water supplied by cooling tower or storage water tank.
However, the water flowing from heat exchanger can't be used in home.
For the water outflow the cooling system will inflow waste water pipe, drinking water can't be
use in heat exchanger. Please keep the water pressure of heat exchanger near 0.14MPa.
Full ventilation in divided water tank cooling system or heat exchanger cooling system is
necessary. For the burning in engine need enough air, and the ventilating in machine room
and the cooling of radiant heat bring from genset need air too.

To divided water tank cooling system and heat exchanger cooling

system: some engines with turbo charge and (air to air)
supercharge cooling system can't apply divided water tank
cooling system. While some engines with (air to water)
supercharge cooling system are fit for this system.

The engine with (air to air) supercharge cooling system apply the
heat exchanger cooling system, will lead output power loss.

7.2.4 Cooling water treatment

In low temp area, cooling water may be frozen, so the anti –frozen measure of cooling water
in genset is necessary. The detail is: when you pouring the pure cooling water into genset,
please add antifreeze fluid contains 40% ~60% ethylene glycol at the same time. The best
solution is homogeneous mixing water and antifreeze fluid in special container firstly, and
preheats the genset after pouring.
Install a jacket water heater for genset will be better. The power of jacket water heater is main
load 220VAC or 1-phase/3-phase voltage 380VAC. When genset is stopping, the heater can
auto heat the water according to the ambition temp and water temp in genset, and keep the
water temp in genset between +5~+40℃.
In the non -frozen area, it’s recommended to homogeneous mixing cooling water and anti
–rust fluid with proper proportion to avoid pipe rust, and ensure the smooth recycling of water
and the good performance of cooling system.

To prevent the metal rusting in cooling system, anti- trust fluid

in pure water is necessary.

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8. Reduction of noise level
In the area with high demanding of environment, you should pay more attention
on decreasing noise and reducing pollution when you installation.

Common measure to decrease noise level:

Applying noise reduction machine room.
Applying soundproof or super soundproof generating sets.
The noise pollution created by working generating sets can be divided into 2
aspects: noise transmission
created by machine and noise transmission created by air. The former is vibration
expanding from
genset to brace structure, such as cement base, or to linkage structure. The
noise intensity depends on
the balance degree inside genset, shock insulation degree of bumper system, the
quality of machine
and the shocking frequency of genset.
In order to effectively control the noise transmission by air, following 3 parts is
very important:
1. Exhausting noise
It’s the obvious noise exhaust from machine room. Install a high efficiency
muffler such as high
efficient residential muffler to control. Additionally, to reduce the exhaust noise
more efficient, and decrease the noise and gas pollution from working genset,
please design and install the exhaust system higher than normal so that the
pollution can be exhausted to the higher place of the building top. In
principle, the distance between vent and the highest building in the circular with
the diameter of
60m is no less than 5m. Meanwhile, to gain the better reduction effect, the
exhaust system in the machine room should be contracted thermal insulation
materials.
2. Machine noise
Silence treating all circulating parts of the machine room, then the machine noise
will be reduced furthest. Detail measures are: install high efficiency mufflers
which are special for diesel genset on air inlet and air exit; install special silencing
door for machine room. If the width and height is enough, the condition for air
inlet and exhaust is good, and requirement for environment is high, please
apply secondary muffling measure for inlet and exhaust equipment, and
make special muffling room for air inlet and air exit. If requirement is higher,
please stick proper muffling materials on the walls and ceiling of the machine
room additionally.
To resist the transmission of machine noise, please choose proper thickness and
frame for the walls of machine room. More detail please contact with local agent
and franchiser, or contact with the manufacturer directly.

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To avoid the operator working in the noise, all startup control screen, gauges and
switchboards should be installed in a separate soundproof control room.
3. Radiator noise
The measure is the same as the machine noise.
To reduce the expense, high standard is needless, please refer to the standard of
local environment department and the operational requirement of itself when
designing and constructing
To reduce the adverse effect of noise and foul gas, the position of machine room
need far away from center area. Additionally, TH soundproof series is making of
soundproof metal shell with reasonable design and reliable performance. This
series decrease noise greatest and possessing the performance for all-weather.
Trailer soundproof genset and truck type soundproof genset are adapting to
outdoors, and meet the customer's requirement furthest.

wrong installation, operation, maintenance and replacement will cause

serious accident and damage of the genset. Please operate by a
trained and certificated people.

The genset isn’t earTHSing when it out of the factory. Genset

earTHSing must refer to the site condition. Wrong earTHSing and
protection will cause serious accident.

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 Chapter 7 Preparation before Start-up
For initial users of generating sets, reading the following the illustration is

mandatory before operation.

（1）Operating manual of Diesel engine,

（2）Operating manual of Alternators,

（3）Operating manual of control panels,

‹ Check and make sure there is no abnormity of connecting fittings, fastener

and control parts, such as loosen, and lock. Check and make sure the
connecting joints of cable are fasten and correct, and no poor contact.

‹ Check the storage of diesel; make sure it’s enough for running in set working

time.

‹ Turn the switch from fuel tank to fuel transfer pump, and clean the air in fuel

system with governor.

‹ Make sure the cooling water in cooling tank is full.

‹ Set the main switch of generating sets on and off.

‹ Check and make sure the circuit of electric start system is correct, and the

capacity of storage battery is enough.

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 Chapter 8 Start Up

Details about start of generating sets, please refer to the instruction of control

system. After the generating sets working normally, close the main switch, work

in load. Operators must monitor the gauges of voltage, frequency, current, and

power, power factor, oil pressure, oil temp, and water temp, charge current and

rotating speed momentarily. Any indicate value exceed the rated value, check

and apply efficient measure immediately. After recovery, generating sets will work

continuously.

When generating sets working, you may need to open the cover board to check
o or regulate the controller. Some wire holders or components with electricity will
show in air. To avoid serious accidents and damage of generating, only trained
operators with electric maintenance qualification could operate.

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 Chapter 9 Procedure for Normal Stop

‹ Decrease the load gradually, turn off the main switch

When unloaded, transform rotating speed to idling gradually, after the

temperature of water and oil of generating sets under 70℃, then stop the
generating sets.

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 Chapter 10 Maintenances And Services

Proper maintenance ensures the diesel genset runs smooTHSy with long duration and

guarantees power supply. All the customers are required to perform the maintenances

according to the following steps.

1. Before start-up

① Clean the surface of genset.

② Check the coolant liquid level in water tank.

③ The liquid level should be within the limit of 3cm under weld face of tank cover, please

do not overflow.

④ Check and make sure the air cleaner is not blocked；

If blockage indicator is in red area, cleaner should be replaced as soon as

the genset stops running. Press the red button to reset the indicator after
replacement. The replaced air filter is not allowed to be reused. Check the
cleaner every8 hours when the genset runs

⑤ Check the lubricant level of diesel engine.

Make sure the liquid level is between maximum scale and minimscale.
Check the liquid lever every 8 hours when the genset runs continuously.
The replaced oil filter is not allowed to be reused.

2. After start-up

① Check screw bolts of all rotating parts, especially the connecting bolts of injection pump,

water pump, belt pulley and fan.If necessary,please stop and dispose the machine.

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② Check tri-leakage phenomenon and clear it if necessary.

③ Check the generator bearing temperature is normal or not.

④ Excluded from the operation found in the simple failure and abnormal phenomenon。

3. Every 50 hours

In addition to the maintenance items above, the following steps are required,

① Check the battery；

The liquid level should be 10mm above lead plate. Check battery voltage and charge it when

necessary.

② Check tri-leakage phenomena

③ Check tri-filter system. Replace it when necessary.；

④ Check and adjust the tightness of fan belt.

⑤ Add or change the coolant in water tank when necessary.；

⑥ Check the fastness of connection terminals of generator and electric parts.

4. Every 250 hours

① Replace oil (Discharge the oil when heating the genset.)

Please wear eye-protection glasses. There is explosive gas and corrosive

vitriol inside the battery. Ignition near battery may cause explosion.

② Replace oil filter and bypass oil filter

Use special tools to demount the filter. Make sure the new filter is filled with oil so as to empty

the air inside, and then screw it by hands. Screw three or four turns after sealing plate is

placed. Start the genset to check the oil-leakage, stop the genset to check the oil level.

③ Replace the air filter；

④ Replace the diesel oil filter

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Use special tools to demount the filter. Lubricate the gasket and screw the new filter filled with

clean diesel oil by hands. Screw one or two turns after sealing plate is placed.

No dust is allowed in the fuel system. Replace it after the genset is

completely cooled lest the diesel spills onto the exhaust pipe and causes
fire.

⑤ Check and adjust valve clearance

5. Every 400 hours

Check and fasten triangular belt Unscrew the holding screw before fasten the belt conveyer

of synchronous alternator. Belt between each pulley may be pushed down 10mm. Belts used

in pairs should be replaced together. Fan belt is equipped with auto-fastening set Check and

make sure the radiator and intercooler are not blocked. (If they are attached)

6. Every 800 hours

If condition permits, please clean the grease accumulated in fuel tag thoroughly.

① Check and make sure there is no leakage in oil pipe of turbocharger.；

② Check and make sure there is no leakage at the interface part of air valve.

③ Check all the air valves and make sure they are not damaged. Replace it when necessary

and screw tight all the screws；

④ Check the oil injector pressure and atomization. Clean the injector parts and adjust injector

pressure when necessary. Replace the injector nozzle when it’s invalid.

⑤ Check the advance angle of oil injection pump and replace oil inside.

⑥ Clean the fuel tank and pipe.；

⑦ Clean oil sump tank and oil filter

⑧ Check and fasten the connecting rod bolt, main bearing stud and bolt of gas tank cap

⑨ Check the specific weight of battery electrolyte, add it when necessary.

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⑩ Check proofreading instrumentation；

⑾ Check and adjust excitation circuit.

7. Every 1200 hours

① Fulfill all the tasks need to be done after every 800 hours

② Check the valve clearance. Engineers and technicians who have been trained are

required to do it

Stop the genset while checking.

8. Every 2400 hours or based on demand.

① Fulfill all the tasks need to be done after every 1200 hours

② Check the oil injection nozzle.

Engineers and technicians who have been trained and qualified

required checking the nozzle

③ Let professional technicians check the turbocharger, and complete a general examination

to diesel engine and its attachments.

9. Every6 months

①Replace coolant filter

Turn off the coolant tap, demount the filter by special tools, replacea new one and turn on the

tap.

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10. Every 12 months

① Fulfill all the tasks need to be done after every 6 months

② If the genset is equipped with air compressor, please replace the air filter on it.

Steps: Turn on the valve clamp device, demount the filter and destroy it, install a new one and

fasten the bolt.

③ Clean the cooling system/replace the coolant (Only for genset without coolant filter)。

11. Every 24 months

① Clean cooling system/ replace the coolant (Only for genset with coolant filter)

② Check the leakage

High coolant temperature are possibly caused by low coolant liquid level, temp valve

malfunction, fan malfunction, and block in side cooler /radiator or other part of cooling

system.

Remark: different genset, the maintenance step will be different. Thedetails please

change according to your genset.

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 Chapter 11 Usual faults and solution

Diesel engine

1. The engine does not start or runs too slowly

Processing method：

A) Checking electrolyte level. You can supply it, if not

Reason
enough. Charging the battery. Changing the battery,
A) Charge is not enough for battery.
if necessary.
B) DC Current
B) DC Current
C) One of semiautomatic protective
C) Pressing the button of the protective tube and
tubes
making it reset.
in the terminal box uncouples.
D)Getting rid of all of the breaking faults and poor
D) Poor contact/ lines break.
contacting faults. Checking if the contactor is

oxygenized. If necessary, clearing them.

E) Key-switch faults
E) Changing key-switch.
F) Startup relay faults
F) Changing the startup relay
G) Startup motor faults
G) Contacting the authorized officer.
H) Any faults in start lines.
H) Any faults in start lines. H) Checking all the other
I) Lubricating oil temperature is low,
start lines
the viscosity is too large
I) Fixing the lubricant oil pan heater

J) The lubricant oil type is wrong

K) The other reasons influence the

J) Changing the lubricant oil and filter. Ensure make
engine revolution
use of the right lubricant oil.

K) Checking if the crankshaft can be flexible twist.

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2. Engine is difficult to start, but exhaust smoke

Reason Reason Processing method

A) Engine's revolution is too low A) Refer to "can't drive or drive speed is low".

when startup motor drives it. B) Refer to our customer handbook "How to

B) Making use of the cold start gears operate the cold start system".

is wrong. C) Refer to our customer handbook. Checking

C) Preheating is not enough. semiautomatic protective tubes. If

necessary, pressing the reset button and

checking lines, chain button and preheating

relays. If need change the preheating

D) Fuel filter is blocked. components, you must contact the

E) Air in fuel system authorized officer.

D) Changing the fuel filter

F) Inlet line is blocked. E) Getting rid of air in fuel. Screwing up the

G) Gas handling system blocked joint of fuel pipe and fuel filter.

H) Water in fuel. F) Clearing inlet line

I) The fuel type or grade is wrong. G) Clearing air duct

J) Injector fault or type is wrong. H) Changing fuel. Adding oil water separator.

K)Sucker's and oil return tube's joints I) Replacement of the correct fuel

loose in injector. J) Test or adjust pressure. Changing injector.

K) Screwing up the joints.

L) Oil transfer pump faults.

M) Injection pumps fault. L) Checking and repairing oil transfer pump. If

N) Fuel feeding timing faults. necessary, you can change it.

O) Distribution timing faults. M) Please request pump agent to check it.

P) Compression pressure is low. N) Looking over the injection pump's data and

Q) Fuel cut-off valve is blocked adjusting it.

R) Discharge pipe is blocked. O) Adjusting data and making it meetpecification.

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 P) Refer to "Compression pressure is low".

Q) Refer to "Fuel cut-off valve's faults may

occur".

R) Checking if discharge pipe is blocked.

3. Engine can start, No exhausted smoke

Reason
Processing method
A) No fuel in fuel box
A) Adding fuel.
B) Stop electromagnet faults.
B) Checking stop electromagnet. If necessary

change it.
C) Fuel cut-off valve faults
C) Refer to "Fuel cut -off valve's faults may

occur".
D) No fuel is injected from injection.
D) Screwing off the fuel pipe from fuel pump to

cylinder head. And the same time starting

engine, checking if there is fuel outflow.

E) Oil transfer pump's and Inlet line's
E) Screwing up all the pipe joints of filters from
joints loose.
fuel box to fuel pump.
F) Fuel filter or inlet line is blocked.
F) Changing fuel filter, and checking if the fuel

soft pipe is blocked.

G) No fuel in fuel pump.
G) Add fuel to fuel pump.
H) Gas handling system or discharge
H) Checking if gas handling system or dischar
air
air system is blocked.
system is blocked.
I) Contacting agent
I) Fuel pump's drive shaft is broken.
J) Contacting agent
J) Gear pump is damaged or gears

are abraded
K) Checking and repairing oil transfer pump. If
K) Oil transfer pump faults.
necessary, changing it.

L) Checking, clearing and changing injection.

L) Jet hole of injection is blocked.

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4. Engine starts but stops again

Reason Processing method

Reason：
A) Getting rid of air in fuel. Screwing up the
A) Air in fuel system.
joint of fuel pipe and fuel filter.

B) Checking fuel box's up rise.

B) Fuel system is leaked or blocked.
C) Changing fuel filter
C) Fuel filter is blocked.
D) Clean the Inlet
D) Inlet line is blocked.
E) Replacement of the fuel correct
E) The fuel type or grade is wrong.
F) Changing fuel. Adding oil water separator
F) Water in fuel.
G) Refer to our customer handbook. Checking
G) H) Preheating is not enough.
semiautomatic protective tubes. If

necessary, pressing the reset button and

checking lines, chain button and preheating

relays. If need change the preheating

components, you must contact the

authorized officer.

H) Gas handling system blocked.

H) Clearing air duct.
I）Pressure pipe is damaged.
I）Fixing new pressure pipe.

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5. Black exhaust smoke

Processing method

A）Checking if gas inlet system is blocked.

Reason：
B) Checking, adjusting or changing injector.
A）Gas inlet system blocked.
C）Replacement of the fuel correct
B) Injector faults or type isn't right.
D）Checking if discharge pipe is blocked and
C）The fuel type or grade is wrong.
dimensions are right.
D）Discharge pipe is blocked
E）Refer to "Coolant temperature is lower than
E）Temperature is too low for engine.
normal".
F ） Clearance dimension is wrong
F）Adjusting the dimension of clearance
between gas gates.
gates. between gas gates
G）Air duct leak between turbocharger
GChecking if oil return tube is blocked
and cylinder head.
H）Checking if oil return tube is blocked, twisted
H Oil return tube is blocked
and hollowed.
I）Because temperature or altitude is too
I）According to the engine sales handbook
high air is thin.
modifying it
J）Fuel feeding timing faults.
J）Looking over the injection pump's data an

adjusting it.

6. Low lubricant oil pressure

Reason Processing method

A) Lubricant oil level is poor. A) Checking if lubricant oil leak. Add or release
B) Lubricant oil pressure gauge lubricant oil.
faults. B) Checking lubricant oil scale.
C) Lubricant oil is diluted by fuel. C) Checking lubricant oil pressure gauge.
D) Lubricant oil grade is wrong. D) Changing lubricant oil. If lubricant oil is diluted by
E) Lubricant oil temperature exceeds fuel again, Checking lubricant oil grade.
normal value. E) Checking, clearing or changing lubricant oil
F) Lubricant oil filter is smudged. cooler.
G) Cranked bearing is abraded or F) Changing lubricant oil filter.
damaged. G) Checking or changing cranked bearing.
H) Lubricant oil pump is abraded. H) Checking, repairing or changing lubricant oil

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I) Reducing valve isn't closed. pump.
J) Reducing valve is damaged. I) Changing reducing valve.
K) Inlet line faults on lubricant oil J) Changing reducing valve.
pump. K) Checking, repairing or changing inlet line and
clearing nutsch filter.

7. Reeking blue or white smoke.

Processing method
A) Changing lubricant oil and filter. Ensuring make
Reason use of the right lubricant oil type.
A) Lubricant oil type is wrong. B) Fixing, checking and repairing cold startup
B) Cold startup system faults. devices. If necessary, changing it.
C) Temperature is too low for engine. C) Refer to "Coolant temperature is lower than
D) Lubricant oil is too much in engine. normal".
E) Seal gaskets and bearings are D) Checking lubricant oil level.
abraded in turbocharger. E) Repairing or changing turbocharger.
F) The fuel type or grade is wrong. F) Starting engine in a temporary fuel box in
G) Engine had been overhaul life. differentiate.
H) Cylinder head leaks water. G) Overhaul engine.
H) Checking cylinder head and cushion. If
necessary, changing it.

8. Engine can not get rated speed.

Reason Processing method

A) Engine load is heavy relative to A) Reducing load or making use of low grade.
rated power. B) Checking speed in hand tachometer or digit
B) Tachometer faults. tachometer.
C) Control shaft of accelerograph be C) Checking accelerograp excursion.
adjusted wrong. D) Checking if inlet line is blocked. If necessary,
D) Inlet line is blocked. changing it.
E) Speed governor faults or setting E) Checking and adjusting speed governor.
wrong F) Checking and adjusting speed governor.
F) Speed governor's highest limited G) Changing fuel. Adding oil water separator.
speed setting low.
G) Water in fuel.

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9. Engine can not stop.

Reason Processing method

A) One of semiautomatic protective A) Pressing the button of the protective tube and
tubes in the terminal box uncouples. making it reset.
B) Poor contact/ lines break. B) Getting rid of all of the breaking faults and poor
C) stop button faults contacting faults. Checking if the contactor is
D) Stop electromagnet faults. oxygenized. If necessary, you must clear it.
E) Fuel cut-off valve faults. C) Changing stop button
F) Oil return tube is blocked D) Checking stop electromagnet. If necessary, you
can change it.
E) Refer to "Fuel cut -off valve's faults may occur".
F) Checking if oil return tube is blocked, twisted and
hollowed.

10. High lubricant oil pressure

Reason Processing method

A) Reducing valve isn't opened. A) Changing reducing valve.

11. Low coolant temperature

Reason Processing method

A) Coolant level is low. A) Adding coolant.
B) Radiator is blocked or damaged. B) Cleaning it as our customer handbook. If
C) Radiator soft pipe is blocked or necessary, repairing it.
hollowed. C) Checking soft pipe. If necessary, changing it.
D) Fan belt looses. D) Checking belt's tightness, and screwing up.
E) Lubricant oil level is poor. E) Adding or releasing lubricant oil. Checking
F) Cool fan head is damaged or lubricant oil scale.
loosed. F) Checking fan head. Repairing, changing or
G) Radiator pressure head is re-fixing it.
damaged or type is wrong. G) Checking radiator pressure head. If necessary,
H) Thermometer faults. repairing it.
I) The shutter of radiator didn't open H) Checking and repairing it. If necessary, repairing
enough. it.
J) Air filter is blocked or type is wrong. I) Check/fix shutter. If necessary, change it
K) Injectors faults or type is wrong. J) Checking and changing it.
L) Discharge pipe is blocked. K)Checking, adjusting and changing it
M) Fan is damaged. L) Checking if discharge pipe is blocked and
N) Radiator air duct or water duct is dimensions are right.
blocked. M) Changing it.

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O) Coolant is poor in system. N) Checking and cleaning it.
P) Air is collected in cool system. O) Adding it.
Q) Water pumps fault. P) Discharging air in cool system.
R) Temperature controller faults or Q) Checking, repairing and changing it.
type is wrong. R) Checking and changing it.
S) There is air in cool system. S) Checking if there is leaking on the side of suction
T) Injection pumps fault. hose clamp .Checking there is air leaking on cylinder
U) Fuel feeding timing faults. head.
V) Distribution timing faults. T) Checking it by agent.
W) Cylinder cushions leak. U) Looking over the injection pump's dates and
X) Pistons are damaged. adjusting it.
V) Adjusting dates and making it meet specification.
W) Checking it.
X) Changing cylinder sleeves and pistons.
Examining the reasons.

12. High fuel-consumption

Reason Processing method

A) Air filter is blocked or type is A) Examining the reasons. If necessary, changing it.
wrong. B) Checking, adjusting and changing it
B) Injectors faults or type is wrong. C) Refer to "Coolant temperature is lower than
C) Temperature is too low for engine. normal".
D) Clearance dimension is wrong D) Adjusting and checking the dimension of
between gas gates. clearance between gas gates.
E) Pressure regulator faults or setting E) Repairing or re-adjusting it
is wrong. F) Looking over the injection pump's data and
F) Fuel feeding timing faults. adjusting it.
G) The control shaft of accelerograph G) Checking accelerograph excursion.
is adjusted wrong. H) According to the engine sales handbook.,
H) Because temperature or altitude is modifying it
too high, air is thin. I) Checking the highest load. If necessary, reducing
I) Engine is overload. load.
J) Fuel leaks inner or outer. J) Discharging leak.
K) Fuel box air is blocked. K) Clearing and fixing air drain.
L) Discharge pipe is blocked. L) Checking if discharge pipe is blocked and
M) Cold startup system faults. dimensions are right.
N) Air gates are blocked. M) Fixing, checking and repairing cold startup
O) Compression pressure is low. devices. If necessary, changing it.
N) Cleaning, changing or refacing it.
O) Refer to "Compression pressure is low".

- 35 -
13. Engine knock cylinder

Reason Processing method

A) Oil transfer pump faults. A) Checking and repairing oil transfer pump. If
B) Injector faults or type isn't right. necessary, change it.
C) Cold startup system faults. B) Checking, adjusting or changing injector.
D) The fuel type or grade is wrong. C) Fixing, checking and repairing cold startup
E) The control shaft of accelerograph devices.If necessary, changing it.
is adjusted wrong. D) Making use of good quality and lower
F) Temperature is too high for engine. sulphurcontent diesel. Recommending the max
G) Clearance dimension is wrong 0.05%
between gas gates. sulphur content.
H) Lubricant oil is too much or type is E) Checking accelerograph excursion.
wrong. F) Refer to "engine temp is higher than normal".
I) Inlet line leaks air. G) Adjusting and checking the dimension of
J) Fuel feeding timing faults. clearancebetween gas gates.
K) Air gates are blocked. H) Looking over user manual. Making use of the
L) Compression pressure is low. correct capability and type of lube.
M) Cranked bearings are abraded I) Checking if there is leaking. Changing the
and damaged. brokendown
N) Valve springs are broken. components.
J) Looking over the injection pump's setting data and
adjusting it.
K) Cleaning, changing or refacing it.
L) Refer to "Compression pressure is low".
M) Changing it. Checking lubricant oil replacing
period.
N) Changing it.

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14. High lubricant oil consumption

Reason Processing method

A) Seal gaskets and bearings are A) Repairing or changing turbocharger.
abraded in Checking lubricant oil replacing period.
turbocharger. B) Refer to "Pistons, Piston rings, Bearings
B) Piston rings are abraded or and bearing locations are abraded".
damaged. C) Refer to "Pistons, Piston rings, Bearings
C) Cylinder sleeves and pistons and bearing locations are abraded".
abraded or D) Changing lubricant oil or filter. Ensure
damaged. make use of the correct lubricant oil.
D) Lubricant oil grade is wrong.

15. Engine runs unstably

Reason Processing method

A) Fuel ducts are blocked. A) Checking and changing it.
B) Oil transfer pump faults. B) Checking and repairing oil transfer pump. If
C) Fuel filter is smudged. necessary, changing it.
D) Governor spring is adjusted and C) Changing it.
fixed wrong. D) Adjusting and checking it.
E) Injector faults or type isn't right. E) Checking adjusting and changing it.
F) Fuel box air is blocked. F) Cleaning and fixing vent pipe.

G) Air in fuel system. F) Cleaning and fixing vent pipe.

H）Air filter blocked or type is wrong H）Change it. Ensure the correct type.

I）Engine speed governor system is I）Checking and cleaning

stagnated J）Checking and adjusting gas valve gap

J）Gas Valve gap is wrong

K ） Checking and adjusting lube oil volume. Or

K）Lubricant oil is too much or type is change the right lube oil type.

wrong L）Checking and getting rid of it. Checking if the

L）Discharge pipe is blocked discharge tube dimension is correct

M）Injection pump faults M）Contacting agent

N）Compression pressure is low N）Refer to “Compression pressure is low”

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O）Air valve are blocked O）Cleaning valve shaft and duct hole

P）High-pressure oil tube is wrong or P）Rectifying or changing

fixed wrong Q）Changing it.

Q）Valve springs are broken

16. Engine Vibration

Reason: Adjusting method:

A）Injector faults or type isn’t right A）Checking, adjusting or repairing the injector, or

B）Engine speed governor system is changing injector

stagnated B）Checking and cleaning it

C）Engine temperature is too high C）Checking and adding coolant, fan, thermostat,

D）Cooling fan faults checking leakage of water

D）Repairing fan
E）Engine assembly faults

E）Contact authority’s engineer

F）Injection pump fault

F）Contacting agent to check and repair the injection

G）Compression pressure is low
pump
H）The axiality between flywheel and
G）Refer to “Compression pressure is low”
flywheel casing don’t meet the

requirement H）Contacting agent

17. Engine unstable

Reason: Adjusting method

A）Throttle rod gap is too large A ） Adjusting correct gap, if necessary changing

B）Air in oil inlet pipe components.

B）Checking if there is a leakage. Changing the

C）Fly block of speed governor is

- 38 -
stagnated damaged units

C）Repairing it, if necessary, change it.

18.Pistons, Piston rings, Bearing and Bearing locations are abraded,

include cylinder sleeve are abraded

Reason: Adjusting method:

A）There is leakage between air filter A）If necessary, change parts. Ensure no leakage

and turbocharger between air filter and turbocharger

B）Fuel includes too much sulphur. B ） Checking fuel type. Contacting supplier.

Recommending the max sulphur content is 0.05%

19.High Crankcase pressure

Reason: Adjusting Method

A）Air drain is blocked A）Checking if air drain blocked

B）Cylinder sleeves are abraded B ） Refer to “Pistons, piston rings, bearing and

C ） Piston rings are stagnated, bearing locations are abraded”

abraded or broken C ） Refer to “Pistons, piston rings, bearing and

D）Gas valve shaft or gas valve ducts bearing locations are abraded”

are abraded D）Changing gas valves or gas valve ducts

E）Piston are damaged E ） Refer to “Pistons, piston rings, bearing and

bearing locations are abraded”

- 39 -
20. Low compression pressure

Reason: Adjusting Method:

A）Air filter or air inlet system blocked A）Clean air inlet system or change air filter

B）Valves gap is wrong B）Check, adjust valve gap

C）Distribution timing faults C）Adjust and make it to meet specification

D）Cylinder cushions leakage D）Change cylinder head gasket

E）Gas valve can not operate flexibly E）Clean, change or reface gas valve

F）Cylinder sleeves are abraded F ） Refer to “Pistons, piston rings, bearing and

G）Air leakage between gas valve bearing locations are abraded”

and valve seating G）Change, reface gas valve and valve seating

H）Piston ring stagnated, abraded or H）Change piston ring

broken I）Change gas valve and valve duct

I ） Valve shaft or valve ducts are

J）Change gas valve springs
abraded

J）Valve springs broken

- 40 -
21. Fuel valve faults

Examining Item: Examining Method:

A）Fuel valve voltage A）At the working position, electromagnetic valve coil

B）Clatter of Fuel valve voltage should be 24VDC

B）Making key switch turn to the working position,

C）Overflow valve
then turn to the “0” position. Listen if there is a clatter

of valve. If necessary, checking magnet operation,

push start button and stop button in turns, the fuel

valve should have clatters. (if necessary, repeat it.)

C）Checking if overflow valve of injection pump can

be inversion sealed, if not, change it.

Note: Detailed faults and solution of diesel engine refer to the operating instruction of

diesel engine

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 Alternator

1. No voltage

A．Checking if the connection of AVR excitation short wires is correct and firm

B．Checking diesel genset’s speed

C．Checking alternator’s remnant magnetism voltage, if necessary, charge magnetism.

D．Checking alternator and AVR according to excitation apart testing method

2. Unstable voltage

A．Checking if the speed of genset is stability.

B．Checking if steady setup of AVR is correct.

3. High voltage

A．Checking if the genset’s speed is too high

B．Checking if the load of genset is capacitive load. (factor exceeds.)

C. Adjusting the voltage setting resistor of AVR

4. Low voltage without load

A．Checking if the engine speed is too low.

B．Checking if the connection is firm between AVR and external voltage potentiometer. If no

external voltage potentiometer, please checking if the connection is short connecting.

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5. Low voltage with load

A．Make sure if the engine speed is normal;

B．Make sure if setup is correct between AVR and low frequency protecting voltage

potentiometer;

C．Make sure that the AVR is normal according to excitation apart testing method.

D．Make sure if revolving diodes damage.

Electrical control

1. When the key turns to “Start” or press the “START”, genset doesn’t

start.

A．Make sure that key can operate normally

B．Checking the faults is indicated. If necessary, repair and reset faults.
C．Checking if battery voltage is low. If it is too low, battery should be re-charged. If it is
normal, checking if voltage signal is send to all of controlling annulus correctly step by step
in drawing.
D．Checking if emergency button has been loosed.

2. After pressed “Start”, the set cannot be started manual /automatic

A．Checking if emergency button has been loosed.

B．Checking if controlling key is at “STOP” position.
C．Checking if faults are indicated. If necessary, repair and reset faults.
D．Checking if battery voltage is low. If it is too low, battery should be re-charged. If it is
normal, checking if voltage signal is sent to all of controlling annulus correctly step by step in
drawing, oil electromagnetic valve and starter motor etc
E． If there are not problems with exterior connection of the electrical control, should change
relevant governor units.

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3. The start motor running, but the generating set not working

A． Check the fuel level, and make sure the fuel pipe connect exactly.

B． For mechanical governor type, check the installation of electromagnetism valve is correct or not.
the
C． For electric governor type, check the EPG power is right connect and the voltage is correct.

D． For electric governor type, when the start motor running, use ammeter to check the MPU has right

AC voltage signal or not.

E．Check the speed rate is correct

F．Check the fuel transfer system is block or not

G．Check the air filter is block or not)

H．In the cold zone, should pre-heater before start

4. High water temperature alarm/stop

A． Check overload or not

B． Check the radiator is block or not

C． Check the elasticity of the belt

D． Check the water level is enough after the generating set cooling completely.

E． Check the water temperature sensor

F． Check the setting is correctly of not for the RMS-10,AFM-25,IG-CU control module.

G． Check the thermostat valve could be open or not

H． Check the clearance between the radiator and fans is correct or not.

J． Make sure the temperature in generating set room not over 40.

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5. Low oil pressure alarm/stop

A． Check the oil level

B． check the oil’s quality and viscosity

C． Check the oil’s temperature

D． Check the oil pressure sensor is damaged or not

E． Check the setting for the oil pressure alarm is correct for the MRS-10,AFM-25,IG-CU

control module.

F． Check the oil filter or oil system is block or not.

6. Excessive speed faults cut down

A． Check the speed meter is right or not

B． For the mechanical governor type, check the sensitive of the fuel valve, and make sure the

correct adjustment.

C． For the mechanical governor type, check the sensitive of the fuel valve, check the action of

the execution system is correct, make sure the EPG in the right setting)

D． Reset the overload protection date

7.
E． High Voltage
Check alarm
the setting of the overload protection is correct or not, for the MRS10, AMF25,

IG-CU control module.

F． Recovery the Alarm on the control panel, after fix the problem.

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7. High Voltage alarm

A． Measure the current output voltage

B． Make sure the meter date is correct

C． If the current voltage is higher, then check and adjust the AVR according the process.

D． Make sure the loading is non-compliant, the power rate doesn’t exceed.

E． Make sure the speed and frequency is correct.

F． If the current voltage is right, then check the circuit part is correct or not.

G． Check the setting is correct or not for the high voltage alarm, for the MRS10, AMF25, IG-CU

control module.

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8. Low voltage alarm

A． Measure the current output voltage.

B． Make sure the meter date is correctly.

C． If the current voltage is lower, then check and adjust the AVR according the process)

D． Make sure the speed and frequency is correct.

E． If the current voltage is right, then check the circuit part is correct or not.

F． Important point, check three fuss that in the back of the alternator terminal box is right or

connect correct.

G． Make sure there is no big difference between the three phase voltages.

H． Make sure have no phase lack.

I． Make sure when alarm, the change of the loading is small.

J． Make sure not over loading.

K． Check the setting is correct or not for the high voltage alarm, for the MRS10,AMF25,IG-CU

control module.

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9.Genset can`t drive load

9.A．
TheCheck the voltage
generator is correct
can’t or not.
loading
B． Check the loading character, make sure have no overloading and power rate exceed.
C． Make sure all the setting and the position of MCCB is correct.
D． If with ATS, the important point is check the ATS and concerning parts.
E． Check all the connection of the ATS control, make sure all correct.
F． Make sure the ATS switch position not in Manual position.
G． When the switch of the ATS on the Auto position, make sure the main electricity without voltage.
H． Make sure the line between ATS and generator has right connected.
I． Make sure the main AC contactor of the ATS working nice, no block.

10.Can’t manual stop

A． Check the key and control switch in the right position.

B． Make sure the electric control parts all right.

C． Check the fuel electromagnetism valve is right, if necessary, change it.

D． For the electric governor type, make sure the all setting of the EPG is correct.

E． Make sure the setting of fuel pump is correct.

F． Make sure the generating set is running under the manual model, for the MRA10, AMF25, IG-CU control

module.

11.Can’t auto stop in the Auto running model

A． Make sure the main electricity completely recovery.

B． Make sure the main electricity sensor have no action.

C． Make sure the set is still in the delay of auto stop process or not.

D． Check the fuel electromagnetism valve is right, if necessary, change it.

E． For the electric governor type, make sure the all setting of the EPG is correct.

F． Make sure the setting of fuel pump is correct.

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12. Can’t realize the remote control

A． Make sure the remote control software is right installed in the PC.

B． Make sure the connection and the communication date setting of the remote control is correct.

C． When the communication version is dial, make sure the Modem in the generator will be right detection,

and make sure the date setting of the Modem is correct.

D． Make sure the communication line is right, no block.

E． Make sure the connection between the communication model and communication port of the set is

correct.

13. Can’t realize remote emergency cut down.

A. Ensuring genset has realized remote communication.

B. Ensuring control has been fixed protocol adaptor. And connection is correct..
C. Ensuring wire connections are correct and not lose.
D. Ensuring genset is the auto standby mode.
E. Ensuring remote control password has been inputted correctly.

Mentioned above are common faults, details faults and solution

Remark: The faults and solution of generators are different.please

referring to operating manual of genset.

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 Chapter 12 Maintenance And Instruction Of Battery
1. Operating principle
The accumulator of diesel genset is consisted of several individual battery grids with lead (Pb)
plates insides. They are immersed in the well-proportioned (H2SO4) electrolyte, and
continuously generate DC signals from chemical reaction of Pb and vitriol. The chemical
reaction in the battery is reversible, which means the battery can be recharged and
re-discharged as the following formula:
Pb+H2SO4= PbSO4+2H-+2e+

2. Electrolyte
The electrolyte in the lead-acid battery is diluents vitriol solution with specific concentration.
It’s mixed with vitriol and pure water in special ratio, which causes chemical reaction of sheet
metal and becomes conducting medium.

3. Density
Density is unit to measure density. The density of full charged battery should be 1.27 at
temperature of 25 ℃. The vitriol concentration of electrolyte is lower, the density is lower.
When the accumulator is discharging, chemical reaction will reduce density of vitriol in
electrolyte. So, the concentration of electrolyte reflects the charge situation of accumulator.
The most simple and reliable method to check the density of electrolyte is to use araeometer
which is a global glass pipette, draw some electrolyte out of the accumulator by pipette, the
scale at the same level with glass buoy of araeometer indicates the density of electrolyte.
In the process of checking the density of electrolyte, customers should pay attention to the
following aspects:
1. To ensure a real result, please don’t measure the density as soon as the battery grids
have been filled with liquid. Charge the battery to smooTHSy mix the water and
deposited vitriol the density measured in this way is reliable.
2. The density measured after genset runs long time is higher than the real value.
3. Adjust density
In the area of ambient temperature higher than 25 ℃ (77℉), should use density 1.240
electrolyte, because this higher temperature could make electrolyte more active, and medium
concentration electrolyte could extend use period of battery. On the contrary, in the cold area,
should fill in heavier density electrolyte, in some case, could use density 1.290—1.300
electrolyte.
Araeometer scale should be adjusted under the temperature 25℃(77℉), density of
electrolyte should be adjusted according to local temperature, that is, every 5.5℃(10℉) rise
in temperature, the reading is 0.004 more. while if the real temperature is 5.5℃(10℉)lower
than the referenced temperature, the reading is 0.004 less.

Slowly add the electrolyte into the accumulator to prevent the

liquid from splashing

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4. Maintenance of accumulator

In the process of maintenance, it’s required to wear acid proof apron, face mask
and eye-protector. If the electrolyte spills on the skin or clothing, wash it by water at
once

The accumulator attached with genset is no electrolyte when it arrives at the customer’s, add
smooTHSy mixed electrolyte at proper density before using it. Unscrew the cap of battery
grid, slowly pour the electrolyte to the middle of two scales up the sheet metal, and close the
upper scale. Don’t use it at once until the accumulator is discharged for 15 minutes.
Customers can connect the accumulator with the charging set if it’s available.
The charging time should be within 4 hours at the first time, or the life period of accumulator
will be shortened.
The charging time can be extended on the following cases.
1. The storage time is over 3 months; charge time can be over 8 hours.
2. Ambient temperature is continuously over 30℃(86℉)or the relative humidity is
continuously over 80%,charge time can be over 8 hours.
3. The storage time is over one year; charge time can be over 12 hours.
4 If the charger current is inadequate, the charge time should be extended at proper
proportion.
5. When the charge is about to finish, check the liquid level of electrolyte, add standard
electrolyte of
proper specific density if necessary.
What needs to note, the charge current and charge time depends on the accumulator
condition and
quantity of electricity remain in the accumulator.

When the accumulator is charged, unscrew the filter cap or gas nozzle; check
the liquid level of electrolyte. Adjust it with distilled water when necessary.

Turn on the charger to observe normal charging rate. Capacity (Amp-hours) depends on
accumulator
condition and charged level. Charging current will decrease with the saturation of battery.
Disconnect
the charger and let the accumulator rest for a while before checking the charging situation,
use araeometer to measure the density of each battery.
Liquid will be evaporated a little under normal operation, so the accumulator liquid needs to

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be charged
at any moment. Clean the accumulator surface, especially around its charging intake to keep
the dirt
out of the battery grids, and then take off the spout plug and charge distilled water to proper
liquid level.
Besides, to exhaust waste gas and prevent the globule from curdling inside the battery grid,
it’s
required to uncover the vent hole to ensure the air circulation.

5. Charge Accumulator

Make sure it’s charged in draughty environment without spark or naked flame around.
Don’t charge it in windy or snowy environment. Keep the charger away from water.
There are three types of charge accumulator: Charging set equipped by our customers
themselves, battery floating set installed in control panel, charging set attached with genset.
These three charging equipments have different working condition; the brief introduction is as
follows:
1. If the genset is set as manual start of control panel, our customers need to install another
charger to
the accumulator on long time storage condition, because there is no battery floating set in the
control panel.

Make sure the charging set is disconnected before diesel genset starts.

2. The control panel of THS-series genset attached with accumulator. There is floating set
indicating
charging voltage inside the panel, with single commercial power of standard voltage
(220VAC)as its
power supply, which prevents genset from over-discharge in long time storage, which causes
damage
of batter and affects genset start-up. Customers are only required to correctly connect single
phase mains power of 220VAC with relative connecting terminal in the control panel. No
need to install charging set. The battery floating set is capable of continuous charging for
24hours. Its merits are: No extra maintenance to accumulator is required after the power
supple is correctly connected. Besides, because it’s is provided with special charging method
as well as overall protection of over voltage and over current, the charging process does no
harm to the accumulator under standard voltage of 220VAC. After genset starts, electric
control will automatically disconnect floating circuit, which well protects the charging set and
accumulator.
3 When diesel genset is running, electric connection of genset ensures the floating set will be

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automatically disconnected with accumulator. And the attached charging set of genset will
keep
charging to the accumulator. The floating set won’t charge automatically until the genset
stops
running.

High temperature can also damage the accumulator. The temperature of accumulator is
forbidden to over 48℃ in the process of charging.

6. Charging faults and solutions

Fault No.1 No charging current
Reason Fault clearance
Charge cable is not correctly connected with Check and clean cable and terminal
accumulator terminal is not good
Accumulator is damaged or charging voltage Replace the accumulator or adjust the
is too low. voltage
No voltage from mains power, wrong Check the mains situation and its connection
connection with charger
Charger fuse is burned out Replace it with new one
Rectifier diode is damaged Replace it with new one

Fault No. 2: No Charging current display

Reason Fault clearance
Charging ammeter Replace it with new one
Fault No. 3: Low charging efficiency
Reason Fault clearance
Mains voltage is lower Check the mains supply situation
The tap of charger transformer is wrong Check whether the mains whether
correspond with tap or not
Terminal of charging cable is loose Check and fasten the terminals
Fault No. 4: Charging terminals heats
Reason Fault clearance
Bad connection of terminal Clean and reconnect terminals
Terminal screw is loose Clean and fasten the screw

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 Unit Conversion Table

Metric system change to British British system change to Metric

system system
Metric British British Metric
Coefficient Coefficient
System System System System
mm inch 0.03937 inch mm 25.40
Length cm inch 0.3937 inch cm 2.540
m foot 3.2808 inch m 0.3048
2 2
mm sq.in. 0.00155 sq.in. mm 645.2
Area 2 2
m sq.ft. 10.76 sq.ft. m 0.093
3 3
cm cu.in. 0.06102 cu.in. cm 16.388
3 3
liter,dm cu.ft. 0.03531 cu.ft. liter,dm 28.320
3 3
Volume liter,dm cu.in. 61.023 cu.in. liter,dm 0.01639
liter,dm3 imp.gallon 0.220 imp.gallon liter,dm3 4.545
3 3
liter,dm U.S.gallon 0.2642 U.S.gallon liter,dm 3.785
m3 cu.ft. 35.315 cu.ft. m3 0.0283
Force N Ibf 0.2248 Ibf N 4.448
Weight kg Ib 2.205 Ib kg 0.454
kW Hp(metric) 1.36 Hp(metric) kW 0.735
Power kW Bhp(British) 1.341 bhp(British) kW 0.7457
kW BTU/min 56.87 BTU/min kW 0.0176
Torque Nm Ibf ft 0.738 Ibf ft Nm 1.356
MPa psi 145.038 psi MPa 0.0069
Pa mmH2O 0.102 mmH2O Pa 9.807
Pressure Pa inH2O 0.004 inH2O Pa 249.098
kPa inH2O 4.0 inH2O kPa 0.24908
mH2O inH2O 39.37 inH2O mH2O 0.0254
kJ/kWh BTU/bhp 0.697 BTU/bhp kJ/kWh 1.435
kJ/kg BTU/Ib 0.430 BTU/Ib kJ/kg 2.326
Energy Work
MJ/kg BTU/Ib 430 BTU/Ib MJ/kg 0.00233
kJ/kg Kcal/kg 0.239 Kcal/kg kJ/kg 4.184
Fuel g/kWh g/hp 0.7355 g/hp g/kWh 1.36
Consumption g/kWh Ib/hp 0.00162 Ib/hp g/kWh 616.78
2 2 2 2
Inertia kgm Ibft 23.734 Ibft kgm 0.042
Flow I/s cu.ft/min. 2.1189 cu.ft/min. I/s 0.47194
Speed m/s ft. /min. 196.85 ft. /min. m/s 0.00508
Temp. 0F=9/5×0C+32 0C =5/9×(0F -32)

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