This document is an owner's manual for an air-cooled diesel engine generator set manufactured by BISON. The manual provides comprehensive guidance on maintaining and repairing the generator, covering all aspects from technical specifications to operation and troubleshooting.
Function Description
The BISON air-cooled diesel generator set is designed to provide electrical power. It is a portable mobile solution suitable for field operations during project construction, and various other applications including pipeline construction and metal welding where electrical power is not readily available. The generator is equipped with an air-cooled, four-stroke diesel internal combustion engine, a direct fuel injection system, and features like recoil starter or an optional electric starter, a large fuel tank, automatic voltage stabilizer, NFB circuit protector, AC and DC outputs, and low oil pressure sensor.
Important Technical Specifications
The manual details several models, including BS3500DSE, BS5000DSE, BS5500DSE, BS6500DSE, BS8500DSE, and BS1600DSE, each with varying power outputs and engine models.
Generator Specifications (for all models):
- Phase type: Single phase/Three phase
- Frequency (Hz): 50 or 60
- Voltage (AC) (V): 110, 120, 220, 230, 240 (for single phase/three phase) or 220/380 (for three phase)
- Voltage (DC) (V): 12
- Current (DC) (A): 8.3
- Speed (rpm): 3000 or 3600
- Power factor (COSΦ): 1.0/0.8 (Three phase)
Specific Model Ratings:
- BS3500DSE: Rated power (KVA) 2.8 (50Hz) / 3.0 (60Hz)
- BS5000DSE: Rated power (KVA) 4.2 (50Hz) / 4.6 (60Hz)
- BS5500DSE: Rated power (KVA) 4.5 (50Hz) / 5.0 (60Hz)
- BS6500DSE: Rated power (KVA) 5.0 (50Hz) / 5.5 (60Hz)
- BS8500DSE: Rated power (KVA) 6.0 (50Hz) / 6.5 (60Hz)
- BS1600DSE: Rated power (KVA) 8.5 (50Hz) / 9.0 (60Hz)
Diesel Engine Set Specifications:
- Type: Single-cylinder, vertical, 4-stroke, air-cooled, direct-injection
- Cooling system: Forced air cooling by flywheel fan
- Lubricating system: Pressure splash, duplex type lubrication
- Starting system: Recoil manual start and Optional electric start
Engine Models and Output:
- S178FAE (for BS3500DSE): Continuous (HP) 5.1 (50Hz) / 5.9 (60Hz), Maximum (HP) 5.36 (50Hz) / 6.6 (60Hz). Bore×Stroke (mm) 78×64. Displacement (L) 0.305. Lube-oil capacity (L) 1.1. Fuel tank capacity (L) 15.
- S186FE (for BS5000DSE, BS5500DSE): Continuous (HP) 7.8 (50Hz) / 8.9 (60Hz), Maximum (HP) 8.6 (50Hz) / 9.9 (60Hz). Bore×Stroke (mm) 86×70. Displacement (L) 0.406. Lube-oil capacity (L) 1.65. Fuel tank capacity (L) 15.
- S188FBE (for BS6500DSE): Continuous (HP) 8.2 (50Hz) / 9.8 (60Hz), Maximum (HP) 9.2 (50Hz) / 11.0 (60Hz). Bore×Stroke (mm) 88×75. Displacement (L) 0.456. Lube-oil capacity (L) 1.65. Fuel tank capacity (L) 12.5.
- S192FE (for BS8500DSE): Continuous (HP) 10.2 (50Hz) / 11.5 (60Hz), Maximum (HP) 10.9 (50Hz) / 12.2 (60Hz). Bore×Stroke (mm) 92×75. Displacement (L) 0.498. Lube-oil capacity (L) 1.8. Fuel tank capacity (L) 12.5.
- S1100FE (for BS1600DSE): Continuous (HP) 15 (50Hz) / 16.5 (60Hz), Maximum (HP) 20 (50Hz) / 20 (60Hz). Bore×Stroke (mm) 2-86×72. Displacement (L) 0.836. Lube-oil capacity (L) 1.7. Fuel tank capacity (L) 25.
Usage Features
Safety Precautions:
- Electris shock and short circuits: Never touch the generator if wet. Ground the generator to prevent electrical shocks.
- Fire prevention: Use only light diesel fuel. Keep flammable fuels away. Ensure proper ventilation.
- Inhaling exhaust gases: Never inhale exhaust gases; operate in well-ventilated areas.
- Accidental burns: Never touch the muffler and cover after the engine has been used, as they remain hot.
- Battery safety: The electrolyte liquid contains sulfuric acid; wear protective gear.
Preparation before Operation:
- Fuel tank: Use only light diesel fuel, filtered clean. Never let dust and water mix with fuel. Avoid overfilling.
- Air filter element: Do not wash the air filter; replace if dirty or damaged.
- Fill engine oil: Fill to the upper limit (Top limit(H)) on the dipstick. Use appropriate SAE oil based on ambient temperature. Change oil every 1 month or 20 hours, or every 3 months or 1000 hours.
- Check air filter: Loosen the butterfly nut, take off the air filter off and take the air filter element out. Clean or replace the filter core.
- Checking the generator welder: Ensure the switch is in the "off" position before starting.
- Checking the operation of the diesel engine: Low-pressure alarm system.
Starting the Generator Set:
- Manual starting: Put the fuel switch in the "ON" position. Turn the handle of the engine to the "RUN" position. Pull the recoil starter handle out until you feel resistance, then pull it vigorously.
- Electric starting: Insert key into ignition to "off" position, put speed handle in "Run" position, turn start switch clockwise to "START" position for 1-2 seconds.
- Battery: Check the height of the electrolytic solution in the battery once a month. Avoid overfilling.
Proper Operation of the Generator Set:
- Operating the diesel engine: Pre-heat the diesel engine for 3 minutes under no load conditions. Check lubricating oil level. Adjust speed limit regulation nut or fuel adjustment bolt.
- Checks during engine operation: Check for abnormal noises and performance.
- Loading: Raise revolutions per minute (turn the speed handle to the max setting) to get maximum power. The automatic voltage regulator device will excite and do this for long periods of time. For rated speed, refer to technical specifications. Observe the voltmeter, it should point to 220V ± 5%(50HZ), (For 60HZ set, it will be 240V ±5%). This is the reading of the voltage at the ac socket.
- Charging the battery: For electric starter generator, the 12V battery is automatically charged through the regulator when it is running. Do not use the generator for long periods of time. Do not connect negative and positive terminals together. Do not reverse the polarities. When charging, the battery produces flammable gases.
- Stopping the generator: Take the electrical load off. Turn generator air switch off. Put the speed handle in the "RUN" position and let the engine run for 3 minutes after unloading. Do not stop the diesel engine immediately. Press down on the brake handle. If equipped with an electric starter, turn the key to the "off" position. Put the fuel handle to the "S" position. Pull slowly on the recoil handle until you feel resistance.
Maintenance Features
The manual provides a detailed maintenance schedule for various components, categorized by interval (Everyday, 1st month or after 20 hours, 3rd month or 100 hours, 6th month or 500 hours, Every year or 1000 hours).
Maintenance Schedules:
- Check and fill enough fuel: Everyday
- Discharge fuel: 1st month or after 20 hours
- Check and fill enough engine oil: Everyday
- Check whether it leaks oil: Everyday
- Check and screw each fastened part: Everyday
- Exchange engine oil: 1st month or after 20 hours (1st time), 3rd month or 100 hours (2nd time late), 6th month or 500 hours (Exchange)
- Clean filter of engine oil: 6th month or 500 hours (Exchange)
- Exchange air filter element: If operated at dusty region, the period of maintenance should be shorten (Exchange)
- Clean filter of fuel: Every year or 1000 hours (Exchange)
- Check high pressure oil pump: 6th month or 500 hours
- Check nozzle: 6th month or 500 hours
- Check fuel pipe: 6th month or 500 hours (If necessary, exchange it)
- Adjust the gaps of air intake and air exhausted gate: 1st month or after 20 hours (1st time)
- Grind air intake and air exhausted gate: Every year or 1000 hours
- Exchange piston ring: Every year or 1000 hours
- Check electrolytic solution of accumulator: Every month
- Check electric brush and slide ring: 6th month or 500 hours
- Check insulation resistance: The time of stop is over 10 days
Specific Maintenance Procedures:
- Changing the engine oil: Take the oil cover out. Take off the oil drain plug when the diesel engine is still hot. Fill with proper engine oil.
- Replacing the oil filter: Replace the oil filter every 6 months or 500 hours of operation.
- Air filter maintenance schedule: Clean air-filter every 6 months or 500 hours of operation. Do not use detergent to clean air filter element.
- Fuel filter maintenance: The fuel filter should be cleaned often to keep the engine running at maximum performance. The recommended time period for cleaning the fuel filter is 6 months or 500 hours of operation. Loosen the small screws on the fuel switch and remove the fuel filter form the port. Use diesel fuel to clean the fuel filter.
- Cylinder head bolt tensions: The cylinder head bolts should be tightened to specifications.
- Battery check: Make sure the electrolytic solution of the battery is full. Perform checks on the battery once a month.
Storing for Long Periods of Time:
- Start the diesel engine for 3 minutes then stop it.
- When the engine is still hot, change the engine oil with new engine oil of the proper grade.
- Pull the rubber plug out of the cylinder head cover and put 2CC of lubricating oil in it, then cover the plug hole up again.
- For manual starting generators, press the decompression handle down and pull the recoil handle 2 or 3 times.
- For electric started generator, press the decompression handle down and crank the engine for 2-3 seconds.
- Finally, pull the recoil starter until you feel resistance; this is when the piston is on the compression stroke where the intake and exhaust valves are closed.
- Clean the engine and store it in a dry place.
Overhauling and Troubleshooting:
The manual includes a table of common malfunctions and their remedies, such as "Not enough fuel" (Add enough fuel), "The switch of fuel is not at 'OPEN' position" (Turn the switch of fuel to 'OPEN' position), "High-pressure pump and nozzle do not inject fuel or the injected amount is less" (Disassemble the nozzle and adjust it at test table), and "Accumulator has not electricity" (Charge the accumulator or exchange it).
Remote Control Instructions:
The manual also covers basic remote control operations, including how to start and stop the generator using the remote. It specifies that the remote control is a precision-fabricated device and advises against dropping it. If the remote control reduces or if the light is dark, replace the battery (23A, 12V). If the remote control was chosen to start the generator, the remote control should be chosen to stop the unit.
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