GY 6000 DSAX - Martin Diesel Inc
Contents
1. STOP Read absolutely and be duly attentive GENERAL ADVICE If the advice is not re spected damage can happen to persons or things HIGH VOLTAGE Attention High Volt age There can be parts in voltage dangerous to touch The non observance of the advice implies danger to life FIRE Danger of flame or fire If the advice is not respected fires can happen HEAT Hot surfaces If the advice is not re spected burns or damage to things can be caused EXPLOSION Explosive material or danger of explosion in general If the advice is not re spected there can be explosions WATER Danger of short circuit If the advice 5 not respected fires or damage to persons can be caused SMOKING Cigarettes can cause fire or ex plosion If the advice is not respected fires or explosions can be caused ACIDS Danger of corrosion If the advice is not respected the acids can cause corrosion with damage to persons or things WRENCH Use of tools If the advice is respected damage can be caused to objects and to persons SYMBOLS WHICH INDICATE WHAT MUST BE DONE TO AVOID INJURY Use only with safety clothing It is compulsory to use the personal pro tection means given in equipment Use with only safety material EN It is prohibited to use water to quench fires on the electric machines Use only with non inserted voltage It is prohibited to make interventions before hav2. 11 09 01 HP007M6 9GB USE AND MAINTENANCE PREPARING THE UNIT BATTERY The battery included with this generator is an Absorbent Glass Mat AGM type battery It does not require any maintenance and cannot leak even if turned on it s side SEA LUBRICANT ordrstck Check the level of the engine oil using appropriate oil dipstick the level vorne should be between the minimum and ax maximum marks If necessary add more oil RECOMMENDED SAE VISCOSITY GRADES For the type and viscosity of oil refer to owner s manual for the engine supplied with the machine It is recommended that 15W40 oil be used in the YANMAR diesel engine Ux NOTE Before starting the engine read the instruc tions in the owners manual for the engine FUEL Fill the tank with good quality diesel fuel GG ATTENTION Diesel fuel is highly inflammable before filling the tank stop the en gine Do not fuel in the presence of open flames If fuel is spilled the engine clean it Eed Immediately before starting up the engine GROUND CONNECTION is obligatory to connect the ground connection point by means of a sure efficient cable please fol low the local installation rules and or regulations in force in order to integrate or ensure the working of various electric protection devices referring to the several distribution systems TT TN IT The unit can be started only when the above op
3. ing disinserted the voltage No smoking It is prohibited to smoke while filling the tank with D fuel SYMBOLS WHICH GIVE ADVICE ON HOW TO AVOID INJURY AND DAMAGE Use only with safety tools adapted to the specific use It is advisable to use tools adapted to the various mainte nance works Use only with safety protections MP It is advisable to use protections suitable for the different daily checking works Use only with safety protections is advisable to use all protections while shift ing the machine Use only with safety protection M er Itis advisable to use protection suitable for the different daily checking works 27 3 00 35672M2 1G USE AND MAINTENANCE IMPORTANT SAFETY INFORMATION IMPORTANT ENGINE FUELLING Stop engine when fuelling us Read and understand these instructions Gun id 4 TT rz Before installing operating or servicing this equipment read do not use electric tools when fueling the operating manuals of the welder and of the engine r Not observing the information in the manuals can result in e the fuel cap slowly to let out the fuel va ersonal injury and or damage to the equipment and other 4 3 not over fill the tank ts Respect all safety regulations and laws when operting this Avoid spilling fuel on hot NIINE equipment Wipe up spilled fuel before starting engine Shut off fuel cock if present or r
4. DIESEL INC Defiance Ohio 43512 30737 Phone 1 419 782 9911 Fax 1 419 782 6741 Internet www martindiesel com Email sales martindiesel com
5. activates again check the rating of the load and the wiring between load and generator Remove the load and reset Isometer or GFI Check without the load If they activate there is an isolation fault or leakage to ground in the generator or internal wiring If not reconnect the load If they are activated with the load attached there is an isolation fault or leakage to ground in the load or related cables Disconnect the load and see if the voltage is normal If there is not output replace the alternator 27 7 01 HQ002M40 2G USE AND MAINTENANCE MAINTENANCE WARNING e Maintenance and repair work should only be done by qualified personnel e Stop the engine before doing any work on the machine If for any reason the machine must be operated while working on it be careful not to touch rotating parts hot surfaces live wires etc which may be unprotected e Remove protective guards only when necessary to perform maintenance and re MOVING place them immediately after the maintenance 15 completed HOT surface PARTS e Use suitable tools and wear suitable clothes can can injure e Do not modify the machine without prior authorization hurt you MAINTENANCE OF THE MACHINE Maintenance refers to all operations regarding the control and replacement of mechanical and electrical parts sub ject to wear In addition it refers to the control and topping up or replacement of fluids such as fuel oil and battery acid and the
6. GY 6000 DSAX Viartin Diesel INDEX M GB INDEX M 1 1 M 2 2 1 M 2 5 M 2 6 M 2 7 M3 M 4 1 M 6 9 M 20 1 M 21 1 M 22 1 M 31 M 37 M 39 6 M 40 2 M 43 M 43 1 1 M 45 M 51 M 53 M 60 M 61 1 M 61 2 R 1 HP 10 11 12 KA 13 NOTE SYMBOLS AND SAFETY PRECAUTIONS IMPORTANT SAFETY INFORMATION INSTALLATION ADVICE INSTALLATION PACKING TRANSPORTING AND MOVING CTM2 ASSEMBLY PREPARING THE UNIT STARTING THE ENGINE STOPPING THE ENGINE LEGEND CONTROLS USING THE GENERATOR ENGINE PROTECTION TROUBLE SHOOTING MAINTENANCE MAINTENANCE STORAGE TECHNICAL SPECIFICATIONS DIMENSIONAL DRAWING ELECTRICAL SYSTEM LEGENDE ELECTRICAL SYSTEM ENGINE ELECTRICAL SYSTEM GENERATOR SPARE PARTS LIST EXPLODED VIEW MACHINE EXPLODED VIEW ACCESSORIES 11 09 01 HP007M1G INTRODUCTION Dear Customer We wish to thank you for having bought our product We have made it to the highest standards and it will serve you for many years Before using the machine please read this manual atten tively Follow the instructions to avoid problems improper use of the machine and incorrect maintenance The manual is an integral part of the machine and should be kept together with the machine some of the figures contained in this manual are only to identify the described parts and may not correspond ex actly to those on the machine in your possession GENERAL INFORMATION In the envelope where you found this manual t
7. HP007R1G GY 6000 DSAX 41 29 04 03 HP007HP26 GY 6000 DSAX 7 POS 11 13 14 15 16 21 21 24 19 11 20 16 18 SSS ep Ch Te P OL Y Gi d al 9 j ft TARTINGL Og COLISEUM STARTING RENT mete ay 3 6 240 6 ul 6 LI o n N TA e lt I 23 22 CODE CODE POS 7 1 HP007C030 102013290 23 01 02 11 GY 6000 DSAX 62 63 POS CODE POS CODE POS 50 37280821 58 256602228 66 356722050 75 372821031 CODE POS CODE 309509005 am 52 37280975 60 372802212 69 372802139 53 37280226 61 37280815 70 102802200 94 372822020 62 356720100 71 0071050 J 55 356722070 63 562106 72 356728200 56 343339601 64 10730080 73 8356708000 97 356728005 65 74 20902422 2 23 09 02 HP007HP12 KA 13 GB 2 372800130 assy n m m AE EE AA m ip NE ELVMZOOIH 10 60 11 m m lege mm Lind a m nam m muri e m 7 7 7 77 l bea mm ERR msn a CUm E MS EL CODE 372801160 lt OD TOON CON CO CN POS MARTIN
8. chine Hot air and or exhaust gas which 1 recircu lated wll cause overheating of the machine and poor combustion in the engine Make sure that the machine does not move dur ing operation Protect the machine from rain and do not put it in a loca tion where there is danger of flooding Water infiltration can cause short circuits which can be dangerous for persons and can damage the machine The degree of protection of the machine 49 is written the rating plate and in this 448 ual the Technical Data page MOVING THE MACHINE Before moving the machine turn off the engine and disconnect all cables which could impede the move 20 7 01 HQ002M2 6GB GY 6000 DSAX INSTALLATION Central lifting eye Cover opening Air entry generating set Cover opening Engine air entry Fuel filling inside 29 08 01 HP007M2 7G USE AND MAINTENANCE M UNPACKING GENERAL PACKING INFORMATION Upon receipt of the goods make sure that the product has not been damaged during transport In case of damage or missing items you must inform your freight forwarder immediately Packing materials must be disposed of according to local regulations UNPACKING THE MACHINE 1 Take the machine C out of the carton Locate the Users Manual B which is packed together with the engine manual and accessories in a plastic envelope A This envelope may be under or i
9. d Sa TOMLNOD N N s w die ats sth EE EEN 3 T os N 3 jo s voel 1 NO c ele C LOWZOOdH 10 60 50 020901966 0000507 NS9EI0de7 WSC 0009 AD 4u Bug 43166590 au EIN 510 eed 3102008810 BUILD Z AOvIg ONS3N 8 11419 Xy E 3019 7119 18 340122 uiuo uag Bed eg 4 0550 gt lt LLJ ES 03405503 y Dr SERIA 52 NE ERE E 40109 YaN3937 N lt FEE no a e Lu TASH II Nr VOG AOFG YOE Or C OCI WOZIAD E vOC AQC m N3345 30H3A oct Dey fo q Tal 9 N339 3043A 38108504 24093 93EAQCLUA OW 0D amp 2 EE EICH EICH GY 6000 DSAX SPARE PARTS LIST The company guarantees that any request for spare parts will be satisfied To keep the machine in full working order when replacement of company spare parts is required always ask for genuine parts only gt The requested data are to be found on the data plate located on the machine structure quite visible and easy to consult When ordering spare parts it is recommended to indicate serial number 2 3 model generating set 4 position no 5 quantity 12 09 01
10. ediate danger for persons as well for things Not following the advice can result in serious injury or death IMPORTANT ADVICE Advice to the User about the safety WAR N gt The information contained in the manual can be This heading warns of situations which could result in in changed without notice jury for persons or damage to things Potential damages caused in relation to the use of these instructions will not be considered because these are only indicative Remember that the non observance of the indica tions reported by us might cause damage to per CAUTION sons or things It is understood that local dispositions and or laws must be respected To this advice can appear a danger for persons as well as for things for which can appear situations bringing mate rial damage to things IMPORTANT Situations of danger no harm to persons or things N OTE Do not use without protective devices provided ATT E N T Removing or disabling protective devices the machine is prohibited These headings refer to information which will assis you SEENEN in the correct use of the machine and or accessories condition The machine must be in good working order before being used Defects especially those which regard the safety of the machine must be repaired before using the machine 27 3 00 35672M2G USE AND MAINTENANCE M SYMBOLS AND SAFETY PRECAUTIONS lt SYMBOLS gt 5
11. eing used cannot exceed the rating shown on the data plate Exceeding the maximum rating of the generator can damage the engine THERMAL OVERLOAD PROTECTION When the socket is overloaded the thermal overload protection device cuts in and stops the current In this case disconnect the load and reset the thermal overload protection device by pressing the button or the ON switch If the protection continues to shut off check the load cables connections etc to find the fault and if they are OK call an authorized Service Center 7 PRESS RESET Do not manually hold the button or switch in the ON position if it will not hold by itself Doing so prevents it from cutting off the current and will result in damage to the generating set GROUND FAULT INTERRUPTER SWITCH Turn on the safety switch by pushing it upwards The GFI is a safety device which protects the circuit in the event of a malfunction In this case the switch disconnects the three and single phase circuit when in any part of the electric connections a current leakage of more than 30 mA occurs THERMAL MAGNETIC BREAKER Turn on the thermal magnetic breaker by pushing it to the ON position The thermal magnetic breaker is a safety device which protects the circuit in the event of a malfunction In this case the switch disconnects single phase circuit when in any part of the electric connections a s
12. el 29 04 03 HP007M51G MD GY 6000 DSAX DIMENSIONAL DRAWING DIMENSIONS 930 2 nr 4x 014 03 09 01 HP007M53G USE AND MAINTENANCE M ELECTRICAL SYSTEM LEGENDE Alternator Capacitor G F l Fuse 230V 1phase socket 110V 1 phase socket Hour counter Fuel level transmitter Oil pressure switch Fuel warning light Battery charge warning light Oil pressure warning light Starter motor Battery Battery charge voltage regulator Solenoid valve Thermal magnetic circuit breaker E A S connector Relay Circuit breaker Fuel electro pump 12V Start Local Remote selector Hz V A analogic instrument 04 09 01 HP007M60GB L L9INZOOdH 10 60 50 0009 9961 0000507 Ysa 0009 A9 Du 3 eq 1240534 ol 4u si suoyeuDasiq Pula el gt lt 73 53 5194 300 7 sewue euibu3 gt lt SE ae Eed a gt EH lt gt gt ON lt 2 oO uf T um m TEE C Rate O ISZ 9 gt E KZ er E mane I 34 05508 9 g 5 i 6 0 60 3 9 209 847 2908 re geg 0 1 O Wi 2 1956 quM 6 ge CUT 7 2 ri 9 S i 131 rei 0 Ou in ot HOLIMS 0 Gh toen
13. emove fuel from WARNING tank before moving machine Do not remove or disable protective devices FOR BATTERY EQUIPPED UNITS ONLY Poe N on Hie Sparks may cause the explosion of battery vapours WATER COOLED ENGINES ONLY Slowly unscrew the cooling liquid cap of a hot en gine to allow vapours to escape Hot vapor and heated cooling liquid under pressure can burn face eyes skin Do not use the machine if it is not in good technical con dition The machine must be in good working order before be ing used Defects especially those which regard the safety of the machine must be repaired before using the machine JL FIRST AID In case the operator shold be sprayed by accident from corrosive liquids hot toxic gas or what ever event which may cause serious injuries or death predispose the first aid in accordance with the ruling labour accident standards or of local instructions okin contact Wash with water and soap Eyes contact Irrigate with plenty of water if the irritation persists contact a specialist Do not induce vomit as to avoid the intake of vomit into the lungs send for a doctor If you suppose that vomit has entered the lungs as in case of spontaneous vomit take the subject to the hospital with the utmost urgency In case of exposure to high concentration of vapours take immediately to a non polluted zone the person involved a A FIRE PREVENTION In case the working zone for whatsoever cause g
14. erations have been correctly performed 11 09 01 HP007M20G USE AND MAINTENANCE M STARTING THE ENGINE cs Control these items daily Do not alter factory adjustments and not touch sealed parts STARTING Make sure that the accelerator lever or the switch Is at its minimum setting Insert the electric protection device D Z2 N2 lever to wards above OFF x Open the fuel valve Put the engine accelerator in the Stop position Turn the ignition key Q1 to the Start position until the engine starts andthen re lease it 55 NOTE for security the starter key should be kept by qualified personel Once the engine has started let it run at low speed for some minutes to warm it up To use accelerate the engine to maximum with the accel erator lever If the engine fails to start do not crank for more than 15 seconds Wait at least 4 minutes before trying again CAUTION RUNNING IN During the first 50 hours of operation do not use more than 60 of the maximum output power of the unit and check the oil level frequently 11 09 01 007 21 16 USE AND MAINTENANCE M STOPPING THE ENGINE LE Before stopping the engine you must turn off or disconnect the load or disinsert the electrical protection device D Z2 N2 by moving the lever downward let the engine idle for a few minutes Put the engine accelerator in the Stop posi
15. here is also a manual for the engine In some countries the warranty card is also included as well as tools or accessories as may be required for the machine Please check the con tents carefully before disposing of the bag Our machines are designed specifically for the generation of electrical power for use in welding and or power genera tion USES OTHER THAN THOSE MENTIONED ARE NOT PERMITTED and if used for such other uses the company cannot be responsible for damages to the ma chine persons or things resulting from such use Our products are made in conformity with international Safety norms and according to good engineering practice in order to prevent injury to persons or damage to things You are responsible to inform those working with the ma chine about the personal safety norms in force to protect them from injury gt Notice in line with our policy of continuous im provement of our products we reserve the right to in troduce improvements so that the machine and or its accessories may not be exactly as shown in this manual USE AND MAINTENANCE NOTE 27 3 00 35672M11G USE AND MAINTENANCE M SYMBOLS AND SAFETY PRECAUTIONS SYMBOLS IN THIS MANUAL SAFETY PRECAUTIONS The symbols used in this manual are designed to call your attention to important aspects of the operation of DANGEROUS the machine as well as potential hazards and dangers for persons and things This heading warns of an imm
16. hort circuit or a current absorption occurs above the data specified on the label of the unit Hour counter which indicates the hours of effective operation of the unit 27 7 01 HQ002M37G USE AND MAINTENANCE M DZ The engine is equipped with a system which shuts down the engine in the event the oil pressure is too low Low oil pressure is also indicated by the red warning lamp on the control panel There is also a red battery charger warning lamp on the control panel which lights up if the battery is not being charged There is a thermal protection device to protect the battery in case there is too much charging current The thermal protection is reset by pressing the but ton If the thermal protection should continue to inter vene check the battery charger and its connections the charge condition of the battery Once the cause of the problem has been removed stop the engine by turning the starter key to the OFF position and restart the engine In this way the protection will be assured The above mentioned devices function when the ig nition is turned on 27 3 00 35672M39 6G USE AND MAINTENANCE m TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE WHAT TO DO SYNCHRONOUS ALTERNATORS No output 1 Overload circuit breaker activated 2 GFI or Isometer have been activated 3 Stator burned out 1 Remove the load and insert the circuit breaker Reconnect the load If it
17. les and tighten the connections IMPORTANT When carrying out maintenance operations be careful to avoid polluting the environment with the materials used during maintenance Follow all local health and safety regulations 11 09 01 007 43 1 16 USE AND MAINTENANCE M STORAGE In case the machine will not be used for more than 30 days it should be stored in a suitable area where it is protected from the elements to prevent rusting corrosion and other damage to the machine DIESEL ENGINES lf the machine will be stored for short periods of time it is advisable to start the engine every 10 days and operate it for 15 30 minutes under load This will distribute the oil recharge the battery and prevent blockage of the injection system For long periods of storage refer to the engine manufac turer s manual Clean the machine carefully Cover the machine with a plastic cover and store in a dry place IMPORTANT When carrying out the operations to prepare the machine for storage be careful to avoid polluting the environment with the materials used during maintenance Follow all local health and safety regulations 27 7 01 HQ002M45G GY 6000 DSAX TECHNICAL SPECIFICATIONS The generating set GY 6000 DSAX transforms the mechanical energy generated by an internal combustion engine into electric energy through an alternator They are designed for industrial and professional use The engine a
18. nd alternator are directly coupled and mounted on a steel frame using elastic supports which reduce vibration and noise ALTERNATOR GENERAL SPECIFICATION Note M OUTPUT single phase Type 1 phase synchronous self excited self regulated brushless Insulation H Duty cycle Output a 240 120 21 U 240 120 64 5 2 Cos L9 6 B NE NMAR 00 EE 4 stroke Displacement 406 406 KVA kW V A Hz iter nr kW HP rom er lt gt Model N gt oO oO NE E Power kW HP 74 10 peed mm 36 liter gal Cooling system Engine oil capacity tarter electric a uel diesel liter gal 6 0 42 1 Protection 23 Battery 33Ah Dry weight Kg Ibs 200 440 Dimensions Lxwxh mm 1020 x 645 x 930 inches 40 16 x 25 4 x 36 61 Fuel tank capacity liter gal 23 6 Above values are valid without accessory CTM2 Maximum output according to ISO 3046 1 CO C lt lt lt c 2 D o 2 5 IS SD lt The output indicated is guaranteed at 20 C and at an atmospheric pressure of 760 MM HG sea level using 2 diesel fuel DF 2 Output will be 20 less when using JP 8 fuel Output is derated for temperature and elevation as follows 3 for each 10 C above 20 C and 1 3 for every 100m above sea lev
19. nside the machine 2 Check the rating plate on the machine and confirm that the serial number and model are the same as shown on the packing note invoice NB For further information on preparing the unit for use refer to the related parts of this manual 27 7 01 HQ002M3G TRANSPORT AND DISPLACEMENTS COVERED UNITS AND SKID NOTE In case you should transport or move the machine keep to the instructions as per the figures e Make the transportation when the machine has no petrol in its tank no oil in the engine and and electrolyte in the battery Be sure that the lifting devices are correctly mounted adequate for the weight of the machine with it s packaging and conform to local rules and regulations Only authorized persons involved in the transport of the machine should be in the area of movement USE AND MAINTENANCE DO NOT LOAD OTHER PARTS WHICH CAN MODIFY WEIGHT AND BARICENTER POSITION IT IS STRICTLY FORBIDDEN TO DRAG THE MACHINE MANUALLY OR TOW IT BY ANY VEHICLE model with no CTM accessory If you did not keep to the instructions you could damage the structure of the machine 06 09 01 HP007M4 1GB Note Lift the machine and assemble the parts as shown in the drawing The CTM accessory cannot be removed from the machine and used separately actioned manually or following vehicles for the transport of loads or any wav for used different from the machine movements CTM2 M ASSEMBLY
20. oes on fire with flames liable to cause se AM vere wounds or death follow the first aid as described by the ruling norms or local ones EXTINCTION MEANS Appropriated Carbonate anhydride or carbon dioxyde powder foam nebulized water Not to be used Avoid the use of water jets Other indications Cover eventual shedding not on fire with foam or sand use water jets to cool off the surfaces close to the fire Wear an autorespiratory mask when heavy smoke is present Useful warnings Avoid by appropriate means to have oil sprays over metallic hot surfaces or over electric contacts switches plugs etc In case of oil sprinkling from pressure circuits keep in mind that the inflamability point is very low t o db X D H 197 46 ng WARNING THE MACHINE MUST NOT BE USED IN AREAS WITH EX PLOSIVE ATMOSPHERE 27 7 01 HQ002M2 5G USE AND MAINTENANCE INSTALLATION ADVICE Ze DIESEL ENGINES e Use in open space with fresh air flow or vent ex haust gases far from the work area POSITIONING THE MACHINE Place the machine on a level surface at a distance of at least 1 5 m from buildings or other structures If the surface is not level be sure that the angle of the machine does not exceed the values shown in the draw ings below 10 LL 20 max 10 Assure that the hot air and or exhaust gas from the machine are vented and are not recirculated in the ma
21. regular cleaning of the machine Repairs refers to the substitution of worn or damaged parts and repairs should be carried out by Authorized Service Centers Refer to the Engine Manufacturer s Manual for the main tenance instructions for the engine Periodic maintenance should be performed according to the schedule shown in this manual 27 7 01 HQ002M43G USE AND MAINTENANCE a MAINTENANCE ELECTRIC START UNITS The battery included with this generator set does not require any regular maintenance The battery is automatically charged while the engine is running at speed gt N B In the models with safety protections in case the battery is not being charged check the thermal protection or fuse PROCEDURE FOR RECHARGING A BATTERY The battery can be recharged with any commercial bat tery charger However prolonged recharging at voltages above 14 8V can be harmful to the battery DRY AIR FILTER CLEANING Replace the air filter cartridge every 200 hours when us ing the unit in a clean environment In a dusty environment the filter cartridge must be re placed every 100 hours SYNCHRONOUS ALTERNATOR No maintenance is necessary as the alternator has no brushes or slip rings and there are no devices for regula tion of the output WARNING LABELS AND DECALS Check warning labels and decals once a year and re placed if missing or unreadable CABLES AND CONNECTIONS Periodically check the condition of the cab
22. tion Turn the ignition key Q1 to the OFF position Close the fuel valve Remove the plugs 11 09 01 007 22 16 GY 6000 DSAX CONTROLS MI 59 END OD 72 N1 01 16 Q1 F B3 59B Earth terminal Frequency meter Fuse Fuel level transmitter 25 jFuelprfiller Start local Remote control Hour counter Warning level light Voltmeter D Ground fault interrupter 30 151 DESCRIPTION 03 09 01 HP007M31G USE AND MAINTENANCE M USING THE GENERATOR amp In no case should the generator output be connected to the mains or any other source of electrical energy ATTENTION Once the machine is running see page M 21 the sockets are live even if no load is attached USING THE GENERATOR Make sure the unit is properly grounded See pages M20 21 for instructions on preparing starting and stopping the engine Nominal voltage Maximum variation from nominal asynchronous Synchronous Connect the load to the generating set sockets Be sure to use cables of the correct size for the load The green lamp located above the AC sockets indicate that there is voltage at the sockets Note if the green lamp does not light up check if the overload protection and or GFI has been activated If they are inserted check that the engine is running at maximum speed When drawing power from more than one socket the total power b
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