Owner`s Manual
Contents
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5. EE No Load Frequency Revolving Speed aloza 50Hz RUN 52 5Hz about 1575 Caution In either case of incorrect frequency adjust the frequency by FREQUENCY ADJUSTING SCREW setting frequency to the above frequency under no load 50Hz almost will be obtained at the rated output load Jel Adjusting the voltage regulate dial set it to the required voltage 50Hz RUN 415V Turn the circuit breakers to ON to send power to the load side Danger Electric Shock Injuries Before turning the circuit breakers to ON to send power to the load side always ensure that any circuit breaker and switch of loads are positioned to OFF In the case the generator and the load are away from each other proceed with the above steps communicating well with the other person by the load in order to prevent from accident 31 9 2 During Operation 1 Post startup check e Make sure that all meters gauges and displays are working properly Refer to 5 Equipment e Check for any unusual vibration or noise Check for any unusual color from the exhaust Under normal condition the exhaust gas has no color or light bluish color Caution e lf finding out abnormality consult with our authorized distributor or our engineering section in order to repair without using the machine 2 Adjustment during operation e Make subtle adjustment to voltage using the Voltage Regulate Dial by monitoring Voltage M
6. gt D fuel when changing filter e Extract the air in fuel line after filter changing finishes Refer to 9 2 During Operation Ensure that there is no fuel leakage after reinstallation e Filter Part No Isuzu Part No 8943370220 7 Drain water in fuel tank Remove the Fuel Drain Plug Fuel Drain Lever Fuel Drain Plu Turn the Fuel Drain Lever to OPEN i Draining the water out turn the Fuel Drain Lever to CLOSE Tighten the Fuel Drain Plug 40 8 Change coolant Change 2 years or 1000 hours Remove the radiator plate first and open the radiator cap cover Radiator Cap Cover T TE ES I Remove the radiator cap Loosen the radiator drain lever and the drain plug on the engine side After draining finishes tighten the radiator drain lever and the drain plug on the engine side Drain the sub tank stay and drain coolant in the sub tank Reinstall the sub tank and fill coolant up to MAX P SESEZ ga A ee level Fill coolant into radiator up as far as the water inlet level Tighten the radiator cap Close the radiator cap cover and Reinstall the radiator plate e c e oq dme Caution e Refer Coolant to 8 2 Checking Coolant Water 41 11 Long term storage Danger Electric Shock Injuries Before performing any equipment check or maintenance stop the engine and remove the engine key The perso
7. 6145 2009 YAMABIKO CORPORATION Printed in Japan
8. Temperature from 15 to 40 degree Celsius m Relative Humidity less than 80 m Altitude Less than 300m Power Supply for submersible Pump etc Power Supply for lightings etc Power Supply for electric tools home appliances 4 Parts Components 4 1 Outer and Main Components Engine Check Door Radiator Lug for rope Alternator check door Lifting Lug Lug for rope ed PE 3 BERE TIE T Output Terminal Cover Fuel Inlet Lug for Rope Air Cleaner Oil Gage Alternator Check Door Water Separator Battery Fuel Tank Fuel Drain Oil Filter Cil Drain Plug Outer Fuel Inlet Coolant Drain Fuel Filter Outer Fuel Outlet 4 2 Operation Panel See x e UD late Main Circuit Breaker Oil Pressure Gauge 2 Volt Meter 13 Fuel Gauge Jg Frequency Meter Emergency Stop Button Panel Light Switch 16 Preheat Lamp DC 8 Volt Meter Selector Switch 19 Pilot Lamp rem 4 3 Output Panel Side Door Output Terminal Cover 1 Phase ELCB 3 Phase ELCB Ur 3 Phase Receptacle d lt P 20A P ALTRE ZA NS 9 1 Phase 1 ptacl 15 Bonnet Grounding Terminal 5 1 Monitor Lamp WATER TEMP OIL PRESS CHARGE The equipment is incorporated in monitoring function of WATER TEMP BATTERY CHARGING amp OIL PRESSURE Un
9. The value of shows the sub tank volume 26 8 3 Checking Fan Belt x Refer to the user s manual for Engine separately also Danger Injuries Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the maintenance should always keep the key Close and lock all doors during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Caution Burns Do nottouch the engine and muffler during operation and immediately after stopping the equipment for the temperature can reach extremely high level 1 Fan Belt Tension The tension is proper when the fan belt has 8 to 10mm slacks when applying a finger pressure about 98N approximately 10kgf at midpoint between fan pulley and alternator pulley 2 Condition Check for any damage on the fan belt Replace if necessary Caution Refer to the User s manual for Engine for adjusting and replacing of the fan belt 8 4 Checking fuel Caution Fire e Always wipe drip of Diesel fuel or oil Do not use this equipment when a leak is found Repair the equipment before use Check for the fuel level in the tank Add if necessary Caution Use Diesel fuel ASTM D975 No 2 D in the event ambient temperature reaches down to 5 C Always use the Diesel fuel strainer Tank Cap e Fill the fuel tank slightly less than the FULL ta
10. This position is also used during cold season to preheat Glow Plug STOP RU N PREHEAT Caution Do not leave the switch to this position while the engine is stopped Otherwise the battery is discharged 3 Start This position is to start the engine When the key is released the setting will automatically return to Operating Preheating gt position 2 Emergency Stop Button This button is used to stop the engine in emergency By inserting the button the engine stops Be sure to restore the starter switch to STOP and re set the button turning clockwise after using the emergency stop button 3 Main Circuit Breaker By turning this circuit breaker on the control panel to ON Power will be transferred to the output receptacles and to the load side The breaker trips to OFF either overload or short circuit 13 Caution Do not use this breaker as the ON OFF switch to the load 4 3 Phase Circuit Breaker 1 Phase Circuit Breaker E Each receptacle 3 Phase and 1 Phase is incorporated with circuit breaker respectively The breaker trips on overload or short circuit on 2 to stop power transmission to load 3P Breaker 1P Breaker Caution Do not use this breaker as the ON OFF switch to the load 5 3 Phase Earth Leakage Circuit Breaker 3P ELCB 1 Phase Earth Leakage Circuit Breaker 1P ELCB Each receptacle 3 Phase and 1 Phase is incorporated with ELCB respectively When c
11. such as inside a room or in a tunnel Caution Suffocation from exhaust gas Do not point the exhaust fume toward pedestrians or buildings Caution Fire Always operate this equipment on flat surface and at least 1 meter away from any objects wall box etc e Temperature around muffler and exhaust can get extremely high Keep any inflammable items such as fuel gas paint etc away from the equipment B Always set the equipment on hard flat surface B Keep the equipment at least 1m from a wall or any obstacles to allow workable space to access the control panel and opening of the panel door Caution e This equipment must be operated on hard and flat surface Operating under any other conditions may result in malfunctions Do not block the airflow from radiator vent or muffler exhaust It may result in reduced engine performance overheating or damage to the electrical parts Operating in dusty area or salty air by the ocean or any other particulate environment may result in clogged radiator which may cause overheating other malfunctions and insulation deterioration Use extreme care frequent checks and maintenance 18 7 Connecting Load 7 1 Select Load Cable Select the cable with proper gauge based on its allowable amperage and the distance between the generator and the machinery to be connected Caution Damage to properties e lf the load exceeds the allowable amperage th
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13. FF Which shows NORMAL 3 Phase ELCB In the event you cannot complete every step of the above procedure to the end the device is out of order Consult with our authorized distributor or our engineering section and ask to repair 22 3 Earth leakage circuit breaker ELCB has activated When the ELCB has activated repair the leakage point and restore it by the following procedure Overload happens when the breaker activates but the Earth leakage breaker does not activate Turn the 3 Phase ELCB to ON to restore Turn the 1 Phase ELCB to RESET to restore By the above procedure you can reset the ELCB to ON positions 23 8 Initialization and Pre check Danger Electric Shock Injuries e Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the maintenance should always keep the key Caution Fire Burns e When checking engine always stop the engine and keep away from fire Wait until the engine cools down before performing any checks Caution Fire Always wipe drip of fuel or oil Do not use this equipment when a leak is found Repair the equipment before use 8 1 Checking engine oil x Please refer to the user s manual for Engine separately When checking for engine oil be sure to keep The equipment leveled and insert not screw in forcibly the oil gauge all the way in Prior to starting the equipment ma
14. ISO 9001 CERTIFIED OWNERS AND OPERATORS MANUAL SOUND PROOF DIESEL ENGINE GENERATOR DGA20E caution Do not operate the equipment before you have read and understood the instructions for use Table of Contents 1 Safety Guidelines 2 Specifications 2 1 Data 2 2 Ambient Condition 3 Use 4 Parts 4 1 Outer and Main Components 4 2 Operation Panel 4 3 Output Panel 5 Equipment 5 1 Monitor Lamp 5 2 Meters 5 3 Fuel Line Changeover Valve 3 Way Valve 6 Transportation amp Installation 6 1 How to transport 6 2 Installation 7 Connecting load 7 1 Select Load Cable 7 2 Connecting Load Cable 7 3 ELCB Grounding Initialization and Pre check 8 1 Engine Oil 8 2 Coolant Water 8 3 Fan Belt 8 4 Fuel 8 5 Fuel Oil and Coolant Leakage 8 6 Battery Operation 9 1 Initialization and Preparation 9 2 During Operation 9 3 Stopping 9 4 Protection Feature 9 5 Connect to External Fuel Tank 10 Check and Maintenance 11 Long Term Storage 12 Troubleshooting 13 Generator Circuit Diagram 14 Engine Circuit Diagram 20 750801 3400 Introduction Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator This user manual was created to ensure the safe operation of this equipment Therefore the manufacturer of this equipment strongly recommends that the user follow the instructions herein to avoid unnecessary
15. accidents and repairs e Please operate this equipment after thoroughly reviewing and understanding the contents of this manual Please attach this manual if the equipment will be sub leased e Please store this manual near the equipment for easy reference Following convention will be used throughout the manual to indicate the degree of cautions Can cause serious injuries or death Can cause minor injuries or damage to the equipment or other properties Other types of caution Even some of the items noted in Cautions may lead to serious injuries Please read all item and follow all the safety guidelines 1 Safety Guidelines Danger Suffocation from exhaust fume e Exhaust fume from the engine contains many elements harmful to human Do not operate this equipment in poorly ventilated area such as inside a room or in a tunnel Danger Electric Shock e Do not insert metal objects such as or wire into plug in receptacles Do not touch wiring or electric parts inside the equipment during operation Ground the every grounding terminal to the earth as set in the manual If even one of all is unconnected by mistake or accident it will be much more dangerous for human than the NO RELAY case because leaking current inevitably goes through the body Even when the in the load is grounded to the earth be sure to connect the terminal of bonnet in the equipment sure to ch
16. adable or damaged place new label at the appropriate location as specified in the following figure When ordering the label use the following part numbers Injuries No 19402 00210 Caution coolant No 19402 00295 Safety Precaution 19402 00306 Caution Electric Shock No 19402 00215 2 Specifications 2 1 Unit DGA20E Generating Method Rotating Filed Brushless 3 Phase Synchronous Generator Rated Output Rated Voltage V 415 1500 Phase amp Wiring 3 Phase 4 Wire PowerFadot OB Insulation Class F ExcitingMethod SelfExcitation Brushless 4 Poles V Rated Current 27 8 Generator Method Vertical Water cooled 4 Cycle Diesel Engine Model No Isuzu BV ALE1 Cylinder bore x troke 4 85 x 96 Continuous Rated 1500 Displacement 2 179 Combustion Method Swin Chambered Cooling Method Water cooling radiator F gt Lubricating Trochoid pump force feed lubrication B Staring Saner Motor Dies Ol SSA Class CD or higher 2 11 0 DyWeiht 69 7 C e 2 2 Ambient Condition Be sure to use the equipment under the following ambient condition range Otherwise the condition may cause damage insufficient output or durability shortage to the equipment m Ambient
17. ank Set the fuel intake position 15 20mm above from the external fuel intake bottom line otherwise water or garbage in the tank may come into the fuel line In order to avoid engine malfunction due to air suction set the fuel return at the same level as the fuel intake level in the external tank 34 Refer air extraction to 9 2 During Operation Just after having connected to external fuel tank there may be a case that engine speed is unstable and engine stops due to insufficient air extraction Therefore be sure to confirm that the air is extracted completely and the engine speeds keeps stable before leaving the equipment under people less operation 10 Check Maintenance Danger Electric Shock Injuries Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the maintenance should always keep the key Caution Fire Burns e When checking engine always stop the engine and keep away from fire Wait until the engine cools down before performing any checks Caution Fire Always wipe any drip of fuel or oil Do not use this equipment when a Leak is found Repair the equipment before use To optimize the use of this generator we recommend the periodical equipment checks and maintenance based on following maintenance matrix Use the hour meter as a guide for the operating time Caution The authorized technicians only s
18. attery Charge Monitor Lamp Charging Lamp When the battery turns unable to be charged during operation the battery charge monitor lamp will flash In the event this occurs stop the engine consult with the authorized distributor or our engineering section CHARGE Caution e The battery charge monitor cannot detect the degradation of the battery nor the battery fluid level Check the battery fluid level periodically Refer to 8 6 Checking Battery 10 5 2 Meters Meters in the engine 1 Hour Meter iis age 3 OOOOH Hour Meter keeps track of utilization time Use this meter to schedule your Periodical Maintenance Note that the Hour Meter will operate as long as the start switch is at ON position regardless of whether the engine is running or stopped 2 Water Temperature Gauge Water Temperature Gauge displays the temperature of engine coolant Normal temperature may vary depending on the environment but it should be between 80 C and 95 C lt Caution gt If the temperature exceeds normal value disconnect the load idle the engine at 1000min and wait until the reading falls to the normal temperature range 3 Oil Pressure Gauge ee 4 Oil Pressure Gauge displays the pressure of engine oil Normal pressure may vary depending on the environment but it should display 2 9 4 9 x 100kPa 3 5kgf cm However under cold weather the pressure gauge may display higher reading Contin
19. aust can get extremely high Keep any inflammable items such as fuel gas paint etc away from the equipment Always operate this equipment on flat surface and at least 1 meter away from any objects wall box etc Do not connect AC output to any indoor wiring Always wait until the equipment cools down before placing any covering materials for storage Burns Never open the radiator cap during operation or just after engine stops as hot vapor may belch out Do not touch the engine and muffler during operation and immediately after stopping the equipment for the temperature can reach extremely high When checking engine oil or changing oil always stop the engine and wait until the engine cools down If you open either the oil gauge or the oil plug during operation hot oil may cause some injury Injuries When lifting the equipment always use a lift hook Do not lift a handle for it may cause equipment to drop due to handle breaking off Always place the equipment on a flat and stable surface to keep the equipment from sliding When starting the engine turn off the connected equipment and set the circuit breaker to OFF position Do not move the equipment during operation When performing equipment check and maintenance always stop the engine Do not operate the equipment if the equipment is being modified or if the parts are removed Location of Warning labels When warning label becomes unre
20. defective 2 3 4 Alternator is defective Voltage regulator dial is defective 4 Frequency is low AVR is defective Unbalanced loads sharing to each terminal Wrong frequency is used Loads total exceeds the rated current The Main breaker positions at between ON and OFF Short circuit on the load 2 45 Check Change air filter element Ask our distributor to repair Change to clean fuel Ask our distributor to repair Drain water in water separator fuel filter or fuel tank Ask our distributor to repair Warm up driving is needed Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Balance the loads sharing to each terminal Set the switch to the load frequency Decrease the loads to meet the rated output Once turning the lever to OFF turn it to ON Check the load circuit 4d1Snf v ADVI 10A
21. der normal condition when the starter switch changes from STOP to RUN all the lamps of BATTERY CHARGING and OIL PRESSURE turn ON When the engine starts all the lamps turn OFF When abnormality is detected about WATER TEMP and OIL PRESSURE the corresponding monitor lamp will flash and the engine is automatically shutdown When the automatic shutdown is engaged turn the starter switch to STOP position once and then restart the engine In the event the automatic shutdown happens after that check which lamp turns ON or OFF and point out where is the abnormality 1 Coolant Water Temperature Monitor Lamp Danger Injuries Close all doors and place during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Caution Burns Do not open the radiator cap while operating this equipment or immediately after stopping the equipment to avoid sustaining burns from hot vapor e Do not touch the engine and muffler during operation and immediately after stopping the equipment for the temperature can reach extremely high When the water temperature rises over 110 C the coolant water temperature monitor lamp will flash and the automatic shutdown of engine will be engaged When this occurs check the coolant water reservoir tank and replenish if needed Refer to 8 2 Checking coolant water If the water level is normal there may be a possibility of loose fan belt or water
22. ditive was recommended See your authorized dealer to find out if this has changed 8 5 Checking Fuel Engine Oil and Coolant leakage Caution Fire Never use this equipment when a leak is found Repair the equipment first of all Be sure to check for any fuel leak at the fuel hose connections and oil and coolant leak by opening side doors 28 8 6 Checking Battery Caution Injuries to eyes and skin e Battery fluid contains diluted sulfuric acid Avoid contact with eyes skin on clothing If the acid comes in contact especially with eyes flush with a lot of water and contact physician or doctor immediately Caution Explosion e When the liquid level is below the LOWER level never use the equipment nor recharge battery e Battery may emit some combustible gas so keep it away from fire and sparks Jab Check the fluid level If the level is near or lower than the LOWER LEVEL add distilled water until the fluid level reaches the UPPER LEVEL limit Jeb Make sure that the battery cables are firmly secured to the posts Tighten the clamps more if necessary lt Caution gt Check the hydrometer of the battery fluid If it falls below 1 23 the battery requires recharging Please call our authorized distributor or our engineering section Replacing the battery Remove the clamp and cable from Jab negative post from the battery always remove negative side first Remove the ba
23. e damage to the cable may be damaged in overheating e lfthe cable is either too long or too small gauge there will be greater voltage drop between cables which brings voltage drop to loads It may result in reduced performance in the connected loads malfunction or damages Caution e itis recommended to select the proper gauge and length of cable in consideration of the maximum 5 marginal drop only for the rated voltage between the terminals of loads and generator via the cables B Expedient Formula the voltage drop of cables e 3 Phase 3 Wire 1 Length m Voltage Drop V x x Current x 3 58 Dia mm e 1 Phase 2 Wire 1 Length m Voltage Drop V x Current A x2 58 Dia mm 19 7 2 Connecting Load Cable Danger Electric Shock Before connecting or disconnecting a load cable from output receptacles always turn a circuit breaker to OFF position stop the engine and remove the engine key The person performing the maintenance should always keep the key Caution Fire e Do not connect AC output to any indoor wiring Caution Divide loads into 3 circuits proportionally as possible when using the maximum output power especially and connect them to each phase 5 respectively Be careful to limit the current under the rated current per the phase Note that the 1 phase output power decreases when 3 phase output power is used s
24. eaning Changing Air Filter Element Loosen the air cleaner fixing bolt and remove the cleaner cap Jab Loosen the wing nut and remove the air filter element Clean or change an air filter element and reinstall it in the reverse order lt Caution gt Be sure to set the cleaner cap at the arrow mark upside Clean the element more often Air Cleaner where the equipment is used in dusty condition Air Cleaner e Element Part No Isuzu Part No 9142150140 Clean Air Filter Element lt Dried contaminants adhered gt Blast the compressed air to element from inside lt Carbon and oil adhered gt Change to a new filter Clog Indicator The clog indicator to display clog in the air filter element is incorporated to air filter unit Whenever RED SIGNAL appears in the indicator window clean or change element regardless of operation hour After cleaning or changing finishes push the reset button to release the RED SIGNAL 38 4 Drain water the Water Sedimentor Fuel Lever Every 500 hours Ring Nut When the Float red is coming up to 20mm Cup from the bottom drain the water OSES Gauze Filter Turn the Fuel Lever to CLOSE _ Float Red Turn the ring nut counterclockwise and remove the cup and Gauze Filter Dispose water or dirt When dirt is adhered to t
25. eck the resistor value of the equipment periodically so that you can avoid the electric shock caused by electric leakage Before connecting or disconnecting a load cable from output receptacles always turn the circuit breaker to OFF position Before performing any equipment check maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Suffocation from exhausting fume Do not point the exhaust fume toward pedestrians or building Injuries to eye and skin Battery fluid contains diluted sulfuric acid Avoid contact with eyes skin or on clothing If the acid comes in contact especially with eyes flush with a lot of water and contact your physician immediately Explosion Do not use the equipment or charge the battery in the case the battery fluid level is lower than the LOWER level Battery may emit some combustible gas so keep it away from fire and sparks Fire The equipment uses Diesel Oil as a fuel When refueling always stop the engine and keep away from fire Moreover always wait until the engine cools down before refueling Always wipe any drip of Diesel fuel or lubrication oil Do not use this equipment when a leak is found Repair the equipment before use Temperature around muffler and exh
26. enerator Bonnet of the load Caution Inthe event you cannot ground the generator to the earth consult with the authorized distributor or our engineering section Bonnet grounding terminal 21 2 Operation Check Danger Electric Shock Injuries Before turning Breaker or ELCB to ON position ensure that the breakers or the switches of loads are positioned to OFF You should communicate well with the electrician by the load side when operating Breaker or ELCB Before operating the generator check always if the device can work Ensure that the breakers and the switches of loads are positioned to Ensure every breaker to set OFF H p NIC Refer 4 2 Operation Panel P ES 3 E 7 4 3 Output Panel Main Breaker 1 Phase Breaker Battery isolator Following the procedure in 9 1 3 Phase Breaker Initializing Preparation start an engine Turn every breaker and ELCB to ON Push the RESET Green button on the 1 Phase ELCB Confirm the red lamp on the 1 Phase ELCB turned ON and the indicator on the 3 Phase ELCB turns RED display Indicator Push the TEST button Yellow on 3 Phase ELCB Indicator changes to Green from RED and ELCB trips to OFF Which shows NORMAL Test button Yellow E 4L L i Push the TEST button Blue on 1 Phase ELCB Red lamp turns to OFF and ELCB trips to O
27. er Position External Fuel Inlet gt lt PS S Caution After having used the outer fuel and removed piping be sure to set the lever to A position and fix the plugs External Fuel Return 3 way Valve 2 Using fuel from external fuel tank Connect hoses from the external fuel tank to the external fuel intake and the external fuel return ports and set the lever for 3 way valve to B position You can now supply the fuel m me h From the external gas tank Ts i 1 l X For detailed instructions refer to 9 5 Connecting to External Fuel Tanka 16 6 Transportation and installation 6 1 How to transport Danger Injuries e When lifting the equipment always use a lift hook Never use roping lug for lifting the unit for it may cause equipment to drop 1 Lifting the equipment Always use a Lift lug when lifting the equipment for transportation 2 Transporting the equipment When transporting the equipment make sure that the equipment is secured properly with ropes tied to the roping lugs through Caution Always use extreme care when loading unloading and transporting the equipment otherwise damages and malfunction of the equipment may bring 17 6 2 Installation Danger Suffocation from exhaust gas e Exhaust fumes from the engine contains many elements harmful to humans Do not operate this equipment in poorly ventilated area
28. ers on the marked points in the lower equipment firstly and then stack the upper equipment on it All the ties should be the same size dimension and longer than the width of the lower generator Do not stack more than 2 units The lower generator should be bigger than the upper generator in size and weight Do not operate the stacking stacked equipment 12 Troubleshooting 4 Danger Electric Shock Do not operate the equipment if the equipment or you are wet e Before performing any equipment check or maintenance stop the engine Caution Injuries When performing equipment check and maintenance always stop the engine Caution Fire Burns Never get fire near to the equipment When checking engine oil or changing oil always stop the engine and wait until the engine cools down If you open either the oil gauge or the oil filler cap during operation hot oil may cause some injury Follow the guideline below when performing any troubleshooting If you cannot resolve the problems by this troubleshooting guide contact our authorized distributor or our engineering section to request the repair 43 Symptom Presumable Cause 1 Starter motor does not drive or speed is low Starter motor drives but engine does not start Engine does not start Ambient temperature falls down below zero Engine starts but stalls immediately Engine oil pressure is low Overheated Battery Iso
29. eter during operation m Extracting the air out of the fuelling system for engine stop due to no fuel XRefer to the User s manual for Engine This generator is equipped with automatic extracting feature Thus if the engine stops due to running out of fuel follow the next steps to extract the air out Add fuel to the fuel tank Turn the starter switch to RUN position It will take approximately 30 seconds to extract the air out ole 9 3 Stopping Turn the switch on the equipment and the circuit breaker on the load to OFF Turn every circuit breaker to OFF position Turn the starter switch to STOP Jel Keep the engine NORMAL SPEED on No Load for about 3 minutes Jesl Turn the battery isolator to OFF 32 9 4 Protection Feature This equipment is equipped with automatic shutdown feature and display of the location of trouble against trouble during operation In the event of the automatic shutdown or alarm lamp flashing turn off the engine and investigate the trouble shown by alarm lamp Protection Feature List Activates due to high water temperature in engine Engine Warning Lamp Abnormality Activate due to low oil pressure in the engine Default 0 98x100kPa 1 0kgf cm Monitor Lamp Activates in battery charge Impossible Activates in current leakage Activates in overload Insufficient Current Leakage x indicates the automatic activation 33 9 5 Connecting to External Fuel Tank Jab Turn
30. f resistance check To 36 1 Change engine oil oma omes Remove the Oil Filter cap gt t e l Oil Filter R he Oil Drain Plug and Oil Gauge Sa emove the Oil Drain Plug an Filler Cap then turn the Oil Drain Lever to 7 in OPEN and drain the engine oil mS Pour the oil to the upper level checking the height with the Oil Gauge Tighten the Oil Filler Cap x D D 5 E D lt D s O O 2 TI 5 D 5 3 0 5 U e Caution e For the volume and the type of engine oil to use and to replace refer to 8 1 Checking Engine Olla Oil Drain Plug 2 Oil Filter Change Initial 50 hours Drain the engine oil fully as described in 1 Change Engine Oil Loosen and remove the Oil Filter using an oil filter wrench Smear a little engine oil on the rubber gasket of the new oil filter ocrew a new filter into place and tighten it by hand until the gasket contacts the seat Then give it additional 3 4 1 turns using an oil filter wrench after the gasket touch the seal surface Supply engine oil 7 hel amp 3 Caution e f an oil filter wrench is not at hand contact our authorized distributor or our engineering section to replace Oil Filter Part No Isuzu Part No 8944567411 3 Cl
31. he Gauze Filter clean the filter by compressed air Reinstall in the reverse order Caution Be sure to confirm that there is no dirt on O RING when installing the cup Be sure to confirm that there is no fuel leakage from the water sedimentor by turning the fuel lever to OPEN 5 Drain water in fuel filter Every 200 hours Fuel Filter Every 500 hours Turn the Fuel Lever on the Water Sedimentor to CLOSE Remove the Fuel Filter by filter wrench Dispose the water in the Fuel Filter When changing the Fuel Filter smear the oil to the Gasket slightly Put the filter by hand until the Gasket touches the seal and turn the filter at 2 3 turn by filter wrench Turn the Fuel Lever on the Water Sedimentor to CLOSE e eel 39 Caution sure to confirm that there is fuel leakage in the fuel line by running the engine e When a filter wrench is unavailable please get in touch our authorized distributor or our service division to get Be sure to wipe out the spilled fuel in the fuel line when removing the fuel filter e Fuel Filter Part No Isuzu Part No 8943940791 6 Change filter in the magnet pump for automatic fuel extraction Turn the cover located at the bottom of pump counter clockwise and remove filter Jal Reinstall a replacing filter in the reverse AT order Caution e Puta tray under the lever in order to catch spilled COVER
32. hould perform all maintenance work except for the pre startup checks e Request for the maintenance items with mark to our authorized dealer or our engineering section This chart only covers the simple checks and maintenance as for the engine For more detailed guide please refer to the User s Manual for the engine Always use our genuine parts only for replacement 35 Startup Every Every Every Every Description check 200hrs 400hrs 500hrs 1000hrs Claneachpats ghenng o T T Engine oil checks addoi o To J J o y o Engine oil change 1 time at 50 hr mark fea Tod Oil Filter change 1 time at 50 hr mark 282 Exhaust color check Coolant change Or _ Drain excess water and sediments in the water separator Drain water from fuel filter or Drain water a fuel tank eer Tet filter in engine feed pump Clean Change filter in the magnet pump for air extraction in fuel line Replace Leak check fuel oil and coolant Replacing fuel hose Or Clean or replace air cleaner element t dns Battery fluid level check Lo fF ___ Battery hydrometer check O 2 5 Radiator Flush check and agus engine vave clearance e Fuel injection timing check Generator side Various meter and alarm lamps check of
33. ide a room or in a tunnel Caution Suffocation from exhaust gas e Do not point the exhaust fume toward pedestrians or buildings Caution Fire Temperature around muffler and exhaust get extremely high levels Keep any inflammable items such as fuel gas paint etc away from the equipment Always operate this equipment on flat surface and at least 1 meter away from any objects wall box etc Caution Injuries Always place the equipment on a flat and stable surface to keep the equipment from sliding When starting the engine turn off the connected equipment and set the circuit breaker to OFF position Turn every circuit breakers to OFF position Turn the Battery Isolator to ON position Set the Starter Switch to OPERATION PREHEAT position Set the starter switch to START and Breaker start the engine immediately after the 3 Phase Breaker Preheat Lamp Preheat Lamp turns OFF from ON Saer ANNEN 1 Phase Breaker Caution e Preheating time varies by coolant temperature It completes in 1 5 seconds usually Do not drive the starter motor more than 10 seconds successively f you need to restart wait at least 30 seconds before the retry 30 Release the starter switch as soon as the engine is started Keep the engine idle for about 5 minutes Set the throttle lever to RUN Ensure that the tachometer shows the following frequency at no load
34. imultaneously Be careful to limit the total current under the rated output current when using 1 Phase and 3 Phase output simultaneously 20 7 3 Earth Leakage Circuit Breaker ELCB and Grounding Danger Electric Shock Ground the every grounding terminal to the earth as set in the manual If even one of all is unconnected by mistake or accident it will be much more dangerous for human than the NO RELAY case because leaking current inevitably goes through the body Even though all the bonnets of the loads have been grounded to the earth the earth grounding terminal and the outer bonnet canopy grounding terminal should be grounded to the earth Grounding should be made after the engine is stopped Whenever the Earth leakage breaker is activated you should always repair the leaking place first of all The generator is provided with the earth leakage circuit breaker ELCB to detect any Leakage produced due to such the trouble as insulation failure of the load while the generator is running and to cut off the circuit for protection against any accident such as electrical shock resulting from the trouble The specification of ELCB e Rated Sensitive Current 30mA or below Grounding resistance 5000 or below Sensitive time Within O 1second 1 Grounding Work The qualified electrician should perform the grounding of the following 2 points 500 Q or below Bonnet Canopy grounding terminal of the g
35. ke sure to fill the engine oil to the MAX line through the oil filler LOWER LIMIT UPPER LIMIT OIL GAUGE Caution Check engine oil volume IN 10 20 MINUTES LATER always after stopping engine or replenishing fuel e ifthe equipment is not leveled you cannot obtain accurate oil level Do not overfill the engine oil The excessive amount of engine oil may damage the engine OK TOO ENOUGH MUCH 1 Selecting proper engine oil Use the API class CD grade or higher 2 Use the engine oil for Diesel engine with proper viscosity based on the temperature refer to the chart below 24 Viscosity and temperature SAE20 20W SAE10W 30 SAE15W 40 20W 40 3 Replacing Engine Oil Volume Unit Liter Lubrication Oil including the oil in filter 8 5 0 4 Value in shows the oil in filter 8 2 Checking Coolant water x Refer to the User s Manual for Engine also 4 Danger Injuries e Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the maintenance should always keep the key Caution Burns Do not open the radiator cap while operating this equipment or immediately after stopping the equipment to avoid sustaining burns from hot vapor or water Do not touch the engine and muffler during operation and immediately after stopping the equipment for the tempe
36. lator is OFF Battery output is weak Battery is deteriorated Battery terminal is corroded Starter switch or relay is defective Starter motor is defective Fuel is insufficient Fuel filter is clogged Gauze filter is clogged Water is interfused in fuel line Air is interfused in fuel line Poor piping connection to external fuel tank Fuel tank selector lever 3 way valve position is wrong Fuel cut solenoid motor does not work Fuel is frozen Water in fuel line is frozen Pre heater is defective Fuel filter is clogged Gauze filter is clogged Water is interfused in fuel line Air is interfused in fuel line Poor piping connection to external fuel tank Air filter element is clogged Lubricant oil is insufficient Lubricant oil is insufficient Oil filter is clogged Oil Pressure switch is defective Oil pressure meter is defective Wrong oil is used Engine thermostat is defective Water temp sensor is defective Water temp meter is defective Fan belt tension is weak Coolant is insufficient Radiator core is clogged 44 Battery terminal is OFF or loose 3 Turn Battery Isolator to Check battery liquid or Charge Change battery Fix Tighten terminal Clean terminal Ask our distributor to repair Ask our distributor to repair Add fuel Clean Change fuel filter Clean Change gauze filter Drain water in water separator fuel filter or fuel tank Extract the air Check piping co
37. leakage in coolant lines Check it after the engine cools down 6 lt Caution gt Be sure to check the volume in the radiator sub tank WATER TEMP before operation as it cannot detect the water temperature When the water volume is insufficient 2 Oil Pressure Monitor Lamp Low Oil Pressure Danger Injuries Close all doors and place during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Caution Burns Do not touch the engine and muffler during operation and immediately after stopping the equipment for the temperature can reach extremely high Do not open the radiator cap while operating this equipment or immediately after stopping the equipment to avoid sustaining burns from hot vapor When checking engine oil or changing oil always stop the engine and wait until the engine cools down If you open either the oil gauge or the oil plug during operation hot oil may cause some injury When the engine oil pressure drops below 0 98 x 100kPa 1kgf cm during operation the oil pressure monitor lamp will flash and the Fs automatic shutdown will be engaged When this occurs check the engine oil level and replenish to the OILPRESS maximum level if needed lt Caution gt e The engine oil pressure monitor cannot detect the degradation of engine oil itself Please check the engine oil periodically and change if needed Refer to 8 1 Checking engine oila 3 B
38. n performing the maintenance should always keep the key Caution Fire Injuries Temperature around muffler and exhaust can get extremely high levels Keep any inflammable items such as fuel gas paint etc away from the equipment When checking engine always stop the engine and keep away from fire Wait until the engine cools down before performing any checks Caution Fire Always wipe any drip of Diesel fuel or oil Do not use this equipment when a leak is found Repair the equipment before use 1 Storage Procedures If the generator will not be used for more than two months perform the following maintenance and storage procedures Jib Remove battery Jab Change engine Drain fuel in the fuel tank and fuel filter Clean all parts cover the equipment and store it in the place where dust and humidity are less as possible lt Caution gt Charge the removed battery once a month Refer to the owner s manual for engine about the engine storage maintenance 42 2 Stacking Danger Injuries If you have to stack two generators at warehouse always proceed with the following steps Ensure that there is no dent on bonnet loose bolt or no bolt in the equipment Always place the equipment horizontal on a flat and stable surface to be endurable for the total weight and to keep the equipment from sliding When lifting the equipment always use a lift hook Always place ties sleep
39. nk level he engine is designed to use either No 1 D or No 2 D Diesel fuel However for economical purpose use lm Fuel Inlet No 2 D Diesel fuel whenever possible at the temperature less than 7 C No 2 D fuel may pose operating problems At the much colder temperature use No 1 D fuel if available or use winterized No 2 D blend of 1 D and 2 D Fuel Strainer 27 This blended fuel is usually called also No 2 D It can used in colder temperature than NO 2 D fuel which has not been winterized Check with service station operator to be sure you can get the proper blend fuel Fuel requirements NOTICE The fuel injection pump injector or other parts of the fuel system and engine can be damaged if you use any fuel or fuel additive other than those specifically recommended by Isuzu Such damage is not our responsibility and is not covered by the Warranty To help avoid fuel system or engine damage please heed the following e Some service stations mix used engine oil with diesel fuel Some manufacturers of large diesel engines allow this however for your diesel engine do not use the diesel fuel which has been contaminated with engine oil Besides causing engine damage such fuel can also affect emission control Before using any diesel fuel check with the service station operator to see if the fuel has been mixed with engine oil Do not use any fuel additive At the time this manual was printed no other fuel ad
40. nnection check lever 3 way valve Check Change fuse Check Change fuel cut solenoid Use winterized fuel Drain water in fuel line Ask our distributor to repair Clean Change fuel filter Clean Change gauze filter Drain water in water separator fuel filter or fuel tank Extract the air Check piping connection Check Change air filter element Supply lubricant oil Supply lubricant oil Change oil filter Ask our distributor to repair Ask our distributor to repair Change to proper kind and viscosity oil Ask our distributor to repair Ask our distributor to repair Ask our distributor to repair Check Adjust fan belt Check Supply coolant Clean radiator core Black smoke comes out from Muffler White smoke comes out from Muffler Pointer hand does not move in voltage meter Pointer hand does not goes up to the rated voltage The voltage drops drastically when connecting to load Cannot turn the breaker to ON pora quo a 2 3 Air filter element is clogged Fuel injection nozzle is 2 defective 3 Improper fuel is used Too much or too little oil to cylinder Water is interfused in fuel line Fuel injection nozzle is defective Coolant temperature is too low Engine thermostat is defective Voltage meter is defective 1 AVR is defective 2 Disconnected circuit loose 3 terminal or departed 4 Initial exciter is defective 4 5 5 1 Voltage meter is defective 1 AVR is
41. rature can reach extremely high levels Check the radiator and coolant reservoir tank for water and add water in case of shortage 1 Checking Radiator Adding water Remove the radiator plate and open the radiator cap cover Remove the radiator cap Jab Fill up water to the radiator water inlet top Reinstall the cap and tighten it Close the radiator cap cover and reinstall the radiator plate 25 2 Checking Coolant in sub tank Adding coolant 3 LY Sub Tank Check to see if the water coolant level is between and MIN line the sub tank Fill up to the MAX line if the water coolant level is low Caution Be sure to use the long life coolant LLC for the aluminium radiator only The coolant should be mixed good quality softened tap water with anti freezing and anti rust liquid At ex factory the LLC mix ratio is 30 liquid and 70 water is installed Isuzu Genuine LLC Besco LLC Super Type E sure to use the same LLC into sub tank The mix ration should be changed to ambient temperature but between 30 50 e When replenishing LLC be sure to use the same brand as the LLC left in the radiator and sub tank Never use the mixed LLC by different brands Be sure to change wholly in less than 2 years or 1000 hours Mixture ratio for reference only Ambient 5 3 Coolant Volume Unit L Total Coolant Volume including sub tank 8 2 0 9
42. the 3 way valve lever to B position Caution Always stop the engine when working on the fuel line e Always wipe any drip of Diesel fuel or oil not use this equipment when a leak is found Repair the equipment before use Ensure that there is no fuel leakage on the fuel line after the fuel line working finished Turn the 3 way valve lever to A position Installed tank use position External Fuel Tank Disconnect the P T 1 2 plugs from the external fuel intake and the external fuel return and then connect the hoses from the external fuel tank as shown below External tank use position Extract the air out from the connected hoses By the above procedure it makes possible to use an external fuel tank r External Fuel Inlet 4 f Ss SS EO External Fuel Return 3 way Valve lt Caution gt Use always oil proof hose in 8 10mm inner diameter as connecting hose The fuel level in the external fuel tank should be 0 to 3m higher than the bottom of the equipment Otherwise it may A side Lever Position B side Lever Position cause engine malfunction or stoppage To avoid any leak from the external fuel intake and return ports always turn the lever for 3 way valve to A position whenever piping work is performed Use extreme caution when connecting the hoses If the lever position is set improper the fuel may leak from either the built in fuel tank or the external fuel t
43. ttery fixing clamp dU rT a 7 CZ ee ATTAIN Lu PIU E LIT fom 7 E A I HL AU POT M ae LU r 111 Ed zn ii Ig A 10111 Lr 4 GELT Ree d i VEL ie d emove tne trom poslitiVe 111 11 LE ETT Jg 1h 4 a Rel FF AI 11 o JM Eje iL Fixing Clamp a es n Ll m TF t SS a v gm F E cV mem f F in 1 A uu c ie aed Es m m NI ee M 5 nV 1 dL ul LF VU d x 11 j GA oy 1 1 j WI _ MIS k ls rj Ja Remove the battery from the seat X Reinstall a new battery in the reverse order always install the cable to the positive post of the new battery first 29 9 Operation 9 1 Initialization and Preparation e gd c Danger Suffocation from exhaust gas Exhaust fumes from the engine contains many elements harmful To humans Do not operate this equipment in poorly ventilated area such as ins
44. ue idling until the pressure falls to normal range It shows the volume in the fuel tank When filled up it shows Fa When the hand is approaching to Ea the volume is coming to empty Replenish fuel enough promptly 11 Generator Gauges 1 Volt Meter Voltage Meter displays the output voltage Phase to Phase from the generator A Please check and confirm it showing 415V at 50Hz during 2 Ampere Meter Ampere Meter displays the output current Phase from the A generator Q 3 Frequency Meter Frequency meter will display the frequency of the generator Please check it showing 50Hz during operation 1 Preheat Lamp When the starter switch is turned to lt Run Preheat gt position the preheat lamp will be turned ON The preheat lamp will be turned OFF after preheating completes showing the engine start possible Caution Preheating time varies to coolant temperature usually about 1 5 seconds 2 Pilot Lamp The lamp indicates whether or not the equipment is generating electricity when the engine is running e 12 3 Panel Light Panel light turns ON to illuminate the panel when turning the switch by the light to ON O 2 1 Starter Switch 1 Stop When the switch is set to this position all power will be off peur The switch must be set to this position to remove the key 2 Run Preheat The switch must be set to this position during operation
45. urrent leak occurs it trips to stop power transmission to load 1P ELCB Caution Do not use this breaker as the ON OFF switch to the load 6 Volt Meter Selector Switch By changing the switch the voltmeter displays the voltage between the lines 7 Ampere Meter Selector Switch The phase current displays in the meter by switching to each phase R S and T position 14 8 Battery Isolator When turning the switch to OFF the engine electric circuit does not activate due to no battery power OFF position ON position Voltage Regulator 1 Voltage Regulator The dial adjusts generator output voltage PR By turning the dial clockwise you can increases the voltage By turning the dial counter clockwise you can decrease the voltage 15 5 3 Fuel Line Changeover Valve 3 way valve Caution Fire e Always stop the engine when performing any work on the fuel line Always wipe any drip of Diesel fuel or engine oil Do not use this equipment when a leak is found Repair the equipment before use Be sure to confirm that there is no leakage in the piping By switching the 3 way valve you can use fuel from external fuel tank In this case the built in tank fuel cannot be used 1 Using fuel from built in fuel tank The lever for 3 way valve is set to A when the equipment is shipped Outer fuel inlet and return are closed with plugs PT1 2 Use fuel as they are A side Lev
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