DGK150D - Shindaiwa
Contents
1. W33 W22. 6 4 1 External View Part Names 6 4 2 Operation Panel Part Names 8 4 3 Main Terminal Board 8 9 Sai Warning InmdiealolS zs 22 9 0 99 0 0 00323 9 22 09 9 5 2 Meters and 12 5 3 Fuel Piping Switch 3Way Fuel Valve 18 Transporting lnstalling chu ccu 19 6 1 Transport FTOCOQUIGS 19 6 2 Installation 20 Load COMMC COINS e EE DO 21 7 1 Load Cable Selection 21 7 2 Connecting Load 22 Pre Operation Inspection 2 2 23 8 1 Checking Engine eese 23 8 2 Checking Coolant eese 24 8 3 Checking the Fan 25 8 4 Checking the 26 8 5 Checking for Fuel Oil and Coolant Leaks 27 8 6 Checking the 27 Operating Procedu
3. SAE15W 40 20W 40 3 Engine Oil Replacement Amount Unit L Total Lubrication Oil Amount 38 0 8 2 Checking Coolant Be sure to also read the separate Engine Instruction Manual ee a 0 OP pj 2 CAUTION BURNS 2 V4 Do not open the radiator cap immediately after stopping the engine to avoid sustaining burns from hot vapor Hot steam gushes out from the coolant sub tank if the generator overheats Do not touch the coolant sub tank Check that the sub tank coolant level is in between FULL and LOW If the sub tank coolant is lower than the LOW level add coolant to the sub tank and radiator 1 Filling the Sub Tank Jib Remove the sub tank cap dab Fill the sub tank with coolant until it reaches the FULL line Jab Re attach the cap Sub tank Cap Sub tank 24 2 Filling the Radiator Radiator Cap ib Remove the radiator cap Fill with coolant through the filler neck until the radiator is full Jab Re attach and tighten the radiator cap Sub tank lt NOTE gt Use Long Life Coolant 30 LLC for engine coolant Always use potable water when mixing the coolant Use same type of coolant with identical mixture ratio for the reservoir tank Mixture ratio of the LLC should be based on the outside temperature as per below chart Do not use a high LLC mixing rate unless absolutely necessary Doing so could result in overhea
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6. The fuel meter on the control panel will only display the fuel level for the internal fuel tank Fuel Strainer Fuel Inlet NOTE Use Diesel fuel ASTM D975 No 2 D in the event ambient temperature reaches down to 5 degree Celsius Always use the Diesel Fuel Strainer Fill the fuel tank slightly less than the FULL tank level Fuel requirements Tank 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 additive was recommended See your authorized dealer to find out if this has changed 26 The engine is designed to use either Number 1 D or No 2 D diesel fuel However for better fuel economy use No 2 D diesel fuel whenever
7. OWNER S AND OPERATOR S MANUAL Diesel engine Generator DGKISOD Vertical Water Cooled 4 Cycle Diesel Engine CAUTION Do not operate the Generator or any other appliance before you have read and understood the instructions for use and keep near for ready use DGK150D 01 X750 022 26 4 X750801 390 4 Introduction Thank you for purchasing this Shindaiwa soundproof diesel engine generator This manual has been created to ensure safe usage of this generator Be sure to read this manual before operation Improper operation handling of this generator will result in an accident or malfunction Handling Operation of this generator can only be performed by persons who understand the contents of this manual and can handle operate the generator in a safe manner Persons who suffer from an illness are taking medicine or not feeling way such that safe operation would be negatively affected must not operate this generator Work performed using this generator and handling operation of this generator must be in accordance with corresponding laws and regulations based on such laws Consult with the authorized distributor where this generator was purchased if you have any inquiries regarding the corresponding laws Always be sure to include this manual when loaning out this generator and instruct operating personnel to read this manual before operation otore this manual in a specified location where it will be secure and availabl
8. 5 2 Meters and Gauges Engine Meters and Gauges 1 Hour Meter Displays the operating time Use this to schedule periodic inspection Be careful as the hour meter operates when the starter switch is at RUN regardless of whether the engine is running or stopped HOUR METER 01010101010 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 75 to 90 degrees Celsius lt NOTE gt f the needle the water temperature meter exceeds the standard value immediately stop the equipment being used allow the generator to cool by idling the engine and wait until the water temperature decreases 3 Fuel Gauge It shows the volume in the fuel tank When filled up it shows When the indicator is approaching to EJ the amount of fuel is close to empty Replenish fuel enough promptly Generator Meters and Gauges 1 Voltmeter Voltmeter displays the output voltage Phase to Phase from the generator Please check and confirm it showing 415V at 50Hz and 480V at 60Hz during operation Ammeter displays the output current Phase from the generator 3 Frequency Meter 1 Glow Lamp 3 2 Pilot Lamp 3 Frequency meter will display the frequency of the generator Please check it showing 50Hz or 60Hz during operation When the start switch is
9. Reset the thermal relay o ircuit Di 13 Generator QN9 L1 TWNIWHSL LAdLNO QN9 ee Wo2 26 Mcoov VT HOLIMS ST YIAO SONVHD HOLIMS TWNINYAL T bid M313H110 2 o z QNnON9 01 Qvo OL GNNOYS OL 01 AOBP Slb o Q 8 SNOITLOANNOD AZ2C OrC 35VHd 319415 SNOILOSNNOD AO8P Slp 35YHd 33uUHl VS 0SC C12 A A LINI A M END MS BJZ Y3LSNCAY 391 10A 1 UdJ0081 0081 03345 HOLIMS OL ON 86 ZH88 S5r A008 0 H313W 110A 10 193 ACLOD WA 119 V V 2 09 ZHOS HOLIMS H3A0 39NVYH2 YALAWWY V0Sc 0 ddldW AONANODAYS 354 JAWV COLL ee 2 EE oft 104 C11 auge 7 C WOIWENGS ov 48 UXINITAO
10. circuit loose terminal or departed Initial exciter is defective Alternator is defective Voltage meter is defective AVR is defective Voltage regulator dial is defective Frequency is low Voltage meter is defective AVR is defective AVR is defective Unbalanced loads sharing to each terminal Total loads exceeds the rated current Frequency Speed Switch set is wrong The breaker positions stays between ON and OFF Short circuit on the load Terminal cover opened The thermal relay activates 47 Check Change air filter element Contact your distributor to repair Change to clean fuel Contact your distributor to repair Drain water in water sedimenter fuel filter or fuel tank Contact your distributor to repair Warm up driving is needed Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Contact your distributor to repair Balance the loads sharing to each terminal Decrease the loads with in the rated output Set the Speed Switch correct Turning the lever to OFF first then turn it to ON position Check the load circuit Close terminal cover
11. cover Never allow flame to come close to the generator e Always keep environmental contaminants such as dust and moisture from building up on the terminal block and generator control box or arcing from the terminals to the generator control box or terminal block mounting screws may result CAUTION BURNS z a Do not touch the engine and surrounding components immediately after stopping the equipment while temperature can reach extremely high Do not open the radiator cap immediately after stopping the engine to avoid sustaining burns from hot vapor Hot steam gushes out from the coolant sub tank if the generator overheats Do not touch the coolant sub tank Always be sure to stop the engine and allow the engine to cool when performing inspection or maintenance of engine oil Opening the oil level indicator or oil filler cap during operation will result in hot oil cause personal injury CAUTION INJURY Always be sure to use lifting hooks when moving the generator and lift it slowly at a completely vertical angle Personnel performing lifting work must wear protective gear such as helmets safety shoes and gloves e Remove the wood ties if using anchors to secure the generator Position the generator on a level stable surface so that it cannot slide or move in any manner Before starting operation always be sure to turn off all switches of equipment using the generator and all breakers to OFF Do
12. dsb Turn the 3way fuel valve lever to the B side Fuel Intake Fuel Return Position for using the external tank Plug R1 27 Plug R1 2 Bleed air from the external tank das connecting hose Fuel can be supplied from the external tank after completing the above procedures lt NOTE gt 3 Way valves 3 Way valves If using a hose for the piping use oil resistant lt A gt position lt gt hose with an internal diameter of 9 to 10 mm e Set the fuel level of the external fuel tank 0 to meters above from the bottom of this generator The fuel level of the external fuel tank being lower than this generator will result in poor engine operation or shut off Turn the 3way fuel valve lever to the A side in order to prevent fuel from flowing out from the External fuel tank m 4 15 20mm external tank fuel inlet return Turn the lever completely as far as possible If the lever is not completely pressed to either side it might not be possible to supply fuel causing the engine to stop Set the supply side so that it is 15 to 20 mm above the underside of the tank in order to prevent foreign material or water from being suctioned from inside the external fuel tank Set the external fuel tank return side at the same height as the supply side in order to prevent poor engine operation due to air mixed in with the fuel Re
13. filler cap 2 Remove the oil drain plug and turn the spigot a Oil Filler Cap Oil Level Indicator counterclockwise to open the ball valve and drain the engine oil Oil Drain Plug After the oil has been completely drained turn the dab spigot clockwise to close the ball valve and tighten the oil Ball Valve drain plug Jab Add oil through the oil filler until it is at the maximum level while checking the fuel level using the oil level indicator dsb Attach the oil filler cap lt NOTE gt Refer to section 8 1 Checking Engine Oil for engine oil Oil Drain Plug replacement amounts and types After reinserting the oil drain plug and shortly after starting the engine be sure to always check that there is no oil leakage 2 Replacing the Oil Filter Thereafter Every 500 hours Drain the engine oil Refer to section 1 Engine Oil Replacement Gasket Hemowve the oil filter using a filter wrench opread a thin layer of oil on a new oil filter gasket Screw the new filter into place and tighten it by hand until the gasket contacts the seat Then give it additional 1 turn to seat the filter using an oil filter wrench Add engine oil to the generator Shortly after starting the engine always be sure to check that there is no oil leaking from the seal surface Oil Filter 36 B Oil filter tightening torque 63 7 4 9 Nm 6 5 0 5 kgfm NOTE Reque
14. is completed in approximately 30 seconds lt NOTE gt e Start the engine and check that the air is completely bled from the system If air bleeding is not complete engine rotation will not be stable In that case repeat the air bleeding operation 9 3 Stopping Operation CAUTION BURNS z Do not touch the engine and surrounding components immediately after stopping the equipment while temperature can reach extremely high Turn the switches and breakers on the load side to OFF Turn the circuit breaker on the operation panel to OFF The engine cools down for approximately three minutes Turn the starter switch to STOP ae 31 9 4 Protective Functions le WARNING INJURY 25 Pe Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key CAUTION BURNS of a Do not touch the engine and surrounding components immediately after stopping the equipment while temperature can reach extremely high Hot steam gushes out from the coolant sub tank if the generator overheats Do not touch the coolant sub tank This generator is equipped with automatic shutdown feature and display of the foult location or any malfunction In event of the automatic shutdown or a
15. not move the generator during operation Do not operate the generator if it has been modified or any parts have been removed A CAUTION PROPERTY DAMAGE f using this generator for medical equipment check before use with the medical equipment manufacturer doctor hospital or similar entity Check that the generator output setting output terminal connection and load power source are consistent Cable burnout can occur due to generated heat if the load current exceeds the allowable current of the cable he voltage drop between cables is large if the cable is excessively long or thin resulting in decreased input voltage to equipment using the generator thereby causing decreased performance faulty operation and malfunction Warning Caution Label Locations If warning or caution labels become damaged and difficult to read replace with new labels in the indicated locations Order labels using part number indicated in the parenthesis D Warning Injury Part no X505 007550 2 Warning Electric Shock Part no X505 007560 3 Caution GM Spec LLC Part no X505 004650 Warning Caution Part no X505 007571 5 Warning Keep Terminal Part no X505 007580 2 Specifications 2 1 Specifications oynchronous Alternator 5 2 g lt Winding Sphae 4wie Powerfactor O 96 J 80 df Insulation class Excitation SelfExcitation Brushl
16. order always install the cable to the positive post of the new battery first 2 BATTERY B V S X Hemove the clamp and cable from negative post from the battery on the right side always remove negative side first Hemove the hold down clamp from the battery on the right side Remove the clamp and cable from positive post from the battery on the right side Remove the right side battery from the seat X Reinstall the new battery in the reverse order always install the cable to the positive post of the new battery first lt NOTE gt Make sure that the removed cable does not come in contact with the battery post 28 9 Operating Procedures 9 1 Initial Startup Pre Check 3 A WARNING SUFFOCATION FROM EXHAUST FUME AA Do not operate the generator in poorly ventilated areas such as an indoors or tunnels as the exhaust gas of the engine contains substances that are harmful to human health Do not direct exhaust fumes at pedestrians or buildings WARNING INJURY Pe Before turning the circuit breaker to ON position ensure that the breaker or the switch of loads are positioned to OFF Operate the circuit breaker well communicating with the electrician by the load side Close all doors and lock them during operation CAUTION FIRE Do not bring flammable items such as fuel gas and paint or items that are highly combustible near the generator as th
17. the equipment while temperature can reach extremely high CAUTION FIRE Always be sure wipe any spilled fuel or oil 8 1 Checking Engine Oil Q Be sure to also read the separate Engine Instruction Manual CAUTION BURNS Always be sure to stop the engine and allow the engine to cool when performing inspection or maintenance of engine oil Opening the oil level indicator or oil filler cap during operation will result in hot oil cause personal injury To check the engine oil keep the equipment leveled remove oil level indicator to be wiped and then re insert the dipstick fully Prior to start the engine make sure to fill the engine oil through the oil filler until it reaches below from MAX line Oil Filler Cap Level Indicator Check engine oil volume IN 10 20 MINUTES LATER always after stopping engine or replenishing fuel An accurate oil level reading cannot be obtained if the generator is not leveled Do not overfill the engine oil 7 Excessive amount of engine oil will damage the engine 2 E d OK NOT TOO Oil Filler Cap ENOUGH MUCH 23 1 Types of Engine Oil Use the API class CD grade or higher 2 Engine Oil Viscosity Use a diesel engine oil with an appropriate viscosity corresponding to the ambient temperature refer to the table O Relation of Viscosity Temperature SAE20 20W SAE40 SAE10W Temp degree Celsius
18. turned to the Run Preheat position the Glow Lamp will light to indicate that the glow plugs are energized and preheating the engine cylinders When the preheating is completed the lamp will go off indicating that the engine is ready to be started Preheating time may vary from 1 to 15 seconds depending on the coolant temperature The pilot lamp is located on the generator control panel and indicates whether or not the engine is running When the lamp is lit the engine is running When the lamp is not lit the engine is not running 3 Panel Light The panel light is located on the generator control panel and is used to illuminate the generator and engine control panels This light is turned on and off with the panel light toggle switch which is also located on the generator control panel next to the panel light This light can only be energized when the engine is running 1 Starter Switch D Stop When the switch is set to this position all power will be off The switch must be set to this position to remove the key 2 Run Preheat The switch must be in this position during operation This position also is used to begin the engine preheat cycle and to remove air from the fuel system lt NOTE gt Do not leave the switch to this position while the engine is stopped Otherwise the battery is discharged S Start This position will allow user to start the engine When the key is released the setting will automati
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20. ARNING INJURY A Always be sure to use lifting hooks when lifting up the generator The other thing could result in the generator falling This lifting hook is designed to lift the generator only Do not lift any additional added weight such as fuel tanks and or trailers with this lifting hook No persons should be under a lifted generator CAUTION INJURY Always be sure to use lifting hooks when lifting up the generator and raise it slowly at vertical angle completely Personnel performing lifting work must wear protective gear such as helmets safety shoes and gloves Do not move the generator during operation B Lifting Procedures Always be sure to use lifting hooks when lifting up the generator and raise it slowly at vertical angle completely Lifting Hook lt NOTE gt Handle this generator with extreme care when raising lowering and transporting Rough handling of this generator may result in damage or malfunction 6 2 Installation Procedures 3 A WARNING SUFFOCATION FROM EXHAUST FUME AA Do not operate the generator in poorly ventilated areas such as indoors or tunnels as the exhaust gas of the engine contains substances that are harmful to human health Do not direct exhaust fumes at pedestrians or buildings CAUTION FIRE Do not bring flammable items such as fuel gas and paint or items that are highly combustible near the generator as the muffler ex
21. Cup filter wrench Remove the fuel filter element and water sedimenter element Drain Plug Install a new fuel filter element and water sedimenter element Replace the O ring of the outer case Fill the case with clean fuel so that it is easy to bleed air from the fuel lines anne amp aaa Tighten the outer case using the specified filter wrench B Drain plug tightening torque 1 5 to 2 5 Nm 0 15 to 0 25 kgfm B Outer case tightening torque 29 4 Nm 3 0 kgfm B Aijr bleeding plug tightening torque 7 9 to 11 7 Nm 0 8 to 1 2 kgfm lt NOTE gt After replacing the filter always air out the fuel system Refer to 9 2 Procedures during Operation e Fuel filter element ISUZU Part No 898143 0410 Water Sedimenter element ISUZU Part No 898074 2880 7 Fuel System Air Bleeding The entry of air into the fuel system will cause hard engine starting or engine malfunction When performing maintenance such as emptying the fuel tank draining for the water sediment and the fuel filter element is done be sure to conduct air bleeding procedure Loosen the air bleeding screw located on top of the main fuel filter housing Air Bleeding Plu Turn the starter switch to the RUN position but do not dis start the engine to operate electromagnetic pump Operate the manual priming pump on fuel filter to bleed remaining air Tighten the air bleeding plug of fuel filter After tightening all the air
22. bleeding plugs operate the manual priming pump until resistance is felt Priming Pump Secure the priming pumps at the original position and then start the engine If the engine does not Start repeat the procedure B Air bleeding plug tightening torque 7 9 to 11 7 Nm 0 8 1 2 kgfm 8 Electromagnetic Pump Filter Cleaning Every 500 hours Electromagnetic Pump Hemove the wirings attached on the pump cover Rotate the cover with a wrench and remove it Jab Turn the cover located at the bottom of pump counter clockwise and remove filter aret Filter Clean the filter with the compressed air and rinse It in the fuel oil before installing the filter and the Gasket gasket Pump Cover Jab Reinstall in the reverse order lt NOTE gt Put a tray under the lever in order to catch spilled fuel when changing filter Extract the air in fuel line after filter changing finishes Refer to 9 2 Procedures during Operation Ensure that there is no fuel leakage after reinstallation 40 Electromagnetic Pump Filter element ISUZU Part No 898071 4010 Electromagnetic Pump Gasket ISUZU Part No 898071 4040 9 Clean Strainer in Engine Feed Pump Fuel Suppuly Pump Jib Remove eyebolts Jab Remove strainer in eyebolts dab Clean the strainer with the compressed air and rinse it in the fuel oil and reinstall in the reverse order lt NOTE gt Put a tray unde
23. cally return to lt RUN gt position 2 Emergency Stop Button This button is used to stop the engine in emergency Keep pressing the button until the engine comes to complete stop lt NOTE gt Keep pressing the button until the engine stops in several seconds After the engine stops be sure to return the starter switch to the STOP position 3 Circuit Breaker 4 Thermal Relay Heset Button lt NOTE gt 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 when overload or short circuit occur This relay sends the signal to the circuit breaker to trip off when over current flows in the circuits When the breaker trips off it is set at the middle in between ON and OFF position Reset the breaker to the ON position according to the following procedure D Stop the engine 2 Open the control panel and push the reset button of the thermal relay Do not change the preset value of the thermal relay 5 Voltmeter Selector Switch The voltmeter selector switch is a 5 position switch located on the control panel to the left of the voltmeter The voltmeter selector switch selects which phase voltage is displayed on the voltmeter Positions Off There are two off positions on the voltmeter selector switch One at the full clockwise position and one at the full counter clockwise position of
24. djust the voltage regulator dial to the specified voltage For three phase load 50Hz 60Hz 415V 480V For single phase load 50Hz 60Hz 240V 277V Jeb Turn the breakers to ON to start power transmission WARNING ELECTRIC SHOCK INJURY 2 Before turning the circuit breaker to ON position ensure that the breaker or the Switch of loads are positioned to OFF Operate the circuit breaker well communicating with the electrician by the load side 30 9 2 Procedures during Operation 1 Checks after Startup Make sure that all meters and indicators are in normal status Refer to section 5 Equipment Check that there is no abnormal vibration or noise Check that the exhaust gas color is normal When operation is normal the exhaust gas should be colorless or slightly bluish NOTE f abnormality is found stop using this generator and request the authorized distributor where the generator was purchased to repair the generator 2 Adjustment during Operation During load operation check the voltmeter and properly adjust the voltage using the voltage regulator dial Bleeding air from the fuel system when the engine stops due to running out of fuel this generator is equipped with an automatic air bleeding mechanism Perform the following procedures when the engine stops to bleed the air automatically Jib Add fuel to the generator Jal Turn the starter switch will be RUN Air bleeding
25. e for consulting at any time Order another copy from the authorized distributor where this generator was purchased if this manual becomes dusty grimy or torn Consult with the authorized distributor where this generator was purchased if you have any inquiries regarding any points related to this generator and manual When inquiring about this generator be sure to provide the model name and serial number If disposing of this generator do so in a manner that is in compliance with laws related to industrial waste Contact the authorized distributor where the generator was purchased if you have any inquiries regarding proper disposal Caution notice ranks in this manual are classified as follows A WARNING Indicates a potentially hazardous situation which if not avoided can result in death or serious injury A CAUTION Indicates a potentially hazardous situation which if not avoided can result in minor or moderate injury and property damage lt NOTE Other types of cautions and indications Note that A CAUTION items can also lead to major accidents under some circumstances if not correctly followed All caution notices are important Be sure to follow all of them 10 11 12 13 14 Table of Contents Safety Instructions 2 SDecIlICatlols nb dete ts dcs 5 251 SOSCIIGAU ONS i pedea p E 5 2 2 AIMDIENE GONGIONS 6 PAD DING AVION ree 6
26. e is stopped when working on fuel line Always be sure to wipe up any spilled fuel After working on the piping check that there is no Diesel fuel leakage By switching three way valve fuel will be supplied from the external tank In that case the built in tank will not 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 In addition both the external fuel intake and the external fuel return are safeguarded with R1 2 plugs Do not remove the plugs when using the built in fuel tank 3 Way valves lt A gt position External External Fuel Intake Fuel Return 3 Way valves Plug R1 2 Plug R1 2 A position NOTE Always set the lever for 3 way valve back to A position and cover the external fuel intake and return port with the supplied plugs after the hoses are removed 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 from the external fuel tank For detail instruction refer to 9 5 Connecting with External Fuel Tank pu Tj m OE H 3 Way valves B position 3 Way valves To External Fuel Tank lt gt position 6 Transporting Installing 6 1 Transport Procedures W
27. e muffler exhaust gas and other parts become extremely hot Position this generator 1m or more from walls or other hindrances and on a level surface CAUTION INJURY Do not operate the generator if it has been modified or any parts have been removed Position the generator on a level stable surface so that it cannot slide or move in any manner Before starting operation always be sure to turn off all switches of equipment being used and all breakers to OFF Jib Turn every circuit breaker to OFF position Jab Turn the starter switch to the lt START gt position If the temperature is cold turn the starter switch to lt PREHEAT gt and the pre heating indicator lights up The light turns off after preheating is completed After the light turns off start the engine NOTE he preheating time varies depending on the coolant temperature but generally is completed in approximately one to fifteen seconds Do not continuously operate the starter motor for 10 sec or more f repeating starter switch operation wait 30 sec or more between operating Be aware that smoke might be generated when the engine is started 29 Circuit Breaker Ki x Glow Lamp H gt Starter Switch Ki Q g Voltage Adjust Regulator After starting the engine remove your hand from the starter switch Allow the engine to run with no load for at least 10 minutes aac A
28. ent has dried contaminants it may be cleaned by blowing compressed air from the inside f the element has carbon or grease it should be replaced with Reset Button new element B 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 5 Draining Water from the Fuel Filter and Water Sedimenter Pre Operation Every 250 hours Drain water when the float red inside the cup has come up to the bottom part of the filter element Air Bleeding Plug Loosen the air bleeding plug Loosen the drain plug on the bottom to drain the water When water draining is completed tighten the drain plug on the bottom Tighten the air bleeding plug Drain Plug ae aa B Drain plug tightening torque 1 5 to 2 5 Nm 0 15 to 0 25 kgfm B Aijr bleeding plug tightening torque 7 9 to 11 7 Nm 0 8 to 1 2 kgfm 38 NOTE After draining finishes extract the air in fuel line Refer to 9 2 Procedures during Operation 6 Cleaning Changing Fuel Filter and Water Sedimenter Every 250 hours Air Bleeding Plug Every 500 hours Loosen the air bleeding plug Loosen the drain plug on the bottom to drain the fuel Hemove the outer case of the filter using the specified
29. er motor Battery output is weak Check battery liquid or Charge does not drive Battery is deteriorated Change battery or speed is low Battery terminal is OFF or loose Fix Tighten terminal Battery terminal is corroded Clean terminal Starter switch or relay is defective Contact your distributor to repair Starter motor is defective Contact your distributor to repair Starter motor Fuel is insufficient Add fuel drives but Fuel filter is clogged Clean Change fuel filter engine does Gauze filter is clogged Clean Change gauze filter not start Water is interfused in fuel line Drain water in water sedimenter fuel filter or fuel tank Air is interfused in fuel line Extract the air Poor piping connection to external fuel Check piping connection Engine does not start tank Fuel tank selector lever 3 way valve Check lever 3 way valve position is wrong 8 1 Check Change fuse Work 8 2 Check Change fuel cut solenoid Fuel cut solenoid motor does not Ambient temperature falls down below zero Engine starts but stalls immediately Engine oil pressure is low Overheated 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 cl
30. ess No of poles Types 1 5 Vertical Water cooled 4 cycle Diesel Engine Model Manufacturer OO a O 6HK1 ISUZU Combustion system Direct Fuel Injection with Turbo Charger p Cooling method oo 1 Radiator Lubricating method Foreedlubrcalion C Stringmethod Electric start Fuel 4 Lubicantol 280 Charging dynamo capacity Batey 105 418 2 12 V 100AH a 5 2 2 Ambient Conditions Use this generator in ambient conditions as described below Failure to provide these conditions can result in problems such as malfunction insufficient output and reduced durability Ambient temperature 15 to 40 degree Celsius B Relative humidity 8596 or less B Elevation 1000 m or less 3 Applications Power source for submerged pumps and similar civil engineering equipment Power source for lighting and similar equipment Power source for electrical tools and household appliances A CAUTION PROPERTY SECONDARY DAMAGE Do not use for any application other than those listed above f using this generator for medical equipment check before use with the medical equipment manufacturer doctor hospital or similar entity 4 Part Names 4 1 External View Part Names Lifting Hook Operation Panel Door Engine Check Door Coolant Sub Tank LEFT SIDE Air C
31. fer to section 9 2 Procedures during Operation for air bleeding e Some air may remain in hoses or pipes immediately after connecting the external fuel tank resulting in unstable engine speed and engine stoppage Do not leave the generator unattended for unmanned operation until you have confirmed that the engine speed is stable 33 10 Inspection Maintenance __ WARNING ELECTRIC SHOCK INJURY 2 25 ROA Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key Do not touch the generator if the Alternator or casing becomes wet during operation Do not operate the equipment if the equipment or you are wet Do not lift up using tie downs Use of such could result in the generator falling No persons should be under a suspended generator CAUTION FIRE Always be sure to wipe any spilled fuel or oil LZ CAUTION BURNS z DA Do not touch the engine and surrounding components immediately after stopping the equipment while temperature can reach extremely high Do not open the radiator cap immediately after stopping the engine to avoid sustaining burns from hot vapor Always be sure to stop the engine and allow the engine to cool when performing inspection or maintenance of engine oil Opening the oil level indicator or oil filler cap during operation will result in hot o
32. haust gas and other parts become extremely hot Keep this generator 1m or more from walls or other hindrances and on a level surface e Remove the wood ties if using anchors to secure the generator Do not connect the generator output to indoor wiring B if installing this generator set up barriers or fencing completely around the boundary line of the construction area and take measures to prevent persons not involved in the construction from entering the area Always set the generator on a hard flat and leveled surface that serves as the foundation Keep the generator 1 m or more from walls or other hindrances so that the operation panel door and left right check doors are accessible for internal inspection maintenance Caution This equipment must be operated on hard and flat surface Operating under any other conditions may result in a fault or 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 20 7 Load Connections 7 1 Load Cable Selection CAUTION PROPERTY DAMAGE e Cable burnout can occur due to generated heat if the load curre
33. he battery if the fluid level is below the minimum level Do not create sparks or bring flame near the battery as it generates flammable gas Check the fluid level and add distilled water when it is near the lower level until it reaches the upper level Jal Check the terminals for looseness and tighten if loosen lt NOTE gt It is necessary to recharge the battery when the specific gravity of the battery fluid is 1 23 or less Request the authorized distributor where the generator was purchased to recharge the battery LOWER LEVEL Y UPPER LEVEL 27 Replacing the Battery TERMINAL TERMINAL lt NOTE gt Two batteries are connected in series order Whenever you replace battery or disconnect cables always proceed with the following steps otherwise battery Fixing Rod may short circuit BATTERY A BATTERY B 1 BATTERY A Gs Remove the clamp and cable from negative post from the battery on the right side always remove negative side first Remove the clamp and cable from positive post from the battery on the right side Remove the clamp and cable from negative post from the battery on the left side always remove negative side first Remove the hold down clamp from the battery on the left side Remove the clamp and cable from positive post from the battery on the left side Remove the left side battery from the seat Reinstall the new battery in the reverse
34. il cause personal injury CAUTION INJURY Personnel performing lifting work must wear protective gear such as helmets safety shoes and gloves Always be sure to use lifting hooks when moving the generator and lift it slowly at a completely vertical angle Perform periodic inspection and maintenance according to the following table in order to constantly maintain this generator in good working condition Use the hour meter as a reference for the operating time NOTE All procedures except for pre operation inspection should be performed by specialized technicians Request the authorized distributor where the generator was purchased to perform the procedures in the table with a 9 This chart only covers the simple checks and maintenance for the engine For more detailed guide please refer to the User s Manual for the engine Always be sure to use genuine parts or those indicated specifically for replacement parts Use a container to catch fluid bled from this generator that is large enough to prevent the fluid from spilling on the ground Dispose of oil fuel coolant LLC filter battery and other hazardous materials according to laws and regulations concerning industrial waste Contact the authorized distributor where the generator was purchased if you have any inquiries regarding proper disposal 34 When check doors are open during maintenance take measures so that unrelated personnel cannot accide
35. larm lamp flashing turn off the engine and investigate the fault location Protection Feature List No Symptoms Circuit Automatic Breaker Engine OFF Shutoff Engine coolant temperature is too high temperature default at 105 degrees Celsius High Coolant Oil pressure Engine oil pressure dropped drop default at 100kPa 14 5 psi Insufficient When the battery can no longer battery arge hold charge the engine is detected Operates if the intake air Hight Boost temperature of the intake manifold Temp is excessively high default at 85 degrees Celsius Operates if the engine speed is Engine excessively high during operation Over speed default at 2 070 rpm 60 Hz and 1 725 rpm 50 Hz n Operates if some fault affecting Diagnosis indicate the automatic feature A indicate the function might operate 32 9 5 Connecting with External Fuel Tank FIRE Always make sure that the engine is stopped when working on the fuel line Always be sure to wipe up any spilled Diesel fuel After working on the piping check that there is no Diesel fuel leakage Jib Turn the 3way fuel valve lever to the A side j Position for using the internal tank ER Disconnect the R1 2 plugs from both the RH Jab external fuel intake and an external fuel _ return and connect the hoses from an P external fuel tank as shown below External External
36. leaner PCV Filter Terminal Cover Alternator Check Door Fuel Inlet Fuel Tank Receptacle Board Cover Ki Fuel Filter Electromagnetic Pump Oil Filler Cap amp Oil Level Indicator Fuel Drain Oil Drain Water Sedimenter Oil Filter Terminal block Alternator Check Door EGR Cooler RIGHT SIDE Radiator Engine Check Door Coolant Drain 3Way Fuel Valve Battery External Tank Fuel Inlet External Tank Fuel Return Accessories Owners Manual Engine Key 2 pieces 4 2 Operation Panel Part Names Voltmeter Selector Swten ff 4 3 Main Terminal Board Main Terminals Plexiglass Cover 5 1 Warning Indicators le WARNING INJURY 25 ao Close all doors and place locks during operation to avoid injuries by unintentionally contact with moving parts such as the cooling fan and fan belt Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key CAUTION BURNS z Do not touch the engine and surrounding components immediately after stopping the equipment while temperature can reach extremely high DIAG BOOST CHARGE OILPRESS OVERHEAT OVER SPEED O O O O O Q This generator is equipped with the following warning indicators DIAG diagnostic BOOST boost temperature CHARGE battery charging OIL PRESS oil pressure OVER HEAT water tempe
37. n will result in hot oil cause personal injury When the engine oil pressure drops below 100 kPa 1 02 kgf cm 14 5 psi during operation the oil pressure monitor lamp will flash and the automatic shutdown will be engaged When this occurs check the engine oil level and replenish to the maximum level if needed NOTE This oil pressure warning indicator cannot detect oil deterioration Change the engine oil periodically Refer to section 8 1 Checking Engine Oil 3 BATTERY Battery Charge Warning Indicator Low Battery Voltage The BATTERY warning indicator lights up when charging is not possible during operation If this occurs contact the authorized distributor where the generator was purchased NOTE This battery charging warning indicator cannot detect battery deterioration or insufficient battery fluid Refer to section 8 6 Checking the Battery 4 Diagnosis Indicator Always be sure to stop the engine and allow the engine to cool when performing inspection or maintenance of engine oil Opening the oil gauge or oil filler cap during operation will result in hot oil cause personal injury If the electronic control module detects a fault that could affect engine operation it will flash the diagnosis lamp to indicate that further diagnosis as to the source of fault is necessary This will not shut the engine down If this occurs contact the authorized distributor where the generator was pu
38. nt exceeds the allowable current of the cable The voltage drop between cables is large if the cable is excessively long or thin resulting in decreased input voltage to equipment using the generator thereby causing decreased performance faulty operation and malfunction Select cable for use that has sufficient thickness and an allowable current possible for use giving consideration to the distance from the generator to the equipment using the generator NOTE Select cable with a thickness that ensures that the voltage drop across the cable will be within 596 of the rated voltage Expedient Formula The voltage drop of cables e 3 Phase 3 Wire 1 Length m Voltage Drop V x Current 58 Dia mm e 1 Phase 2 Wire 1 Length m Voltage Drop V Current A x2 58 Dia mm 21 7 2 Connecting Load Cables WARNING ELECTRIC SHOCK AN e Before connecting or disconnecting the load cables to from the output terminal always turn the output circuit breakers to the OFF position stop the engine and remove the engine key The person performing the maintenance should always keep the key Close the output terminal cover before operating Do not touch the generator if the Aiternator or casing becomes wet during operation CAUTION FIRE f Do not connect the generator output to indoor wiring lt NOTE gt When connecting a load check that
39. ntally come close to the generator Close all doors and covers if you are going to be away from this generator n the event you are using Fuel Oil A as a fuel the interval of replacing engine oil oil filter and fuel filters and the inspection of fuel injection nozzle will be more frequently at every half the hours shown in the matrix Daily Every Every Every Engine Side Cleaneachparts tightening Engine oil checks add L4 ene Ol hr Meena f time as mark Arad Wo emer T M 7 time at P hr mark iem I Coolantlevelcheck addcoolant level check add coolant Exhaust color check Coolant change bleeding EGR Lr te ft ae e 1o the fuel filter and water sedimenter Clean eel Pe water sedimenter element Clean Replace Drain water from fuel tank eS Change filter in the electromagnetic oua for air extraction in fuel line Cleaninsidefueltank inside fuel tank Leak check fuel and coolant e Replacing fuel hose or 1yr Clean or replace air cleaner element s Battery fuia levetcheck OT _ ooo So o Battery hydrometercheck _ JoJ Y Radiator Flush RadiatorFlush Cleaning Check and adjust engine valve clearance Compessonchek Alternator side Various meter and alarm lamps check 39 1 Engine Oil Replacement as Thereafter Every 500 hours Jib Remove the oil
40. ogged Oil Pressure switch 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 46 Use winterized fuel Drain water in fuel line Contact your distributor to repair Clean Change fuel filter Clean Change gauze filter Drain water in water sedimenter 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 Contact your distributor to repair Change to proper kind and viscosity oil Contact your distributor to repair Contact your distributor to repair Contact your 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 Indicator does not move in voltage meter Indicator does not goes up to the rated voltage Indicator exceeds the rated voltage The voltage drops drastically when connecting to load Cannot turn the breaker to ON position Air filter element is clogged Fuel injection nozzle is defective 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 AVR is defective Disconnected
41. ogs o V gt fid V 570 v 305 36 28 d BEN 0013 Wo gt 2 90 863 2 2 50 CYH 3719NV WYO p t El afaj ERA 563 66 9 im lg v rd YOSNSS mig 2 LENO 100 535 A78 8270 yw Y3LYM ic HO apap A005 1 A009 walesy ZSA 783 fyg 8470 405135 TWNINU3L 30010 31010 Walger 8 Lavis EO BLA i pu Od gmzE CEA M xui gt gt A 8 S770 1 55349 710 ualuvic ang OO AMAA APA N T0 gt 2010 A7 S20 305 35 JONG ia awm e Inc ay 4 WK 6 8 M 5 0 bel 8013 gt i NdW STONY 3INYHO B amp A009 A M m OE zh d n E id em 570 a HOSN3S Lana AMZ 30010 LLA ed H S0 V D u3iuvis waa pret L 85 exulr3soD ott SIA 6013 Eor dW3L 15008 92N2 c 8 C XWHLP386 163 gl 7 919146 HOSN3G _ WL zt 21 563 teg ma ov GES M OEND APA gt LL GIO IN 62A tez we 553434 15009 NCISU OTN E 9 SBA 280 Siem Snia HEY gt lt g 9 092474 0994W togl ZENO EENI 1 1 S A 97 M 0 i is dW3l 31 S VINI om 8 lt Z A HOSN3S Q ino saiwvis EN yi E i GENO
42. on with a flat hard floor capable of withstanding the double stacking weight Always be sure to use lifting hooks when lifting this generator Insert wood ties of the same size and that are wider than this generator between each generator and set another generator on top of the ties Never stack more than two levels and do not set a generator on top that is larger in weight size than that on the bottom Do not operate the generator when it is double Insert wood ties stacked 12 Troubleshooting 9 le WARNING ELECTRIC SHOCK INJURY A 25 ao Do not touch output terminals or internal electric parts while the generator is operating Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key CAUTION FIRE Never allow flame to come close the generator CAUTION BURNS z Do not touch the engine and muffler after stopping the engine while temperature can reach extremely high Inspect this generator when operation is poor to determine the fault malfunction Request the authorized distributor where the generator was purchased to perform maintenance if you cannot find any faults malfunctions during inspection 45 Suspected cause Start
43. or to cool before covering with the protective cover CAUTION BURNS z Do not touch the engine and surrounding components immediately after stopping the equipment while temperature can reach extremely high 1 Storage Procedures Perform the following maintenance procedures before storing this generator if it is not going to be used for two months or more Remove the battery Refer to section 8 6 Checking the Battery Replace the engine oil Refer to section 10 Inspection Maintenance 1 Engine Oil Replacement Drain the fuel from the fuel tank and filter Refer to section 10 Inspection Maintenance 6 Cleaning Changing Fuel Filter and Water Sedimenter Refer to section 10 Inspection Maintenance 10 Draining Water from Fuel Tank Remove the starter key and store in a secure location Clean up all generator components and store in a dry and dust free location Also cover when storing so that rain cannot enter through the suction or exhaust ports Be lt NOTE gt Adjust the fluid of the removed battery to the appropriate level and recharge approximately every month 44 2 Double Stacking Procedures WARNING INJURY Always be sure to observe the following items when double stacking this generator in a warehouse or similar location e Check that the Top cover of this generator is not dented and that bolts are not loosen or missing e Set a locati
44. positioned to OFF Operate the circuit breaker well communicating with the electrician by the load side CAUTION EYE SKIN INJURY Wear rubber gloves and other protective wear to protect eyes skin and clothing from the battery fluid which contains diluted sulfuric acid If the battery fluid contacts eyes or skin wash out immediately with a sufficient amount of clean water Be sure to receive medical treatment especially if the fluid contacts the eyes 9 SU e CAUTION EXPLOSION 4 Never use or recharge the battery if the fluid level is below the minimum level Do not create sparks or bring flame near the battery as it generates flammable gas Gh CAUTION FIRE Do not bring flammable items such as fuel gas and paint or items that are highly combustible near the generator as the muffler exhaust gas and other parts become extremely hot Keep this generator 1m or more from walls or other hindrances and on a level surface Do not connect the generator output to indoor wiring his generator uses diesel fuel Always be sure to stop the engine and not bring flames close when inspecting fuel or refueling Wait until the engine has cooled before performing such procedures Do not use this equipment when leak is found and repair the leaking location before operating Always be sure to wipe up any spilled fuel or oil Allow the generator to cool before covering with the protective
45. possible At temperatures less than 7 degree Celsius No 2 D fuel may pose operating problems see Cold Weather Operation which follows At colder temperatures use No 1 D fuel if available or use a winterized Number 2 D a blend of No 1 D and No 2 D This blended fuel is usually called No 2 D also but can be used in colder temperatures than No 2 D fuel which has not been winterized Check with the service station operator to be sure you can get the properly blended fuel Note that diesel fuel may foam during a fill up This can cause the automatic pump nozzle to shut off even though your tank is not full NOTICE Do not use home heating oil or gasoline in your diesel engine either may cause engine damage 8 5 Checking for Fuel Oil and Coolant Leaks CAUTION FIRE Do not use this equipment when leak is found and repair the leaking location before operating Open the check door and check for fuel oil and coolant leakage from fuel piping connections and similar locations 8 6 Checking the Battery CAUTION EYE SKIN INJURY Wear rubber gloves and other protective wear to protect eyes skin and clothing from the battery fluid which contains diluted sulfuric acid If the battery fluid contacts eyes or skin wash out immediately with a large amount of water Be sure to receive medical treatment especially if the fluid contacts the eyes CAUTION EXPLOSION Never use or recharge t
46. r the lever in order to catch spilled fuel when loosing the lever Gaskets are attached to both ends of joint pipe Be careful not to lose and install them in the unit without fail Change both gauze filter and eyebolt when gauze filter is damaged Extract the air in fuel line after gauze filter washing finishes Refer to 9 2 Procedures during Operation Ensure that there is no fuel leakage after reinstallation Engine Feed Pump Strainer ISUZU Part No 898074 9550 Joint Pipe Eye Bolt 0 Y ls LJ A S Aas 2 A d ANS T1 UN H M LA in We 1 d TA A D n EX V KW TID N e POR EE m Hs N ANS KO SA Q 4 gt O VN Lo ANZ V V EBD WS N Li 25 N 4 d Engine Feed Pump Engine Feed Pump X Fuel Suppuly Pump EVO RDI Oil Filler Cap NN ZA e XN lt 7 A E a 13 Ue ex NN 4 SES MY AV ch NA V PCV Filter Cil Separator Ny NCC WS S Strainer 41 10 Draining Water from Fuel Tank Every 250 hours db Turn the spigot counterclockwise to open the ball valve and drain the water Ball Valve After the water has been completely drained turn the spigot clockwise to close the ball valve Fuel Drain 11 Changing Coolant Water F
47. rature and OVER SPEED engine overspeed Warning indicators light up if some fault occurs during operation and the engine might be automatically stopped depending on the type of fault Under normal operating conditions these monitoring lamps will come on momentarily when the engine is first started but will go off very shortly thereafter 1 WATER TEMP Coolant Temperature Warning Indicator High Water Temp sustaining burns from hot vapor Hot steam gushes out from the coolant sub tank if the generator overheats Do not touch the coolant sub tank When the water temperature reaches 105 degree celsius the coolant water temperature monitor lamp will flash and the automatic shutoff will be engaged When this occurs check the coolant water reservoir tank and replenish if needed Refer to 8 2 Checking Coolant If the water level is normal there may be a possibility of loose fan belt or water leakage in coolant lines Check it after the engine cools down NOTE The coolant temperature cannot be detected if the coolant level is excessively low Always be sure to check the coolant level in the radiator coolant sub tank before starting work 2 OIL PRESS engine oil pressure Warning Indicator Low Oil Press CAUTION BURNS 2 e Always be sure to stop the engine and allow the engine to cool when performing inspection or maintenance of engine oil Opening the oil gauge or oil filler cap during operatio
48. rchased NOTE This battery charging warning indicator cannot detect battery deterioration or insufficient battery fluid Refer to section 8 6 Checking the Battery 5 Boost Indicator Always be sure to engine and allow the engine cool when performing inspection or maintenance of engine oil Opening the oil gauge or oil filler cap during operation will result in hot oil cause personal injury If the inlet temperature to the inlet manifold exceeds 85 degree celsius the boost temperature lamp will flash but will not shut the engine down If this occurs contact the authorized distributor where the generator was purchased 6 Over Speed Indicator Always be sure to stop ihe engine and allow the engine to cool when performing inspection or maintenance of engine oil Opening the oil gauge or oil filler cap during operation will result in hot oil cause personal injury This generator is equipped with this function that automatically stops the engine if some fault occurs in the engine causing the engine speed to increase a considerable amount If the engine speed increases to 2 070 rpm 60Hz and 1 725 rpm 50Hz or more during operation the overspeed and engine malfunction indicators light up and the engine is automatically stopped When this occurs it is probable that there is some internal malfunction of the engine If this occurs contact the authorized distributor where the generator was purchased
49. res 29 9 1 Initial 29 9 2 Procedures during Operation 31 9 9 SlODDING ODSFAllOLi 31 9 4 Protective FUNCIONS successes euet che 32 9 5 Connecting with External Fuel 33 Inspection Maintenance eere eee 34 Long Term Storad 2 2 E 44 TROUDICSNOOUING epo 45 Generator Circuit Diagram ccce eere eene 48 Engine Electrical Circuit Diagram 49 1 Safety Instructions 3 WARNING SUFFOCATION FROM EXHAUST FUME Do not operate the generator in poorly ventilated areas such as indoors or tunnels as the exhaust gas of the engine contains substances that are harmful to human health Do not direct exhaust fumes at pedestrians or buildings A WARNING ELECTRIC SHOCK Before connecting or disconnecting the load cables to from the output terminal always turn the output circuit breakers to the OFF position stop the engine and remove the engine key Close the output terminal cover before operating Do not insert a pin wire or other metal object into the electrical outlet Do not touch the generator if the Alternator or casing become
50. s wet during operation Do not touch output terminals or internal electric parts while the generator is operating e f even one of all is unconnected by mistake or accident it will be much more dangerous for human body than the NO RELAY case because leaking current inevitably goes through the body Even though all the earth terminals of the loads have been grounded to the earth the bonnet grounding terminal should be grounded to the earth here is always a danger of being electrocuted by short circuit Be sure to test generator s insulation resistance periodically Grounding should be made after the engine is stopped ly WARNING INJURY ab re 2 Close all doors and lock them during operation Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key Always be sure to use lifting hooks when lifting up the generator The other thing could result in the generator falling his lifting hook is designed to lift only the generator Do not lift any additional added weight such as fuel tanks and or trailers with this lifting hook No persons should be under a lifted generator Before turning the circuit breaker to ON position ensure that the breaker or the switch of loads are
51. st the authorized distributor where the generator was purchased to perform this procedure if you do not have a filter wrench e Oil filter part no ISUZU Part No 113240 2322 3 Replacing the PCV Oil Separator Filter Wipe clean around the PCV filter PCV Filter Jb cap taking care so that no Separator foreign particles entry Remove the PCV filter cap Jal Remove the PCV filter element dsb Install the new PCV filter element Jab Install the PCV filter cap ini 9 Element PCV filter Oil Separator lt NOTE gt e PCV filter element Air Cleaner 4 Air Filter Element Cleaning Replacement Every 250 hours A Every 500 hours Y Jib Loosen the bolt that is holding the air cleaner and remove the cleaner cap Cleaner Cap Fixing Bolt Unscrew the wing nut and remove the filter element Clean or replace the filter element and reinstall it in reverse order Cleaner Cap COLLIE LA Z 2 552 20 4 2 LOLI LLP ALL 4 72 22562727 52 7 0 25 P2527 AZ 2552 522 Air Cleaner Inner Element Outer Element 37 NOTE Always make sure that the arrow mark on the cleaner cap is pointing upward Clean more frequently if used in dusty environment Outer element ISUZU Part No 114215 1880 Clog Indicator e Inner element ISUZU Part No 114215 0340 B To clean the air filter element f the elem
52. the generator output setting output terminal connection position and load power source are all matching f using the N terminal be careful that the currents of each phase are uniformed f using three phase output simultaneously with a single phase three wire type output use in a range where the total current does not exceed the rated current f using three phase output simultaneously with a single phase three wire type output be careful as it is possible for the outputs to mutually affect each other Use proper tools when connecting a load to sufficiently tighten the connection Failure to sufficiently tightened will result in cable burnout Terminal cover must remain closed during operation or breaker will be tripped B Three Phase Output Terminal For three phase load O Terminal voltage is 415V 480V at 50Hz 60Hz Load For single phase load Terminal voltage is 240V 277V at 50Hz 60 2 Load Load Load 22 8 Pre Operation Inspection e ll WARNING ELECTRIC SHOCK INJURY ZZ 25 Pe Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt CAUTION BURNS Do not touch the engine and surrounding components immediately after stopping
53. the switch In either off position the voltmeter will not display any voltage L1 L2 In the L1 L2 position the voltmeter will display the phase voltage between L1 and L2 L2 L3 In the L2 L3 position the voltmeter will display the phase voltage between L2 and L3 13 11 In the L3 L1 position the voltmeter will display the phase voltage between L3 and L1 6 Ammeter Selector Switch The ammeter selector switch is a 5 position switch located on the control panel to the left of the ammeter The ammeter selector switch selects which phase current is displayed on the ammeter Positions Off There are two off positions on the ammeter selector switch One at the full clockwise position and one at the full counter clockwise position of the switch In either off position the ammeter will not display any amps This switch must be in the L1 or L3 position to read single phase current L1 In the L1 position the ammeter indicates the 3 Phase amps for L1 and single Phase amps for L1 L2 In the L2 position the ammeter indicated the 3 Phase amps for L2 L3 In the L3 position the ammeter indicates the 3 Phase amps for L3 and single Phase amps for L3 Voltage Regulator Voltage Regulator Que The dial adjusts generator output voltage G Turn the dial clockwise to increase or counter clockwise to decrease the voltage 5 3 Fuel Piping Switch 3Way Fuel Valve CAUTION Always make sure that the engin
54. ting or malfunction Replace LLC every 1 years or 1 000 hours Long Life Coolant Mixture ratio for reference only Ambient temperature 15 C 20 C 30 C Celsius 3 Coolant Amount Unit L Total Coolant Amount 23 8 1 5 Value in parenthesis is the sub tank capacity 8 3 Checking the Fan Belt Be sure to also read the separate Engine Instruction Manual 1 Fan Belt Tension Tension should be optimum when the fan belt has 6 to 8mm slacks when applying finger pressure about 100N approximately 10kgf at midpoint between fan pulley and alternator pulley 25 2 Fan Belt Condition Check the fan belt for damage and replace if any damage or other fault is found 3 Replacing the Fan Belt Request the authorized distributor where the generator was purchased to replace the fan belt lt NOTE gt Use of a loose or damaged fan belt could result in overheating or insufficient charging Refer to the User s manual for Engine for adjusting and replacing of the fan belt 8 4 Checking the Fuel CAUTION FIRE This generator uses diesel fuel Always be sure to stop the engine and remove engine key Wait until the engine has cooled before performing inspection or periodical maintenance Always wipe any drip of Diesel fuel or oil Do not use this equipment when leak is found Repair the equipment before use Check if there is a sufficient amount of fuel and add fuel if insufficient
55. uel Drain Every 1 years or 1000 hours Remove the radiator cap Loosen the draining plug on both the engine and radiator After draining all the water tighten the draining plug on both the engine and radiator Loosen the fastener that holds the sub tank and drain all the water nstall the sub tank back and fill the coolant water to the MAX level Fill the radiator with coolant water to the top Reinstall the radiator cap 4 lt gt For the types of engine oil to use refer to 8 2 Checking Coolant WHHb to Radiator Cap Coolant Drain External Tank External Tank Fuel Inlet Fuel Return Sub tank 42 12 Bleeding air from EGR cooler Bleeding air Every after coolant change Loosen the air release plug of the EGR cooler in order to bleed air from within the EGR and improve cooling performance dal When coolant flows out from the air release plug tighten the air release plug B bleeder plug tightening torque 24 5 to 30 5 Nm 2 5 to 3 1 kgfm Air Bleeder Plug 43 11 Long Term Storage WARNING INJURY Pe Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key CAUTION FIRE Always be sure to wipe up any spilled fuel or oil Allow the generat
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