e eISO 9001 CERIilFIED

OWNER'S ANDOPERATORS MANUAL

SOUND-PROOFDIESEL ENGINE GENERATOR

DGA50C

AcAuTloN

Do not operate theequipment before you have read and understoodthe instructions for use.

lable of Contents

1 . Safety Guidelines

2. Specifications

2-1. Data 2-2. Ambient Condition3. Use4. Parts

4-1. 0uter and Main Components 4-2. 0peration Panel 4--3. 0utput Panel

5. Equipment 5-1. Monitor Larnp

5-2. Meters 5-3. Fuel Line Changeover Valve

(3-Way Valve)6. Transportation & Installation

6-1. How to transport 6-2. Installation

7. Connecting Ioad

7-1. Select Load Cable 7-2. Connecting Load Cable 7-3. ELCB and Grounding8. 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

9. 0peration

9-i. Initialization and Preparation

9-2. During Operation 9-3. Stopping 9-4. Protection Feature 9--5. Connect to External Fuel lank

10. Check and Maintenance11. Long ferrn Storage

12. Troubleshooting

13. Generator Circuit Diagram

14. Engine Circuit Diagram

Page1

55

66667899

11

16

17171819192021

242425272728283030323333343543444748

Shiitdaiwa Corperratien

71230-94311

lntroduction

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 accidents and repairs.

ee Please operate this equipment after thoroughly reviewing and understanding the

contents of this manual.

ee Please attach this manual, if the equipment will be sub-leased.

es PIease store this manual nearthe equipment foreasy reference.

es Following convention

the degree of cautions.

will be u$ed throughout the manual to indicate

ODanger Cancauseseriousinjuriesordeath.

Acaution Cancauseminorinjuriesordamagetotheequipmentorotherproperties.

<Caution> Othertypesofcaution

@ Even $ome of the items noted in ifA Cautiondi may lead to serious injuries.

Plea$e read all item and follow all the safety guidelines.

1 Safety Gutdelines

Q

Q

Danger : Suffocation from exhaust fume

g 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 : EIectric Shock $ Do not insert metal objects (such as pin or wire) into plug-in receptacles.

ge 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 dangerou$ for human than the NO--RELAY case, becau$e leaking

current inevitably goes through the body.

ew Even when the ELCB in the load is grounded to the earth, be sure to

connect the terminal of bonnet in the equipment.

* Be sure to check the resistor value of the equipment periodically so that

you can avoid the electric shock caused by electric Ieakage

g Before connecting or disconnecting a load cable from output receptacles,

always turn the circuit breaker to OFF position.

1

pt 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.

o Danger : Injuries

dy Close all doors and place locks during operating this equipment, to avoid

injuries by unintentionally touching cooling fan and fan belt.

A Caution

pt

: Suffocation from exhausting fume Do not point the exhaust fume toward pedestrians or building.

Acautien :

@

lnjuries 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.

A caution : Expiosion

g Do not u$e the equiprnent or charge the battery, in the case the battery

fluid level is lower than the LOWER level.

g Battery rnay emit some cornbustible gas, so keep it away from fire and

sparks.

A caution

ig

ge

#

@

gge

: 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 i$ found. Repair the equipment before use.

femperature around muffler and exhaust can get extremely high. Keep

any inflammable items ($uch 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.

A caution : Burns

g Neveropen the radiator cap during operation orjust afterengine stops

as hot vapor may belch out.

g Do not touch the engine and mufflerduring operation and irnmediately

after $topping the equipment, for the temperature can reach extremely

high.

2

ee 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.

A caution : injurie$

g When Iifting the equipment, always use a lift hook. Do not lift a handle,

for it may cau$e equiprnent to drop due to handle breaking off.

g AIways 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.

g Do not move the equipment during operation.

@ When performing equipment check and maintenance, always stop the

englne. @ Do not operate the equipment, if the equipment is being modified or if

the parts are removed.

3

M Location ofWarning labels When warning label becomes unreadable or damaged,

place new Iabel at the appropriate location as specified in the following figure.

When ordering the Iabel, use the following part numbers.

1.2.3.4.

lnjuries

CautionSafetyCaution

(coolant )

Precaution (EIectric Shock)

(No. 1 9402-O021 O)

(No. 1 9402-O0295)(No. t 9402--O0306)

(No. 1 9402-O021 5)

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2-1. Data

Unit DGA50CGeneratingMethod - RotatingFiled,Brushless3-Phase

SynchronousGeneratorkVA 50

RatedOutputkW 40

RatedVoltage V 415RatedCurrent A 69.6

6'tg68(LE)

RatedFrequency Hz 50

RatedSpeed Min'i 1500

Phase&Wiring - 3-Phase3-WirePowerFactor e/o 80

InsulationCIass m Alternator:FExciter:BExcitingMethod m SelfExcitation(Brushless)

Poles m 4

Method - Vertical,Water-cooled4-Cycle,DieselEngine

ModelNo. m- lsuzuBB-･4BGITCylinder-borextroke mm 4-105x125ContinuousRated

SpeedkW{PS} 48.5{66.0}

Speed Min"3 1500Displacement L 4.329

CombustionMethod - DirectInjection(Turbo-charged)

CoolingMethod - Water-coolingradiator2'9ur

Lubricating - Trochoidpump,force-feedlubricationStarting - StarterMotor

Fuel - Diesel

Oil- SAECIassCDorhigher

FuelTankCapacity L 160

LubricantVolume L 13.2(includingfilter1.1L)

CoolantVolume L 17(includingsub-tank1.5L)

StarterMotorCap. V-kW 24-4.5AlternaterCap. V-A 24-20

Battery - 95D31Rx2Length mm 2000Width mm 950

g.m8E'a'

Height mm 1430

DryWeight kg 1431

lnstalledWeight kg 1590

5

2-2. Ambient Condition Be sure to use the equipment under the following arnbient condition range.

Otherwise the condition may cause damage, insufficient output or durability

shortage to the equipment

ew Ambient : 1-emperature: from -15 to 40 degree Celsius

pt Relative : Humidity: Iess than 80%

g Altitude : Less than 300m

3 USe

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Power

Power

Power

Supply for

Supply for

Supply for

submersible Pump, etc.

Iightings, etc.

electric tools, home appliances

4 Parts (Components)

4-1. 0uter

Lifting Lug

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xErnergency Stop Button

a

Operation Panel Door

Fuel lnlet

and Main Components

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MagnetPumpforautoAir

Oil Drain Plug

6

4-2. Operation Panel

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18

1 MainCircuitBreaker 13 FuelGauge

2 VoltMeter 14 HourMeter

3 AmpereMeter 15 EmergencyStopButton

4 FrequencyMeter 16 PreheatLamp

5 PanelLightSwitch 17 StarterSwitch

6 PanelLight 18 Batterylsolator

7 VoltageRegulator t9 PilotLamp

8 VoltMeterSelectorSwitch 20 3-PhaseBreaker(50A)GREEN

9 AmpereMeterSelectorSwitch 21 3-Pha$eBreaker(32A)RED

10 MonitorLamp 22 3--PhaseBreaker(20A)YELLOW

11 WaterTemperatureMeter 23 1-PhaseBreaker(15A)BLUE

12 OilPressureGauge

7

4n3t Output Panel

3-Phase ELCB 1-Phase ELCB

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BonnetGrounding3-PhaseReceptacle

Terminal(20A)3-PhaseReceptacle3-phaseReceptacle(50A) (32A)

1-Phase

Receptacle

(i5A)

8

5 Equipment

5-l. Monitor Lamp

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The equiprrient is incorporated in monitoring function of WATER TEMR BATTERY

CHARGING & OIL PRESSURE.Under normal condition, when the starter switch changes from STOP to RUN, all the

lamps of BATTERY CHARGING and OIL PRESSURE tum ON. When the enginestarts, 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 po$ition

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 femperature Monitor Larnp

Danger : lnjuries

pt CIose all door$ and place during operating this equipment, to avoid injuries

by unintentionally touching cooling fan and fan belt.

A Caution : Burns

g Do not open the radiator cap while operating this equipment or

immediately after stopping the equipment, to avoid sustaining burns from

hot vapor,dy Do not touch the engine and rnuffler during operation and immediately

after stopping the equipment, for the temperature can reach extremely

high.

When the water temperature rises over 1050C, the coolantiwater temperature

monitor Iamp will flash, and the automatic shutdown of engine will be engaged.

When this occurs, check the coolantiwater reservoir tank, and replenish if needed.

(Referto ff8-2 Checking coolantiwaterx )

lf the water Ievel i$ normal, there may be a pos$ibility of loose fan belt

or water leakage in coolan{ lines. Check it after the engine cools down.oti <Cgution> @ Be sure to check the volume in the radiator sub-tank

wnTER reMP before operation as it cannot detect the watertemperature

When the water volume is insufficient.

9

(2 Oil Pressure Monitor Lamp (Low Oil Pressure)

o Danger : Injuries

& CIose all doors and place during operating this equipment, to avoid

injuries by unintentionally touching cooling fan and fan belt.

A Caution: Burns

@ De 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 thi$ equipment or irnmediately after stopping the equipment, to avoid su$taining bums

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 injuiy.

OILPRESS

When the engine oil pressure drops below O.98 x 1OOkPa {1 kgf/cm2}

during operation, the oil pressure monitor lamp will fla$h, and the

automatic shutdown will be engaged.

When this occurs, check the engine oil level, and replenish to the

maxirnum Ievel if needed.

<Caution> @ The engine oil pressure monitor cannot detect the degradation of engine oil

itself. Please check the engine oil periodically, and change if needed.

(Referto ge8-l. Checking engine oildi )

(3) Battery

tsCHARGE

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, $top

the engine consult with the authorized distributor or our

engineering section.

<Caution>ew The battery charge monitor cannot detect the degradation of the battery

nor the battery fluid level. Check the battery fluid level periodically.

(Referto f8-6. Checking Batterys )

10

5-2. Mete rs

Meters in the engine

(1) Hour Meter

xeugeesrER

wtpm+Hour Meter keeps track of utilization time. Use this meter

to $chedule 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 femperature Gauge

7'

ee seisgg<

Water -lemperature Gauge displays the temperature of engine

coolant. Normal temperature may vary depending on the

environment, but it should be between 750C and 1000C.

<Caution>pt lf the temperature exceeds normal value, disconnect the load,

idle the engine at 1OOOmin-i, and wait until the reading falls to

the normal temperature range.

(3) Oil Pressure Gauge

2" ,lllllllll/ilssg#,O ' Oil Pressure Gauge displays the pressure of engine oil. Normal

pres$ure may vary depending on the environment, but it should

display 2.9--4.9 x 1OOkPa (3-5kgf/cm2). However, under cold

weather, the pressure gauge may display higher reading.

Continue idling until the pressure falls to normal range.

(4) Fuel Gauge

lt shows the volume in the fuel tank.

When filled up, it shows ffFdi .

When the hand is approaching to geEdi ,

empty. Repleni$h fuel enough promptly.

the volume is coming to

11

Generator Gauges

(1) Volt Meter

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Voltage Meter displays the output voltage (Phase to Phase) from

the generator.

PIease check and confirm it showing 415V at 50Hz during

operation.

(2) Ampere Meter

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Ampere Meter displays the output current (Phase)

generator.

from the

(3) Frequency Meter

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Frequency meter will display the frequency of the

Please check it showing 50Hz during operation.

generator.

Lamps

(1) Preheat Lamp

sXWhen the starter switch is turned to <Preheat> 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 within 25 second$.

(2) Pilot Lamp

The Iamp indicates whether or not the equipment is generating

electricity when the engine is running.

12

(3) Panel Light

ov

Panel light turns ON to illuminate the panel, when turning the

switch (by the light) to ON.

Switchs

(1) Starter Switch

a. stop STOP When the switch is set to thisPREHEArr

RuN position, all powerwill be off# The switch must be set to this S"l:ART fo× position to remove the key.

2. Run The switch must be set to this position during operation.

<Caution> $ Do not leave the switch to this position, while the engine is stopped. Otherwise

the battery i$ discharged.

3. Start

This position is to start the engine. When the key is released, the setting will automatically return to <RUN> position.

4. Preheat

This position is used during cold season, to preheat Glow PIug.

(2) Emergency

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Stop Button

This button is u$ed to stop the engine in ernergency.

By in$erting the button, the engine stops.

Be sure to restore the $tarter switch to STOP and re-set

the button, turning clockwi$e after using the emergency stop

button.

(3) Main Circuit Breaker

By turning this circuit breaker on the control panel to ON,

N

"ft

Power will be transferred to the output receptacles and to the

Ioad side.

The breaker trip$ to OFF, either overload or short-circuit.

13

<Caution> g Do not use ELCB as the ON/OFF switch to the Ioad.

(4) 3-Phase Circuit Breaker

1-Phase Circuit Breaker

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3PBreaker

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u o1 P Breaker

Each receptacle, 3-Phase and 1-Phase is

incorporated with circuit breaker respectively.

The breaker trips on overload or $hort-circuit on

to stop powertransmission to load.

<Caution>

ig 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)

OQi[]QLicrnRig"

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3PELCB

Each receptacle, 3-Phase and 1-Phase is

incorporated with ELCB re$pectively.

When current leak occur$, it trip$ to stop

power transmission to load.

<Caution> et Do not use this breaker as the ON/OFF switch to the

Ioad

(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

o

ow

@o

O

OFF position

o@esi'o

D

ON positien

When turning the switch to OFF, the engine

electric circuit dees not activate due to no

battery power.

Voltage Regulator

(1) Voltage Regulator

asb

The dial adjusts generator output voltage.

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)

A caution : Fire

g Always stop the engine when performing any work on the fuel line. dy 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. dy Be sure te confirm that there is no Ieakage 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-mway valve is set to

A when the equipment is shipped.

Outer fuel inlet and return are

closed with plugs (PTI/2).

Use fuel as they are.

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A side Lever PositioR

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External Fuel Return (P"l"1/2)

<Caution> es After having used the outer fuel and removed piping, be $ure to set the lever to A position

and fix the plugs.

(2) U$ing fuel from external fuel tank

Connect hoses from the external fuel tank to the external fuel intake and the external fuel

retum ports, and set the lever for 3--way valve to B position.

Ybu caR now supply the fuel from

the external gas tank.

For detailed instructions, refer to

r9--6.Connecting to External Fuel

fanks

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/.."-- ..!,"Y .-' B side Lever Position

3--way valve E,...,Miii....I`L"`/tli'li`i'".e.'$il',}iags'i.j.,Srx"

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External Fuel ReturB

16

6 Transpomation and ' installation

64. How to transport

ox

Danger : Injuries

When lifting the equipment, always use a lift hook.

Never use roping lug for lifting the unit, fer 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 equiprnent, make

sure that the equipment i$ secured properly

with ropes tied to the roping lugs through.

(iiiiiilil ea-

×

<Caution> $ Always use extreme care when loading, unloading, and transporting the equipment,

otherwi$e damages and malfunction of the equipment may bring.

17

6-i2. InstaIIation

O Danger : Suffocation from exhaust gas

es Exhaust fumes from the engine contains many elements harmful to humans. Do not operate this equipment in poorly ventilated area, such as inside a

room or in a tunnel

A caution : suffocation from exhaust gas

ee Do not point the exhaust fume toward pedestrians or buildings.

A caution : Fire

g AIways operate this equipment on flat surface and, at leasM rneter away from any objects (wall, box, etc.).

ag Temperature around muffler and exhaust can get extremely high. Keep an inflammable items (such as fuel, ga$, paint, etc.) away from the equipment.

ee AIways set the equipment on hard, flat surface.

ee Keep the equipment at least lm from a wall or any obstacles, to allew workable

space to access the control panel and opening of the panel door.

<Caution> pt This equipment must be operated on hard and flat surface. Operating under any

other conditions may result in malfunctions.

g Do not block the airfIow from radiator vent or muffler exhaust. It may result in

reduced engine perforrnance, overheating, or damage to the electrical parts.

ge 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 CableSelect the cable with proper gauge, based on its allowable amperage

distance between the generator and the machinery to be connected.

and the

A caution : Damage to properties

@ lf the Ioad. exceeds the allowable amperage, the damage to the cable ma

be damaged in overheating. ' @ If the cable is either too Iong or too small gauge, there will be greater voltag

drop between cables which brings voltage drop to loads. It may result in reduced performance in the connected Ioads, malfunction, or damages.

<Caution> g lt is recommended to $elect the propergauge and length of cable, in

consideration of the maximum 5% marginal drop only for the rated voltage,

between the terminals of Ioads and generator via the cables.

ge Expedient Formula:

@ 3-Phase 3-Wire

Voltage Drop (V) =

the

1

×

58

voltage drop

Length

of cables

(m)

Dia (mm2)× Current (A) × J--3

@ 1-Phase 2-Wire

Voltage Drop (V) =

1

58

x

Length (rn)

Dia (mm2)× Current (A) x2

19

7'2n Connecting Load Cable

Q Danger : EIectric Shock

ee 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.

A Caution : Fire

ig Do not connect AC output to any indoor wiring.

<Cautien>

g Divide loads into 3 circuits proporkionally as possible, when using the rnaximum

output power especially, and connect them to each phase (R,S,T) respectively.

g Be careful to limitthe current under the rated current per the phase.

ew Note that the 1-phase output power decreases when 3-phase output power is

used simultaneously.

g Be careful to limit the total current under the rated output current when

using i-Phase and 3-Phase output simultaneously.

20

7-3. Earth Leakage Circuit Breaker (ELCB) and Grounding

O Danger : EIectric Shock

dy Ground the every grounding terminal to the earth as $et in the manual. If even one of all is unconnected by mistake or accident, it will be

much more dangerous for hurnan than the NO-RELAY case, because leaking current inevitably goes through the body. ee 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 afterthe engine is stopped. ig Wheneverthe Earth leakage breaker is activated, you should always repair the Ieaking 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 accid' ent $uch

as electrical shock resulting from the trouble.

tw

&

The specification of ELCB;

Rated Sensitive Current: 30mA (or below) (Grounding resistance: 500Q or below)

Sensitive time: Within O.1$econd

(1) Grounding Work

The qualified electrician $hould perforrr}

the grounding of the following 2 points

(500 9 or below).

@ The Bonnet (Canopy) grounding terminal

of the generaton

e The Bonnet of the load.

<Caution>ee In the event you cannot ground the

generator to the earth, consult with the

authorized distributor or our engineering

section.

Eva

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mo -o ooil "'fiL-･

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1

21

(2) Operation Check

O Danger : Electric Shock 1 lnjuries

& Befo re tu rning ELCB to ON position,

ensure that the breakers or the switches of Ioads are positioned to OFF.

You should communicate well with the electrician by the load side

when operating ELCB.

Before operating the generator, check always

if the device can work.

@ Actuation test of the Earth Leakage Circuit Breaker

Ensure that the breakers and the switches

of loads are positioned to OFF.

Ensure every breaker to set OFF.

Reierto ge4-2.0peration Panels and

ge4-3.0utput Paneldi

Following the procedure in 9-1,

Initializing / Preparatien,start an engine.

Turn every breaker and ELCB to ON.

Pu$h the RE$ET (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.

D

1-Phase ELCB

Lamp

RESET button (Green)

TEST button (Blue)

Push the TEST button (Yellow) on 3-Phase

ELCB.

Indicator changes to Green from RED

and ELCB trips to OFF, Which shows

NORMAL.

Push the TEST button (Blue) on 1-Phase ELCB.

Red lamp turns to OFF and ELCB trips to OFF,

Which shows NORMAL.

v[=I] Clndica

Test/it/ ZY

Q

v/rv

a

3-Phase ELCB

fest button (Yellow)

In the event you cannot complete every $tep of the above procedure to the end,

the device i$ out of order. Consult with our authorized di$tributor or our engineering

section and ask to repair.

22

(3) 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.)

Tum 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 lnitialization and Prekcheck

O Danger : EIectric Shock / Injuries

g 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.

A caution : Fire i Burns

g When checking engine, always stop the engine, and keep away from fire. Wait until the engine cools down, before performing any checks.

A caution : Fire

g Always wipe any drip of fuel or oil. Do not use thi$ equipment when a Ieak is found. Repairthe equipment before use.

8--1. Checking engine oil

xPIease refer to the user's manual fer 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, make sure to fill the

engine oil to the UPPER LIMIT line through the oil filler,

<Caution> g Check engine oil volume IN 1 0-20 MINUTES

LATER, always after stopping engine or

repleni$hing fuel.

g lf the equipment is not leveled, you cannot

obtain accurate oil level.

g Do not ove rfill the engine oil. The excessive

amount of engine oil rnay damage the engine.

(1) Selecting proper engine oil

Use the API class CD grade or higher.

Oil Filler Oil Gauge

///'tlX'iliillriFl･i&llies"'fx¥¥,,i,iiiiiiiii,,,,,,ge-))ts,g

LOWER L;MIT UPPER LIMiT

w[{li

v

O!L GAUGE

×,,N"' &.gllllmal

e×

TOlMwwCwwK-."l,

(2) Use the engine oil for Diesel engine with proper viscosity, based on the temperature

(refer to the chart below).

24

dy Viscosityandtemperature

Tem p{c}

SAE2el2eWAtu SAE40

SAEIeW.-dl

ts

SAE30A

pt

N r ---I b

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llilillll

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SAEtOW-30AN

ndSAEt5W40I20W-40

b

N

(3) Replacing Engine Oil Volume (Unit: Liter)

Lubrication Oil (including the oil in filter)

13L2 (1.i)

Nlalue in O shows the oil in filter

8-2. Checking Coolant / Water

× Referto the User's Manual for Engine also.

O Danger : Enjurges

ew Before performing any equipment check or maintenance, stop the engine,

and remove the engine key. The person performing the maintenance $hould always keep the key.

A 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 muffIer during operation and immediately after $topping the equipment, for the temperature can reach extremely

high Ievels.

Check the radiator and coolant reservoir tank for

water and add water in ca$e of shortage.

(1) Checking Radiator / Adding water

4 ReMOve the Radiator plate

g Remove the Radlator Cap

4 Fm up water to the radiator water iniet top.

4 Reinstall the cap and tighten it.

4 Rem$tall the Radiator plate

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Lt..-".-.nv...M.1th,.-.( /H- .i

Radiator plate /. .i`i"

/t ve t'.rrr-tt- -h - m- "-: )Nt '".- -ri- m.-'I -r-"(' l ll

s" -.l/ -･"i=il't/)ge;'.'H l l i`

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Llr=.=-=...dn--ww-"ww----;:=-:.--:

Radiator Cap

l't ' !1-.Wx.lrilre;:l" si"

';'.X. 'Xii 'kx.

>lt

Mv:.- vltli'"

"'t

lnlet

Sub fank :f /wn T<"..s.-')r))..l.

"J- 1iiLtll'lti;'wu"'tllil,ill,.tll,III'iilill'i;Miigptttll

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FULL

LOW

25

(2) Checking coolant in Sub lank /Adding coolant

Check to see if the water/coolant level is between FULL and LOW line in

the Sub fank.

4 Fill up to the FULL Iine, if the water/coolant level is low

<Caution>@ Use soft water, such as tap water.

g If the outside ternperature is near freezing, use Long Life Coolant (LLC)(30%

rnixture LLC is used, when shipped frorn factory).

@ Use same type of coolant with identical mixture ratio for the Sub lank.

$ Mixture ratio of the coolant should be between 30 to 50%, depending on the

ambient temperature.

ig When replenishing LLC, be sure to use the same brand as the LLC Ieft in the

Radiator and Sub Tank.

g Never use the rnixed LLC by different brands or specifications.

g Replace LLC every 2 years or 1000 hour$.

Mixture ratio (for reference only) :

Ambienttemperature

-150C -230C -350C

Mixtureratio 3oo/, 4oe/, soo/,

(3) Coolant Volume

Unit: L

fotal Coolant Volume (including Sub lank)

17 (1.5)

The value of ( ) shows the Sub lank volume.

26

8-3. Checking Fan Belt

X Refer to the user's manual for Engine separately also.

Q Danger : injuries

@ Before perferming any equipment check or maintenance, stop the engine, and remeve the engine key. The person performing the maintenance should always keep the key. es CIo$e and lock all doors during operating this equipment, to avoid injuries by

unintentionally touching cooling fan and fan belt.

A cautien : Bums

g Do not touch the engine and muffler during operation and immediately after $topping the equipment, for the temperature can reach extremely high Ievel.

(1) Fan Belt fension

The tension is proper when the fan belt has 8

to 12mm slacks, when applying a finger pressure (about 98N {approximately 10kgfi) at

midpoint between fan pulley and AIternator Pulley.

(2) Condition

Check for any damage on the Fan Belt. Replace if necessary.

(98N>

N t7i>L.slacks ,.N-,;"ttt･.-.,ii2rk,i}iEt,.s.

k,tt'7

<Caution> pt Refer to the <User's manual for Engine> for adjusting and replacing of the Fan Belt.

8-4. Checking fuel

x

Caution : Fire

Always wipe any drip of Diesel fuel or oil.

Do not use this equipment when a Ieak 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

down to -soc.

& Alway$ use the Diesel Fuel Strainer

g Fill the fuel tank slightly less than the FULL tank Ievel.

& The engine is designed to use either No.1-D or No.2-D

Diesel fuel. However, for economical purpose, use

No.2-D Diesel fuel whenever possible at the

temperature les$ than -70C, No.2-D fuel may pose

operating problerns. At the much colder temperature,

use No.1-D fuel (if available) or use winterized No.2-D

(blend oM-D and 2-D).

ambient temperature reaches

Fuel Strainer

×

Fuel lnlet

- 'lank Cap

27

This blended fuel is usually called also No.2-D. It can be 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.

g Fuel requirements:

N077CE: the fuel itzl'ection pump, ity'ector or other parts of the fue/ system and

engine can be damaged if you use any fuel or fuel additive other than thosespecifica/ly recommended by /suzu.

Such damage is not our responstoili44 and is not covered by the VlierTanty7b heip avoid fue/ system or engine damage, please heed the following:

@ Some setvice stations mix used engine oil with diese/ fueL Some manuiecturers of /aige diese/ engines allow this; howeve4 for your diesel engine, do not use the diese/ fuel which has been contaminated with engine

o". Besides causing engine damage, such fuel can a/so ahect emission controL Before using any diese/ fueL check wtth the service station operator

to see if the fuel has been mixed with engine o".

@ Do not use any ftiel additive. At the time this manua/ was printect no other

fuel additive was recommended. (See your authorized dea/er to find out if

this has changed)

8-5. Checking Fuel, Engine Oil, and Coolant leakage

A caution : Fire

g Never use this equipment when a leak is found. Repair the equipment fi rst of all.

Be $ure to check for any fuel Ieak at the fuel hose connections, and oil and coolant

leak by opening Side Doors.

8-6. Checking Battery

A caution : injuries to eyes and skin

e Battery fluid contains diluted sulfuric acid. Avoid contact with eye$, skin

or on clothing. If the acid comes in contact, especially with eyes,

flush with a lot of water, and contact physician or doctor immediately.

A caution: Expiosion

$ When the liquid Ievel is below the LOWER level, never use the equipment nor recharge battery.

op Battery may emit some combustible gas, so keep it away frorn fire and

sparks.

Check the fluid level. If the level is near or lower than the LOWER LEVEL,

add di$tilled water until the fluid level reaches the UPPER LEVEL limit.

Make sure that the battery cables are firmly secured to the posts. Tighten

the clamps more if necessary.

<Caution> g Check the hydrometer of the battery fluid. If it falls below 1.23, the

battery requires recharging. PIease call our authorized distributor or our

engineering $ection.

28

es Replacing the Battery

<Caution> ee Dual batteries has been connected in a series.

Always follow the below instruction when replacing

the Battery or Remove the Battery cables to avoid

Battery short circuit.

(t) Replacing the Right ( R ) side Battery

Disconnect the negative (-) terminal from the Right Battery always.

4 DiSCOnnect the positive (+) terminal from the R Batteiy

4 Disassemble the fixing clamp of the R Battery

4 Remove the R Battery

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crtt-tttN----tmut-ptt.t-nv-..

Fixing Clamp

Disconnect the negative (-) terminal from the Left side L Battery.

XReinstall a new Battery in the reverse order (always install the cable to the

positive (+) post ef the new Battery first).

(2) Replacing the Left ( L ) Batteiy

4 Disconnect the positive (+) terminal from the L Battery

4 Disassemble the fixing clamp of the L Battery

4 Remove the L Battery

XReinstall a new Battery in the reverse order (always install the cable to the

positive (+) post of the new Battery first).

<Caution> e Make $ure that the Battery cables are firmly secured to the posts.

Tighten the clarnps more if necessary.

Be careful to secure the removed cable are insulated and does not contact with

terminal post to avoid electrical $hock.

29

9 Operation

9--1. Initialization and Preparation

Danger : Suffocation from exhaust gas

@ Exhaust fumes from the engine contains many elements harmful Tb humans. Do not operate this equipment in poorly ventilated area, such as inside a room or in a tunnel

A caution : suffocation from exhaust gas

@ Do not point the exhaust fume toward pedestrians or buildings.

A caution : Fire

@ femperature around muffIer and exhaust can get extremely high levels. Keep any inflarnmable items (such as fuel, gas, paint, etc.)

away from the equipment. ee Always operate this equipment on flat surface and, at leasM meter away from any objects (wall, box, etc.).

A caution:injuries

g Always place the equipment on a flat and stable surface,

to keep the equipment from $Iiding. g When starting the engine, turn off the connected equipment and set the circuit breaker to OFF position.

Tum every circuit breakers to OFF

position.

Turn the Battery lsolator to ON po$ition.

Set the Starter Switch to OPERATION / PREHE/kCl- position.

Set the $tarter switch to START and start the engine immediately after the

Preheat Lamp turns OFF from ON.

Breakers Preheat Lamp

<Caution>@ Preheating time varies by coolant

femperature, u$ually within 25 seconds.

es Do not drive the starter motor more than

10 second$ succes$ively.

@ lf you need to restart, wait at Ieast 30

$econds before the retry.

l--nt-Mt

WG)es･Em･

za.ESE]Of-

L:±

o

[{IE]N(S}

.ee';esiiEI](S).

N6]/esgeRegulator

StarkerSwitch

Battery lsolator

Release the Starter Switch,

Keep the

as soon as the engine is started

engine idle for about 5 minute$.

30

Ensure that the tachometer shows the follewing frequency at no load.

NoLoadFrequency(RevolvingSpeed)

50HzRUN 52.5Hz(about)(1575min-i)

<Caution> dy By setting frequency to

will be obtained at the

the above frequency

rated output Ioad.

under no load, 50Hz(almost)

Adjusting the Voltage Regulate Dial, set it to the required voltage.

50Hz RUN 415V

Tum the circuit breakers to ON to send power to the load side.

o pt

Danger : Electric Shock 1 lnjuries

Before turning ELCB to ON to send power to the load side,

always ensure that any circuit breaker and switch of loads are positioned to

OFEln the case the generator and the Ioad are away from each other, proceed

with the above steps, communicating well with the other person by the load

in order to prevent frem accident.

31

9-2. During Operation

(1) Post startup check

g Make sure that all meters (gauges) and displays are working properly.

(Referto5. Equipment)

ee Check forany unusual vibration or noise.

@ Check for any unusual color from the exhaust. Under normal condition,

the exhaust gas has no color or light blui$h coler.

<Caution> dy If finding out abnormality, con$ult with our authorized distributor or our

engineering section in order to repair, without using the machine.

(2) Adjustrnent during operation

g Make subtle adjustment to voltage using the Voltage Regulate Dial, by monitoring

Voltage Meter during operation.

pt Extracting the air out of the fuelling system for engine stop due to no fuel

l*{Refer to the User's rnanual 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.

<Caution> g ln the case air is in the fuel line, the engine speeds is unstable.

In the case, perform the vacuum again.

32

9-3. Stopping

Turn the switch on the equipment and the circuit breaker on the load to

OFF.

4 Turn every circuit breakerto OFF position

4 Keep the engine NORMAL SPEED on NO LOAD for about 3 minutes

4 Turn the Starter switch to sTop

4 Turn the Battery lsolator to oFF

9-4. Pretection 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, tum off the engine and investigate the trouble

shown by alarm lamp.

Protection Feature List

No.Action

Abnormality

ELCBTrip

BreakerTrip

EngineAutomatic

Shutdown

Warning

LampFlash

Cause

1 HighWaterTemperature - - 0 o

Activatesduetohighwatertemperatureinengine

Default1050C

2

gE.s!I6'do2

LowOilPre$sure - - o o

Activateduetolowoilpres$ureintheengine

DefaultO.98×100kPa{1.0kgf/cm2}

3Battery

ChargeIBsufficient - - - o

ActivatesinbatterychargeImpossible

4 CurrentLeakage o - - -ActivatesincurrentIeakage

5 Overload - o - - Activatesinoverload

xo indicates the automatic activation.

33

9-5. Connecting to Extemal Fuel Tank

A caution

ee Always stop the engine, when working on the fuel line.

es Alway$ wipe any drip of Diesel fuel or oil. Do not use this equipment

when a Ieak is found. Repair the equipment before use. g Ensure that there is no fuel leakage on the fuel Iine after the fuel line

working finished.

Turn the 3-way valve Iever to A

(lnstalled tank use position)

position.

DisconRect the P/T 1/2 plugs from the

External Fuel Intake and the External Fuel

Return, aRd then connect the hoses from

the Extemal Fuel lank, as shown below.

ig2i,,

Tum the 3-way Valve Lever to B

position,

(External tank use position)

Extract the air out from the

connected hoses.

By the above procedure, it rnakes

possible to use an External Fuel

lank.

<Caution>

dy Use always oil-proof hose in 8-10mm

inner diameter as connecting ho$e.

$ The fuel level in the external fuel tank

should be O to 3m higher than the bottom

of the equipment. Otherwise, it may

cause engine malfunction or $toppage.

g fo avoid any leak from the external fuel

'Aiiiii'intM'li;'"'"X.lltgllliliee/kz;i,iiiifgf,%walvaive

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;'-'ftliillX:ask,g,fi"g/i'1nd,,i'1,,,

External Fuel Return (PTf/2)

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A side Lever Position

/

..x

,/g'tsi"#:>ililpl

-.-" ." .iJ .ttB side Lever Position

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 ho$es. If the lever position is set

improper, the fuel may Ieak from either the Built-in Fuel fank or the External Fuel

lank.g Set the fuel intake position 15-20mm above frorn the External Fuel lntake bottom

Iine, otherwise water or garbage in the tank may come into the fuel line.

g In order to avoid engine malfunction due to air suction, set the fuel retum at the

same level as the fuel intake level in the External lank.

ag Referairextractionto if9--2. DuringOperationth

34

@ Just after having connected to External Fuel lank, there may be a case that

engine speed is unstable and engine stops due to insufficient air extraction.

Therefore, be sure to confirrn that the air is extracted completely and the engine

speeds keeps stable before Ieaving the equipment under people-less operation.

10 Check 1 Maintenance

o @

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.

A caution : Fire/Burns

ee When checking engine, always $top the engine, and keep away from fire. Wait until the engine cools down, before performing any checks.

A caution : Fire

pt AIways wipe any drip of fuel or oil. Do not use this equipment when a

Leak is found. Repairthe equipment before use.

Tb optimize the use of this generator, we recommend the periodical equipment checks

and maintenance, based on following maintenance matrix. U$e the hour meter as a

guide for the operating time.

<Caution> dy The authorized technicians only should perform all maintenance work, except for

the pre-startup checks.

g Request forthe maintenance items with @ mark to ourauthorized dealeror our

engineering section.

pt This chart only covers the simple checks and maintenance as for the engine.

For more detailed guide, please refer to the User's Manual forthe engine.

g Always use ourgenuine parts only for replacement.

35

DescriptionStartup

checkEvery200hrs

Every400hrs

Every5OOhrs

Every

1OOOhrs

EngineSide

Cleaneachparts/tightening oEngineoilchecks/addoil oEngineoilchange(7Sttimeat50hrmark) o oOilFilterchange(7S`timeat50hrmark)

o o

Coolantlevelcheck/addcoolant oExhaustcolorcheck oCoolantchange o

or2yr.Drainexcesswaterandsedirnentsinthe

waterseparatoro

oCleanDrainwaterfromFuelFilterorreplace oClean

oReplace

DrainwaterfromFuelTank oCIeanwaterseparatorandcleanGauzeFilterinEngineFeedPump

oCIean

ChangefHterintheMagnetPumpforairextractioninfuelline

oReplace

CleaninsideFuelTank tw

Leakcheck(fuel,oil,andcoolant) oReplacingfuelhose &

or1yr.

CleanorreplaceAirCleanerElement oClean

oReplace

Batteryfluidlevelcheck oBatteryhydrometercheck oFanBeltcheck oRadiatorFlushCleaning e

q

Checkandadju$tEngineValveclearance pt

Compre$$ioncheck e

Fuelinjectionnozzlecheck e

Fuelinjectiontimingcheck pt

Generatorside

VariousmeterandalarmIampscheck oOperationcheckofELCB oGroundingresistancecheck olnsulationtest o

36

(1) Change engine oil

lnitial 50hours

2ndandafter Every200hours

Remove the Oil Filler Cap. ,

Remove the Oil Drain Plug and then tum

The Oil Drain Lever to OPEN and drain

engine oil.

Turn the Oil Drain Lever to CLOSE

and tighten the Oil Drain PIug.

Add oil through oil filler to fill it up to the

MAX Ievel while checking the oil level on

the oil level gauge.

Tighten the Oil Filler Cap.

Oil Filler Oil Gauge

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Oil Drain cock

<Caution>

ew Forthe volume and the type of engine oil to

use and to replace, referto M8-1. Checking

Engine Oilm .

(2) Oil Filter Change

lnitial 50hours

2ndandafter Every400hours

Drain the engine oil fully, as described

in (1) CHANGE ENGINE OIL

Loosen and remove the oil filter, usingan oil filter wrench.

s"/･"i/g.ilg,,xxee,,/geee,,,,

Drain Plug Oil Filter

Smear a little engine oil on the rubber gasket of the new oil filter.

Screw a new filter into place and tighten

it by hand until the gasket contacts the

seat. Then, give it additional 2/3 turn$,

using an oil filter wrench after the gasket

teuch the seal surface.

4 suppiyengine oil.

/.Q

37

<Caution> ee lf an oil filter wrench is not at hand, contact our authorized distributor or our

engineering section to replace.

@ Oil Filter Part No.

lsuzu Part No. 8943212190

(3) Cleaning / Changing Air Filter EIement

Clean Every200hours

Change Every500hours

Loosen the Air Cleaner Fixing Bolt and

remove the Cleaner Cap.

Air Cleaner

&,!S,f:gliil-#fu2,i'ksc''`illill,.,,l

illj

l

s

Loosen

the Air

the Wing Bolt

Filter EIement.

and remove

Clean or change an Air Filter

Element and rein$tall it in the

reverse order.

Cleaner Cap

o$"e

g'

g, O (iz{{[g

Air Filter Elernent

f@ f

<Caution> pt Alway$ make sure that the arrow mark on the Cleaner Cap is pointing upward.

g Clean more frequently, ifthe equipment used in dusty envirenment

e Element Part No.lsuzu Part No. 9142151351

pt Clean Air Filter Element

<Dried contaminants adhered>

BIa$t the compressed air to Element from inside.

<Carbon and oil adhered>

Change to a new Filter.

ec CIoglndicator

The clog indicator to display clog in the Air Filter

Elernent is incorporated to air filter unit.

g Whenever RED SIGNAL appears in the indicator

window, clean or change Element regardless of

operation hour.

op After cleaning or changing finishes, push the

reset button to release the RED SIGNAL.

( -.

3-

Clog Indicator

･;if =mu"aj

pt--di･-

pt

x

';'

x

.#s

-:!I;

Re$et Button

y

Red Signal

38

(4) Drain water in the Water Sedimentor

Check Startup

Clean Every200hours

When a float (red) in the cup is floating at

drain level, drain water.

4 Loosen the cock

After draining finishes, tighten the

Cock.

Cup

Float

Cock

iilEI-"･Xi '.i-IIIIIII- {.i-il..,

sg.i r, ft $ng6'-E･

'a-･- :

kj.-- ik ntww3

-M#/ Water Drain Level

<Caution> g After draining finishes,

(Refer to r9-2.During

(5) Maintenance of the Fuel

extract the

Operationdi

Filter

air in

･)

Drain Every200hours

Change Every500hours

fuel

Loosen the fixing $crew of the Fan Guard

Iocated on the side of the Fuel Filter.

Remove the Fan Guard.

g Disassemble Fuel Filter using ilter wrench

4Drain the remaining water from the Filter

Apply little amount of the diesel fuel onto

new Fuel Filter Gasket.

line.

Fuel Filter Fan Guard

111es'///'ec1enisests/keerw

Tighten the Fuel Filter using finger until the filter

gently seated to the bracket,

Ga$ket

Then tighten the Filter 2/3 rotation using fuel filterwrench.

4 Reassemble the Fan Guard to the original position with fixing screw

<Caution> e Do not operate the generatorwithout reassembling the Fan Guard to aveid injury.

@ After draining finishes, extract the air in fuel line.

(Refer to rr9-2.During Operationdi .)

@ Fuel Filter Part No.

lsuzu Part No. 1132400791

39

(7) Clean Gauze Filter in Water Separator

Clean Every 500 hours

Loosen the Cock and then loosen

the air extraction plug.

Turn the ring nut counter-clockwise

to remove the cup and the Gauze Filter

after the fuel inside does not come out

from the lever.

Air Extraction PlugRmgNut LfCiiirWZiii,iii-iliilllllillll･t.g.i.,,,"s

,Ii e ft (llsiiS;,.(] ee

2eoPattms/.nigiiiy,GauzeFiiter

cockpaLIilli

Water Drain Level

Wash the Gauze Filter in Diesel fuel and

reverse order.

reinstall the unit in the

TighteningTorque

RingNut 15Nrn{1.5kgfm}

AirExtractionPlug 1ONm{1.0kgfrn}

<Caution> e Clean the Filter more frequently as Gauze Filter is clogged in shorter period

when using the fuel from the oil drum than other fuel source.

g Put a tray under the lever in order to catch spilled fuel when loo$ing the lever.

ee Extract the air in fuel line after Gauze Filter wa$hing finishes.

(Refer to ge9-2.During Operationdi .)

e Ensure thatthere is no fuel leakage after

reinstallation.

(8) Clean Gauze Filter in Engine Feed Pump

CIean Every 500 hours

4Remove Eyeboits

4Rerriove Gauze FHter in Eyebolts

Wash Gauze Filters in Diesel fuel and

Reinstall in the reverse order.

11"g(i･i"l"tsn-.,

IIiXl.glSl,ii'ilii.iii,

i -i ;kev 111, 'il zl

ec.wreelp

-nv-h-.....rw ,a-e

Eyebolt

.. -.t ii'te"' if

Joint Pipe

--usN"ww ･tiv ''

Joint Pipe

//:e･//jiee,.ne

"I;.;lli -f/iL-.tt; S-llk,iss<v

Eyebolt

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klt-

Eyebolt tightening torque 24.5Nm {2.5kgfm}

<Caution> ag Put a tray under the iever in order to catch $pilled fuel when loosing the lever.

dy Ga$ket$ are attached to both end$ ofjoint pipe. Be careful not to lose and install

them in the unit without fail.

40

ee ChangebothGauzeFilterandeyebolt

when Gauze Filter is damaged.

ee Extract the air in fuel line after Gauze Filter washing

finishes.

(Referto M9-2.During Operations .)

dy Ensure that there is no fuel leakage after

reinstallation.

ee Eyebolt Part No. (Gauze Filter included)

'ew/GAUZE FILTER

guEYEBOLTS

Isuzu Part No. 8970631550

(9) Change Filter in the Magnet Pump for automatic fuel extraction

Change Every 1OOO hours

Turn the Cover, located at the bottom of

pump, counter--clockwise and remove Filter.

Reinstall a replacing Filter in the reverse

order.

<Caution> @ Put a tray under the lever in order to catch $pilled

fuel when changing Filter.

g Extract the air in fuel line after filter changing

(Refer to r9-2.During Operational .)

g Ensure that there is no fuel Ieakage after

g Filter Part No.

'O MApGuNMEpT @

/@ FiurER (liil})

covER --t- (i{IIIII}I

w-

finishes.

reinstallation.

1$uzu Part No. 8943370220

(1O) Drain water in fuel tank

Drain Every 200 hours

Turn the Fuel Drain Lever to OPEN.

After draining water, turn the Fuel Drain

Lever CLOSE.

Fuel Drain Cock

/ ...,"...;....- S'sN. .iK t 't i-t,e,,k.'"･･::;""-""1,'ii,/,-･'i"S"-'x-I.-.Ill'//;11.i.L.'.';'9t",)tt;.,///t.l.:･

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Oil DraiB Cock

41

(11) Change Coolant

Change 2 years orlOOO heurs

4 Remove the Radiator piate

4 Remove the Radiator cap

Loosen the Radiator Drain Cock and the

side.

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Radiator Remove the Sub fank Stay

and drain coolant in the Sub lank.

g level

scEJ iniet ievei

S Tighten the Radiator cap

4 Reinstall the Radiator plate

<Caution> ge Refer Coolant to r8-2. Checking Coolant/VVaterdi

i･itl.ii･,11-i'iirtny"'j･i-t--･li/i /--･:g/L' '×'"i-･r"L..･.it,lr,iiH;/ /'/li

Radiatorplate/t.li.ti .". "tNx'kl';

xN - /li.///i･tl･illi'l'ii"tliil'lllliii"ii'Il"IlIIi-i'ii'il,'`}-:'･'i/,'ly"`x'-st/

("`'":' 'pt...s-pt･- '"ag.tilivitEitf;.:l ,I l C'

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Water Inlet Radiator Cap

Drain Plug on the engine

"rribos"`,t",fi::iKlii/ll:.li,k},,,tiii;iiiEi2i;{`i?i･.i,llliiil.xiillllil

Drain Cock DraiR PIug

Reinstaiithesubfankandf"i,..,,,,,p,,,u,,:"t/i'iipmiii･'illllllli,11111'ljl/I/i,,/l"ii"li'111i'li'ii;li' /'",X/ltlll,i!lll/::-e,,111･iilit,-rlill/11i///111,//ll'/ill///li'g-....J

Fiiicooia"tintoRadiatorupa,f,,,,th..,t., 11111ti/i';tll'l;itL'l'l:Tl'l':'i/llilii/Ilili'//.rliill(ll/f"!illl'pmll･i/t/trtlllililii'J"'X';'S'iC'i/t/.,i'.`:/;:'lllll'::i""iZ';'

CoolantDrain FuelDrain

Sub "lank sub "lank $tay

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42

11 Long-term isterage

o Danger : Electric Shock/Injuries

e Before performing any equipment check or maintenance, stop the engi.ne, and remove the engine key. The person performing the

maintenance should always keep the key.

A Caution : Firellnjuries

dy -lemperature 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.

A Caution : Fire

ig AIway$ wipe any drip of Diesel fuel or oil. Do not use this equipment

when a leak is found. Repairthe equiprnent before use.

(1) Storage Procedures

lf the generator will not be used for more than two months, perform the following

maintenance and storage procedures.

.JY7

Remove

Change

Drain

Batte ry.

engine oil.

fuel in the Fuel fank and Fuel Filten

Clean all parts, cover the equipment, and store it in the place where du$t and

humidity are les$ a$ possible.

<Caution> S Charge the rernoved Battery once a month.

ee Refer to the owner's manual for engine about the engine storage/rnaintenance.

43

(2) Stacking

O Danger:lnjuries

lf you have to stack two generators at warehouse, always proceed with thefollowing steps.

e Ensure that there is no dent on bonnet, loose bolt er no bolt in the equipment.

ig Always place the equipment horizontal on a flat and stable $urface to be

endurable for the total weight, and to keep the equipment from sliding.

g When lifting the equipment, always use a lift hook.g Always place ties (sleepers) on 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 Iower generator.

ge 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.

gx x

12 TroubEeshooting

og

Danger : Electric Shock

Do not operate the equipment, if the equipment or you are wet.

Before performing any equipment check or maintenance, $top the engine.

A caution : injuries

ge When performing equipment check and maintenance, always stop the

engme.

A cautien: FireiBurns

g Never get fire near to the equiprnent. @ 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 perforrning any troubleshooting. If you cannot resolve

the problems by this trouble$hooting guide, contact our authorized distributor or our

engineering section to reque$t the repair

44

Symptom PresumableCause Action

Startermotordoesnot 1.BatterylsolatorisOFF 1.TurnBatterylsolatortoON

driveorspeedislow. 2.Batteryoutputisweak 2.Check/batteryIiquid/or

3.Batteryisdeteriorated Charge

4.Batteryterminali$OFForloose 3.Changebattery

5.Batteryterminaliscorroded 4.Fix/Tightenterminal

6.Starterswitchorrelayis 5.Cleantermina[

defective 6.Askourdistributortorepair

7.Startermotorisdefective ZAskourdistributortorepair

ti Startermetordrives 1.Fuelisinsufficient 1.Addfuelsuco

butenginedoesnot 2.Fuelfilterisclogged 2.Clean/Changefuelfilter

6=

start 3.GauzeFilterisclogged 3.Clean!ChangeGauzeFilter

88e

4.Waterisinterfusedinfuelline 4.Drainwaterinwaterseparator,fuelfilterorfuel

sm

5.Airisinterfusedinfuelline tankLiii

6.Poorpipingconnectionto 5.Extracttheair

externalfueltank 6Checkpipingconnection

ZFuelTankSelectorLever 7.checklever(3-wayvalve)

(3-wayvalve)po$itioni$ 8-1.Check/Changefuse

wrong 8-2.Check/Changefuelcut

8.Fuelcutsolenoid(motor)does soleneid

notwork

<Ambientternperature 1.Fuelisfrozen 1.Usewinterizedfuel

fallsdownbelowzero> 2.Waterinfuellineisfrozen 2.Drainwaterinfuelline

3.Pre-heaterisdefective 3.Askourdistributortorepair

Enginestartsbutstalls 1.Fuelfilterisclogged 1.Ciean/Changefueifilter

immediately 2.GauzeFilterisclogged 2.Clean/ChangeGauzeFilter

3.WaterisinterfusedinfueHine 3.Drainwaterinwaterseparator,fuelfilterorfuel

4.Airisinterfusedinfuelline tank

5.Poorpipingconnectionto 4.Extracttheair

externalfueltank 5.Checkpipingconnection

6.Airfilterelementisclogged 6.ChecklChangeairfilter

7.Lubricantoilisin$uificieRt element

7.Supplylubricantoil

ERgineoilpressureislow 1.Lubricantoilisinsufficient 1.Supplylubricantoil

2.0ilfilterisclogged 2.Changeoilfilter

3.0ilPressureswitchis 3.Askourdistributortorepair

defective 4.Askourdi$tributortorepair

4.0ilpressuremeteris 5.Changetoproperkindanddefective viscosityoil

5.Wrongoilisused

Overheated 1.Enginetherrr;ostatis 1.Askourdistributortorepair

defective 2.Askourdistributortorepair

2.Watertempsensoris 3.Askourdistributortorepair

defective 4.CheckIAdjustfanbelt

3.Watertempmeterisdefective 5.ChecklSupplycoolant

4.Fanbelttensionisweak 6.Cleanradiatorcore

5.Coolantisinsufficient

6.Radiatorcoreisclogged

45

BlacksmokecomesoutfromMuffler

1.Airfilterelementisclogged

2.Fuelinjectionnozzleis

defective

3.Improperfuelisused

1.Check/Changeairfilter

element

2.Askourdistributortorepair

3.Changetocleanfuel

White$mokecomesoutfromMuffler

1.Toomuchortoolittleoilto

cylinder

2.WaterisinterfusedinfuelIine

3.Fuelinjectionnozzleis

defective

4.Coolanttemperatureistoolow

5.Enginetherrnostatisdefective

1.Askourdistributortorepair

2.Drainwaterinwaterseparator,fuelfilterorfuel

tank

3.Askeurdistributortorepair

4.Warm-updrivingisneeded5.Askourdistributorterepair

Pointer(hand)doesnotmove

inveltagemeter

1.Voltagemeteri$defective

2.AVRisdefective

3.DiscoBnectedcircuit,Ioose

terminalordeparted

4.Initialexciterisdefective

5.Alternatorisdefective

6.AVRprotectivedevicehas

activated

1.Askourdi$tributortorepair

2.Askourdistributortorepair

3.Askourdi$tributortorepair

4.Askourdistributortorepair

5.Askourdistributortorepair

6.PresstheAVRresetbuttoRtoreleasetheprotective

device

Pointer(hand)doesnotgoes

uptotheratedvoltage

1.Voltagemeterisdefective

2.AVRisdefective

3.Voltageregulatordialis

defective

4.Frequencyislow

1.Askourdistributortorepair

2.A$kourdistributortorepair

3.Askourdistributortorepair

4.A$kourdistributortorepair

Pointerexceedstherated

voltage

1.Voltagemeterisdefective

2.AVRisdefective

3.Improperconnectionoftheload

cable:

l.Askourdistributortorepair

2.Askourdistributortorepair

3.Settheloadcableontheproperoutputterminal

position.

Thevoltagedrop$drastically

whenconnectingtoload

1.AVRi$defective

2.Unbalancedloadssharingto

eachterminal

3.Wrongfrequencyisused

4.Loadstotalexceedstherated

current

5.AVRprotectivedevicehasactivated

1.Askourdistributortorepair

2.Balancetheload$sharingto

eachterminal

3.Settheswitchtotheload

frequency

4.Decreasetheloadstomeettheratedoutput

5.PresstheAVRresetbutton

toreleasetheprotective

device

CannotturnthebreakertoON 1.TheMaiBbreakerpo$itionsat

betweenONandOFF2.$hortcircuitontheload

3.Whentheshortcircuithasdetected:

1.0nceturningtheIeverto

OFF,turnittoON

2.Checktheloadcircuit

3.Repairtheshertcircuitpoint.

46

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