e e

ISO 9001
CERIilFIED

lable of Contents Page

OWNER'S AND 1 . Safety Guidelines 1

OPERATORS MANUAL 2. Specifications

2-1. Data
5
5
2-2. Ambient Condition 6
3. Use 6
SOUND-PROOF 4. Parts 6
4-1. 0uter and Main Components 6
DIESEL ENGINE GENERATOR 4-2. 0peration Panel 7
4--3. 0utput Panel 8

DGA50C 5. Equipment
5-1. Monitor Larnp
5-2. Meters
9
9
11
5-3. Fuel Line Changeover Valve 16
(3-Way Valve)
6. Transportation & Installation 17
6-1. How to transport 17
6-2. Installation 18
7. Connecting Ioad 19
7-1. Select Load Cable 19
7-2. Connecting Load Cable 20
7-3. ELCB and Grounding 21
8. Initialization and Pre-check 24
8-1. Engine Oil 24
8--2. Coolant / Water 25
8-3. Fan Belt 27
8-4. Fuel 27
8-5. Fuel, Oil and Coolant Leakage 28
8･-6. Battery 28
9. 0peration 30
9-i. Initialization and Preparation 30
9-2. During Operation 32
AcAuTloN 9-3. Stopping 33
9-4. Protection Feature 33
9--5. Connect to External Fuel lank 34
Do not operate the 10. Check and Maintenance 35
equipment before you 11. Long ferrn Storage 43
have read and understood 12. Troubleshooting 44
the instructions for use. 13. Generator Circuit Diagram 47
14. Engine Circuit Diagram 48

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 will be u$ed throughout the manual to indicate

the degree of cautions.

ODanger Cancauseseriousinjuriesordeath.

Cancauseminorinjuriesordamagetotheequipmentor
Acaution otherproperties.

<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 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.

Q 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 : Suffocation from exhausting fume

pt 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 : Fire
ig 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.
ge 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.).

g Do not connect AC output to any indoor wiring.

ge 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. lnjuries (No. 1 9402-O021 O)

Caution (coolant ) (No. 1 9402-O0295)
3.

Safety Precaution (No. t 9402--O0306)

4. Caution (EIectric Shock) (No. 1 9402-O021 5)

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2 spb'eifiCdt'i6riS

2-1. Data
Unit DGA50C
GeneratingMethod - RotatingFiled,Brushless3-Phase
SynchronousGenerator
kVA 50
RatedOutput
kW 40
6'tg68(LE)

RatedVoltage V 415
RatedCurrent A 69.6
RatedFrequency Hz 50
RatedSpeed Min'i 1500
Phase&Wiring - 3-Phase3-Wire
PowerFactor e/o
80
InsulationCIass m Alternator:FExciter:B
ExcitingMethod m SelfExcitation(Brushless)
Poles m 4
Method - Vertical,Water-cooled4-Cycle,DieselEngine
ModelNo. m- lsuzuBB-･4BGIT
Cylinder-borextroke
mm 4-105x125
ContinuousRated
kW{PS} 48.5{66.0}
Speed
Speed Min"3 1500
Displacement L 4.329
2'9ur

CombustionMethod - DirectInjection(Turbo-charged)
CoolingMethod - Water-coolingradiator
Lubricating - Trochoidpump,force-feedlubrication
Starting - StarterMotor
Fuel - Diesel
Oil - SAECIassCDorhigher
FuelTankCapacity L 160
LubricantVolume L 13.2(includingfilter1.1L)
CoolantVolume L 17(includingsub-tank1.5L)
StarterMotorCap. V-kW 24-4.5
AlternaterCap. V-A 24-20
Battery - 95D31Rx2
g.m8E'a'

Length
mm 2000
Width 950
mm
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

& Power Supply for submersible Pump, etc.

ee Power Supply for Iightings, etc.
ee Power Supply for electric tools, home appliances

4 Parts (Components)

4-1. 0uter and Main Components

Altemator
check
oorRopingLugRadiatorEngineChec
Lifting Lug Roping Lug
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Ernergency Stop Button Battery

ts

Fuel Filter

elDOOrslibTankOilFillerRopingLug
Operation Panel Door
OilGage x
X>,××Air91eaner x
AirCIeanerCheckDo
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Fuel lnlet i -
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OuterFuelOutlet
MagnetPumpforautoAir

Oil Drain Plug

6
4-2. Operation Panel

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22@ IS734131211 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 g o
Terminal(20A) 3-PhaseReceptacle3-phaseReceptacle
(50A) (32A)

8
5 Equipment

5-l. Monitor Lamp

￠<ShN
CttmaE

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 engine
starts, all the lamps turn OFF.
When abnormality is detected about WATER TEMP and OIL PRESSURE, the
corresponding monitor lamp will flash, and the engine is automatically shutdown.
When the automatic shutdown is engaged, turn the starter switch to STOP 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

oti or water leakage in coolan{ lines. Check it after the engine cools down.
<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.

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
OILPRESS 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 Charge Monitor Lamp (Charging Lamp)

When the battery turns unable to be charged during operation, the

ts battery charge monitor lamp will flash. In the event this occurs, $top
the engine consult with the authorized distributor or our
engineering section.
CHARGE

<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

Hour Meter keeps track of utilization time. Use this meter

xeugeesrER

wtpm+ 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

Water -lemperature Gauge displays the temperature of engine
7' coolant. Normal temperature may vary depending on the
environment, but it should be between 750C and 1000C.
ee se
isgg<
<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 , the volume is coming to
empty. Repleni$h fuel enough promptly.

11
 Generator Gauges

(1) Volt Meter

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

>g,i,ljl.Z.''･i･･･,. the generator.
PIease check and confirm it showing 415V at 50Hz during
ooo operation.

(2) Ampere Meter

iiSlilllt.Xt･,t･,..
Ampere Meter displays the output current (Phase) from the
generator.
DOo

(3) Frequency Meter

Nsss""-i"lttetttttit
Frequency meter will display the frequency of the generator.
he Please check it showing 50Hz during operation.
ooo

Lamps
(1) Preheat Lamp

When the starter switch is turned to <Preheat> position, the

sX 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

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

switch (by the light) to ON.

ov

Switchs

(1) Starter Switch

a. stop
PREHEArr STOP When the switch is set to this
RuN position, all powerwill be off#
S"l:ART
The switch must be set to this
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 Stop Button

Iiiiiiiiiiiii[[iiliiliii

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

By in$erting the button, the engine stops.
Be sure to restore the $tarter switch to STOP and re-set
eNk,,,iiiiiiiiiiii} the button, turning clockwi$e after using the emergency stop
button.

(3) Main Circuit Breaker

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

Power will be transferred to the output receptacles and to the
"ft Ioad side.
The breaker trip$ to OFF, either overload or short-circuit.

N
13
<Caution>
g Do not use ELCB as the ON/OFF switch to the Ioad.

(4) 3-Phase Circuit Breaker

1-Phase Circuit Breaker

o o o o Each receptacle, 3-Phase and 1-Phase is

tu tmtm incorporated with circuit breaker respectively.
1;;

rhmta" :-=' .L j,,,L

,

u The breaker trips on overload or $hort-circuit on

o o o o to stop powertransmission to load.
3PBreaker 1 P Breaker

<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
[]Q
Each receptacle, 3-Phase and 1-Phase is
incorporated with ELCB re$pectively.
FI
LicrnRig"

When current leak occur$, it trip$ to stop

power transmission to load.

k"
w
o a <Caution>
3PELCB 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

When turning the switch to OFF, the engine

o@
electric circuit dees not activate due to no
o
@ O D battery power.
ow
o esi'
o
OFF position ON positien

Voltage Regulator
asb

(1) Voltage Regulator

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
K'//L-:y/tt.i.$$$.dex"/S//g"¥･kt,itsw.a:"a've
A when the equipment is shipped.
Outer fuel inlet and return are
closed with plugs (PTI/2).
Use fuel as they are.
i'#.l';;lii/fst""ihVg"llli:pt,ik,'gei,`･iS,,g'ttil,i,i,',iti,,

I,}ESli,,Xgl"lilissttwh}･

//..V///1,tl,,l,? External Fuel Return (P"l"1/2)

A side Lever PositioR

<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 3--way valve
E,...,Miii....I`L"`/tli'li`i'".e.'$il',}iags'i.j.,Srx"
r9--6.Connecting to External Fuel
fanks
i-vi,,.,,i,i, 'ai,,

,$'lk,,lilll!S-LesE,zgge l.:. J..'..:g:;-- pt) ' He"'5-' ":- (g.itde...,.,,: ･;･:':'11:l i;-ff･

i･-->..fs., <,:fL,,".i"L {,l;../k.itt.i'i･l}'"' .>..,sl,,,di･;"""

l<li"' '. il}i)c'/<'x """'h)i>.IX, sL,,lfs- ":`"f"''

..-f/'"' x'Zl,f,,,.,,:--)>;xltt'(',;', '" X'"'t, ExterRal Fuennlet

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

16
6 Transpomation and ' installation

64. How to transport

o
x
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.

(iiiiiilil
(2) Transporting the equipment
When transporting the equiprnent, make
sure that the equipment i$ secured properly
with ropes tied to the roping lugs through.
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 Cable

Select the cable with proper gauge, based on its allowable amperage and the
distance between the generator and the machinery to be connected.

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: the voltage drop of cables

@ 3-Phase 3-Wire
1 Length (m)
Voltage Drop (V) = × × Current (A) × J--3
58 Dia (mm2)

@ 1-Phase 2-Wire
1 Length (rn)
Voltage Drop (V) = x × Current (A) x2
58 Dia (mm2)

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.

The specification of ELCB;

tw Rated Sensitive Current: 30mA (or below) (Grounding resistance: 500Q or below)
& Sensitive time: Within O.1$econd

(1) Grounding Work

Eva

The qualified electrician $hould perforrr}

oo
mo -o fiL-･
ttttttt-t-t-
'<.･,<.E,>i.//i
,(C･P.l
il

the grounding of the following 2 points o

7'X.XLi.Y{
"'

(500 9 or below). i it<?･)Ylli

lrtym' Kirr7 (tet'

@ The Bonnet (Canopy) grounding terminal
?tL'i'i{i'i},r).,,iS),im"cn

9e sneg3S VWI
ltciil
of the generaton ,'i
./
lilll'llliitti' >76ts,,"z' L3･Sllel 7rBKI"

e The Bonnet of the load.

.]

o.
i OLM

eq #: i

L. nd 1
<Caution>
ee In the event you cannot ground the
generator to the earth, consult with the
Bonnet Grounding ferrninal
authorized distributor or our engineering
section.

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, D Lamp

Initializing / Preparatien,start an engine.
RESET button (Green)

Turn every breaker and ELCB to ON.

TEST button (Blue)
Pu$h the RE$ET (Green) button on
the 1-Phase ELCB. 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.
v[=I] C lndica

Push the TEST button (Yellow) on 3-Phase

Z
Test button (Yellow)
fest
ELCB. it/ /
Indicator changes to Green from RED
and ELCB trips to OFF, Which shows Y
v/rv
NORMAL.
Q a
3-Phase ELCB
Push the TEST button (Blue) on 1-Phase ELCB.
Red lamp turns to OFF and ELCB trips to OFF,
Which shows NORMAL.

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

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

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 LOWER L;MIT UPPER LIMiT O!L GAUGE
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.
w v e
×

[{li ×
(1) Selecting proper engine oil ,,N"' &.gllllma

l TOl
MwwCwwK-."l,

Use the API class CD grade or higher.

(2) Use the engine oil for Diesel engine with proper viscosity, based on the temperature
(refer to the chart below).

24
dy Viscosityandtemperature
SAE2el2eWAtu SAE40

pt
SAE30A
SAEIeW.-dl

llilillll
N
ts
r ---I b

Iiii i l l
iEi!.I,l･

lilil:
il'iIIIlil'liilll
::::::::::t::::::: :::::::: :::i:t:t:::i:
::::::::::::::::;; r:::::::ir.r.r.:
lii{i:liiliil

l o l : : : : ; ; ; : ; : ; : ; : : : : : : : : :::::-l--------t--------#
::::::.:.:.t.t.r.:
Tem .,,i,l
p
{c}
･-....Iil'

::::::::
152530
::::::::----

SAEtOW-30A
N b
SAEt5W40I20W-40
nd
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 !:.:.rl-e".Tll.T-;-[l,L･1-L/'l'..t･ l.i,･i･ 't;･
l't ' !1-.
Wx.lrilre;:l"
si"
Lt..-".-.nv...M.1th,.-.( /H- .i
water and add water in ca$e of shortage. Radiator plate /. .i`i" ';'.X. 'Xii 'kx.

(1) Checking Radiator / Adding water /t ve t'.rrr-tt- -h - m- "-: )Nt

lt
>
Mv:.- vltli'"
'".- -ri- m.-'I -r-"(' l ll
4 ReMOve the Radiator plate s" -.l/ -･"i=il't/)ge;'.'H l l i`
"'t

..;-･･z.ll."=.i; kfF)':"l'L,L{'-.-i l

Llr=.=-=...dn--ww-"ww----;:=-:.--: lnlet
g Remove the Radlator Cap Radiator Cap

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

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

4 Fm up water to the radiator water iniet top.

tti

LOW
I:

,ve&tktt･,-tec?,
k
!tls
lil

l E
i.

E
[
I

4 Reinstall the cap and tighten it.

il

!l･#
F･ll

iEiii
Ll'la

4 Rem$tall the Radiator plate

1:lllt ･-･
)2E.j.l"lt1:trt<.t".k"'

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) :
Ambient
-150C -230C -350C
temperature
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 (98N>

pressure (about 98N {approximately 10kgfi) at N

midpoint between fan pulley and AIternator t7i>L.
slacks ,.N-,;"
Pulley. ttt･.-.,ii2rk,i}iEt,.s.

(2) Condition ,tt'7

Check for any damage on the Fan Belt.
Replace if necessary.
k
<Caution>
pt Refer to the <User's manual for Engine> for adjusting and replacing of the Fan Belt.

8-4. Checking fuel

Caution : Fire

x 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 ambient temperature reaches
down to -soc.
Fuel Strainer
& Alway$ use the Diesel Fuel Strainer
Fuel lnlet
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 - 'lank Cap

(blend oM-D and 2-D).

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 those
specifica/ly recommended by /suzu.
Such damage is not our responstoili44 and is not covered by the VlierTanty
7b 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> +Post--Post+Post-Post

I-.-va}:･:tLN) l [ - > -
ee Dual batteries has been connected in a series. !tz
l-4 K-･
l}i'/Sigi･i･lllills./L'llliliil･'k･,-g-iizll･
vuKgfas,,ybl-t

Always follow the below instruction when replacing tht"E･Yss` -S.xeiit--/Tii/gfi

lisiKz,zr-IE.k'ieiff{r-i'/
the Battery or Remove the Battery cables to avoid
Battery short circuit. ww
,{1,IE･!t-;.,k/-fitsii k･-.lwheEl}'i:i･t-i-¥isz:}-@-//'j
--

-/･,,X

(t) Replacing the Right ( R ) side Battery ttt-ttttt"tt -tttt-

"-----.pt
pt.
.-nv---n-''"

t-nyttttH-t"tttttt"tttt-ttttt-t-Mttt""tntrv ew"t.wini----""r
crtt-tttN----tmut-ptt.t-
nv-..
Disconnect the negative (-) terminal from
the Right Battery always. Fixing Clamp

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

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

4 Disassemble the fixing clamp of the R Battery

4 Remove the R 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
l
<Caution> WG)es･Em･
.ESE]O
--nt-Mt
@ Preheating time varies by coolant za

femperature, u$ually within 25 seconds. [{IE]N(S}

f-
L:±
es Do not drive the starter motor more than .ee';esiiEI](S).
10 second$ succes$ively.

N6]/es
o

@ lf you need to restart, wait at Ieast 30

$econds before the retry.
StarkerSwitch
geRegulator
Battery lsolator

Release the Starter Switch, as soon as the engine is started

Keep the 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 the above frequency under no load, 50Hz(almost)
will be obtained at the rated output Ioad.

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
OFE
ln 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

Action
Engine Warning
No. ELCB Breaker Automatic Lamp Cause
Trip Trip Shutdown Flash
Abnormality

1
Activatesduetohighwater
HighWater temperatureinengine
Temperature - - 0 o Default1050C
gE.s!I6'do2

Activateduetolowoil
2 LowOil pres$ureintheengine
Pre$sure - - o o DefaultO.98×100kPa
{1.0kgf/cm2}

Battery
3 Activatesinbatterycharge
Charge
IBsufficient - - - o Impossible

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 position.

(lnstalled tank use position)

DisconRect the P/T 1/2 plugs from the ig2i,,

External Fuel Intake and the External Fuel

Return, aRd then connect the hoses from
the Extemal Fuel lank, as shown below.

Tum the 3-way Valve Lever to B

position,
'Aiiiii'intM'li;'"'"X.lltgllliliee/kz;i,iiiifgf,%walvaive
(External tank use position)

Extract the air out from the

connected hoses. t,! tt.lx, ,'i/l,i.'.-; -lht`it}}).,,. x.,"- - -i.,.'`..'-"':T.: "='L-･--;:"d, -"=-- . 2} l,f,f; gve 5effv

;'-'ftliillX:ask,g,fi"g/i'1nd,,i'1,,,
By the above procedure, it rnakes
possible to use an External Fuel
lank.

External Fuel Return (PTf/2)

<Caution>
dy Use always oil-proof hose in 8-10mm lill)".)`･,ii,,>i kxt.-,-l'lll,.., ,..

inner diameter as connecting ho$e. ,/g'tsi"#:>ililpl

.1,i･li,i･?-iikilliiii.tttt,,i'i(･i)-11
$ The fuel level in the external fuel tank ..x

should be O to 3m higher than the bottom

of the equipment. Otherwise, it may /- / // /.:f-
/ .x/ .HA.. -'! 1/ .ul"-.:""-pt /
/. -.-"

." .iJ .tt

cause engine malfunction or $toppage. B side Lever Position
A side Lever Position
g fo avoid any leak from the external fuel
intake and return ports, always turn the lever for 3-way Valve to A position
whenever piping work is performed.
* Use extreme caution when connecting the ho$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
 Startup Every Every Every Every
Description
check 200hrs 400hrs 5OOhrs 1OOOhrs
EngineSide
Cleaneachparts/tightening o
Engineoilchecks/addoil o
Engineoilchange(7Sttimeat50hrmark) o o
OilFilterchange(7S`timeat50hr o o
mark)
Coolantlevelcheck/addcoolant o
Exhaustcolorcheck o

oor2yr.
Coolantchange

oClea
Drainexcesswaterandsedirnentsinthe
o
waterseparator

on
DrainwaterfromFuelFilterorreplace

Clean
oReplace

DrainwaterfromFuelTank o

oCIean
CIeanwaterseparatorandcleanGauze
FilterinEngineFeedPump
ChangefHterintheMagnetPumpforair oReplace

extractioninfuelline
CleaninsideFuelTank tw

Leakcheck(fuel,oil,andcoolant) o

&or1yr.
Replacingfuelhose
oClean

CleanorreplaceAirCleanerElement oReplace

Batteryfluidlevelcheck o
Batteryhydrometercheck o
FanBeltcheck o
eq

RadiatorFlushCleaning
Checkandadju$tEngineValveclearance pt

Compre$$ioncheck e
Fuelinjectionnozzlecheck e
Fuelinjectiontimingcheck pt

Generatorside
VariousmeterandalarmIampscheck o
OperationcheckofELCB o
Groundingresistancecheck o
lnsulationtest o

36
(1) Change engine oil

lnitial 50hours
2ndandafter Every200hours

Remove the Oil Filler Cap. ,

Oil Filler Oil Gauge

Remove the Oil Drain Plug and then tum //11,'i/ i/.'{z;,1-rtr,/l'I,}l//･I{-II･il :'･ :i ': :""rl-..../t/''"" ""'/]li.I//11'i'}.f -il-'･:`;･:ke- -･ ･l/ ･･

The Oil Drain Lever to OPEN and drain ''li k ij} iillii'ililiil'illi'liiwa?}i .//,,ili",lf

engine oil.

Turn the Oil Drain Lever to CLOSE

:gsif-$--lilllii,}iliiliis}$;ii,i..t/$s.ltii's2gptlijv
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 oiiDi//,Np"Yiiilllllli<'"Eigiii"-ige-":gx----s.i..i'

the oil level gauge.

Tighten the Oil Filler Cap. 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

s"/･"i/g.ilg,,xxee,,/geee,,,,
lnitial 50hours

2ndandafter Every400hours

Drain the engine oil fully, as described

in (1) CHANGE ENGINE OIL

Loosen and remove the oil filter, using

an oil filter wrench.
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

/.Q

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 suppiy engine oil.

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

Air Cleaner

Clean Every200hours &,!S,f:gliil-#fu2,i'ksc''`illill,.,,

l
i s
Change Every500hours llj

l
Loosen the Air Cleaner Fixing Bolt and
remove the Cleaner Cap.

Loosen the Wing Bolt and remove

Cleaner Cap
the Air Filter EIement.

o$"e

Clean or change an Air Filter g, O (iz{{[g

g'
f@
Element and rein$tall it in the f
reverse order.
Air Filter Elernent

<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> Clog Indicator

BIa$t the compressed air to Element from inside. ･;if =mu"aj

<Carbon and oil adhered> ( -. pt--di･-

Change to a new Filter. pt

3- ';'

x
ec CIoglndicator .#s

The clog indicator to display clog in the Air Filter x

Elernent is incorporated to air filter unit.
g Whenever RED SIGNAL appears in the indicator
window, clean or change Element regardless of Re$et Button
operation hour.
:!I;
-
op After cleaning or changing finishes, push the
Red Signal
reset button to release the RED SIGNAL.

38
y
(4) Drain water in the Water Sedimentor

Check Startup

Clean Every200hours
iilEI-"･Xi '.i-IIIIIII- {.i-il..,

sg.i r, ft $ng6'-E･

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

drain level, drain water. 'a-･-
:
4 Loosen the cock Float
kj.-- i
k ntww3
-M#/
After draining finishes, tighten the
Cock. Cock Water Drain Level

<Caution>
g After draining finishes, extract the air in fuel line.

(Refer to r9-2.During Operationdi ･)

(5) Maintenance of the Fuel Filter

Fuel Filter Fan Guard

Drain Every200hours
111es'///'ec1enisests/keerw
Change Every500hours

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 Ga$ket

Apply little amount of the diesel fuel onto

new Fuel Filter Gasket.

Tighten the Fuel Filter using finger until the filter

gently seated to the bracket,
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 Air Extraction Plug

RmgNut LfCiiirWZiii,iii-iliilllllillll･t.g.i.,,,"s

,Ii e ft (llsiiS;,.(] ee
Loosen the Cock and then loosen 2eoPattms/.nigiiiy,GauzeFiiter
the air extraction plug.

Turn the ring nut counter-clockwise cockpaLIilli

to remove the cup and the Gauze Filter
Water Drain Level
after the fuel inside does not come out
from the lever.

Wash the Gauze Filter in Diesel fuel and reinstall the unit in the

reverse order.

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

Eyebolt Joint Pipe
CIean Every 500 hours
11"g(i･i"l"tsn-.,
..
-.t ii' te"' if --u :iiiW,igess
sN"ww ･tiv ''

//:e･//jiee,.ne
4Remove Eyeboits
IIiXl.glSl,ii'ilii.iii,

ililllli･,l,I---:k,:

i -i ;k
4Rerriove Gauze FHter in Eyebolts ev 111, 'il zl
1'<II･']･-7L; - - xlls"

ec.wreelp .de, 4-iYl･gti--?il,,･k

?ll',t4'"
;;;l'
Wash Gauze Filters in Diesel fuel and l"s1s`'
"I;.;lli -f/iL-.tt; S-llk,iss<v klt-

rw ,a-e
Reinstall in the reverse order. -nv-h-.....

Joint Pipe Eyebolt

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. '
ew/GAUZE FILTER
ee Extract the air in fuel line after Gauze Filter washing
finishes. guEYEBOLTS
(Referto M9-2.During Operations .)
dy Ensure that there is no fuel leakage after
reinstallation.
ee Eyebolt Part No. (Gauze Filter included)

Isuzu Part No. 8970631550

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

O
Change Every 1OOO hours
'

Turn the Cover, located at the bottom of

pump, counter--clockwise and remove Filter.
MApGuNMEpT @
Reinstall a replacing Filter in the reverse /@
order. FiurER (liil})
covER --t- (i{IIIII}I
<Caution>
@ Put a tray under the lever in order to catch $pilled w-
fuel when changing Filter.
g Extract the air in fuel line after filter changing finishes.
(Refer to r9-2.During Operational .)
g Ensure that there is no fuel Ieakage after reinstallation.
g Filter Part No.

1$uzu Part No. 8943370220

(1O) Drain water in fuel tank

Fuel Drain Cock
Drain Every 200 hours / ...,"...;....- S'sN. .iK t 't i-t,e
,,k.'"･･::;""-""1,'ii,/,-･'i"S"-'x-I.-.Ill'//;11.i.L.'.';'9t",)tt;.,///t.l.:･

Turn the Fuel Drain Lever to OPEN. :.i-.tliTlli3rii$gtF..tug7

After draining water, turn the Fuel Drain

Lever CLOSE.

Oil DraiB Cock

41
(11) Change Coolant 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';

Change 2 years orlOOO heurs
/li.///i･tl･illi'l'ii"tliil'lllliii"ii'Il"IlIIi-i'ii'il,'`}-:'･'i/,'ly"`x'-st/
xN -
4 Remove the Radiator piate ("`'":' 'pt...s-pt･- '"ag.tilivitEitf;.:l ,I l C'

-1.t.-' .,-k} ----- s:.nv

4 Remove the Radiator cap
Radiator Cap Water Inlet

Drain Plug on the engine

Loosen the Radiator Drain Cock and the
side.

"rribos"`,t",fi::iKlii/ll:.li,k},,,tiii;iiiEi2i;{`i?i･.i,llliiil.xiillllil
-i3]-11'2ft,',t,r￡,i,rAa.,l"/nl,?,R.℃",kliS'l,:.e"r3,i"iiiiiiillllllli.111111111i,/e,,,1111tlif//<illgiiii"ly-f･g-i(ik,..

Radiator
Drain Cock DraiR PIug
Remove the Sub fank Stay
Reinstaiithesubfankandf"i,..,,,,,p,,,u,,:"t/ /'",X/ltlll,i!lll/::-e,,111･iilit,-rlill/11i///111,//ll'/ill///li'g-....J
i'iipmiii･'illllllli,11111'ljl/I/i,,/l"ii"li'111i'li'ii;li'

and drain coolant in the Sub lank.

g level
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';'

scEJ iniet ievei

CoolantDrain FuelDrain

S Tighten the Radiator cap Sub "lank sub "lank $tay

tsf{;#sLtpc",...;Jl,"i>L
1}Enct$.v.ix/esssmu
4 Reinstall the Radiator plate 1il-l･rw
iill 'i'

E
El
ll,l

I
i'

<Caution>
l,l;i

I
ge Refer Coolant to r8-2. Checking Coolant/VVaterdi u
i
igl,i
l,,i:li

-teQ$
g, li; v.-,V

x. s,.-c･--,-...l-S'(ny---"tu`i'iii--'--{'" ii
I ,1isc

Eigifii?-rv,
l,l･

l
xl,i't'"

I
t'
･'<lt'il.{i.:sgiiissi{!.. {}",SS,,E}i/.J'.)>lh;.:v" ℃ i.I i

×･-"･.s.gg".$k

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.

Remove Batte ry.

Change engine oil.

Drain fuel in the Fuel fank and Fuel Filten

.JY7 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 the
following 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
Startermotordoesnot 1.BatterylsolatorisOFF
driveorspeedislow. 2.Batteryoutputisweak
3.Batteryisdeteriorated
4.Batteryterminali$OFForloose 3.Changebattery
5.Batteryterminaliscorroded
6.Starterswitchorrelayis
defective
7.Startermotorisdefective
Startermetordrives 1.Fuelisinsufficient
suco
Action
1.TurnBatterylsolatortoON
2.Check/batteryIiquid/or
Charge
4.Fix/Tightenterminal
5.Cleantermina[
6.Askourdistributortorepair
ZAskourdistributortorepair
1.Addfuel

ti
butenginedoesnot 2.Fuelfilterisclogged 2.Clean/Changefuelfilter
68
= 8s

start 3.GauzeFilterisclogged 3.Clean!ChangeGauzeFilter

4.Waterisinterfusedinfuelline 4.Drainwaterinwater
separator,fuelfilterorfuel
e

5.Airisinterfusedinfuelline tank
m

Liii
<Ambientternperature
fallsdownbelowzero>
Enginestartsbutstalls
immediately
ERgineoilpressureislow
6.Poorpipingconnectionto
externalfueltank
ZFuelTankSelectorLever
(3-wayvalve)po$itioni$
wrong
8.Fuelcutsolenoid(motor)does
notwork
1.Fuelisfrozen
2.Waterinfuellineisfrozen
3.Pre-heaterisdefective
1.Fuelfilterisclogged
2.GauzeFilterisclogged
3.WaterisinterfusedinfueHine
4.Airisinterfusedinfuelline
5.Poorpipingconnectionto
externalfueltank
6.Airfilterelementisclogged
7.Lubricantoilisin$uificieRt
1.Lubricantoilisinsufficient
2.0ilfilterisclogged
3.0ilPressureswitchis
defective
4.0ilpressuremeteris
defective
5.Extracttheair
6Checkpipingconnection
7.checklever(3-wayvalve)
8-1.Check/Changefuse
8-2.Check/Changefuelcut
soleneid
1.Usewinterizedfuel
2.Drainwaterinfuelline
3.Askourdistributortorepair
1.Ciean/Changefueifilter
2.Clean/ChangeGauzeFilter
3.Drainwaterinwater
separator,fuelfilterorfuel
tank
4.Extracttheair
5.Checkpipingconnection
6.ChecklChangeairfilter
element
7.Supplylubricantoil
1.Supplylubricantoil
2.Changeoilfilter
3.Askourdistributortorepair
4.Askourdi$tributortorepair
5.Changetoproperkindand
viscosityoil

5.Wrongoilisused
Overheated 1.Enginetherrr;ostatis
defective
2.Watertempsensoris
defective
3.Watertempmeterisdefective
4.Fanbelttensionisweak
5.Coolantisinsufficient
6.Radiatorcoreisclogged
45
1.Askourdistributortorepair
2.Askourdistributortorepair
3.Askourdistributortorepair
4.CheckIAdjustfanbelt
5.ChecklSupplycoolant
6.Cleanradiatorcore
Blacksmokecomesoutfrom 1.Airfilterelementisclogged
Muffler
2.Fuelinjectionnozzleis
defective
3.Improperfuelisused
White$mokecomesoutfrom 1.Toomuchortoolittleoilto
Muffler cylinder
2.WaterisinterfusedinfuelIine
3.Fuelinjectionnozzleis
defective
4.Coolanttemperatureistoolow
5.Enginetherrnostatisdefective
Pointer(hand)doesnotmove 1.Voltagemeteri$defective
inveltagemeter 2.AVRisdefective
3.DiscoBnectedcircuit,Ioose
terminalordeparted
4.Initialexciterisdefective
5.Alternatorisdefective
6.AVRprotectivedevicehas
activated
Pointer(hand)doesnotgoes 1.Voltagemeterisdefective
uptotheratedvoltage 2.AVRisdefective
3.Voltageregulatordialis
defective
4.Frequencyislow
Pointerexceedstherated 1.Voltagemeterisdefective
voltage 2.AVRisdefective
3.Improperconnectionoftheload
cable:
Thevoltagedrop$drastically 1.AVRi$defective
whenconnectingtoload 2.Unbalancedloadssharingto
eachterminal
3.Wrongfrequencyisused
4.Loadstotalexceedstherated
current
5.AVRprotectivedevicehas
activated
CannotturnthebreakertoON 1.TheMaiBbreakerpo$itionsat
betweenONandOFF
2.$hortcircuitontheload
3.Whentheshortcircuithas
detected:
46
1.Check/Changeairfilter
element
2.Askourdistributortorepair
3.Changetocleanfuel
1.Askourdistributortorepair
2.Drainwaterinwater
separator,fuelfilterorfuel
tank
3.Askeurdistributortorepair
4.Warm-updrivingisneeded
5.Askourdistributorterepair
1.Askourdi$tributortorepair
2.Askourdistributortorepair
3.Askourdi$tributortorepair
4.Askourdistributortorepair
5.Askourdistributortorepair
6.PresstheAVRresetbuttoR
toreleasetheprotective
device
1.Askourdistributortorepair
2.A$kourdistributortorepair
3.Askourdistributortorepair
4.A$kourdistributortorepair
l.Askourdistributortorepair
2.Askourdistributortorepair
3.Settheloadcableonthe
properoutputterminal
position.
1.Askourdistributortorepair
2.Balancetheload$sharingto
eachterminal
3.Settheswitchtotheload
frequency
4.Decreasetheloadstomeet
theratedoutput
5.PresstheAVRresetbutton
toreleasetheprotective
device
1.0nceturningtheIeverto
OFF,turnittoON
2.Checktheloadcircuit
3.Repairtheshertcircuitpoint.
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