OWNER’S AND OPERATOR’S MANUAL

Vertical, Water-Cooled 4-Cycle Diesel Engine

CAUTION
Read this manual and familiarize yourself with this contents for your safety. Do not
operate or maintain this product unless you fully understand followed by the content
in this manual.

DG150MM-200/TWN
X753-007 93 0
X753801-330 0
Introduction

Thank you for purchasing this Shindaiwa soundproof diesel engine generator.

 This manual has been created to ensure safe usage of this generator. Be sure to read this
manual before operation. Improper operation/handling of this generator will result in an
accident or malfunction.

 Handling/Operation of this generator can only be performed by persons who understand the
contents of this manual and can handle/operate the generator in a safe manner. Persons who
suffer from an illness, are taking medicine or not feeling way such that safe operation would be
negatively affected must not operate this generator.

 Work performed using this generator and handling/operation of this generator must be in
accordance with corresponding laws and regulations based on such laws. Consult with the
authorized distributor where this generator was purchased if you have any inquiries regarding
the corresponding laws.

 Always be sure to include this manual when loaning out this generator and instruct operating
personnel to read this manual before operation.

 Store this manual in a specified location where it will be secure and available for consulting at
any time. Order another copy from the authorized distributor where this generator was
purchased if this manual becomes dusty, grimy or torn.

 Consult with the authorized distributor where this generator was purchased if you have any
inquiries regarding any points related to this generator and manual.
When inquiring about this generator, be sure to provide the model name and serial number.

 If disposing of this generator, do so in a manner that is in compliance with laws related to

industrial waste. Contact the authorized distributor where the generator was purchased if you
have any inquiries regarding proper disposal.

 Caution notice ranks in this manual are classified as follows.

WARNING A statement proceded by the triangle attention symbol and the

word “WARNING” contains information that should be acted upon
to prevent serious bodily injury.

CAUTION A statement proceded by the triangle attention symbol and the

word “CAUTION” contains information that should be acted upon
to prevent mechanical damage.

<Note> Contains other types of information and should read carefully and
understand.

 Note that CAUTION items can also lead to major accidents under some circumstances if
not correctly followed.
All caution notices are important. Be sure to follow all of them.
 Table of Contents

1. Safety Instructions ............................................................................. 2

2. Specifications ..................................................................................... 5
2-1. Specifications.............................................................................. 5
2-2. Ambient Conditions ..................................................................... 6
3. Applications ........................................................................................ 6
4. Part Names .......................................................................................... 6
4-1. External View/Parts Names ........................................................ 6
4-2. Operation Panel Part Names ...................................................... 8
4-3. Output Panel Part Names ........................................................... 9
5. Equipment ......................................................................................... 10
5-1. Warning Indicators .................................................................... 10
5-2. Meters and Gauges .................................................................. 11
5-3. Fuel Piping Switch (3 Way Valve) ............................................. 15
6. Transporting/Installing ..................................................................... 15
6-1. Transport Procedures ............................................................... 15
6-2. Installation Procedures ............................................................. 16
7. Load Connections ............................................................................ 17
7-1. Load Cable Selection ............................................................... 17
7-2.Connecting Load Cables ........................................................... 18
7-3. Earth Leakage Relay and Grounding ....................................... 20
8. Pre-Operation Inspection ................................................................. 22
8-1. Checking Engine Oil ................................................................. 22
8-2. Checking Coolant ..................................................................... 23
8-3. Checking the Fan Belt ............................................................. 24
8-4. Checking the Fuel ................................................................... 25
8-5. Checking for Fuel, Oil and Coolant Leaks ................................ 25
8-6. Checking the Battery ................................................................ 25
9. Operating Procedures ................................................................... 27
9-1. Initial Startup/Pre-Check ........................................................... 27
9-2. Procedures during Operation.................................................... 28
9-3. Stopping Operation ................................................................... 29
9-4. Protective Functions ................................................................. 29
9-5. Connecting with External Fuel Tank ......................................... 30
10. Inspection/Maintenance ................................................................. 32
11. Long-Term Storage ......................................................................... 39
12. Troubleshooting ............................................................................. 40
13. Generator Circuit Diagram ............................................................. 43
14. Engine Electrical Circuit Diagram ................................................. 45

1
1. Safety Instructions

WARNING : EXHAUST GAS POISONING

 Do not operate the generator in poorly ventilated areas such as indoors or tunnels, as the
exhaust gas of the engine contains substances that are harmful to human health.
 Do not direct exhaust fumes at pedestrians or buildings.

WARNING : ELECTRIC SHOCK

 Do not operate the equipment with any doors or covers open.
 Before connecting or disconnecting load cables to/from the output terminal, always turn the
output circuit breakers to the “OFF” position, stop the engine, and remove the starter key.
 Close the output terminal cover before operating.
 Do not insert a pin, wire or other metal object into the electrical outlet.
 Do not touch the generator if the Alternator or casing becomes wet during operation.
 Do not touch output terminals or internal electric parts while the generator is
operating.
 Do not change the frequency selector switch while the engine is running.
 Ground the every earth grounding terminal to the earth as set out in the manual.
 If even one of all is unconnected by mistake or accident, it will be much more
dangerous for human body than the NO-RELAY case, because leaking current
inevitably goes through the body.
 Even though all the earth terminals of the loads have been grounded to the earth,
the bonnet grounding terminal should be grounded to the earth.
 Grounding should be made after the engine is stopped.
 Whenever the Earth leakage relay is activated, you should always repair the leaking
place first of all.
 Always be sure to stop the engine and remove the starter key before performing any
equipment check or maintenance.

WARNING : INJURY
 Close all doors and lock them during operation.
 Do not open the check door during operation. Keep away from moving parts such as cooling
fan and fan belt..
 Always be sure to stop the engine and remove the starter key when performing inspection
or maintenance.
 Use the lifting hook to lift the machines, and do not lift up the unit using tie-downs. Use of
such could result in the generator falling.
 Do not lift any additional weight such as fuel tanks or trailers.
 No persons should be under a suspended generator at all time.
 Always be sure to check that the breakers on load side and switches for any equipment
using the generator are at “OFF” before turning the breaker to “ON”. Also be sure to advise
personnel on the load side that power will be turned on or off before operating the breaker.
 Do not modify the equipment and do not operate with parts removed.

CAUTION : EYE/SKIN INJURY

 Wear rubber gloves and other protective wear to protect eyes, skin and clothing from the
battery fluid which contains diluted sulfuric acid. If the battery fluid contacts eyes or skin,
wash out immediately with a sufficient amount of clean water. Be sure to receive medical
treatment, especially if the fluid contacts the eyes.
2
CAUTION : EXPLOSION
 Never use or recharge the battery if the fluid level is below the minimum level.
 Do not create sparks or bring flame near the battery as it generates flammable gas.

CAUTION : FIRE
 Do not carry flammable items (such as fuel, gas and paint) or items that are highly
combustible near the generator as the muffler, exhaust gas and other parts become
extremely hot.
 Position this generator 1 m or more from walls or other hindrances, and on a level surface.
 Do not connect the generator output to indoor wiring.
 This generator uses diesel fuel. Always be sure to stop the engine and not bring flames
close when inspecting fuel or refueling. Wait until the engine has cooled before performing
such procedures.
 Do not use this equipment when leak is found, and repair the leaking location before
operating.
 Always be sure to wipe up any spilled fuel or oil.
 Allow the generator to cool before covering with the protective cover.
 Never allow flame to come close to the generator.

CAUTION : ELECTRIC SHOCK

 Do not sprinkle water on the equipment and do not use where exposed to rain.

CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after stopping the engine
as they are still extremely hot.
 Do not open the radiator cap immediately after stopping the engine. Doing so will result in
hot steam gushing out.
 Hot steam gushes out from the coolant sub-tank if the generator overheats. Do not touch the
coolant sub-tank.
 Always be sure to stop the engine and allow the engine to cool when performing inspection
or maintenance of engine oil. Opening the oil gauge or oil filler cap during operation will
result in hot oil gushing out.

CAUTION : INJURY
 Always be sure to use lifting hooks when lifting up the generator, and slowly lift it straight up.
 Personnel performing lifting work must wear protective gear such as helmets, safety shoes
and gloves.
 Remove the wood ties if using anchors to secure the generator.
 Position the generator on a level stable surface so that it cannot slide or move in any
manner.
 Before starting operation, always be sure to turn off all switches of equipment using the
generator and all breakers to “OFF”.
 Do not move the generator during operation.
 Do not operate the generator if it has been modified or any parts have been removed.
 Securely fix the equipment with rope or similar item so that it cannot move when transporting
by truck or other vehicle.

3
 CAUTION : PROPERTY DAMAGE
 Do not use the equipment for any improper applications. Improper usage can result in an
accident or malfunction.
 If using this generator for medical equipment, check before use with the medical equipment
manufacturer, doctor, hospital or similar entity.
 Check that the generator output setting, output terminal connection and load power source
are consistent.
 Cable burnout can occur due to generated heat if the load current exceeds the allowable
current of the cable.
 The voltage drop between cables is large if the cable is excessively long or thin, resulting in
decreased input voltage to equipment using the generator, thereby causing decreased
performance, faulty operation and malfunction.
 Warning/Caution Label Locations
If warning or caution labels become damaged and difficult to read, replace with new
labels in the indicated locations. Order labels using part number indicated in the
parentheses.

 Injury (Part no. : X505-007550)

 Electric shock (Part no. : X505-007560)
 Burn (Part no. : X505-007830)
 Caution: gm spec LLC (Part no. : X505-007840)
 Warning/Caution (Part no. : X505-008690)
 Injury (Part no. : X505-010350)
 Fire (Part no. : X505-007650)

A→ ←B

SIDE A SIDE B

4
 2. Specifications

2-1. Specifications
Model Unit DG150MM-200
Rotating Field, Brushless 3-Phase
Generating Type -
Synchronous Alternator
Rated Frequency Hz 50 60
kVA 125 150*1
Rated Output
kW 100 120
Alternator

Rated Voltage V 200 [400] *2 220 [440] *2

Rated Current A 361 [180] *2 394 [197] *2
Winding - 3-phase, 4-wire
Power factor % 80
Insulation class - F
Excitation - Self-Excitation(Brushless)
No. of poles - 4
Types - Vertical Water-cooled 4-cycle Diesel Engine
Model (Manufacturer) - 6D16-TLE2D (MITSUBISHI)
No. of Cylinders (bore x stroke) mm 6 (118 X 115)
kW 113 135
Continuous rated output
PS 153.6 183.5
-1
Rated speed min 1500 1800
Displacement L 7.54
Direct Fuel Injection
Combustion system -
(Turbocharged with Intercooler)
Engine

Cooling method - Radiator

Lubricating method - Forced lubrication
Starting method - Electric start
Fuel - Diesel Fuel （ASTM No. 2-D）
Lubricant oil - CD or CF-4 class
Fuel tank capacity L 250
Lubricant volume (Full) L 20
Cooling water volume L 26
Starting motor capacity V-kW 24 – 5
Charging dynamo capacity V-A 24 - 35
Battery - 105E41R x2
Length mm 3230
Width mm 1100
Unit

Height mm 1500
Dry Weight kg 2270
Installed Weight kg 2540
*1: For the output at 136kVA or below, set the voltage selector at 200V. For 130kVA or below,
set the voltage selector at 380V.
*2:The values in brackets are optional data, when modified to 400/440V by the dealers only.
As default 3-phase output is set at 200/220V, contact your authorized distributor to adjust
the terminal lug setting if necessary to obtain 400/440V for 3-phase output.

5
2-2. Ambient Conditions
Use this generator in ambient conditions as described below. Failure to provide
these conditions can result in problems such as malfunction, insufficient output and
reduced durability.
■ Ambient temperature:-15 to 40 degree Celsius
■ Relative humidity: 85% or less
■ Elevation: 300m or less

3. Applications
 Power source for submerged pumps and similar civil engineering equipment
 Power source for lighting and similar equipment
 Power source for electrical tools and household appliances

CAUTION : PROPERTY/SECONDARY DAMAGE

 Do not use for any application other than those listed above.
 If using this generator for medical equipment, check before use with the
medical equipment manufacturer, doctor, hospital or similar entity.

4. Part Names

4-1. External View/Parts Names

Radiator Plate
Tie-Down

Lifting Hook

Operation Panel Door

Fuel Inlet

Cleaning Panel

6
 Coolant Sub-Tank Oil Level Indicator Oil Filter Fuel Filter (Main)
Radiator (Inside) Air Cleaner
Intercooler
Alternator Check Door

Battery
Oil Drain Plug
Engine Check Door Oil Drain Valve (Inside)
Elctromagnetic Fuel Pump (Inside)
3 way Fuel Valve
Water Separator (Pre Fuel Filter)
Fuel Drain Plug External Fuel Ports
Fuel Drain Valve (Inside)
Coolant Drain Hose

Alternator Check Door Oil Filler Engine Check Door

Output Terminal Cover Battery

Terminal Cover Battery

Accessories

Owner’s Engine
and Warranty
Operator’s Manual
Manual
Starter Key (2 pcs.) Door Key (2 pcs.)

Grounding Rod

7
4-2. Operation Panel Part Names

★
Located inside of
the operation panel.

① 3-Phase Circuit Breaker ⑪ Over Load Pre-caution Lamp

② Voltmeter ⑫ Preheat Lamp
③ Ammeter ⑬ Voltage Regulator
④ Frequency Meter ⑭ Ammeter Selector Switch
⑤ Water Temperature Gauge ⑮ Starter Switch
⑥ Fuel Gauge ⑯ Throttle Lever
⑦ Hour Meter ⑰ Frequency Adjust Screw
⑧ Pilot Lamp ⑱ Earth Leakage Relay
⑨ Warning Indicators ⑲ ★
Frequency Selector Switch (inside)
⑩ 400/440V Output Lamp

8
4-3. Output Panel Part Names

① 3-Phase Output Terminal “R” ⑥ 1-Phase Circuit Breaker

② 3-Phase Output Terminal “S” ⑦ 1-Phase Output Terminal
③ 3-Phase Output Terminal “T” ⑧ 1-Phase Receptacle
④ 3-Phase Output Terminal “O” ⑨ Bonnet Grounding Terminal
⑤ Earth Leakage Terminal

9
5. Equipment

5-1. Warning Indicators

WARNING : INJURY
 Do not open the check door during operation. Keep away from moving parts
such as cooling fan and fan belt.
 Always be sure to stop the engine and remove the starter key when performing
inspection or maintenance.

CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after
stopping the engine as they are still extremely hot.

This generator is equipped with the following warning indicators: CHARGE (battery
charge), OIL PRESS (engine oil pressure), WATER TEMP (coolant temperature),
AIR FILTER (air cleaner clogging), and WATER SEPARATOR (water separator
amount). An indicator illuminates if a malfunction/fault occurs during operation and
the engine automatically stops depending on the fault type. If the equipment is
normal, the CHARGE and OIL PRESS warning indicators illuminates when the
starter switch is switched from STOP to RUN, and all warning indicators turn off
when the engine is started.

(1) WATER TEMP (Coolant Temperature) Warning Indicator (High Water

Temp.)

CAUTION: BURNS
 Do not open the radiator cap immediately after stopping the engine.
Do so will result in hot steam gushing out.
 Hot steam gushes out from the coolant sub-tank if the generator overheats. Do
not touch the coolant sub-tank.
If the coolant temperature rises above 100 °C during operation, the WATER TEMP
and ENGINE warning indicators illuminates, and the engine automatically stops. If
this occurs, hot steam will gush out of the coolant sub-tank. Check the coolant
sub-tank coolant level after the generator cools and add coolant to the coolant
sub-tank if it is insufficient. (Ref.“8-2. Checking Coolant”) If the coolant is at the
specified amount, it is probable that the fan belt is loose or there is a coolant leak.
Wait for the engine to cool and inspect for these problems.
< Note>
 The coolant temperature cannot be detected if the coolant level is excessively low. Always
be sure to check the coolant level in the radiator coolant sub-tank before starting work.

10
(2) OIL PRESS (engine oil pressure) Warning Indicator (Low Oil Press.)

CAUTION: BURNS
 Always be sure to stop the engine and allow the engine to cool when
performing inspection or maintenance of engine oil. Opening the oil gauge or
oil filler cap during operation will result in hot oil gushing out.
If the engine oil pressure drops below 0.98 x 100 kPa during operation, the OIL
PRESS and ENGINE warning indicators illuminates, and the engine automatically
stops. If this occurs, check the engine oil level and add engine oil until it reaches
the maximum level.
< Note >
 This oil pressure warning indicator cannot detect oil deterioration. Change the engine oil
periodically. (Ref.“8-1. Checking Engine Oil”)
(3) BATTERY (Insufficient Charging) Warning Indicator (Low Battery Voltage)
The BATTERY warning indicator illuminates when charging is not possible during
operation. If this occurs, contact the authorized distributor where the generator was
purchased.
< Note >
 This battery charging warning indicator cannot detect battery deterioration or
insufficient battery fluid. (Ref.“8-6. Checking the Battery”)
(4) AIR FILTER (Air Cleaner Clogging) Warning Indicator
The AIR FILTER warning indicator illuminates if the air cleaner element becomes
clogged during operation. If it is illuminated, immediately stop the engine and clean
or replace the air cleaner element. (Ref.“10. Inspection/Maintenance (3) Air Filter
Element Cleaning/Replacement”)
(5) WATER SEPARATOR (Water Separator Amount) Warning Indicator
The WATER SEPARATOR warning indicator lights up if the liquid stored in the
water separator exceeds approximately 80 ml during operation. If it lights up,
immediately stop the engine and drain the liquid stored in the water separator.
(Ref.“10. Inspection/Maintenance (4) Draining Water from the Water
Separator”)
5-2. Meters and Gauges
Engine Meters and Gauges
(1) Hour Meter
Displays the operating time. Use this to schedule periodic inspection. Be
careful as the hour meter operates when the starter switch is at RUN
regardless of whether the engine is running or stopped.
(2) Water Temperature Gauge
Water Temperature Gauge displays the temperature of engine coolant.
Normal temperature may vary depending on the environment, but it
should be between 75 to 90 °C.
< Note >
 If the temperature exceeds normal value, disconnect the load, idle the
engine at 700min-1, and wait until the indication falls to the normal
temperature range.

11
(3) Fuel Gauge
It shows the volume in the fuel tank.
When filled up, it shows 『F』.
When the needle indicator is approaching to『E』, the fuel tank is empty.
Replenish fuel enough promptly.

Generator Meters and Gauges

(1) Voltmeter
The voltmeter displays the 3-phase output voltage (voltage between
R-T) from the generator.Check that 200V is displayed at 50Hz and 220V
at 60Hz during operation.Check that 400V is displayed at 50Hz and
440V at 60Hz during operation if using at the 3-phase 200V setting.
(2) Ammeter
Displays the output current (phase current) of the generator. Turn the
ammeter selector switch to “R+U” to display the output current of the
3-phase R phase and 1-phase U phase. Turn the switch to “T+W” to
display the output current of the 3-phase T phase and 1-phase W phase.
“S” displays the output current of 3-phase output terminal S.
(3) Frequency Meter
Frequency Meter will display the frequency of the generator.
Please check it showing 50Hz or 60Hz during operation.

Lamps
(1) Preheat Lamp
Turn the starter switch to the “PREHEAT” position.
The preheat lamp converts to “red” after approx. 15 sec. after preheating
completes.
< Note >
 Do not leave the starter key at “PREHEAT” over 30 sec. otherwise it
may damage the preheating feature.
(2) Pilot Lamp
The pilot lamp turns on during power generates.

(3) Over Load Pre-caution Lamp , and Output Terminal for Lighting of
Additional Lamp (Aux Lamp Terminal)
This lamp starts to flash if the output exceeds around 80% of the rated
output. Use this generator in a range that does not exceed the rated
output while the lamp is flashing. The lamp turns off when the output
drops below 80% of the rated output.
This generator is equipped with an Aux Lamp Terminal. DC 24 V is
output to the Aux Lamp Terminal at the same time as when the Over
Load Pre-caution Lamp is flashing. Refer to the circuit drawing below if
using the Aux Lamp Terminal for a lamp or similar device with a different
setting.

12
< Note >
 Connect a lamp that is DC24V/2A/48W or less to the Auxiliary Lamp Terminal.
 The pre-caution lamp flashes when more than 80% of the rated output lasts for 20
seconds.
(4) 400/440V output Lamp
This lamp illuminates if 400/440V are supplied from the output terminal
and turns off if 200/220V are supplied. Check the rated voltage of the
device being used.
< Note >
 Check that the voltages of the generator output setting, output
terminal connection and load power source are consistent.

Switches
(1) Starter Switch
① Stop
When the switch is set to this position, all power will be off.
The switch must be set to this position to remove the key.
② Run/Preheat
The switch must be set to this position during operation.
This position is also used during cold season, to preheat GlowPlug.
< Note >
 Do not leave the switch to this position, while the engine is stopped.
Otherwise the battery is discharged.
③ Preheat
This position is used during cold season, to preheat Glow Plug.
④ Start
This position is to start the engine. When the key is released, the
setting will automatically return to <Run> position.
(2) Frequency Selector Switch
This switch functions a covert the frequency for 50Hz or 60Hz. It locates
inside of the operation panel. Loosen the two screws and open the
operation panel. The settimg and frequency in equipment shoud be
identical.
< Note >
 operation panel should only be opened by an authorized service
technician.Extreme caution should be used when opening the
operation panel to check that no loads are connected before using the
frequency switch or touching any components.

13
(3) Circuit Breaker
By turning this circuit breaker on the operation panel to “ON”, Power will
be transferred to the 3-Phase load side.
By turning this circuit breaker on the output panel to ON,Power will be
transferred to the 1-Phase output receptacles and to the load side.
The breaker trips to “OFF”, either overload or short-circuit.

(4) Earth Leakage Relay

Sensing the earth leakage current, the unit (relay) send a signal To the
3-phase and the 1-phase breaker to trip-off in order to shut-off The circuit to
the terminals (loads).
< Note >
 Do not use this relay as the “ON/OFF” switch to the load.

Voltage Regulator and Throttle Lever

(1) Voltage Regulator
The dial adjusts generator output voltage.
By turning the dial clockwise, an operator can increases the voltage.
By turning the dial counter-clockwise, an operator can decrease the
voltage.

(2) Throttle Lever

Fixing Nut
The throttle lever is to adjust the engine speed.
Set the lever to “IDLING” position when the
engine starts and warms up or cools down.
When the rated power is used, set the lever to
RUN (50 or 60Hz).
Frequency
(3) Frequency Adjusting Screw Adjusting Screw Throttle Lever
Set the throttle lever to RUN and loosen the
fixing nut.
Frequency increases when turning the screw
positions “HIGH”. Position the screw to “LOW”
to decrease the frequency.
< Note >
 The equipment is set at 50Hz at delivery from the factory. For the 60Hz areas,
change to 60Hz according to the above procedure.
 Make sure that the frequency set by selector switch and equipment should be
identical.
(4) Ammeter Selector Switch

S
This switch is for selecting the output current indicated by the ammeter.
R+U T+W Change the switch to display the following output terminal current on
the ammeter.
・Switch Selection
○“R+U”:3-phase R phase + 1-phase U phase (total)
○“S”:3-phase S phase
○“T+W”:3-phase T phase + 1-phase W phase (total)

14
 5-3. Fuel Piping Switch (3 Way Valve)

CAUTION : FIRE
 Always make sure that the engine is stopped when working on piping.
 Always be sure to wipe up any spilled fuel.
 After working on the piping, check that there is no fuel leakage.
Change the 3 way valve to switch to supply fuel from the external tank. In that case,
the internal fuel tank is not used.
(1) If using the internal fuel tank
The 3 way valve is turned to the “A” side when the generator is shipped from the
factory.
< Note >
 When disconnecting piping from the external tank, turn the lever to the “A” side, and attach
the connecting hose to the external tank fuel inlet/return.
(2) If using an external fuel tank
Connect hoses from the external fuel tank to the external fuel inlet and the external
fuel return. Change the lever of the 3 way valve to the “B” side to supply fuel from the
external tank. (Ref.“9-5. Connecting with External Fuel Tank”)

3 Way Valve

External Fuel Return

Position “A”
External Fuel Inlet

Position “B”

Inlet Port Retun Port

Inlet for External
Fuel Supply

6. Transporting/Installing

6-1. Transport Procedures

WARNING : INJURY
 Do not lift up the unit using tie down. Use of such could result in the generator falling.
 No persons should be under a lifted generator at all time.

CAUTION : INJURY
 Always be sure to use lifting hooks when lifting up the generator, and raise it
slowly at a completely vertical angle.
 Personnel performing lifting work must wear protective gear such as helmets,
safety shoes and gloves.
 Do not move the generator during operation.

(1) Lifting Procedures

Always be sure to use lifting hooks when lifting up the generator, and raise it slowly at
a completely vertical angle.

15
 (2) Transport
When transporting this generator, tie rope to the left and right tie downs, and securely
fix the generator.

Lifting Hook Tie-Down

< Note >

 Handle this generator with great care when raising, lowering and transporting. Rough
handling of generator can result in damage or malfunction.
6-2. Installation Procedures

WARNING : EXHAUST GAS POISONING

 Do not operate the generator in poorly ventilated areas such as indoors or
tunnels, as the exhaust gas of the engine contains substances that are harmful
to human health.
 Do not direct exhaust fumes at pedestrians or buildings.

CAUTION : FIRE
 Do not carry flammable items (such as fuel, gas and paint) or items that are
highly combustible near the generator as the muffler, exhaust gas and other
parts become extremely hot.
 Operate this generator 1 m or more from walls or other hindrances, and on a
level surface.
 Remove the wood ties if using anchors to secure the generator
 Do not connect the generator output to indoor wiring.

 If installing this generator, set up barriers or fencing completely around the

boundary line of the construction area and take measures to prevent persons not
involved in the construction from entering the area.
 Always set the generator on a hard, flat and leveled surface that serves as the
foundation.
 Keep the generator 1 m or more from walls or other hindrances so that the
operation panel door and left/right check doors are accessible for internal
inspection/maintenance.
< Note >
 This equipment must be operated on hard and flat surface. Operating under any
other conditions may result in malfunctions.
 Do not block the airflow from radiator vent or muffler exhaust. It may result in
reduced engine performance, overheating, or damage to the electrical parts.
 Operating in dusty area or salty air (by the ocean), or any other particulate
environment may result in clogged radiator, which may cause overheating, other
malfunctions and insulation deterioration. Use extreme care, frequent checks and
maintenance.

16
 7. Load Connections

7-1. Load Cable Selection

CAUTION : PROPERTY DAMAGE
 Cable burnout can occur due to generated heat if the load current exceeds the
allowable current of the cable.
 The voltage drop between cables is large if the cable is excessively long or
thin, resulting in decreased input voltage to equipment using the generator,
thereby causing decreased performance, faulty operation and malfunction.

Select cable for use that has sufficient thickness and an allowable current possible
for use,giving consideration to the distance from the generator to the equipment
using the generator.
< Note >
 Select cable with a thickness that ensures that the voltage drop across the cable will be
within 5% of the rated voltage.

 Load Cable Selection Tables

(Ex.) If used voltage is 220V and voltage drops by 11 V.

3-phase: Cabtyre cables

(Unit: AWG)
Length 100 ft (30 m) 200 ft 300 ft 400 ft 500 ft 600 ft
Current or less (61 m) (91 m) (122 m) (152 m) (183 m)
50 A 8 6 6 4 2 2
100 A 6 4 2 2 1/0 2/0
200 A 2 1/0 2/0 3/0 4/0 4/0
300 A 1/0 2/0 4/0 4/0 4/0 6/0
400 A 1/0 2/0 4/0 4/0 4/0 6/0
(Unit: mm2)
Length 50 m
75 m 100 m 125 m 150 m 200 m
Current or less
50 A 8 14 14 22 30 30
100 A 14 22 30 38 50 60
200 A 38 50 60 80 100 125
300 A 50 60 100 100 125 150
400 A 50 60 100 100 125 150

(Ex.) If used voltage is 100V and voltage drops by 5V.

1-phase: Cabtyre cables
(Unit: AWG)
Length 100 ft (30 m) 200 ft 300 ft
Current or less (61 m) (91 m)
10A 10 10 8
20A 8 6 4
30A 6 4 4
50A 4 2 2
100A 2 1/0 2/0

17
 (Unit: mm2)
Length 50 m
75 m 100 m
Current or less
10A 5.5 5.5 8
20A 8 14 22
30A 14 22 22
50A 22 30 30
100A 30 50 60

7-2.Connecting Load Cables

WARNING : ELECTRIC SHOCK

 Before connecting or disconnecting the load cables to/from the output
terminal, always turn the output circuit breakers to the “OFF” position, stop
the engine, and remove the starter key.
 Close the output terminal cover before operating.
 Do not touch the generator if the Alternator or casing becomes wet during operation.

CAUTION : FIRE
 Do not connect the generator output to indoor wiring.

< Note >

 When connecting a load, check that the generator output setting, output terminal connection
position, and load power source are all matching.
 If using the O terminal, be careful that the currents of each phase are uniform.
 Use proper tools when connecting a load to sufficiently tighten the connection. Failure
to sufficiently tighten the connection will result in cable burnout.
 The 1-Phase terminals and receptacles output power are originated from the R and T Phase
output powers.

(1) 3-Phase Output Terminal

 For 3-phase load

Terminal voltage is 200/220 V [400/440 V] (50/60Hz).
* The values in brackets are for when set to 400/440V.

Load
125/150kVA（100/120kW）

18
 For 1-phase load
Terminal voltage is 115/127 V [230/254V] (50/60Hz).
* The values in brackets are for when set to 400/440V.

Load Load Load

TOTAL 100/120kVA（100/120kW）

 For 1-phase load

Terminal voltage is 200/220 V [400/440 V] (50/60Hz).
* The values in brackets are for when set to 400/440V.

Load Load Load

TOTAL 100/120kVA（100/120kW）

Total output capacity

3-phase load 1-phase load
Unit R-S-T
Total
R-O,S-O,T-O R-S,S-T,T-R
kVA 125/150 41.5/50 72.2/86.6 125/150
kW 100/120 41.5/50 72.2/86.6 100/120

19
 (2) 1-Phase Output Terminals and Receptacle

 For 1-phase load

 The terminal Voltage: 100V/110V at 50Hz/60Hz only.
In the case of no use of 3-Phase output power, refer to the Following drawing
and chart

U1 U0 W1 W0
CON1

CON2

U1-U0 W1-W0
Sub Total

Total

Voltage 100V/110V only

Unit U1-U0 W1-W0 CON1 CON2 Sub Total Total
10 / 11 10 / 11 1.5/1.65 1.5/1.65 10 / 11 20 / 22
kVA
[10 / 11] [10 / 11] [1.5/1.65] [1.5/1.65] [10 / 11] [20 / 22]
10 / 11 10 / 11 1.5/1.65 1.5/1.65 10 / 11 20 / 22
kW
[10 / 11] [10 / 11] [1.5/1.65] [1.5/1.65] [10 / 11] [20 / 22]
* Figures in brackets are used when set to 400/440 V.

< Note >

 If using a 1-phase 100/110 V (between output terminals U1-UO and W1-WO), connect an
equivalent load between U1-UO and W1-UO
 If using a 1-phase output terminal simultaneously with a receptacle output, make sure that
currents passing through R phase is less than the rated current of this generator.

7-3. Earth Leakage Relay and Grounding

WARNING : ELECTRIC SHOCK

 Ground the every grounding terminal to the earth as set in the manual.
 If even one of all is unconnected by mistake or accident, it will be much more
dangerous for human than the NO-RELAY case, because leaking current
inevitably goes through the body.
 Even though all the bonnets of the loads have been grounded to the earth, the
bonnet grounding terminal should be grounded to the earth.
 Grounding should be made after the engine is stopped.
 Whenever the Earth leakage relay is activated, you should always repair the
leaking place first of all.
The generator is provided with the earth leakage breaker relay to detect any
leakage produced due to such the trouble as insulation failure of the load while the
generator is running and to cut off the circuit for protection against any accident
such as electrical shock resulting from the trouble.The specification of the earth
leakage relay;
 Rated Sensitive Current: 30mA (or below) (Grounding resistance: 500Ω or below)
 Sensitive time: Within 0.1 sec.

20
(1) Grounding Work
The qualified electrician should perform Earth
the grounding of the following 3 points Leakage
(500Ωor below). Terminal

 The Bonnet grounding terminal of the generator.

Bonnet
 The Earth leakage terminal of the generator.
Grounding
 The Bonnet of the load. Terminal

< Note >

 In the event you cannot ground the generator to
the earth, consult with the authorized distributor. Grounding Rod
(2) Operation Check

WARNING : ELECTRIC SHOCK

 Before connecting or disconnecting the load cables to/from the output
terminal, always turn the output circuit breakers to the “OFF” position, stop the
engine, and remove the starter key.
 Close the output terminal cover before operating.
 Do not touch the generator if the generator or casing becomes wet during
operation.

Before operating the generator, check always if the device can work.
● Actuation test of the Earth Leakage Relay and 3-Phase Circuit Breaker
Breaker
Ensure that the breakers and the switches of loads
1
are positioned to “OFF”.
2 Ensure that the 3-Phase circuit breaker and the
1-Phase circuit breaker are positioned to “OFF”.
(Ref."4-2.Operation Panel")

3
Following the procedure in 9-1, Initial Startup /
Pre-Check,start an engine. Earth Leakage Relay

4 Turn the 3-Phase circuit breaker and the 1-Phase 1-Phase Circuit Breaker
circuit breaker to “ON”.
Push the TEST button on Earth Leakage Relay.
5
When the button is pushed, the earth leakage
indicator turns “ON” and circuit breakers are
positioned in the middle between “ON” and “OFF”
positions simultaneously, the device works
normally.

6 Push the reset button. The earth leakage indicator

TEST button
turns “OFF” subsequently.

7 Turn (Push-down) the 3-Phase circuit breaker

(lever) and the 1-Phase circuit breaker (lever) to
“OFF” position.
In the event you cannot complete every step of the
above procedure to the end, the device is out of order. Indicator RESET button
Consult with our authorized distributor or our
engineering section and ask to repair. Earth Leakage Relay

21
 (3) Earth leakage Relay has activated
If the earth leakage breaker relay has been activated, the earth leakage indicator
turns ON, and the 3-Phase circuit breaker and the 1-Phase circuit breaker (lever) is
tripped and positioned in the middle between ON and OFF.
When this occurs, stop the engine and repair the location of earth leakage before
restarting operation.（In the case the earth leakage indicating lamp does not turn to
ON simultaneously, the cause is Over-Loaded.）

8. Pre-Operation Inspection

WARNING : ELECTRIC SHOCK/INJURY

 Always be sure to stop the engine and remove the starter key when
performing inspection or maintenance.
 Do not open the check door during operation. Keep away from moving parts
such as cooling fan and fan belt.

CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after
stopping the engine as they are still extremely hot.
CAUTION : FIRE
 Always be sure to wipe up any spilled fuel or oil.

8-1. Checking Engine Oil

To check the engine oil, keep the equipment in leveled position, remove the oil level
indicator and wipe so that no oil remains, and then re-insert the dipstick fully. Prior
to starting the engine, make sure to fill the engine oil through the oil filler until it
reaches the MAX line.
< Note >
 Wait approximately five minutes or more after stopping the engine or adding oil before
checking the oil level again.
 An accurate oil level reading cannot be obtained if the generator is not placed in leveled
position.
 Do not overfill oil to avoid engine damage. MIN MAX
Oil Level
Indicator

Oil Level Indicator Oil Filler

OK Not Too
Left side Right side Enough Much

(1) Engine Oil

Only use API Service Classification “CD” or “CF-4” class.

22
 (2) Engine Oil Viscosity
Use a diesel engine oil with an appropriate viscosity corresponding to the ambient
temperature (refer to the table).
 Relation of Viscosity/Temperature

SAE30

Temp. -30 -15 0 15 25 30 40

(°C)
SAE 10W-30

(3) Engine Oil Replacement Amount

10W
(Unit: L)
Total Lubrication Oil Amount
20 (2)
Value in parentheses is the filter capacity.
8-2. Checking Coolant

CAUTION : BURNS
 Do not open the radiator cap immediately after stopping the engine. Do so
will result in steam gushing out.
 Hot steam gushes out from the coolant sub-tank if the generator overheats.
Do not touch the coolant subtank.

Check that the subtank coolant level is in between FULL and LOW. If the subtank
coolant is lower than the LOW level, add coolant to the subtank and radiator.

(1) Filling the Coolant Sub-Tank

Coolant
Sub-Tank
1 Remove the coolant sub-tank cap.
Fill the sub-tank with coolant until it reaches the FULL
2
FULL line.

3 Re-install the cap. LOW

(2) Filling the Radiator

1 Remove the radiator plate and radiator cap.

2 Fill with new coolant through the filler neck until the
radiator is full.
3 Re-install and tighten the radiator cap.
4 Re-install the radiator plate. Radiator Plate
Radiator Cap &
Filler Neck
< Note >
 Be sure to only use long life coolant (LLC) for the aluminum radiator. The coolant
should be mixed with good quality softened tap water, and contain anti-freezing
and anti-rust components.
 The LLC mix ratio is 30% liquid and 70% water when shipped from the factory.
(Mitsubishi Genuine LLC)
 Be sure to use the same LLC in the sub-tank.
 The mix ratio should be changed according to the ambient temperature but should
remain between 30 and 50%.
23
  Do not increase the LLC mixture ratio unless necessary. Doing so could result in
overheating or another fault/malfunction.
 When replenishing LLC, be sure to use the same brand as the LLC remaining in
the radiator and sub-tank.
 Never use an LLC mixture of two different brands.
 Be sure to completely change every two years or 1,000 hours or less.
 LLC is a toxic substance. Wear rubber gloves and other protective wear when
handling.
 If someone mistakenly ingests LLC, induce vomiting immediately and seek medical
care.
 If LLC gets on skin or clothing, wash with water immediately.
 LLC is flammable. Store in a location where flame is prohibited and it cannot be
accessed by children.
 Engine coolant could leak if the radiator is not completely tightened or there is a
gap in the seating face. Always be sure to securely tighten the radiator cap.
 Do not add engine coolant past the FULL level line of the coolant sub-tank.
(3) Coolant Amount
(Unit: L)
Total Coolant Amount
26(2.3)
Value in parentheses is the coolant sub-tank capacity.

8-3. Checking the Fan Belt

(1) Fan Belt Tension
Press the fan belt by your finger with approx. 98N.
When the belt slick is between 10-15mm, the tension
is normal.
(2) Fan Belt Condition
Visually inspect the belts for signs of wear, missing
grooves, slick or any damage. Replace the belts if
any damage is found.
(3) Fan Belt Adjustment Mounting bolt

1 Loosen the mounting bolts that locates on the

upper and lower position in the alternator.

2 Insert a wrench or a breaker bar under the

alternator and pull the alternator by the wrench or
abreaker bar.
3 Retighten the two mounting bolts.

4 Check the belt tension. If the belt is not tighten

enough, loosen the alternator bolts and try again. Alternator Mounting bolt

< Note >

 If the belts have been damaged or is showing signs of excessive wear, it should
be replaced instead of simply tightened.

24
 (4) Replacing the Fan Belt
Contact a local dealer to replace the fan belt.
< Note >
 Slick spots can cause a belt to slip and may be precursors to overheating and
cracking.
 NEVER operate the generator without the belt guard has been removed.

8-4. Checking the Fuel

CAUTION : FIRE
 This generator uses diesel fuel. Always be sure to stop the engine and not
bring flames close when inspecting fuel or refueling. Wait until the engine has
cooled before performing such procedures.
Check if there is a sufficient amount of fuel and add
fuel if insufficient. The fuel meter on the operation Fuel Inlet Fuel Strainer
panel will only display the fuel level for the internal
fuel tank.
< Note >
 Use Diesel fuel, ASTM D975 No.2-D in the event ambient
temperature reaches down to –5 °C.
 The fuel supply pump, injectors and other parts of the fuel
system and engine can be damaged if any fuel or fuel
additives are used other than those specifically
recommended by the engine manufacturer. Tank Cap Fuel Cover
 Always use the Diesel Fuel Strainer.
 Fill the fuel tank slightly less than the FULL tank level.

8-5. Checking for Fuel, Oil and Coolant Leaks

CAUTION : FIRE
 If fuel or oil is leaking, repair the leaking location before operating.

Open the check door and check for fuel, oil and coolant leakage from fuel piping
connections and similar locations.

8-6. Checking the Battery

CAUTION : EYE/SKIN INJURY

 Wear rubber gloves and other protective wear to protect eyes, skin and
clothing from the battery fluid which contains diluted sulfuric acid. If the
battery fluid contacts eyes or skin, wash out immediately with a large amount
of water. Be sure to receive medical treatment, especially if the fluid contacts
the eyes.
CAUTION : EXPLOSION
 Never use or recharge the battery if the fluid level is below the minimum
level.
 Do not create sparks or bring flame near the battery as it generates
flammable gas.

25
 1 Check the fluid level, and add distilled water
when it is near the lower level until it
reaches the upper level.
Upper Level
Check the terminals for looseness and Lower Level
2
tighten if loose.

< Note >

 It is necessary to recharge the battery when the specific gravity of the battery fluid is 1.23 or
less. Request the authorized distributor where the generator was purchased to recharge the
battery.
 Replacing the Battery
Two batteries are connected in series order. Whenever you replace battery or
disconnect cables, always proceed with the following steps, otherwise battery may
short-circuit.
8.6.1 Replacing the battery installed on the right side toward the operation panel
Hold-Down (－) Post (＋) Post Hold-Down Clamp
(＋) Post
Clamp (－) Post

Right side battery

Left side battery

Remove the clamp and cable from negative (-) post from the battery on the left
1
side. (Always remove negative side first.)
Remove the clamp and cable from positive (+) post from the battery on the left
2
side.
Remove the clamp and cable from negative (-) post from the battery on the right
3
side. (always remove negative side first.)
4 Remove the hold-down clamp from the battery on the right side.
Remove the clamp and cable from positive (+) post from the battery on the right
5
side. Remove the right side battery from the seat.
※Reinstall the new battery in the reverse order. (always install the cable to the
positive (+) post of the new battery first.)
8.6.2 Replacing the battery installed on the left side toward the operation

1
Remove the clamp and cable from negative (-)
(＋) Post Hold-Down (－) Post
post from the battery on the left side. (always Clamp
remove negative side first.)

2
Remove the hold-down clamp from the battery
on the left side.

3 Remove the clamp and cable from positive (+)

post from the battery on the left side.

4 Remove the left side battery from the seat.

Left side battery
※Reinstall the new battery in the reverse order
(always install the cable to the positive (+) post
of the new battery first.

26
9. Operating Procedures

9-1. Initial Startup/Pre-Check

WARNING : EXHAUST GAS POISONING
 Do not operate the generator in poorly ventilated areas such as an indoors
or tunnels, as the exhaust gas of the engine contains substances that are
harmful to human health.
 Do not direct exhaust fumes at bystanders or buildings.

WARNING : INJURY
 Always be sure to check that the breaker on load side and switches for any
equipment using the generator are at “OFF” before turning the breaker to
“ON”. Also be sure to advise personnel on the load side that power will be
turned on before operating the breaker.
 Close all doors and lock them during operation.

CAUTION : FIRE
 Do not carry flammable items (such as fuel, gas and paint) or items that are
highly combustible near the generator as the muffler, exhaust gas and other
parts become extremely hot.
 Position this generator 1 m or more from walls or other hindrances, and on
a level surface.
CAUTION : INJURY
 Do not operate the generator if it has been modified or any parts have been
removed.
 Position the generator on a level stable surface so that it cannot slide or
move in any manner.
 Before starting operation, always be sure to turn off all switches of equipment
being used and breaker to “OFF”.

< Note >

 Check that the surrounding area is safe before starting the engine.
 When there are multiple workers who are working together, they must mutually
signal each other before starting the engine.
 Do not use in an area with high temperature or humidity, or an area with a large
amount of dust.
 Do not open any doors during operation. Operating with door open can negatively
affect cooling effect, resulting in an equipment malfunction.
 Use ear protection if the level of noise is high. Failure to do so could result in
hearing damage.
 Please be careful about a strong wind and the opening and shutting of the door at
the sloping place enough. A door is open suddenly and is closed, and a finger might
be sandwiched.
Turn the circuit breaker for 3-phase and Throttle Lever Preheat 3-Phase Circuit
1 Lamp Breaker
1-phase to OFF.
2 Check that the frequency set by the
selector switch and equipment shoud be
identical.
< Note >
 Frequency being set at the frequency
selector switch and actual output shall
be reconciled otherwise it cannot
preserve the rated voltage. Frequency Starter
Adjust Screw Switch

27
 3 Set the throttle lever to “IDLING”. 1-Phase Circuit Breaker

4 Turn the starter switch to “START”, and start the

engine.
< Note >
 In a cold environmental condition, turn the
starter switch to “PREHEAT” position.The
preheat lamp converts to red after approx. 15
sec., after preheating completes.
 Do not leave the starter key at “PREHEAT” over 30 sec. otherwise it may
damage the preheating feature.
 Do not continue operation the starter motor for 10 sec. or more.
 Remain an interval for 30 sec. each at least if the starter should continuously
operated.
5 After starting the engine, remove your hand from the starter switch.

6 Let engine idles for approximately for five minutes.

7 Set the throttle lever to “RUN” and adjust frequency with the frequency adjust
screw.
Rated frequency No-load frequency
50Hz(1,500min-1) 52.5Hz(1,575min-1)
60Hz(1,800min-1) 63.0Hz(1,890min-1)
8 Adjust the voltage regulator dial to the specified voltage.
50Hz Operation 200V [400V]
60Hz Operation 220V [440V]
* The values in brackets are for when set to 400/440V.
9 Turn the breaker to “ON to start AC power delivery.

9-2. Procedures during Operation

(1) Checks after Startup

 Make sure that all meters and indicators are in normal status. ( Ref. “5. Equipment”)
 Check that there is no abnormal vibration or noise.
 Check that the exhaust gas color is normal. When operation is normal, the exhaust gas
should be colorless or slightly bluish.
< Note >
 If abnormal, stop using this generator and request authorized distributor where the
generator was purchased to repair the generator.
(2) Adjustment during Operation
During load operation, check the voltmeter and finely adjust voltage using the
voltage regulator dial.
 Bleeding air from the fuel system when the engine stops due to running out
of fuel
If air enters the fuel system, it must be expelled in accordance with the following
procedure before the engine can be started. It is not sufficient only to fill the fuel
tank.
28
 1 Refuel. Air bleed plug
2 Turn the starter switch to “RUN” and activate the
electromagnetic pump. Do not turn the starter key to Fuel Filter
“START” and start the engine. (Main)

3 Loosen the air bleed plug mounted the fuel filter.

Cover the the air bleed plug with a soft cloth.

4 Tighten the air bleed plug after babbles are not

confirmed visually.
Air bleeder plug tightening torque
8 ~ 12 N･m(0.8 ~ 1.2 kgf･m)
Do not overtorque the air bleed plug.
5 Wipe and clean if it spilled fuel.
Set the throttle lever to “IDLING”. Start the engine. Repeat the stop #3 if the
6
engine did not start.
7 Start the engine and check that the air is bled off completely from the fuel system.
The fuel injection pump will be air-bled automatically when the engine is started.

8 Make sure that there is no leaking the fuel from the seal point.

9-3. Stopping Operation

CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after
stopping the engine as they are still hot.

1 Turn the switches and breakers on the load side to “OFF”.

2 Turn the circuit breaker for 3-phase and 1-phase to OFF.

3 Set the throttle lever to “IDLING”.

4 The engine cools down for approximately 3 minutes.

5 Turn the starter switch to “STOP”.

9-4. Protective Functions

WARNING : INJURY
 Do not open the check door during operation. Be careful of pinching or
catching of moving parts such as the cooling fan and fan belt.
 Always be sure to stop the engine and remove the starter key when
performing inspection or maintenance.

CAUTION : BURNS
 Do not open the check door during operation. Keep away from moving parts
such as cooling fan and fan belt.
 Hot steam gushes out from the coolant subtank if the generator overheats.
Do not touch the coolant subtank.

This generator is equipped with functions to automatically stop operation when there
is a fault/malfunction during operation, and one to warn the operator of the fault

29
 location by use of indicator lamps. Check the fault location when the engine is
automatically stopped or an indicator lamp lights up to stop the engine.

Protection Feature List

Earth
Action Engine Warning
Leakage Breaker
No. Automatic Indicator Cause
Relay Trip
Abnormality Shutdown Blinking.
Active
High Water Activates due to high water temperature
1    
Temperature in the engine. Default 100°C

Low Oil Activate due to low oil pressure in the

2    
Pressure engine. Default 0.98  100 kPa
Monitor Lamp

Battery
3 Charge   －  Activates in battery charge Impossible.
Insufficient
The element is clogged making it
Air Filter
4     necessary to clean or replace the
Clogging Up
element.
Water
When the water separator is full of
5 Separator    
Fluid Level water.

6 Current Leakage     Activates in current leakage.

Activates in overload.
Flashes when at approx 80% of rated
7 Overload     output.
Load rejection when the rated output is
exceeded.
*  indicates the automatic activation.

9-5. Connecting with External Fuel Tank

CAUTION : FIRE
 Always make sure that the engine is stopped when working on piping.
 Always be sure to wipe up any spilled fuel.
 After working on the piping, check that there is no fuel leakage.

1 Turn the 3 way valve toward position “A”. 3 Way Valve

(to supply fuel from the internal tank.)
2 Remove the connecting hose from the
3 way valve.
3 Remove the plate.
4 Pass the fuel hose from the external tank
through the inlet for the external fuel
supply and connect the inlet and outlet External Fuel Ports Plate
valve in the 3 way valve.
5 Turn the 3 way valve lever to the Return Side Connecting Return Port
position “B”. (to supply fuel from the Hose
external tank.)
6 Bleed air from the hoses from the
external tank. Steps to supply fuel from
the external tank completed. Inlet Side Inlet Port

< Note > Position “A” Position “B”

 Protect the piping connecting the

30
 external fuel tank and this generator with
corrugate tubing or similar in order to prevent External Tank
interference between the generator internal parts
and the external fuel ports.
 If using a hose for the piping, use oil-resistant
hose with an internal diameter of 8 to 9 mm.
 Set the fuel level of the external fuel tank from 0
to 3 m from the underside of this generator. The
fuel level of the external fuel tank being lower
than this generator will result in poor engine
operation or stoppage.
 Turn the 3 way valve lever to the “A” side in order to prevent fuel from flowing out
from the external tank fuel inlet/return.
 Turn the lever completely as far as possible. If the lever is not completely pressed
to either side, it might not be possible to supply fuel causing the engine to stop.
 Extend the supply side outlet 15 to 20 mm above the bottom of the external tank in
order to prevent foreign material or water from being suctioned.
 Set the external fuel tank return side inlet as same height as the supply side in
order to prevent poor engine operation due to air mixed in with the fuel.
 Refer to section “9-2.(2) Adjustment during Operation” for air bleeding.
 Some air may remain in hoses or pipes immediately after connecting the external
fuel tank resulting in unstable engine speed and engine stoppage.
 Do not leave the generator unattended for unmanned operation until you have
confirmed that the engine speed is stable.

31
10. Inspection/Maintenance

WARNING : ELECTRIC SHOCK/INJURY

 Do not touch output terminals or internal electric parts while the generator is
operating.
 Do not open the check door during operation. Keep away from moving parts
such as cooling fan and fan belt.
 Always be sure to stop the engine and remove the starter key when
performing inspection or maintenance.
 Do not lift up using tie downs. Use of such could result in the generator
falling.
 No persons should be under a suspended generator at all time.

CAUTION : FIRE
 Always be sure to wipe up any spilled fuel or oil.

CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after
stopping the engine as they are still hot.
 Do not open the radiator cap immediately after stopping the engine. Do so
will result in steam gushing out.
 Hot steam gushes out from the coolant subtank if the generator overheats.
Do not touch the coolant subtank.
CAUTION : INJURY
 Personnel performing suspension work must wear protective gear such as
helmets, safety shoes and gloves.
 Always be sure to use lifting hooks when suspending the generator, and raise
it slowly at a completely vertical angle.

Perform periodic inspection and maintenance according to the following table in

order to constantly maintain this generator in good working condition. Use the hour
meter as a reference for the operating time.
< Note >
 All procedures except for pre-operation inspection should be performed by specialized
technicians.
 Request authorized distributor where the generator was purchased to perform the
procedures in the table with a “”.
 Always be sure to use genuine parts or those indicated specifically for replacement parts.
 Use a container to catch fluid bled from this generator that is large enough to prevent the
fluid from spilling on the ground.Dispose of oil, fuel, coolant (LLC), filter, battery and other
hazardous materials according to laws and regulations concerning industrial waste.Contact
authorized distributor where the generator was purchased if you have any inquiries
regarding proper disposal.
 When check doors are open during maintenance, take measures so that unrelated
personnel cannot accidentally come close to the generator. Close all doors and covers if
you are going to be away from this generator.
 Please be careful about a strong wind and the opening and shutting of the door at the
sloping place enough. When door is opened or closed suddenly, a finger might be
sandwiched.

32
 Description Daily Every Every Every
250 hrs. 500 hrs. 1,000 hrs.
Each parts

(Clean/Tightening)
Engine oil

(Check/Add)
Engine oil 
1st time at 
(Replace) 60 hrs.
Oil filter 
1st time at 
(Replace) 60 hrs.
Coolant

(Check/Add)
Coolant (Replace/ 
Radiator Flush) or 2 years
Exhaust color

(Check)
Water separator

(Check/Drain 
(Drain)
excess water and sediments)
Water separator/element

(Replace)
Fuel filter/element

(Replace)
Fuel tank

(Drain water)
Fuel tank

Engine

(Clean)

Clean gauze filter in engine feed pump (Clean)
Check for leaks

(Fuel/Oil/Coolant)
Fuel/Cooling

Water/Oil Hoses and Anti-Vibration Rubber
or 1 year
(Replace)
Air filter element  
(Clean/Replace) (Clean) (Replace)
Battery fluid level

(Check/Add)
Battery gravity

(Check)
Fan belt tension

(Check)
Fan belt

(Replace)
Radiator and Intercooler
(Clean) 

Valve clearance

(Check/Adjust)
Fuel injector

(Check)
Elimination of carbon in the exhaust

pipe line and muffler

Indicators, Gauges Alarms (Check) 

Generator

Operation check of Earth Leakage Relay 

Grounding resistance check 

Insulation test 

33
(1) Engine Oil Replacement
First Time 60 hrs.
Thereafter Every 250 hrs.
Oil Filler cap
1 Place a suitable pan under the oil drain plug.

2 Remove the oil filler cap.

3 Remove the oil drain plug together with a

packing. Turn and open the oil drain valve and
drain the engine oil. Oil Level Indicator

4 Close the oil drain valve after drained.

Retighten the oil drain plug together with a
new packing.Do not reuse the packing.
Packing part no.:V106-000210
Oil Drain Valve
Add oil through the oil filler until it is at the (inside)
5
maximum level while checking the oil level
using the oil level indicator.
6 Attach the oil filler cap. Oil Drain Plug
with Packing

< Note >

OPEN
 Refer to section “8-1. Checking Engine Oil” CLOSE
for engine oil replacement amounts and types.
Packing
 After reinserting the oil drain plug and shortly
after starting the engine, be sure to always
Oil Drain Valve
check that there is no oil leakage.
Oil Drain Plug

(2) Replacing the Oil Filter

Fist time 60 hrs.
Thereafter Every 500 hrs.
1 Drain the engine oil. ( Ref.“(1) Engine Oil Oil Filter
Replacement” )
2 Place a suitable pan under the oil filter to collect
receive the oil when it is drained out. Remeve the
drain plug and drain the oil in the filter.
3 Remove the oil filter element by a filter remover. Drain plug

4 Use the Mitsubishi genuine oil filter element. Oil filter

element part no.:ME130968 (Mitsubishi part no.) Gasket

5 Apply oil to the surface of the gasket. Mark

6 Insert the oil filter element by hand until the gasket Loosen
contacts the seal surface. (Do not use a filter wrench.)
Turn the filter element by 1・1/8 to 1・3/8 turns to Tighten Drain plug
7
clockwise. Use the markings in the filter element for
reference. Oil Filter Element

8 Add new lubricant oil. Wipe off the spilled fuel.

9 Start the engine. Make sure that there is no leaking the oil from the sealing point.
< Note >
 Contact a local dealer if you are unsure to step the procedure above or if you do
not have a filter remover.
 When attaching the Element, check that there is no foreign material adhering to
the gasket.

34
(3) Air Filter Element Cleaning/Replacement
Clean 250 hrs.
Clip
Replace Every 1000 hrs. Cleaner Cap
1 Remove the air cleaner clips and cleaner. Air Cleaner

2 Remove the air filter element.

Clean or replace the air filter element, and reinstall Vacuator Valve
3
it in reverse order. Air filter element part no.:
ME442325 (Mitsubishi part no.)
< Note >
 Always be sure to turn the cleaner cap in the direction Cleaner Cap
indicated by the arrow. Air Filter Element
 Replace the elements earlier if using in an
excessively dusty location.
 Do not add oil as this generator uses a dry element.
 Clear foreign material by pinching the vacuator valve
once a week in normal operating conditions or daily if
operating in a location that is excessively dirty or
dusty. Wipe away any dirt or moisture that has
adhered to the parts.
 Never touch the elements for any reason except cleaning.
 Cleaning the air filter element
If dry dust is adhering. : Blow compressed air from inside the element.
If carbon or oil is adhering : Replace with new parts.
(4) Draining Water from the Water Separator
Check Daily
3-Way Valve
Clean every 250hrs. or when the
Clean warning lamp “WATER
SEPARATOR” is blinking.
1 Turn the selector lever mounted the inlet hose in
3- way valve to “Y” direction. So the fuel supply
from the internal tank is cut.
2 Set a container to catch spilled water.
3 Loosen the air bleeder plug of the fuel filter Inlet hose
sufficiently.
4 Loosen the faucet on the bottom to drain water. “X”

5 Tighten the faucet and the air-bleeding plug after “Y” Selector leve
drained the water.
Faucet tightening torque Air Bleeder
1.5 ~ 2.5 N･m(0.15 ~ 0.25 kgf･m) Plug
Air bleeding plug tightening torque
8 ~ 12 N･m(0.8 ~ 1.2 kgf･m)
Do not overtorque the drain plug and air bleeder plug.
6 Turn the selector lever to "X" direction.
Faucet
7
Bleed air to the fuel system. (Ref.“9-2.(2)
Adjustment during Operation”)
8 Start the engine. Make sure that there is no leaking the oil from the sealing point.
< Note >
 When the outer case is filled with water, drain and separate water from the
fuel tank. (Ref.“10.(7) Draining Water from the Fuel Tank”)

35
 (5) Pre Fuel Filter Replacement (Water Separator)
Replace Every 500 hrs.
3 Way Valve
1 Turn the selector lever mounted the inlet hose in 3
way valve to “Y” direction. So the fuel supply from
the internal tank is cut.
2 Set a container to catch spilled fuel.
3 Loosen the air bleeder plug of the fuel filter Inlet hose
sufficiently.
4 Loosen the faucet on the bottom to drain the fuel. “X”

5 Remove the fuel filter element.

“Y” Selector leve
6 Install the new fuel filter element.

7 Replace the O-ring of the outer case. Fuel Filter element

Air Bleeder
Plug
8 Spread a thin layer of fuel on a new O-ring.

9 Thread the outer case by hand, (do not use a

filter wrench) and it in until the O-ring contacts
the seal surface, and then tighten it using the
special filter wrench.
10 Tighten the drain plug on the bottom and the
air-bleeding plug. Outer case

Drain plug tightening torque Faucet

1.5 ~ 2.5 N･m(0.15 ~ 0.25 kgf･m)
Air bleeding plug tightening torque Filter Wrench
8 ~ 12 N･m(0.8 ~ 1.2 kgf･m)
Outer case tightening torque
18 ~ 22 N･m(1.8 ~ 2.2 kgf･m)
Do not overtorque the drain plug and air bleeder
plug.
11
Turn the selector lever mounted the inlet hose in
3 way valve to “X” direction. So the fuel path
from the internal tank is reopened.
12 Wipe off the spilled fuel on any component.

13 Bleed the air from the fuel system. (Ref.“9-2.(2) Adjustment during Operation”)

14
Start the engine. Make sure that there is no leaking the fuel from the sealing
point.
< Note >
 When attaching the outer case, check that there is no foreign material adhering to the
O-ring.
 After attaching, be sure to always start the engine and check that there is no fuel leakage.
 If water is accumulate in the cup, draining water from the fuel tank and the water separator.
 Filter element ( Including O-ring ) part no.: G260-000120
 Filter Wrench part no.: X602-000450

36
(6) Fuel Filter Replacement（Main Filter）
Replace Every 500 hrs.
Mating Mark
1 Remove the fuel filter element by a filter remover.

2 Use the Mitsubishi genuine fuel filter element. Fuel filter (Main)
Fuel filter element part no. :ME056670(Mitsubishi
part no.)
3 Apply fuel to the gasket in the fuel filter element.

4 Install the oil filter by hand until the gasket

contacts the seal surface.
5 Tighten the filter by 2/3 turn to clockwise with
filter wrench. Gasket
6 Start the engine. Make sure that there is no
leaked fuel from the seal point. Mark
Fuel Filter Element
< Note >
 When attaching the Element, check that there is assembly
no foreign material adhering to the gasket.
(7) Draining Water from the Fuel Tank
Drain Water Every 250 hrs.
Fuel Drain Valve
1 Place a suitable pan under the drain plug. (inside)

Remove the fuel drain plug together with a OPEN

2
packing. Turn and open the fuel drain valve and
drain the water.
Close the drain valve after drained. Retighten CLOSE
3
the fuel drain plug together with a new packing.
Do not reuse the packing. Fuel Drain Plug
Packing part no.:V106-000190 with Packing

4 Make sure that there is no leaking the fuel

from the seal point.
(8) Coolant Replacement
Every 2 yrs. or Every 1000 hrs.
Replace
(whichever come first)

Coolant
Radiator Plate Sub-Tank
Drain Valve
FULL

LOW
Drain Hose

Radiator Cap &

Filler Neck

1 Place a suitable pan under the drain hose.

2 Remove the radiator plate and the radiator cap.
3 Loosen the drain valve.

4 Retighten the drain valve after drained.

5 Remove the coolant sub-tank and drain coolant from the sub-tank, if necessary.

37
 6
Reinstall the sub-tank and fill the sub-tank with new coolant to “FULL” marking in
the sub-tank.

7 Fill the radiator with new coolant to the opening of the radiator cap. Use a jug if
necessary.Fill the radiator with coolant/water to the top.
8 Reinstall the radiator cap and fasten the radiator plate.

9 Make sure that there is no leaking after reinstalled the drain plug.

< Note >

 Refer to section “8-2. Checking Coolant” for more information.
(9) Elimination of carbon in the exhaust pipe line and muffler

WARNING : EXHAUST GAS POISONING

 Do not operate the generator in poorly ventilated areas such as an indoors or
tunnels, as the exhaust gas of the engine contains substances that are
harmful to human health.
 Do not direct exhaust fumes at bystanders or buildings.
WARNING : INJURY
 Always be sure to check that the breakers on load side and switches for any
equipment using the generator are at “OFF” before turning the breaker to
“ON. Also be sure to advise personnel on the load side that power will be
turned on before operating the breaker.
 Close all doors and lock them during operation.

CAUTION : FIRE
 Do not carry flammable items (such as fuel, gas and paint) or items that are
highly combustible near the generator as the muffler, exhaust gas and other
parts become extremely hot.
 Position this generator 1 m or more from walls or other hindrances, and on a
level surface.
CAUTION : INJURY
 Do not operate the generator if it has been modified or any parts have been
removed.
 Position the generator on a level stable surface so that it cannot slide or
move in any manner.
 Before starting operation, always be sure to turn off all switches of equipment
being used and all breakers to “OFF”.

Clean Every 250 hours

The carbon will be easier to be accumulated when the unit runs at less than 30% of
rated output. Accumulation of carbon (soot, unburned fuel) in the exhaust system
could cause only a system decrease or an engine fault occurs. To eliminate soot and
unburned fuel, run the unit at more than 70% of the rated output for about half an hour,
until the exhaust gas become mostly colorless.
< Note >
 When the unit runs at rated power suddenly, accumulation of carbon in the exhaust system
might cause back fire incident. Operate the generator starting from 50% of the rated output
and then increase load gradually after confirming exhaust gas become colorless. Do not
carry flammable items that are highly combustible near the generator.

38
11. Long-Term Storage

WARNING : INJURY
 Always be sure to stop the engine and remove the starter key when
performing inspection or maintenance.

CAUTION : FIRE
 Always be sure to wipe up any spilled fuel or oil.
 Allow the generator to cool before covering with the protective cover.

CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after
stopping the engine as they are still extremely hot.

(1) Storage Procedures

Perform the following maintenance procedures before storing this generator if it is not
going to be used for two months or more.

1 Remove the battery.

(Ref.“8-6. Checking the Battery Replacing the Battery”)
2 Replace the engine oil.
(Ref.“10. Inspection/Maintenance (1) Engine Oil Replacement”)
3 Drain the fuel from the fuel tank and filter.
(Ref.“10. Inspection/Maintenance (4)Draining Water from the Water Separator”)
(Ref.“10. Inspection/Maintenance (7) Draining Water from the Fuel Tank”)
4 Remove the starter key and store in a secure location.

5
Clean up all generator components, and store in a dry and dust-free location. Also cover
when storing so that rain cannot enter through the suction or exhaust ports.
< Note >
 Adjust the fluid of the removed battery to the appropriate level and recharge
approximately every month.

39
 (2) Double-Stacking Procedures

WARNING : INJURY
Always be sure to observe the following items when double stacking this generator in
a warehouse or similar location.
 Check that the hood of this generator is not dented,
and that bolts are not loose or missing.
 Set in a location with a flat hard floor capable of
withstanding the double-stacking weight.
 Always be sure to use lifting hooks when lifting this
generator.
 Insert wood ties of the same size and that are wider
than this generator between each generator, and set
another generator on top of the ties.
 Never stack more than two levels, and do not set a
generator on top that is larger in weight/size than that
on the bottom.
 Do not operate the generator when it is double
stacked.

12. Troubleshooting

WARNING : ELECTRIC SHOCK/INJURY

 Do not touch output terminals or internal electric parts while the generator is
operating.
 Do not open the check door during operation. Keep away from moving parts
such as cooling fan and fan belt.
 Always be sure to stop the engine and remove the starter key when
performing inspection or maintenance.

CAUTION : FIRE
 Never allow flame to come close to the generator.

CAUTION : BURNS
 Do not touch the engine and muffler after stopping the engine as they are still
extremely hot.

Inspect this generator when operation is poor to determine the fault/malfunction.

Request the authorized distributor where the generator was purchased to perform
maintenance if you cannot find any faults/malfunctions during inspection.

Problem Suspected cause Action

Starter motor 1. Battery output is weak. 1. Check / battery liquid / or

Engine does not start

does not drive Charge.

or speed is 2. Battery is deteriorated. 2. Change battery
low. 3. Battery terminal is OFF or loose. 3. Fix / Tighten terminal
4. Battery terminal is corroded. 4. Clean terminal
5. Starter switch or relay is defective. 5. Ask our distributor to repair
6. Starter motor is defective. 6. Ask our distributor to repair

40
 Problem Suspected cause Action

Starter motor 1. Fuel is insufficient 1. Add fuel

runs but 2. Fuel filter is clogged 2. Clean/Change fuel filter
engine does 3. Water is interfused in fuel line 3. Drain water in water
not start. separator, fuel filter or fuel
tank
4. Air is interfused in fuel line 4. Extract the air
5. Poor piping connection to external fuel 5. Check piping connection
Engine does not start.

tank
6. Fuel tank selector lever (3 way valve) 6. Check lever (3 way valve)
position is wrong
7. Fuel cut solenoid (motor) does not work 7-1. Check/Change fuse
7-2. Check/Change fuel cut
Solenoid
8. Fuel pump defective 8-1. Check/Change fuse
8-2. Check/Change fuel pump

<Ambient 1. Fuel is frozen 1. Use winterized fuel

temperature 2. Water in fuel line is frozen 2. Drain water in fuel line
falls down 3. Pre-heater is defective 3. Ask our distributor to repair
below zero.>

Engine starts but 1. Fuel filter is clogged 1. Clean/Change fuel filter

stalls immediately. 2. Water is interfused in fuel line 2. Drain water in water
separator, fuel filter or fuel
tank
3. Air is interfused in fuel line 3. Extract the air
4. Poor piping connection to external fuel 4. Check piping connection
tank
5. Air filter element is clogged 5. Check/Change air filter
element
6. Lubricant oil is insufficient 6. Supply lubricant oil
7. Emergency operation/Fault detection 7. Ask our distributor to repair

Engine oil pressure 1. Lubricant oil is insufficient 1. Supply lubricant oil

is low. 2. Oil filter is clogged 2. Change oil filter
3. Oil Pressure switch is defective 3. Ask our distributor to repair
4. Wrong oil is used 4. Change to proper kind and
viscosity oil
Overheated 1. Engine thermostat is defective 1. Ask our distributor to repair
2. Water temp sensor is defective 2. Ask our distributor to repair
3. Water temp meter is defective 3. Ask our distributor to repair
4. Fan belt tension is weak 4. Check/Adjust fan belt
5. Coolant is insufficient 5. Check/Supply coolant
6.Radiator core is clogged 6. Clean radiator core
Black smoke comes 1. Air filter element is clogged 1. Check/Change air filter
out from muffler. element
2. Fuel injection nozzle is defective 2. Ask our distributor to repair
3. Improper fuel is used 3.Change to clean fuel

41
 Problem Suspected cause Action

White smoke comes 1. Too much or too little oil to cylinder 1. Ask our distributor to repair.
out from muffler 2. Water is interfused in fuel line 2. Drain water in water
separator, fuel filter or fuel
tank
3. Fuel injection nozzle is defective 3. Ask our distributor to repair
4. Coolant temperature is too low 4. Warm-up driving is needed
5. Engine thermostat is defective 5. Ask our distributor to repair
Needle indication 1. Voltage meter is defective 1. Ask our distributor to repair
Does not move in 2. AVR is defective 2. Ask our distributor to repair
Voltage meter 3. Disconnected circuit, loose terminal or 3. Ask our distributor to repair
departed
4. Initial exciter is defective 4. Ask our distributor to repair
5. Alternator is defective 5. Ask our distributor to repair
6.AVR protective device operation 6. Replace AVR fuse
Needle indication 1. Voltage meter is defective 1. Ask our distributor to repair
does not goes up to 2. AVR is defective 2. Ask our distributor to repair
the rated voltage 3. Voltage regulator dial is defective 3. Ask our distributor to repair
4. Frequency is low 4. Ask our distributor to repair
Needle indication 1. Voltage meter is defective 1. Ask our distributor to repair
exceeds the rated 2. AVR is defective 2. Ask our distributor to repair
voltage 3. Improper load cable connection 3. Correctly set the connection
location to the output
terminal
The voltage drops 1. AVR is defective 1. Ask our distributor to repair
drastically when 2. Unbalanced loads sharing to each 2. Balance the loads sharing
connecting to load terminal to each terminal
3. The current of the used equipment 3. Change to a device with an
exceeds the rated current available capacity
Loads total exceeds the rated current
4. Over load 4. Decrease the loads to meet
the rated output
5. AVR protective device operation 5. Replace AVR fuse
6. Frequency selector is wrong setting 6. Set to properfrequency
Cannot turn the 1. The breaker positions at between 1. Once turning the lever to
breaker to “ON” “ON” and “OFF” “OFF”, turn it to “ON”
position 2. Short circuit on the load 2. Check the load circuit
3. Earth Leakage Relay operates 3. Repair the earth leakage
location
The breaker trips to 1. Current monitor setting is incorrect. 1. Ask our distributor to repair
“OFF” position at
light load
The overload 1. Current monitor setting is incorrect. 1. Ask our distributor to repair
pre-caution lamp
flashes at 80% or
less of the rated
output.
The overload 1. Current monitor setting is not correct. 1. Ask our distributor to repair
pre-caution lamp
does not flashes at
80% or more of the
rated output.

42
13. Generator Circuit Diagram

(1) 200/220V

43
(2) 400/440V

44
14. Engine Electrical Circuit Diagram

45
©2019