Owner S and Operator S Manual: Vertical, Water-Cooled 4-Cycle Diesel Engine
Owner S and Operator S Manual: Vertical, Water-Cooled 4-Cycle Diesel Engine
CAUTION
Do not operate the Generator, or any other appliance, before you have read and
understood the instructions for use and keep near for ready use.
DG25MK-200/TWN
X753-007 03 0
X753801-080 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.
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
1. Safety Instructions
WARNING : INJURY
Close all doors and lock them during operation.
Close all doors and place locks during operating this equipment, to avoid injuries by
unintentionally touching cooling fan and fan belt.
Before performing any equipment check or maintenance, stop the engine, and remove the
engine key. A person performing the maintenance should always keep the key.
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 lifted generator.
Before turning the circuit breaker to ON position, ensure that the breaker or the switch of loads
are positioned to OFF.
Operate the circuit breaker, well-communicating with the electrician by the load side.
2
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.
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 bring flammable items (such as fuel, gas and paint) or items that are highly combustible
near the generator as the muffler, exhaust gas and other parts become extremely hot.
Keep this generator 1m or more from walls or other hindrances, and on a level surface.
Do not connect the generator output to indoor wiring.
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 : BURNS
Do not touch the engine and surrounding components immediately after stopping the equipment,
while temperature can reach extremely high.
Do not open the radiator cap immediately after stopping the engine, to avoid sustaining burns
from hot vapor.
Hot steam gushes out from the coolant sub-tank if the generator overheats. Do not touch the
coolant sub-tank.
Always be sure to stop the engine and allow the engine to cool when performing inspection or
maintenance of engine oil. Opening the oil level indicator or oil filler cap during operation will result
in hot oil cause personal injury.
CAUTION : INJURY
Always be sure to use lifting hooks when moving the generator, and lift it slowly at a completely
vertical angle.
Personnel performing lifting work must wear protective gear such as helmets, safety shoes and
gloves.
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.
3
CAUTION : PROPERTY DAMAGE
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.
4
2. Specifications
2-1. Specifications
Model Unit DG25MK-200
Rotating Filed, Brushless 3-Phase
Generating Type -
Synchronous Alternator
Rated Frequency Hz 50 60
kVA 20 25
Rated Output
kW 16 20
Alternator
Height mm 1000
Dry Weight kg 625
Installed Weight kg 705
*1: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
4. Part Names
Lifting Hook
Tie-Down
Tie-Down
Operation Panel Door
Fuel Inlet
6
Radiator Plate
Radiator
Fuel Filter
Coolant Sub-Tank
Alternator Check Door
Engine Check Door
Oil Filter
Accessories
7
4-2. Operation Panel Part Names
8
4-3. Output Panel Part Names
9
5. Equipment
WARNING : INJURY
Close all doors and place locks during operation, to avoid injuries by
unintentionally contact with moving parts such as the cooling fan and fan belt.
Before performing any equipment check or maintenance, stop the engine, and
remove the engine key. A person performing the maintenance should always
keep the key.
CAUTION : BURNS
Do not touch the engine and surrounding components immediately after
stopping the equipment, while temperature can reach extremely high.
This generator is equipped with the following warning indicators: CHARGE (battery
charge), OIL PRESS (engine oil pressure), WATER TEMP (coolant temperature), OVER
SPEED (engine overspeed), AIR FILTER (air cleaner clogging), and WATER
SEPARATOR (water separator amount). An indicator lights up 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 PERSS warning indicators light up when the
starter switch is switched from STOP to RUN, and all warning indicators turn off when the
engine is started.
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 115 °C during operation, the WATER TEMP and
ENGINE warning indicators light up, 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. (Refer to
section “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 0.49 x 100 kPa during operation, the OIL PRESS
and ENGINE warning indicators light up, 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. (Refer to section “8-1. Checking Engine Oil”.)
11
(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 1000min-1, and
wait until the reading falls to the normal temperature range.
(3) Fuel Gauge
It shows the volume in the fuel tank.When filled up, it shows 『F』.
When the hand is approaching to『E』, the volume is coming to empty.
Replenish fuel enough promptly.
Lamps
(1) Preheat Lamp
When the starter switch is turned to <Preheat> position, the preheat
lamp will be turned ON. The preheat lamp will be turned OFF after
preheating completes showing the engine start possible.
< Note >
Preheating time varies to coolant temperature, usually about 3-10 seconds.
(2) Pilot Lamp
This lights up when the engine is operating to indicate that power is
being generated.
(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 current exceeds around 80% of the
rated current. Use this generator in a range that does not exceed the
rated current while the lamp is flashing. The lamp turns off when the
output current drops below 80% of the rated current.
This generator is equipped with an Aux Lamp Terminal. DC 12 V is output to the Aux Lamp
Terminal at the same time as when the Over Load Pre-caution Lamp is flashing.
12
Refer to the circuit drawing below if using the Aux Lamp Terminal for a lamp or similar
device with a different setting.
Switches
(1) Starter Switch
1. Stop
When the switch is set to this position, all power will be off. STOP
RUN
The switch must be set to this position to remove the key.
PREHEAT
2. Run
The switch must be set to this position during operation. START
Over-Current Protectors
(1) Thermal Relay (Over Load)
This relay sends a trip signal to the 3-Phase circuit breaker and
the 1-Phase breaker when an over-current flows in the
circuit.When the breaker is tripped, it is set at the middle
between ON and OFF. If this occurs, reset the breaker
according to the following procedure.
Adjustment
Stop the engine. Dial
1
2
Wait approximately 1 minute before attempting Thermal Relay
to reset the breakers to allow the thermal relay (Over Load)
to automatically reset.
3 Turn the breakers to the “OFF” position.
4 Turn the breaker to the “ON” position.
FREQUENCY
50Hz 60Hz
Output Volt 200V 208V 200V 220V
Adjustment Dial Value 2.9 2.8 3.6 3.3
14
(2) Thermal Relay (Over Load Pre-caution Lamp)
If changing the frequency or voltage, change the Thermal Relay
(Over Load Pre-Caution)
Thermal Relay (Over Load Pre-caution Lamp)
adjustment dial according to the following table.
FREQUENCY
50Hz 60Hz
Output Volt 200V 208V 200V 220V
Adjustment Dial Value 2.2 2.1 2.7 2.5
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 fuel valve to switch to supply fuel from the external tank. In that
case, the internal fuel tank is not used.
3Way Fuel
Valve
15
6. Transporting/Installing
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.
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.
CAUTION : FIRE
Do not bring flammable items (such as fuel, gas and paint) or items that are
highly combustible near the generator as the muffler, exhaust gas and other
parts become extremely hot.
Keep this generator 1m or more from walls or other hindrances, and on a
level surface.
Remove the wood ties if using anchors to secure the generator
Do not connect the generator output to indoor wiring.
16
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.
7. Load Connections
17
(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
40A 4 2 2
(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
40A 22 30 30
18
7-2. Connecting Load Cables
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.
When 3-phase output is used simultaneously with a 1-phase output, total current shall not
exceed the rated current.
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 Phase output
powers.
R S T O
Load 20/25kVA(16/20kW)
For 1-phase load:
Terminal voltage is 115/127 V [230/254 V] (50/60Hz).
* The values in brackets are for when set to 400/440V.
R S T O
Load 6.7/8.3kVA(6.7/8.3kW)
19
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.
R S T O
Load Load
TOTAL 11.5/14.4kVA(11.5/14.4kW)
U1 U0 CON1
CON2
U1-U0
Total
20
7-3. Earth Leakage Relay and Grounding
21
(2) Operation Check
Before operating the generator, check always if the device can work.
● Actuation test of the Earth Leakage Relay and Breaker
1 Ensure that the breakers and the switches of 3-Phase Circuit Breaker
loads are positioned to OFF.
2 Ensure that the 3-Phase circuit breaker and the
1-Phase circuit breaker are positioned to OFF.
(Refer to "4-2.Operation Panel")
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.
Indicator RESET button
Earth Leakage Relay
In the event you cannot complete every step of the above
procedure to the end,the device is out of order. Consult with our authorized distributor or
our engineering section and ask to repair.
(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.)
22
8. Pre-Operation Inspection
CAUTION : BURNS
Do not touch the engine and surrounding components immediately after
stopping the equipment, while temperature can reach extremely high.
CAUTION : FIRE
Always be sure to wipe up any spilled fuel or oil.
Oil Level
Indicator
OK Not Too
Enough Much
23
Relation of Viscosity/Temperature
SAE30
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 Sub-Tank
Sub-tank
1 Remove the sub-tank cap.
FULL
2 Fill the sub-tank with coolant until it reaches the
FULL line. LOW
24
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.
25
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 panel will only Fuel Fuel Strainer
Inlet
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 Tank Cap Fuel Cover
additives are used other than those specifically recommended
by the engine manufacturer.
Always use the Diesel Fuel Strainer.
Fill the fuel tank slightly less than the FULL tank level.
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.
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.
26
< 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.
9. Operating Procedures
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 bring flammable items (such as fuel, gas and paint) or items that are
highly combustible near the generator as the muffler, exhaust gas and other
parts become extremely hot.
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.
27
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.
28
(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
This generator is equipped with an automatic air bleeding mechanism. Perform the
following procedures when the engine stops due to running out of fuel to easily bleed
the air from the system.
2 Turn the starter switch to RUN. Air bleeding is completed approximately in 30 sec.
CAUTION : BURNS
Do not touch the engine and surrounding components immediately after
stopping the engine as they are still hot.
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 engine 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 hot.
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 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.
29
Protection Feature List
Earth
Engine Warning
Action Leakage Breaker
No. Automatic Indicator Cause
Abnormality Relay Trip
Shutdown Flash
Active
High Water Activates due to high water temperature
1
Temperature in the engine Default 115°C
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.
30
< Note >
Protect the piping connecting the external fuel tank and this generator with corrugate tubing or
similar in order to prevent 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 3way fuel valve lever to the “A” side in order
to prevent fuel from flowing out from the external tank 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 15~20mm
not be possible to supply fuel causing the engine to
stop.
Set the supply side so that it is 15 to 20 mm above the
underside of the tank in order to prevent foreign
material or water from being suctioned from inside the
external fuel tank.
Set the external fuel tank return side at the same height as the supply side in order to prevent
poor engine operation due to air mixed in with the fuel.
Refer to section “9-2 Procedures 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
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
Every Every
Every Every Every Every Every
Description Daily 1,000 1,500
100 hrs 200 hrs 400 hrs 500 hrs 800 hrs
hrs hrs
Each parts
(Clean/Tightening)
Engine oil
(Check/Add)
Engine oil 1st time
(Replace) at
50 hrs
Oil filter (Replace) 1st time
at
50 hrs
Coolant
(Check/Add)
Coolant (Replace/
Radiator Flush)
Exhaust color
(Check)
Water separator
(Check/Drain
excess water (Drain)
and sediments)
Fuel filter/element
(Clean/Replace) (Clean) (Replace)
Fuel tank
(Drain water)
Water separator
and Gauze filter
(Clean)
Engine
Fuel tank
(Clean)
Check for leaks
(Fuel/Oil/Coolant)
Fuel/Cooling
Water/Oil Hoses
and Anti-Vibration or 1 year
Rubber (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 fins
(Clean)
Valve clearance
(Check/Adjust)
Fuel injector
(Check)
Elimination of
carbon in the
exhaust pipe line
and muffler
Indicators, Gauges
Alarms (Check)
Operation check of
Generator
Earth Leakage
Relay
Grounding
resistance check
Insulation test
33
(1) Engine Oil Replacement
First Time 50 hours
Thereafter Every 200 hours
1 Set a container to catch spilled engine oil.
Oil Filler
Cap
2 Remove the oil filler cap.
6 Shortly after starting the engine, always be sure to check that there is no oil leaking
from the seal surface.
< Note >
Request the authorized distributor where the generator was purchased to perform this procedure
if you do not have a filter wrench.
Oil filter part no.: 16414-32432 (Kubota part no.)
34
(3) Air Filter Element Cleaning/Replacement
Clip
Clean 100 hours Air Cleaner
Cap
Replace Every 400 hours
35
(5) Fuel Filter Cleaning/Replacement
Cleaning Every 200 hours
Replace Every 400 hours
You can install a large fuel filter to this generator. To install, first remove the standard fuel
filter from the stay and install the large fuel filter.
Large fuel filter part no.:1K947-43012 (Kubota part no.)
Large fuel filter element part no.:1K947-43171 (Kubota part no.)
3 After the water has been drained, reinsert the fuel drain plug
with new packing (with rubber seal).
< Note >
Replace the packing of the fuel drain plug with new packing each time the water is drained.
Packing part no.: V106-000110
After reinserting the fuel drain plug, be sure to always check that there is no fuel leakage.
給水口
4 Remove the coolant drain plug and packing.
5 After the coolant has been drained, reinsert the
coolant drain plug with new packing.
Radiator Cap
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6 Remove the subtank and flush the coolant from
the subtank.
7 Reattach the subtank to its original position and fill
with coolant until it reaches the FULL level.
8 Fill the radiator with coolant until it reaches the
filler neck. Sub tank
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 bring flammable items (such as fuel, gas and paint) or items that are
highly combustible near the generator as the muffler, exhaust gas and other
parts become extremely hot.
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.
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Clean Every 200 hours
Accumulation of carbon (soot, unburned fuel) in the exhaust pipe line and muffler could
cause only a system derates or an engine fault occurs. To destroy the soot and unburned
fuel, run the unit at rated power for some period of time until the exhaust gas become
mostly colorless every 200 hours operation time. The carbon will be easier to be generated
when the unit operates at less then 30% of rated power. In this case, perform the above
procedures at shorter interval time.
< Note >
When the unit operates at rated power, accumulation of carbon in the exhaust pipe line and
muffler might be lead to back fire incident. Do not bring flammable items that are highly
combustible near the generator.
WARNING : INJURY
Before performing any equipment check or maintenance, stop the engine,
and remove the engine key. A person performing the maintenance should
always keep the key.
CAUTION : FIRE
Always be sure to wipe up any spilled fuel or oil.
Allow the generator to cool before covering with the protective cover.
CAUTION : BURNS
Do not touch the engine and surrounding components immediately after
stopping the equipment, while temperature can reach extremely high.
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.
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(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 Top cover of this generator is not
dented, and that bolts are not loosen 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
CAUTION : FIRE
Never allow flame to come close to the generator.
CAUTION : BURNS
Do not touch the engine and muffler after stopping the engine while
temperature can reach extremely high.
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Problem Suspected cause Action
Starter motor 1. Battery output is weak 1. Check / battery liquid/ or
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
7. ECU(Engine Controller) is defective 7.Ask our distributor to repair
Battery Isolator is OFF
Starter motor 1. Fuel is insufficient 1. Add fuel
drives but 2. Fuel filter is clogged 2. Clean/Change fuel filter
engine does 3. Gauze filter is clogged 3. Clean/Change gauze filter
Engine does not start
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Problem Suspected cause Action
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
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
Pointer (hand) does 1. Voltage meter is defective 1. Ask our distributor to repair
not move in voltage 2. AVR is defective 2. Ask our distributor to repair
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
Pointer (hand) does 1. Voltage meter is defective 1. Ask our distributor to repair
not goes up to the 2. AVR is defective 2. Ask our distributor to repair
rated voltage 3. Voltage regulator dial is defective 3. Ask our distributor to repair
4. Frequency is low 4. Ask our distributor to repair
Pointer exceeds the 1. Voltage meter is defective 1. Ask our distributor to repair
rated voltage 2. AVR is defective 2. Ask our distributor to repair
3. Improper load cable connection 3. Correctly set the connection
location to the output terminal
4. Voltage switch is set to 400V 4.Set the voltage switch to 200V
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 laod 4. Decrease the laods 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 OFF,
breaker to ON ON and OFF turn it to ON
2. Short circuit on the load 2. Check the load circuit
3. Earth Leakage Relay operates 3. Repair the earth leakage
location
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13. Generator Circuit Diagram
(1) 200/220V
42
(2) 400/440V
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14. Engine Electrical Circuit Diagram
44
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