Ducar DF1800H Owner'S Manual Download Page 33 | Manualshive

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MAINTENANCE

Spark Plug Service

In order to service the spark plug, you will need a spark plug wrench (commercially available).
Recommended spark plugs: F7TC

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.
If the engine has been running, the muffler will be very hot. Be careful not to touch the muffler.
1.

Remove the spark plug cap.

2. Clean any dirt from around the spark plug base.
3. Use a spark plug wrench to
remove the spark plug.

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- 33 -

4. Visually inspect the spark plug.

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Summary of Contents for DF1800H

Page 1: ... 1 Owner s Manual GENERATOR DF1800H DFD1800H DFY1800H DF2500H DFD2500H DFY2500H ...

Page 2: ...to fact that hazardous operating and maintenance procedures may result in injury to or death of personnel if not strictly observed CAUTION A caution is used to alert the user to fact that hazardous operating and maintenance procedures may result in damage to or destruction of equipment if not strictly observed NOTE A note is used to give helpful information ...

Page 3: ...r work shall be carried out only by specially trained personnel Contents SAFETY 5 Safety Label Locations 5 Safety Information 6 CONTROLS 9 Engine Switch 9 Recoil Starter 9 Fuel Valve Lever 10 Chock Rod 10 Ground Terminal 11 Oil Alert System 11 AC Circuit Breaker 12 GENERATOR USE 13 Connection to Building Electrical System 13 Ground Terminal 13 ...

Page 4: ... STOPPING THE GENERATOR 20 SERVICE 20 MAINTENANCE 24 Maintenance Safety 25 Emission Control System Information 27 Maintenance Schedule 29 Engine Oil Change 30 Air Cleaner Service 31 Spark Plug Service 4 33 TRANSPORTING STORAGE 36 ASSEMBLY OF PARTS 39 TROUBLESHOOTING 43 SPECIFICATIONS 45 WIRING DIAGRAM 46 ...

Page 5: ...48 SAFETY SAFETY LABELL LOCATIONS These labels warn you of potential hazards that can cause serious injury Read them carefully If a label comes off or becomes hard to read contact your Generator dealer for a replacement 5 ...

Page 6: ...and by observing safe operating procedures Operator Responsibility Know how to stop the generator quickly in case of emergency Understand the use of all generator controls output receptacles and connections Be sure that anyone who operates the generator receives proper instruction Do not let children operate the generator without parental supervision Carbon Monoxide Hazards Exhaust contains poison...

Page 7: ...electric power to cause a serious shock or electrocution if misused Using a generator or electrical appliance in wet conditions such as rain or snow or near a pool or sprinkler system or when your hands are wet could result in electrocution Keep the generator dry If the generator is stored outdoors unprotected from the weather check all electrical components on the control panel before each use Mo...

Page 8: ...lose the generator in any structure Keep flammable materials away form the generator The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot Let the engine cool before storing the generator indoors Gasoline is extremely flammable and is explosive under certain conditions Do not smoke or allow flames or ...

Page 9: ...s been wiped up before starting the generator CONTROLS 9 Engine Switch To start and stop the engine Switch position OFF To Stop the engine ON To run the engine electric start recoil start START To start the engine only for electric start Recoil Starter To start the engine pull the starter grip lightly resistance is ...

Page 10: ... prevent damage to the starter CONTROLS Fuel Valve Lever The fuel valve is located between the fuel tank and carburetor When the valve lever is in the ON position fuel is allowed to flow from the fuel tank to the carburetor Be sure to return the fuel valve lever to the OFF position after stopping the engine 10 ...

Page 11: ...ound terminal is connected to the frame of the generator the metal non current carrying parts of the generator and the ground terminals of each receptacle Before using the ground terminal consult a qualified electrician electrical inspector or local agency having jurisdiction for local codes or ordinances that apply to the intended use of the generator Oil Alert System The oil alert system is desi...

Page 12: ...RCUIT BREAKER The AC circuit breaker will automatically switch OFF if there is a short circuit or a significant overload of the generator at the receptacle If the AC circuit breaker is switched OFF automatically check that the appliance is working properly and does not exceed the rated load capacity of the AC circuit before switching the circuit breaker ON again The circuit breaker may be used to ...

Page 13: ...being connected to any of the120V 3 prong receptacles select the 120V ONLY position CONTROL Switch Position 120 240V The 120Vand 120 240Vreceptacles can be used simultaneously 120V ONLY ONLY the 120V receptacles can be used Do not use the 120 240V receptacle in this position The most power will be available at the 30A 120V locking plug receptacle 13 ...

Page 14: ...ch which isolates generator power from utility power is available through authorized generator dealer WARNING Improper connections to a building electrical system can allow electrical current from the generator to back feed into the utility lines Such back feed may electrocute utility company workers or others who contact the lines during a power outage and the generator may explode burn or cause ...

Page 15: ...ower cord to the generator Make sure that it is in good working order Faulty appliances or power cords can create a potential for electrical shock If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn it off immediately Disconnect the appliance and determine whether the problem is the appliance or if the rated load capacity of the generator has been exceeded Make sur...

Page 16: ...the generator may not switch the circuit breaker OFF but will shorten the service life of the generator GENERATOR USE 16 AC OPERATION 1 Start the engine see page 13 2 Switch ON the AC circuit breaker 3 Plug in the appliance NOTICE Be sure that all appliances are in good working order before connecting them to the generator If an appliance ...

Page 17: ...for any one receptacle If an overloaded circuit causes the AC circuit breaker to switch OFF reduce the electrical load on the circuit wait a few minutes and then reset the circuit breaker PRE OPERATION CHECK ENGINE OIL NOTICE Engine oil is a major factor affecting engine performance and service life Non detergent and 2 stroke engine oils will damage the engine and are not recommended 17 Check the ...

Page 18: ...ed when the average temperature in your area is within the indicated range PRE OPERATION CHECK 1 Remove the oil filler cap and wipe the dipstick clean 2 Check the oil level by inserting the dipstick into the filler neck without screwing it in 4 If the level is low fill to the top of the oil filler neck with the recommended oil Fuel Check the fuel gauge and refill the tank if the fuel level is low ...

Page 19: ...pacity 15L 4 US gal PRE OPERATION CHECK NOTICE Fuel can damage paint and plastic Be careful not to spill fuel when filing your fuel tank Damage caused by spilling fuel is not covered under warranty Use unleaded gasoline with a pump octane of 86 or higher This engine is certified to operate on unleaded gasoline Unleaded gasoline produces fewer engine and spark plug deposits and extends exhaust syst...

Page 20: ...ds of gasoline If spark knock or pinging persists see an authorized to manual NOTICE Running the engine with persistent spark knock or pinging is misuse and the Distributor s Limited Warranty dies not cover parts damaged by misuse STARTING THE ENGINE STOPPING THE ENGINE Starting the Engine 1 Make sure that the AC circuit breaker is in the OFF position The generator may be hard to start if a load i...

Page 21: ...engine In an emergency To stop the generator in an emergency turn the engine switch to the OFF position In normal use 1 Turn the AC circuit breaker to the OFF position 2 Turn the engine switch to the OFF position 3 Turn the fuel valve lever to the OFF position SERVICE Always do as the following so as to keep the generator in a sound condition WARNING 1 Always connect the 2 If the generator is to s...

Page 22: ...prevent misusing with higher start current fist SERVICE 3 The following table gives reference information for connecting the electric appliances to the generator 22 ...

Page 23: ...SERVICE 4 Connecting methods are illustrated as follow a Correct b Correct 23 ...

Page 24: ...lectrician dose this job Improper connecting between the generator and loads may cause damage to the generator even a fire MAINTENANCE The Importance of maintenance Good maintenance is essential for safe economical and trouble tree operation It will also help reduce air pollution WARNING 24 ...

Page 25: ...ormed by generators or other qualified mechanic The maintenance schedule applies to normal operating conditions If you operate your generator under sever conditions such as sustained high load or high temperature operation or use it in unusually wet or dusty conditions consult your servicing needs and use Maintenance replacement or repair of the emission control devices and systems may be preforme...

Page 26: ...u begin any maintenance or repairs This will eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you operate the engine Burns from hot parts Let the engine and exhaust system cool before touching MAINTENANCE Injury from moving parts Do not run the engine unless instructed to do so Read the instructions before you begin an...

Page 27: ...intain and repair it To ensure the best quality and reliability use only new genuine parts or their equivalents for repair or replacement MAINTENANCE Emission Control System Information Soured of Emissions The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen is very important because under certain conditions they react t...

Page 28: ...emoval or alteration of any part of the intake fuel or exhaust systems Altering or defeating the governor linkage or speed adjusting mechanism to cause the engine to operate outside its design parameters MAINTENANCE Problems That May Affect Emissions If you are aware of any of the following symptoms have your engine inspected and repaired by your servicing dealer Hard starting or stalling after st...

Page 29: ...dversely affect emission performance The manufacturer or rebuild of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations Maintenance Follow the maintenance schedule on page 12 Remenber that this schedule is based on the assumption that your machine will be used for its designed purpose Sustained high load or high temperature oper...

Page 30: ...d generator dealer unless the owner has the proper tools and is mechanically proficient See the Shop Manual 3 For commercial use long hours of operation to determine proper maintenance intervals MAINTENANCE ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining 1 Remove the drain plug and sealing washer remove the oil filler cap and drain the oil 2 Reinstall...

Page 31: ...ly Service more frequently when operation the generator in extremely dusty areas NOTICE Never run the generator without the air filter Rapid engine wear will result 1 Unsnap the air cleaner cover clips remove the air cleaner cover and remove the element 2 Wash the air cleaner element in a solution of household detergent and warm water then rinse thoroughly or wash in nonflammable or high flashpoin...

Page 32: ...e engine has not been run for a long time the sediment cup should cleaned 1 Turn the fuel valve lever to the OFF position Remove the sediment cup O ring and filter 2 Clean the sediment cup O ring and filter in nonflammable or high flash point solvent 3 Reinstall the filter O ring and sediment cup 4 Turn the fuel valve lever ON and check for leaks ...

Page 33: ...To ensure proper engine operation the spark plug must be properly gapped and free of deposits If the engine has been running the muffler will be very hot Be careful not to touch the muffler 1 Remove the spark plug cap 2 Clean any dirt from around the spark plug base 3 Use a spark plug wrench to remove the spark plug 33 4 Visually inspect the spark plug ...

Page 34: ...n by hand to prevent cross threading 7 After the spark plug is seated tighten with a spark plug wrench to compress the washer If installing a new spark plug tighten 1 2turn after the spark plug seats to compress the washer If reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer NOTICE The spark plug must be securely tightened An improperly tightened...

Page 35: ...d every 100 hours to maintain its efficiency MAINTENANCE Clean the spark arrester as follows 1 Loosen the screw by the exhaust port of the muffler and remove the spark arrester 2 Use a brush to remove carbon deposits from the spark arrester screen Inspect the screen for breaks or tears and replace it if necessary 3 Install the spark arrester in the reverse order of removal 35 ...

Page 36: ...evel to prevent fuel spillage Fuel vapor or spilled fuel may ignite WARNING Contact with a hot engine or exhaust system can cause serious burns or fires Let the engine cool before transporting or storing the generator Take care not to drop or strike the generator when transporting Do not place heavy objects on the generator ...

Page 37: ...HARO STARTING Less than 1 month No preparation required 1 to 2 months Fill with fresh gasoline and add gasoline conditioner 2 months to 1 year Fill with fresh gasoline and add gasoline conditioner Drain the carburetor float bowl 1 year or more Fill with fresh gasoline and add gasoline conditioner Remove the spark plug Put a tablespoon of engine oil into the cylinder Turn the engine slowly with the...

Page 38: ... storage life Contact your authorized generator dealer for conditioner recommendations TRANSPORTING STORAGE 38 Storage 1 Drain the carburetor by loosening the screw Drain the gasoline into a suitable container WARNING Gasoline is extremely flammable and is explosive under certain conditions Perform task in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the...

Page 39: ...resistance is felt At this point the piston is coming up on its compression stroke and both the intake and exhaust valves are closed Storing the engine in this position will help to protect is from internal corrosion ASSEMBLY OF PARTS Battery To install the battery proceed as follows 1 Assemble the battery with nuts bolts and washers 2 Connect the starting cable to the starting motor terminal alon...

Page 40: ...ing cable 3 Protective frame 4 Battery bracket 5 Battery guard 6 Retaining frame 7 Battery with a rating of 12V 36Ahh 8 Negative wire ASSEMBLY OF PARTS Installation method of battery 1 Put the battery on the frame of battery Note the pole face inside of the frame 2 Hang one end of the tie rod in the holes both sides of the battery then drill the other end through the holes of fixing board ...

Page 41: ...cation of battery recommended 12V 36AH ASSEMBLY OF PARTS 2 Don t connect the anode and negative pole erroneously when use the battery 3 The battery need to be injected electrolyte before use 4 The height of electrolyte need to be inspected each month When the height is low please inject distilled water or pure water between upper level and low level Don t use electrolyte and tap water 5 The batter...

Page 42: ... very serious go to the doctor for help 3 Please note that if the battery is smirched by gasoline oil or organic impregnant the rind of the battery will be damaged 4 When replacing the new battery please send the old battery to recycle bin Don t discard it optionally ASSEMBLY OF PARTS NOTICES Check and make sure that the electrolyte level of each battery cell is between is upper and lower level ma...

Page 43: ...den as supply liquid The accumulator after added liquid should be used in time It should be termly charged if hasn t been used for a long time Charge requirement of the accumulator charge 3 5hours according to 1 10 current of rated capacity of the accumulator Avoid overcharge overdid charge Back charge is forbidden ASSEMBLY OF PARTS Wheel Fit the four wheels to the generator with bolts and nuts Be...

Page 44: ...TROUBLESHOOTING When the engine will not start 44 NO Refill the fuel tank Is there fuel in the tank NO Isthereenoughoilintheengine YES YES NO Is the spark plug in good condition YES ...

Page 45: ... loosen the drain screw To check TROUBLESHOOTING No electricity at the AC receptacles When the GFCI RESET button is extended When the GFCI RESET button is not extended 45 Unplug all appliances and equipment and inspect the GFCI operation Take the generator to an authorized manual Replace the electrical appliance or equipment Take the electrical appliance or equipment to an electrical shop for repa...

Page 46: ... for any defects ON DEFECTS Take the generator to an authorized manual Reset the circuit protector YES ON SPECIFICATIONS DF1800H DFD1800H Model DFY1800H DF2500H DFD2500H DFY2500H DF3000H DFD3000H DFY3000H Rated Frequency 50Hz 60Hz Rated Power 1 3kw 1 5kw 2 0kw 2 2kw 2 5kw 2 8kw 1 5kw 1 8kw 2 2kw 2 4kw 2 8kw 3 1kw Rate Voltage 230V 240V 120 240V 110 220V Generator Power Factor 1 0 Engine Model DJ16...

Page 47: ...ork Time full load Dimensions l w h mm 600mm 440mm 445mm Generating set Dry Weight kg 32kg 35kg 35kg 39kg 38kg 41kg WIRING DIAGRAM Bl Bl Bl R R R W W W W Y G Y G Bl Bl Bl W R Bu Bu R W Bl W Bl W O i l al er t uni t Bl R D LED Bl G r Bl Bu Bu D c coi l 1 Bu Bu Sub f i ed coi l G ener at or w i r i ng di agr am Fi el d coi l R W M ai n coi l Bu Bu W Bl G r R Br eaker Engi ne bl ock C cnt r ol box di...

Page 48: ...14AW G R 14AW G W12AW G Bl 14AW G 2 Y G Q VR 2 5m m Y G Q VR 2 5m m 2 2 2 2 2 R Bl 14AW G Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 2 5m m Q VR 1 5m m Q VR 2 5m m Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 2 5m m Q VR 1 5m m 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Bl WQ VR 0 5m m O I L ALEER T U N I T Y G Q VR 0 5m m Bl Q VR 0 5m m Bl Q VR 0 5m m Bl Q VR 0 5m m C ont r ol pa...

Page 49: ... 5m m Q VR 1 5m m Bl 14AW G R 2 2 2 2 2 2 Y G Q VR 2 5m m Y G Q VR 2 5m m 2 Bl 14AW G W12AW G R 14AW G R 14AW G W12AW G W14AW G Bl 14AW G W12AW G R 14AW G Socket Socket Br eaker R 14AW G Y G Q VR 2 5m m G r 14AW G Bl 14AW G W14AW G W Bu Bu R M ai n coi l WQ VR 0 75m m Bu Q VR 0 75m m Bu Q VR 0 75m m R Q VR 0 75m m Q VR 0 75m m Fi el d coi l Sub f i ed coi l Bl W Bl W R Br Bu Br R Br Bu Bl Bl Bl Y ...

Page 50: ...14AW G G r 14AW G R 14AW G Br eaker Y G Q VR 2 5m m Socket Socket R 14AW G W12AW G Bl 14AW G W14AW G W12AW G R 14AW G R 14AW G W12AW G Bl 14AW G 2 Y G Q VR 2 5m m Y G Q VR 2 5m m 2 2 2 2 2 2 R Bl 14AW G Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 2 5m m Q VR 1 5m m Q VR 2 5m m Q VR 1 5m m Q VR 1 5m m Q VR 1 5m m Q VR 2 5m m Q VR 1 5m m 2 2 2 2 2 2 2 2 2 2 2 2 2 2 C ont r ol pa...

Page 51: ...Q VR 0 5m m Y G LED D I N 5408 R 3KΩ Bl Q VR 0 5m m Bl Q VR 0 5m m 2 Bl Q VR 0 5m m 2 Bl WQ VR 0 5m m O I L ALEER T U N I T Bl WQ VR 0 5m m W Y G Y G Y G Y G R Bl Bl W W W R R G r G r R Socket Socket R R R R R G r W Bl Bu Bu Bu Bu R W W R 20A Socket Excitation coil M agnet i c f i el d R M ai n coi l W Bl G r R W ...

Page 52: ...G Bl Br R Bu Socket C ont r ol panel bl ock R Bl Bu Br Br Bl W Bl W D C coi l 1 LB LB LB LB G r Bl W R G r Bl W M ai n coi l R M agnet i c f i el d Excitation coil Socket 20A R W W R Bu Bu Bu Bu Bl W G r R R R R R Socket Socket R G r G r R R W W W Bl Bl R Y G Y G Y G Y G W ...

Page 53: ...l bl ock Br Br R R Br Br Bl W Bl W Bu Bl Bl R Br R Bl D LED D C coi l 1 LB LB LB LB G r Bl W R G r Bl W M ai n coi l R M agnet i c f i el d coi l Excitation coil Socket 20A R W W R Bu Bu Bu Bu Bl W G r R R R R R Socket Socket R G r G r R R W W W Bl Bl R Y G Y G Y G Y G W ...

Page 54: ...r indicator light turns green 2 When the load reaches the maximum power indicator light runs red the buzzer alarms 3 When the load exceeds the maximum power for 1 minute it automatically switches off the output 4 Press the switch the generator set works again Automatic Generator System AGS ...

Page 55: ...rt the machine And add oil if it glitters a Be sure the load won t be overloaded then install the generator set b Usually the AGS switch on the control panel will be on automatic position and the key on running position 2 To put the choke switch on the off position OPTIONAL EQUIPMENT Alarm System 1 The indicator light will be on when oil is insufficient and machine starts the indicator light will ...

Page 56: ...ine engine distance between more than 50m Requirement 1 Turn off the machine manually after remote starting is acceptable 2 Turn off the machine by remote key after manually start is acceptable 3 Turn off the machine by remote key after remote start is acceptable ...

Page 57: ... electromagnetism valve 5 Once the remote start broken manually start will be another option 6 Remote start be useless after start OPTIONAL EQUIPMENT 7 After recoil start remote turn off is acceptable Min start voltage 6 2V When turn off by remote key it should last 8 seconds Remote start should last 4seconds ...

Page 58: ... 58 WARING Please make sure the 12V DC line connect to battery before starting otherwise the remote start system will be damaged during machine running ...

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