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ESE 904 - 1304 DBG DIN

Status: at

January 2013

9 Replacement parts

The replacement parts needed to run the generator are de-
scribed in this section.

The alternator is divided into these component groups:

•

Frame with covers, tank and engine

•

Generator and electronics

•

Standard accessories

•

Special accessories

•

Special equipment

9.1 Frame with covers, tank and engine

Fig. 9-1: Operating and alternator side replacement parts

Содержание ESE 1104 DBG ES FS DIN

Страница 1: ...No 151003 ESE 904 DBG ES DIN Article No 151013 ESE 904 DBG ES FS DIN Article No 151023 ESE 1104 DBG ES DIN Article No 151015 ESE 1104 DBG ES FS DIN Article No 151025 ESE 1304 DBG ES DIN Article No 15...

Страница 2: ...099 January 2013 2013 ENDRESS Elektroger tebau GmbH This documentation and parts thereof are subject to copy right Any use or modification beyond the restrictions of the Copyright Act is forbidden and...

Страница 3: ...ESE 904 1304 DBG DIN 25 3 1 Components of generator ESE 904 1304 DBG DIN 25 3 1 1 Components of the operating and alternator side 26 3 1 2 Exhaust and engine side components 27 3 1 3 Control panel com...

Страница 4: ...nal start device 56 5 6 Battery charge conservation 57 5 7 3 way fuel tap fuelling device 60 5 8 Exhaust hose 63 6 Maintenance 65 6 1 Maintenance plan 65 6 2 Maintenance work 66 6 2 1 Charge battery 6...

Страница 5: ...53 Fig 5 4 Remote start device with Harting plug 54 Fig 5 5 Remote start device with CAN plug 55 Fig 5 6 Connecting up an external start device 56 Fig 5 7 Connecting up the battery charge conservatio...

Страница 6: ...able 8 2 Ambient conditions for the generator 78 Table 8 3 Generator performance reduction dependent on the ambient conditions 78 Table 8 4 Maximum line length of the distribution network as a functio...

Страница 7: ...on on using the generator safely and appropriately Complying with this information helps to avoid hazards reduce repair costs and downtime increase the reliability and service life of the generator Ho...

Страница 8: ...e generator Operating instructions and maintenance instructions for the engine Briggs Stratton Corporation Briggs Stratton Service Germany Briggs Stratton Corporation Circuit diagram for the generator...

Страница 9: ...ol indicates activities during which there is an explosive hazard possibly with lethal consequences Dangerous electrical voltage This warning symbol indicates activities during which there is the dang...

Страница 10: ...General information 10 ESE 904 1304 DBG DIN Status at January 2013 Notes...

Страница 11: ...designed to operate electrical equipment with appropriate power output requirements Oth er applications can lead to injury to the operating personnel and to damage to the generator as well as other da...

Страница 12: ...intenance or repair work Defectively performed maintenance or repair work Unintended use 2 2 Intended use The generator produces electricity in place of the power grid in order to supply a mobile dist...

Страница 13: ...nalysed and evaluated before beginning the design and planning of the ESE 804 1104 1304 DBG DIN generator were the residual risks identified using a risk anal ysis tool Structurally unavoidable residu...

Страница 14: ...tor may be caused by Inappropriate handling Operating fluids fuel lubricants engine oil etc Exhaust gas emission Noise emission Fire hazard Leaking battery acid Material damage to the generator can oc...

Страница 15: ...functionality can be limited by Inappropriate handling Inappropriate maintenance or repair work Unsuitable operating fluids An installation altitude greater than 100 metres above sea level An ambient...

Страница 16: ...afety Regulations in practice be trained and instructed according to the rules of con duct in the event of malfunctions occurring have the physical and mental abilities to carry out his responsibiliti...

Страница 17: ...rformed within the individual life cycles Life cycle Activity Danger zone Work area Transport in the vehicle Radius of 1 0 m none by the operating per sonnel Radius of 1 0 m Operation Setting up Opera...

Страница 18: ...equalization earthing for FI 6 Reference note read operating in structions 2 Motor model plate 7 Short operating instructions interior Reference note regarding short oper ating instructions exterior...

Страница 19: ...tential equalization earthing for FI Reference note hot surface Reference note ca ble extension Reference note fuel note Reference note read operating instructions Short operating in structions inner...

Страница 20: ...s on the generator must be in place and in a clearly legible condition The operational reliability and functionality must be checked before and after each use operation The generator must only be used...

Страница 21: ...tor s danger zone Open flames and light are prohibited in the generator s dan ger zone Consumption of alcohol drugs medications or other mind altering substances is prohibited The authorised personnel...

Страница 22: ...and or equipment components safety separated circuit The entire drawn output must not exceed the maximum nom inal output of the generator Do not operate the generator without a sound damper It is pro...

Страница 23: ...t required for more than 30 days Store the generator in a dry and locked room Use a petrol additive to prevent resinous residues in the fuel system One copy of these operating instructions must always...

Страница 24: ...24 ESE 904 1304 DBG DIN Status at January 2013 Notes...

Страница 25: ...N The components and functionality of the generator are de scribed in this section 3 1 Components of generator ESE 904 1304 DBG DIN The generator components are distributed on all four sides Fig 3 1 V...

Страница 26: ...ents of the operating and alternator side Fig 3 2 Components of the operating and alternator side 1 Generator lid 5 Tank 2 Generator 6 Electrical compartment 3 Potential equalisation screw for an opti...

Страница 27: ...side components Fig 3 3 Exhaust and engine side components 1 Air filter 7 Spark plug connector 2 Tool pouch 8 Oil dipstick 3 Briggs Stratton engine 9 Exhaust 4 Carrying handle 10 Exhaust heat shield...

Страница 28: ...rol panel components 1 Hinged window 6 START STOP switch 2 Line circuit breaker 7 Emergency OFF button 3 Multi function control display 8 Signal tone speaker 4 Shockproof attachment sockets 230 V AC 9...

Страница 29: ...plug wrench 4 Test probes 2 User information operating instruc tions for the engine as well as these operating instructions 5 Spark plugs 2x 3 Testing cable Fig ure abo ve Oil channel 3 1 4 2 Special...

Страница 30: ...kproof and CEE sockets with a nominal voltage of 230V and or 400V 50 Hz supply the power An integrated voltage regulator controls the voltage of the alternator in the nominal speed range of the altern...

Страница 31: ...Status at January 2013 ESE 904 1304 DBG DIN 31 Notes...

Страница 32: ...accessory see 3 1 4 2 is not attached At least one person per carrying handle WARNING A slipping or falling device can crush hands or feet Keep the device s weight in mind about 125 to 155 kg dependin...

Страница 33: ...follows 1 Prepare the work site 2 Transport the generator to the operating site 3 Attach the exhaust hose if necessary a special accesso ry see 3 1 4 2 The alternator is set up and ready for use 4 3...

Страница 34: ...ely Use a filling aid WARNING The wrong fuel destroys the motor Use only lead free ROZ 95 premium petrol Refuel the generator as follows 1 Set the fuel cock to closed Fig 5 10 1 as necessary 2 Unscrew...

Страница 35: ...disconnected WARNING Operating fluids can burn or explode Prevent leaking of engine oil and petrol Do not use starting aids Avoid open flames and sparks WARNING Exhaust gases can cause fatal asphyxia...

Страница 36: ...36 ESE 904 1304 DBG DIN Status at January 2013 Fig 4 1 Actuate manual choke Fig 4 2 Standard design of operating panel Fig 4 3 Emergency starting the pump...

Страница 37: ...warming up phase of about one minute WARNING Devices with a remote start device are fitted with an automatic choke You do not need to use the manual choke on the motor 1 Covering hood Fig 3 3 13 compl...

Страница 38: ...the fuel cock to closed Fig 5 10 1 as necessary 5 Allow the device to cool down The generator is switched off WARNING In an emergency the generator can be stopped by pressing the emergency OFF switch...

Страница 39: ...ductor to an existing po tential equalisation line Do not connect the generator to an existing electrical grid You can connect devices using Schuko or CEE sockets Fig 4 4 Connecting up consumers appli...

Страница 40: ...y or death Do not earth the generator Do not connect protective conductor to an existing po tential equalisation line Do not connect the generator to an existing electrical grid Fig 4 5 Check the prot...

Страница 41: ...IN 41 Test lamp Meaning lights up green protective conductor is OK stays off Protective conductor defective not present Table 4 1 Protective conductor test lamp The protective conductor potential equa...

Страница 42: ...or goes dark To bring the E MCS 4 0 back into a ready to operate condition again the START STOP switch must first be turned into the position STOP The display intensity is dependent on the ambient bri...

Страница 43: ...the genera tor must be switched off Only active if the special Warning signal II Firecan option is fitted If the display glows red see Fig 4 6 12 then the generator s recharging function is not workin...

Страница 44: ...h display is red then the frequency is too high If the low display is red then the frequency is too low The single L1 to L3 phases see Fig 4 6 18 are displayed separately Voltage U see Fig 4 6 17 If t...

Страница 45: ...of 10 10 80 green 80 100 yellow and 100 110 red If the OFF symbol glows red see Fig 4 6 4 and the buzzer sounds the EMERGENCY OFF button has been pressed The buzzer can be acknowledged using the ackn...

Страница 46: ...ot simply be thrown into the refuse bin Observe all local laws and regulations concerning correct disposal of such parts and substances Your author ised ENDRESS generator dealer is happy to advise you...

Страница 47: ...Status at January 2013 ESE 904 1304 DBG DIN 47 Notes...

Страница 48: ...ce conforming to VDE 0100 540 can be used such as the main earth ing line in buildings WARNING The generator must be earthed In this special case the generator must be earthed The above mentioned safe...

Страница 49: ...te the test switch seeFig 5 1 10 The switch position displays the result seeFig 5 1 20 Symbol Meaning Position I Switch does not trigger FI protection switch is defec tive Position 0 Switch triggers F...

Страница 50: ...st button see Fig 5 2 1 The displayed symbol see Fig 4 6 9 indicates the re sult the buzzer also sounds for insulation monitoring with this and it can be acknowledged over the acknowledge ment button...

Страница 51: ...sed by the device 2 The reset button see Fig 5 2 2 must be pressed after switching off and disconnecting the device so that the unit can be operated again Action Operation Press once Acknowledge the b...

Страница 52: ...can be used again 1 Plug in the consumer and switch on The displayed symbol see Fig 4 6 8 and the position of the circuit breaker indicate the result Symbol Significance lights up red Insulation faul...

Страница 53: ...LED lights up green Idle down is activated The idling speed reduction is active for about 5 minutes after engine start and then lowers the rotational speed of the en gine in as far as no load is enga...

Страница 54: ...start Connect up the remote start device as follows with the Harting socket Fig 5 4 Remote start device with Harting plug Battery charging retention might occur simultaneously when using the remote s...

Страница 55: ...with CAN plug Battery charging retention might occur simultaneously when using the remote start device 1 Insert plug for the remote start operating status genera tor connecting cable into the remote s...

Страница 56: ...external energy source connecting cable e g starter battery external start socket into the external start socket and lock in place by turning to the right External start device is ready for use The en...

Страница 57: ...for the starter battery charge conservation device 2 Insert plug for the external energy source e g a battery charging device charge conservation device socket connecting cable and lock in place by t...

Страница 58: ...ttery charging device charge conservation device socket connecting cable and lock in place by turning to the right The battery charge conservation device is ready to oper ate Disconnect the battery ch...

Страница 59: ...battery charging device charge conservation device socket connecting cable in place The battery charge conservation device is ready to oper ate Disconnect the battery charge conservation device as fol...

Страница 60: ...e devices own tank and the fuelling device Fig 5 10 3 way fuel tap Switch position Operation 1 CLOSED 2 OWN TANK 3 EXTERNAL FUELLING Table 5 6 Switchingpositions of the 3 way fuel tap Establish a conn...

Страница 61: ...ling device as follows 1 Pull off cover plugs from quick action coupling 2 Place the quick action coupling Fig 5 11 1 on the exter nal fuelling connection Fig 5 11 2 3 The quick action coupling engage...

Страница 62: ...ister is attached Change an empty canister during operation as follows 1 Place the full canister next to the empty canister 2 Open sealing cap on the full canister 3 Set the fuel cock to the internal...

Страница 63: ...s can cause fatal asphyxiation Provide for sufficient ventilation Use an exhaust gas hose Only operate the alternator outdoors Fig 5 12 Connecting the exhaust hose Connect up the exhaust hose as follo...

Страница 64: ...January 2013 Disconnect the exhaust hose from the generator by 1 Turn the exhaust hose grip to the left 2 Pull the exhaust hose off the muffler s exhaust hose con nection Exhaust hose is now disconnec...

Страница 65: ...l ly every 100 h annual ly annual ly Checking the electrical safety before each start up Checking the oil X Change the oil X3 X 1 Change oil filter X Cleaning the air filter X 2 Clean area around muff...

Страница 66: ...Charge battery Charge the battery according to the handling regulations supplied by the manufacturer see 1 1 in order to maximise service life 6 2 2 Replacing the starter battery 1 Unscrew the batter...

Страница 67: ...assing when charging batteries Flames sparks an open light and smoking are prohibit ed Avoid sparks when handling cables and electrical devic es as well as electrostatic discharge Avoid short circuits...

Страница 68: ...clean cloth 2 Reinsert the dipstick and take it out again Drain off some of the oil if the level is above the upper mark and refill with oil if the level is under the lower mark see below The oil leve...

Страница 69: ...at an angle of 30 5 Unscrew the oil drainage screw Fig 6 3 1 and allow the oil to drain completely Engine oil has been drained 6 Screw in the oil drainage screw again 7 Then refill with fresh oil The...

Страница 70: ...tart socket socket charging retention and or remote start de vice 1 Open the fuse holder 2 Replace a fuse 3 Close the fuse holder The fuse has been replaced Fig 6 4 Replacing a fuse Fuse type Amperes...

Страница 71: ...ety Only appropriately authorised personnel may check the elec trical reliability The electrical reliability must be checked in accordance with the applicable VDE regulations EN and DIN standards and...

Страница 72: ...is defective Call service staff Strong voltage fluctuations occur The engine runs irregularly Call service staff The speed control works er ratically or insufficiently Call service staff The engine d...

Страница 73: ...ov er are clogged Clean ventilation holes The oil level is too low Add oil The fuel filter is clogged Replace the fuel filter The engine splutters The 20 litre standard contain er is empty Change the...

Страница 74: ...art equipment fuse is defective Replace the fuse The engine does not start in external start mode The external start equipment plug is not inserted properly Insert the external start equipment plug co...

Страница 75: ...Status at January 2013 ESE 904 1304 DBG DIN 75 Notes...

Страница 76: ...76 ESE 904 1304 DBG DIN Status at January 2013 8 Technical specifications The technical specifications concerning use of the generator are described in this section Fig 8 1 Generator dimensions...

Страница 77: ...30 230 V Rated current 3 11 5 15 9 17 3 A Rated current 1 21 7 26 1 30 4 A Voltage tolerance idling nominal output 5 5 5 Weight ready for use 124 147 148 kg Tank capacity lead free normal ROZ91 fuel 1...

Страница 78: ...on the ambient conditions Line max line length Unit HO 7 RN F NSH u 1 5 mm2 60 m HO 7 RN F NSH u 2 5 mm2 100 m Table 8 4 Maximum line length of the distribution network as a function of the cable cro...

Страница 79: ...Status at January 2013 ESE 904 1304 DBG DIN 79 Notes...

Страница 80: ...generator are de scribed in this section The alternator is divided into these component groups Frame with covers tank and engine Generator and electronics Standard accessories Special accessories Spec...

Страница 81: ...andle black E130579 4 Inset handle made of soft PVC E133316 4 Plastic end cap for pipe 25 2 40 151003 1 Generator tank yellow 50 151003 2 Earth strap copper 60 E133301 4 Vibration dampers D40x40 M8 70...

Страница 82: ...Protective cap for battery terminal 140 163040 1 Battery 12V 18A for electrical starting only 150 151003 1 Generator 160 E502114 90 1 Air baffle plate 170 E502085 10 1 Manual compartment 180 E502111 1...

Страница 83: ...ngine Vanguard 16HP for ESE 804 DBG ES DIN E131589 1 Engine Vanguard 20HP for ESE 1104 DBG ES DIN E131590 1 Engine Vanguard 22HP for ESE 1304 DBG ES DIN 310 692519 1 Paper filter 692520 1 Pre filter 3...

Страница 84: ...rator fan blade 600 E131433 1 Generator regulator for 8 5kVA 13kVA 610 E134151 E134152 2 conductor through clamp 4 conductor through clamp 620 E130975 Mini changer relay 630 E131799 1 Noise filter 700...

Страница 85: ...1 Line circuit breaker ESE 1304 DBG ES DIN E134046 3 Line circuit breaker E134047 1 Line circuit breaker 780 E500762 90 1 Mounting rail housing 1 RAL 9005 E500763 90 1 Mounting rail housing 2 RAL 900...

Страница 86: ...9 5 Replacement parts for fuses Position Part number Quantity Item designation 800 E132672 1 Flat fuse holder E132680 1 Flat fuse insert 20 A DIN 72581 Part 3 E132735 1 Flat fuse insert 15 A DIN 72581...

Страница 87: ...used 910 E130545 1 Test probes 920 E130446 1 100 cm measuring line 930 1 Engine operating manual B S 940 E130534 1 Spark plug wrench 1000 E100592 1 Fuelling device special accessory 1010 E100593 1 20...

Страница 88: ...88 ESE 904 1304 DBG DIN Status at January 2013 Fig 9 7 Replacement parts forspecial accessories...

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