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Service the power generator ESE 604 (ES) DHG DIN

ESE 604 DHG (ES) DIN

Status: October 2018

Service the power generator ESE 604 (ES) DHG DIN

Generator maintenance is described in this section.

Only personnel from the manufacturer may carry out mainte-
nance or repair work not described in this section.

6.1

Maintenance plan

The maintenance work specified in this summary must be car-
ried out after the indicated time intervals.

Maintenance work

Maintenance interval, according to what arises first

First

month /

20h

every 3

months /

50h

every 6

months /

100h

Every

year /

300 h

HONDA
instruc-

tions for

use

Checking the electrical safety

before each start-up

Check and top off motor oil

Check fit of screws, nuts, and

bolts

Changing the oil

(X)

P.9

Cleaning the air filter

(X)

P.10-11

Replace air filter insert

Clean the deposits beaker

Clean the spark plug and adjust

the distance between electrodes

Change the spark plug

Cleaning the spark catcher

Check and adjust valve

clearance

Workshop

manual

Remove combustion residues

from the cylinder head

Clean and adjust carburettor

(X)

Fuel tank and filter

(X)

Overhaul engine if necessary

every 1000h

(3)

Table 6.1: Generator maintenance plans

1) Check after the first 20 operating hours
2) Check
3) Have performed by a specialist or the Endress Service Station

Содержание ESE 604 DHG DIN

Страница 1: ...Translation of the ORIGINAL OPERATING INSTRUCTIONS ESE 604 DHG DIN Article No 156001 ESE 604 DHG ES DIN Article No 156011...

Страница 2: ...ober 2018 2018 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 subjec...

Страница 3: ...es and work areas 19 2 5 Signs on the generator 20 2 6 General safety instructions 22 3 Description of the power generator ESE 604 DHG DIN 27 3 1 Components of the power generator ESE 604 DHG DIN 27 3...

Страница 4: ...d lowering in idle 56 5 4 Remote start device 57 5 5 External start device 60 5 6 Battery charge maintenance 61 5 7 12V connection for supplying accessories with power 63 5 8 3 way fuel valve Refuelli...

Страница 5: ...socket according to DIN 14690 61 Fig 5 8 BEOS charge current socket 62 Fig 5 9 MagCode charge current socket 63 Fig 5 10 Connection socket for a 12V accessory 64 Fig 5 11 3 way fuel valve 65 Fig 5 12...

Страница 6: ...e length of the distribution network as a function of the cable cross section 84 Table 9 1 Replacement parts for frame with covers 88 Table 9 2 Replacement parts for an engine with an exhaust and fuel...

Страница 7: ...n 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 How...

Страница 8: ...ng instructions and maintenance instructions for the engine Briggs Stratton Corporation Briggs Stratton Service Germany Briggs Stratton Cor poration Circuit diagram for the generator Test protocol for...

Страница 9: ...bols Advanced Organizer The Advanced Organizer informs you briefly about the con tents of the following chapter Note The reference note informs you about the most effective and or most practicable way...

Страница 10: ...ials This warning symbol indicates activities during which there is an explosive hazard possibly with lethal consequences Dangerous electrical voltage This warning symbol indicates activities during w...

Страница 11: ...General information Status at October 2018 ESE 604 DHG ES DIN 11 Notes...

Страница 12: ...generators are designed to operate electrical equipment with appropriate power output requirements Other applications can lead to injury to the operating personnel and to damage to the generator as we...

Страница 13: ...rectly performed maintenance or repair work Defectively performed maintenance or repair work Unintended use 2 1 1 Intended use The generator produces electricity in place of the power grid in order to...

Страница 14: ...e incorrect use or inappropriate handling of the generator nullifies the manufacturer s EC Declaration of Con formity and automatically thereby the operating licence Foreseeable incorrect use or inapp...

Страница 15: ...ge to other property Limited performance or functionality You can avoid existing residual risks by observing and follow ing these guidelines the special warning notices on the generator the general sa...

Страница 16: ...sion Fire hazard Leaking battery acid Material damage to the generator can occur through Inappropriate handling Overloading Overheating Too low high oil level of the engine Non compliance with the ope...

Страница 17: ...n 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 temperature exce...

Страница 18: ...l Safety Regulations in practice be trained and instructed according to the rules of conduct in the event of a malfunction occurring have the physical and mental abilities to carry out his re sponsibi...

Страница 19: ...ctivities to be undertaken 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 personnel Radius of 1 0 m Operatio...

Страница 20: ...ence note read operating in structions 20 Note on power network 90 Reference note maintenance intervals 30 Note on the hot surface 100 Reference note no naked flames 40 Note 3 way fuel valve 110 Warni...

Страница 21: ...xtension 30 Hot surfaces 40 Potential equalization earthing for FI 50 External refuelling 60 Note sound emission 70 Type plate 80 Read the operating manual 90 Reference note en gine maintenance 100 Re...

Страница 22: ...he generator s danger area Protect the generator against moisture and precipitation rain snow during operation Protect the generator against dirt and foreign matter during operation The authorised per...

Страница 23: ...The generator is to be carried by at least one person per car rying handle The generator is only be set up on sufficiently firm ground The generator may only be set up on even ground The electrical s...

Страница 24: ...intenance or repair tasks may only be carried out by specially trained and authorised specialists Always remove the ignition key and the spark plug sockets before beginning maintenance and or repair w...

Страница 25: ...ruction manual The packaging material must be recycled according to the en vironmental protection regulations applicable at the place of use The workplace must be protected against contamination by le...

Страница 26: ...General Safety Regulations 26 ESE 604 DHG ES DIN Status October 2018 Notes...

Страница 27: ...enerator ESE 604 DHG DIN The components and functionality of the generator are de scribed in this section 3 1 Components of the power generator ESE 604 DHG DIN The generator components are distributed...

Страница 28: ...of the operating and generator side Fig 3 2 Components of the operating and generator side 1 Carrying handle 2 Exhaust 3 Spark plug connector 4 Fuel filter 5 3 way fuel valve optional 6 Fixing points...

Страница 29: ...side components Fig 3 3 Engine and maintenance side components 1 Tank cover 2 Fuel tank 3 Motor switch 4 Oil filling screw with a dipstick 5 Oil drain screw 6 Drive motor 7 Potential equalization eart...

Страница 30: ...0 2 CEE socket 400V 16A DIN49462 3 Schuko shockproof power sockets 230 V DIN49442 4 Motor starter switch 5 Reset button for the insulation moni toring 6 Test button for the insulation monitoring 7 Fu...

Страница 31: ...es Fig 3 5 Components of the standard accessories 1 Spark plug wrench 2 User information operating instructions for the engine as well as these operating instructions 3 Spark plug 3 1 4 2 Special acce...

Страница 32: ...spension Splash proof earthed power and CEE sockets with a nominal voltage of 230 and or 400 V 50 Hz supply the power An integrated voltage regulator controls the voltage of the generator in the nomin...

Страница 33: ...Description of the power generator ESE 604 DHG DIN Status at October 2018 ESE 604 DHG ES DIN 33 Notes...

Страница 34: ...ted Exhaust hose a special accessory see 3 1 4 2 is not at tached At least one person per carrying handle WARNING A slipping or falling device can crush hands or feet Take the weight of about 110kg in...

Страница 35: ...l Set up the generator as follows 1 Prepare the work site 2 Transport the generator to the work site 3 Attach the exhaust hose if necessary a special accessory see 3 1 4 2 The generator is set up and...

Страница 36: ...ed down Avoid open flames and sparks WARNING Leaking engine oil can contaminate the soil and ground water Do not fill the tank completely Use a filling aid WARNING Using the wrong fuel will destroy th...

Страница 37: ...tor The following requirements must be met Electrical safety check see 6 3 Fuel tank has been filled see 4 3 A possibly connected fuelling device special accessory sufficient oil level fill with engin...

Страница 38: ...flammable materials at the operating site Avoid explosive materials at the operating site WARNING Heat or moisture destroys the device Avoid overheating sufficient ventilation Avoid moisture Start the...

Страница 39: ...al devices can be connected and or hooked up af ter a warming up phase of about one minute Fig 4 3 Electrical start 1 Push the choke lever Fig 4 2 to the far left completely for a cold engine appropri...

Страница 40: ...nual choke on the engine 4 5 Switching the generator off Proceed as follows to shut down the generator WARNING Hot parts can ignite flammable and explosive materials Avoid flammable materials at the o...

Страница 41: ...r generator ESE 604 DHG DIN Status at October 2018 ESE 604 DHG ES DIN 41 3 Turn the key switch Fig 4 3 into pos STOP The generator is switched off See Chapter 5 4Remote start device Special equipment...

Страница 42: ...nerator Do not connect protective conductor to an existing poten tial equalisation line Do not connect the generator to an existing electrical grid You can connect devices using Schuko or CEE sockets...

Страница 43: ...s connected Switch the consumer off as follows 1 Switch consumer off Consumer is switched off Disconnect a consumer from the control panel as follows 1 Remove plug 2 Screw cover onto the socket The co...

Страница 44: ...wing requirements must be met generator has been started see 4 4 device is connected see 4 6 device switched off Fig 4 5 Check the protective conductor 1 Insert test cable into socket Fig 4 5 2 2 Hold...

Страница 45: ...he position STOP The display intensity is de pendent on the ambient brightness sensor see Fig 4 5 5 Fig 4 6 Multi functional display The display Fig 4 6 1 is active when the generator starts or is act...

Страница 46: ...4 6 10 during the pro tective earth lead test see chapter 4 7 Protective earth lead test the protective earth leads for the attached devices are OK If the protective earth conductor function is not a...

Страница 47: ...and 100 110 red If the display is red for single phase utilisation asymmetric load then the load should be distributed evenly over the 3 existing phases Load P see Fig 4 6 7 For a 1 and 3 phase load...

Страница 48: ...gine oil etc cannot 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 ha...

Страница 49: ...Operate power generator ESE 604 DHG DIN Status at October 2018 ESE 604 DHG ES DIN 49 Notes...

Страница 50: ...to VDE 0100 540 can be used such as the main earthing line in buildings WARNING The generator must be earthed In this special case the generator must be earthed The above mentioned safety warnings wi...

Страница 51: ...tion 1 3 Activate the test switch seeFig 5 1 10 The switch position displays the result seeFig 5 1 20 Symbol Significance Position I Switch does not trigger FI protection switch is defective Position...

Страница 52: ...a DIN generator The following requirements must be met generator has been started see 4 4 Circuit breaker see Fig 3 4 1 in Pos 1 1 Disconnect all consumers from the generator 2 Press the test button s...

Страница 53: ...without switching off during operation 1 Press the Reset button see Fig 5 2 2 to acknowledge the error message The horn is muted only for Stage 2 The symbol in the display continues to be lit up 2 Sw...

Страница 54: ...ndard the consumer should only be used again when it has first been checked and repaired by an electrician 5 2 2 Insulation monitoring with switch off The following requirements must be met generator...

Страница 55: ...t 34 5 k stays off Connected unit is OK Table 5 5 Insulation monitoring whilst running without switching off If an insulation fault exists and the unit was previously OK when tested without a device c...

Страница 56: ...l it engages 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...

Страница 57: ...emote start device are fitted with an auto matic choke You do not have to use the manual choke during an electrical start Connect up the remote start device as follows Fig 5 4 Connecting up a remote s...

Страница 58: ...ice is disconnected Start the engine manually as follows Fig 5 5 Example of an electrical start in combination with a remote start device 1 The EMERGENCY OFF button Fig 5 5 2 must not be pressed 2 Pla...

Страница 59: ...cy the generator can be stopped by press ing the EMERGENCY OFF switch Fig 4 3 1 The but ton is turned to the left or the right to restart the aggre gate until the locking is removed again We request t...

Страница 60: ...plug for the external energy source connecting ca ble e g starter battery external start socket into the ex ternal start socket and lock in place by turning to the right External start device is read...

Страница 61: ...maintenance option The following requirements must be met generator is ready for operation a suitable external charging device ready for operation 12V connection socket according to DIN 14690 Fig 5 7...

Страница 62: ...anti clockwise 2 Connect the plug on the external charging device e g battery charging device with the socket 3 Tighten the screw connection on the external charge plug clockwise in order to lock the...

Страница 63: ...arging de vice e g battery charging device The battery charge maintenance unit is disconnected 5 7 12V connection for supplying accessories with power Apart from charge maintenance the 12V connection...

Страница 64: ...use 4 Unfasten the plug on the accessory plug by turning anti clockwise 5 Remove plug 6 Screw on protective cap Fig 5 10 2 of the 12V connec tion socket by turning clockwise The 12V accessory is disco...

Страница 65: ...t between the de vice s own tank and the refuelling device Fig 5 11 3 way fuel valve Switch position Operation 1 CLOSED 2 OWN TANK 3 EXTERNAL REFUELLING Table 5 6 Switchingpositions of the 3 way fuel...

Страница 66: ...el pump Connect up fuelling device as follows 1 Pull off cover plugs from quick action coupling 2 Place the quick action coupling Fig 5 12 1 on the exter nal fuelling connection Fig 5 12 2 3 The quick...

Страница 67: ...g device The canister 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...

Страница 68: ...G Exhaust gases can cause fatal asphyxiation Provide for sufficient ventilation Use an exhaust gas hose Only operate the generator outdoors Fig 5 13 Connecting the exhaust hose Connect up the exhaust...

Страница 69: ...r 2018 ESE 604 DHG ES DIN 69 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...

Страница 70: ...300 h HONDA instruc tions for use Checking the electrical safety before each start up Check and top off motor oil Check fit of screws nuts and bolts Changing the oil X 1 X P 9 Cleaning the air filter...

Страница 71: ...engine oil for cooling and inner cooling It is also very important to use the correct engine oil both for refilling and when changing the oil and to adhere the stipulated maintenance intervals Refer t...

Страница 72: ...ine should ideally be slightly warm allow a cold engine to run for 5 min then stop it and allow it to cool for 2 min Fig 6 2 Oil dipstick Check the oil level as follows 1 Unscrew the dipstick Fig 6 2...

Страница 73: ...een refilled Change the oil as follows 1 Remove the oil dipstick Fig 6 2 2 2 Prepare the oil collecting tray 3 Unscrew oil drain screw Fig 6 2 1 carefully and wait until oil has completely run off int...

Страница 74: ...he POSITIVE termi nal Battery is disconnected Fig 6 3 Replacing the battery 4 Prepare a new battery 5 The battery cables must first be screwed onto the POSITIVE terminal then onto the NEGATIVE termina...

Страница 75: ...it 6 2 3 Replacing fuses Replacing fuses only for the special accessory external start socket socket charging retention and or remote start de vice 1 Open the fuse holder 2 Replace the fuse 3 Close th...

Страница 76: ...tive conductor system of the attached consumer takes over the function of the potential equalization device The terminal Fig 3 4 12 is connected with this potential equalization device It is not neces...

Страница 77: ...so abide by the operating manual provided by the engine manufacturer Visual inspection for externally visible defects such as dam aged insulation connectors ca ble leaks noises If the generator is fit...

Страница 78: ...s de fective 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 do...

Страница 79: ...on tank cover 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 con tainer is empty Ch...

Страница 80: ...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 equip ment plug c...

Страница 81: ...Troubleshooting Status at October 2018 ESE 604 DHG ES DIN 81 Notes...

Страница 82: ...cifications 82 ESE 604 DHG ES DIN Status October 2018 8 Technical specifications The technical specifications concerning use of the generator are described in this section Fig 8 1 Generator dimensions...

Страница 83: ...use 110 kg Tank capacity lead free normal ROZ91 fuel 6 5 l Fuel consumption at a 75 load approx 2 1 l h Running time at a 75 load PRP approx 3 1 h Length 700 mm Width 440 mm Height 580 mm Sound press...

Страница 84: ...di tional Unit 1 100 m 4 10 C Table 8 4 Generator power reduction dependent on standard reference 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...

Страница 85: ...Technical specifications Status at October 2018 ESE 604 DHG ES DIN 85 Notes...

Страница 86: ...un the generator are de scribed in this section The generator is divided into these component groups frame with covers tank and engine Generator and electronics Standard accessories Special accessorie...

Страница 87: ...E130186 4 Polyamide expansion rivets E130692 4 12 8 18 3 spacer sleeve E133023 4 M12 x 45 cylindrical screw E130350 4 Hexagon nut M 12 30 E131296 4 Vibration dampers 40 E503877 99 1 Refuelling bracket...

Страница 88: ...guard 16HP ES Cooler clean for 854 and 604 120 E130563 1 M8 wingnut E131063 1 Earth strap in copper 130 E503873 00 1 Engine heat conduction plate 140 E503882 92 1 Silencer elbow 150 E131975 1 Silencer...

Страница 89: ...or ESE 854 163040 1 Battery 12V 18h 200 E130422 1 Hinged window No 40980 E100091 1 Mounting rail TS 35 7 5 0 21 m E503858 10 2 Terminal strip holder yellow E130177 3 Circuit breaker 2B 16 2 pin E10054...

Страница 90: ...mounting socket 270 E131799 1 EFXY3R2 interference elimination filter 280 E133007 3 Schuko attachment socket Table 9 2 Replacement parts for an engine with an exhaust and fuel sys tem When placing an...

Страница 91: ...l start Fig 9 4 Replacement parts for fuses Item Part number Quantity Article name 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 7...

Страница 92: ...ebau GmbH Neckartenzlinger Str 39 D 72658 Bempflingen Telephone 49 0 71 23 9737 0 Telefax 49 0 71 23 9737 50 Email info endress stromerzeuger de www www endress stromerzeuger de 2018 ENDRESS Elektroge...

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