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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.

California Proposition 65

WARNING

Batteries, battery posts, terminals and related accessories contain lead and lead
compounds, and other chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

WARNING : ELECTRIC SHOCK / INJURY



Do not touch output terminals or internal electric parts while the generator is
operating.



Do not open the check door when the starter switch is in the AUTO or START position.
It will cause injury by rotating parts such as cooling fans and fan belt.



Always turn the starter switch to the STOP position and stop the engine, then close

and lock OPERATION PANEL DOOR before checking or maintaining the engine or
any equipment.



Always be sure to use “Lifting Hook” when lifting up the generator. Using other parts
when lifting up the generator could cause the result of falling.



No persons should be under a suspended generator at all time.

CAUTION : FIRE



Always be sure to wipe up any spilled fuel or oil.

CAUTION : BURNS



Do not touch the engine and surrounding components immediately after stopping the
engine as they are still extremely 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 sub-tank if the generator overheats. Do not
touch the coolant sub-tank.



Do not touch the SCR system and surrounding components immediately after

stopping the engine as they are still extremely hot.

CAUTION : INJURY



Personnel performing suspension work must wear protective gear such as helmets,
safety shoes and gloves.



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

10. Inspection/Maintenance

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Содержание DGK125F

Страница 1: ...e outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel WARNING Cancer and reproductive Harm www P65Warnings ca gov WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defec...

Страница 2: ......

Страница 3: ...eration 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 manu...

Страница 4: ... Transport Procedures 25 6 2 Installation Procedures 25 7 Load Connections 26 7 1 Load Cable Selection 26 7 2 Connecting Load Cables 27 8 Pre Operation Inspection 31 8 1 Checking Engine Oil 31 8 2 Checking Coolant 32 8 3 Checking the Fan Belt 33 8 4 Checking the Fuel 34 8 5 Checking the DEF Diesel Exhaust Fluid 34 8 6 Checking the Spill Containment 35 8 7 Checking for Fuel Oil and Coolant Leak 35 ...

Страница 5: ...ooling fans and fan belt Always turn the starter switch to the STOP position and stop the engine then close and lock OPERATION PANEL DOOR before checking or maintaining the engine or any equipment Always be sure to use Lifting Hook when lifting up the generator Using other parts when lifting up the generator could cause the result of falling Do not attempt to lift the equipment with any additional...

Страница 6: ...at there is no fuel leakage Absolutely never inspect or perform maintenance to the equipment near fire or other open flame Do not put anything other than DEF gasoline diesel fuel etc in the DEF tank Also do not put DEF diluted with water or other liquids CAUTION ELECTRIC SHOCK Do not sprinkle water on equipment or used where exposed to rain CAUTION BURNS Do not touch the engine and surrounding com...

Страница 7: ...or similar item to avoid any unexpected move when transporting by truck or other vehicle CAUTION PROPERTY DAMAGE Do not use the equipment for any improper applications Improper usage can result in an accident or malfunction If using this generator for medical equipment check before use with the medical equipment manufacturer doctor hospital or similar entity Check that the generator output setting...

Страница 8: ...ition 65 Gen Part no X505 010400 EPA emission complied notice Part no X505 008400 Warning Fire Part no X505 007650 Notice Capacity of the external tank Part no M709 000370 Terminal cover instructions Part no M704 002250 Continuous output Part no M705 001610 Warning Electric shock Part no X564 000570 DEF AdBlue Complied notice Part no M708 000070 Warning Injury Part no X505 007550 Caution GM SPEC L...

Страница 9: ...odel Manufacturer 4HK1X ISUZU No of Cylinders bore stroke in mm 4 4 53x4 92 115x125 Continuous Rated Output hp 152 3 Rated Speed rpm 1 800 Displacement cu in liters 316 9 5 193 Combustion System Direct injection Turbo charged Cooling Method Water cooled Starting Method Electric Fuel No 2 D S15 EPA regulation Diesel Exhaust Fluid ISO 22241 or API standard Lubricating Oil API service type CJ 4 class...

Страница 10: ... for lighting and similar equipment Power source for electrical tools and household appliances 4 1 External View Part Names CAUTION PROPERTY SECONDARY DAMAGE Do not use for any application other than those listed above If using this generator for medical equipment check before use with the medical equipment manufacturer doctor hospital or similar entity 3 Applications 4 Part Names Inspection Clean...

Страница 11: ...el Valve Oil Drain Plug Electromagnetic Fuel Pump Fuel Filter Pre Fuel Filter Main Oil Filter External Fuel Inlet External Fuel Return Oil Level Gauge Turbo Charger Cover SCR Check Panel Tie Hole Tie hole Inspection Cleaning Panel DEF Tank Check Panel Tie Hole ...

Страница 12: ...Cover Receptacle Cover Remote Start Terminal Receptacle Panel Fan Guard Battery Coolant Sub Tank Engine Check Door Air Cleaner Alternator Check Door Radiator Intercooler Coolant Drain Plug Fuel Tank Inside Intercooler Drain Plug ...

Страница 13: ...10 Engine Warranty Manual Accessories Owner s and Operator s Manual Product Warranty Manual DEF Tank Check Panel Supply Module Filter DEF Tank Muffler SCR Dosing Module SCR Check Panel ...

Страница 14: ...EF Level Pilot Lamp Hour Meter Voltage Regulator Glow Lamp Ammeter Selector Switch Starter Switch Breaker Trip Selector Switch Throttle Switch Warning Indicators Accessory Switch SCR Indicators Voltage Selector Switch Oil Pressure Water Temperature Speed Monitor Load Bank Control Switch Oil Pressure Water Temperature Speed Selector Switch Auto start Panel Optional ...

Страница 15: ...e rated at 20 amps All twist lock receptacles are rated at 50 amps Single Phase Circuit Breaker 50A Single Phase Circuit Breaker 20A Single Phase Twist Lock 240 120V Receptacle 50A Single Phase GFCI 120V Receptacle 20A Remote Start Terminal Three Phase Output Terminals Single Phase Output Terminals ...

Страница 16: ...eed the rated current 5 2 Available Output Monitor The available generated output for each output power source is displayed digitally Note Consider the digitally displayed available output as an approximate estimate Be sure to thoroughly consider the displayed value and the used load capacity when using a load such as a motor with large starting capacity The displayed output capacity might not be ...

Страница 17: ...e engine will be automatically stopped If this occurs flush the liquid stored in the spill containment Refer to section 10 Inspection Maintenance 14 Flushing Liquid in Spill Containment Note Water can also accumulate in the spill containment due to rain entering into the generator Accordingly you should periodically flush liquid accumulated within the generator However you should flush water accor...

Страница 18: ...nt battery fluid Refer to section 8 8 Checking the Battery 2 OIL PRESS Engine Oil Pressure Warning Indicator Low Oil Press If the engine oil pressure drops below 7 psi 0 48 x100 kPa during operation the OIL PRESS warning indicators illuminates and the engine will be automatically stopped If this occurs check the engine oil level and add engine oil until it reaches the maximum level Note This oil p...

Страница 19: ...he engine Contact authorized engine distributor or manufacture for repair options 5 AIR FILTER Air Cleaner Clogging Warning Indicator The AIR FILTER warning indicator illuminates if the air cleaner element becomes clogged during operation If it illuminates immediately stop the engine and clean or replace the air cleaner element Refer to section 10 Inspection Maintenance 3 Air Filter Element Cleani...

Страница 20: ...rning indicator illuminates if the coolant temperature is high the oil pressure is low the engine overspeeds the battery voltage is low or some other engine fault occurs during operation If this occurs a malfunction code is displayed on the engine and available output monitors and the engine automatically stops or the engine output is reduced If the ENGINE warning indicator illuminates contact the...

Страница 21: ... down upon DEF gets empty When replenishing diesel fuel check the amount of DEF in the tank and replenish DEF as necessary DEF LEVEL Lamp Action LAMP DEF remaining amount DEF LEVEL DEF REFILL DEF NO POWER SHUTDOWN ESCAPE MODE Less than 100 More than 75 All Lamp Turn ON Less than 75 More than 50 4 Lamp Turn ON Less than 50 More than 25 3 Lamp Turn ON Less than 25 More than 10 2 Lamp Turn ON Less th...

Страница 22: ...AMP MODE PURGE PERIODIC PURGE FORCE PURGE PERIODIC PURGE Turn ON Turn ON FORCE PURGE Turn ON Turn ON 3 DEF Indicator This lamp is lit or starts blinking to alert an error relating to SCR system which includes shortfall of DEF using DEF of low quality or disconnection of sensors Warning status ranges from stage Ⅰto stage Ⅲ The engine will shut down at stage 3 In this case conduct inspection and rep...

Страница 23: ...e the operation panel and tighten the knob Set the ACCESSORY switch to OFF and use the safety cap to cover it Set the STARTER SWITCH selector to START position Note ESCAPE MODE is available for total up to 30 minutes On and after 30 minutes the procedure above described is never applicable and the engine never restarts Upon completing repair during ESCAPE MODE it automatically switches back to the...

Страница 24: ...hows the amount of fuel in the tank All lamps are lit when the amount reaches to the maximum level and FULL is lit The lit lamp decreases as the amount of fuel in the tank reaches to EMPTY The fuel level on the control panel will only display the fuel level for the internal fuel tank 4 Fuel Leak Warning Indicator Fuel Leak Warning Indicator illuminates if the Fuel stored in the fuel tank leaked If...

Страница 25: ...he voltage cannot be accurately measured if set to L2 3 Frequency Meter Displays the frequency of the power source Check that 60 Hz is displayed during operation Indicators 1 Glow Lamp This lamp illuminates when the starter switch is on START positon This lamp turns off when pre heating is completed This lamp turns off and the generator starts Note Pre heating time depends on the coolant temperatu...

Страница 26: ...t followed by the single phase breaker Simultaneous 3 1 The three phase and single phase breakers trip simultaneously 1 3 The single phase breaker trips first followed by the three phase breaker 5 Ammeter Selector Switch This switch is for selecting the output current indicated by the ammeter Change the switch to display the following output terminal current on the ammeter Switch Selection L1 U Th...

Страница 27: ... hoses from the external fuel tank to the external fuel inlet and the external fuel return Change the lever of the 3way fuel valve to the A side to supply fuel from the external tank Refer to 9 6 Connecting with External Fuel Tank for corresponding procedures 5 8 Load Bank Control Switch This equipment is adopted Load Bank Control Switch to prevent accumulating carbon debris in a muffler or emissi...

Страница 28: ...er a lifted generator CAUTION INJURY Always be sure to use Lifting Hook 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 WARNING EXHAUST GAS POISONING Do not operate the generator in poorly ventilated areas such as indoors or...

Страница 29: ...r or overheating resulting in malfunction fault or reduced insulation of electrical components Be sure to thoroughly inspect and perform maintenance if using in such locations 7 1 Load Cable Selection Select cable for use that has sufficient thickness and an allowable current for use and distance from the generator to the equipment using the generator Note Select cable with a thickness that ensure...

Страница 30: ...00 A 1 3 0 250 A 1 0 4 0 300 A 2 0 350 A 2 0 400 A 3 0 7 2 Connecting Load Cables 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 N terminal be careful that the currents of each phase are uniform WARNING ELECTRIC SHOCK Always turn all the breakers OFF place the starter switch in the STOP pos...

Страница 31: ...is possible for the outputs to mutually affect each other Use proper tools when connecting a load to sufficiently tighten the connection Failure to sufficiently tighten will result in cable burnout Terminal cover must remain closed during operation or breaker will trip 1 Three Phase Output Terminal For three phase load Terminal voltage is 208 240 480 V For single phase load Terminal voltage is 120...

Страница 32: ...eptacle For single phase three wire type load U W terminal voltage is 240 V U N terminal voltage is 120 V W N terminal voltage is 120 V For single phase 240 V load For single phase 120 V load Single phase 120V receptacle single phase 240 120V receptacle ...

Страница 33: ... V Note If using a single phase 120 V between output terminals U N and W N connect an equivalent load between U N and W N If using a single phase three wire output terminal simultaneously with a receptacle output make sure that currents passing through each phase is less than the rated current of this generator If using at the three phase 480 V setting the output voltage of the single phase three ...

Страница 34: ...ine Oil Use only API service type CJ 4 class 2 Engine Oil Viscosity Grades Use a diesel engine oil with an appropriate viscosity corresponding to the ambient temperature refer to the table WARNING INJURY Do not open the check door when the starter switch is in the AUTO or START position It will cause injury by rotating parts such as cooling fans and fan belt Always turn the starter switch to the S...

Страница 35: ...attach and tighten the radiator cap Attach the radiator plate Note Use GM SPEC 6277M or equivalent Use a 50 50 mix of Long Life Coolant LLC Always use potable water when mixing the coolant Use LLC with the same mixture ratio in the coolant sub tank Do not increase the LLC mixture ratio unless necessary Doing so could result in overheating or another fault malfunction If adding LLC be sure to use t...

Страница 36: ...lt 1 Fan Belt Tension Press the middle of the fan belt with a force of approx 98N and check whether the amount of deflection is within the range of standard values Standard value amount of deflection 0 2 0 3 in 2 Fan Belt Condition Check the fan belt for damage and replace if any damage or other fault is found 3 Fan Belt Adjustment Remove the fan guard Loosen the Lock nut and Mounting Bolt of the ...

Страница 37: ...tandard defined for AUS 32 or the API American Petroleum Institute standards Adding liquids etc other than DEF may result in a malfunction of the SCR system Do not fill with DEF past the FULL position of the DEF tank The level gauge mounted in front of the DEF tank is intended to prevent oversupply and overflow of DEF not to measure the remaining amount of DEF Check the remaining amount of DEF on ...

Страница 38: ...e check door and check for fuel oil and coolant leakage from fuel piping connections and similar locations 8 8 Checking the Battery Check the fluid level and add distilled water until it reaches the upper level when the fluid level is near the lower level Check the terminals for looseness and tighten properly CAUTION FIRE If fuel or oil is leaking repair the leaking location before operating CAUTI...

Страница 39: ...t Remove the clamp and cable from positive post from the battery Remove the hold down clamp from the battery Remove the battery from the seat Install the battery by performing the above procedures in the reverse order First connect the positive cable of the replaced battery Note Make sure that the removed cable does not come in contact with the battery post Do not disconnect the battery cable imme...

Страница 40: ...e engine contains substances that are harmful to human health Do not direct exhaust fumes at bystanders or buildings WARNING INJURY Always be sure to check that the breakers on load side and switches for any equipment using the generator are at OFF before turning the breaker to ON Also be sure to advise personnel on the load side that power will be turned on before operating the breaker Close all ...

Страница 41: ...s to ON to start AC power delivery 2 Auto Start Use the VOLTAGE REGULATOR dial to adjust the voltage to the specified value Turn on the three phase and single phase breakers on the operation panel of this machine Set the ACCESSORY switch to OFF position and use the safety cap to cover it Set the STARTER SWITCH selector to AUTO position The engine starts when the REMOTE START terminal closes Note T...

Страница 42: ...xcessive load as the available power is only one half 9 3 Procedures during Operation 1 Checks after Startup Make sure that all meters and indicators are in normal status Refer to section 5 Equipment Check that there is no abnormal vibration or noise Check that the exhaust gas color is normal When operation is normal the exhaust gas should be colorless or slightly bluish Note If abnormal stop usin...

Страница 43: ...t for approximately 1 minute and loosen the air bleeder plug to remove the air from the fuel filter Repeat Steps 3 through 5 at least 3 times until air does not come out from the air bleeder plug Securely tighten the air bleeder plug and wipe off the fuel spread around Set the ACCESSORY switch to OFF and use the safety cap to cover it Start the engine If the engine does not start at this time repe...

Страница 44: ...rator will not be used for a prolonged period If you leave the selector in the AUTO or START position the standby current may drain the battery 2 Auto Stop The engine stops when the REMOTE START terminal opens Set the STARTER SWITCH selector to STOP Note Never turn accessory switch ON during operation The engine keeps running while accessory switch is ON Set the STARTER SWITCH selector to STOP pos...

Страница 45: ...uid has exceeded the specified level making it necessary to flush the fluid 7 Spill Containment Fluid Overflow Spill containment accumulated fluid has exceeded the specified level making it near the fill 8 Engine Malfunction Some other engine fault occurs during operation 9 SCR System Monitor Lamp DEF Empty DEF remaining amount 0 SCR system error and DEF quality abnormality An abnormality occurs i...

Страница 46: ...om the external tank fuel inlet return Turn the lever completely as far as possible If the lever is not completely pressed to either side it might not be possible to supply fuel causing the engine to stop Set the supply side so that it is 0 6 to 0 8 in 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 S...

Страница 47: ... before checking or maintaining the engine or any equipment Always be sure to use Lifting Hook when lifting up the generator Using other parts when lifting up the generator could cause the result of falling No persons should be under a suspended generator at all time CAUTION FIRE Always be sure to wipe up any spilled fuel or oil CAUTION BURNS Do not touch the engine and surrounding components imme...

Страница 48: ...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 Description Daily Every 250 hrs Every 500 hrs Every 750 hrs Every 1 000 hrs E...

Страница 49: ...rs Radiator and Intercooler Clean Valve clearance Check Adjust Supply pump filter Check Clean Fuel injector Check Elimination of carbon in the exhaust pipe line and muffler DEF leakage DEF filter replacement SCR system in the Supply module SCR system inspection Dosing module inspection SCR system Generator Indicators Gauges Alarms Check Insulation test Others Spill containment fluid Check Drain Sp...

Страница 50: ...e up any spilled engine oil 2 Replacing the Oil Filter Replace Every 500 hours Drain the engine oil Refer to section 1 Engine Oil Replacement Remove the oil filter using a filter wrench Spread a thin layer of oil on a new oil filter gasket Thread the oil filter by hand do not use a filter wrench and it in until the gasket contacts the seal surface and then tighten it with one turn using filter wre...

Страница 51: ... the air cleaner inlet duct Refrain from using commercially available cleaning agent to remove dust clinging to the sensor otherwise the engine output will be reduced Outer Element part no P821938 Isuzu part no Inner Element part no P821963 Isuzu part no Cleaning the air filter element outer element If dry dust is adhering Blow compressed air from inside the element If carbon or oil is adhering Re...

Страница 52: ...g After attaching be sure to always start the engine and check that there is no fuel leakage Always be sure to wipe up any spilled fuel Main filter element part no 8983129180 Isuzu part no After replacing the filter always air out the fuel system Refer to section 9 3 Procedures during Operation Adjust the interval from every 500 hours to every 250 hours depending on the fuel management and refuel ...

Страница 53: ...ours to every 250 hours depending on the fuel management and refuel status 7 Electromagnetic Fuel Pump Filter Cleaning Replacement Clean Replace Every 500 hours Place a container under Fuel Pump to catch spilled fuel Turn the cover located at the bottom of pump counter clockwise and remove cover Remove the filter and gasket Clean the filter with the compressed air and rinse it in the fuel before i...

Страница 54: ...er together with the joint bolt The supply pump strainer is assembled into the joint bolt located at the inlet side of the supply pump This joint bolt is a component which cannot be disassembled so do not pull out the strainer inside Engine Supply Pump Joint Bolt Including Strainer part no 8980749550 Isuzu part no Fuel packing part no 8982513450 Isuzu part no 9 Supply Module Filter Replacement Rep...

Страница 55: ... the plug or wrap it in seal tape After the water has been drained reinsert the fuel drain plug Note After reinserting the fuel drain plug be sure to always check that there is no fuel leakage 11 Coolant Replacement Replace Every 1000 hours or every 1 year Set a container to catch spilled coolant Remove the radiator plate Remove the radiator cap Remove the radiator coolant drain plug Apply sealant...

Страница 56: ...r and oil has been drained reinsert the drain plug Note After reinserting the drain plug be sure to always check that there is no leakage 14 Flushing Liquid in Spill Containment Check Daily Set a container to collect liquid from the flushing port of the drain plug on the front of this generator Remove the drain plug Note If oil or other liquid is mixed in with the flushed liquid this indicates tha...

Страница 57: ...such as indoors or tunnels as the exhaust gas of the engine contains substances that are harmful to human health Do not direct exhaust fumes at bystanders or buildings WARNING INJURY Always be sure to check that the breakers on load side and switches for any equipment using the generator are at OFF before turning the breaker to ON Also be sure to advise personnel on the load side that power will b...

Страница 58: ...en high pressure cleaning inside the rear cover is performed please make sure that the wiring connector of the SCR system and the electronic control device do not come into direct contact with water Failure to observe this precaution will cause malfunction or malfunction CAUTION BURNS Do not touch the SCR system and surrounding components immediately after stopping the engine as they are still ext...

Страница 59: ...intenance 14 Flushing Liquid in Spill Containment Store in a secured location Clean up all generator components and store in a dry and dust free location Also cover when storing so that rain cannot enter through the suction or exhaust ports Note Adjust the fluid of the removed battery to the appropriate level and recharge approximately every month WARNING INJURY Always turn the starter switch to t...

Страница 60: ...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 WARNING ELECTRIC SHOCK INJURY Do not touch output terminals or internal electric parts while the gen...

Страница 61: ...Engine starts but stalls immediately 1 Fuel filter is clogged 2 Water is interfused in fuel line 3 Air is interfused in fuel line 4 Mistake of connecting with external tank 5 Air filter element is clogged 6 Lubricant oil is insufficient 7 Emergency operation Fault detection 1 Clean Replace fuel filter 2 Drain water in fuel filter or fuel tank 3 Extract the air 4 Check fuel piping 5 Check Replace a...

Страница 62: ...ted voltage 1 Voltage meter is defective 2 AVR is defective 3 Voltage regulator dial is defective 1 Contact distributor or dealer for repair 2 Contact distributor or dealer for repair 3 Contact distributor or dealer for repair Pointer exceeds the rated voltage 1 Voltage meter is defective 2 AVR is defective 3 Improper load cable connection 4 Voltage switch is set to 480 V 1 Contact distributor or ...

Страница 63: ...60 13 Generator Circuit Diagram ...

Страница 64: ...61 14 Engine Electrical Circuit Diagram ...

Страница 65: ...62 ...

Страница 66: ...63 ...

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Страница 68: ... 2020 ...

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