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.
DGM60MK/LU
X750-020 73 3
X750801-370 3
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.
 If disposing of this generator, do so in a manner that is in compliance with laws related to
industrial waste. Contact the authorized distributor where the generator was purchased if you
have any inquiries regarding proper disposal.
 Caution notice ranks in this manual are classified as follows.
WARNING : Indicates a potentially hazardous situation which, if not
avoided, can result in death or serious injury
CAUTION : Indicates a potentially hazardous situation which, if not avoided,
can result in minor or moderate injury and property damage.
< NOTE > :
Other types of cautions and indications.
 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.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Safety Instructions .......................................................................... 2
Specifications .................................................................................. 5
2-1. Specifications ............................................................................ 5
2-2. Ambient Conditions ................................................................... 6
Applications ..................................................................................... 6
Part Names ....................................................................................... 6
4-1. External View/Part Names ........................................................ 6
4-2. Operation Panel Part Names .................................................... 8
Equipment ........................................................................................ 9
5-1. Output three-phase and single-phase simultaneously............... 9
5-2. Available Output Monitor ........................................................... 9
5-3. Warning Indicators .................................................................... 9
5-4. Meters and Gauges ................................................................. 11
5-5. Spill Containment .................................................................... 14
5-6. Fuel Piping Switch (3Way Fuel Valve) ..................................... 15
Transporting/Installing .................................................................. 16
6-1. Transport Procedures .............................................................. 16
6-2. Installation Procedures ............................................................ 17
Load Connections ......................................................................... 18
7-1. Load Cable Selection .............................................................. 18
7-2. Connecting Load Cables ......................................................... 19
Pre-Operation Inspection .............................................................. 22
8-1. Checking Engine Oil ................................................................ 22
8-2. Checking Coolant .................................................................... 23
8-3. Checking the Fan Belt ............................................................. 24
8-4. Checking the Fuel ................................................................... 24
8-5. Checking the Spill Containment .............................................. 25
8-6. Checking for Fuel, Oil and Coolant Leaks ............................... 25
8-7. Checking the Battery ............................................................... 26
Operating Procedures ................................................................... 27
9-1. Initial Startup/Pre-Check.......................................................... 27
9-2. 240/480-V Switching Function ................................................. 28
9-3. Procedures during Operation .................................................. 29
9-4. Stopping Operation ................................................................. 29
9-5. Protective Functions ................................................................ 30
9-6. Connecting with External Fuel Tank ........................................ 31
Inspection/Maintenance ................................................................ 32
Long-Term Storage ........................................................................ 40
Troubleshooting............................................................................. 41
Generator Circuit Diagram ............................................................ 44
Engine Electrical Circuit Diagram ................................................ 45
1
1.
Safety Instructions
WARNING : EXHAUST GAS POISONING
 Do not operate the generator in poorly ventilated areas 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 : ELECTRIC SHOCK
 Before connecting or disconnecting load cables to/from the output terminal, always turn the output
circuit breakers to the OFF position, stop the engine, and remove the ignition key.
 Close the output terminal cover before operating.
 Do not insert a pin, wire or other metal object into the electrical outlet.
 Do not touch the generator if the generator or casing becomes wet during operation.
 Do not touch output terminals or internal electric parts while the generator is operating.
WARNING : INJURY
 Close all doors and lock them during operation.
 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.
 Use the lifting hook to lift the machines, and do not lift up by 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 suspended generator.
 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 or off before operating the breaker.
 Do not use the fuel tank lifting hook to lift up when the fuel tank that contains fuel, and also do not
lift up with the fuel tank and spill containment as a single unit. Doing so could result in the tank
falling.
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.
2
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 3 ft. (1 m) 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.
 If fuel spills, always be sure to open the spill containment drain valve and drain off the spilled fuel.
 If fuel or oil is leaking, 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 engine as
they are still hot.
 Do not open the radiator cap immediately after stopping the engine. Doing 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.
 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.
CAUTION : INJURY
 Always be sure to use lifting hooks when lifting up the generator, and slowly lift it straight up.
 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.
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.
3
 Warning/Caution Label Locations
If warning or caution labels become damaged and difficult to read, replace with new labels in
the indicated locations. Order labels using part number indicated in the parenthesis.


Injury
Simul-Phase
(Part no. : X505-004630)
(Part no. : X505-006960)



Caution: gm spec LLC
Caution: fire
Caution: do not change
(Part no. : X505-004650)
(Part no. : X505-004880)
(Part no. : X505-004620)


Injury
Danger caution
(Part no. : X505-006970)
(Part no. : X505-004660)

Burn
(Part no. : X505-004400)


Spill containment bolt
Terminal cover instructions
(Part no. : M707-000380)
(Part no. : M704-002250)
○
Continuous output
(Part no. : M705-000650)
11
4
2.
Specifications
2-1. Specifications
Model
Unit
Generator Type
-
Rated Frequency
Hz
kVA
kW
kVA
kW
V
V
A
A
A
A
A
Three phase
Rated Output
Alternator
Single phase
Rated Voltage
Unit
Engine
Rated Current
Power Factor
Insulation class
Excitation
No. of Poles
Type
Model(Manufacturer)
No. of Cylinders
(bore × stroke)
Continuous Rated
Output
Rated Speed
Displacement
Combustion System
Cooling Method
Lubricating Method
Starting Method
Fuel
Lubricating Oil
Fuel Tank Capacity
Lubricant Volume
Cooling Water Volume
Starting Motor Capacity
Charging Alternator
Capacity
Battery Capacity
Length
Width
Height
Dry Weight
Installed Weight
Three phase
Single phase
Three phase-208V
Three phase-240V
Three phase-480V
Single phase-120V
Single phase-240V
-
DGM60MK/LU
Revolving Field Brushless AC
Simultaneous 3 Phase-120V/240V
1 Phase
60
60
48
36/ [18] *1
36/ [18] *1
208/240/ [480] *1
120/139/240/[277] *1
144
144
72
150×2 [75 x 2]*1
150 [75]*1
Three phase 0.8, Single phase 1.0
F
Self Excitation (brushless)
4
Vertical Water-Cooled 4-Cycle Diesel
Kubota V3800DI-TI
(in./mm)
4 (3.94×4.72/100×120)
hp
77
rpm
Cu.in./liters
gal./liters
gal./liters
gal./liters
V-kW
1800
230/3.769
Direct Injection (Turbo-charged)
Radiator
Forced Lubrication
Electric
No. 2-D EPA regulation
CF class or higher
111/420
3.5/13.2 (including filter 0.1/0.4)
3.3/12.5 (including sub-tank 0.4/1.6)
12-3.0
V-W
12-960
in./mm
in./mm
in./mm
lbs./kg
lbs./kg
12V-92AH
78/1970
35/880
64/1630
2843/1290
3703/1680
*1: Output is that shown in brackets if using with the 240/480-V switching function set to 480 V.
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: 5 to 104 °F (-15 to 40 °C)
■ Relative humidity:
80% or less
■ Elevation:
984 ft. (300 m) 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
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.
4.
Part Names
4-1. External View/Part Names
Lifting Hook
Tie-Down
Tie-Down
Terminal Cover
Operation Panel Door
Fuel inlet
Fuel Drain plug
Spill Containment Drain valve
Spill Containment Drain plug
6
Radiator Plate
w
Tie-Down
Radiator
Oil Separator
サ
ブ
タ
ン
ク
* Shown with side-plate removed.
Air Cleaner
Tie-Down
Coolant Sub-Tank
Alternator Check Door
Engine Check Door
Oil Level Indicator
Battery
Oil Filter
Fuel Tank
Fuel Filter
Fuel Pre-Filter
Oil Filler
Water Separator
External Tank Fuel Inlet
External Tank Fuel Return
3way fuel valve
Oil Drain plug
Coolant Drain plug
Accessories
Owners
Manual
Starter Key (2 pieces)
7
4-2. Operation Panel Part Names

3-Phase Circuit Breaker

1-Phase Circuit Breaker

Voltmeter

Ammeter

Frequency Meter

Pilot Lamp

Voltage Regulator

Ammeter Selector Switch

Breaker Trip Selector Switch

Warning Indicators
○
○
○
○
○
○
○
○
○
○
11
Engine Monitor
12
Oil pressure/Water Temperature/Speed
Selector Switch
13
Display Selector Switch
14
Available Output Monitor
15
Fuel Meter
16
Hour Meter
17
Pre-Heating Indicator
18
Starter Switch
19
Throttle Switch
20
Voltage Selector Switch
8
5.
Equipment
5-1. Output three-phase and single-phase simultaneously
This generator is capable of outputting three-phase and single-phase three-wire
simultaneously. (Three-phase output terminal and single-phase three-wire output terminal are
equipped individually.)
Neither switching operation of output nor switching operation of wiring is needed.
Single-Phase Three-Wire Output Terminal
Three-Phase Output Terminal
L1
L2
L3
N/G
U
W
N/G
< NOTE >
 Refer to section “7-2. Connecting Load Cables” for Load Connections.
 If using three-phase output simultaneously with a single-phase three-wire type output, use
in a range where the total current does not exceed the rated current.
5-2. Available Output Monitor
The available generated output for each output power source is displayed digitally. You can
use the display selector switch to change the display in the following order: three-phase,
single-phase three-wire U-W output, and single-phase three-wire U-N/G output. Three-phase
output is constantly displayed when the engine is stopped.
< NOTE >
 Consider the digitally displayed available output as an
approximate estimate. Be especially sure to thoroughly
consider the displayed value and the used load capacity when
using a load such as that of a motor with a large starting
capacity.
 The displayed output capacity might not be correct values if
using a four-wire connection (single-phase using the N/G
terminal) for a three-phase output power source. Connect to a
single-phase/three-line type power source if using a
Display Selector
Switch
single-phase power source.
 If “- -” is displayed for the available output, it means that usage
has exceeded the rated capacity. Immediately stop the equipment being used and reduce the
load capacity of the equipment.
5-3. Warning Indicators
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.
9
CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after
stopping the engine as they are still hot.
This generator is equipped with the following warning indicators: BATTERY (battery charge),
OIL PRESS (engine oil pressure), WATER TEMP (coolant temperature), OVER SPEED
(engine overspeed), AIR FILTER (air cleaner clogging), SPILL CONTAINMENT (spill
containment amount), and ENGINE (engine malfunction). An indicator lights up if a
malfunction/fault occurs during operation and the engine automatically stops depending on the
fault type. Moving the starter switch from STOP to RUN causes the following indicators to light
up for approximately 0.5 sec.: OIL PRESS, WATER TEMP, and ENGINE.
(1) WATER TEMP (Coolant Temperature) Warning Indicator (High Water Temp.)
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 230 °F 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.
(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 7 psi (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”.)
10
(3) OVER SPEED (Engine Overspeed) Warning Indicator
This generator is equipped with a function such that the engine is automatically stopped if an
engine fault occurs causing the engine speed to increase excessively. If the engine speed
rises above 2070 rpm during operation, the OVER SPEED and ENGINE warning indicators
light up, and the engine automatically stops. If this occurs, it is probable that some
malfunction has occurred in the engine. Contact the authorized distributor where the
generator was purchased.
(4) BATTERY (Battery Charge) Warning Indicator (Low Battery Voltage)
The BATTERY warning indicator lights up when charging is not possible during operation. If
charging is not possible and the battery voltage drops below 8 V, the ENGINE warning
indicator also lights up and the engine automatically stops. If this occurs, contact the
authorized distributor where the generator was purchased.
< NOTE >
 This battery charging warning indicator cannot detect battery deterioration or insufficient battery
fluid. (Refer to section “8-7. Checking the Battery”.)
(5) AIR FILTER (Air Cleaner Clogging) Warning Indicator
The AIR FILTER warning indicator lights up if the air cleaner element becomes clogged
during operation. If it lights up, immediately stop the engine and clean or replace the air
cleaner element.
(Refer to section “10. Inspection/Maintenance (3) Air Filter Element Cleaning/
Replacement”.)
(6) SPILL CONTAINMENT (Spill Containment Amount) Warning Indicator
The SPILL CONT warning indicator lights up if the liquid stored in the spill containment
exceeds approximately 10 gal. during operation. If it lights up, immediately stop the engine
and flush the liquid stored in the spill containment.
(Refer to section “10. Inspection/Maintenance (8) Flushing Liquid in Spill Containment”.)
(7) ENGINE (Engine Malfunction) Warning Indicator
The ENGINE warning indicator lights up 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 lights up, contact the authorized distributor where the
generator was purchased.
5-4. Meters and Gauges
Engine Meters and Gauges
(1) Hour Meter
Oil Press
Displays the operating time. Use this as a rough estimate
for managing the timing of periodic inspection. Be careful
as the hour meter operates when the starter switch is at
RUN regardless of whether the engine is running.
Water Temp
Speed
Fuel Meter
Selector
Switch
Hour Meter
時間計
11
(2) Engine Monitor
Displays the engine speed, water temperature and oil pressure. Switching the selector
switch changes the display in the following order: Speed  Water temp  Oil press. Engine
speed is first displayed when the engine is started.
 Speed
Displays the engine speed. 1800 rpm is displayed when at 60 Hz.
 Water Temp
Displays the temperature of the engine coolant. Normal temperature displayed during
operation should generally between 158 and 203 °F depending on use conditions.
< NOTE >
 If the coolant temperature rises above 212 °F(100°C), immediately stop all equipment using the
generator, and idle the engine while cooling it to lower the coolant temperature.
 Oil Press
Displays the pressure of the engine lubrication system. Normal pressure displayed during
operation should generally between 35 and 57 psi depending on use conditions.
However, the pressure will rise above this range immediately after starting a cold engine.
Idle the engine until it reaches the normal pressure.
(3) Fuel Meter
Displays the amount of fuel in the internal fuel tank. When the tank is full, all lamps are lit up
and FULL is displayed. The amount of lamps lit up decreases as the amount of fuel
decreases as it approaches EMPTY. Add fuel immediately when only one lamp is displayed.
The fuel meter on the control panel will only display the fuel level for the internal fuel tank.
Generator Meters and Gauges
(1) Voltmeter
The voltmeter displays the three-phase output
voltage (voltage between L1-L3). Check that
240 V is displayed during operation. Output
voltage for single-phase three-wire (voltage
between U-W) is the same voltage as the three-phase output voltage (voltage between
L1-L3). Accordingly, use the voltage meter displayed value as a reference.
* Check that 480 V is displayed during operation if using at the three-phase 480-V setting.
The voltage of single-phase three-wire output of “U-W Voltage” is a value that is one half of
the displayed voltage meter value.
(2) Ammeter
Displays the output current (phase current) of the generator. Turn the ammeter selector
switch to “L1+U” to display the output current of the three-phase L1 phase and single-phase
U phase. Turn the switch to “L3+W” to display the output current of the three-phase L3
phase and single-phase W phase. “L2” displays the output current of three-phase output
terminal L2.
< NOTE >
 If measuring the output current for a single-phase three-wire type, turn the ammeter selector
switch to “L1+U” or “L3+W”. The 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.
12
Indicators
(1) Pre-heating Indicator
Pilot Lamp
The pre-heating indicator lights up when the starter switch is at
PREHEAT. The pre-heating indicator turns off when
pre-heating is completed to indicate that it is possible to start
the generator.
< NOTE >
 Pre-heating time depends on the coolant temperature, and
should be completed in approximately 0.5 to 15 sec.
(2) Pilot Lamp
Pre-Heating Indicator
This lights up when the engine is operating to indicate that
power is being generated.
Switches
(1) Starter Switch
Breaker Trip
Selector Switch
 STOP
The engine is stopped and all power is
cut off when in this position. The key
can be inserted and removed when in
this position.
 RUN/PREHEAT
Position for operating the generator. It
is also the position for air heater
preheating in order to increase
startability in cold condition.
Starter
Switch
3-Phase
Breaker
1-Phase
Breaker
Am Meter
Selector Switch
< NOTE >
 Do not leave the generator in this position with the engine stopped.
Doing so will cause the battery to drain.
 START
Position where the engine is started. If you remove your hand from the key, the switch
automatically returns to RUN.
(2) Breakers
These switches are for transmitting electrical power to the load side. Turn to ON to output
voltage to the output terminals. Transmission of electricity to the load side is cut off when
there is a short circuit or overload on the load side.
< NOTE >
 Do not operate these breakers to operate or stop a load.
13
(3) Breaker Trip Selector Switch
This switch is for selecting the tripping order of the three-phase and single-phase breaker
when there is a short circuit or overload on the load side. If the three-phase or single-phase
breaker is selected for precedence in tripping, the selected breaker will trip first when the
total generator output exceeds the rated capacity.
After that, the other breaker will also trip if the generator output exceeds the rated capacity
again.
 Switch Selection
 “3  1”: The three-phase breaker trips first 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.
(4) 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”: Three-phase L1 phase + Single-phase three-wire U phase (total)
 “L2”: Three-phase L2 phase
 “L3+W”: Three-phase L3 phase + Single-phase three-wire (total)
< NOTE >

If measuring the output current for a single-phase three-wire type, turn the ammeter selector
switch to “L1+U” or “L3+W”. The voltage cannot be accurately measured if set to “L2”.
Voltage Regulator/Engine Speed Switch
(1) Voltage Regulator
This dial is for regulating voltage output by the generator. Turn the dial
clockwise to increase the voltage and counterclockwise to decrease it.
(2) Engine Speed Switch
 Throttle Switch
This switch is for changing the engine speed. Set to IDLING when starting,
warming up and cooling down the engine, and set to RUN during rated
operation.
5-5. Spill Containment
The bed of this generator is equipped with a spill containment (structure for preventing
leakage of liquids) so that any spilled liquid will not leak to outside of the generator when oil or
fuel is spilled or leaks. Before starting operation, check if there is accumulated liquid in the
spill containment. Flush out any liquid that has accumulated. Refer to section “8-5. Checking
the Spill Containment” for inspection procedures. Refer to section “10.
Inspection/Maintenance (8) Flushing Liquid in Spill Containment” for flushing procedures.
The generator is equipped with the following in order to prevent liquid from spilling in case you
forget to flush the liquid: The operation panel is equipped with an indicator that lights up when
its sensor is triggered as the spill containment capacity accumulated enough liquid to reach
the 1/4 full (approx. 10 gal.) level.
14
< 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 according to the frequency/amount of rainfall.
 The types of liquids that can accumulate in the spill containment include oil, fuel, coolant and
battery fluid such that it is not possible to distinguish between rainwater and other liquids. Dispose
of flushed liquids according to the applicable laws and regulations.
5-6. Fuel Piping Switch (3Way Fuel Valve)
CAUTION:
 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 three-way fuel valve to switch to supply fuel from the external tank. In that case,
the internal fuel tank is not used.
(1) If using the internal fuel tank:
The three-way fuel valve is turned to the “A” side when the generator is shipped from the
factory.
< NOTE >
 When disconnecting piping from the external tank, turn the lever to the “A” side, and attach the
bundled plug to the external tank fuel inlet/return.
(2) If using an external fuel tank:
Pass the fuel hose from the external tank through the external fuel ports and connect to
the external tank fuel inlet/return of the 3way fuel valve. Change the lever of the 3way fuel
valve to the “B” side to supply fuel from the external tank.
Refer to “9-6. Connecting an External Fuel Tank” for corresponding procedures.
< 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.
3Way Valve
External Fuel Ports
Inlet port
Return port
Position B
Position A
15
6.
Transporting/Installing
6-1. Transport Procedures
WARNING : INJURY
 Do not lift up the unit using tie downs. 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.
(1) Lifting Procedures
Always be sure to use lifting hooks when lifting up the generator, and raise it slowly at a
completely vertical angle.
(2) Transport
When transporting this generator, tie rope to the left and right tie downs, and securely fix the
generator.
Lifting
Hook
Tie-Down
< NOTE >
 Handle this generator with great care when raising, lowering and transporting. Roughly handling
this generator can result in damage or malfunction.
16
6-2. Installation Procedures
WARNING : EXHAUST GAS POISONING
 Do not operate the generator in poorly ventilated areas 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.
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.
 Operate this generator 3 ft. (1 m) 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.
 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.
 Position this generator on a hard, flat and leveled surface that serves as the foundation.
 Position this generator 3 ft. (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 generator is manufactured presupposing that it will be installed on a flat, hard and leveled
surface that serves as the foundation. Accordingly, care must be taken as using under any other
installation conditions can result in a fault or malfunction.
 Do not place any objects where they will interfere with the radiator or muffler exhaust ports.
Objects interfering with these ports will result in reduced engine output, overheating, and electrical
component fault/malfunction.
 Operating the equipment in dusty or excessively salty location can result in a clogged radiator 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.
17
7.
Load Connections
7-1. Load Cable Selection
CAUTION : PROPERTY DAMAGE
 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.
Select cable for use that has sufficient thickness and an allowable current possible for use,
giving consideration to the distance from the generator to the equipment using the generator.
< NOTE >
 Select cable with a thickness that ensures that the voltage drop across the cable will be
within 5% of the rated voltage.
 Load Cable Selection Tables
(Ex.) If used voltage is 240 V and voltage drops by 12 V.
Three-phase: Cabtyre cables
(Unit: AWG)
Length 100 ft (30 m)
or less
Current
50 A
100 A
150 A
200 A
10
8
6
4
200 ft
(61 m)
8
4
2
1
300 ft
(91 m)
6
2
1
1/0
400 ft
(122 m)
4
1
1/0
2/0
500 ft
(152 m)
4
1
2/0
3/0
(Ex.) If used voltage is 120 V and voltage drops by 6 V.
Single-phase Cabtyre cables
(Unit: AWG)
Length
Current
10 A
20 A
30 A
50 A
100 A
130 A
170 A
200 ft (61 m)
or less
10
8
6
4
1
1/0
2/0
18
300 ft (91 m)
400 ft (122 m)
8
6
4
2
2/0
3/0
4/0
8
4
2
1/0
3/0
4/0
-
600 ft
(183 m)
2
1/0
3/0
4/0
7-2. Connecting Load Cables
WARNING : ELECTRIC SHOCK
 Before connecting or disconnecting the load cables to/from the output
terminal, always turn the output circuit breakers to the OFF position, stop the
engine, and remove the ignition key.
 Close the output terminal cover before operating.
 Do not insert a pin, needle or other metal object into the electrical outlet.
 Do not touch the generator if the generator or casing becomes wet during
operation.
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 N/G terminal, be careful that the currents of each phase are uniform.
 If using three-phase output simultaneously with a single-phase three-wire type output, use in a
range where the total current does not exceed the rated current.
 If using three-phase output simultaneously with a single-phase three-wire type output, be careful
as it 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 tightened 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 240/480 V.
L1
L2
L3
N/G
Load
 For single-phase load:
 Terminal voltage is 139/277 V.
L1
Load
L2
Load
L3
Load
19
N/G
 For single-phase load:
 Terminal voltage is 240/480 V.
L1
L2
Load
L3
Load
N/G
Load
(2) Single-Phase Three-Wire Output Terminal and Receptacle
 For single-phase three-wire type load:
 U-W terminal voltage is 240 V.
 U-N/G terminal voltage is 120 V.
 W-N/G terminal voltage is 120 V.
 For single-phase 240 V load:
U
W
 For single-phase 120 V load:
U
N/G
Load
Load
W
N/G
Load
 Single-phase 120-V receptacle, single-phase 240/120-V receptacle
CON1
CON3
Load
Load
CON2
CON4
Load
Load
20
CON5
CON6
CON7
Load
Load
Load
 Power available for use by each output terminal and receptacle are as show below.
CON1
CON3
Load
Load
CON2
CON4
CON5
CON6
CON7
Load
Load
Load
U
W
N/G
U-W 、U-N/G 、W-N/G
W-N/G
Load
U-N/G
Load
Use is possible up to the kVA as shown below.
1-phase, 3-wire
output terminal
U-W
1-phase 120-V receptacle
CON1
CON2
CON3
CON4
1-phase 240/120-V
receptacle
CON5 CON6 CON7
36/ [18]
Total
36/ [18]
2.4
2.4
2.4
2.4
U-N/G
18/ [9]
W-N/G
18/ [9]
* Figures in brackets are used when set to 480 V.
7.2
7.2
7.2
36/ [18]
36/ [18]
< NOTE >
 If using a single-phase 120 V (between output terminals U-N/G and W-N/G), connect an
equivalent load between U-N/G and W-N/G.
 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-wire type is
single-phase 240/120 V, which is the same as the three-phase 240-V setting. Accordingly, care
must be taken to not draw an excessive load as the available power is only one half.
21
8.
Pre-Operation Inspection
WARNING : INJURY
 Always be sure to stop the engine and remove the engine key when
performing inspection or maintenance.
 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.
CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after
stopping the engine as they are still hot.
CAUTION : FIRE
 Always be sure to wipe up any spilled fuel or oil.
8-1. Checking Engine Oil
To check the engine oil, keep the equipment level, remove the oil level indicator and wipe the
end of it so that no oil remains, and then re-insert the dipstick fully. Prior to starting the engine,
make sure to fill the engine oil through the oil filler so that it reaches the MAX line.
< NOTE >
 Wait approximately five
minutes or more after
stopping the engine or
adding oil before checking
the oil level again.
 An accurate oil level
reading cannot be obtained
if the generator is not
leveled.
 Do not overfill with oil.
Doing so will damage the engine.
MIN
Oil Level Indicator
MAX
Oil Level
Indicator
Oil Filler
OK
Not
Enough
Too
Much
(1) Types of Engine Oil
Use only API service-type CF class or better.
(2) Engine Oil Viscosity
Use a diesel engine oil with an appropriate viscosity corresponding to the ambient
temperature (refer to the table).
 Relation of Viscosity/Temperature
SAE30
Temp.
(°F)
-22
5
32
59
SAE 10W-30
22
10W
77
86
(3) Engine Oil Replacement Amount
Total Lubrication Oil Amount
3.5 (0.1) gal
Value in parenthesis is the filter capacity.
8-2. Checking Coolant
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
2
3
Remove the sub-tank cap.
Fill the sub-tank with coolant until it reaches the
FULL line.
Re-attach the cap.
FULL
LOW
(2) Filling the Radiator
1
2
3
4
5
Radiator
Plate
Remove the radiator plate.
Remove the radiator cap.
Fill with coolant through the filler neck until the
radiator is full.
Re-attach and tighten the radiator cap.
Attach the radiator plate.
Filler Neck
給水口
Radiator Cap
< NOTE >
 Use a 50:50 mix of Long Life Coolant (LLC) for engine coolant.
Use GM SPEC 6277M or equivalent.
 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 the same brand/type that is still in the generator.
 Do not mix different brands/types. Doing so could result in a chemical reaction and the creation of
toxic substances.
 Change the LLC every 1,000 hours.
 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.
23
 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.
(3) Coolant Amount
Total Coolant Amount
3.3 (0.4) gal
Value in parenthesis is the sub-tank capacity.
8-3. Checking the Fan Belt
(1) Fan Belt Tension
Press your finger against the middle of the fan belt. If the
slack is 1/4 to 1/2 inch, the tension is normal.
(2) Fan Belt Condition
Check the fan belt for damage and replace if any damage or
other fault is found.
Slack
(3) Fan Belt Adjustment
1
2
3
Loosen the alternator installation bolts and nuts (two
locations), rotate the adjustment bolt and adjust the fan
belt tension.
Securely tighten the alternator installation bolts and
nuts (two locations).
Check that the fan belt tension is correct.
Nut
Adjust
Bolt
Alternator
(4) Replacing the Fan Belt
Bolt
Request the authorized distributor where the generator was
purchased to replace the fan belt.
< NOTE >
 Use of a loose or damaged fan belt could result in overheating or insufficient charging.
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.
 If fuel spills, always be sure to open the spill containment drain valve and
drain off the spilled fuel.
(Refer to section “10. Inspection/Maintenance (8) Flushing Liquid in Spill
Containment”.)
Check if there is a sufficient amount of fuel and add fuel if insufficient.
The fuel meter on the control panel will only display the fuel level for the internal fuel tank.
24
< NOTE >
 The fuel injector pump, injectors and other parts of the fuel system and engine can be damaged if
any fuel or fuel additives are used other than those specifically recommended by the engine
manufacturer.
 Refer to the Engine Instruction Manual for the recommended
Fuel Strainer
Fuel Inlet
fuels.
 Always be sure to use the fuel strainer attached to the fuel
inlet.
 Carefully add fuel until the tank is full.
Tank Cap
Fuel Cover
8-5. Checking the Spill Containment
CAUTION : FIRE
 If fuel or oil is leaking, repair the leaking location before operating.
Open the check door and check the inside of the spill containment. Flush out any accumulated
liquid. Refer to section “10. Inspection/Maintenance (8) Flushing Liquid in Spill
Containment” for flushing procedures.
< NOTE >
 The types of liquids that can accumulate in the spill containment include oil, fuel, coolant and
battery fluid such that it is not possible to distinguish between rain water and other liquids.
Dispose of flushed liquids according to the related laws and regulations.
8-6. Checking for Fuel, Oil and Coolant Leaks
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.
25
8-7. Checking the Battery
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 large amount
of 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.
1 Check the fluid level, and add distilled water when it is near the lower level until it
reaches the upper level.
2 Check the terminals for looseness and tighten if loose.
< 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.
(-) Post
() Post
Upper Level
Hold-Down
Clamp
Lower Level
 Replacing the Battery
1 Remove the battery negative (-) cable. (Always be sure to remove the negative (-) side
first. )
2 Remove battery hold-down clamp.
3 Remove the battery positive (+) cable.
4 Remove the battery.
* Install the battery by performing the above procedures in the reverse order.
(First connect the positive (+) cable of the replaced battery. )
26
9.
Operating Procedures
9-1. Initial Startup/Pre-Check
WARNING : EXHAUST GAS POISONING
 Do not operate the generator in poorly ventilated areas such as an 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 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 3 ft. (1 m) or more from walls or other hindrances, and
on a level surface.
CAUTION : NJURY
 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.
Turn the three-phase and single-phase breakers on the operation panel to OFF.
2 Turn the Throttle switch to IDLING.
3 Turn the Starter switch to PREHEAT.
4 When the pre-heating indicator changes from lit up to off, immediately change the
switch to START and start the engine.
Pre-Heating
1
3-P Breaker
Indicator
1-P Breaker
< NOTE >
 Pre-heating time depends on the coolant
temperature, and completes in
approximately 0.5 to 15 sec.
 Do not continuously operate the starter
motor for 10 sec. or more.
 If repeating starter switch operation, wait 30
sec. or more between operating.
 Be aware that smoke might be generated
when the engine is started.
Starter
Switch
27
Throttle
Switch
Voltage
Regulator
5 After starting the engine, remove your hand from the starter switch.
6 The engine idles for approximately five minutes.
7 Turn the Throttle switch to RUN.
8 Adjust the voltage regulator dial to the specified voltage.
9 Turn the breakers to ON to start power transmission.
9-2. 240/480-V Switching Function
WARNING : ELECTRIC SHOCK
 If performing any electric voltage switching, turn all breakers to OFF and stop
operation.
 Lock the generator using a padlock so that no one except for designated
operators can operate switches.
CAUTION : PROPERTY DAMAGE
 Check that the voltages of the generator output setting, output terminal
connection and load power source are consistent.
1 Turn the three-phase and single-phase breakers on the operation panel to OFF and
stop operation.
2 Turn the lever of the voltage selector switch to the desired output setting.
3 Three-phase 240/480-V power is output to the three-phase output terminal. Refer to
section “7-2. Connecting Load Cables”.
4 Start the engine and turn the three-phase breaker to ON to transmit power to the
three-phase output terminal.
3-P 240V
Push
3-P 480V
1-P Breaker
Starter Switch
3-P Breaker
Padlock
< NOTE >
 If using at the three-phase 480-V setting, the output voltage of the single-phase three-wire type is
single-phase 240/120 V, which is the same as the three-phase 240-V setting. Accordingly, care
must be taken to not draw an excessive load as the available power is only one half.
28
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 using this generator and request the authorized distributor where the generator
was purchased to repair the generator.
(2) Adjustment during Operation
During load operation, check the voltmeter and finely adjust the 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.
1 Add fuel to the generator.
2 Turn the starter switch to RUN. Air bleeding is completed in approximately 30 sec.
< NOTE >
 Turn the throttle switch to IDLING, start the engine and check that the air is completely bled from
the system. If air bleeding is not complete, engine rotation will not be stable. In that case, repeat
the air bleeding operation.
9-4. Stopping Operation
CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after
stopping the engine as they are still hot.
1 Turn the switches and breakers on the load side to OFF.
2 Turn the three-phase and single-phase breakers on the operation panel to OFF.
3 Turn the Throttle switch to IDLING.
4 The engine cools down for approximately three minutes.
5 Turn the starter switch to STOP.
29
9-5. Protective Functions
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.
Protection Feature List
No.
Action
Abnormality
Breaker
Trip
Engine
Automatic
Shutdown
Warning
Lamp
Flash
Cause
Activates due to high water temperature
in the engine
Default 230°F
Activate due to low oil pressure in the
engine
Default 7 psi (0.49  100 kPa)
High Water
Temperature



2
Low Oil
Pressure



3
Battery
Charge
Insufficient



Activates in battery charge Impossible
Engine
Overspeed



Engine speed is 115% or more (2070
rpm or more)
Air Filter
Clogging Up



6
Spill
Containment
Fluid Level



7
Engine
Malfunction

()




4
5
8
Monitor Lamp
1
Overload
*  indicates the automatic activation.
30
The element is clogged making it
necessary to clean or replace the
element.
Spill containment accumulated fluid has
exceeded the specified level making it
necessary to flush the fluid.
Water temperature is high, oil pressure
is low, battery voltage is low, engine
overspeeds, or some other engine fault
occurs during operation
Activates in overload
9-6. Connecting with External Fuel Tank
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.
1
Turn the 3way fuel valve lever to the
“A” side.
(Position for using the internal tank.)
2
Remove the plugs(R3/8”) from the
3way fuel valve.
3Way
Valves
External
Fuel Ports
3
Pass the fuel hose from the external
tank through the external fuel ports and connect to the external
tank fuel inlet/return of the 3way fuel valve.
4
Turn the 3way fuel valve lever to the “B” side.
(Position for using the external tank.)
Bleed air from the external tank connecting hose. Fuel can be
supplied from the external tank after completing the above
procedures.
5
< NOTE >
Position A
Inlet
Side
Return
Side
Plug(R3/8”)
Return
Port
Inlet
Port
Position B
 Protect the piping connecting the external fuel tank and
this generator with corrugate tubing or similar in order to
External Tank
prevent interference between the generator internal parts
and the external fuel ports.
 If using a hose for the piping, use oil-resistant hose with
0.6~0.8 in
an internal diameter of 0.31 to 0.35 in (8 to 9 mm).
 Set the fuel level of the external fuel tank so that it is from
0 to 10 ft. (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 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.
 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 “9-3 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
WARNING : ELECTRIC SHOCK/INJURY
 Do not touch output terminals or internal electric parts while the generator is
operating.
 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.
 Do not lift up using tie downs. Use of such could result in the generator
falling.
 No persons should be under a suspended generator.
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 the 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 the 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.
32
Description
Daily
Each parts
(Clean/Tightening)
Engine oil
(Check/Add)

Engine oil
(Replace)
Others
Generator
Engine
Oil filter (Replace)
Coolant
(Check/Add)
Coolant (Replace/
Radiator Flush)
Exhaust color
(Check)
Water separator
(Check/Drain
excess water
and sediments)
Main & Pre-fuel
filter (Replace)
Electric fuel pump
filter (Replace)
Fuel tank
(Drain water)
Water separator
and Gauze filter
(Clean)
Fuel tank (Clean)
Check for leaks
(Fuel/Oil/Coolant)
Fuel hose
(Replace)
Air cleaner element
(Clean/Replace)
Battery fluid level
(Check)
Battery gravity
(Check)
Fan belt tension
(Check)
Fan belt (Replace)
Radiator and fins
(Clean)
Valve clearance
(Check/Adjust)
Fuel injector
(Check)
Supply pump
(Check)
Oil separator filter
(Replace)
Indicators, Gauges
(Check)
Alarms (Check)
Every
200 hrs
Every
400 hrs
Every
500 hrs
Every
800 hrs
Every
1000 hrs
Every
1500 hrs
Every
3000 hrs


1st time
at
50 hrs

1st time
at
50 hrs






(Drain)


(Replace)

(Replace)


(Clean)




(Clean)

(Replace)











Insulation test
Spill containment
fluid (Check/Drain)
Spill containment
(Check/Clean)
Every
100 hrs


33
(1) Engine Oil Replacement
First Time
Thereafter
50 hours
Every 200 hours
Oil Level
Indicator
1 Remove the oil filler cap.
Oil Filler Cap
2 Remove the oil drain plug and drain the engine oil.
Oil Filler
3 After the oil has been drained, reinsert the oil drain plug
with new packing.
4 Add oil through the oil filler until it is at the maximum level
while checking the fuel level using the oil level indicator.
5 Attach the oil filler cap.
Oil Drain plug
Packing
< NOTE >




Refer to section “8-1. Checking Engine Oil” for engine oil replacement amounts and types.
Replace the packing of the oil drain plug with new packing each time the oil is replaced.
Packing part no.: 6C090-58961 (Kubota part no.)
After reinserting the oil drain plug and shortly after starting the engine, be sure to always check
that there is no oil leakage.
(2) Replacing the Oil Filter
First Time
Thereafter
1
2
3
4
5
6
50 hours
Every 400 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, and turn by hand (do not use a
filter wrench) from when the gasket contacts the seal surface
until it is securely tightened.
Add engine oil to the generator.
Shortly after starting the engine, always be sure to check that
there is no oil leaking from the seal surface.
Gasket
< 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.: 1C020-32434 (Kubota part no.)
(3) Air Filter Element Cleaning/Replacement
Clean
Replace
100 hours
Every 400 hours
1 Remove the air cleaner clips and cleaner cap.
2 Remove the outer element.
3 Clean or remove the outer element. Replace by performing the above procedures in
reverse order.
34
< NOTE >
 Inner air element must not be reused even if it is cleaned.
 Replace the inner element when replacing the outer
element.
 Always be sure to turn the cleaner cap in the direction
indicated by the arrow.
 Replace the elements earlier if using in an excessively
dusty location.
 Do not add oil as this generator uses a dry element.
 Clear foreign material by pinching the vacuator valve
once a week in normal operating conditions or daily if
operating in a location that is excessively dirty or dusty.
Wipe away any dirt or moisture that has adhered to the
parts.
 Never touch the elements for any reason except
cleaning.
 Element part no.
Kubota Part No.
Clip
Air Cleaner Cap
Air Cleaner
Inner Element
Outer Element
Vacuator
Valve
Air Cleaner Cap
Outer Element
59700-26112
Inner Element
55231-26151
 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:
Replace with new parts.
(4) Draining Water from the Water Separator
Check
Clean
Daily
Every 200 hours
Drain water when the float (red) inside the cup floats to
the water draining position.
1
2
3
4
5
Close
Close the fuel valve.
Open
Loosen the lower valve.
After water has been drained, tighten the lower valve.
If foreign material is adhering to the gauze filter in the
Faucet
cup, remove the cup, float and gauze filter, and clean
by blowing compressed air from the inside of the
gauze filter.
Reassemble the gauze filter, cup and float to their original location.
Lever
Cup
Gauze Filter
Water Drain Level
Float (Red)
< NOTE >
 When attaching the cup, check that there is no foreign material adhering to the O-ring.
 After attaching, open the fuel valve, and be sure to always start the engine and check that there is
no fuel leakage.
35
(5) Fuel Filter Replacement (Main and Pre-Filters)
Replace
Every 400 hours
Remove the fuel filter using a filter wrench.
Spread a thin layer of oil on a new fuel filter gasket.
Thread the fuel filter by hand, and turn by hand (do not use a
filter wrench) from when the gasket contacts the seal surface
until it is securely tightened.
4 Shortly after starting the engine, always be sure to check
that there is no fuel leaking from the seal surface.
1
2
3
Gasket
< NOTE >
 Be sure to wipe away any fuel that has spilled out of the piping when removing the filter.
 Fuel filter part no.: Main filter 1K947-43171 (Kubota part no.)
Pre-filter 16631-43562 (Kubota part no.)
(6) Draining Water from the Fuel Tank
Drain Water
1
2
Every 200 hours
Remove the fuel drain plug and packing (with rubber seal).
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.
Fuel Drain Plug
 Packing part no.: V106-000110
ぱっ
 After reinserting the fuel drain plug, be sure to always check that there is no fuel leakage.
(7) Coolant Replacement
Replace
1
2
3
4
5
6
7
8
9
Every 1000 hours
Radiator Plate
Remove the radiator plate.
Remove the radiator cap.
Remove the coolant drain plug and packing.
After the coolant has been drained, reinsert the coolant
drain plug with new packing.
Remove the subtank and flush the coolant from the
subtank.
Reattach the subtank to its original position and fill with
coolant until it reaches the FULL level.
Fill the radiator with coolant until it reaches the filler
neck.
Re-attach and tighten the radiator cap.
Attach the radiator plate.
< NOTE >
 Refer to section “8-2. Checking Coolant” for coolant
information.
36
Filler Neck
Radiator Cap
Sub-tank
FULL
LOW
Water Drain
Plug
 Replace the packing of the coolant drain plug with new packing each time the coolant is changed.
 Packing part no.: 6C090-58961 (Kubota part no.)
 After reinserting the coolant drain plug and shortly after starting the engine, be sure to always
check that there is no coolant leakage.
(8) Flushing Liquid in Spill Containment
Check
1
2
Daily
Set a container to collect liquid from the flushing port of the drain valve on the front of
this generator.
Remove the drain valve plug (R 1/2) and open the valve lever.
< NOTE >
 When removing or attaching the plug, hold the drain valve fixed using a spanner or similar tool
and turn the plug.
 If oil or other liquid is mixed in with the flushed liquid, this indicates that there is an oil leak. In such
case, check for the leak location.
 The types of liquids that can accumulate in the spill containment include oil, fuel, coolant water
and battery fluid such that it is not possible to distinguish between rain water and other liquids.
Dispose of flushed liquids according to the related laws and regulations.
3
Close the valve lever after the liquid has been flushed, and apply sealant coating to the
plug or wrap it in seal tape.
Drain Faucet Lever
Drain Faucet
Loosen
Drain Faucet
Drain Faucet
Lever
Close
Fixing
Tighten
Plug
Plug(R1/2”)
Open
(9) Electric Fuel Pump Filter Replacement
Replace
1
2
3
4
Every 1000 hours
Turn the bottom cover of the pump
counter-clockwise to disassemble the pump body.
Remove the filter element and seals.
Install the new filter element and seals in the
reverse order.
To bleed the air from the fuel system,turn the
starter switch to the run position,but do not start
the engine,for 30 second.
Electric
Fuel Pump
FILTER
< NOTE >
 Fuel filter part no.:17266-52300 (Kubota part no.)
37
COVER
(10) Spill Containment Cleaning/Inspection
WARNING : INJURY
 Do not use the fuel tank lifting hook to suspend a gas tank that contains fuel,
and do not suspend with the fuel tank and spill containment as a single unit.
Doing so could result in the tank falling.
Clean
Every 500 hours
Separate the spill containment from this generator to clean and inspect the spill containment.
Separate the spill containment according to the following procedures.
1 Remove the wiring connector.
2 Remove the fuel hoses (supply and return sides).
3 Remove the four spill containment fixing bolts (M16).
< NOTE >
 Prepare a container to receive the fuel remaining in the fuel piping that will flow out of the
removed fuel piping.
4 Lift the generator, separate the spill containment and set the generator on a flat surface.
5 After cleaning and inspecting the inside of the spill containment, reassemble the spill
container with this generator by performing the above procedures in the reverse order.
6 Reassemble the fuel piping and wiring connector to their original positions.
< NOTE >
 Always be sure to connect properly in between supply and return route of fuel hose(s).
 After reassembling, bleed air from the fuel system.
(Refer to section “9-3. Procedures during Operation”.)
 After reassembling, check that there is no fuel leakage.
 Spill Containment Cleaning/Inspection
1 Use a high-pressure cleaner or similar equipment to clean the inside of the spill
2
3
4
5
containment.
Remove the drain plug (R1”) to drain the cleaning water.
After cleaning, allow water to accumulate and check that the spill containment has no
internal leakage.
Next, check that there no rust has developed inside of the spill containment. If rust has
developed, remove the rust and clean again.
After the procedures have been completed, apply sealant coating to the plug (R1) or
wrap it in seal tape.
< NOTE >
 If the fluid drained when cleaning the spill containment contains oil
or grease, dispose of it according to the related laws and
regulations.
 If the spill containment has a leak, contact the authorized distributor
where the generator was purchased.
38
Drain Plug (R1”)
Lifting Hook
Wire Connector
Bolt
Bolt
Fuel Tank
Inlet Port
Wire Connector
Fuel Line (Inlet Side)
Fuel Line (Return Side)
Spill Containment
39
Return Port
(11) Oil Separator Filter Replacement
Replace
Every 1000 hours
1 Remove the cover, and remove the O-ring and oil separator filter.
2 Assemble a new O-ring to the cover and spread a thin layer of oil on the O-ring.
3 Assemble a new oil separator filter and tighten the cover by hand.
Loosen
Oil Separator
Tighten
Cover
O-ring
Oil Separator
Filter
< NOTE >
 Replace with a new O-ring each time the oil separator filter
is replaced.
 Oil separator filter part no. (with O-ring)
1J419-05811 (Kubota part no.)
Oil Separator
11. Long-Term Storage
WARNING : INJURY
 Always be sure to stop the engine and remove the engine key when
performing inspection or maintenance.
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 engine as they are still hot.
(1) Storage Procedures
Perform the following maintenance procedures before storing this generator if it is not going
to be used for two months or more.
1 Remove the battery.
(Refer to section “8-7. Checking the Battery Replacing the Battery”.)
2 Replace the engine oil.
(Refer to section “10. Inspection/Maintenance (1) Engine Oil Replacement”.)
3 Drain the fuel from the fuel tank and filter.
(Refer to section “10. Inspection/Maintenance (5) Fuel Filter Replacement (Main
and Pre-Filters)”.)
(Refer to section “10. Inspection/Maintenance (6) Draining Water from the Fuel
Tank”.)
40
4 Clean up and inspect inside of the spill containment.
(Refer to section “10. Inspection/Maintenance (9) Spill Containment
Cleaning/Inspection”.)
5 Remove the starter key and store in a secure location.
6 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.
(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 hood of this generator is not dented,
and that bolts are not loose 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
WARNING : ELECTRIC SHOCK/INJURY
 Do not touch output terminals or internal electric parts while the generator is
operating.
 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 : FIRE
 Never allow flame to come close to the generator.
CAUTION : BURNS
 Do not touch the engine and muffler after stopping the engine as they are still
hot.
41
Inspect this generator when operation is poor to determine the fault/malfunction.
Request the authorized distributor where the generator was purchased to perform
maintenance if you cannot find any faults/malfunctions during inspection.
Engine does not start
Problem
Suspected cause
Action
Starter motor
1. Battery output is weak
1. Check battery fluid or charge
does not drive
2. Battery is deteriorated
2. Replace Battery
or speed is 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
Starter motor
1. Fuel is insufficient
1. Add fuel
drives but
2. Fuel filter is clogged
2. Clean/Replace fuel filter
engine does
3. Gauze filter is clogged
3. Clean/Replace gauze filter
not start
4. Water is interfused in fuel line
4. Drain water in water separator, fuel filter
or fuel tank
5. Air is interfused in fuel line
5. Extract the air
6. Fuel pump defective
6-1. Check/Replace fuse
6-2. Check/Replace fuel pump
7. Emergency operation/Fault detection
7. Ask our distributor to repair
<Ambient
1. Fuel is frozen
1. Use winterized fuel
temperature
2. Water in fuel line is frozen
2. Drain water in fuel line
falls down
3. Pre-heater is defective
3. Ask our distributor to repair
Engine starts but
1. Fuel filter is clogged
1. Clean/Replace fuel filter
stalls immediately
2. Gauze filter is clogged
2. Clean/Replace gauze filter
3. Water is interfused in fuel line
3. Drain water in water separator, fuel filter
4. Air is interfused in fuel line
4. Extract the air
5. Air filter element is clogged
5. Check/Replace air filter element
6. Lubricant oil is insufficient
6. Add lubricant oil
below zero>
or fuel tank
7. Emergency operation/Fault detection
7. Ask our distributor to repair
Engine oil pressure
1. Lubricant oil is insufficient
1. Add lubricant oil
is low
2. Oil filter is clogged
2. Replace oil filter
3. Oil Pressure switch is defective
3. Ask our distributor to repair
4. Oil pressure meter is defective
4. Ask our distributor to repair
5. Wrong oil is used
5. Change to proper kind and viscosity oil
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/Add coolant
6. Radiator core is clogged
6. Clean radiator core
Black smoke
1. Air filter element is clogged
1. Check/Change air filter element
comes out from Muffler
2. Fuel injection nozzle is defective
2. Ask our distributor to repair
3. Improper fuel is used
3. Change to clean fuel
Overheated
42
White smoke
1. Too much or too little oil to cylinder
1. Ask our distributor to repair
comes out from
2. Water is interfused in fuel line
2. Drain water in water separator, fuel filter
Muffler
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 not
1. Voltage meter is defective
1. Ask our distributor to repair
move in voltage meter
2. AVR is defective
2. Ask our distributor to repair
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)
1. Voltage meter is defective
1. Ask our distributor to repair
does not goes up
2. AVR is defective
2. Ask our distributor to repair
to the rated
3. Voltage regulator dial is defective
3. Ask our distributor to repair
Pointer exceeds
1. Voltage meter is defective
1. Ask our distributor to repair
the rated voltage
2. AVR is defective
2. Ask our distributor to repair
3. Improper load cable connection
3. Correctly set the connection location to
4. Voltage switch is set to 480 V.
4. Set the voltage switch to 480 V.
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 to each
voltage
the output terminal.
connecting to load
terminal
terminal
3. The current of the used equipment
exceeds the rated current.
3. Change to a device with an available
capacity.
4. Over load
4. Decrease the loads to meet the rated
5. AVR protective device operation
5. Replace AVR fuse
1. The Main breaker positions at between
1. Once turning the lever to OFF, turn it to
output
Cannot turn the
breaker to ON
ON and OFF
ON
2. Short circuit on the load
2. Check the load circuit
43
13. Generator Circuit Diagram
44
14. Engine Electrical Circuit Diagram
45
©2014