OWNER’S MANUAL Air-cooled diesel engine generator set DG4LE / DG6LE 1
PREFACE Thank you for purchasing products from EASTERN TOOLS & EQUIPMENT, INC. We appreciate your business. The following manual is only a guide to assist you and is not a complete or comprehensive manual of all aspects of maintaining and repairing your generator. The equipment you have purchased is a complex piece of machinery. We recommend that that you consult with a dealer if you have doubts or concerns as to your experience or ability to properly maintain or repair your equipment.
TABLE OF CONTENTS Overall view of the generator set Chapter 1 Technical Specifications and Data 1-1 Technical specifications and data 1-2 Basic operating parameters 1-3 General dimensions and overview of the generators 1-4 Electric wiring diagrams for various models of generators Chapter 2 Operating the Diesel Generator 2-1 Main points of safety during operation of the generator 2-2 Preparation before operation 2-3 Checking the operation of the diesel engine 2-4 Starting the generator set 2-5 Procedures fo
1. Overall view of DG3LE series 3. Overall view of DG6LE series 2. Overall view of DG4LE series 4.
CHAPTER 1. TECHNICAL SPECIFICATIONS AND DATA Technical specifications in SI units Item Model 3LE Series Generator Generator Type Frequency (Hz) Rated power (Kw) Cont. power (kW) Voltage (AC) (V) Voltage (AC) (V) Current (DC) (A) Speed (rpm) Power factor (cos ϕ) Phase type Number of poles Excitation Insulation Engine model Type Diesel Engine Output Continuous (kw) Maximum (kw) Bore x Stroke (mm) Displacement (cc) 60 2.8 2.6 Fuel tank capacity (L) Dry weight Dimensions (LxWxH) (mm) 60 4.0 3.
Technical specifications in English units Item Model 3LE Series Generator Generator Type Frequency (Hz) Rated power (HP) Cont. power (HP) Voltage (AC) (V) Voltage (AC) (V) Current (DC) (A) Speed (rpm) Continuous (HP) Maximum (HP) Bore x Stroke (in) Diesel Engine Outp ut Displacement (cu. in) Cooling system Lubricating system Lube-oil capacity (oz) Starting system Fuel tank capacity (USgal) Dry weight (lb) Dimensions (LxWxH) (in) 6LE Series Single phase AC generator 60 3.75 3.49 60 5.36 4.
1-2 Basic operating parameters 1-1.1 Under the given conditions, the generator will output the specified power in the table listed below. Table 1. Height above sea level (ft) Ambient temperature (oF) RH 0 +60 (+20 oC) 60% <3280.8 (<1000 m) 41~104 (5-40 oC) 90% 1-3 General dimensions and overview of the generators 1-3.
Wiring diagrams for the LE models 1-4 Electric wiring diagrams for various models of generators 8
CHAPTER 2 OPERATING THE DIESEL GENERATOR 2-1 General main points of safety during operation of the generator set. In order to operate the generator set safely, please follow all the instructions provided in this manual carefully. Doing so otherwise may lead to accidents and or equipment damage. 2-1.1 Fire prevention The proper fuel for the diesel generator set is light diesel fuel. Do not use gasoline, kerosene and or other fuels other than light diesel fuel.
Fig 2-1 Fig 2-2 Note: When connecting devices to the generator, make sure all other devices are rated lower than the generators output. Any generator socket should not be overloaded over its regulated limit 2-1.5 Other safety points Before operating this generator, all operators should have a good knowledge of how to break the circuit if any accidents occur. Also, all operators should be familiar with all the switches and functions of the generator before using this machine.
2-2 Preparation before operation 2-2.1 Fuel choices and fuel treatment Air filter element Fuel tank Use only light diesel fuel. The fuel should be filtered clean. Never let dust and water mix with fuel in the fuel tank. Otherwise it will clog the fuel lines and oil nozzles. It may also damage your pressure pump. Note: It is dangerous to overfill the fuel tank. Never exceed the red piston in the filter. Do not wash the air filter. The element is made of dry material, which does not permit washing.
2-2.2 Filling engine oil Remove the dipstick from the engine Make sure the generator is on level ground, and fill the engine with 15W40 engine oil. Put the dipstick back into the hole to check the engine oil level. Engine oil is the most important factor in determining the life of your generator engine. If you use poor engine oil or if you don’t change the oil regularly, the piston and cylinder will wear easily or seize up.
2-2.3 Checking the air filter (1) Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out. (Note: Only certain welder generator sets have an electric fan incorporated on them.) Butterfly nut Before starting the generator, make sure the air switch is in the “Off” position. Starting the generator with the switch in the “On” switch is very dangerous. Air filter cover Do not use detergent to wash the air filter element.
butterfly nut and open the outer cover. Before you start the engine, please fill the fuel tank and engine oil first. Then, check to see if there are air bubbles in the engine. If there are, follow these procedures. Loosen the connecting nut between the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles. Then replace the connecting nut and tighten it. 2-3 Checking the operation of the diesel engine 2-3.
1. Insert key into ignition and put it in the “off” position. 2. Put the speed handle in the “Run” position. 3. Turn the start switch clockwise to the “START” position; (to set the silent type, first turn it clockwise to the “RUN” (ON) position for 1-2 seconds. The electromagnetic iron will be triggered, now turn it clockwise to the “START” position. 4. After the diesel engine is started, remove your hand from the switch handle; the switch will automatically reset itself to the “ON” position. 5.
Important Notice: All of our units come with a dry battery for shipping safety purposes. In order to get your generator started for the first time; the battery must be filled with battery acid which can be purchased at a local automotive supply store and slowly charged (trickle charged) for a day. After charging, the battery may be used. To properly maintain your battery; check the height of the battery acid once a month.
2-5 Procedures for starting the generator set This procedure applies to the L series recoil starting style models.
2-6.2 Checks during engine operation 2-6 Proper operation of the generator set 2-6.1 Operating the diesel engine 1. Pre-heat the diesel engine for 3 minutes under no load conditions. 2. First check the height of the lubricating oil level, if it is low, refill it. Our diesel engines are equipped with an alarm system that will notify you if the oil pressure is too low. The alarm system will shut down the engine if the oil pressure is too low. 3.
technical specifications of what the generator can output. In order to reset the generator after overdrawn power, let it sit for several minutes. If the indication of the voltmeter is too high or too low, adjust the speed accordingly. If there are problems, stop the generator immediately and fix the issue. 4. During operation, the generator should be in a place that has very good ventilation. Never cover the engine to solve a ventilation problem, as this will damage your equipment.
6. Finally, pull slowly on the recoil handle until you feel resistance (this is when the piston is on the compression stroke, where the intake and exhaust valves are closed). What this does is prevent the engine from rusting when not in use. 2-8 Stopping the generator 1. Take the electrical load off the generator. 2. Put the speed handle in the “RUN” position and let the engine run for 3 minutes after unloading. Do not stop the diesel engine immediately let it warm down.
CHAPTER 3 MAINTENANCE 3-1 Maintenance schedules Keeping your generator well maintained will prolong the life of your generator. Everything needs to be checked including the diesel engine, generator, control cabinet, and frame. For overhauling procedures, please refer to the instruction manual of the relative subassembly. If you need these manuals, please call our company and we will send you one. Before starting the maintenance, make sure the diesel engine is off.
3-1.3 Fuel filter maintenance 3-1.1 Changing the engine oil (every 100 hours) 1. The fuel filter should be cleaned often to keep the engine running at maximum performance. 2. The recommended time period for cleaning the fuel filter is 6 months or 500 hours of operation. a. To do this, first drain the fuel from the fuel tank. b. Loosen the small screws on the fuel switch and remove the fuel filter form the port. Use diesel fuel to clean the fuel Dipstick filter.
3-2 Storing for long periods of time If your generator needs to be stored for long periods of time, the following preparations should be made. 1. Start the diesel engine for 3 minutes then stop it. 2. When the engine is still hot, change the engine oil with new engine oil of the proper grade. 3. Pull the rubber plug out of the cylinder head cover and put 2CC of lubricating oil in it, then cover the plughole up again. 4.
CHAPTER 4 TROUBLESHOOTING 4-1 Troubleshooting procedures If you are still having trouble, please contact with your nearest dealer or with our company directly if necessary. 4-2 Questions and doubts If you do not understand anything or have any questions, please feel free to contact your local dealer or with our company directly. Below is a list of some information you should have ready before contacting your local dealer or us. 1. 2. 3. 4. Model of diesel engine generator and engine model number.
CHAPTER 5 GENERATOR PARTS DIAGRAMS AND LISTINGS Figure 5-2. Overall view of engine generator assembly Table 5-1.
Figure 5-3.
Table 5-2. Please refer to figure 5-3.
Figure 5-4. Electric panel parts drawing Table 5-3.
Figure 5-5. Generator head assembly Table 5-4.
Figure 5-6. Fuel system components Table 5-5. Please refer to figure 5-6.
LIMITED WARRANTY Eastern Tools & Equipment, Inc. will repair or replace, free of charge, any part or parts of the generator that are defective in material or workmanship or both. Transportation charges on parts submitted for repair or replacement under this Warranty must be borne by purchaser. This warranty is effective for the time period and subject to the conditions provided for in this policy.
Improper maintenance: The life of an engine or your equipment depends upon the conditions under which it operates, and the care it receives. Some applications, such as tillers, pumps, and rotary movers, are very often used in dusty or dirty conditions, which can cause what appears to be premature, wear. Such wear, when caused by dirt, dust, spark pug cleaning grit, or other abrasive material that has entered the engine because of improper maintenance is is not covered by warranty.
List for comments from users Date of Manufacture Name of user Model Number Address of user Occupation Place of purchase Packaging conditions Operating conditions Parts Conditions Malfunction problem Opinions or suggestions Note: Please mail the above card to: Eastern Tools & Equipment, Inc.
Appendix: 1. Attached list of tools, fittings, and subassemblies Order No. 1 2 3 4 Name Air-cooled diesel welder and generator set Kit Plastic cover Plug and power supply Qty 1 1 1 1 Remarks 2. Attached technical documents Order No.
EASTERN TOOLS & EQUIPMENT, INC. TEL: 1-626-960-6299 FAX: 1-626-960-6244 WEB SITE.http://easterntools.
