Owner’s Manual Model DG6LE Air-cooled diesel engine generator set
PREFACE Thank you for purchasing products from EASTERNTOOLS & 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 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 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 Proper operation of the generator set 2-6 Loading 2-7 Stopping the generator Chapter 3 Maintenance 3-1 Mainte
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com CHAPTER 1.TECHNICAL SPECIFICATIONS AND DATA 1-1 Technical specifications and data DG6LE Generator Generator Type Single phase AC generator Frequency 60 Hz AC Rated power 5.0 kW AC Voltage 120/240 V DC Voltage 12 V DC Current 8.3 A Speed 3600 rpm Power factor(cosΦ) 1.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com 1-2 Basic operating parameters 1-2.1 Under the given conditions, the generator will output the specified power in the table listed below. Table 1. Height above sea level (ft) 0 <3280.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com CHAPTER 2 OPERATING THE DIESEL GENERATOR 2-1 Main points of safety during operation of the generator 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.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com Fig 2-1 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.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com 2-2 Preparation before operation 2-2.1 Fuel choices and fuel treatment Fuel tank Air filter element Use only light diesel fuel. The fuel should Do not wash the air filter. be filtered clean. element is made of dry material, which Never let dust and water mix with fuel in the fuel tank. does not permit washing. Otherwise it will clog the fuel lines and oil nozzles.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com 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. Model Ambient temperature recommended values Classification of maintenance for A.P.I. diesel enging The lubricating oil must be CC or CD grade. 186FA Capacit Litre (fl oz) 1.65 (55.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com 2-2.4 Checking the generator 2-2.3 Checking the air filter Indicating lamp (1) Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out. Hours Start switch Breaker Butterfly nut Air filter cover AC output socket (Note: DC output Only certain generator sets have an electric fan incorporated on them.) Do not use detergent to wash the air filter element.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 2-3 Checking the operation of the diesel engine Web Site: easterntools.com Fuel switch 2-3.1 Low-pressure alarm system. ETQ diesel engines have a low-pressure sensor system where if the oil pressure drops too low, the sensor will shut the engine off. (2) Turn the speed handle of the engine to the The purpose “RUN” position. of having this system is to ensure that the engine does not seize up.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com (1) Put the fuel switch in the “On” position. the battery will drop. (2) Insert key into ignition and put it in the “off” improper ignition. This can lead to When the diesel engine is operating, let the ignition retain on the “ON” position. position. (3) Put the speed handle in the “Run” position. (4) In cold climate, it is difficult to start the engine.
EASTERN TOOLS & EQUIPMENT INC 2-4.3 Tele: (888)908-6200 Web Site: easterntools.com Battery Important Notice: PURPOSES. ALL OF OUR UNITS DO NOT COME WITH A BATTERY FOR SHIPPING SAFETY In order to get your generator started for the first time;the battery must be purchased at a local hardware or automotive supply store. Please verify the dimensions of the generator battery tray with the size of battery to be purchased.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com cause of the problem. 2-5 Proper operation of the generator set If no problems are found, please contact your local dealer or our nearest company branch. 2-5.1 Operating the diesel engine 2-6 Loading (1) Preheat the diesel engine for 3 minutes under no load conditions. 2-6.1 Load conditions Exert loads in accordance with the specified (2) First check the height of the lubricating oil parameters.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com 2-6.3 Charging the battery Speed handle (1) For the electric starter on the generator , the 12V battery is automatically charged through the regulator on the side of the engine when it is running. (2) If the generator is not used for long periods of time, the battery should be disconnected to avoid energy loss from the battery. Note: 1.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com (3) Press down on the brake handle. (4) If equipped with an electric starter, turn the key to the “OFF” position. (5) Put the fuel handle to the “OFF” position. (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). Breake handle What this does is prevent the engine from rusting when not in use.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com CHAPTER 3 MAINTENANCE 3-1 Maintenance schedules Keeping your generator well maintained will prolong the life of your generator. checked including the diesel engine, generator, control cabinet, and frame. Everything needs to be 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.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 3-1.1 Changing the engine oil (every 100 hours) Web Site: easterntools.com Note: Never start the engine without the air filter. This can cause serious damage to the engine if foreign objects enter the intake system. Always change the air filter on time. Take the oil cover off. Remove the oil drain plug when the diesel engine is still hot. Be careful of hot oil and hot engine as you may get burned. The bolt is located at the bottom of the cylinder.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com 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) For manual starting generator, press the decompression handle down and pull the recoil handle 2 or 3 times.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com CHAPTER 4 TROUBLESHOOTING 4-1 Troubleshooting procedures Causes of malfunction Remedy Diesel cannot be started. Not enough fuel. Add enough fuel. The switch of fuel is not at “OPEN”position. Turn the switch of fuel to“OPEN”position. High-pressure pump and nozzle do not inject fuel or the injected amount is less. Speed control lever is not at “RUN”position. Check level of lubrication oil.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com CHAPTER 5 GENERATOR PARTS DIAGRAMS AND LISTINGS Figure 5-1. Table 5-1.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com Figure 5-2. Exploded view of frame assembly Table 5-2. Please refer to figure 5-2.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com Figure 5-3. Electric panel parts drawing Table 5-3.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com Figure 5-4. Generator head assembly Table 5-4.
EASTERN TOOLS & EQUIPMENT INC Figure 5-5. Fuel system components Table 5-5. Please refer to figure 5-5. Number Tele: (888)908-6200 Part Description Web Site: easterntools.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com 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.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com Normal wear: Engines and generators, like all mechanical devices, need periodic parts service and replacement to perform well. Warranty will not cover repair when normal use has exhausted the life of a part of an engine. Improper maintenance: The life of an engine or your equipment depends upon the conditions under which it operates, and the care it receives.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com (10) Routine tune-up or adjustment of the engine. (11) Engine or engine component failure, i.e., combustion chamber, valves, valve seats, valve guides, or burned starter motor winding, caused by the use of alternated fuels such as, liquefied petroleum, natural gas, altered diesel’s etc. Warranty is available only through service dealers, which have been authorized by Eastern Tools & Equipment, Inc.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com which is provided to our by Eastern Tools & Equipment, Inc. pursuant to California law, Eastern Tools & Equipment, Inc. also provides to original purchasers of new Eastern Tools & Equipment, Inc. engines. Eastern Tools & Equipment, Inc. Limited Warranties for New engines & other Equipment associated with the engine (Eastern Tools & Equipment, Inc. Products Warranty), which is enclosed with all New Eastern Tools & Equipment, Inc.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com PRODUCT REGISTRATION CARD For more efficient customer service, please fill out the information below and mail to Eastern Tools & Equipment, Inc. Product Warranty and Registration Division,600 Industrial Parkway Norwalk,OH 44857 Model No._________________ Engine Serial No.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com LIST FOR COMMENTS FROM USERS Name of user Date of Manufacture Address of user Model Number Place of purchase Occupation Packaging conditions Operating conditions Parts Conditions Malfunction problem Opinions or suggestions Note:Please mail the above card to: Eastern Tools & Equipment, Inc.
EASTERN TOOLS & EQUIPMENT INC Tele: (888)908-6200 Web Site: easterntools.com APPENDIX: (1) Attached list of tools, fittings, and subassemblies Order No. 1 2 3 Name Air-cooled diesel generator set Kit RV adapter Qty 1 1 1 Remarks Qty 1 Remarks (2) Attached technical documents Order No.
EASTERN TOOLS & EQUIPMENT, INC. TEL:1-909-390-8989 FAX:1-909-390-6068 For sales, call toll free 1-888-696-2345 WEB SITE.http://easterntools.
