ESE Power Generator: Translation of The Original Oper-Ating Manual
ESE Power Generator: Translation of The Original Oper-Ating Manual
Notes on printing All descriptions, technical details and illustrations refer to the version of the gen-
erator for printing.
We reserve the right to make modifications in terms of ongoing technical devel-
opment. This operating manual does not include technical modifications that oc-
curred after printing.
The colours in this operating manual do not always comply completely with the
actual designs due to technical printing reasons.
2
Table of Contents
1 Directories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1 Welcome to ENDRESS! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 Your product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.1 A device description and intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3 included in delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.4 Labels on the generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.1 Transporting and preparing your generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.2 Refuelling your generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
7.3 Starting the generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
7.4 Operating the E-MCS 6.0 control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7.4.1 Descriptions of the operating and display buttons. . . . . . . . . . . . . . . . . . . . . . . . . .39
7.4.2 Display window on the control module’s screen . . . . . . . . . . . . . . . . . . . . . . . . . . .41
7.5 Low load diesel engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7.6 Turning off your power generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7.7 Turn off your generator in the event of an EMERGENCY . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.8 Connection of power consuming equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
8.1 Maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
8.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
8.3 Starter battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.3.1 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.3.2 Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
8.4 Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.4.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
3
8.4.2 Changing the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
9 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
11 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
4
Directories
1 Directories
1.1 List of illustrations
5
About this manual
NOTICE!
The complete documentation is an integral part of the device and you must
adhere to it.
► All of the integral parts of the documentation must always be accessible to
the operating personnel and they should be kept with the device.
6
About this manual
DANGER!
Electrical voltage
Risk of suffering potentially deadly electrocution by touching live parts
► Only use undamaged connecting lines
► Avoid all damp / wetness when connecting consumers
► Never operate the power generator with an opened control panel
The standard mentioned classifies the safety risks according to different risk po-
tentials. To understand and avoid dangers to one’s health and even life, please
be sure to read the explanations given in Chapter 4.1 .
Safety symbols
These warning notices are usually used in a safety symbol which also emphasis-
es the type of danger; see next example. A list of the safety symbols used in this
operating manual can be found in Chapter 3.3 . The safety symbols never stand
alone.
NOTICE!
Use of wrong or outdated fuel damages or destroys the engine.
► Only use released diesel fuel.
► Observe the shelf life of the fuel according to the supplier.
► Observe the Operating manual from the engine manufacturer
7
About this manual
Additional notices for operation or for function of a unit are marked with the
adjacent symbol.
NOTICE!
The adjacent symbol is situated anywhere where the supplier documenta-
tion must be read and observed and refers to,
► appropriate information,
► tasks or
► action steps.
References to details and components in figures are made with blue bordered
position numbers in the text such as the example of CE signs on the type plate
demonstrates, see Fig. 3-3 .
8
Product identification
3 Product identification
3.1 Welcome to ENDRESS!
We are pleased that you have made the decision to purchase a ENDRESS
power generator. You have purchased a high-performance product into
which we have embodied decades of our experience and have integrated
many functions oriented on daily use. Through careful selection of high
quality components and materials in combination with the proverbial Swa-
bian engineering performance you have in your possession a device which
will operate reliably for many years, also under the hardest of operating
conditions.
9
Product identification
10
Product identification
• Never refuel the generator’s own tank when it is hot. Overflowing fuel and
outflowing fuel vapours can ignite on hot parts of the device.
• The generator is never to be connected up to other energy distribution sys-
tems (e.g. public power supply) or to other energy generation systems (e.g.
other generators, solar plant, etc.). To start with this is usually not permitted
by the energy supply company. In both cases this will inevitably lead to se-
vere damage and possibly also severe injury.
• Never place the generator in explosion-prone environments. The individual
components of the generator are not designed EX-protected.
• Never operate the generator in rooms, narrow pits or vehicles. The combus-
tion exhaust gases contain poisonous substances including the odourless
but deadly gas carbon monoxide (CO) which, when breathed in, can accu-
mulate in cases of poor air circulation to reach deadly concentrations. Also a
lack of fresh air circulation leads to overheating and possible damage to the
generator right through to destruction.
• For the same reasons of risk, never divert exhaust gases for the purposes of
heating rooms or vehicles.
• Never clean the generator with the aid of a high pressure cleaner or a strong
jet of water.
• Never allow water to find its way inside the generator. Never pour water over
the generator and never clean it using a water hose or a high pressure clean-
er.
• Never operate the generator in any area where it could be flooded by high
water or any other events. The Protection Class of the device (see Chapter
12 ) allows operation for spray water, however not in the case of floods.
11
Product identification
Item Name
Supplier documentation
Tool kit
12
Product identification
13
Product identification
Warning
Mortal danger from toxic
combustion gases when the
engine is running
Risk of burns
Hot surfaces
Note
Lift the unit only from here
(crane loading eyes)
Prohibition signs
Smoking and open flames
are prohibited
Note
Fuel quality
Warning
Warning about a general
hazard
Note
Forklift loading pockets
(forklift pockets)
14
Product identification
Warning signs
Dangerous voltage
For electricians only
Type plate
Prohibition signs
No naked flames
15
For your safety
16
For your safety
17
For your safety
DANGER!
Mortal danger due to an electric shock if live parts are touched.
► Never operate the device if it is in a damaged condition.
► Never operate the electrical consumers and connecting cable (power con-
suming equipment) in a damaged condition.
► Never feed directly into existing networks that are already connected to a
power source (e.g. power supplier, solar plant, etc.).
► Never operate the device with wet hands.
The majority of injuries and damage to equipment can be avoided if all instruc-
tions given in this manual and all instructions attached to the device are followed.
The generator must not be modified in any way, also not temporarily. This can
lead to a mortal risk to operating and deployed personnel and damage to the gen-
erator as well as the consumers being used.
Operating company and Operating personnel may only use the generator ac-
cording to regulations contained in the whole technical documentation (hereinaf-
ter referred to as appropriate use).
Every instance of inappropriate use as well as all activities on the generator
which are not described in these instructions are forbidden misuse outside the
legally defined limits of liability of the manufacturer. In return all claims for dam-
ages and claims made under warranty to ENDRESS-Elektrogerätebau GmbH
which are associated with misuse are null and void.
18
For your safety
DANGER!
DANGER describes a danger which represents a high level of risk,which
can lead to death or severe injuries,when not avoided.
► The individual points provide instructions and
► notices as aids to avoid the danger
► or to reduce the risk to an acceptable level.
WARNING!
WARNING describes a danger which represents a medium level of
risk,which can lead to death or severe injuries,when not avoided.
► The individual points provide instructions and
► notices as aids to avoid the danger
► or to reduce the risk to an acceptable level.
CAUTION!
CAUTION describes a danger which represents a low level of risk,which
can lead to minor or medium level injurieswhen not avoided.
► The individual points provide instructions and
► notices as aids to avoid the danger
► or to reduce the risk to an acceptable level.
NOTICE!
ATTENTION! describes a situation or action that might result in damage to
equipment and/or malfunctions if it is not prevented.
► The individual points provide instructions and notices
► as an aid to avoid or prevent damage to equipment.
19
For your safety
DANGER!
Mortal danger due to an electric shock if live parts are touched.
► Never operate the device if it is in a damaged condition.
► Never operate the electrical consumers and connecting cable (power con-
suming equipment) in a damaged condition.
► Never feed directly into existing networks that are already connected to a
power source (e.g. power supplier, solar plant, etc.).
► Never operate the device with wet hands.
DANGER!
Engine exhaust gases contain poisonous and partially invisible gases such
as carbon monoxide (CO) and carbon dioxide (CO2).
Risk of death due to poisoning or asphyxiation.
► Ensure that there is good ventilation during the whole period of operation.
► Only operate the generator in the open.
► Never direct the exhaust gases into rooms or pits.
DANGER!
Danger of severe or mortal injuries being incurred from falling loads.
► Never stand under or close to a suspended load, also not to provide assis-
tance.
► Ensure that there is no person in the area of swivel of the lifting device.
► Use all suitable measures to prevent the suspended load from swaying.
DANGER!
Leaking engine oil and fuel can burn or explode.
A risk of suffering severe even deadly burns.
► Prevent engine oil or fuel from leaking out.
► Remove leaked operating fluids immediately and appropriately.
► Never use an additional start aid.
► Smoking, naked flames and sparks are forbidden.
DANGER!
Hot parts can ignite flammable and explosive materials.
A risk of suffering severe even deadly burns.
► Never operate the generator in the vicinity of combustible or flammable ma-
terials.
► Never operate the generator in an environment prone to an explosion.
20
For your safety
WARNING!
There is a risk of explosion and fire in the case of inappropriate handling
and spark development when working with the battery.
Danger from spraying sulphuric acid. Danger of suffering severe even deadly
burns and chemical burns. Danger of being blinded.
► Never lay electrically conductive parts on the starter battery.
► Flames, sparks, an open light and smoking are prohibited.
► Avoid sparks when handling cables and electrical devices, as well as electro-
static discharge.
► Avoid short-circuits.
► Wear acid-resistant protective clothing.
WARNING!
Escaping corrosive acid fumes or sulphuric acid during and after the
charging process. A risk of suffering severe or even deadly burns.
► Only work with acid-resistant protective equipment.
► Clean surfaces covered in acid immediately using adequate amounts of wa-
ter.
► Only charge the starter battery in a well ventilated environment.
CAUTION!
Certain surfaces on the device can get very hot whilst it is running.
Risk of burns
► Never touch any engine parts (in particular the exhaust system) for a few min-
utes after ceasing operation.
► Always leave hot engine parts to cool down before touching them.
CAUTION!
A high device weight. Risk of crushing from improper handling during op-
eration or transport.
► Only lift the generator with the aid of all handles provided or by using a suit-
able hoist.
► During transport on vehicles, ensure that there is the prescribed load secur-
ing in place.
► With it in a raised condition, never come close to or stand under the genera-
tor.
21
For your safety
NOTICE!
Leaking engine oil and operating fluids can contaminate the soil and
groundwater.
► Ensure that the generator is transported horizontally and mounted.
► Make all efforts, at all costs, to prevent escaping of operating fluids.
► Dispose of contaminated soil immediately and according to regulations.
NOTICE!
Use of wrong or outdated fuel damages or destroys the engine.
► Only use the fuel displayed on the sign (Fig. 3-3 ).
► Observe the possibly enclosed documentation for the fuel release of the en-
gine manufacturer
► Observe the shelf life of the fuel according to the supplier.
► Observe the engine operating manual.
NOTICE!
Excessive heat or moisture can destroy the device.
► Always ensure that there is a good supply of air and heat removal.
► Never operate the generator in rooms or narrow pits.
► Never clean the device with the aid of a strong jet of water or high pressure
cleaner.
► Never allow water to find its way inside the generator.
22
For your safety
23
For your safety
Service and maintenance Within the outer limits of the device when
switched on Generators
24
Checking the electrical safety
DANGER!
There will be no RCD personal protection during operation if the earthing
of the Generators is faulty.
Mortal danger from electrocution
► The use of an RCD (FI circuit breaker) for personal protection requires proper
earthing of the Generators and this must be undertaken by a qualified elec-
trician before the initial commissioning.
► The effectiveness of this protective measure should be regularly checked by
an electrician.
► Check the personal protection according to the check intervals given in Tab.
5-1 .
In addition to the details given above, the electrical safety of the generator is to
be checked by a qualified electrician at regular intervals. The periods between
testing must be established in such a way that the generator and all work equip-
ment to be connected can, according to the general status of knowledge, opera-
tional experiences or on the basis of specific evidence, be safe to use in the
period between the two inspections.
NOTICE!
The operator is responsible for defining and adhering to the test intervals
. Above all one must ensure observance of the respectively valid national
regulations.
This responsibility also extends to any additional equipment installed in
conjunction with the device.
25
Checking the electrical safety
First start-up at the op- • See Chapter 7 and also abide by the operating manual Operating
erating location provided by the engine manufacturer personnel
• Visual inspection for externally visible defects such as
transport damage.
Start-up on a daily basis • See Chapter 7.3 and also abide by the operating man- Operating
ual provided by the engine manufacturer personnel
• Visual inspection for externally visible defects (such as
damaged insulation, connectors, cable; leaks, noise)
• If the power generator is fitted with insulation monitoring
and/or an RCD, then the operating personnel must run
protective device function tests every working day. The
operating personnel must be trained to do this.
Retest at the latest once • According to BGI/GUV-I 5090 “Repeated testing of mo- Qualified
every six months bile electrical equipment“) electrician
• Sample test report according to
DGUV information 203-032 *)
26
Description of the device
27
Description of the device
28
Description of the device
Air filter
29
Description of the device
30
Commissioning
7 Commissioning
The following chapter explains the basic procedure for initial or repeated
generator start-ups in "Manual" mode. Follow the working steps described
below when you put your generator into operation for the first time or re-
start it again after transporting it.
DANGER!
Danger of severe or mortal injuries being incurred from falling loads.
► Never stand under or close to a suspended load, also not to provide assis-
tance.
► Ensure that there is no person in the area of swivel of the lifting device.
► Use all suitable measures to prevent the suspended load from swaying.
NOTICE!
Leaking engine oil and operating fluids can contaminate the soil and
groundwater.
► Ensure that the generator is transported horizontally and mounted.
► Make all efforts, at all costs, to prevent escaping of operating fluids.
► Dispose of contaminated soil immediately and according to regulations.
31
Commissioning
32
Commissioning
Transporting by 1. Connect up to the crane eyes to the lifting device approved for use with
crane the unit’s heavy weight and secure it against falling off.
2. Raise the power generator slowly and evenly.
3. Move the power generator slowly into its place of use.
4. Lower the device slowly and evenly.
5. Unhook the lifting device.
The generator has been transported to its place of use and installed.
DANGER!
Leaking engine oil and fuel can burn or explode.
A risk of suffering severe even deadly burns.
► Prevent engine oil or fuel from leaking out.
► Remove leaked operating fluids immediately and appropriately.
► Never use an additional start aid.
► Smoking, naked flames and sparks are forbidden.
33
Commissioning
NOTICE!
Leaking fuel can contaminate soil and groundwater.
► Take note of the residual quantity in the tank and its maximum filling capacity.
► Always bear in mind that the fuel gauge reacts only after a time delay.
► Fill the tank to a maximum of 95%.
► Always use a filling aid (e.g. funnel).
NOTICE!
Use of wrong or outdated fuel damages or destroys the engine.
► Only use the fuel displayed on the sign (Fig. 3-3 ).
► Observe the possibly enclosed documentation for the fuel release of the en-
gine manufacturer
► Observe the shelf life of the fuel according to the supplier.
► Observe the engine operating manual.
NOTICE!
When selecting the fuel, please note that if you use bio-diesel, then the war-
ranty is no longer fully guaranteed.
► Only the fuel recommended by the engine manufacturer is to be used.
► Abide by the fuel notes given in the engine manufacturer’s operating instruc-
tions.
34
Commissioning
35
Commissioning
DANGER!
Leaking engine oil and fuel can burn or explode.
A risk of suffering severe even deadly burns.
► Prevent engine oil or fuel from leaking out.
► Remove leaked operating fluids immediately and appropriately.
► Never use an additional start aid.
► Smoking, naked flames and sparks are forbidden.
DANGER!
Engine exhaust gases contain poisonous and partially invisible gases such
as carbon monoxide (CO) and carbon dioxide (CO2).
Risk of death due to poisoning or asphyxiation.
► Ensure that there is good ventilation during the whole period of operation.
► Only operate the generator in the open.
► Never direct the exhaust gases into rooms or pits.
Starting the motor 1. Turn the main switch into the "ON" position.
2. Turn the controller’s switch into the "ON" position.
The control module's display will come on and the controller will run up.
3. Wait until the start screen is displayed (see Fig. 7-7 ).
4. Set up "Manual" mode on the display by pressing the mode button (right ar-
row) once.
5. Press the “Start“ button once.
The engine will start up after the preheating phase.
The engine has started.
The green control LED shows you the readiness state of the Generators.
Familiarise yourself with the complete operating procedure for the E-MCS 6.0
control module before the initial commissioning of the power generator, see
Chapter 7.4 .
NOTICE!
Do not apply load to the generator immediately after a cold start.
► Allow the generator engine to warm up for a few minutes before switching on
a load when the generator has not been operating for more than eight hours
(or for very low external temperatures).
36
Commissioning
NOTICE!
Automatic mains switching is deactivated in the “ “ control mode.
The power generator will not start if the power supply has failed.
► Only use the “ “ control mode for temporary purposes and only if starting
the Generators must be prevented.
► After you have finished accessing the unit, you must ensure that the control
module is back in the “ “ mode.
37
Commissioning
NOTICE!
Automatic mains switching is deactivated in the “ “ control mode.
The power generator will not start if the power supply has failed.
► Only use the manual control mode for temporary purposes or if automatic
mains switching is not needed.
► After you have finished accessing the unit, you must ensure that the control
module is back in the “ “ mode.
DANGER!
Dangerous electrical voltage is still present even when the power genera-
tor is switched off
Mortal danger from electric shock if live parts are touched.
► Access only for electricians in areas marked with an adjacent warning sign.
► Maintenance work on the generator is only to be undertaken after an electri-
cian has switched off the power generator and it is completely voltage-free.
38
Commissioning
START ENGINE Press this button to start the power generator if the
control mode has been selected, see
39
Commissioning
SELECTION MENU
This function can only be enabled by service personnel.
ENTER BUTTON
Press this button and hold it down. Press one of the buttons simulta-
neously to set the screen's contrast.
Item Description
MAINS FAULT The red LED will flash if the power supply from the mains is faulty. It will be
continuously lit after the power generator has been started and remain so until the mains fault
has been eliminated.
MAINS VOLTAGE OK The green LED diode lights up of there is a voltage present from the
generator and the measured parameters lie within the limit values.
MAINS CHANGEOVER CONTACTOR ON This LED lights up green if the connected distri-
bution network is being supplied from the public mains system (only with an external change-
over contactor).
GENERATOR VOLTAGE OK The green LED lights up if voltage from the generator is pres-
ent and the measured parameters lie within the limit values.
40
Commissioning
Item Description
GENERATOR FAULT The red LED will flash if the power supply from the power generator
is faulty. It will go out if the button is pressed after the problem has been eliminated. The
fault is still present if it remains permanently lit.
Alarm list If an alarm is triggered, the alarm list will be displayed on the screen and you
should select the entry that is preceded by an *. Proceed as follows to acknowl-
edge the alarms:
1. If there are several entries present should use the arrow keys to select the
entry that you want.
2. Press the button to acknowledge the alarm.
The * character will disappear.
The entry will only disappear after the error has been eliminated.
41
Commissioning
NOTICE!
Damage to the drive motor or other Generators components that was
caused by low load operation that is contrary to our recommendations (see
below) and/or those of the engine manufacturer will void any warranty or
liability claims.
NOTICE!
Avoid, as far as possible, short-term operation or operation without a load
or with a basic load that is too low. Follow these recommendations if the
engine manufacturer does not provide detailed information or he provides
different information:
► Run your Generators at a minimum of 30% - 40% of the rated nominal output
(see nominal output in Chapter 12 Technical data).
► Avoid short-term operations where the engine does not reach its operating
temperature.
► Run the engine at regular intervals for at least one hour at maximum load
(see Chapter 8.1 Maintenance plan as well).
► Take note of the instructions provided by the engine manufacturer
42
Commissioning
CAUTION!
The EMERGENCY-STOP smash button is only to be used in the event of a
dangerous situation arising in an emergency.
Risk of injuries if consumers are suddenly switch off.
► Always switch off the generator normally as described in Chapter 7.6 .
Requirements: Actuating the EMERGENCY-STOP smash button must always be possible with-
out any preconditions. Ensure that the EMERGENCY-STOP smash button is
easily accessible at all times.
43
Commissioning
DANGER!
Mortal danger due to an electric shock if live parts are touched.
► Never operate the device if it is in a damaged condition.
► Never operate the electrical consumers and connecting cable (power con-
suming equipment) in a damaged condition.
► Never feed directly into existing networks that are already connected to a
power source (e.g. power supplier, solar plant, etc.).
► Never operate the device with wet hands.
DANGER!
There will be no RCD personal protection during operation if the earthing
of the Generators is faulty.
Mortal danger from electrocution
► The use of an RCD (FI circuit breaker) for personal protection requires proper
earthing of the Generators and this must be undertaken by a qualified elec-
trician before the initial commissioning.
► The effectiveness of this protective measure should be regularly checked by
an electrician.
► Check the personal protection according to the check intervals given in Tab.
5-1 .
44
Maintenance
8 Maintenance
Generators maintenance is described in this section. It may only be per-
formed by qualified specialist personnel.
Maintenance and repair which is neither described in this operating manual
nor in the possibly also delivered operating and maintenance instructions
may only be undertaken by authorized service personnel from the manu-
facturer.
NOTICE!
Please note that, in the case of a concluded warranty agreement, you will
lose all rights to make claims if your generator is not serviced according to
manufacturer regulations.
NOTICE!
Always abide by the accompanying operating and maintenance instruc-
tions provided by the engine manufacturer when carrying out maintenance
work on the drive motor.
The most important maintenance tasks are described in the following overview
of the schedule and scope of the necessary maintenance work. Always abide by
the maintenance schedule given in the accompanying operating and mainte-
nance instructions provided by the engine manufacturer:
45
Maintenance
Tab. 8-1 FPT engine maintenance schedule, source FPT engine operating and mainte-
nance instructions
DANGER!
Mortal danger from unintentional generator start up.
Danger of burns and being caught by rotating parts.
► Before accessing the generator you must switch it off and secure it so that
unintentional starting of the machine is prevented under all circumstances.
(see Chapter 7.2 as well).
46
Maintenance
CAUTION!
Certain surfaces on the device can get very hot whilst it is running.
Risk of burns
► Never touch any engine parts (in particular the exhaust system) for a few min-
utes after ceasing operation.
► Always leave hot engine parts to cool down before touching them.
NOTICE!
Also always read about the checking and maintenance work which con-
cerns the electrical safety of the generators in the chapter “Checking the
electrical safety“.
NOTICE!
Your Generators was fitted with a maintenance-free starter battery in the
factory.
► It is imperative that you abide by the accompanying battery handling instruc-
tions.
WARNING!
There is a risk of explosion and fire in the case of inappropriate handling
and spark development when working with the battery.
Danger from spraying sulphuric acid. Danger of suffering severe even deadly
burns and chemical burns. Danger of being blinded.
► Never lay electrically conductive parts on the starter battery.
► Flames, sparks, an open light and smoking are prohibited.
► Avoid sparks when handling cables and electrical devices, as well as electro-
static discharge.
► Avoid short-circuits.
► Wear acid-resistant protective clothing.
47
Maintenance
1. Attach the starter battery according to the regulations from the battery and
charger manufacturers.
2. Set a suitable charge current for the charger if necessary.
3. Switch off the charger of expiry of the charging time.
4. Disconnect the starter battery from the charger.
5. Allow the starter battery to rest for about thirty minutes.
6. Install the starter battery again in the generator (see Chapter 8.3.2 ).
The starter battery is charged.
If the generator cannot be started after fully charging the battery, there is a defect
in the starter power circuit of the generator. Contact your service partner.
NOTICE!
The starter battery from the factory is maintenance-free throughout its en-
tire service life.
► Never try to open the battery - risk of destruction.
WARNING!
There is a risk of explosion and fire in the case of inappropriate handling
and spark development when working with the battery.
Danger from spraying sulphuric acid. Danger of suffering severe even deadly
burns and chemical burns. Danger of being blinded.
► Never lay electrically conductive parts on the starter battery.
► Flames, sparks, an open light and smoking are prohibited.
► Avoid sparks when handling cables and electrical devices, as well as electro-
static discharge.
► Avoid short-circuits.
► Wear acid-resistant protective clothing.
48
Maintenance
1. Pull off pole protection cap (if fitted) from the battery’s negative pole and the
negative cable Fig. 8-1 -must always be the FIRST cable to be disconnect-
ed from the battery.
2. Pull off pole protection cap (if fitted) from the battery’s positive pole and the
positive cable Fig. 8-1 -must always be the LAST cable to be disconnected
from the battery.
3. Undo the two fixing nuts and then remove the retaining bracket Fig. 8-1
from the battery.
4. Remove the battery from the power generator.
The starter battery is now removed.
5. Prepare a new starter battery (abide by the battery manufacturer’s instruc-
tions).
6. Place the starter battery in the battery compartment.
7. Use the retaining bracket Fig. 8-1 to secure the starter battery in place .
8. FIRST attach the plus cable Fig. 8-1 to the positive pole of the battery and
then pull the red pole protection cap over the pole if necessary.
9. Fasten the negative cable Fig. 8-1 LAST to the minus pole of the battery
and then pull the pole protection cap over the pole if necessary.
10. Turn the battery disconnector switch into the ON position (image )
The starter battery has been replaced. The generator can now be started.
49
Maintenance
50
Maintenance
Pump lever
and old oil suction pump
Oil dipstick
CAUTION!
The engine and operating equipment on the generator can get very hot
while running.
Risk of burns
► Never touch any engine parts (in particular the exhaust system) for a few min-
utes after ceasing operation.
► Allow the engine to cool off for at least five minutes before changing or check-
ing the engine oil.
NOTICE!
Follow the instructions given in the accompanying operating and mainte-
nance instructions provided by the engine manufacturer to ensure that the
precise procedure is used.
51
Maintenance
NOTICE!
Leaking engine oil contaminates the soil and groundwater.
► Use a suitable oil catching receptacle.
► Old oil is a special waste and may only be disposed of over suitably qualified
collection points.
CAUTION!
The engine and operating equipment on the generator can get very hot
while running.
Risk of burns
► Never touch any engine parts (in particular the exhaust system) for a few min-
utes after ceasing operation.
► Allow the engine to cool off for at least five minutes before changing or check-
ing the engine oil.
Draining the engine Proceed as follows to pump out the old oil after implementing the preced-
oil ing handling steps in accordance with the engine manufacturer's mainte-
nance instructions:
Requirements: The power generator is switched off
When it is still hot: Wait until the engine oil has cooled down to approx. 30°C
– 50°C.
When it is cold: Run the engine until it has heated up accordingly.
1. Unwind the oil drainage hose and guide its end into a suitable oil collecting
tank (take note of the oil filling quantity).
2. Open the oil filling opening for better venting .
3. Open the shut-off valve.
4. Operate the pump lever on the old oil suction pump .
The old oil will pass through the drainage hose and run into the collecting tray.
5. Clean and stow away the oil drainage hose again when no more old oil
comes out.
6. Close the shut-off valve.
The engine's old oil has now been pumped out.
52
Maintenance
NOTICE!
The other procedures for changing the engine oil correspond with the de-
tails given in the engine's operating and maintenance instructions. Take
note of the other maintenance and disposal of operating equipment in-
structions that can be found there.
53
Storage
9 Storage
It is important to store the device at a suitable storage location as soon as your
generator is no longer being used.
• The storage location must be roofed and must not be subjected to standing
water, aggressive vapours or soiling as well as major accumulation of dust.
• Protect your device with a cover made out of breathable material.
• Ensure that the storage temperature and air humidity lie within the specified
limits (see Technical data).
NOTICE!
Due to the limited shelf life of the different operating fluids, it is important
for decommissioning for more than one month that additional measures
for storage are taken. While doing this observe the instructions given in the
attached operating and maintenance instructions from the engine manu-
facturer.
54
Disposal
10 Disposal
Your device, which is an electrical or electronic device, is subject to European Di-
rective 2012/19/EU (“WEEE directive“) which is implemented in Germany in na-
tional law through the decree regulating the use of dangerous substances in
electrical and electronic equipment (ElektroStoffV). This regulates disposal and
use of recycling waste electrical equipment. The adjacent icon with a crossed-out
wastebasket on your device states that it must not be disposed of in the house-
hold waste at the end of its service life.
As a private end-user (a so-called b2c customer) there are free collecting points
(recycling centre) near you for electrical equipment as well as possible also other
collection points available for reuse of devices. The addresses can be obtained
from your city or communal authority. In as far as the old electrical and electronic
equipment contains personal data, you are responsible yourself for its deletion
before giving it back.
Pure b2b devices (devices which, for appropriate use, or exclusively are only
used the commercial area) must not be disposed of over public collecting points
in Germany and further EU countries. Speak to your authorised ENDRESS gen-
erator dealer about handing back your recycling waste electrical equipment. The
dealer is also your point of contact for any differing regulations on the respective
country of deployment. There are also possible agreements in the purchase con-
tract to observe.
Please observe the pertinent environmental protection regulations when dispos-
ing of the old oil. We recommend bringing the oil in a closed container to an old
oil collection centre for disposal. Never put used engine oil in the domestic waste.
Storage or introduction of old oil into nature is associated with very high fines.
An inappropriately disposed of battery can greatly damage the environment.
Give back your old battery directly free of charge to your dealer when purchasing
a new one.
Always observe the valid local regulations and laws concerning correct disposal
of all old parts and operating materials. Please contact your ENDRESS service
partner for a replacement.
55
Troubleshooting
11 Troubleshooting
The following table is an aid for you to use in a case where faults arise
during use. Based on experience a number of malfunctions can already be
removed by operating personnel or the possible causes limited. In all other
cases contact your service partner as described in the table. The same ap-
plies for faults which are not listed in the table.
If a fault cannot be removed using the remedies described, shut down your gen-
erator and secure it against further use. Contact your service partner and give
him an explanation, not only of the symptoms but also the possible causes which
you can already exclude based upon the table. In this way you are supporting the
diagnostic process so that the fault can often already be identified over the tele-
phone or through written exchange with our specialists.
NOTICE!
The following table does not make any claims to completeness and does
not mention any faults which can be caused by operating error.
► In order to avoid operating errors, please exactly follow the instructions in the
existing and delivered documentation.
The engine turns but does not Spark plug connector detached Firmly put the spark plug con-
start. nector in place again
The spark plug is very dirty or defec- Clean the spark plug and ad-
tive just or replace it
Engine oil level too low (oil lack auto- Bring the engine oil level up to
matic switch-off) the maximum
56
Troubleshooting
Engine oil level too low (oil lack auto- Bring the engine oil level up to
The engine starts but stops
matic switch-off) the maximum
again shortly afterwards
Spark plug connector detached Firmly put the spark plug con-
nector in place again
The generator is running but The electronic voltage regulator is Contact your service partner
the output voltage is outside of wrongly adjusted or defective
tolerance
The load of the attached power con- Connect up a piece of power
suming equipment is too high consuming equipment with a
low output
The engine oil level is too high Draining off excess engine oil
The air filter insert (paper) is dirty or Clean the air filter insert or re-
The engine smokes contaminated with oil place it
The air filter insert (foam) is dirty Clean the air filter insert and
re-oil it
The engine is still in the warm up Wait until the engine has
phase reached its operating tem-
perature
The generator is running at a
high speed and with strong The carburettor is wrongly adjusted Contact your service partner
voltage fluctuations or defective
57
Troubleshooting
Please contact our customer service for further fault diagnosis as well as pro-
curement of original spare parts and wear parts at
58
Technical data
12 Technical data
The following table contains the technical data for your generator.
59
Replacement parts
13 Replacement parts
Maintenance and replacement parts can be obtained quickly and easily
from your responsible ENDRESS service partner or ENDRESS dealer. You
can alternatively obtain support from our central customer service
by telephone: +52 (442) 192.9100
by email: [email protected]
Have the item and serial number of your device ready for identification.
As a registered user you can obtain rapid and uncomplicated access to a range
of services over our home page to obtain suitable original spare parts for main-
tenance and repair work. Using your internet browser please go to
https://endressparts.com
and click on the area “Documentation and replacement parts“.
60
Replacement parts
NOTES
61
Replacement parts
NOTES
62
Replacement parts
Keyword index
A Starting 35
alarm list 41 T
C Turning off 42
Control mode U
AUTO 38 under the operator's obligations 25
MANUAL 37
OFF 37 W
switching 39 Warning notices 18
control mode 37 WEEE directive 55
control module 37
Control panel 28 30
Crane loading lug 28
Customer service 60
D
DIN ISO 3864 7
display windows 41
E
Earthing 25
earthing 10
Electrical safety 25
EMERGENCY-STOP smash button 30 43
energy supply company 11
evaluated 18
Exhaust gases 20 36
H
Home page 60
I
Imprint 2
included in delivery 12
M
misuses 10
O
operating manual 7
Operating personnel 18 23
Own tank 33
R
refuel 33
Resetting an error message 39
S
safety instructions 16
Safety symbols 16
Standards
DIN EN ISO 12100 18
DIN EN ISO 8528-13 18
DIN VDE 82079-1 6
ISO 3864 18
ISO 7010 16
standards
DIN EN 60204 18
starter battery 47
63
Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen, Germany