Endress ESE 604 DHG DIN Quick guide

Translation of the
ORIGINAL OPERATING INSTRUCTIONS
ESE 604 DHG DIN Article No. 156001
ESE 604 DHG ES DIN Article No. 156011

2ESE 604 DHG (ES) DIN Status: October 2018
ENDRESS
Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen
Telephone: + 49 (0) 71 23 / 9737 –0
Telefax: + 49 (0) 71 23 / 9737 –50
Email: [e-mail]
www: http://www.endress-stromerzeuger.de
E136079_i05
October 2018
© 2018, ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to copy-
right. Any use or modification beyond the restrictions of the
Copyright Act is forbidden and subject to penalty without the
consent of ENDRESS Elektrogerätebau GmbH.
This applies in particular to copies, translations, microfilming,
as well as storage and processing in electronic systems.
Manufacturer and
publisher
Document number
Publication date
Copyright

Table of Contents
Status at: October 2018 ESE 604 DHG (ES) DIN 3
Table of Contents
1General information..........................................................................................7
1.1 Further documents and documentation..............................................................8
1.2 Used signs and symbols....................................................................................9
1.2.1 General signs / symbols .......................................................................................9
2General Safety Regulations............................................................................12
2.1 Important safety warning..................................................................................12
2.1.1 Intended use...................................................................................................... 13
2.1.2 Foreseeable incorrect use or inappropriate handling........................................ 14
2.1.3 Residual risks .................................................................................................... 15
2.2 Operating personnel –qualifications and obligations .......................................18
2.3 Personal protective equipment.........................................................................18
2.4 Danger zones and work areas.........................................................................19
2.5 Signs on the generator.....................................................................................20
2.6 General safety instructions...............................................................................22
3Description of the power generator ESE 604 DHG DIN ...............................27
3.1 Components of the power generator ESE 604 DHG DIN.................................27
3.1.1 Components of the operating and generator side............................................. 28
3.1.2 Engine and maintenance side components ...................................................... 29
3.1.3 Control panel components................................................................................. 30
3.1.4 Accessory components ..................................................................................... 31
3.2 Function and mode of operation.......................................................................32
4Operate power generator ESE 604 DHG DIN ................................................34
4.1 Transporting the generator...............................................................................34
4.2 Setting up the generator...................................................................................34
4.3 Refuelling the generator...................................................................................35
4.4 Starting the generator......................................................................................37
4.5 Switching the generator off ..............................................................................40
4.6 Connecting up to consumers ...........................................................................42
4.7 Check the protective conductor........................................................................44

Table of Contents
4ESE 604 DHG (ES) DIN Status: October 2018
4.8 Monitoring the operating status using the multifunction display........................45
4.10 Putting the generator out of service .................................................................48
4.11 Disposal...........................................................................................................48
5Using special fittings / accessories...............................................................50
5.1 FI circuit breaker (RCD)...................................................................................50
5.2 Insulation monitoring using E-MCS 4.0............................................................52
5.2.1 Insulation monitoring without switching off........................................................ 52
5.2.2 Insulation monitoring with switch off.................................................................. 54
5.3 Speed lowering in idle......................................................................................56
5.4 Remote start device.........................................................................................57
5.5 External start device ........................................................................................60
5.6 Battery charge maintenance............................................................................61
5.7 12V connection for supplying accessories with power......................................63
5.8 3-way fuel valve / Refuelling device .................................................................65
5.9 Exhaust hose...................................................................................................68
6Service the power generator ESE 604 (ES) DHG DIN...................................70
6.1 Maintenance plan.............................................................................................70
6.2 Maintenance work............................................................................................71
6.2.1 Engine oil........................................................................................................... 71
6.2.2 Replacing the starter battery ............................................................................. 74
6.2.3 Replacing fuses................................................................................................. 75
6.3 Checking the electrical safety ..........................................................................76
7Troubleshooting..............................................................................................78
8Technical specifications.................................................................................82
9Replacement parts..........................................................................................86
9.1 frame with covers, tank and engine..................................................................86
9.2 Generator and electronics................................................................................89
9.3 Fuses...............................................................................................................91

Table of Contents
Status at: October 2018 ESE 604 DHG (ES) DIN 5
List of illustrations
Fig. 2-1: Signs on the generator..................................................................................20
Fig. 3-1: Views of the generator...................................................................................27
Fig. 3-2: Components of the operating and generator side..........................................28
Fig. 3-3: Engine and maintenance side components...................................................29
Fig. 3-4: Control panel components.............................................................................30
Fig. 3-5: Components of the standard accessories......................................................31
Fig. 3-6: Components of the special accessories ........................................................31
Fig. 4-1: Fuel valve and choke lever............................................................................36
Fig. 4-2: A hand start...................................................................................................38
Fig. 4-3: Electrical start................................................................................................39
Fig. 4-4: Connecting up to consumers.........................................................................42
Fig. 4-5: Check the protective conductor.....................................................................44
Fig. 4-6: Multi-functional display..................................................................................45
Fig. 5-1: FI protection switch .......................................................................................51
Fig. 5-2: Insulation monitoring using E-MCS 4.0..........................................................52
Fig. 5-3: Switching the idle down on pressure switch...................................................56
Fig. 5-4: Connecting up a remote start device.............................................................57
Fig. 5-5: Example of an electrical start in combination with a remote start device........58
Fig. 5-6: Connecting up an external start device..........................................................60
Fig. 5-7: 12V connection socket according to DIN 14690 ............................................61
Fig. 5-8: BEOS charge current socket.........................................................................62
Fig. 5-9: MagCode charge current socket....................................................................63
Fig. 5-10: Connection socket for a 12V accessory.......................................................64
Fig. 5-11: 3-way fuel valve...........................................................................................65
Fig. 5-12: Connect up fuelling device ..........................................................................66
Fig. 5-13 Connecting the exhaust hose.......................................................................68
Fig. 6-1: Viscosity ranges for engine oil.......................................................................71
Fig. 6-2: Oil dipstick.....................................................................................................72
Fig. 6-3: Replacing the battery ....................................................................................74
Fig. 6-4: Replacing a fuse............................................................................................75
Fig. 8-1: Generator dimensions...................................................................................82
Fig. 9-1: Operating and alternator side replacement parts...........................................86
Fig. 9-2: Engine and exhaust side replacement parts..................................................87
Fig. 9-3: Replacement parts Generator and electronics...............................................89
Fig. 9-4: Replacement parts for fuses..........................................................................91
List of tables
Table 2.1: Danger zones and work areas on the generator.........................................19
Table 2.2: Signs on the generator ...............................................................................21
Table 4.1: Protective conductor test lamp....................................................................44
Table 5.1: FI protection switch test..............................................................................51
Table 5.2: Insulation monitoring without switching off..................................................52
Table 5.3: Insulation monitoring without switching off during operation........................53
Table 5.4: Insulation monitoring plus switching off.......................................................54
Table 5.5: Insulation monitoring whilst running without switching off ...........................55
Table 5.6: Switchingpositions of the 3-way fuel tap .....................................................65

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6ESE 604 DHG (ES) DIN Status: October 2018
Table 6.1: Generator maintenance plans.....................................................................70
Table 6.2: Location of the fuses..................................................................................75
Table 7.1: Problems arising during generator operation ..............................................80
Table 8.1: Generator technical data ............................................................................83
Table 8.2: Ambient conditions for the generator..........................................................84
Table 8.3: Standard reference conditions for the generators.......................................84
Table 8.4: Generator power reduction dependent on standard reference conditions...84
Table 8.5: Maximum line length of the distribution network as a function of the cable
cross-section.............................................................................................84
Table 9.1: Replacement parts for frame with covers....................................................88
Table 9.2: Replacement parts for an engine with an exhaust and fuel system.............90
Table 9.3: Replacement parts for fuses.......................................................................91
General note: The illustrations in these operating instructions do not always
comply completely with the actual design, in particular with re-
gard to the colour, and are to be considered as the depiction
of basic principles.
We reservetheright tomake modifications interms of ongoing
technical development.
These instructions do not include technical modifications that
occurred after printing.

General information
Status at: October 2018 ESE 604 DHG (ES) DIN 7
1General information
These operating instructions must be read carefully and un-
derstood before using the generator.
These operating instructions are intended to familiarise you
with the basic operation of the generator.
These operating instructions contain important information on
using the generator safely and appropriately.
Complying with this information helps to:
avoid hazards
reduce repair costs and downtime
increase the reliability and service life of the generator.
However, not only these operating instructions but also the
laws, regulations, guidelines, and standards applicable in the
country of use and at the site of operation must be observed.
These operating instructions only describe the generator op-
eration.
A copy of these operating instructions must be available to
the operating personnel at all times.

General information
8ESE 604 DHG (ES) DIN Status: October 2018
1.1 Further documents and documentation
In addition to these operating instructions, the following docu-
ments are relevant for the generator:
Operating instructions and maintenance instructions for
the engine (Briggs & Stratton Corporation)
Briggs & Stratton Service Germany (Briggs & Stratton Cor-
poration)
Circuit diagram for the generator
Test protocol for the power generator
Regulations for handling the battery
The operating manual and the maintenance instructions
from the engine manufacturer are integral components of
these instructions and must be observed.

General information
Status at: October 2018 ESE 604 DHG (ES) DIN 9
1.2 Used signs and symbols
The signs and symbols in these operating instructions help
you to use the operating instructions and the device quickly
and safely.
1.2.1 General signs / symbols
Advanced Organizer
The Advanced Organizer informs you briefly about the con-
tents of the following chapter.
Note
The reference note informs you about the most effective
and/or most practicable way to use the equipment and these
operating instructions.
1. Operating steps
2. …
3. The defined sequence of the operating steps facilitates
correct and safe use of the equipment.
Result
The result of a sequence of operating steps is described here.
NOTE

General information
10 ESE 604 DHG (ES) DIN Status: October 2018
1.2.2 Safety symbols
The safety warning symbol indicates that a source of danger
exists. The safety warning symbols used in the work area of
the machine/plant and the entire technical documentation cor-
respond to the Council Directive 92/58/EEC - Minimum re-
quirements for the provision of safety and/or health signs at
work.
Warning of a general hazard
This warning symbol indicates activities where several
causes can lead to risks.
Potentially explosive materials
This warning symbol indicates activities during which there is
an explosive hazard, possibly with lethal consequences.
Dangerous electrical voltage
This warning symbol indicates activities during which there is
the danger of an electric shock, possibly with lethal conse-
quences.
Poisonous substances
This warning symbol indicates activities during which there is
the danger of poisoning, possibly with lethal consequences.
Environmentally damaging substances
This warning sign indicates activities during which the envi-
ronment could be endangered, possibly with catastrophic
consequences.
Hot surfaces
This warning symbol indicates activities during which there is
the danger of burns, possibly with lasting consequences.

General information
Status at: October 2018 ESE 604 DHG (ES) DIN 11
Notes

General Safety Regulations
12 ESE 604 DHG (ES) DIN Status: October 2018
2General Safety Regulations
This section describes the basic safety regulations for operat-
ing the generator.
Whoever operates the generator or works with it must read
this chapter and comply with its regulations in practice.
2.1 Important safety warning
ENDRESS generators are designed to operate electrical
equipment with appropriate power output requirements. Other
applications can lead to injury to the operating personnel and
to damage to the generator as well as other damage to equip-
ment.
The majority of injuries and damage to equipment can be
avoided if all instructions given in this manual and all instruc-
tions attached to the generator are followed.
The generator must not be modified in any way. This can lead
to an accident occurring and damage to the generator as well
as devices.

General Safety Regulations
Status at: October 2018 ESE 604 DHG (ES) DIN 13
WARNING!
The following actions are not permitted.
Operation in explosion-prone environments
Operation in fire-prone environments
Operation in confined areas
Operation from a vehicle platform that has not been
swung out
Operation without the necessary safety redundancies
Operation in existing power supply networks
Refuelling when hot
Refuelling during operation
Spraying with high-pressure cleaners or fire-extinguish-
ing equipment
Safety equipment removal
Incorrect vehicle installation
Non-compliance with maintenance intervals
Failure to measure and test for early damage identifica-
tion
Failure to replace wearing parts
Incorrectly performed maintenance or repair work
Defectively performed maintenance or repair work
Unintended use
2.1.1 Intended use
The generator produces electricity in place of the power grid,
in order to supply a mobile distribution system.
The generator is only to be used outdoors within the indicated
voltage, output, and nominal rpm ranges (see nameplate).
You are also permitted to use it on a vehicle extension or swiv-
elling platform in both extended and swung out states, provid-
ing that the air circulation can be uninterrupted on all sides of
the generator and that the exhaust gases are dispersed cor-
rectly. This is especially relevant when the side with the instru-
ment panel and the side with the exhaust gas connection must
be unrestricted.
The methods that will be used to install the generator on these
vehicle platforms require written approval from the distributor
that supplied the generator.

General Safety Regulations
14 ESE 604 DHG (ES) DIN Status: October 2018
The generator is not to be connected up to other energy dis-
tribution systems (e.g. public power supply) or to other energy
generation systems (e.g. other generators).
The generator is not to be used in explosion-prone environ-
ments.
The generator is not to be used in fire-prone environments.
The generator must be operated according to the specifica-
tions in the technical documentation.
Everyinappropriate useor all activities onthegenerator which
are not described in these instructions is forbidden misuse
outside the legally defined limits of liability of the manufac-
turer.
2.1.2 Foreseeable incorrect use or inappropriate handling
Foreseeable incorrect use or inappropriate handling of the
generator nullifies the manufacturer's EC Declaration of Con-
formity and automatically thereby the operating licence.
Foreseeable incorrect use or inappropriate handling include:
Operation in explosion-prone environments
Operation in fire-prone environments
Operation in confined areas
Operation from a vehicle platform that has not been swung
out
Operation without the necessary safety redundancies
Operation in existing power supply networks
Refuelling when hot
Refuelling during operation
Spraying with high-pressure cleaners or fire-extinguishing
equipment
Safety equipment removal
Incorrect vehicle installation
Non-compliance with maintenance intervals
Failure to measure and test for early damage identification
Failure to replace wearing parts
Incorrectly performed maintenance or repair work
Defectively performed maintenance or repair work
Unintended use

General Safety Regulations
Status at: October 2018 ESE 604 DHG (ES) DIN 15
2.1.3 Residual risks
The residual risks were analysed and evaluated using a risk
analysis tool before beginning the design and planning of the
generator according to DIN EN 12100 and DIN EN ISO 60204
in their respectively valid version.
Structurally unavoidable residual risks during the entire ser-
vice life of the ESE 604 DBG (ES) DIN generator can be:
Risk of death
Risk of injury
Environmental hazards
Material damage to the generator
Material damage to other property
Limited performance or functionality
You can avoid existing residual risks by observing and follow-
ing these guidelines:
the special warning notices on the generator
the general safety instructions given in these operating in-
structions
the specific warnings given in these operating instructions
The specific standing instructions(the relevant operational
conditions) issued by fire-brigades, civil defence and other
relief organisations
Risk of death to persons at the generator can be caused by:
Incorrect use
Inappropriate handling
Missing protective equipment
Defective or damaged electrical components
Fuel vapours
Engine exhaust gases
Too large a distribution network configuration
Risk of death

General Safety Regulations
16 ESE 604 DHG (ES) DIN Status: October 2018
Risk of injury to persons at the generator can be caused by:
Inappropriate handling
Transport
Hot components
Recoiling starter rope on the engine
Environmental hazards involving the generator may be
caused by:
Inappropriate handling
Operating fluids (fuel, lubricants, engine oil, etc.)
Exhaust gas emission
Noise emission
Fire hazard
Leaking battery acid
Material damage to the generator can occur through:
Inappropriate handling
Overloading
Overheating
Too low/high oil level of the engine
Non-compliance with the operating and maintenance
specifications
Unsuitable operating fluids
Unsuitable hoisting gear
Material damage to other equipment in the operating area of
the generator can be caused by:
Inappropriate handling
An overvoltage or an undervoltage
Incorrect installation in a vehicle
Risk of injury
Environmental hazards
Material damage to the
generator
Material damage to other
property

General Safety Regulations
Status at: October 2018 ESE 604 DHG (ES) DIN 17
The generator's performance or functionality can be limited
by:
Inappropriate handling
Inappropriate maintenance or repair work
Unsuitable operating fluids
An installation altitude greater than 100 metres above sea
level
An ambient temperature exceeding 25°C
Too large a distribution network configuration
Welding generator's
performance or
functionality limitations

General Safety Regulations
18 ESE 604 DHG (ES) DIN Status: October 2018
2.2 Operating personnel – qualifications and obligations
Only appropriately authorised personnel may work with or on
the generator.
The authorised operating personnel must:
be of age.
be trained in first aid and be able to provide it.
be familiar with the accident prevention regulations and
generator safety instructions and be able to apply them.
have read the chapter “General Safety Regulations”.
has understand the content of the chapter “General Safety
Regulations”.
be able to use and implement the content of the chapter
“General Safety Regulations” in practice.
be trained and instructed according to the rules of conduct
in the event of a malfunction occurring.
have the physical and mental abilities to carry out his re-
sponsibilities, tasks, and activities on the generator.
be trained and instructed in his responsibilities, tasks and
activities on the alternator.
have understood the technical documentation concerning
his responsibilities, tasks and activities on the alternator
and be able to implement these in practice.
2.3 Personal protective equipment
This personal protection equipment must be worn during all
activities at thegenerator described in these operating instruc-
tions:
hearing protection
protective gloves
hard hat
protective shoes
fireproof protective clothing (in areas where the danger of
fire is high)

General Safety Regulations
Status at: October 2018 ESE 604 DHG (ES) DIN 19
2.4 Danger zones and work areas
The danger zones and work places (work areas) around the
generator are determined by the activities to be undertaken
within the individual life cycles:
Life cycle
Activity
Danger zone
Work area
Transport
in the vehicle
Radius of 1.0 m
none
by the operating
personnel
Radius of 1.0 m
Operation
Setting up
Operating
Radius of 5.0 m
refuel
Radius of 2.0 m
Service and
maintenance
Cleaning
Radius of 1.0 m
Shutting down
Maintenance
Table 2.1: Danger zones and work areas on the generator

General Safety Regulations
20 ESE 604 DHG (ES) DIN Status: October 2018
2.5 Signs on the generator
These signs must be fitted on the generator and be kept in a
clearly legible condition:
Fig. 2-1: Signs on the generator
10
Abridged operating instructions (inside
cover)
80
Reference note - read operating in-
structions
20
Note on power network
90
Reference note - maintenance intervals
30
Note on the hot surface
100
Reference note - no naked flames
40
Note - 3-way fuel valve
110
Warning of dangers incurred during
engine operation
50
Terminal for potential equalisation
(earthing for RCD)
120
Note - do not adjust the engine speed
set at the works
60
Note - sound emission
130
Note - fuel quantity / quality
70
Type plate
10
60
70
80
90
100
130
20
30
40
110
120
50