ETQ DG4LN User manual

OWNER’S MANUAL
Air-cooled diesel engine generator set
DG4LN / DG6LN
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. You will save time
and the inconvenience of having to go back to the store if you choose to write or call us
concerning missing parts, service questions, operating advice, and/or assembly questions.
Our air-cooled diesel generators have some of the following features:
• Lightweight construction
• Air cooled
• Four-stroke diesel internal combustion engine
• Direct fuel injection system
• Recoil starter or an optional electric starter
• Large fuel tank
• Automatic voltage stabilizer
• NFB circuit protector
• AC and DC outputs
• Low oil pressure sensor
The ETQ air-cooled diesel generators are widely used when electrical power is scarce.
Our generators provide a portable mobile solution in supplying power for field operations
during project construction. Some other known applications include pipeline
construction and metal welding when electrical power is not available.
This manual will explain how to operate and service your generator set.
If you have any questions or suggestions about this manual, please contact your local
dealer or us directly. Consumers should notice that this manual might differ slightly
from the actual product as more improvements are made to our products. Some of the
pictures in this manual may differ slightly from the actual product as well. Eastern
Tools and Equipment, Inc. reserves the right to make changes at any time without
notice and without incurring any obligation.
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TABLE OF CONTENTS
Page number
Overall view of the generator set 4
Chapter 1 Technical Specifications and Data 5
1-1 Technical specifications and data 5
1-2 Basic operating parameters 7
1-3 General dimensions and overview of the generators 7
1-4 Electric wiring diagrams for various models of generators 8
Chapter 2 Operating the Diesel Generator 11
2-1 Main points of safety during operation of the generator 11
2-2 Preparation before operation 13
2-3 Checking the operation of the diesel engine 16
2-4 Starting the generator set 16
2-5 Procedures for starting the generator set 19
2-6 Proper operation of the generator set 21
2-7 Loading 21
2-8 Stopping the generator 23
Chapter 3 Maintenance 24
3-1 Maintenance schedules 24
3-2 Storing for long periods of time 26
Chapter 4 Troubleshooting 27
4-1 Overhauling and troubleshooting procedures 27
4-2 Questions and doubts 27
Chapter 5 Generator Parts Diagrams and Listings 28
LimitedWarranty 34
Product Registration Card 35
List for comments from users 36
Appendix 37
1. Attached list of tools fittings, and subassemblies 37
2. Attached technical documents 37
3

4
2. Overall view of the DG4LN series
1. Overall view of the 6LN series

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CHAPTER 1. TECHNICAL SPECIFICATIONS AND DATA
1-1 Technical specifications and data (in SI units)
Item Model DG4LN DG6LN
Generator Type 2 electrode single-phase synchronous brushless
alternator
Excitation Self-excitation voltage
Voltage system Condenser compensation system
Frequency (Hz) 60 60
Rated power (kW) 3.5 5.5
Max rated power (kW) 4.0 6.0
AC rated voltage (V) 120 / 240
DC rated output (V-A) 12-8.3
Speed (rpm) 3600 3600
Generator
Power factor (cos ϕ) 1.0
Engine type ETQ178FG ETQ186FG
Type Single-cylinder, vertical, 4-stroke, air-cooled, direct
injection
Continuous (kw) 4.40 6.6Output Maximum (kw) 4.92 7.34
Bore x Stroke (mm) 78 x 62 86 x 70
Displacement (cc) 296 406
Lube-oil capacity (L) 1.1 1.65
Diesel Engine
Fuel tank capacity (L) 15 15
Dry weight (kg) 138 160
Set
Dimensions (L x W x H)
(mm) 845 x 530 x 705 920 x 530 x 705

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Technical specifications in English units
Item Model DG4LN DG6LN
Generator Type 2 electrode single-phase synchronous brushless
alternator
Excitation Self-excitation voltage
Voltage system Condenser compensation system
Frequency (Hz) 60 60
Rated power (kw) 3.5 5.5
Max. rated power (kW) 4.0 6.0
AC rated voltage (V) 120 / 240
DC rated output (V-A) 12-8.3
Speed (rpm) 3600 3600
Generator
Power factor (cos ϕ) 1.0
Engine type ETQ178FG ETQ186FG
Type Single-cylinder, vertical, 4-stroke, air-cooled, direct
injection
Continuous (HP) 5.9 8.85Output Maximum (HP) 6.6 9.85
Bore x Stroke (in.) 3.07 x 2.44 3.39 x2.76
Displacement (cu. in) 18.1 24.8
Lube-oil capacity (oz) 37.12 55.75
Diesel Engine
Fuel tank capacity (US gal) 3.57 3.96
Dry weight (lbs) 304 352
Set
Dimensions (L x W x H)
(in.) 33.3x20.9x27.8 36.2x20.9x27.8

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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 (
o
F) RH
0 +60 (+20
o
C) 60%
<3280.8 (<1000 m) 41~104 (5-40
o
C) 90%
1-3 General dimensions and overview of the generators
1-3.1 General dimensions of the LN series generators
1-3.2 Generator model numbering code
D G 4 L N = Diesel Generator 4KW Low Noise

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1-4 Electric wiring diagrams for various models of generators
Wiring diagrams for the LN models

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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. Keep all flammable fuels away
from the generator as the generator may spark and ignite these gases. In order to prevent
fires from occurring and to provide enough ventilation for people and the machine, keep
the diesel generator at least 1.5 meters away from buildings and or other equipment.
Always operate your diesel generator on a level site. If the generator is operated on an
incline, the lubricating system within the engine will not perform well and may lead to
failure of the engine.
2-1.2 Prevention from inhaling exhaust gases
Never inhale exhaust gases emitted by the engine. The exhaust gases contain toxic
carbon monoxide. Never operate your generator in places with poor ventilation. In order
to operate this machinery indoors, a suitable ventilation system for the building is
required to draw the poisonous exhaust gases out.
2-1.3 Prevention from accidental burns
Never touch the muffler and its cover when the diesel engine is running. Never touch the
muffler and cover after the diesel engine has been used, as the muffler remains hot for a
good period of time.
2-1.4 Electric shock and short circuits
Never touch the generator if the generator is wet. Also never touch the generator if your
hand is wet. Never operate your generator if the weather conditions call for any type of
precipitation such as rain, snow, or fog. To prevent electrical shocks, the generator
should be grounded. Use a lead to connect the grounding end of the generator to the
grounding surface of choice. Please refer to Fig. 2-1 and Fig. 2-2 before beginning to use
the electric generator.

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Fig 2-1 Fig 2-2
N
ote: 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 re
g
ulated 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. While operating the
generator, wear safe shoes and suitable clothes during operation. Always keep children
and animals away from the generator.
2-1.6 Battery
The electrolytic liquid of the battery also known as battery acid contains sulfuric acid. In
order to protect your eyes, skin, and clothing, wear protective gear when working with
the battery. If you come in contact with the electrolytic liquid, wash it immediately with
clean water. Also, if the electrolytic liquid comes in contact with your eyes, see a doctor
immediately.

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2-2 Preparation before operation
2-2.1 Fuel choices and fuel treatment
Air filter element
Do not wash the air filter. The
element is made of dry material,
which does not permit washing.
When the output of the diesel
engine is bad or the color of the
exhaust gas is abnormal, replace the
air filter element. Never start the
diesel engine without the air filter.
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.
N
ote: It is dangerous to overfill the
fuel tank. Never exceed the red piston
in the filter.
a. After purchasing fuel, put it
into a drum and let it sit for 3-
4 days.
b. 3-4 days later, insert half of
the fuel sucker into the drum,
(water and impurities stay in
the lower portion of the
drum)
N
ote:
N
ever smoke near the opening of
the fuel tank. Do not let sparks get
near the fuel or fuel tank and do not
overfill tank. After filling, tighten
the fuel cap.

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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. Also, the life of the other parts in your engine such as
bearings, and other rotating parts will shorten considerably.
Although there is an alarm system to check for low oil pressure, it is always a good idea
to check the amount of oil inside the engine. If the oil level is low, fill it before starting
the engine. A good time to drain the oil from the engine is when the diesel engine is still
hot. If the engine is fully cooled, it is more difficult to drain all the oil out or some
impurities will remain in the engine.

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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.
Do not use detergent to wash the air
filter element. When the
performance of the engine decreases
or when the color of the exhaust
gases is bad, exchange the filter
element. Never start the engine
without the air filter as foreign
objects may enter the intake and
damage the engine.
(2) After replacing the air filter
element, replace the cover and
tighten the butterfly nut firmly.
2-2.4 Checking the generator welder
(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
The generator should be grounded in
order to prevent electric shock.
Use dry compressed air (with
pressure about 1.96 x 105 Pa) to
blow the dust out in the electric
control cabinet and at the surface of
the generator. Check to see how
clean the surface of the sliding ring
is. Check the pressure of the carbon
brush. Also, check whether the
position of the carbon brush at the
slide rig is correct and the fixture is
reliable with a good contact.
According to the electric wiring
diagram, check to see whether the
connecting wire is correct and the
connected place is firm.
Use a 500 M Ωmeter to measure the
insulation resistance of the electrical
part. The resistance should be no
less than 5M Ω. When measuring
devices, make sure the AVR is
turned off. Otherwise, it will burn
the AVR. (For the low noise set, the
inspection may not be performed).
2-2.5 The fuel and oil in a new
engine is drained before sold.

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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.
2-3Checking the operation of the
diesel engine
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. The purpose of having this
system is to ensure that the
engine does not seize up. If there
is not enough oil in the engine,
the temperature of the oil will be
raised too high. On the contrary,
if there is too much oil in the
engine, the engine oil can slow
the engine down considerably.
2-3.2 How to open the case door/cover
(1) Open the case door: turn the
handle counterclockwise and
open the door. Do these
checks daily.
(2) Loosen the outer cover bolt
of the air filter and outer
cover of the oil nozzle, and
then check the air filter.
(3) Check the outer cover of the
oil nozzle. Loosen the
butterfly nut and open the
outer cover.
2-3.3 Engine break in
When you purchase a brand new
engine, the engine must be
properly broken in. The break in
period is about 20 hours.
(1) Avoid overloading the
engine when brand new
(2) Change the engine oil
according to specifications.
An oil change for a brand
new engine is about 20 hours
or every month, an older
engine, the oil change is
about 100 hours or three
months.
2-4Starting the generator set
2-4.1 Manual starting.
Start the engine in accordance with
procedures below:
(1) Put the fuel switch in the
“On” position.
Knob han
dle
Fuel switch
(2) Turn the handle of the
engine to the “RUN”

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1. Insert key into ignition and
put it in the “off” position.
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.
(3) Pull the recoil starter handle
out until you feel resistance.
It will reset to its original
position automatically. The
handle should be reset into
its recoil device slowly to
prolong the life of the engine
starter.
4. After the diesel engine is
started, remove your hand
from the switch handle; the
switch will automatically
reset itself to the “ON”
position.
(4) In cold climate, it is difficult
to start the engine. To
remedy this, pull the rubber
plug out from the rocker of
the diesel engine and fill 2
ml of engine oil. Before
starting, put the rubber plug
back in place. If you don’t
put the rubber plug back in
place, rain, dust and other
dirt can enter into the diesel
engine. It will cause the
parts inside the diesel engine
to wear quickly and lead to
engine failure.
2-4.2 Electric starting
The procedures for preparing to start the
engine are the same as the manual
starting engine.
5. If the engine is not starting
after 10 seconds of cranking,
wait about 15 seconds before
trying it again. If you crank
to long, the voltage of the
battery will drop. This can
lead to improper ignition.
When the diesel engine is
operating, let the ignition
retain on the “ON” position.
N
ote:
If you crank the starter to long, the
battery may be drained too much to
p
rovide enough energy for proper
engine ignition. Also, when the diesel
engine is operating, let the key retain
in the “ON” position.

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2-4.3 Battery
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. If the level of
the liquid drops too low, fill it with distilled water until it reaches the high mark. If there
is not enough battery acid, then the diesel engine cannot be started. It is important to
keep the liquid level between the high and low limits.
If the level in the battery is to high, the liquid may flow out and end up on surrounding
parts resulting in corrosion of these parts.
Note: Avoid too much or too little of battery acid. Check and fill it once a month if
necessary.

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2-5Procedures for starting the generator set
This procedure applies to the L series recoil starting style models.

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